11883734-clark Npr 17 Npr 20 Forklift Service Repair Workshop Manual Download

SM-587 NPR 17/20

CLRRK

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

Service Manual SM -587

NPR-345

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

NPR-17 NPR-20

TABLE OF CONTENTS w

Group No-Section No.-Page No.

01 Planned Maintenance Procedures PM-l thru 29 02 Lubrication Charts

01-1-l

03 Battery Service

12-1-1

04 Multi-Function Control Handle Switches 13-1-1

Groun No-Section No.-Page No.

Item

3 1 Hydraulic Control Valves & Solenoid Control Valves, Remove & Replace30- l- 1 32 Auxiliary Reach & Tilt Valve Overhaul 30-2- 1 33 Lift Control Valve Overhaul

30-3- 1 30-4- 1

05 Electric Motor Service -- General

16-2-1

34 Lowering Solenoid Valve

06 Traction Motor Service

16-3-1

35 Auxiliary Solenoid Valve

07 Pump Motors

16-5-1

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

39 Reach Cylinder Overhaul

32-3-l

11 EV-T15 Solid State Control Status Code 19-3-1 12 Oscillator Card Settings and Tests

19-4-1

13 Steering Control Adjustments (EV-T5PS)19-5-1 19-6-1

14 Wiring Diagrams 15 Directional, Lift & Lower Switches and Transducer Adjustment 16 Periodic Electrical Checks

( Reach & Tilt Control Valves)

30-5-l

40 Upright & Pantograph Remove & Replace and Roller Shim Adjustments

34-l-l

41 Pantograph & Fork Carriage R&R and Roller Shim Adjustments

34-2-l

19-7-1

42 Rail Lift Cylinder Overhaul

34-3- 1

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

26 Brake Pedal Adjustment

23-4- 1

Pictorial Indexes are provided on the following four pages.

27 Hydraulic Pressure Checks

26-l-l

Index ............................ ....Page 6/7

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 Contents - 1 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Pictorial Index

INDEX

Pictorial Index #1 NPR-345

/

Dee 94

23

Index-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

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 PM-28 Replace Brake Linings ........................................................... Group-Section-Page Group ........................................................................ 01 Lubrication Chart and Instructions.. ................................ .01-l-01 thru 07 12-l-01 thrllO8 12 Battery Service Instructions ............................................. 13 Multi-Function Control Handle Switches ....................... .13-l-01 thru 05 16 Electric Motor Service - General .................................... .16-2-01 thru 09 16-3-01 thru 11 16 Traction Motor Service ................................................... 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.. ............................................. 19 Electrical Sequence of Operation .................................... 19 Instructions - Status Codes for EV-T15 Control.. ............ 19 Oscillator Card Settings ...................................................

.17-l-01 thru 09 .19-2-O 1 thru 5 1 .19-3-01 thru 15 19-4-01 thnlo4

19 Steering Control Adjustments.. ....................................... 19 Wiring Diagrams ............................................................

.19-5-01 thru 06 19-6-01 thru 03

19 F&R Switches, Up & Down Switches, Transducer Adjl . .19-7-01 thru 10 .19-8-01 thru 16 19 Periodic Electrical Checks .............................................. 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 Wheel & Tire, Caster ...................................................... 23 Brake, Traction Motor ..................................................... 23 Brake, Caster .................................................................

22-l-01 thnlo3 22-2-01 thru 04 23-l-01 thru 08 .23-2-01 thru 09

.23-3-01 thru 02 23 Bleeding Procedure, Brake ............................................. 23 Brake Pedal and Cylinder(s) Check & Adjustment ........ ..23-4-O 1 thru 02

SM-587

Copyrighted Material Index-3 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Pictorial Index

INDEX

Pictorial Index :#2 NPR-345

Dee 94

Index-4 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

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 29 Hydraulic Sump Tank, Filter and Strainer Service .......... ...29-l- 1 thru 29 Hydraulic Schematic Diagram ........................................ ..29-2- 1 thru ..29-4- 1 thru 29 Hydraulic Pump Overhaul.. .............................................

05 07 02 05

30 Hydraulic Control Valves and Solenoid Control Valves, .30-1-l thru 14 Remove & Replace ..................................................... 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 34 Lift Cylinder, Rail - Overhaul Procedures.. ....................... .34-3-l thru 34 Lift Cylinder, Free Lift - Overhaul Procedures.. ............... ..34-4- 1 thru .34-5-l thru 34 Lift Fork Inspection ......................................................... 34 Lift Chain Inspection, Lubrication and Specifications.. .... ..34-6- 1 thru 35 Load Wheel Service Procedures ....................................... .35-l- 1 thru 40 NPR-345 Specification Listing ........................................ ..40-l- 1 thru .40-2-l thru 40 Service Weights ............................................................... 40 Lubricants and Shop Supplies ...........................................

SM-587

Copyrighted Material Index-5 Intended for CLARK dealers only Do not sell or distribute

12 05 05 04 06 02 13 04

40-3-l thru 14

Dee 94

INDEX m

Group No-Section No.-Page No.

Axle

Ttem

Grout No-Section No.-PaPe No.

Motors Articulation Adjustment

20-l-l

Battery Remove & Replace

12-1-1

Service

12-1-1

Brakes

General

16-2-1

Traction

16-3-1

Auxiliary/Steer Pump

16-7-1

Pantograph & Fork Carriage 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

Pedal Adjustment

23-4- 1

Master Cylinder

23-4- 1

Caster Service Checks

PM-17

Control Panel

Periodic Electrical Checks Cable & Wire Routing

19-8-1 19-8-1

Planned Maintenance Procedures PM- 1 thru 29 Caster Special Socket Adapter PM-24 Pressure Checks

Contactors

17-1-1

Oscillator Card, Remove & Replace

19-10-l

Cylinders

Steering

26-l-l

Lift Circuit

26-l-l

Auxiliary Reach & Tilt

26-l-l

Pump Overhaul

Tilt Cylinder Overhaul

32-2- 1

Sequence of Operation

Reach Cylinder Overhaul

32-3- 1

Electrical

Rail Lift Cylinder Overhaul

34-3-l

Free Lift Cylinder Overhaul

34-4- 1

Diagrams Electrical

19-6-1

Hydraulic

29-2- 1

Drive Unit Overhaul

29-4- 1

19-2-1

Solid State Control Status Codes (EV-T15)

19-3-1

Oscillator Card Settings/Tests

19-4-1

Steering Adjustments (EV-TSPS)

19-5-1

Directional, Lift & Lower

19-7-1

Switches 20-2- 1

Lift Chains

Multi-Function Control Handle 13-l- 1

Inspection

34-6-2

Lubrication

34-6-6

Remove & Replace

34-6-6

Transducer Adjustment

19-7-1

Lubrication Charts & Specifications Dee 94

01-1-l Index - 6 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

INDEX Upright & Pantograph Lift Chains

34 - Manual Insert

Remove & Replace

34-l-l

Roller Shim Adjustments

34-l-l

Remove & Replace

30-l-l

Auxiliary Reach & Tilt

30-2- 1

Lift Control

30-3-l

Lowering Solenoid

30-4- 1

Valves

Auxiliary Solenoid Valve ( Reach & Tilt)

30-5-l

Reach & Tilt Selector

30-6-l

Side Shifter Solenoid Control

30-7-l

Specifications Service Weights

40-l-l 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

SM-587

Traction

22-l-l

Caster

22-2- 1

Load

35-l-l

Copyrighted Material index7 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Cautions The following is a list of “CAUTIONS” connected with the operation andmaintenance of trucks equipped with Solid State Control Panels.

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. Be sure you know and understand the meaning of these instructions, signs and messages. Damage to the truck or serious injury to you or other persons may result if these messages are not followed. If warning decals are damaged they must be replaced. Contact your Clark dealer for replacements.

NOTICE

This message is used when special information, instructions or identification is required relating to procedures, equipment, tools, pressures, capacities and other special data.

IMPORTANT

This message is used when special precautions should be taken to ensure a correct action or to avoid damage to or malfunction of the truck or a component.

A!

CAUTION

This message is used as a reminder of safety practices which can result in personal injury if proper precautions are not taken.

A

WARNING

This message is used when a hazard exists which can result in serious personal injury or death, proper precautions are not taken.

A

DANGER

This message is used when an extreme hazard exists.

if

A

WELDING ON TRUCKS

1.

Make sure the truck has no grounds.

2

Disconnect truck battery.

3.

Protect electrical wiring and components from weld spatter with a shield.

4.

Ventilate battery or remove battery from truck.

If the above is not followed, damage can result to wiring and electrical components on a solid state control truck.

SM-587

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

Dee 94

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. Solid State Controls should be cleaned at regularintervals. Blowing dirt off with an air hose (that is restricted to 30 psi [207 kPa]) periodically will, for the most part, eliminate any serious cleaningproblems. Should the need arise for a more thorough cleaning, water may be hosed over the control and if necessary a mild detergent applied such as that used in washing dishes in our home. The detergent should be rinsed off and the controls must be thoroughly air dried before putting truck into service. Periodic cleaning, such as those mentioned above, should preclude the need for using a degreaser. However, if a degreaser is used we recommend the following: Only approved solvents should be used to clean Solid State Control Components. Use Clark #I1801146 Degreaser, or the equivalent to MS- 180 Freon TF Degreaser and Cleaner.

A

CHECK POLARITY

Battery Polarity must be correct or the truck will not operate. 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. This manual cannot possibly anticipate all such variations and provide advice or precautions as to each. Accordingly, anyone departing from the instructions provided in this manual through procedures used or choice of tools, materials, and parts may jeopardize his or her personal safety and/or the safety of the vehicle user.

Appropriate servicemethodsandproperrepairprocedures are essential to the safe, reliable operation of industrial trucks as well as the personal safety of the individual doing the work. This Service Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure successful repair and reliable truck operation.

Improper or careless techniques cause accidents. Don’t take chances with incorrect or damaged equipment. Read and understand the procedures for safe operation and maintenance outlined in this manual.

There are numerous variations in procedures, techniques, tools and parts for servicing industrial trucks, as well as in the skill of the individual doing the work.

Drive and work safely and follow the safety signs and their messages displayed in the work area, on the truck and in this manual. Dee 94

ii

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

SM-587

Cautions

GENERAL PRECAUTIONS

Thefollowing list contains general precautions that should be followed when working on a lift truck.

Service Electric Truck Batteries in a well-ventilated area to avoid the danger of lighting explosive gases, clear of pedestrians and with adequate overhead clearance and on a flat, level surface.

Set the parking brake. Place chocks to the front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement.

Always wear safety glasses for eye protection.

Follow the Safety Instructions outlinedin Group 12, “Handling Storage Batteries”.

Remove rings, watches, loose jewelry and open clothing before working on a vehicle, to avoid serious injury. Do not smoke while working on a vehicle. Putpowerkey switchintheOFFposition,unless otherwise required by the procedure.

A!

Use safety stands or blocks whenever a procedure requires you to be under the vehicle.

Always Discharge the Capacitors prior to working on or around electrical components. Refer to the instructions outlined in Group 19, “Discharging Capacitors”.

CAUTION

Avoid contact with Battery Acid. The battery contains corrosive acid which can cause injury. Follow the instructions outlined in Group 12 “Handling Storage Batteries” and those instructions received with your battery and charger.

SM-587

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

Dee 94

Foreword This Service Publication provides information

Procedures have been made easier to use by

covering normal service, maintenance and repair of the Clark industrial lift trucks noted on the cover. It has been specifically prepared to help owners and service personnel maintain these trucks in efficient and safe operating condition.

providing specific steps only when necessary and general instructions required to explain the activity, component, assembly, or process being worked on. The technician is expected to include obvious additional steps of standard procedure for removal, disassembly, cleaning, inspection, reassembly, installation, etc., as needed.

This manual is intended for use by persons who are trained and authorized to do lift truck maintenance. It is designed to provide essential information about the correct and safe service maintenance and repair of the truck by trained mechanics or service technicians.

Tobe better prepared to do the necessaryservice work, take time to completely read the entire procedure, including any special instructions, before starting any work.

The information is organized by use of the Basic Group Numbering System used in the

The technician is cautioned and expected to... ... before beginning to work.

Master Parts Book and the Customer Parts Manuals. The manual includes:

*Take time to completely read (entire) procedures, including any special instructions.

P.M.

Planned Maintenance Procedures including precautions and safe maintenance recommendations.

ABOUT PLANNED MAINTENANCE

01-40

The Planned Maintenance Procedures

Service specifications, adjustments, maintenance and overhaul procedures including lubrication charts, recommended lubricants and service weights, etc.

located in the front of this manual provide a basic step by step guide which should be followed in servicing the vehicle. Adjustment Procedures, Specifications, Lubrication Guides, Overhaul Procedures and other data are found in the rear of this manual listed under Group and Section Numbers. Refer to the index.

General and detailed service and repair procedures are outlined (as required) for each

Regular, correct maintenance and care of industrial trucks is not only important for long and efficient truck life but it is essential for safe operation. The importance of proper maintenance through planned service, inspection and qualified repairs cannot be emphasized too strongly. Preventive maintenance instructions are provided for reference in setting-up and conducting a recommended periodic Planned Maintenance (PM) program.

component or subsystem. Some procedures include explanations that are common to several components or subsystems.

The Pictorial Index lists components or systems by Basic Group Number of Major Parts. Additional content listings are placed at the beginning of each Section in the manual. The Table manual.

of Contents list the pages in this

NOTICE The descriptions and specifications included in this manual were in effect at the time of printing. Clark reserves the right to discontinue models at any time, or make improvements and changes in specifications or design without notice and without incurring obligation. Specifications, torques, pressures, measurements, adjustments, illustrations and other items may change at any time. Contact your authorized CLARK dealer for information on possible updates or revisions. Dee94

iv

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

SM-587

Foreword

An effective PM program should incorporate two basic phases:

~

1. An insnection net-formed bv the driver or maintenance man at the beginning of each shift. This is a quick visual check for obvious damage and leaksandafunctionaltest...acheckoffluidsand

water levels, lights (if so equipped), instruments and warning devices. 2. The Planned Maintenance routine is based on 50 to 250 operating hours ... with the interval

Inspection Forms To insure that the daily inspection and PM are properly performed, we recommended the use of inspection forms. Such forms not only provide a guide for the inspections and maintenance requirements for eachvehicle, they will assist you in determining when to schedule a vehicle for major repairs. Consequently theserepairscanbedonewithoutthedisruptiveeffect of unscheduled down time.

being determined by operating conditions.

Records will tell you how often PM

should be done. l

l

If an oneration is clean and not strenuous, a PM interval can be extended. If an oneration is extremelv dirtv and strenuous, the PM interval may have to be reduced.

NOTE

Refer to the Operator’s Manual, located on the truck, for additional information on the operation, care and maintenance of your truck.

Contact your authorized Clark dealer for more information on maintenance and repair of these t?-UCkS.

If the PM is faithfully followed, needs for repair, major adjustment and component replacement will be discovered and such work can be scheduled eliminating unnecessary downtime and cost. For instance, brake checks which are part of the PM will uncover the need for adjustments and/or repairs which may be required periodically. The objectives of PM are: 1. To reduce costly unscheduled downtime. 2. Reduce maintenance costs. 3. Increase vehicle productivity. 4. Increase personal safety of drivers and other personnel.

SM-587

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

Dee 94

Planned Maintenance Procedures

The Planned Maintenance Procedures Outlinedon the following pages are organized in five basic catagories. They are: 1. Walk Around Visual Inspection. 2. Operational Tests. 3. Cleaning. 4. Checks and Minor Adjustments.

The nature of problems found during aP.M. shouldbe noted in the “comments” portion of the check sheet. Whenever a system or comnonent is faultv or unsafe, it must be noted on the check sheet andreported to the designated authority at the conclusion of the P.M.

5. Lubrication. Each catagory is preceded with a summary of the inspections, checks, tests, etc., that should be performed in each catagory.

P.M. CHECK SHEET

1. Visual Inspection

A special coding system on the P.M. Check sheet allowstmckcondition tobereportedwithaminimum number of words. As the P.M. is performed, a mark should be made in the appropriate box of the component being checked. l

l

l

l

(4) indicates the particular truck component or system has been checked. (x) indicates the component or system is in need of a minor adjustment or service (not part of the normal P.M.) that should be taken care of in the near future. (r) indicates there is a potential problem that couldresult in damage to acomponent or system and requires attention. (s) indicates the need for urgent repair or replace ment of a component or system and the truck should be shut down as possible property damage or personel injury may result.

SM-587

Code

$ = 1

O.K.

O.K.

X = Adjust (Not P.M.)

I

Potential r = Repair or Replace ~~~~~~~~ s = Requires Shop Repair ‘...‘.‘.:.:.:.:.:.:.:.:.:., ..:.:.:.:.:.:.:.:.:.:.:.:.:.:.: ..v.:. .(.,.,.(.(.,.,.,.,.,. .,.,. .,..,.,. .,.

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

Dee 94

Planned Maintenance Procedures

l

Visible frame damage.

l

Tire Wear and/or lodged foreign objects in tire tread and/or badly darnaged side walls.

l

Overhead Guard for security of mounting (loose or missing fasteners) and damage.

l

Visible fluid leaks.

l

Presence and condition of covers, pads, floor mat, decals and truck data plate.

l

Safety Screen and/or Glass for security of mounting and damage.

l

Visible signs of wear and/or damage to upright.

l

Load Back Rest for security of mounting and damage.

l

Check that “ground chain link” is touching the floor.

Visual Inspection 1. Insuect Batterv Plugi BzTruck Receutacle l

l

Disconnect battery from truck. Pull back on the battery disconnect lever located at the right front corner of the console. Inspect the spring battery receptacle terminals. Burned noted on the P.M.

Battery Plug 7

Truck

loaded terminals in the truck and check the battery plug or pitted terminals should be check sheet. tsconnect Batterv and check Spring Loaded Terminals

Dee 94

PM-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Planned Maintenance Procedures

2. Check for Obvious Oil Leaks and peneral condition of Frame & Overhead Guard .

Make a quick overall inspection for oil leaks. If oil leaks are found, at this time, or later in the P.M., fuc the minor leaks and report on the check sheet any leaks which will require major repair.

3. Check condition of covers, pads and floor mat. .

Inspect name plates, warning decals and truck date plate for damage and to be sure none are missing. Be sure warning and instructional decals are readable.

4. Check safety screen and/or glass for security of mounting and damage.

.

Check overhead guard for damage and security of mounting. Be sure the legs of the overhead guard are mounted securely and are not damaged, cracked or bent.

Check for Obvious Leakage

5. Batterv Retainers .

Check battery retainers for damage. Make certain retainers are locked in position at each end of the battery compartment.

SM-587

CopyrightedPM-3 Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Planned Maintenance Procedures

6. Inmect Wheels & Tire .

Check for obvious damage to tires on the load, caster and drive wheels. Look for excessive tire wear, cuts, breaks, “chunking” or bond failure between the tires and wheels. Remove objects that are embedded in the tire. Make sure grease fittings are not damaged and none are missing. Be sure drive wheel fasteners are secure and none are missing. If they are loose, torque them to specifications. Fasteners must be tightened using a diagonal sequence as shown below (lettered A through G).

Retorque drive wheel fasteners afterthefirst2OOhoursofoperation.

Wheel

Wheel & Tire

& Tire

Fastener Tightening Sequence

D

F

B

@

A

G E

C

TORQUE

FASTENERS TO: 124 - 139 LB. FT. (168 - 188 N*M)

Dee 94

PM-4 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Planned Maintenance

Check Mullti-Function operation.

control for freedom of

Check battery connection.

l

Check brakes.

l

Check hour meter.

l

Check steering.

l

Check control plugging.

l

Check acceleration.

Check horn. Check key switch and dash display.

Procedures

Check upright operation. l

Check speed limit switch operation.

Operational Tests

Move control through all functions checking for freedom of movemenet.

a. Check Controls NOTE

Battery connector should be disconnectedandkey switch turned OFF before making these checks.

l

Inspect multi-function control handle for freedom of operation. Move control to the full forward and rearward positions. Then move it into the full left and full right positions. The control must operate freely without binding and spring return to neutral.

Check the Multi-Function Control for Freedom of movement. Control should spring l

Connect battery.

SM-587

CopyrightedPM-5 Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Planned Maintenance Procedures

b. Check horn to be sure it operates.

c. Turn key switch ON.

Check the Diamostic Disdav & Kev Switch l

l

l

l

Digital readout should display “8888” for about one second after you turn the key switch ON. This indicates that the digital readout is okay. then, either the battery symbol or the wrench symbol light should come ON.

Digital Readout \

Battery Symbol: When the battery syrnbol light comes on, the digital readout shows the percentage of usable remaining battery charge. If the readout registers 19 or less, the readout will flash. Wrench Symbol: If this light comes on, a status code will appear on the digital readout. The status code may indicate an easily correctable “operator fault” or it may indicate that the truck should be serviced. Fault Codes: Codes -01 through -03, -06 and -08 are usually operator fault codes, and can be corrected by the operator as explained in Group 19, Section 3. 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.M.

d. Check the hour meter. Turn the key switch to the OFF position. The hourglass symbol light should come on. The hours registered on the truck should appear on the digital readout for about four seconds. Record this hour meter reading on the PM check sheet.

Dee 94

PM-6

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

I

Wrenchkymb

Battery ‘Symbo

SM-587

Planned Maintenance Procedures

e. Check Hvdraulic Function% .

Aftermaking sureyouhaveoverheadclearance, gently pull back on the Multi-Function Control. The pump motor should turn on and the carriage should begin to elevate. Release the control. It should return to neutral without binding and the pump motor should turn off. The control should not bind when moving it any position.

ReachControl Tilt Control !SideShift Control

(Optional)

Elevate the upright to maximum fork height. As the upright raises, watch for mechanical binding of rails, rollers and damage to hoses and lift chains. Lower the upright to full down position. As the upright lowers, watch for mechanical binding of rails, rollers and damage to hose and lift chains.

Watch the upright to make sure it operatessmoothly between the free lift and rail lift stages. .

Multi-Function Control Handle “Switch Buttons”

Hold in one button at a time and check tilt, reach and side shift (if applicable) for proper operation andrange. Forks should tilt evenly and smoothly. Pantograph should reach and retract smoothly without hesitation. Fork Side Shift operation should be smooth without binding. Note any excessive “slop” or “noise” in the upright that may indicate roller damage or roller reshimming is required. Record any malfunction and/or damage on the P.M. Check List.

Check Brake After checking that you have a clear travel path ahead, move the truck forward at a slow speed. Slowly lift foot from brake pedal. Drive motor should cut off before the brakes apply. Move truck in reverse at a slow rate of speed. Slowly lift foot from pedal, the motor should cut off before the brakes apply. Ifoperation is notsatisfactory ... do not operate the truck. Report condition to designated authOIitJC

SM-587

Copyrighted Material PM-7 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Planned Maintenance Procedures h. Check Steerin .

j. .

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. Next, turn the hand wheel rapidly in both directions. Note on P.M. Check List if steering locks momentarily. This may indicate a malfunction in the hydraulic steering system.

Direction of Travel

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 controlled stop, and accelerate normally in the opposite direction. If plugging is as specified, then repeat the procedure at high speed. The truck should come to a smooth controlled stop in approximately 20feet (6.1Omm) with Multi-Function Control in maximum travel position.

l

l

.

Repeat the procedure at high speed with the Multi-Function Control moved in reverse direction half way. If plugging (braking) is not as specified, refer to the adjustment instructions in Group 19 of this manual. Report condition to designated authority.

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

Now, after checking to see that you have a clear path behind, drive the truck in reverse. Check acceleration from stand still condition through top travel speed. Acceleration shouldbe smooth. Report condition on PM Check List.

1. Check Srxed Limit Switch Oneration l

l

After checking for overhead clearance, elevate upright until the intermediate rail operates the speed limit switch attached to the outer rail assembly. Drive truck forward in a straight line of travel with the control held in top speed position.

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

SM-587

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 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Planned Maintenance Procedures

A

a. Remove Batterv l

l

l

l

l

Disconnect battery from truck receptacle. Remove battery retainers and inspect them for damage. Remove battery from truck. Refer to Croup 12 for removal and safety instructions. Clean off deposits of corrosion on the battery. Check battery cables for fraying and damage. A frayed or damaged cable can cause a short. Report condition on P.M. Check List.

WARNING

The battery contains corrosive acid which= can cause injury. If acid contacts your eyes’ or skin, flush immediately with water and gel:

medical assistance. Do not smoke or allow open flame near the battery. Explosive gas is always present around batteries.

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 components.

Dee 94

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

SM-587

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. d. Air Clean .

Using clean, dry air, and a nozzle extension on the air compressor hose, air clean truck and components.

Battery Roller

Battery RetainerL

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 Intended for CLARK dealers only Do not sell or distribute

Dee94

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 applicable). Recordcommutatorcondition on the P.M. Check List.

and brush lengths

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

Dee 94

PM-l 2

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

SM-587

Planned Maintenance

Procedures

Brake Line Retainers (Bracket and Fastener)

I I Artkula ting

Axle

Brake ComnonentS l

l

Air clean master cylinders located beneath the brake pedal. Blow off the brake lines in the operators compartment. Check brake cylinders, lines and fittings for damage and leakage. Be certain the brake line retainer brackets are in place and tightened securely. Tighten all fasteners and replace any that are damaged or missing.

SM-587

If there is leakage at the connections, tighten the fittings. If leakage still exists, replace darnaged parts. If brake cylinder leakage exists, report condition to designated authority.

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

Dee 94

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 securely.

.

Each axle mounting block is equipped with one bushing and a flush type grease fitting. The grease fitting is accessible through an opening in the top side of the axle weldment or “doghouse” located just beneath the operators compartment floor. Clean the area aroundthefitting andwipe the fittings clean. Be certain they are in good condition.

Dee 94

PM-14 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

...... .>>F.. . . . . .. .. . . . . . . . . . . .. . . ..~.~...... :~:~:::::jj,::~.~.~.~.::::~.~~.~:~:~

V Grease Fitting ::::::::i:i:i:i:i:l:~:~:~:~:~:::~:~:~~:~ ...........:. ....................................................................................... :::::::::::::::::::::::::::i:::.:;:~:~:~:~

iiiliii:i:i:i:i:i:i:i:i:i:ijii:i:,i:i:

..:.:.~,.:.:.:.:.:.:.:.:.:.:.:.: ................................,.. ...._. ,... .......................,.,.,.(.,.,.,.(.,.(.,.,.,~,.,.,. .......................:.:.:,:,: ....,...... ..,... ...,..., .............,.,.,.....,.,.,.,...,.,...,.,., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..,. ... .,..., .....:.: .....,.,.,.(.,.,.,.,.(.,.,.........,. ..,.,.,.,.,.,.,.,.,.,........... .,.,.,.,.,.,.,.(.,.,.,.....,... ,.... .,.,.,.,.,.,.,.,.,.......,... f::::::::~:~:::::::::::~:~:~:~~:$~:~:~: ,...:... ........... .:.:.:.:.~j::::jjjj::j)j:.:.:.:.: .....................................................................................................,...,. ,.... ,.,.... .... ..,.. ,....... .,.,.,..

Truck Frame ::::::::::::::::: ::::::::::::::::: ::::::::::::::::: :jj j:i:jj:: ::::::::::::::::: i;;;;>:;i;;;;;;;; .y>;:::::,::: .:~l.,\di:;j .....

SM-587

Planned Maintenance Procedures j-

Air Clean Caster Wheel & Brake

.

Blow off the caster wheel assembly.

.

Checkforobviousdamageandsecurityofmounting.

.

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 cylinder, spring and linkage.

.

Inspect brake cylinder and lines for leakage.

.

Check the brake spring, linkage and cylinder for damage and security of mounting.

Fasteners
k. Check Brake Sm-iw Len&h l

l

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. Using wrench, turn nut (1) against washer until 2-l/4” (57.2mm) can be measured between inside of one washer to the inside of opposite washer. 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 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Planned Maintenance Procedures AdiustinP for LininP Wear Lining Wear Check

When to ReDlace Brake Lininps

Brake

As brake linings wear, the brake arm will move 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 securely. 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-

.-

Make certain retainer plate is properly located against the brake line fitting. Make certain the retainer plate is tightly secured to the axle frame.

b_

\

-

Fa

Dee 94

PM-l 6

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

SM-587

Planned Maintenance Procedures .

l

Check Caster (Stabilizer) Installation for loose Trunnion Bearinas, Try to move the caster assembly up and down and check for side to side movement. If the bearings appear to be loose, they should be inspected for damage and proper adjustment( Refer to Group 01 for lubrication specifications.) If bearings appear to be fit for further service, then adjust the pivot (trnnnion) bearings as outlined here.

Adjustment l

-

%323 &

M-

IMPORTANT

Lock Nut

Be sure the lock nut is installed with the chamfer side (UP) away from bearing.

Lock Washer l

M-

Unlock bearing lock nut.

Thrust Washer l

_

Grease Shield

+-

bearing Cone Bearing Cup Axle Frame

Using a torque wrench, torque nut to 30 lb.ft. (40.7 N*m). Next, rotatecaster assembly at least two (2) full revolutions. Now, retorque nut to 30 lb.ft. Reneat nrocedure until toraue is stabilized at 30 Ib.ft. (40.7 Nom).

IMPORTANT The above procedure must be repeated until bearing preload is stabilized (you can no longer turn the nutlat the 30 Ib.ft. torque. Once this has beenaccomplished, tighten the lock nut (do not back off nut) to the next available locking tab. Lock the nut in place with washer locking tab. NOTE

Thrust Bearing

Check, adjust and lubricate axle trunnion bearings every “P.M.“. Refer to Lubrication in Group 01.

Mounting Spindle

SM-587

Copyrighted Material PM-l 7 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Planned Maintenance Procedures Hvdraulic Comnartmen$ l

l

l

l

l

Blow off the valves, pump and motor. horn, and steering sensor. Air clean the complete compartment. Blow off the filter, sump tank and hydraulic lines. Be sure area around the sump breather fill cap is clean. Clean area around the fluid level indicator. Visually inspect hydraulic hoses and clamps for damage, leakage and security of mounting. Tighten loose clamps and/or fittings. Note any damage on the P.M. Check List.

Valve & Lines

Puma Motor l

If the motor is equipped with a brush cover, remove the cover.

l

Remove the brushes and inspect them for wear. Refer to the Brush Inspection Chart in Group 16.

l

Inspect commutator bars for “bridging” dust (copper material) while slowly rotating armature. If bridging exists, gently remove the bridging dust using a sharp pointed tool such as a scribe or ground off hacksaw blade. Air clean the commutator after removing bridges.

l

Reinstall brushes and brush cover (if applicable).

l

Record commutator condition and brush lengths on the P.M. Check List.

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

Dee 94

PM-l 8

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

SM-587

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). Debris removed with air pressure can cause injury.

Switches

Electrical Controls ComDartment.

Jeer

.

Completely air clean the compartment floor.

.

Blow off the contactor panel, contactor tips wiring and cables.

.

Blow off the control cards, capacitors and th steer control box.

.

Air clean the Multi-Function Control Handle switches, transducer, wiring, switches and harm ness.

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

Planned Maintenance Procedures Umight .

Blow off the safety screen (or glass), upright chains, lift cylinders and carriage.

.

Check screen/shield for security of mounting.

.

Air clean the packing glands on all cylinders.

.

Air clean the pantograph, valves and piping.

.

Air clean the cylinders and piston rods.

.

Blow off the piston rods.

.

Check rods and glands for obvious damage, nicks, marring, scratches that might damage the cylinder packings. Checkcondition of hydraulic plumbing and connections. Tighten connections if loose. If the cylinders are leaking or rods are damaged note condition on the P.M. Check List.

*

Check lift chains for damage.

.

Check the chain anchor pins (7). Be sure the cotter pins (6) are in place and not damaged.

.

Examine the hydraulic plumbing and connections (5). Tighten loose connections.

.

Check rods and glands for obvious damage, nicks, marring, scratches that might damage the cylinder packings. Checkcondition of hydraulic plumbing and connections. Tighten connections if loose. If the cylinders am leaking or rods are damaged note condition on the P.M. Check List.

.

Check theharness hold-down clamps (4), brackets (2), andconnectors (3) for security of mounting and damage.

l

1

Note condition on P.M. Check List. 1. Fastener 2. Bracket 3. Connector 4.

Clamp

5. Fitting 6. Cotter Pin 7.

Chain Anchor Pin

Dee 94

PM-20

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

SM-587

Planned Maintenance Procedures l

l

Inspect condition of fork retainment pins. 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 condition.

f4-

Retainment Pin Snap Ring

Fork RetainmentPin

+

SM-587

Copyrighted Material PM-21 Intended for CLARK dealers only Do not sell or distribute

Fork

Dee 94

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 illustration above); one set for carriage free lift and one set for inner rail lift.. l

l

anchors at the base of the Inner Rail Assembly (see above). The Inner Rail Lift Chains are routed over Sheaves (C) attached to the Intermediate Rail Assembly. As the Rail Lift Cylinders extend the Intermediate Rail elevates thus the lift chains routed over Sheaves (C) elevate the Inner Rail Assembly.

Adjustment Chain Anchors (Al, located at the back of the Free Lift Cylinder are used to adjust the carriage lift chains. These chains attach to chain anchors at the base of the lift carriage. The carriage chain anchors are not adjustable. Adiustment Chain Anchors (B), located at the back of the Outer Rail Assembly are used to adjust Inner Rail Lift Chains attached to chain

Dee 94

PM-22

l

AllLiftChainsmustbeadjustedtoproperlength and equal tension as outlined on the following pages.

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

SM-587

Planned Maintenance Procedures A CAUTION Never tighten Chain Anchor against weldment. To do so will result in chain carnage. Chain Anchors must be free to pivot in their mounting holes at all times.

Chain Anchor

Maintain Freedom of Movement All Chain Anchors must be free

Weldment

allowing their Spherical Bushings to self align in the machined surface of their anchor weldments. This helps prevent chain “twist” and excessive chain stress that eventually results in chain damage.

Chain Lubrication The most important consideration in field maintenance of lift chains is lubrication. Hard-working, heavily-loaded chains cannot give acceptable wear life without periodic lubrication. As with all bearing surfaces, the joint-wearing surfaces need a layer of oil between mating parts to prevent wear. Keeping a layer of oil on all chain surfaces will: Keep joint wear (chain wear) to a minimum. Prevent or reduce the rate of corrosion. Reduce the chance of pin turning. Keep tight joint in chains to a minium number. Help give smooth, quiet chain action. Lower the chain tension by reducing internal friction in the chain. Use Clark Chain and Cable Lubricant, uart number 886399, for lubrication of chains. Heavy motor oil is also a very good lubricant. The lubricant will penetrate into the chain joint to prevent wear. Applying lubricant to external surfaces willpreventrust, but the lubricant must flow into the bearing surfaces for maximum chain life. SM-587

Spherical Bushing

The frequency of lubrication will change with the operation conditions and the environment. The best lubrication time is during each P.M. (50-250 hours or four weeks maximum actual truck operating time). Trucks that are parked outdoors or in very severe service may need lubrication more often to keep a layer of oil on all chain surfaces. In dirty operating conditions, lubricated chains will gather dirt. Even under these conditions, chain life will be increased by periodic lubrication. Joints get a “paste”of oil and dirt, but joint wear will still be much less than if the chain is permitted to operate dry with metal-to-metal contact between pins and plates (pin and bushing in roller chain). In dirty operating conditions, leaf chain can be more easily lubricated than roller and rollerless chain. The plates in leaf chain give more paths for the lubricant __ . to reach the pin. At every P.M. or four week intervals, clean the chains in a Stoddard type cleaning solvent to remove dirt. Lubricate immediately after the chain is dry. Steam cleaning is not recommended because some clean-

ing solutions contain chemicals which can cause linkplates to crack.

Copyrighted Material PM-23 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Planned Maintenance Procedures Lift Chain Adjustment

Step 2: Adjustment Procedure 1. Loosen jam nut on each chain anchor.

Step 1: Adjustment Check l

l

With the upright fully lowered, check to see if the inner rails protrude l/8 inch above the intermediate rails (both sides).

2. Rotate chain adjustor nut on each chain anchor the same number of turns to position the Inner Rail l/g-inch above the Intermediate Rail.

If they do, check tension of both chains on the longest span. Chain tension should be the same.

3. After completing adjustment, check for equal chain tension ... they should be the same. If not, make a minor adjustment to the chain that has the least tension.

If the above checks are as specified, the Inner Rail Chains do not require adjustment. Check the carriage chains as outlined on the following

4. Finger tighten jam nuts against chain adjustor nuts. Make sure the chains are not twisted and torque jam nuts as instructed in illustration below. Again, check to be sure chains are straight and not twisted.

page. If any one of the above checks are not as specified, adjust the chains as instructed on this page.

Chain Tension should be the same for each chain. You can “feel” chain tension by pushing on each chain by hand. + Spherical Bushing + Chain Adjustor Nut + Jam Nut 4-b

Dee94

PM-24

Torque Specifications Using two wrenches, a torque wrench on the Jam Nut and a second wrench to hold the Chain Adjustor Nut, (A third wrench on the chain anchor is helpful) . .. Torque Jam Nut to: 100 - 200 N*m (74 - 148 Ib.ft.)

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

SM-587

Planned Maintenance Procedures Carriage Chains

Step 4: Adjustment Procedure 1. Loosen jam nut on each chain anchor.

Step 3: Adjustment Check l

l

l

With the upright fully lowered and the pantograph fully retracted, check to see if there is l/2inch clearance between the heel of the forks and the floor, see insert below. Check both forks.

2. Rotate chain adjustor nut on each chain anchor the same number of turns until there is l/2-inch clearance between forks and floor, see illustration insert below.

Ifclearance is as specified, check tension of both chains on the longest span. Chain tension should be the same.

3. Once the l/2-inch clearance has been accomplished, check for equal chain tension ... they should be the same. If not, make a minor adjustment to the chain that has the least tension.

If the above checks are as specified, follow the carriage instructions outlined in Step 5 on the next page. If any one of the above checks are not as specified, adjust the chains as instructed on this page and then continue to Step 6 on the next page.

u

w

4. Finger tighten jam nuts against chain adjustor nuts . Make sure the chains are not twisted and then torque the nuts as instructed in the illustration below. Again, check to be sure chains are straight and not twisted.

Chain Anchor + Spherical Bushing o + Chain Adjustor Nut 8 0 + Jam Nut 4-k Toraue Soecifications f&a [ Using two wrenches, a torque wrench on the Jam Nut and a second wrench Lift Chains connect to to hold the Chain Adjustor Nut, (A Pantograph Carriage. third wrench on the chain anchor is helpful) ... Torque Jam Nut to: 100 - 200 Nom (74 - 148 Ib.ft.)

SM-587

Copyrighted Material PM-25 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Planned Maintenance Procedures IMPORTANT

Carriage Stop - to - Upright Stop

The carriage stop must not be allowed to contact the upright rail stop under any circumstances during normal operation.

Step 5: Adjustment Check

A

CAUTION

Step 6: Adjustment Procedure

Make sure there is adequate overhead clearance.

Loosen jam nut on each chain anchor.

Elevate upright to maximum fork height. Check to see if there is clearance between the “stop” weldment on the Inner Rail and the “stop” weldment on the Pantograph Carriage. For location of these stops, see illustration below. There must be some clearance ... approximately 15 mm (S9 inch) ... between these stops.

Rotate chain adjustor nut on each chain anchor the same number of turns until there is l/8- inch clearance between these stops. Adjust no more than necessary to provide this clearance. Now, torque jam nuts as previously described. Again, check to be sure chains are straight and not twisted.

If the carriage stop contacts the rail stop, adjust chain anchors as outlined in next column .

Carriage stops must not make contact when upright is elevated fork height.

to

maximum

l/O

Chain Anchor + Spherical Bushing + Chain Adjustor Nut + Jam Nut 4-k

Dee 94

Toraue Specifications Using two wrenches, a torque wrench on the Jam Nut and a second wrench to hold the Chain Adjustor Nut, (A third wrench on the chain anchor is helpful) ... Torque Jam Nut to: 100 - 200 Nom (74 - 148 Ib.ft.)

PM-26 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Planned Maintenance

Procedures

1. use nrotectivelubrication fluid. Clark Part Number 1803827. to coat terminals of followirw 111119s; l

EV-T15’

A,B,Y and 2 Plugs (OSC or Traction Control Card)

l

EV-TSPS

‘PL4 Plug

l

DashDisplay

l

Plug

-

PL - DP Plug

Key SwitchTerminals

-

Wire Spades 10 & 1OC and 12 & 12B

l

HornTerminals

-

Wire Terminals 13 (or 13B) and 26

l

Relay Terminals (for optional equipment only)

2. Check Contactor Tips for the following: l

Cleanliness

l

Wear

l

Metal transfer between stationary and movable tips.

3. Check Harness/Cable/Fuse Connections for securitv of mounting and condition of terminals, l

Check for frayed/broken cable strands at terminal crimp, see below.

l

Check for oxidation (white/blue) and discoloration of cable edge on terminal barrel end. This reflects high resistance joint

Broken Wires

Badly Damaged Casing

Cables having small cuts may be repaired with electrical tape. l

Cables having damage as shown above should be removed immediately and replaced with new. Be certain the replacement cable is the exact same length, size and has the proper connector. Make absolutely certain the cable endisproperly crimped anditsconnectionproperly torqued during installation. Every cable and wiring harness on this track is manufactured to an exact specification. A shorter cable or harness willnotfit. If either a harness or cable is routed improperly, it will not$t. Electrical shorts and damaged components may result if the replacement part is the wrong one, or if it is routed incorrectly.

SM-587

4. Check for Grounds l

Meter should register 20,000 ohmsor greater when measured between truck frame and any battery connector terminal.

l

Meter should register 20,000 ohms or greater when measured between any EV-T15 control power terminal and truck frame.

l

Meter should register 20,000 ohms or greater when measured between any EV-TSPS control power terminal and truck frame.

5. Brake Insuection l

Every P.M. check for brake lining wear and adjust, if necessary. Refer to next page.

Copyrighted Material PM-27 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Planned Maintenance

Procedures Notice: AS Brake Linings Wear: l Brake Arm & Rod move inward. 9 Pressure Spring Length increases.

To Adjust for Lining Wear: l

loosen nut (I), as shown.

Nuts are used only at time of new lining Refer to Group 23. -

Rotate Nut (2) inward against the brake arm and continue to tighten (T/T& moves the actuating rod outward compressing the spring.) nut until . . .

_

. . . specified spring length is obtained. l Hand tighten nut (1) against brake arm without rotating the rod. l Using two wrenches, tighten nut (1) while holding nut (2) to secure adjustment. Make certain nuts

l

are tight without disturbing the spring “preload” adjustment.

INSTALL NEW BRAKE LININGS when the brake arm moves to within l/8inch of the boot.

Brake Cylinder A-+Dee 94

PM-28

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

SM-587

Planned Maintenance

Procedures

Every 1,000 Operating Hours Check and Adiust the Followina: l

Forward & Reverses Switches

l

Lift & Lower Switches

l

Transducer

Multi-Function

NOTE RefertoGroup 19,Section 7ofthismanualforspecific procedures.

Reverse Switch

Forward Switch

Transducer

&I Lubrication Refer to Lubrication

0

J

Chart(s) in

Grow 01. Section 1 for all reauired lubrication Doin@ and fluids,

N-

<-

Upright & Pantograph

Hose Sheaves Lift Chains

Control Handle Gears & Spring

Breather,

Steer Shaft & U-Joints

Hydraulic Filter 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 Intended for CLARK dealers only Do not sell or distribute

Dee 94

CLARKM$z;-ia;Handling

GROUP01 Section 1

Lubrication Chart & Illustrations

NPR-345

Lube Chart& Specifications

SM-587

Copyrighted Material 01-1-l Intended for CLARK dealers only Do not sell or distribute

Dee 94

Lubrication

GROUP 01 Lubrication Chart Key

L18l L2 NLGI #I Grade Clark Spec. MS-107B

L3 NLGI #2 Grade

‘Ir

General Purpose Grease with EP additive

Clark Spec. MS-107C

L4 NLGI #2 Grade

General Purpose Grease with EP and Moly additives

Clark Spec. MS-107D

Cold Storage Applications

w Temp Grease ML-G-23827A

L5

MOCO loo0

@ L6

AMOCO 1000 or equivalent Clark Part No. 886399

A multi-purpose grease of refined mineral oil blended with a lithium soap thickener or equal containing anti-wear, anti-rust and anti-oxidants with EP additives, per Clark Specification MS107. A multi-purpose grease of refined mineral oil blended with a lithium soap thickener or equal containing anti-wearanti-rustandanti-oxidants with EP and, 3 to 5% moly additives. A smooth high quality grease of refined mineral oilbase with a lithium soap thickener or equal compounded with corrosion and oxidation inhibitors and containing 1 to 3% moly (molybdenum disulfide) NLGI #2. Drive Unit Crankcase: Drain when oil is at operating temperature.

Chain & Cable Lubricant

B Clark Part No. 885385

l-case of 24 one qt. cans

L7

Clark Part No. 885382 l-caseof 6 one gal. cans Hydraulic Fluid

Cold Storage Applications

Royce 717 or equivalent

::+.,. m:: ::::::::::::::::::::::: ‘.:.:::::::::::,:.~

Ef?I

MIL-F-17111

Hydraulic Fluid

L8 L9 Special Grease

Dee 94

DOT 3

Acheson Gredag 2230 Dow Coming Assy Paste Texaco Texclad 2 or equivalent

Use only high quality hydraulic fluid with Zinc or equivalent Anti-Wear additive which meets the requirements of ASTM D-2882 pump wear test with 50 mg total weight loss maximum per Clark Spec. MS-68

A straw colored hydraulic fluid composed of a blend of highly refined hydrofined mineral oils and additives to impart resistance to oxidation, corrosion, and rusting and to afford greater lubricityandimprovedviscosity-temperaturecharacteristics. Fluid must meet M&F-1711 1. Brake Fluid, Grade DOT 3, as specified by Federal MotorVehicle Safety StandardNo. 116.

A specially formulated (tacky) grease with excellent adherence capabilities.

01-l-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 01

Lubrication Chart

Lube Key Chart

Caster Brake Linkage: Lubricate with engine oil at every PM Brake Inspection. Note Lubricate length of rails at point of “roller Contact” first P.M. only on new trucks.

LL

= Lubricate each time a Load Wheel is replaced or squeaking

occurs. Pack each time the Caster Wheel is replaced. SM-587

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

GROUP 01

Lubrication - Cold Storage & Standard Applications

Every P.M. (250 operating hours maximum) Corrosion Protection Mechanical Paste Lubricant

Using Clark Part No. 2802205 apply to the following Power Cable and Screw-On type wire connections:

r

A,pply to electrical CC 2nnections

All Power Cable ConnectionS l

All Motor Cable Connections.

l

All Control Panel Cable Connections.

any time ley are disconected. Note: Reaulybeforemakinrrthe Dnnection.

All Screw-On Tme Wire Terminals l

All Card retainer screws.

l

Motor Ground Wire (both ends), see below.

l

Reverse Alarm (if so equipped).

l

Strobe Light Connections (if so equipped).

Ground Wire Apply to wire connections any time they are disconnected. Note: ReaDplybeforemakingthe

Dee 94

-

c;I Pump Motor

c

01-l-4

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

SM-587

Lubrication - Cold Storage & Standard Applications

GROUP 01

Every P.M. (250 operating hours maximum) Corrosion Protection Mechanical Lubricant Using Clark Part No. 1803827spray the following: Contactor Panel.

General Note

l

for

l

Drive Control (EV-T15).

l

Steer Control (EV-TSPS).

l

PL and DP plug connections.

Part Numbers:

IMPORTANT Avoid direct spraying on contactor tips. l

Power Cable Connections. A

CAUTION

1803827& 2802295. Apply to electrical connections any time they are disconnected. Note: Reauplvbeforemakinethe connection.

Do not spray motor brushes and commutator. motor openings spraying. l

Cover all prior to

Wire Terminal Screws includinp the follow&

Control Card (1) and Control Card (2). Brake Switch terminals. Steer Interlock Switch on contactor panel. Speed Limit Switch mounted on outer rail tie bar. Switch cover must be removedfor access to screw terminals. l

Push-On Connectors should be snravedt l

Horn terminals

l

Key Switch terminals.

l

Heater Thermostat (Cold Storage). Them0 stat located on contactorpanel.

Electrical Options (Spray all connections). l

Forward Pointing Head Lights (terminals).

l

Strobe Light (terminals)

l

Reverse Alarm terminals (if applicable).

l

Any and all switches used on the option(s).

SM-587

Aux. Motor

Copyrighted Material 01-l-5 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Lubrication - Cold Storage

GROUP 01

COLD STORAGE LUBRICATION Every P.M. (250 operating hours maximum) Apply Anti-Corrosion Spray Clark Part No. 2794748 to the following:

Reach and Tilt Cylinder Rod Ends

l

(spray threaded area only). See below. l

Motor brake adjustment linkages, springs and bleeder screw (donot spray directly into the bleeder screw). See

‘Threaded Areas”

l

Dowel Pin Retainers on pantograph. There are nine (9) pins total.

l

Caster brake adjustment linkages, springs and bleeder screw (do not spray directly into the bleeder screw). See above.

Dee 94

01-l-6

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

SM-587

Lubrication

- Cold Storage

GROUP 01

COLD STORAGE LUBRICATION Hydraulic

Sump Tank

Specifications: Use Hydratic .

\

I

Fluid which meets ML-F- 17 111. (Royce 7 17 or equivalent)

A straw colored hydraulic fluid composed of a blend of highly refined hydrofined mineral oils and additives to impart resistance to oxidation, corrosion, and rusting and to afford greater lubricity and improved viscosity-temperature characteristics. r -

3

B , \ -T-

Grease Fittings Sr>ecifications: Use an extreme low temperature aircraft quality grease meeting ML-G-23827A, product. Temperature range: - 100 to +250”F.

Refer to Lubrication

or equivalent

Chart on Page 3

for remainder of instructions

SM-587

and time intervals.

Copyrighted Material 01-l-7 Intended for CLARK dealers only Do not sell or distribute

Dee 94

GROUP 12 SECTION 1 Battery Contents Battery Service Area ..................................................................

12-1-3 & 4

Handling Storage Batteries ........................................................

12-1-3 & 4

Battery Removal & Installation .........................................................

12-1-5

Battery Maintenance .........................................................................

12-1-6

Battery Installation ...........................................................................

12-1-7

Battery Records ................................................................................

12-1-8

, .... ‘,

BATTERY SERVICE

/

(....i .- .._.___ _ :::;.y

nnrr

;Y’

‘L.

I’..

~.

._._., ,<“\

“-.&.._..~.-;..’ -.

Y\

‘,.,

D

Remove all jewelery before working on the truck

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

Dee 94

GROUP 12

BAllERY

A

WARNING

SULFURIC

THE BATTERY CONTAINS

ACID

CORROSIVE

ACID WHICH CAN YOUR EYES OR SKIN, WITH WATER AND GET MEDICAL

CAUSE INJURY. IF ACID CONTACTS

FLUSH IMMEDIATELY

ASSISTANCE.

Disconnect battery before handling electrical components. Polarity must be correct to prevent damage.

1147748

l

l

A WARNING Electric truck batteries are heavy and awkward to handle. On charge, they give off hydrogen and oxygen which, in certain concentrations, are explosive. Electric truck batteries are also costly, so before you remove, service, or install a truck battery, consult BATTERY MANUFACTURER, for more recommendations and instructions on handling and charging batteries. Carefully read and follow recommendations and instructions.

Dee 94

12-l -2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 12

BAmERY BATTERY HANDLING Change or service batteries only in an area designated for this purpose. l

l

l

-..__.+ Wash Stand A&.

Fire Extinguishe ------4

Be sure this area has provisions to flush and neutralize acid spillage. Be certain the area has proper ventilation to ventilate fumes from gassing batteries. Check to see that there is fire protection. Fire extinguishers should be properly maintained and located in designated areas.

A

DANGER

Explosive gas is always present around batteries, especially when they are being charged. The following should be adhered to. l

l

l

No smoking shall be allowed in the charging area. Battery electrolyte shall never be checked with an open flame. Open flame, sparks, or electric arcs shall never be allowed in the battery charging area.

Persons maintaining storage batteries must wearprotective clothing such as: l

Face and head shields

l

Long shirt sleeves.

l

Gaunlet gloves.

A

WARNING - SULFURIC ACID

THE BAlTERY

CONTAINS CORROSIVE ACID WHICH CAN CAUSE INJURY. IF ACID CONTACTS YOUR EYES OR SKIN, FLUSH IMMEDIATELY WITH WATER AND GET MEDICAL ASSISTANCE.

SM-587

Copyrighted Material 12-1-3 Intended for CLARK dealers only Do not sell or distribute

Dee 94

GROUP 12

BATTERY

Be sure the battery service area is equipped with material handling equipment designed for the purpose of removing and replacing batteries, such as a conveyer or overhead hoist equipped with safety hooks l

Overhead

Hoist

-

Safetv

Hook

/

When using an overhead hoist, be sure to use an insulated spreader bar or similar lifting device.

To prevent side forcesfrom damaging the battery, the distance between the lifting hooks (of the spreader bar) must be adjusted to the same dimension as between the battery lijiting eyes. Make sure the lifting hooks are the correct size tofit the lifting eyes of the battery. l

l

Be sure the hoist is equipped with a chain container to accumulate excess lifting chain. When this is not possible, be sure the battery is covered as shown below.

If the battery does not have a cover of its own, cover it with a non-conductive material such as

sulated Spreader Bar

Typical lllustratior

Plyw~ (Non-Conductive

Cover)

plywood-

Typical Illustration

*

Never lay tools or other metal objects on a battery. Metal objects contacting battery terminals will cause short circuits. The shorted circuits could ignite battery fumes and cause the battery to explode.

Dee 94

12-1-4

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

Typical Illustration

SM-587

GROUP 12

BATTERY Battery Removal

Key Switch Off

Brake Applied

1. Move truck to the designated battery service area. 2. Turn key switch OFJ? and disconnect battery.

Battery Disconnected .

3. Remove battery retainer plate.

Removing

4. The battery must be pushed out of the compartment. A recommended method of handling the battery is to use a platform equipped with rollers similar to the one shown in opposite illustration. l

Battery

Remove Battery Retainer Push Battery onto Platform

If the battery to be handled is uncovered, cover battery with a non-conducting material (plywood, heavy cardboard, etc.) prior to removal from truck. NOTE

Do not wash battery in truck. 5. Once the battery is out of the truck, a lifting device equipped with an insulated spreader bar and safety hook(s) can be used to transport battery. Be sure battery is covered prior to

Transporting Battery

attaching lifting device. l

Chain/ Container

An overhead hoist (of sufficient lifting capacity,

4

I

refer to “Weights” in Group 40) should be used to lift battery. The safety hooks of the insulated spreader bar should be attached to the lifting eyes provided in the battery casing. Insulated Spreader Bar

Uncovered

Batteries:

Cover With

FVywood or Heavy Cardboard

---I=

../.... lad :A

=

---_

-_

-

-ze

L

SM-587

Copyrighted Material 12-l -5 Intended for CLARK dealers only Do not sell or distribute

Dee 94

BATTERY

GROUP 12 Battery Vents l

l

When ChargingBatteries:Theventcapsmust be kept in place to avoid electrolyte spray. Care must be taken to assure that vent caps are functioning. The cap vents must be open to allow the battery to breath. The battery cover must be removed/opened to dissipate heat and explosive gas. When Cleaning Batteries: The vents must be tightly in place.

Battery Cleaning The easiest and most satisfactory method of cleaning a battery is to wash it with a low pressure cold water spray. The battery top can also be washed with a baking soda solution and rinsed with clear water. l

l

Check to be sure all vent caps are tight before washing the battery. Fill a bucket with cold water while adding a box of baking soda to the pail. Stir the solution until dissolved. It is advisable to have this solution around the battery service area at all times.

IMPORTANT Vent Caps must be free of obstruction

and in good condition

Battery top should be clean and free of cracks or breaks. Battery terminals must be clean and solidly mounted. Damaged batteries should be repair or replaced.

l

After washing battery, thoroughly rinse with clear cold water.

Consult

your battery vendor.

Battery Charging Follow theinstructions suppliedby theBattery Charger Vendor.

Battery Electrolyte l

l

Always use a carboy tilter or siphon when handling battery electrolyte.

I

Battery Maintenance To obtain maximum performance and battery life, the instructions supplied by your Battery Vendor should be adhered to.

When mixing electrolyte, always pour acid into water - never pour water into acid. Pouring water into acid will cause a dangerous chemical action.

Dee 94

12-l -6 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 12

BATTERY Clean Battery Compartment l

Using baking soda and water solution, clean the walls and floor of the compartment. Rinse with clear water.

A

Clean Battery Compartment

WARNING

Wear eye protection and protectiveclothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury. l

Blow off the compartment walls and floor with an air hose. Allow to air dry.

REPLACEMENT BAlTERlES

-

Air Hose

1

-

Fl sawa .P,...

“::,..

&

Water Solution

Cautionshould beexercised to use a battery properly sized to the dimensions of the battery compartment. Batteries too small can shift and cause damage to thetruckor injury to the operator or bystanders. For the NPR 17 a minimum battery size of 38.69 x 13.00x 31.50 inches (982,7 x 330,2x 800,l mm) and aminimumweightof 1185lbs.(537,5kg)isrequired. For the NPR 22 a minimum battery size of 38.69 x 15.75 x 3 1.50 inches (982,7 x 400,O x 800,l mm) and aminimumweightof 14OOlbs. (635,Okg)isrequired.

Install Battery If the battery is uncovered, cover the battery with a non-conducting material (i.e.., plywood, heavy cardboard, etc.) prior to installation. l

Push battery into battery compartment.

l

Install battery retainer.

l

Remove non-conductive material from battery.

l

Connect battery to truck.

SM-587

Copyrighted Material 12-1-7 Intended for CLARK dealers only Do not sell or distribute

Dee 94

GROUP 12

BATTERY

KEEPING BAlTERY RECORDS

BAllERlES

Records should be kept to get the best service out of your battery and truck.

Industrial Batteries are used to supply the electrical power to operate an Electric Industrial Truck. Their voltage depends on the number of individual cells they contain. There are approximately 2 volts for each cell in the commonly used lead-acid type battery. Batteries normally range from 6 volts to 72 volts. Their capacity varies depending on the application.

These records should contain: l

Test Date. Each test should be dated for future reference and comparison.

l

Specific Gravity

and Temperature readings.

Each battery cell should be checked and recorded before and after charging. The specific gravity reading of the electrolyte should not be less than 1.260. If below 1.250, the battery should be recharged and tested. l

Only use batteries that comply withfactory tions as to size and capacity and weight.

HOW TO GET MAXIMUM LIFE OUT OF YOUR BAITERY .

Do not add acid to a battery. Only qualified Battery Representatives should determine ijlhis is necessary.

.

When lifting a battery, use a lifting device designed for this purpose

.

Check the electrolyte level before placing a battery on charge. Add water, if required, before charging the battery. The electrolyte level in a battery should be slightly below the lower lip of the filling hole vent. Do not over fill. Over flushing causes loss of electrolyte.

.

Keep the battery clean, dry and in good condition.

.

actual time the battery is on charge. After each charge, check to see if the battery is fully charged. Test the battery before placing it back into service. Record these results.

Keep metal objects and tools away from the top of the battery. Short circuits will cause battery damage and could ignite battery fumes, exploding the battery.

.

Maintain good battery cable connections.

.

Check power cables and wiring for damage.

Visually Inspect for loose terminal connec-

.

Do not over charge a battery.

.

Do not under charge a battery.

.

Follow the instructions provided by your supplier(s) of the battery and battery charging equipment.

.

Maintain accurate battery records. If battery troubles occur, these records will help you and your battery representative determine the nature of the problem.

Variation between each cell tested. The variation in specific gravity reading between cells should not be greater than 15 points (.015). If readings are greater, this indicates there are defective cells.

Thepilotcellshould be changed occasionally to distribute any electrolyte loss over the battery when taking readings. l

l

Load Voltage Tests should be performed and recorded indicating the condition of a battery while it is performing work. Actual Operating hoursof the battery.Record the actual time the battery is in use before putting it on charge..

l

l

spec@ica-

Charging Time. Keep an accuraterecordof the

tions or posts, a cracked case, or damaged cell vent caps and excessive corrosion. This data should be noted to help ascertain work environment and possible trouble areas. For further information, refer to Croup 19, Section 4 in this manual. Check with your local battery supplier for complete battery maintenance procedures and their expertise.

Dee 94

12-1-8

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

SM-587

GROUP 13 Section 1 Multi-Function Control Handle Switches Contents Reach, Tilt and Auxiliary Switches, Remove and Replace . .. .. . .. . .. .. .. .. . 13-l-2 Lift and Lower Switches, Remove and Replace . ... . .. .. .. .. .. .. .. .. .. ... . .. .. .. 13-1-3 Transducer; Forward and Reverse Switches, Remove and Replace..... 13-1-4

Switch Side) -)Q’

PL-9

so-i0 Transduce-

so-7

\\>

Harness

sq7

Lift/Lower Switch

SM-587

~,

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

Dee 94

Reach, Tilt & Aux. Switches

GROUP 13 REACH, TILT AND AUXILIARY SWITCHES Switch Remove & Replace These switches (1) are located in a separate housing within the control handle. The handle grip has two halves (switch side and heel side). Switch Removal 1. Remove fasteners (2 & 3), see opposite illustration. 2. Remove inner fasteners (4 & 5). 3. Pull harness wires free of their retainer slots in

handle (heel side). 3. Remove switch housing (6) from handle. 4. Provide some wire slack in the housing before

removing a switch. 5. Pull switch from housing. 6. Remove wires from switch connections.

switch Installation 1. Connect wires to the new switch and install switch into plastic housing.

Multi-Function

Control

2. Carefully pull wires “taugt” but not so tight as to

cause damage to the connections. Place housing into handle (heel side).

... using a “blunt” instrument so as not to damage wire insulation.

3. Carefully push wires into their retainer slots ...

4. Assemble handle being certain to tighten fasteners (2) thru (3) securely.

IMPORTANT Connector Plugs and Receptacles are permanently labeled with the proper PL (Plug) and SO (Socket/Receptacle) number for easy identification. A

CAUTION

If disconnected,

match plug number with appropriate receptacle number before making a connection. If not, electrical shorts and possible damage to equipment may result. i.e., Plug #PL-6 plugs into pin socket ##SO-6,etc. Clamps, Cable Guides and Marking Tapes: IMPORTANT Cables must be positioned so all tape markers are aligned with or hidden under clamps or guides.

Dee 94

13-1-2

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

SM-587

Switches

GROUP 13

UP (LIFT) AND DOWN (LOWER) SWITCHES Switch Remove & Replace These adjustable switches control lift and lower functions of the upright and are mounted to a bracket on the left side of the handle bracket. See opposite illustration.

witch

switch Removal. 1. Remove cam fastener, washer and cam. See illustration below. 2. Disconnect switch (to be removed) from the wire harness. 3. Remove fasteners securing switch and switch adjustor to bracket. 4. Remove switch adjustor bolt, both lock washers, spring, and switch adjustor. Remove switch.

/

Adjustor Bolt

Installation 1. Install new switch assembly and route wires as illustrated below and on Page 4. 2. Connect switch harness assembly Socket SO-7 to main wire harness Plug PL-7. See Page 1. 3. Refer toGROUP 19, Section7 for switch adjustment procedures.

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

Switches

GROUP 13

-#‘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

Dee 94

under

13-l-4

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

SM-587

Transducer, F & R Switches TRANSDUCER, FORWARD AND SWITCHES Forward and Reverse Switch Remove & Replace Two adjustable switches mounted

to a bracket at the rear of the multi-function control provide forward and reverse direction of travel. A transducer and adjustor plate are attached to a mounting plate at the rear of the control. The transducer provides variable speed control.

Switch Removal l

l

l

GROUP 13 Transducer Installation l

l

l

l

Install new transducer to the transducer plate. Install transducer and transducer plate assembly to bracket. Route the transducer’s wire assembly through the clamp and securely fasten the socket clamp as shown in illustration on page 1. Connect transducer harness Socket SO- 10 to the main wire harness Plug PL-10. Refer to GROUP 19, Section 7 for switch and transducer adjustment procedures.

Disconnect switch harness assembly Plug PL-8 (to be removed) from the main wire harness Socket SO-8. Refer to illustration on page 1. Remove clamp screw and remove the transducer clamp assembly harness from the clamp. Remove adjustor screw and lock washer securing the switches, switch adjustors, lock washers and springs to the switch bracket.

Switch Installation l

Installnew switch, switch adjustors, lock washers and springs in the reverser order of removal. Secure the sub-assembly with adjustor screw(s) and lock washer(s).

l

l

Route switch wires as shown in illustrations on Page 1 and Page 4. Connect switch harness assembly Plug PL-8 to main wire harness Socket SO-8.

Transducer

Remove & Replace

Transducer Removal l

l

l

l

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

SM-587

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

Dee 94

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 Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 16

A

Motors

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 working on truck.

before

::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: ..:.:.:.:.:.:.:.:.:.:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::

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

..

Always wear Safety Glasses

DischargetheCaDacitorsbeforeworkinpontruck l

l

Discharge Capacitors

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 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 without using specified resistor could cause serious injury to yourself and bystanders.

SM-587

unplugged.

16-2-2

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

_

Dee 94

GROUP 16

Motors

Electric Motor Maintenance A planned maintenance program of regular, routine inspections is important for long life and troublefree operation of electric motors. Make and keep records of your inspections. Use these records to help establish correct P.M. intervals and to indicate maintenance required to prevent major problems from occurring during operation.

Inspection Procedures To perform these service procedures, mended that you first:

it is recom-

Motor Insulation

Park truck safely. Fully lower upright.

If a reduction in motor performance has been noted, it may be due to breakdown in motor insulation causing internal grounding or a short circuit.

Apply parking brake. Turn key switch OFF. Disconnect

The presence of any oil on or near motor could indicate either bad bearings or leaking hydraulic system. Determine cause and repair problem before extensive motor damage occurs.

battery from truck recepatacle.

Failures of motor insulation are due to: l

(1) contamination

l

(2) mechanical

l

(3) high temperatures

Discharge capacitors, see page 2.

Motdr Cleanliness Electric motors should be kept clean at all times to prevent shorting, minimize wear, and for best cooling.

l

l

l

Wipe off all dust, dirt, oil, water, etc., from outer surface of motor. Remove any debris from cooling air vents and around motor frame to prevent overheating. Air clean (blow out) open motors using clean, dry (moisture-free) compressed air at [207 kPa] 30 psi. maximum air pressure. Air clean all inner areas around commutator and brushes, including cooling air vents and fan. Wear safety glasses.

SM-587

factors

Contamination includes dirt, moisture, oily vapors, metal chips, carbon dust from brushes, etc. Mechanical factors include shock, vibration, over speed, etc. Operation at prolonged or excessively high temperature will cause insulation to become brittle and crack leading to premature failure. The insulation condition can be judged both visually and by test measurement. Regular, periodic measurements of insulation resistance can give a useful indication of the rate of insulation deterioration. A sudden drop or consistent trend toward low values of insulation resistance give evidence that insulation is deteriorating and that failure may be imminent.

16-2-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Motors

GROUP 16 TEST FOR MOTOR INSULATION “RESISTANCE TO GROUND” (Using a 500 Volt Megger) (Test must be made with motor out of truck). 1. Disconnect battery from truck receptacle.

TEST FOR MOTOR INSULATION “RESISTANCE TO GROUND” (Using a Simpson 260-6~ Volt-Ohmmeter or equivalent calibrated on the RxlO,OOOScale).This test may be made with motor in the truck. 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 one lead of a 500-volt megger to any motor terminal. NOTE: Test ALL terminals individually or by interconnecting with jumper wires. Connect other lead to motor frame. Apply voltage. 5. Resistance should be measure at least 1,OOO,OOO ohms (1 megohm). If less than this, motor should be air-cleaned or dried to attempt to increase insulation resistance.

4. Connect the positive lead of the VOM to all terminal studs of test motor. Use jumperwires to connectbetweenmotorterminals.ConnectVOM negative lead to motor frame. NOTE

Test all terminals individually, or joined together, as noted. 5. VOM must show 1,OOO,OOO ohms ( 1 megohm) 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

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

Dee 94

GROUP 16

Motors

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: or coloring

The surface of the commutator appearing rough, pitted, scored signs of burning or heavy arcing between bars. The pattern will be: .

Streaky film with commutator

.

Bar edge burning.

.

Uneven film.

.

Carbon dust bridging between bars

wear.

Different Grade Brushes; When the brushes being fitted are of a different grade from those used, then it is advisable to remove the film left grade brushes.

previously by the previous

This film removal should be done by scouring with a strip of abrasive cloth (do not use emery cloth) while the armature is rotating. Do not finish with a lapped, highly polished surface. A surface will help moderately abraded commutator the new brushes to run in and the commutator will acquire more readily the film appropriate to the new brush grade.

Operating Conditions Operating environment of lift truck motors varies widely: The following recommendations should be applied as actual conditions dictate. Normal Service: Basically an eightSevere Service: Extended operating hour day of indoor hours, or constant usmaterial handling. age. Extreme Service:

SM-587

Dusty or Sandy Locations

Flour Mills

Cement Plants

Coal Dust Areas

Lumber Mills

Stone-Crushing Areas

16-2-5 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

GROUP 16

Motors

General Brush & Commutator Inspection

7. Check brush shunt for good contact with brush holder. Be sure shunt is not damaged or burned since this may cause brush spring to carry current and lose tension.

1. Remove brush cover(s) and remove brushes from brush holders. Clean brushes and holders. Check brush holders for damage.

8. Clean and check brush box and connector screws. Tighten if loose. Be sure brush box shunt connection is tight.

2. Inspect condition of brushes. Remove each brush from brush holder and inspect brushes and commutator for worn condition and uneven wear.

9. If brushes do not need to be replaced, and commutator is in good condition, install brushes and brush springs into brush holders.

3. Clean commutator surface. Wipe commutator with a dry, lint-free cloth.

DO NOT USE LUBRICANT OR SOLVENT ON COMh4UlYATOR. 4.

Check appearance of commutator surface where brushes ride Inspect commutator bars for burned, damaged or raised areas. The best signs of good commutation are a dark brown highly-polished commutator and uniform glossy brush-wearing surfaces.

Be sure brush spring is correctly placed on brush holder and that brush isfree to slide in brush box.

5. Measure and make a record of brush length at each inspection. The record will verify amount of brush wear and indicate if there is enough brush length remaining until next scheduled inspection. 6

10. Install brush cover on motor case. 11. Check and tighten all motor bolts. Check lower nut on each terminal post. It should be installed finger-tight, then tightened another 114 turn with a wrench.

In general brushes must be replaced when worn to approximately half of original length.

IMPORTANT NEW BRUSHES MUST BE OF SAME SIZE AND GRADE (MATERIAL SPECIFICATION) AS REPLACED BRUSHES. AWAYS REPLACE BOTH BRUSHES AND SPRINGS. DO NOT REUSE OLD SPRINGS.

Shunt-\

\

f-Cross

PressureSpring--+\A

I~rBrush

T!/ 1

.I

Brush -

I

-

AI

Observe how brushes are assembled in brush holders, and position of brush lead (pigtail). New brushes must be installed in same manner.

Box

Retainer Screw

CBrush Box p_ Brush 1 II I

Brush Box-

J

Connector

III

6rus.h BOB Retainer Screw

Hammer Plate FJI-2

rypical lllustation

Dee 94

16-2-6

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

SM-587

GROUP 16

Motors

Brush Inspection Chart REPLACE

BRUSH

-i

IF SPRING TENSION

IS NOT THE SAME

FOR EACH BRUSH, REPLACE

REPLACE PIGTAIL

SPRINGS.

BRUSH IF IS LOOSE

IN THE BRUSH.

IF BRUSH PIGTAIL IS LOOSE AT THE BRUSH HOLDER TIGHTEN

SCREW.

REPLACE

BRUSHES

WHEN WORN TO

Typical Illustration

Dee 94

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

SM-587

GROUP 16

Motors

Typical Inch Pound

Pointer

Typical Foot Pound Torque Went h

Scale

Pivoted Handle

Pointer

IMPORTANT Improperly Torqued Fasteners Can Cause Damage. .

Use an appropriate torque wrench and tighten all fasteners to the torques specified in the illustation on the following page.

Dee 94

16-Z-8

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

SM-587

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.

\

/I

i

!

i \\

IL 2

Wire Harness

:;:>g#:; :::::::::::::::: ::: j::::::::::: :::::::::::::::: :::::::::::::::: y::::::::::::: :::::::::::::::: :::::::::::::::: :::::::::::::::: :::::::::::::::: y:::::::::::::

TM-

IJ1Torque

Dee 94

\

?.Z.W:

------__-Drive Motor Cable Fasteners to: 150 Ib.in. (I 6.9 N*m)

Copyrighted Material 16-2-9 Intended for CLARK dealers only Do not sell or distribute

Al

Torque Cable Guide Nut to 100 Ib.in. (11.3 Nom)

-

SM-587

ELqRK

Material Handling Company

GROUP 16

Section 3 Traction Motors 24 & 36 VOLT Contents General Information . .. .. .. .. .. .. .. .. .. ... . .. . .. . .. ... . .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. . 16-3-3 Motor Disassembly . .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. .. .. . . . . 16-3-5 Component Inspection & Trouble Shooting . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . 16-3-6 16-3-7 Testing . .. .. ...I..................................................................................... 16-3-8 Changing Brushes . .. .. ...f.................................................................... Motor Reassembly . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. . . .. . 16-3-8 Specifications .. ... .. .. .. . ... .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . .. . .. .. .. .. .. . . 16-3-9 & 10 Inspection Charts . .. .. .. .... .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 16-3-11

24 & 36 Volt Ventilated and Enclosed Motors

Note: Open Motor has no band.

“‘tgl m

3/8-l 6 UNC-2A Terminals

Dee 94

Copyrighted Material 16-3-1 Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 16

Motors

A

WARNING

Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris remoJed with air pressure can cause injury.

Remove all Jewelry before working on truck.

Use a Torque Wrench to tighten Terminal Connections. Typical Inch Pound Torque Wrench

Pointer

SM-587

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

GROUP 16

GENERAL Routine Maintenance Schedule with Recorded Findings is the best way to reduce costly shut-downs and repair of equipment during operating hours The goal of any maintenance program, long-life and trouble-free operations, is related to the time spent making inspections and correcting minor problems as they occur. Thekeytoplannedmaintenanceofthebmshandcommutatoris recognizingundesirablebrush and commutator conditions. If this is done, corrective action can be taken before a major component is damaged beyond serviceability. The brushes and commutator should be inspected for even wear and good commutation. Good Commutation: Poor Commutation:

A dark uniform coloring pattern at the brush wearing surface. The surface of the commutator appearing rough, pitted, scored or signs of burning or heavy arcing between bars. The coloring pattern will be: .

Streaky film with commutator wear.

.

Bar edge burning.

.

Uneven film.

.

Carbon dust bridging between bars.

Operating Conditions Operating environment of lift truck motors varies widely: The service frequency shall depend upon the severity of operating conditions. Normal Service: Basically an eighthour day of indoor material handling.

Severe Service: Extended operating hours, or constant usage.

Extreme Service:

Dee 94

Dusty or Sandy Location

Flour Mills

Cement Plants

Coal Dust Areas

Lumber Mills

Stone-Crushing Areas

Copyrighted Material 16-3-3 Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 16

1. Remove brushes.

Motors

3. Remove four screws from drive end head.

c

2. Remove two screws from commutator end head.

4. Remove bearing cap (if from comm equipped) mutator. =S

Remove drive end head with bearing.

6. Install jaw pullers as shown,pusharmatureout of bearing andco tor end head

7. Remove commutator end head and .... Q

Brush Holder Field Coils & Pole Shoes

>ommutator End Head

SM-587

Motor Housing

Armature Assembly

16-3-4

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

Drive End Head

Dec94

GROUP 16

Motors TRACTION MOTOR Disassembly Remove the cover band (if so equipped) from the commutator end of the motor. Use a brush hook to reach into the motor and lift the brush springs. Pull the brushes out of the brush holders.Eitherpositionthebrushesoutsidethemotor or remove the brush retaining screws and remove the brushes from the motor. Scribe or center punch locating marks in the end heads and the &me. Although locating marks are not always necessary because of locating pins in some motors, they can save a lot of time when the motor does not have locating pins. Remove the commutator end head retaining screws or bolts. Almost all motors have a slip fit bearing at the commutator end, andtheend head canberemovedwithverylittletrouble. Remove end head.

IJ

l

Remove the drive end head retaining bolts or screws, it’necessary.

Pull the armature assembly from the housing and field coil assembly. If the bearing remained on the armature shaft, remove bearing from shaft with a bearing puller. When a puller is used, protect the end of the armature shaft with a nut or a thick flat washer. If theshaft, or spline is damaged when removing the end head, the armature or the drive spline usually has to be replaced. Use caution and do

There will be occasions when it will be necessary to remove the ventilating fan and /or drive splines from the the armature shaft. Theventilating fan is, for the most part, cast iron or cast aluminum. Once the fan has been pressed onto the armature, it must be heated to be removed without damage.

Remove Fan A puller is installed and a slight pressure exerted against the fan. Use a small propane torch to heat the area of the fan around the shaft. When the fan becomes loose on the shaft, as evidenced by the puller becoming loose, it should be removed as quickly as possible. Remove Retainer Pin l

Press or drive the spline retaining pin out of the shaft and spline.

Remove Spline

not damage the armature.

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

Dee 94

II

Ventilating Fan

Remove bearing from head.

Remove the drive end head (the bearing may or may not remain on the shaft).

YJ

l

Use a hammer and chisel or drift punch to drive spline out of shaft.

Copyrighted Material 16-3-5 Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 16

Motors Component

Inspection & Trouble Shooting

After the motor components have been thoroughly cleaned and dried, they should be inspected for the following:

burning or heavy arcing between bars. coloring pattern will be:

Drive End Head 1. Check bearing recess for any signs of wear. 2. Checkmountingholesforany strippedorcmsed threads or broken studs.

l

Streaky film with commutator wear.

l

Bar edge burning.

l.

Uneven film.

l

Carbon dust bridging between bars.

Brushes should be inspected for uneven wear and signs of overheating, i.e.

Commutator End Head 1. Check bearing recess for any signs of wear. 2.

Check brush holder insulation for cracks or any signs of burning.

l

Discolored brush shunts

l

Discolored brush springs. Refer to the Brush Chart on page 16-3-11.

3. Check brush holders and springs for wear.

Armature

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

The

Ball bearings that have been pulled off of shafts, pressed out of end heads, or side loaded in such a way as to apply pressure on the balls and races must be replaced. Although the bearing may appear or feel good, the bearing races have been brinelled and will fail within a relatively short period of service.

Brush and Commutator

1. Check security of fan. 2.

Check for loose commutator bars. Loose commutator bars will usually be indicated by excessive wearorbumingonone bar. The commutator can be checked for loose bars by lightly tapping all of the bars with the handle of a plastic or wooden handled screwdriver. A contrasting dull thud or vibration will indicate a loose barin which case, the armature must be replaced.

3. Check for grounded circuits using a test light. Most commercial growlers incorporate a test light as shown in illustration below. .

Check the armature for grounded circuits by placing one test lead of the test lamp on the commutator and the other test lead on the armature shaft. If the test light lights, the armature is grounded.

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

SM-587

16-3-6

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

Dec94

GROUP 16

Motors 4. Standard Winding Armatures are tested on a growler (see illustration below) using a steel strip or hacksaw blade to locate any shorted

Frame and Field Assembly l

windings. l

Check for shorted windings by slowly rotating the armature in the growler while holding the strip or blade so that it passes over each armature core slot. If a winding is shorted, the strip or blade will vibrate and the blade will get hot.

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

Hacksaw Blade

TESTING Frame and Field Assembly Jre

Lights

After thorough inspection, the Frame and Field Assembly should be checked for grounded, open or shorted circuits. Grounded and open circuits can be checkedusinga test light. Most commercial growlers incorporate a test light as shown in opposite illustration.

Grounded Circuit l

NOTE

Ifthearmaturehasbeenturnedand undercut prior to testing, check for and remove any copper buildup or filings between commutator bars and at the commutator riser. This condition will cause an armature tocheckshortedandusuallyresults from a dull undercutting tool. 5. Check commutator bars for any signs of burning. If deep burned sections are evident, either in the brush track or on the riser ends of the commutator bars, an open or short circuit in the armature windings is indicated.

Dee 94

Touch one test lead to a clean bare metal spot on the frame and check all terminals with the other lead. If a grounded condition exists, the test light will light.

Open Circuit l

Check between all connecting terminals with test leads. Ifthe bulb fails tolight, anopencircuit is indicated.

Shorted Circuit l

Shorted windings in series coils are very difficult to detect. Generally, if the coil insulation is sound and these are no signs of overheating, the coil can be presumed good.

Copyrighted Material 16-3-7 Intended for CLARK dealers only Do not sell or distribute

SM-587

Motors

GROUP 16 FRAME AND FIELD SERVICE NOTES

REASSEMBLY

If theinside of the motor is exceptionally dirty and

Reassembly is the reverse of disassembly.

there is evidence of a grounding condition caused by the dirt, the inside of the motor can be given an additional coat of insulating varnish. Red glyptol can be used if a better material is not available, however, we recommend using a class “H” Polyurethane air drying insulating varnish. This is readily available under various brand names from electrical repair or parts houses in aerosol type dispensers.

NOTE

Bearing Installation 1. Whenever ball bearings are pressed into an end head or onto a shaft, always press against the race that is absorbing the pressure. Press on the outer race when installing into end heads.

Before spraying field coils, make sure they are absolutely clean anddry. Protect brush rigging, pole shoe faces and end head seats to keep varnish off.

2. EndHeads having slip-fit bearings are normally retained by a snap ring. Always install new snap ring(s).

FIELD COIL INSTALLATION Good solder connections are important due to the vibrationcharacteristicsencountered by thesemotors which can cause cold or poorly soldered connections to break. l

After Assembly .

The motor should be connected as specified in trouble shooting, and tested to the specifications.

.

When testing motors, the voltmeter connections must be made at the motor terminals.

Prior to installing thejield coils, the connections which require soldering should be buffed or wire brushed clean to remove any oxidation. The connections should then be tinned with a soldering iron. NOTE

We do not recommend using a soldering gun or torch. Soldering guns cannot provide the heat concentration required and soldering torches can damage the insulation. l

Press against the inner race when installing onto a shaft.

After field coil installation, connect the solder joint making sure the solder is flowing properly to avoid a cold soldered joint.

When changing brushes When changing brushes the commutator serviced as follows: l

l

must be

Resurface the commutator by taking only light cuts each time, 0.005”. If re-slotting/undercutting is necessary, the final operation is to lightly sand the commutator with a fine sandpaper to remove any burrs left from the undercutting operation.

Pole Shoe Screw Removal & Installation (Field Coil Removal & Installation)

SM-587

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

Dee 94

GROUP 16

Motors 24-Volt Motor Specifications

This motor is equipped with Standard Winding Connections and meets latest revision of U.L. 583 Motor Specifications l

Frame Size: 6.7” (165.1 mm) Diameter

l

Weight (Approx.): 43 lbs. (19.51 kg)

l

Internal

.

Bearings are sealed and lubricated with high temperature grease for the life of the bearing.

Motor Insulation l

Armature components, Class H

l

Commutator components, Class H

.

Commutator Servicing Diameters l

MaximmDiameter, NEW 2.92”

l

Minimum Diameter for RESLOTTING: 2.80”

l

Min. Diameter for REPLACEMENT:

2.75”

ROTATION: REVERSIBLE C.W.D.E. Forward Vehicle Direction

C.C.W.D.E. Reverse Vehicle Direction

Brush Data 1 Brush per Holder 4 Brushes per Motor Min. Length of Worn Brush 0.42” (10.67 mm) Max. Force per New Brush 29 oz. (825 gm) Max. Force per Worn Brush 12 oz. (340 gm) Brush Drop

Grade: H803

Motor Brush

1.OVolts @ 7 1 Amps Dee 94

Copyrighted Material 16-3-9 Intended for CLARK dealers only Do not sell or distribute

SM-587

Motors

GROUP 16 36-Volt Motor Specifications

This motor is equipped with Standard Winding Connections and meets latest revision of U.L. 583

Motor Specifications l

Frame Size: 6.5” (165.1 mrn)Diameter

l

Weight (Approx.): 43 lbs. (19.51 kg)

l

Internal Bearings are sealed and lubricated with high temperature grease for the life of the bearing.

Fsulation l

Armaturecomponents, Class H

l

Commutator components, Class H

ROTATION: REVERSIBLE C.W.D.E.

CommutatorServicing Diameters 2.92”

Maximum Diameter, NEW: Minimum

Forward Vehicle Direction I

Diameter for RESLOTTING:

Min. Diameter for REPLACEMENT:

2.80”

C.C.W.D.E.

2.75”

Reverse Vehicle Direction

Brush Data l

1 Brush per Holder

l

4 Brushes per Motor

l

Min. Length of Worn Brush 0.42” (10.67 mm)

l

Max. Force per New Brush 29 oz. (825 5)

l

Max. Force per Worn Brush 12 oz. (340 5)

l

BrushDrop

Grade H803

Motor Brush

1.0 Volts @ 71 Amps SM-587

16-3-l

0

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

Dee 94

GROUP 16

Brush Inspection Chart

REPLACE

IF SPRING TENSION

IS NOT THE SAME

FOR EACH BRUSH, REPLACE

SPRINGS.

II I

I

BRUSH

REPLACE

BRUSH IF OIL SOAKED I

I

0.42" REPLACE

BRUSHES

WHEN WORN TO

*_,

NEW BRUSHES

Copyrighted Material 16-3-l 1 Intended for CLARK dealers only Do not sell or distribute

SM-587

GEA-7

COMMUTATOR CHECK CHART FOR COMPARING

COMMUTATOR

SATISFACTORY

COMMUTATOR

LIGHT TAN FILM over entire commutator

MOlYLED

swfoc*

tam is pmbabfy most heqwdy

obrmed

fffm, pppmn

condition of rommutatorr

industry.

nl0t.d

ohen

is one of many

normal

condtionl

seen on (I well-functioning

machine.

SURFACE

STREAKING beg8nnmg

on the commutator of s*rio”s

swfoce sipnols Ihe

met01 nand*r

brush. Check the chart below

to Ihe carbon

for possible

muses.

COPPER

DRAG,

build-up

of commutator

forms most often at Iroiling +*

of bar. Con-

dition is rare

on obnormol

bui ton

covu

flashover

if not hked.

in

THESE

THREADING

al

whan lxmsiva to rwnfocing -

mattiol,

BLOT

with random film pot-

FOR

WATCH

PlYCH

--\

SURFACES

BAR-MARKING, on bon

to numb.l

o sfiihdy in o d&k

of condumm

DANGER

tommutm~r whh

firmlims

mudnansfnoccum

of commutotw

HEAVY

FILM

cpn oppeor

over entire

preo of efficient and normal tar and, if uniform,

per dot.

commute-

b quite occ.ptobfc.

SIGNS

GROOVING

rowIts

h usually kodr

and mpid

do&f panem

by abrasive

bwsh weor.

phere.

b o mechanical condition cowed motwiol

lf grooves

in the brush

form,

or otmor-

start corrective

action.

.

BAR-MARKING

on lh* commutota ingr equolr

SURFACE MARKINGS

produces

surfor*.

bw

w burn...

The number

half or all 410 numbw

of pohr

spots

of these morkon the motor.

.-

HEAVY

SLOT

BAR-MARKING

atching of hailing tern b r&ted

edgo

to number

con

of rommutotor

involve bar. Pot-

of conductors per dot.

Carbon Products General Electric Company East Stroudsburg. Pa. 18301

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

c

lVl;~pria~Handling El!‘!‘RIC

GROUP 16

Section 5 Pump Motors 24 & 36 VOLT Contents General Information . . . .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 16-5-3 Motor Disassembly . .. .. .. . ... .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. .. . . .. .. 16-5-5 Component Inspection & Trouble Shooting . .. .. .. ... . .. .. .. .. .. .. .. . ... .. .. .. .. . . 16-5-6 Testing . . ... .. . ... .. .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. . .. . . 16-5-7 Changing Brushes . .. .. .. .. . .. ... .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. .. . . 16-5-8 Motor Reassembly . . .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . . 16-5-8 Specifications . ... . .... ... . .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. . .. . . 16-5-9 Inspection Charts . .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. 16-5-11

24 & 36 Volt Ventilated and Enclosed Motors 3/8-l 6 UNC-2A Bearing

Bearing I

.;-.

17

-

Name Plate 0

0

Snap -t 112-l 3 UNC-2B A

Dee 94

-

Mounting Bracket

Copyrighted Material 16-5-l Intended for CLARK dealers only Do not sell or distribute

3/8-24 UNF-2B -1

SM-587

Motors

GROUP 16

A

WARNING

Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris remo2ed with air pressure can cause injury.

Remove all Jewelry before working on truck.

Use a Torque Wrench to tighten Terminal Connections. Typical Inch Pound Torque Wrench

Pointer

SM-587

16-5-2

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

Dee 94

GROUP 16

Motors

GENERAL Routine Maintenance Schedule with Recorded Findings is the best way to reduce costly shut-downs and repair of equipment during operating hours The goal of any maintenance program, long-life and trouble-free operations, is related to the time spent making inspections and correcting minor problems as they occur. The key to planned maintenance of the brush and commutator is recognizing undesirable brush and commutator conditions. If this is done, corrective action canbe takenbefore amajor component is damaged beyond serviceability. The brushes and commutator should be inspected for even wear and good commutation. Good Commutation: Poor Commutation:

A dark uniform coloring pattern at the brush wearing surface. The surface of the commutator appearing rough, pitted, scored or signs of burning or heavy arcing between bars. The coloring pattern will be: .

Streaky film with commutator wear.

.

Bar edge burning.

.

Uneven film.

.

Carbon dust bridging between bars.

Operating Conditions Operating environment of lift truck motors varies widely: The service frequency shall depend upon the severity of operating conditions. Severe Service: Normal Service: Extended operating Basically an eighthours, or constant ushour day of indoor age. material handling.

Extreme Service:

Chemical Processing Freezer Operation Processing Plants (Poultry, Meat)

Dee 94

Copyrighted Material 16-s-3 Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 16

Motors

1. Remove brushes.

+

4 3. Remove screws from drive end head.

2. Remove screws-b from commutator end head.

4. Remove drive end head with bearing.

Screw

5. Remove the commutator end head and ..

.

Disassembled

pull armature out of housing.

View

T Bearing

Bearing Field Coils & Pole Shoes

Housing Commutator SM-587

Drive End Head

End Head 16-5-4

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

Dee 94

GROUP 16

Motors ELECTRIC

PUMP MOTORS

Disassembly l

l

l

l

l

l

Remove the cover band (if so equipped) from the commutator end of the motor. Use a brush hook to reach into the motor and lift the brush springs. Pull the brushes out of the brush holders. Either position the brushes outside the motor orremove the brush retaining screws and remove the brushes from the motor. Scribe or center punch locating marks in the end heads and the frame. Although locating marks are not always necessary because of locating pins in some motors, they can save a lot of time when the motor does not have locating pins. Remove the commutator end head retaining screws or bolts. The motors have a slip fit bearing at the commutator end, and the end head can be removed with very little trouble.

rush I prin! s

c-

Remove the drive end head retaining bolts or screws. Separate the armature and drive end head as an assembly from the frame and field coil assembly. Separate the armature from the drive end head. This operation is usually accomplished by pressing the armature out of the drive end bearing. The end head and bearing may have to be removed with a puller. When a puller is used, protect the end of the armature shaft with a nut or a thick flat washer. If the shaft, coupling, or spline is damaged when removing the end head, the armature or the drive spline usually has to be replaced. Use caution and do not damage the armature. Separate the bearing from the end head. The bearing is retained with a snap ring. Remove the snap ring, then press the bearing out of the end head.

Dee 94

Copyrighted Material 18-5-5 Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 16

Motors Component

Inspection & Trouble Shooting

After the motor components have been thoroughly cleaned and dried, they should be inspected for the following:

burning or heavy arcing between bars. coloring pattern will be: l

Streaky film with commutator wear.

l

Bar edge burning.

Drive End Head 1. Check bearing recess for any signs of wear.

0. Uneven fti.

2. Checkmountingholesforanystrippedorcrossed threads or broken studs.

l

Carbon dust bridging between bars.

Brushes should be inspected for uneven wear and signs of overheating, i.e.

Commutator End Head 1. Check bearing recess for any signs of wear. 2.

The

Check brush holder insulation for cracks or any signs of burning.

l

Discolored brush shunts

l

Discolored brush springs. Refer to the Brush Chart on the following pages.

3. Check brush holders and springs for wear.

Bearings

Armature

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

1. Check security of fan.

2. Check for loose commutator bars. Loose commutator bars will usually be indicated by excessive wearor burning on one bar. Thecommutator can be checked for loose bars by lightly tapping all of the bars with the handle of a plastic or wooden handled screwdriver. A contrasting dull thud or vibration will indicate a loose bar in which case, the armature must be replaced.

NOTE

3. Check for grounded circuits using a test light.

Ball bearings that have been pulled off of shafts, pressed out of end heads, or side loaded in such a way as to apply pressure on the balls and races must be replaced. Although the bearing may appear or feel good, the bearing races have been brinelled and will fail within a relatively short period of service.

Most commercial growlers incorporate a test light as shown in illustration below.

.

Check the armature for grounded circuits by placing one test lead of the test lamp on the commutator and the other test lead on the armature shaft. If the test light lights, the armature is grounded.

Brush and Commutator The brushes andcommutator

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

SM-587

16-5-6

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

Dee 94

GROUP 16

Motors 4.

Standard Winding Armatures are tested on a growler (see illustration below) using a steel strip or hacksaw blade to locate any shorted

Frame and Field Assembly l

windings. l

Check for shorted windings by slowly rotating the armature in the growler while holding the strip or blade so thatitpasses over each armature core slot. If a winding is shorted, the strip or blade will vibrate and the blade will get hot. Hacksaw Blade

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

TESTING Frame and Field Assemblv Jre

Lights

L

Switch

/

After thorough inspection, the Frame and Field Assembly should be checked for grounded, open or shorted circuits. Grounded and open circuits can be checked using a test light. Most commercial growlers incorporate a test light as shown in opposite illustration.

Grounded Circuit Growler l

NOTE

Ifthearmaturehasbeentumedand undercut prior to testing, check for and remove any copper buildup or filings between commutator bars and at the commutator riser. This condition will cause an armature tocheckshortedandusuallyresults from a dull undercutting tool. 5. Check commutator bars for any signs of burning. If deep burned sections are evident, either in the brush track or on the riser ends of the commutator bars, an open or short circuit in the armature windings is indicated.

Dee 94

Touch one test lead to aclean bare metal spot on the frame and check all terminals with the other lead. If a grounded condition exists, the test light will light.

Open Circuit l

Check between all connecting terminals with testleads. Ifthebulbfails tolight,anopencircuit is indicated.

Shorted Circuit l

Shorted windings in series coils are very difficult to detect. Generally, if the coil insulation is sound and these are no signs of overheating, the coil can be presumed good.

Copyrighted Material 16X3-7 Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 16

Motors

FRAME AND FIELD SERVICE NOTES

REASSEMBLY

If theinside of the motor is exceptionally dirty and

Reassembly is the reverse of disassembly.

there is evidence of a grounding condition caused by the dirt, the inside of the motor can be given an additional coat of insulating varnish. Red glyptol can be used if a better material is not available, however, we recommend using a class “II” Polyurethane air drying insulating varnish. This is readily available under various brand names from electrical repair or parts houses in aerosol type dispensers.

NOTE

Bearing Installation 1. Whenever ball bearings are pressed into an end head or onto a shaft, always press against the race that is absorbing the pressure. Press on the outer race when installing into end heads.

Before spraying field coils, make sure they are absolutely clean anddry. Protect brush rigging, pole shoe faces and end head seats to keep varnish off.

Press against the inner race when installing onto a shaft. 2. EndHeads having slip-fit bearings are normally retained by a snap ring. Always install new snap ring(s).

FIELD COIL INSTALLATION Good solder connections are important due to the vibration characteristics encountered by these motors which can cause cold or poorly soldered connections to break. l

l

Prior to installing thefield coils, the connections which require soldering should be buffed or wire brushed clean to remove any oxidation. The connections should then be tinned with a soldering iron. NOTE

l

The motor should be connected as specified in trouble shooting, and tested to the specifications. When testing motors, the voltmeter connections must be made at the motor terminals.

When changing brushes When changing brushes the commutator serviced as follows:

We do not recommend using a soldering gun or torch. Soldering guns cannot provide the heat concentration required and soldering torches can damage the insulation. l

After Assembly

l

l

After field coil installation, connect the solder joint making sure the solder is flowing properly to avoid a cold soldered joint.

must be

Resurface the commutator by taking only light cuts each time, 0.005”. If re-slotting/undercutting is necessary, the final operation is to lightly sand the commutator with a fine sandpaper to remove any burrs left from the undercutting operation.

Pole Shoe Screw Removal & Installation (Field Coil Removal & Installation)

SM-587

16-5-8

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

Dee 94

GROUP 16 24-Volt Pump Motor Specifications This motor is equipped with Standard Winding Connections and meets latest revision of U.L. 583 Motor Specifications l

Frame Size: 6.5” (165.1 mm) Diameter

l

Weight (Approx.): 43 lbs. (19.51 kg) Internal Bearings on Pump End and Commutator End. Bearings are double sealed and lubricated with high temperature grease for the life of the bearing.

l

Motor Insulation l

Armature components, Class H

l

Commutator components, Class H

.Commutator Servicing Diameters l

Maximum Diameter, NEW

2.92”

l

Minimum Diameter for RESLOTHNG:

2.80”

l

Min. Diameter for REPLACEMENT:

2.75”

Circuit and Rotation l

Single Rotation

l

CCWDE,

-

to Battery Negative,

+

to Battery Positive.

Brush Data l

1 Brush per Holder

l

4 Brushes per Motor

l

Max. Length of Worn Brush 0.42” (10.67 mm)

l

Min. Force per New Brush

Length 11.13”(28.7n

n> 7

29 oz. (825 gm) l

Max. Force per Worn Brush 12 oz. (340 gm)

l

Brush Drop

Grade: H803

Motor Brush

1.0 Volts @ 71 Amps Dee 94

Copyrighted Material 1 C-5-9 Intended for CLARK dealers only Do not sell or distribute

SM-587

Motors

GROUP 16 36-Volt Pump Motor Specifications

This motor is equipped with Standard Winding Connections and meets latest revision of U.L. 583 Motor Specifications l

Frame Size: 6.5” (165.1 mm) Diameter

l

Weight (Approx.): 43 lbs. (19.51 kg)

l

Internal Bearings on Pump End and Commutator End. Bearings are double sealed and lubricated with high temperature grease for the life of the bearing.

Motor Counlinz A coupler is used to connect the motor to the pump. One half the coupler attaches to the motor and the other half to the pump. Circuit and Rotation Jnsulation Single Rotation Armature components, Class H to Battery Negative, CCWDE, Commutator components, Class H to Battery Positive. + Commutator Servicing Diameters l

l

l

l

l

2.92”

l

Maximum Diameter, NEW:

l

Minimum Diameter for RESLO’ITING: 2.80”

l

Min. Diameter for REPLACEMENT:

2.75”

Brush Data l

1 Brush per Holder

l

4 Brushes per Motor

l

Min. Length of Worn Brush 0.42” (10.67 mm)

l

Max. Force per New Brush 29 oz. (825 gm)

l

Max. Force per Worn Brush 12 oz. (340 gm)

l

BrushDrop

Length-6 1.13”(28.7mm)

7

Grade

1.0 Volts @ 71 Amps SM-587

H803

Motor Brush 16-5-l

0

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

Dee 94

GROUP 16

Motors

Brush Inspection Chart

REPLACE

BRUSH

v CHECK TENSION OF EACH SPRING

IF SPRING TENSION

IS NOT THE SAME

FOR EACH BRUSH, REPLACE

SPRINGS.

REPLACE PIGTAIL

BRUSH IF IS LOOSE

IN THE BRUSH.

IF BRUSH PIGTAIL IS LOOSE AT THE BRUSH HOLDER TIGHTEN

SCREW.

0.42" 1 REPLACE

BRUSHES

WHEN WORN TO HERE.

NEW BRUSHES

Dee 94

Copyrighted Material 16-5-l 1 Intended for CLARK dealers only Do not sell or distribute

SM-587

GEA-7

COMMUTATOR CHECK CHART FOR

COMPARING

COMMUTATOR

SATISFACTORY

LIGHT TAN FILM ov.r entire commutator

MOYYLED

surfoc* is one of many

+em is probably

ohen

nomwl

conditions

seen on a well-funaioning

machine.

condition

SURFACE

begmmng

of r.riow

m.+al

nondw

brush, Check the chart b4o.v

COPPER

DRAG,

mottiol,

forms mos+ okm

din

is ram

on abnomwl

for

sign&

the

possible cousm.

of comnw+&o~

01 boiling edgo of bar. Con-

but can couw

Rashorn

if no+ &ted.

fmqwn+fy

observed

fib,

in industry.

THESE

YHREADING whan lxcwsiw

of tommu+~+or me+ol hondw

+o numkr

BAR-MARKING

on +fw commu+a+or wfoc*. ings wuofs

+x&w

with

Carbon Products General Electric Company East Stroudsburg. Pa. 18301

of
of p&r

of +ft.s,

spo+s mark-

on +fw motor.

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

FILM


ov.r

of efficient and normal

+or and, if uniform,

par Jo+.

by abrasive

weire

commvto-

is quite accep+abfc.

is o mechanical condition caused material

pherm. If grooves

brush wear.

or burn...

or.0

GROOVING

h usually fwdr

bw

HEAVY

panem

SIGNS

fine liner roruhs

occur.

The numbw

half or all +fta numk

a dafinih

DANGER

+o resurfacing of ~ommu+a+w and rapid

PIYCH

a sfiphdy darker

appmm onbanin

nl.a+ed

MARKINGS

SURFACES

SLOT IAR-MARKING,

wf+ft mndom film pat-

FOR

to the carbon

build-up

COMMUTATOR

of commu+q+orr

WATCH

STREAKING on the ~ornrn~t~+or wrbre

mod

SURFACE

--

HEAVY

SLOT

nching

of hailing

+em is r&+ed

in the brush

form,

BAR-MARKING edge

lo numbw

or o+mos_

s+w+ correc+iw

can

action.

involve

of ~ommu+a+or bar. Potof conductors per Jo+.

CMRK

Material

Company

Handling

GROUP 16

Section 7 Auxiliary/Steer Pump Motors 24 & 36 VOLT Contents 16-7-3 General Information .......................................................................... Trouble Shooting Prior to Disassembly ............................................. .l6-7-5 16-7-6 Motor Disassembly ........................................................................... Component Inspection & Trouble Shooting ....................................... 16-7-8 Changing Brushes ............................................................................. 16-7-9 Motor Reassembly ............................................................................ 16-7-9 24-Volt Specifications and Brush Data ............................................ .16-7-10 36 Volt Specifications and Brush Data ............................................ .16-7-11 Brush Inspection Chart .................................................................... 16-7-12

24 & 36 Volt Ventilated and Enclosed Auxiliary/Steer Motors Post Nut Washer Insulator Motor Frame -&-Terminal

01

Kit

Armature Shafi Bearing

Brush Cover

Dee 94

Copyrighted Material 16-7-l Intended for CLARK dealers only Do not sell or distribute

SM-587

Motors

GROUP 16

AWARNING Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.

Remove all Jewelry before working on truck.

Always wear Safety Glasses

Use a Torque Wrench to tighten Terminal Connections. Typical Inch Pound Torque Wrench

Pointer

SM-587

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

Dee 94

GROUP 16

Motors

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. The key to planned maintenance of the brush and commutator is recognizing the undesirable brush and commutator conditions. If this is done, corrective action canbe takenbefore amajor component is damaged beyond serviceability. The brushes and commutator should be inspected for even wear and good commutation. Good Commutation:

A dark uniform coloring pattern at the brush wearing surface.

Poor Commutation:

The surface of the commutator appearing rough, pitted, scored or signs of burning or heavy arcing between bars. The coloring pattern will be: .

Streaky film with commutator wear.

.

Bar edge burning.

.

Uneven film.

.

Carbon dust bridging between bars.

Operating Conditions Operating environment of lift truck motors varies widely: The service frequency shah depend upon the severity of operating conditions.

Normal Service: Basically an eight-

w

Severe Service: Extended

operating hours, or constant usage.

hour day of mostly indoor or out door material handling.

Extreme Service:

Chemical Processing Freezer Operation

ProcessingPlants (Poultry, Meat)

Dee 94

Copyrighted Material 16-7-3 Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 16

Motors

e

+-

Br,ush Cover f

r1

---

, Name plate

L

_--

*

Matching half of coupler attaches to hydraulic pump

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

Dee 94

GROUP 16

Motors AUXILIARY/STEER

MOTORS (PERMANENT MAGNET TYPE)

The permanent magnet motor differs from conventional D.C. motors in that the field winding has been replaced with ceramic magnet pole pieces. Do not

TROUBLE SHOOTING 1

Read the nameplate to become familiar with the motor, especially the rated voltage.

2

Try to turn the shaft by hand. Keep motor leads separated while doing this. If the shaft turns freely go to item 3. If the shaft won’t turn, proceed to item 2A.

2A The shaft could be tight for a number of reasons. This check is to determine if the tightness is of a temporary nature only. Obtain a power source to produce the rated voltage. Do Not Make A Permanent Connection. First touch the motor leads quickly to the power supply just long

impact, drop or squeeze the motors as this can cause damage to the ceramic pole pieces and it will make motor unfit for further use.

PRIOR TO DISASSEMBLY enough to observe if the shaft turns. If it does turn, then hold the motor leads on the power supply for a longer time. If the motor sounds normal, go to item 3. If the motor sounds noisy, it should be taken apart as described herein. 3. If the motor turned freely, connect an ammeter in thecircuit as shown below. Withratedvoltage applied and the shaft running free, the ammeter should read less than 20% of the nameplate full load current. If the motor meets the above conditions then it can be assumed the original problem is external to the motor. A higher current indicates a faulty armature.

Ammeter

PoDwcer SUPPlY

Dee 94

Copyrighted Material 16-7-5 Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 16

Motors

MOTOR DISASSEMBLY

.

Disconnect brush assembly lead.

Caremust be taken when the permanent magnet

.

Lift brush assembly from brush holder.

motor is disassembled, since the magnet pole pieces will attract ferrous metals. This fact dictates motors should be disassembled in an area free of ferrous (iron, steel) metal chips. A

CAUTION

5. Remove any carbon dust or dirt from brush ring assembly. 6. Remove pump drive coupling segment from motor shaft end. 7. Loosen motor assembly thru bolts at commutator end of motor and remove bolts from motor.

Do not place the stator ring (motor housing) in any mechanical holding device (e.g., vise) during the disassembly or assembly operation. Permanent distortion or other damage will result. With the motor disassembled, care must also be taken not to drop the stator ring assembly, since it can be distorted. Motor may be held by clamping on the mounting bracket.

8. Scribe a match mark on drive end cover and housing. .

9. The drive end bearing may now be inspected. 10. Support and hold stator housing firmly on the end cover (a second person is suggested).

IMPORTANT Before disassembling motor, note that there are match marks on the stator assembly housing and the commutator cover. If marks are not visible, use a scribe tool to make match marks. These marks will be used at assembly

11. Pull armature out of assembly in one quick motion.

A

2. Remove brush cover band segments by prying coverpins out of engagement in motor housing.

To avoid damage to either the armature or the permanent magnets, it is recommended that the armature be removed only with the motor housing and armature shaft positioned vertically.

3. Air clean inside of motor around brushes and commutator, using dry (moisture-free) compressed air. The armature should be blown off with compressed air to remove brush dust and dirt from around the commutator and windings.

CAUTION

It is important that the pulling motion on the armature be continuous. Do not pull part way out and release. if this is done, the magnets will pull the armature back into the stator and cause severe damage.

1. Loosen and remove clamping screw in brush cover band.

.

Remove drive end (pump mounting) cover. Using a pry bar, carefully pry on cover to loosen. Tap lightly on pry bar, if necessary.

12. Remove commutator end cover.

NOTE Observe how brushes are assembled in brush holders. Note position of the brush lead (shunt).

.

Remove and save bearing spring washer fi-on the cover bore.

4. Remove the brushes as follows: l

Remove brush spring clip from its mounting on top of brush assembly. Use a brush hook to reach into motor and lift brush springs.

SM-587

16-7-6

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

Dee 94

GROUP 16

Motors

16.:

16.208 \

16 .258 J

STEER PUMP MOTOR

16.200 16.208 16.209 16.211 16.212 16.218 16.223 16.232 16.234 16.238 16.258 16.259 16.274

Dee 94

Motor Assembly, Steer Pump Bearing, Steer Pump Motor Drive End Armature, Steer Pump Motor Bearing, Steer Pump Motor Commutator End Spring Washer, Steer Pump Motor Commutator Brush Kit, Steer Pump Motor Cover, Steer Pump Motor Brush Hole Cover, Steer Pump Motor Brush Hole Terminal Kit, Steer Pump Motor Brush Holder Kit, Steer Pump Motor Frame, Steer Pump Motor Drive End Frame, Steer Pump Motor Commutator End Stator, Steer Pump Motor

Copyrighted Material 1 S-7-7 Intended for CLARK dealers only Do not sell or distribute

End Bearing

SM-587

GROUP 16

Motors Component

Inspection & Trouble Shooting

After the motor components have been thoroughly cleaned and dried, they should be inspected for the following:

burning or heavy arcing between bars. coloring pattern will be:

Drive End Head 1. Check bearing recess for any signs of wear.

l

Streaky film with commutator wear.

2. Checkmountingholesforanystrippedorcrossed threads or broken studs.

l

Bar edge burning.

l.

Uneven film.

l

Carbon dust bridging between bars.

Commutator End Head 1. Check bearing recess for any signs of wear. 2.

Check brush holder insulation for cracks or any signs of burning.

Brushes should be inspected for uneven wear and signs of overheating, i.e.

3. Check brush holders and springs for wear.

l

Discolored brush shunts

l

Discolored brush springs.

Bearings 1. Check bearings by turning them with your fingers. Feel for binding or gritty effects and excessive looseness or wobble. A good bearing should also have a small amount of drag or stiffness caused by the lubrication but should turn smoothly. If the bearing turns very fi-eely, it should be replaced. Bearings should also be changed, if worn out, damaged or removed from armature shaft,

The

Refer to the Brush Chart on the following pages.

Armature 1. Check security of fan. 2.

NOTE Ballbearingsthathavebeenpulled off of shafts, pressed out of end heads, or sideloadedin such a way as to apply pressure on the balls and races must be replaced. Although the bearing may appear or feel good, the bearing races have been brinelled and will fail within a relatively short period of service.

Check for loose commutator bars. Loose commutator bars will usually be indicated by excessivewearorbumingononebar. Thecommutator can be checked for loose bars by lightly tapping all of the bars with the handle of a plastic or wooden handled screwdriver. A contrasting dull thud or vibration will indicate a loose barin which case, the armature must be replaced.

3. Check for grounded circuits using a test light. Most commercial growlers incorporate a test light as shown in illustration below. l

Check the armature for grounded circuits by placing one test lead of the test lamp on the commutator and the other test lead on the armature shaft. If the test light lights, the armature is grounded.

Brush and Commutator The brushes and commutator should be inspected for even wear and good commutation. Good Commutation: A dark uniform coloring pattern at the brush wearing surface. Poor Commutation: The surface of the cornmutator appearing rough, pitted, scored or signs of SM-587

16-7-8

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

Dee 94

GROUP 16

Motors 4.

l

Standard Winding Armatures are tested on a growler (see illustration below) using a steel strip or hacksaw blade to locate any shorted windings. Check for shorted windings by slowly rotating the armature in the growler while holding the strip or blade so that it passes over each armature core slot. If a winding is shorted, the strip or blade will vibrate and the blade will get hot.

r

Hacksaw Blade

NOTE

Bearing Installation 1. Whenever ball bearings are pressed into an end headorontoashaft,alwayspressagainsttherace that is absorbing the pressure. Press on the outer race when installing into end heads. Press against the inner race when installing onto a shaft. 2. EndHeads having slip-fit bearings are normally retained by a snap ring. Always install new snap ring(s). After Assembly .

The motor should be connected as specified in trouble shooting, and tested to the specifications.

.

When testing motors, the voltmeter connections must be made at the motor terminals.

Jre

Lights

L- Switch

/

WHEN CHANGING BRUSHES Growler

When changing brushes the commutator serviced as follows:

NOTE

Ifthearmaturehasbeenturnedand undercut prior to testing, check for and remove any copper buildup or filings between commutator bars and at the commutator riser. This condition will cause an armature tocheckshortedandusuallyresults from a dull undercutting tool.

l

l

must be

Resurface the commutator by taking only light cuts each time, 0.005”. If re-slotting/undercutting is necessary, the final operation is to lightly sand the commutator with a fine sandpaper to remove any burrs left from the undercutting operation.

5. Check commutator bars for any signs of burning. If deep burned sections are evident, either in the brush track or on the riser ends of the commutator bars, an open or short circuit in the armature windings is indicated. stator

1. Check magnets to be sure they are securely mounted and have no cracks.

REASSEMBLY Reassembly is the reverse of disassembly. Dee 94

Copyrighted Material 16-7-g Intended for CLARK dealers only Do not sell or distribute

SM-587

Motors

GROUP 16 24-Volt Auxiliary/Steer Pump Motor Specifications

rhis motor is equipped with Standard Winding Connections and meets latest revision of U.L. 583 Motor Specifications l

Frame Size: 6.5” (165.1 mm) Diameter

l

Weight (Approx.): 43 lbs. (19.51 kg)

l

l

.

Internal Bearings on Pump End and Commutator End. Bearings are double sealed and lubricated with high temperature grease for the life of the bearing. Grade: M-8 Magnets

l

4-Magnets

l

4 Poles

MotorInsulation l

Armature components, Class H

l

Commutator components, Class H.

Circuit and Rotation

CommutatorServicing Diameters

l

Single Rotation

Maximum Diameter, NEW

l

l

CCWDE,

l

Minimum Diameter for RESLOTTING:

2.80”

l

Min. Diameter for REPLACEMENT:

2.75”

2.92”

-

to Battery Negative,

+

to Battery Positive.

++

--

Brush Data 1 Brush per Holder 4 Brushes per Motor Min. Length of Worn Brush 0.42” (10.67 mm) Max. Force per New Brush 29 oz. (825 gm) Max. Force per Worn Brush 12 oz. (340 gm) Brush Drop

Grade: H803

Motor Brush

1.0 Volts @ 71 Amps SM-587

16-7-l

0

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

Dee 94

GROUP 16

Motors 36-Volt Auxiliary/Steer Pump Motor Specifications

This motor is equipped with Standard Winding Connections and meets latest revision of U.L. 583 S Motor Specifications Frame Size: 6.5” (165.1 mm) Diameter Weight (Approx.): 43 lbs. (19.51 kg) Internal Bearingson Pump End and Commutator End. Bearings are double sealed and lubricated

with high temperature grease for the life of the bearing. Motor CouDling A coupler is used to connect the motor to the pump. One half the coupler attaches to the motor and the other half to the pump.

l

Insulation

Circuit and Rotation

l

Armature components, Class H

l

Single Rotation

l

Commutator components, Class H

l

CCWDE, -

Commutator Servicing Diameters

+

to Battery Negative, to Battery Positive.

2.92”

.

Maximum Diameter, NEW

.

Minimum Diameter for RESLOTTING: 2.80”

.

Min. Diameter for REPLACEMENT:

2.75”

Brush Data .

1 Brush per Holder

l

4 Brushes per Motor

l

Min. Length of Worn Brush

,

Width 0.812” (20.8 mm)1

0.42” (10.67 mm) l

Max. Force per New Brush 29 oz. (825 gnI)

l

Max. Force per Worn Brush 12 oz. (340 gm)

l

Brush Drop

Grade HO03

Motor Brush

1.0 Volts @ 71 Amps Dee 94

Copyrighted Material 16-7-l 1 Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 16

Motors

Brush Inspection Chart I

I

REPLACE

IF SPRING TENSION

IS NOT THE SAME

FOR EACH BRUSH, REPLACE

PIGTAIL

REPLACE

SPRINGS.

REPLACE

BRUSH

BRUSH IF IS LOOSE

BRUSH IF OIL SOAKED

IF BRUSH PIGTAIL IS LOOSE AT THE

IN THE BRUSH.

BRUSH HOLDER TIGHTEN

SCREW.

0.42" 1 REPLACE

BRUSHES

WHEN WORN TO HERE.

NEW BRUSHES

SM-587

16-7-l

2

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

Dee 94

GEA-7053

COMMUTATOR CHECK CHART FOR

COMPARING

COMMUTATOR

SATISFACTORY

LIGHT

TAN

ohen

MOTTLED

FILM over entire commutator

surface is one of many

normal

conditions

seen on a well-fundioning

machine.

condition

WATCH

STREAKING beginning

on the oxnmutctor of serious metal

brush. Check the chart

COPPER

DRAG,

below

on abnormal

surface signals the

trander

dition is rare

to the carbon

for possible

build-up

mote&al, forms most ohen at hailing

causes.

of commutator

edge of bar. Con-

but can cause Rashover

SURFACE

tern is probably

if not checkd.

SURFACE

SURFACES

COMMUTATOR

with random film pat-

most frequently

SLOT

BAR-MARKING,

film, appears

observed

related

of

FOR

THREADING

THESE

on bon

to number

with

HEAVY

a slightly darker

GROOVING

fine lines resuhs

is a mechanical

to resurfacing of commutator

phere.

If grooves

HEAVY

SLOT

PITCH

BAR-MARKING

produces

low

surface. The number

ings equals half or all the number

brush wear.

or burned

spots

of these mark-

of poles on the motor.

CAUSES OF POOR COMMUTATOR CONDITION cgn..,ir. Onion. Tk.+I.” MaInO” in. F...q”.“, “hOI i”~pw+on o+ commwt* WV-.a,+* som. p0.dL.l. em”... d++I.” rmditions. ‘or..
Carbon Products General Electric Company Copyrighted East Stroudsburg, Pa. 18301

Material Intended for CLARK dealers only Do not sell or distribute

over entire commute-

is quite acceptable.

SIGNS

by abrasive

on the ~ommutotor

con appear

tar and, if uniform,

of conduc+ors per slot.

when excessive metal transfer occurs. h usually leads and rapid

FILM

areo of efficient and normal

in a definite pattern

DANGER

of commutator

MARKINGS

--

moteriol

condition cowed

in the brush

or otmos-

form, star+ corrective

BAR-MARKING

etching of trailing edge

can

of commuta+or

tern is related to number

qction.

involve bar. Pot-

of conductors per slot.

Cl!!JRK

Material Handling Company

GROUP 17 Section 17 Contactors Contents

Forward & Reverse Contactor Illustration .................................... 17-1-2 Disassembly ...................................................................................... 17-1-3 Forward & Reverse Contactor Illustration .................................... 17-1-4 Parts Inspection ................................................................................. 17-1-5 Forward & Reverse Contactor Illustration .................................... 17-1-6 Reassembly ....................................................................................... 17-1-7 lA, Line & Pump Contactor Illustration ........................................ 17-1-8 Disassembly ...................................................................................... 17-1-9 17-1-9 Parts Inspection ................................................................................. Reassembly ...................................................................................... .17-l-9

Control Panel SM-587

Copyrighted Material 17-1-1 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Contactors

GROUP 17

r ----------

Lock Washer Bolt

sclE%v-

Q%J- Lock Washel Washer 8‘2.7

I I l-

-I

------_--

(If

Conductor

Insulator

* =;5 &

f

L -----

Spring-&

Bracket

Support

J

(Not Serviceable)

Coil

Base

Forward Dee 94

I

Reverse Contactors 17-l -2

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

SM-587

Contactors Forward

GROUP 17

/ Reverse Contactor

A

WARNING

Disconnect battery before working on contactor tips.

Before attempting to disassemble a contactor to install a new contace set, carefully observe location and orientation of each part. 1. Check armature and movable contacts for freedom of movement by depressing movable are with a screwdriver or small rod. Refer to illustration on page 2. .

Check for any restrictions to movement and for retum of parts by action of spring.

2. Inspect contact tips. Look for any worn or eroded surfaces. Look for evidence of tip welding. Inspectforevidenceof any contaminants on tips (paint, dirt, paper or cloth material, etc.) which would impair operation.

.

Do not use sandpaper or file tips. Any damage must be corrected by tip replacement.

.

Tips must be replaced before they wear through and damage copper base.

To remove and replace contact tips:

6. Press downward on Cover (A) and completely back out cover screws until they are free of the contactor base. Do not remove cover yet. 7. Press downward on Cover (B) and disconnect screws from base. Hold pressure on Cover (B) and then remove Cover (A) from the assembly. Set cover and screws to one side. 8. Now remove Cover(B) and screws. Again, note

location of the buss bars, contacts and the large insulators (C)for ease of reassembly. 9. Remove and discard upper contacts. 10. Remove and inspect Insulators (C) for cracks and damage. An insulator found to lx cracked or broken should be replaced with a new one. 11. Remove and discard lower contacts. 12. Hold Bracket (D) with one hand and remove support sub-assembly (armature, contacts, etc.). The return spring should come off with the armature as it fits into a recess in the bottom of the armature. 13. Secure support in a vice equipped with soft jaws using minimum pressure to hold support.

1. Disconnect power cables from contactors. Removebolts with washers, lockwashers and spacers from contacts. Move power cables out of the way.

14. Loosen and remove nut freeing core parts (washer, insulators, movable contacts, spring seats and spring). Not the position and location of each part for proper reassembly. Remove these parts.

2. Disconnect connecting buss bars from contacts.

15. Pull insulator and core bushing from core.

3. Disconnect wiring from contactor coil terminals.

16. Remove armature core with spring from bottom of support and remove support from vice.

4. Remove mounting bolts securing Forward & ReverseContactorAssembly tothecontrolpanel base plate that is attached to the truck. Remove assembly fi-om truck.

17. Remove Bracket (D) from coil and base.

5. Disassemble the contactors. Loosen cover screwson bothcontactors. There are four screws per cover. Note location of contacts so the new

onesmay be installed to thesame location as the old ones.

SM-587

18. Remove coil from base. 19. Disassemble the opposite (Reverse) contactor in same manner. 20. Inspect armature core insulators for cracks, breaks, etc. If parts are found to be damaged, they should be replaced with new ones. 21. Inspect springs for damage. Replace damaged parts with new ones.

Copyrighted Material 17-l-3 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Contactors

GROUP 17 r

--------me

Lock Washer Bolt

s Lock Washer .z 7 Washer E3 l-

----------

Conductor p--

Insulator

L-_-_--l

Bracket

(Not Serviceable)

Coil

Base

Forward

/

Reverse Contactors

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

SM-587

Contactors

GROUP 17

Forward / Reverse Contactor-continued22. Inspect spring seats for damage (cracks, breaks, etc.). Replace damaged parts with new.

23. Inspect the thin washer located on the armature for cracks, etc., and security of mounting.

.

.

.

Material on the armature stem has been “up set” in four places to retain the washer. Inspect all four places to be certain this thin washer is properly retained and free to rotate about the armature stem. Inspect the “cone” surface of the armature and the corresponding surface in the base plate for scoring, etc. Inspect the small white bushing for wear. The bushing I.D. must be perfectly round. If the bushing becomes “egg” shaped (out-of-round), it should be replaced with a new bushing.

24. Inspect coil for damage. IMPORTANT

27. Now, secure the Forward Contactor Assembly Support into the vise using minimumpressure to hold the support. .

Install spring into coil recess.

.

locate white bushing over armature stem and insert armature thru bottom of support positioning armature “tab” into support slot.

.

Install spring and upper spring seat, upper contact, upper insulator, lockwasher and nut onto armature stem. IMPORTANT

Torque Nut to: 18 to 20 lb. in. (2.0 to 2.4 N*m).

28. Remove support and movable contact assembly from the vice.

29. Assemble the Reverse Contactor Support and Movable Contact Assembly in the same manner.

30. Now locate the Forward Contactor Support and

The coil has four blind alignment

holes in the top and two in the bottom These holesmustproperly align with the off-set pins in the bracket and contactor base at reassembly.

Movable Contact Assembly over Bracket (D). IMPORTANT Be certain the armature “tab” is pointing inward toward the center of the contactor base when positioning support over bracket. Refer to the boxed illustration on opposite page.

.

Inspect alignment holes to be certain they are perfectly round and not “egg” shaped (damaged).

.

Inspect coil terminals for damage.

Movable Contact Assembly over its bracket.

.

Replace damaged parts with new ones.

Again, be certain the armature “tab”ispointing inward toward the center of the contactor base.

25. Reassemble the contactors. Install both coils onto contactor base. Terminal connectionsmust point outward - away from cent of base. Be certain the coils are properly located over the base alignment pins. 26. locate Brackets (0) on each coil and onto the base. Be certain the bracket alignment pins properly seat in the holes on the top side of each coil.

SM-587

31. Now locate the Reverse Contactor Support and

32. Install the long lower buss bar and stationary contacts (having threaded holes in one end) into the grooves located on the top side of each contactor support The cable end of the buss bar should extend outward on the right hand side of the forward contactor support and extend outwardon thelefthandsideofthereversecontactor support. Be certain the notches in the buss bar and stationary contacts properly seat with the screw guides of each contactor support.

Copyrighted Material 17-1-5 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Contactors

GROUP 17

-r __---- --

1

Lock Washer Bolt GQ- Lock Washe WasheN 8g 7

Conductor III!

Insulator

k+ m

Fastener Lock Washer Insulator Contact Spring Seat

Bracket

Forward Dee94

I

(Not Serviceable)

Reverse Contactors 17-l -6

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

SM-587

Contactors

GROUP 17

Forward / Reverse Contactor-continued33. Install the short buss bar and stationary contacts (having threaded holes in one end) in the same manner as previously described. Be certain the

notches in each bar-fit properly to the screw guides of each support. 34. Position Insulators (C) over the buss bar/contacts and supports as shown in illustration on opposite page. 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.

35. Assemble spacer, upper buss bar/contacts over the insulators. Make certain the contacts are seated properly in the insulators.

36. Assemble covers (A & B). Make certain covers, buss bars & contacts are in alignment and press both covers downward with one hand ... hold in this position and install all cover screws until snug. Check to be sure all parts are in proper alignment, and position the Power Cable Bolts (with lo&washers, and washers) thru the upper buss bar/contacts and spacers. Tighten bolts finger tight into the lower buss bar/contacts.

37. Tighten cover screws to: 14 to 18 lb. in. (1.6 to 2.0 Nom).

38. Use a bar or rod to move contacts. Be sure movement is free of binding and that tips are in correct orientation and tips contact correct mating parts.

39. Install Forward &Reverse Contactor Assembly to panel base plate.

SM-587

Copyrighted Material 17-l-7 Intended for CLARK dealers only Do not sell or distribute

Dee 94

Contactors

GROUP 17

&-Lock

Nut

_ockWasher

Washer

Spring Seat

r

----

1

Insulator

k -Armature

I I I I I I

tT---g-Spring

I

Assembly

I I I

I I I I

Retainer

I

L -----

Base

I-A, Line & Pump Contactors

Dee 94

17-1-8

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

SM-587

Contactors

GROUP 17

I-A, Line & Pump Contactors

A

7. Remove lock nut, contact set, insulating washer

WARNING

Disconnect battery before working on contactor tips. Before attempting to disassemble a contactor to mstall a new contace set, carefully observe ti

location and orientation of each part. 1. Check armature tid movable contacts for freedom of movement by depressing movable are with a screwdriver or small rod. Refer to illustration on page 8. .

Check for any restrictions to movement and for return of parts by action of the spring.

2. Inspect contact tips. Look for any worn or eroded surfaces. Look for evidence of tip welding. Inspect for evidence of any contaminants on tips (paint, dirt, paper or cloth material, etc.) which would impair operation.

.

Do not use sandpaper or file tips. Any damage must be corrected by tip replacement.

.

Tips must be replaced before they wear through and damage copper base.

and spring fi-om armature stem. Be careful not to disassemble or loose other parts under contact tips on armature assembly.

8. Install spring, washer, new contact set onto stem and secure with lock nut.

9. Assemble contactor by putting moving contact assembly armature shaft into coil plunger with return spring on top of armature shaft. 10. Put top cover over spring and install cover mounting screws. Be sure return spring is in the

cover recess. IMPORTANT

When assembling cover to base (frame) make sure it is installed with thepositive sign (+) markings located properly. Use a bar or rod to move contacts and be sure movement is free of binding. Be certain contact tips are in correct orientation and tips contact correct mating parts.

To remove and replace contact tips: 1. Loosen andremove two cover moun ting screws securing cover to coil frame. Observeposition of

positive (+) murking on the cover. to note locationofspring seat and spring under cover.

2. Removecover.Besure

3. Remove lock nut and lockwasher from each stationary contact stud. 4. Remove contact studs from cover. 5. Install new studs and secure with lock washers and lock nuts. Tighten lock nuts firmly on each stud. 6. Lift armature assembly with movable contact set from coil frame. Observe location of compo-

nents upon removal. SM-587

Copyrighted Material 17-l-9 Intended for CLARK dealers only Do not sell or distribute

Dee 94

MaterialHandling CMRU Company

Group

19

SECTION 2 ELECTRICAL SEQUENCE OF OPERATION

Sequence

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..Page

OPERATIONAL SEQUENCE #1....................................2 Connect the Battery ..................................... ...4 Close the Key Switch .................................... ...6 Close the Key Switch (Continued) ........................ ...8 Steering Function..........................................lO Steering Function (Continued)..............................1 2 Brake Switch & Static Return to Off (SRO) Checks...........1 4 Energizing the Directional Contactors......................16 Turning ON the Transistors.................................1 8 Turning 'OFF' the Transistors, Capacitor Charging and Flyback....................................................2 0 Accelerator, Thermal Protector and Pulse Monitor Trip (PMT)......................................................2 2 1A Contactor Operation.....................................2 4 Plugging...................................................2 6 Plugging (continued).......................................2 8 Plugging (continued).......................................3 0 Travel Speed Limit.........................................3 2 Solenoid Functions.........................................3 4 Lift.......................................................3 6 Lower......................................................3 8 Reach / Retract............................................4 0 Reach / Retract (Continued)................................4 2 Tilt.......................................................4 4 Tilt (Continued)..........................................4 6 Side Shift (Optional)......................................4 8 Side Shift (Continued)....................................5 0

SM-587

19-02- 1 Material Copyrighted Intended for CLARK dealers only Do not sell or distribute

Rev Aug 94

OPERATIONAL

SEQUENCE

#l

This standard schematic is shown with all switches and contactors in their normal 'OFF' position. No circuits are operating. The four basic areas of circuitry are identified.

TRACTION STEER

CONTROL and

HYDRAULIC

AUXILIARY

CONTROL

CONTROL

ACCESSORY

Rev Aug 94

19-02-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

2

r-

I f); I j ;

li

12

12

12

,

..

2

..............

12

..................

,

2

..................

,

2

...........................................

,

EVT 15 CARD .: :......................

................... 2 .................... 2 .................... * ..............)* pB,

..... .... ......

I 12

----41

+XE ,

;

t.........., 0

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

,

0

TB,

. . . . . . . . . . . . . ;..+

24

Fp86

. . . . . . . .._.........

0

..,...........

$

m4

py,3

_.;

. . . . . . . . . . . . . . . . . 6,

. .

. . . . . . . . . . . . . ..___....

6,

. . . . . . . . . . . . . . . . . . . . . . . . j__,

SWITCH rel="nofollow">;,

12

. . . . . . . . . . . . . . . . . . 2, ~15~------+ G

.. . . . . . . . . . . . . ..____...

R 23 ------23

1111111111111111__11I

10

12

. . . . . . . . . . . .. .. . . . . . . , lo-

.. . . . . . . . . . . . . . . . . . . . . . -45

45

; cT810

_NO,D

. . . . . . . . . . . . .. . . . . . .. . 12

18 . ..,. . . . . -... .,O

. . .. . . . .+...%.

. ..,. . . . . . . . .,O

. . .. . . . .,&..??...

_..___.____.._......., l2

_.:I . ..58

. . . _.‘. . . . . ., 58

a ,. . . . . ./.z

FUNCTICN CcnrrRcc

,. . ..i ._.__.____._..........

I I

... .

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

HYDRAULIC FUNCTION CONTROL

OPERATIONAL Connect

the

SEQUENCE

#2

Battery

A.

Battery positive will be applied to terminal PB-1 of the EV-T15 control card through wire #2.

B.

The negative circuit will be completed from terminal PZ-3 of the EV-T15 card through the brown wire, to the control panel negative cable terminal.

C.

The EV-T15 card, through an internal circuit, supplies a controlled capacitor charging current through the white wire at terminal PZ-14, to the positive side of the 1C capacitor of the EV-T15 and PS-1C capacitor of the EV-T5PS power steer control.

D.

The capacitors will charge to battery volts in approximately 2 seconds. When the 1C capacitors are charged to battery volts, the flow of the charging current will stop.

Note:

Status Code -51 will be displayed do not charge to above 85% battery -51 to be displayed for Status Code charging time, when the during the plugged in.

E.

Battery Positive will be applied to the accelerator through wire #2, control fuse 2FU and wire #12 on trucks equipped with solid state transducer accelerator.

Note:

equipped with potentiometer Trucks positive connection. battery

F.

The Negative circuit to the accelerator will be completed through wire #13 to the control panel NEG cable terminal.

G.

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.

H.

The horn is operated by pushing the horn button which will supply battery voltage to the horn through wire #25, and negative through wire #13.

J.

Battery Positive is supplied through wire #2, control fuse 2FU and wire #12 to the key switch.

if the 1C volts. It for about battery is

will

capacitors is normal 2 seconds initially

not

have

Voltages Present: A. B. C. D. E. F. G. H. J.

Battery positive Battery negative Battery positive Battery voltage across 1C capacitors Battery positive Battery negative Approximately 3.7 Volts with handle in neutral Battery positive on wire #25 Battery positive on wire #12

Rev Aug 94

19-02-4 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

r2 24/M

VOLTS

............................................... ................................

P_

6,

...................

i

:......................... 20 .............. . i ;............. 40.. .......................... .

i i30

......................

i ;3

iL---f._

j-----

s-L’29

2-2-2

_...., 0 . . . . . . . . . . . . . +-c

. . . . . . . . . . . . . . . . . 24 IA

10 -/* 0

PB6

......................................

0

,

..................

...............

%.

. 5 ..................

...............

o ..............

,

5 ...................................... , 5 .................. i.. ......., 5

4.. ........

, 5 ..............

,,A!.

8

...................

................

27

..................

i.*

TO4

, 5 ............. {.*m3 ,5

.............

6-----6 ................

6 ............... ..............

27

23 -23

pyo

py,3

JlG i

q, .: .....

0

._,30

...4

i

.. .._........_..........~

o

4

........................

61

0

.............

o

...................

I

pA,,_;. ,,,+_____

i.* T86

PA3 -.I..

I.* p&(

PAZ -_I.. ..............

‘*Fe5

py5 y---y P,M P;3

; oTB,d

;._ . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . &d&%...,, 1

+______---,O_____+

. . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . +.Ta,a

AUX2 a.----__65

61

Pi!

...........

...............

34

.....

54

___+.&.____,3

Sk2

......

. 3 __________I____

SL-3

.................

1 lo-

,2

i ; _.,_ _ _...

I’ , 2

TILT

2 o ........................

i,

26

26..

j

.......................

........

.

__._ .

. .,

s1

: :

. _,58

. . . ..,. .,p._.??.._.

. ..___..........

26

..20

TBge;

,B,

. . . .._........._......

26

.__._.................

20

20

.13

.........

. . . . . . . . . . . . . . . . . , 3 . . .. . . . . . . . . . . . . . . .. .. , 3

; ST010

26 ______...._.. +a jlTB6

16

16

0 _.._ _ _... .,,4...??...

+

....

._........... +T6,,

45

P . . . . . . . . . . . . . . . 26 .._...................

10--x+

{ _... . ..,. . . . . . . . _,O

. . . . . . . . . . . . .._____...55

-45

& _________....__..__......., 0 . . . . . . . . . . . . . \/:

m,

t..

2 o ........................

_--_-----65-----~~T~,~

.J- + .__._........_. RZbCH 55 0 . . . . . . . . . . . . _L *

j

SL-1

; * TBS

0 . . . . . ..___...i.
61

.

26

5

;O

........... PA6 ,.j................. ‘,4 ......... +-+........., 3 ........................

:.+ . . . . . . . . . . . . t . . . . . ;_;

0 .._.___...............,,

i

304b

-

j.* TB.2

iP,y’

. . . . . . . . . . . . . . ..___...............

.

PS-IC

__ _ ..?. . . . . ., 56

.

.+,S

SOLEN3lD FUNCTION axrFcL

..56

. . . . . . .. . . . 3 6 $ . . . . . . . . . . . . . . . . . . . ___.._., 0 . . . . . . . . . . -.._+r...S3 . . ..____.__._. ,/,...% 1_________._._.______------, 0 . . . . . . . . . . . . . v4_..?.!

. . . . . . . . 46 . . . . . . . . 46

12-25

SWITCH Copyrighted Material 19-02-05 Intended for CLARK dealers only Do not sell or distribute K)RN

l-cm

13

94

OPERATIONAL Close

the

SEQUENCE Key

#3

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 voltage battery

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 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.

be displayed Code -15 or -16 will is less than or higher than the function #15. voltage setting,

if the battery preprogrammed

(close)

Voltages Present: A. B. C. D. E. F. G.

Battery positive on all #lO wires. Battery negative. Approximately 11 volts across the coil. Battery positive. Battery positive. Battery negative. Approximately 15 volts.

Rev Aug 94

19-02-6 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

BATTERY

._

l_,.

._

24/36 VOLTS

1 FU 2FU

0

D

61

l-l0

12 10

12 10

10

2

!O 61 lx6

................. .E?.................... ........................ . ...........

w:

12 10

10

I

2

yfxI-;=‘.i

p@j ,.; ............ .... . 3. ............... .. ...... 30 .. .... ......i

10

12 10

10 cI_y*

I

IA

41-41---+

pB6

PW *:

15 ...................................... , 5

6 1 ...................... 6,

5 .... .... ... ...... , 5 .............j.* TB* ...... .. .. ...._FwD” ___.____.___..,

i--_l5A

.....1 ......................_;

SL-1 4 4 ....... .iw& ....... 13

.... .... .... ... .. , 5

iaT

6-6

;

40:

40

10-10

10

t ......... 15

1 1

12v13J

-i_

. . . .-.... . .,a ,. . . . . . .iSL-3 54 ---..?a&.___., 3 . . . . . . . . . .t.

PA4,.j .. . . .. . . .34

..

PA+____

..

20 ................._..... 2. .....................“f * .................. B...............i.* TB6 pAa*_I.__..._.......... ;......... 1fj ..............F!0 ........_..._.... 26 ......... 27 ............_...“2..............i.* pB4 ,,A*-_I..... .......... 26 ...._._.______.____.... i .____..._., 5 ..............\$7 ......._......... R :15 ,-p 23 -23 Ii

10

26

I

*lo-k5 L-lo

,(,,-a lo1 0 ._\fi

_____,

-

1 i 112

SM-587

26

10---G ---,

j*TBM

TB8 *.

...................... 35 .............i.:*,,I,~

_i.,6. ____ AUXZ--es

----‘,(,---

““‘10

.

.............. 5

-________

”

. . . . . . . . . . . . . . . . . . . . . . 28

‘0

:*TB6

. .,58 . ..?. . . . 56 . . ..,.. .j.<785 0 ___>p...%. . ..58 . . ..i s3 10 $ .._.___..._..... 38 ...____.___...._...... 38 .............+,, E\...%..

.....................

.....................

.26

.20

........

13

.A

......................

-13

B I 1;

. . . . . . . . . . . . . &TO8

16

16

20

-13

65 -----;+TB‘Z

-- ..._.................. 55 .............;.
................

~ 2;

SOLENOID NNCTKMl Oa-rRu

46 .......0 .... ... ...... 46 .. .......... .;.+TBa

1o

,&s6________. 4; ___..__. i 12

,~

:.......................;

H3RN SWITCH Material Copyrighted Intended for CLARK dealers only Do not sell or distribute

Aug 94

OPERATIONAL Close

the

SEQUENCE

Switch

Key

#3

(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 reminder will be display

exceed truck hours the preprogrammed hours (functions 19 & 20), a Status displayed for about 1 second between and the -01 display.

maintenance Code -99 the 8888

Voltages Present: H. J. K. L. M.

Approximately 10 volts. Battery volts across the 1C capacitors. Battery positive. NA NA at dash display, approximately 2/3 battery volts at terminal TB-2.

Rev Aug 94

19-02-g Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

BATTERY

*HIwe

r2 2

24136

VOLTS S

FUM?hKITORA

2FU P \...

. .. . .. . .. . . .. . . . .. . . . . . . . . . PS-IC 61

:::::::::::%;:I PS-TP

I I

PSNEG

2

10

50 SrE ER ... . TRAN>CUXR

r

I

I

:......................... 2(J............ ............................ i

m : s; .

I

-.,

61

.....................

t 2

]

$FlELd

2

2

-12-12~12

t

:.EVT .......15 ....CARD .. . ..: 2

-2

j .PB1

2

10

24-----24

” IA

10 -/%

41-4,

f .. . . .. . . , 5 . . . . . .. . . . . . .

_....................... , 5

. . .. . . . . . . . . . . .. .

PY13 0

F y . . . . . . . , 5 . . . . . . . . . . . . . . ,, A. . . . . . . . . . . . . . . . . . . . ‘-15

2,

; * TM . . . . . . . . . .._......2.

. . . . . . . . . . . . . i.*

-+R

-I

1. lo-

12

lO----v~

12

s1

82

13

Two TBlC

. . . . . . . . . . . . . f.cTB,,

45

;snwo

18

._.___................

112

. . . . . . . . . .

83

26

_..20

-26 .._...................

. . . . . . . . . . . . . . . .._.....

2.

1

13

-13

li

18

_____+...S.?...

j*TBs

SOLENOID FUNCTION a?NTRci.

1;

I ‘r SM-587

SL-3 ___+.+.___.,3

28 . . . . . . . . . . . . . ;.oTBa

. -58 . . ..‘-. . . . 58 . . . . .j..T& ___________,o______+?.? . ..58 . ..i s3 10_$. ...__......_...38 ...................... 38 .............&TB4 55 , ,, _~/‘_..__._........ 48 .......f ............. 48 .............+,a :.. . . ........... ... ...; S6 , 0 _v4 .__..._........ 48 . . . . . . . i II

___________,O

54

‘26

. . . . . . . . . . . . . . . . . . . . . . 55

TILT

-45 P \h .._._._..._..... 28

10

61

---------65-----~rTB,2

-J--w * . . . . . . . . . . . . . . 55

,O_,

81

. . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . &,3

AUX2 b------65

. . . . . . . . . . . . . . . . . . ..

26y

j-b TB14

5 “~_~...,5

___________,O_____+

,,+_____

10 ---+TBlS~

10

,o-Es 12

61

p+s

10

1o

:

4.

m

80

c

29-

. .. . . .. . . .J4 _..__.QPQ_...__l 3 ---------, 5 ..__......... j.. TB2 pAd._j

6-6

f-15-z

. ;

pyg *.; . .._________.._._ 4. ,.......................

-----j-p86

lo-lO+TB4

10

3RAK!z

TBI

A i ; .PE* pwc.j................ 3. _....____...............~~............

AL

12-

-

l

HORN SWITCH I&-09 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

-

131

Rev Aug 94

OPERATIONAL Steering

SEQUENCE

#4

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 The amount of current flowing out of the capacitor will negative. 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 PS3REC.

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:

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

Rev Aug 94

19-02-10 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

standing on from the Steer Motor

SM-587

r2 2

STEER SXK SWITCH

2FU

_,

rI

t 12

12

ITCH

1

i

c 10

12

-10 12

10

12

10

12

10

1 12

-t

c -1

R4KE 0 PITCH>!<

LL

10

24-24

”

IA

0 -/+

41-41

, 0 _,

10

30/ 30 4o ..................i ; * PB6 pyo*.!................ 4. .............___.__..... Tm py,3*.I.................61 .............___._...... 6, .....................

i.F-32

o+

Fwrj

SL-1

&++;...... , 3 ...................... , 5 ................. , 5 _._____._____~.~ 44 ._...... m3 p*G+. .............__. ~.________ , 5 ......~...............................

12

.-.....,..,34 5 ................. , 5 ________.._._~.. m2 PA4,.j ~...___.._, 5 ....""..""._..&...'............... 6------6

f______.__., i ~~~~~~~__.~

i

4% . . . . . . . . . . . . . . . . . .

5

. . ..__.......

5

. . . . . . . . . . . . .

,5w&

$

.__.__..._.__.___2,

R

6

. . . . . . . . .. . . . .. . . .. 6

.____._.._.._.._..2,

.. . . . .. . . . .. . . .

pA5+______

54

PA3

2.

. . . . . . . . . . . . . i.*

23-23

m

60

10

5

^t AUX2 _* +______65-----____

, 0 _,

61

+oT014

. . . . . . . . . . . . . . . . . . . . . . 35 .............+B,3

10_Jne??L35 ___________,O_____

PA2

lo+TBl5

10

lo-L5

*_;

. . . . . . . . . . . . . . . .

26

;

___-"___.,3_________ . . . . . . . . . . . . . . . . . . . . . .

2.

. . . . . . . . . . . . . . . . . . . . .

26

$iEf$-l

12

12

; * TB5 i.&TB6

. . . iy3 __....13 ________-

66

62

13

63

1 26

TB7.

-

TBOb

-20

26

2620

TBl.

-13

13

i

____+,2

IFEACH *_..__._.......'55 ...................... 55 .............& TB,,

,0-G-GE45

i_cTBlO 45 P , 0 _--L/c...............26 ...................... 26 .............+

____-______,O 12

I ‘r 112

s1

16

16

______,,4.__5?..._.,

56

.. . ..+.._...._. 56

10-k ___________,O

SM-587

I?

.saENOlD

12

VT= .. . .... ..~.r~~

FUNCTDN Cm-ma

______+.%.....56 .. . ..i , 0 _$....S? ........ 38 .___.___.__.________.. 38 .............j..,Te, , 0 .__---\&..S5 ..........46 .......y............ 46 .............f+T&j 5...__. . . ... ...... , 0 __yI\ ...S6 ........... 46 .......i I 12

-L KIRNSWITCH

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

1:

13 1 Rev

Aug 94

OPERATIONAL

Steering

Function

SEQUENCE

#4

(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. 2. 3. 4. 5.

Note:

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

When more then one signal is present, the demand signal has the- priority on ON-time

highest demand.

RPM

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 (nonadjustable).

M.

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

N.

If over-temperature conditions exist, the a signal on wire #40 from terminal 4PL4 of terminal PY-9 of the EV-T15 control card. will sense the signal at terminal PY-9 and Code -90 on the Dash Display representing 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.

EV-T5PS card will send the steer control to The EV-T15 control card display a Status that the steer control

Voltages Present: J. K. L. M. N. P.

Battery voltage across the capacitors. NA NA NA Battery Negative NA

Rev Aug 94

19-02- 12 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

r2 2

B

1 FU

2FU

MC .I

)R '+-m

6:l

TPS-TP

I

*.

m

s

r-i 12

SWITCH

12

12

10

6'1

rlo c

10

10

I

I

*#,L

10

IO

t=

IA

10 -$

24-24

;.Paz

pw

*.~.__._..__........ 30 ......_......._..___...3 0 .._..._...;

41------41

;*Pm fci

pys ,_.~-~..40*'-'--'40.-'~~

lbTB5

PAS*:------

1

. +---15A

6------6

54

L

^-

-

_

_

_.,

3

.................

...

2..0 ............... 8 ................... i..........15.............. B............... i.. TB6 PA3 _.I................. 2o ..................... ...20 ........................ F f___._.,l5 ................. 27 .................. ................... . 7 .............. ..*pB4

li

261

8

10

lO+TBl5

10

. . . . . . . . . . . . . . . . . . . . . . 35 .............;.*TB,3

Ls?3??!...35

_.i.s

AUX2 _,,b______65

.___________lO_____

lo-

1,, _\/.. 12

_________

d._ TILT -45 P

28-

Te.7.

-

T80.

................. 2. ._..__._.........._2 0 .......................

TlJ,,

-13

13

_____+2

45

+%TEWJ

_____._........ 28 ..........__.__.___... 28 .............j.+TBa

10 -4%

s1

18

18

,,___________10_____+..??,_...58 ',___________lO

65

26

i

.,_____.___.._...5 5 ................_._... 5 5 _.._____.....~.~ TB(,

lo----+-,

;o TOI4

5

lo-+=----5

"'"r'..."'.

58

;+T86 . . . . . .i.(TBS

SOLENOID FUNCTION CONTROL

______~~...~.*.,.....5* .. . ... 1 0 -,r....s3

...........38 ...................... 38 .............~.~ TB4

s5 1 0 -~~,...............48

.......y........48 .............& T&,

S6 1 0 -+._.___..____.4*

.___..._i

12

SM-587

26

:

1;

10

12

PM*

12

K................... I HORNSWITCH

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

131 Rev

Aug 94

OPERATIONAL Brake

Switch

SEQUENCE &

Static

#5 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 (Status Code -02 or -03) must be less than 50% battery volts. 3) Checks the accelerator input voltage at terminal TB-1 of the (Status Code EV-T15 control card. Must be greater than 3.0 volts. -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 positive number dependent on the battery the LED above the battery symbol will be

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).

as a 3 digit and condition, 'ON'.

Voltages Present: A. B. C. D. E. F.

Battery Positive Battery Positive See explanations l-3 above. NA Battery Negative 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 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

mER ax SWITCH

2FU

ri

24/36 VOLTS

IFU

s

WM'PM3TORA

........................................................................*.~~~..... ,...................................... <\

f..!u

r-r 1050

t 12

12

%TCH

12

rlo

12

10

12

10

c 10

10

10 Rx

12

10

10

2

ACCELERATOR 7-T 7

li

12

..._............_.2. 23----23

12

, 0 -s??!K..35 12 ‘,___________,O

_____

j

..___........ +,(f

i

J_e TILT ;-%Ttm 45 -45 P . .._........_.. 26 ..__._..._..._.__..... 26 ______.......+a s1

_____+..?.?

,.______--___,o

_____+..S.?.._. lo-$

16 .,....

56 ..66

_~ s3 ,_.._...._______ 38 n.25 ..........

10 _v4

. . . . . . . . . . . . . . . . . . . . . 55

S6 ...............

..__.? _._......

13

=I*13

_____+Ta,s

lo-

,,___________,o

t-10-

66

IFEACH 0 . . ..__......._. 55

lo-~

12

^________

,O_,

,O_$ 12

...................... 35 ......_.....+. T6,3

e-i_ AUX2 d b______65

16

; *Tm

56

.. . . . . . . /..TBS

/ i

SOLENOID FUNCTKN

icxzsrrm

. ..: ___..__._____.........

46 ....... y.. ...........

38

. . . . . . . . . .._.

46 .............

j.+T&4 ;+ TB3 :.......................

48 ....... .1

.

I 131

SM-587

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

Rev Aug 94

OPERATIONAL Energizing

the

SEQUENCE Directional

#6 Contactors

A.

Moving the multi-function control lever towards the front of the truck will close the forward switch. With the forward switch closed, battery positive will be applied to terminal TB-5 of EVT15 control card through wire #6.

B.

The EV-T15 control will now make the following start-up checks: T2 voltage must be above 12% battery volts. This checks for 1) shorted 1A contactor driver, shorted power transistors, or welded 1A contactor tips. (Status Code -46) T2 voltage must be below 88% battery volts. This checks for 2) shorted forward or reverse contactor drivers, shorted #3 REC, 23 REC or welded forward or reverse contactor tips. (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 (Status Code -42 or PZ-12 and PZ-13 of the EV-T15 control card. -43)

C.

When the EV-T15 control card senses battery positive at terminal TB-5 and 0 volts at terminal TB-6, 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.

Note:

If battery and TB-6 at (Status Code

D.

This will energize the forward contactor coil and in turn, open the normally closed contactor tips and close the normally open tips.

E.

The BV-T15 control card monitors the current flowing through the directional contactor coil circuits. Status Code -23 will be displayed if the current is less than a preset value.

voltage the same -09)

is applied the time,

to both terminals TB-5 control will be shut OFF.

Voltages Present: A. B. C. D. E.

Battery positive at terminal TB-5 See explanations l-3 above. lo-13 volts across the forward contactor coil. NA NA

Rev Aug 94

19-02-16 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

BATTERY >wilc-
r2 EER _ax SWITCH

2FU

.. ..

I-f10 50

t

ri

I FU

12

ETCH

12

10

rlo c

12 10

10

12 10

10

12 10

10

t

I

10

li

I

2

b

13

EVTl5CARD __.. ........ ............!

*,L

10 10 -/‘IA

24 -24

;*Fw

Pea.;

41-41

frm

PY8

l

30

:

40

12

__________+___ 15

REV xs . ... ..............

15

t-

12

*F

15

__________e___

6-6

1 I

27-27

*

15

li 1

26

WI

:

Dpz

,.i

OlSPlAY\

I

\Dp5 10

,311

.+82 ;

lo1 ,, _$

SM-587

. . .._.................

_^

I

-1

I I

j eTB14

35 ....... .... ..+B,3

TB7.

-

Tw*

-20

26

261 20

TBI.

-13

13

j

_____+TB,2

IFEACH * .......... .... 55 . ..... ............. .. 55 .............&TO,, _J_ TILT ;*TBiO 45 -45 P . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . j.oTW

10-h ,p___________,~

_____+...??.,.

,,___________,O

______+.?8

I”

-82

5

AUX2 _-_-_.a 1- “-______65_-----_-_65 ,O-----L

12

._

,a-,3

,‘,~TB15

10

,o_,++%?%..~~

,___________,O

12

::

2b

i&+-+83-83-

lo-k5 12

.......................I

...................

s1

10

,a

. .,58 ._. ..?. .

j+T*6 . . ., 58 . . .. . . ./.rTBs

SOLENOID FUNCTION aavrROL

...___.5 8 .. __.i

, 0 _$ ....s ........ 38 __.__................. 38 .............i_+TBd T............. 48 .............;.QTB~ , 0 ____.A...S5 ........ 48 __.___. ; .... . .. ... .... S6 , 0 _y4 . . . . . . . . . . . . . . 48 . . . . . ...! I

l2

,&_,7 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ,&WiTCH

&

l3

Aug 94

OPERATIONAL Turning

ON

SEQUENCE the

#7

Transistors

A.

The W-T15 control senses that the forward contactor has closed and the motor circuit is not open when it senses that the T2 voltage, through the blue wire at terminal PZ-9, is at battery positive.

Note:

Status Code less than 88%

B.

-24 will battery

be displayed volts.

if

T2

voltage

is

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.

A signal

C.

The EV-T15 control card applies a gate voltage from terminal PZ-4 and PZ-3, through the red and brown wires respectively, to the The transistors turn 'ON' completing gates of both transistors. the drive motor circuit to battery negative.

D.

Current now flows from the battery, through the 1FU fuse, the line contactor, sensor, drive motor armature and field windings, the closed directional contactor tips and through the transistors to battery negative.

E.

Current will also flow from the 1C capacitors through the same drive motor circuit to battery negative. The amount of current flowing out of the capacitors will depend on the percent ON-time of the control.

F.

The interaction of magnetic energy between the motor fields and the armature causes the armature to rotate.

Voltages Present: A. B. C. D. E. F.

Battery positive at terminal PZ-9 (T2). Less than 3.5 volts at terminal TB-1. Not measurable. Battery positive. N/A N/A

Rev Aug 94

19-02-18 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

2FU

-;t Bu(

I

a”, 91

t

t

T

t

I

!I

92

93

50

30

40

20

6'1

rlo

10

10

1 ) ]

_~2+#+~---13EVIlSL‘AHU

24-24

PM,.;_.,......_.34

l5-15yTe2 6

I--_ ‘5-A

R

6

: . TB5

54

pA5+_____

...__i~3...___13 __________ .___ ___-____,3__________

.___

6 ...._........__.._. 6 ___.______.__..~. TB6

PA3 ..;.................20 .__..__.................2 o ,.......................

27-27+m

PA2

;

26

26~

23-23

12

10

10

lo-=5 ,O _++?w. 12

,,___________,O_____ lo-

1

SM-587

-

; *TB14

-20

lBBS m, c

26

-13

65-w--+(2

1-H'.....______._..55 ..................... 5 5 _.._.........+ TB,,

_i.. TILT -45 P 1 0 _&_.___.__......26

12

; .TB15 Twc

35 .........._........... 35 ..__.._._....j.* Ta,$ _.i_ AUX2 4 b_-_---65~----____

45

lo-

12

10 5

j* TBlO

..................____ 26 ._..........+ TBB

lb SoLEralD FUNCTKN

16 lO--.---v~ s1 16 i * ~6 aNma ,,___________,o______+S? .__.._ 56 .. ..“‘..,,.... 56 . . . . . ./.rT85 ,,___________,o_____+...?. .. . ..56 . ..i , 0 _,r....s3 ...........36 ...................... 36 ...............+184 , 0 ____._A...S5........ 46 .......p............. 46 .............j.*T&l c..................... .f S6 , 0 __V4...._......_._48 ._....._i I 12

12

I-DRNSWITCH Copyrighted Material 19-2052-19 Intended for CLARK dealers only Do not sell or distribute

d i-cm

Rev

Aug 94

OPERATIONAL Turning

‘OFF’

SEQUENCE the

#S

Transistors,

Capacitor

Charging

and

Flyback

A.

The control now removes the gate voltage and the transistors turn 'OFF'.

B.

The current stops flowing because .the battery and capacitors no longer have a circuit through the drive motor. The magnetic energy of the drive motor field collapses. This collapsing magnetic field induces a voltage across the field that is opposite to battery voltage.

C.

This reverse voltage forces current to flow through the #3 REC, sensor and armature. This current, called 'FLYBACK CURRENT', continues to drive the armature during the transistor's OFF-time.

D.

Battery current will continue to flow into the 1C capacitors during the transistor OFF-time because the line contactor is This closed and the 1C capacitors have been partially discharged. current will stop flowing when the 1C capacitors are charged to battery voltage.

Voltage Sequence: Too quick to measure.

Note:

Note:

compared to battery Average drive motor current, times as great will be about two to three current, the transistor range. operating in The generated 'ON' and

Rev Aug 94

purpose voltage 'OFF'.

of the spikes

#23

REC created

is by

19-02-20 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

when

to filter the the #3 REC turning

SM-587

r2T 2

2 STEER

2FU

I

24/36

1 FU

VOLTS _

WM’MOTOR

k%

I 12

2

ri 105(

10

2

10

r-i 12

SWITCH

12

5(

rlo -l-P

12

10

10

2

12

10

10

2

12 ACCELERATOR --.Y

t 12

*L

E ” 10

lb

IA

1 0 -/?

EIRAKE 8iWITCH

24 -24

--+a

P83.:

41-41

------+Pfs

PY8 .

30

301

40

40 --I

py,3 *./ . . . . . . ..___._....61 ,.......................

lo-lo+T84

10

;

6

, ......................

b 12

10

_____

12

10

10

104TB15

10

,,~._.___~:.~...35 12 _-________,o

_----+

;oTBM

5

10-9-5

. . . . .._.._.__......... 35 . . . . . . . . . . . . . j.+TB,S

_.i_ AUX2 b______65

_________

65

TB7*

:

TBS*

;

20

20 13

m’y13

_____+,2

..I- * . . .FEPCH . . . . . . . . . . . . 55 .._____.___.__.__......5 5 . . . . . . . . . . . . . +l,,

lo-

A

TILT

lo-

P ._.._.____.....28

10-----u”

s1

__________,o

______+.5?

__________,o

______p...??

j.%TBlO

45

-45

,0-/t

. ..__.._._.._.........

. . . 56

. . . . . .. . .. . . .

;.eTBB

16-----f+TB6

16 .._._. 56

28

. . . .+. . . . . .

56

. . . . . .i.
13

j ;

SOLENOID FUNCTtCN ;ccNTRoL

. ..i

_.

‘O-

, 0 -&..S , 0 -v4..

fi....s.. ...... 38

........... 5 .S6 ...........

......................

46 ..... ..?. ............ .4a ........

38

112

13

j.+,,.,

j.eT83

:....................... .

I -

SM-587

.............

46 .............

1

12

d HORN SWITCH w-2d2-21 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

i-cm

13-

Rev Aug 94

OPERATIONAL Accelerator,

SEQUENCE

Thermal

#9

Protector

and

Pulse

the transistors ON and OFF produces a technique that controls the pulse rate and/or used to control the speed and/or power of the rate and/or longer pulses produces more speed Turning

Monitor

Trip

(PMT)

pulse. A switching length of the pulse is truck. Increased pulse and/or power.

A.

The rate and length of pulses is governed by the accelerator and the current sensor. 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. 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.

B.

If the control is overworked, the transistors and the built-in thermal protector (TP) will get hot. Resistance in the TP will increase and reduce the current limit regardless of accelerator This reduction in current limit is called 'Thermal position. Cutback'. As the control cools, 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.

Note:

Even at reduced current the truck should be able 1A contactor operation.

C.

When the transistors are turned ON, the #3 REC stops conducting.

D.

The blue wire to terminal PZ-9 of the EV-T15 control card allows the control to sense pulsing. If the transistors fail to turn OFF, the card opens the circuit from terminals PB-4 and PB-5 to battery negative so the directional contactor coils de-energize, dropping out (opening) the contactor tips.

E.

The control AGAIN' mode exists. To closed with

limit during thermal to reach sufficient

cutback, speed for

will quickly re-close the proper contactor in a 'LOOK and drop out the contactors (PMT) if the problem still reset the PMT, the key switch must be opened and rethe directional switches and accelerator in neutral.

Voltages Present: A. B.

3.5-4-O volts at creep speed. 0.5 volts or less at top speed. Less than 0.5 volts across the TP is no cutback; greater than 3.4 volts across the TP is severe cutback. Others N/A

Rev Aug 94

19-02-22 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

r2 2

f

2

24/36 LCCK SWITCH

2FU

VOLTS

---a.....~ -“-..................................................................... ‘1

SEER

_

........................................ r P L

PUM’tvKITOR

**.a

...................

ps-ic.

6,

........................... . , ................................. , ................... .

PS-3REC

ri

t li

2

R-10 50

12

ETCH

12

12

$y.

50

Es_

rl” c

10

10

10

10

11

-

50

1ri”;;

$ 1’

:......?n ...................

2 0

,

,

.. . . . . . . . . . .

501

50

I 2

24-24

PA6 +.....

;*m

15-15

10

SL-1 . . . . . . . . . u*- . . . . . . . . .

1.3......_................. i......... _..__.,3 _____-____+____ . . . . .34 . . 0s.e . . . . . . . . . . 44

SL-2

p*4 *_I. . .

l5-_15iT62 F

TBS

p+_____

6 . . . . . . . . . . . . . . . . . . . 6 .. . . .. . . .. . . . . . $

TB6

p*3 ._; . . . . . . . . . . . . . . . . . 2.

6

6

27-27-m

SL-3 ___-“____13

54

_--______+___ .. . . . . . . . . . . . . . . . . . . . . . . j

.. . . . . . . . . . . . . . . . . . . . . . . 2.

PAZ

:

Tw.

j

26

26

l-60,

;

20

20 ___

26

261

;

2 10

10

I

1

10

1o+m5

;*TLw

5

10-x5

...................... 35 .............+J,3

12 65

;

_____+,2

*........___.... 55............_.......... 55 .............i.
16 56

;-* 1% . . . . . . j.rT65

13

; so!_EtalD i FUNCT!CN ;coMRoL

...._____.__.____.._.. 38 .............i.+W

12

._v4

. . . . . . . . . . . . . . . 46 12

-587

13

781-13

I-iORN SWITCH Copyrighted Material 19-2d2-23 Intended for CLARK dealers only Do not sell or distribute

-

m

13 Rev

Aug 94

OPERATIONAL IA

Contactor

SEQUENCE

#10

Operation

The transistor

circuit is capable of delivering approximately 100% of available battery voltage to the drive motor. For full speed and/or power, the 1A contactor is closed to bypass the transistor panel and apply full available battery voltage to the drive motor. A.

Moving the multi-function control handle fully forward will signal the EV-T15 control for maximum drive motor speed / power demand.

B.

The control will increase the rate and/or length of pulses at the preset rate as defined by the Controlled Acceleration (C/A) setting of the EV-T15 control card.

C.

The control continuously monitors the change of motor voltage through the blue wire at terminal PZ-9 of the EV-T15 control card. When the motor voltage stops increasing, the card starts the 1A time delay.

D.

After a short time delay, the card completes the circuit from terminal PB-6 through wire #41, to the 1A contactor coil negative terminal. This energizes the 1A coil.

E.

The 1A contactor power points (tips) close completing the bypass The control will continue to pulse until the 1A circuit. 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.

F.

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. Turning 'ON' the transistors provides an alternate path (up to current limit) for current to flow and thus, squelching (limiting) the arc at the 1A tips as they begin to open.

Note:

The EV-T15 1~ will not cut-back.

Voltages A. B. C. D. E. F.

has close

a

built if the

in thermal control is

hold-off in severe

feature. thermal

Present:

0.5 volts or less. NA NA lo-13 volts across the contactor coil Battery volts across the drive motor. NA

Rev Aug 94

terminals.

19-02-24 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

r2 2

24/36

I

VOLTS

. .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . .

2FU

..

..................ps_,c .......... 6, ...........................

PSBREC

I

rd

61

”

II

t 12

I

II

1.

IPS-TP

12

STEER

SWITCH

12

,,Q' I.

10

92

-

93

50

io

40

20

r10L

12

10

10

12

10

10

12

la

I-t 12

ia

61

24 -24

LRME WITCH

41-41

401

10-10

.............. ... ... 6 , ......................

15-15

SL-1 .._..... iyi .,...

_.._._..._........

___.,3

.. . . . . . .._..............

. . . . . . . .. . . .. . . .. . .

3 __-

i;“;lj . . ..__.

___+a# ,%

. . . . . . . , 3 . .._.___________.___... _______

___-___-__ 2.

. . . . . . . . . . . .. . . . . . . . . .

261

26

10

1o+T615

10

10_+&?z?i..35

. . . . . . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . +j,3

12 .__________,O

_____

*

-L

,0-I 1

,O_,,/% 12

‘-

__---_---

65

____+6,*

55

. . . . . . . . . . . . j.*Ts,,

TILT -455-45 P .__.._.....____26 . . . . . . . . . . . . . . . . . . . . 26

m7c

-

TBoa-

-----20

20

TB1r

-13

13

16

18

lo----y4

,0.-v4

26-

;*TBIO

j*T66

. .

2

1 13

. . . . . . . . . . ;.,T@

. _.58 . . ..f’. . . . . 56 . . . . . .j.rTf,5 .__________,o______p..-s?.... ..58 .. . ..i .__ 36 _..................... 10 -&..S? .____ 36 .............j..$Tw 10-$ ...s5 ............ 46 .......f ............. 48 .............j.qTB3 ______,k...?

26

SOLENOID

Sl

_ ,__________,O

12

AUX2 o______65

* . . .-Ii . . . . . . . . . . . 55 ,......................

lo-

:oTFm

5

lo-=5

13

FUNCTtCN CCNFRCL

13

i. . . . . . . . . . . . . . . . . . . . . .

. . .S6 . . . . . . . . . . . 46 .. . . . . . . i -I

112

SM-587

12

I-DRN SWITCH 19-2052-25 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

d m

131 Rev

Aug 94

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). A.

The multi-function control handle is moved from forward, opening the forward switch.

B.

While the handle is in it's neutral position, both the directional switches are open.

C.

The control stops functioning because the voltage has been removed from terminal TB-5 of the EV-T15 control card.

D.

The forward and IA contactor coils are de-energized and the contactor tips return to their normal position, opening the drive motor circuit.

Note:

The

Rev Aug 94

truck

will

be

coasting

forward.

19-02-26 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

r2 2

24/36

VOLTS

I FU ( ret

2FU

PUwmoR r ;i

,......................................

P

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .s.>W-k \ . . . .._........................ ps_,c

6,

. . . . . . . . . . . . . . . . . . . . . . . . . . . 6,

1 8’

A

. . . . . (Yi-

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,

.. . . .. . . . . . . .. . . .

I

..

61

t 12

12

r’o

10

c 10

h-J 23 REC

12

10

10

m

I:

DRIVEMOTOR R

A2%1

12

10

10

8.l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

ACCELERATOR ___-

I

I

40

lo

I

:

-12-12-12

:.EVT15CARD .......................

II

li

1-2

2----+al

2

;.pen

24 -24

,n

29-

Pm.;

30

301 40

...................... -;

;.

TB3

TBP

---p

,--@

..;

SL-1

44

P,+______

54

._......____.......

--I;

61

c ,.; ....._.......... . . . . . . . . . ** . . . . . . . . . , SL-2 p$$, 9.;... . . .. . . .3‘$ . . . .- . . . . ,

P

3 3

........................f... .. . ___-_--___;_ .__

SL-3 ___-*9___.,3

__________;_.__

. . . . . . . . . . . . . . . . . . . . . 2.

. . . . . . . . . . . . . . . . . .. . . .

13

12

10

10

10~.w.‘_QY...35 12 ___________,o

_----e ,9-,

. . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . &TB,3

-I b______65_________65 AUX2

_____+,*

-J-Faux * . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . . . . . . . . . . 55

. . . . . . . . . . . . . ;.* TO,,

,o-G-d=-45 , 0 _#

45 P

._.............

Sl

12

lo-” ______-____,O ___________,O

_____+.. _____+..??.._. , 9 --+...s3 , 0 .___+.s5 ,O __/*\

TTB14

5

lo-E5

12

26

. . . . . . . . . . . . . . . . . . . . . . 26

16

16

s7. . . . ..56 _.56

. . . ..L’. . . . .

56

TB7.

-

TBo*

-20

20

TBI.

-13

13

26

; *KM t.. . . . .+

. . . ..:

_..__._.._46 .._....? . . . . . . . . . . . . . 46 __.__.___._.. j_+TBJ

l2

2

13 SOLENOID FUNCTKZN mRcc

..__._..... 36 . . . . . . . . . . . . . . . ..___.. 36 . . . . . . . . . . . . . j..,TBa

:___._... . . . . . . . . . . . . .

. . .S6 . . . . . . . . . . . 46 .. . . . ...!

26-

j.%TBlO . . . . . . . . . . . . . j.oT,M

I

SM-587 ’

13

1

12+$f#-13--l

TB1 . ;

61

wFz-w,TcH ,&_*7 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

H3R\l

SEQUENCE

OPERATIONAL Plugging

#ll

(continued)

E.

The operator moves the multi-function control handle through neutral to reverse, closing the reverse directional switch.

F.

With the 6 of the has been neutral. over.

G.

The control now completes the circuit from the reverse contactor coil to battery negative through wire #23 at terminal PB-5 of the EV-T15 control card.

H.

This will energize the reverse contactor coil and in turn, open the normally closed contactor tips and close the normally open tips. This will change the drive motor circuits to the reverse direction.

J.

reverse switch closed, voltage is applied to terminal TBEV-T15 control card. The control senses that the truck moving and that the handle has been moved through This causes the plugging logic in the control to take

The control now gates ON the transistors.

Rev Aug 94

19-02-28 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

l-27

2

2

2FU

ri

t 12

2

STEER Loa< SWITCH

24/3i

1FU

VOLTS

......................................./....................................................................... P

61

61

rr 1050

12

ETCH

12

rlo

c

61

10

12

10

10

li

1IO

10

12

1IO

10

6i

BRAKE SWITCH

10

,o_+..-‘_~...35

..____________.__.....~~...__.___.___ 1-

+

,,___________lO_____ , 0 -,

AUX2 +______65

___-_____

65

, 0 .-\/: 10----v'\ ,,___________jo

45

s1

_____+._57...

10 -h...SB , 0 _\/,...S5

II*

16

16 ._.56

m,-

26-

13

-13

i-%TBlO

. . . ..?.

.

. . .

56

:eT86

. . . . . .;.
1

3

SOLENOID FUNCTlON cm-r&a_

.. . ..i

3

_ __....... 36 .................__... 36 ._..........+ TB, ..........46 .......f............. 46 .............~.~ TB3

S6 1 0 ~~4...~~..~~~~....4*

SM-587

;.*TB,3

26

_____+,2

28 .............+LB ...P.._......... 28 ..._______._._........

,,_________-_10______+..S.?...._.56 12

________________._______) ................ 2. ....._.__._......__.*O

IFEACH 0...............55 .......................55 .............+ TB, ,

10iTILT45

12

-

TBs*

TB15

5

lOLL5 12

m7-

;-aTB14

lo+

10

........!

l2

:......................

I

HOFiiiWITCH ,9$&g Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

&

l3

Re

; I Aug 94

OPERATIONAL Plugging

SEQUENCE (continued)

As the transistors the

forward

#ll

are turned direction because

ON, the truck is continuing to travel in of inertia. 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. K.

The voltage polarity reverses across the armature of the motor, changing the voltage of terminal Al to positive with respect to terminal A2 of the drive motor. This voltage causes the #4 REC to conduct and thus, provides a path for the generated current.

L.

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, as defined by the preset 'PLUG' setting of the control card and by the accelerator position. The control is locked into the plugging mode.

Note:

The plugging distance can be controlled by changing the position of the multi-function (regulating) control handle (accelerator).

M.

The control also over-rides the 1A timer section and will not allow the 1A coil to be energized during the controlled plugging operation.

N.

This slow pulsing will bring the truck to a smooth, controlled stop. The control senses that the truck has stopped by monitoring nearly zero current through the current sensor. The voltage polarity at the armature will return to normal and the truck will start to accelerate normally in the opposite direction.

Rev Aug 94

19-02-30 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

2413.6 VOLTS STEER _CCK SWITCI

2FU

1 FU

61

PSBREC t

n 10

I

5

r-i

PS-POS

PSNEG mm

12

SWITCH

10

12

12

r’oc 10

10

3

-2

3M WITCk

2

2 +mt

-10

” /,L

24-24

-10

,IA "

41-41-p

jrm?

TBI 0;

29-

PB3.:

30

pyo.j

40

3

i . -ma

15-15

-15

-15

TB2

y 6

6-6

-15 *F

-15

"

-15

,R Y

2’0 6:l

13

30 40....._..__......'._.6 , ......................

10-10

-10

30 40

SL-1 PA6 *_+........___. 44 "'."...g&"'""

3 ......................

pnr..~............34 _..__.e...o..,..__13 -__------.

;.TBS

pA5+______.54

I*~06

PA3 ._~_____........_._.20 ._._____.__....._.__....2 o .......................

27-27+P84

___s~-___,3_________.

26

PM*:

261

23 -23

-62 -63

10

10

lo-L5

, o _$..-:_~._.35 ___________,O

-----

AUX2 4L +______65

10

; .T81.5 lB7.

-

5

;DTB”

-20

...................... 35

. . . . . . . . . . . . . &,a

_________

_____

65

TBa*

26

26 20

lB1.

+‘2

* . . . . . . . ..__.... 55 . . . . . . . . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . +,, lO----+J_ TILT i sTB10 45 lo-45 P , 0 _,,,L.............. 26 ...._................. 26 .............~ TB8 104%

"

16

la

___________,o_____.+...S? .. . ..sa . ‘.“‘. . . . . ___________,o

______+.%...56 1 0 _bh...s3........ lo-

56

; **I36 . . . . . .j.(TB~

IP SOLENOID FUNCTlON Cm-rRcc

.. . ..i 36 _____..___.._......... 36 .............~+ To,

13

/Lss..__.. 46 .......f............. 46 ............+ TB3

S6 , 0 __+___________..46

!.....................

........1 - I

112

SM-587

12

K)RN SWITCH w-2052-31 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Km

13A Rev

Aug 94

OPERATIONAL Travel

SEQUENCE

Speed

#12

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. 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. A.

Raising the upright above the free-lift stage will open the SL-1 speed limit switch.

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.

C.

The truck, when starting in a speed limit mode, 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.

Note:

If the the

Note:

'Speed Limit C/A' is set the 'C/A', the truck will normal normal C/A rate.

When revert

the to

speed limit the normal

at a lower value always accelerate

switch is re-closed operation and speed.

the

truck

than at

will

Voltages Present: A. B. C.

Battery negative. Approximately 6 volts. NA

Rev Aug 94

19-02-32 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

r2 2 2FU

t 12

24/36 VOLTS

STEER LCCX SWITCH

rd

_

61

_JPS-TP

I\

n10 50

WtvPPMOTOR

TFI

s PSNEG

12

SWITCH

12

10

n--l

1 3 3040

..................................................................: ACCELER4TOR --7

13 3040

12-12-12 2 24 -24 41-41

PA, ..; .. . . .. . . 34 . . . ._....., SL-3

15-15+T~2 6

6

6

0

3 - ---------

i . TM

pns,+_____.54

;-TM

PA3..I . ...... ..... .... 2. .__..................... 2. ............... ... ... ...

27-27-m

PAZ

:

___-“____,3

26

______----

261

6

10

10+

10

,0__-&.~...35

12

,.___________,o

_----

AUX2 ‘+_.i_ b______65_-__-____

,,_______-___,(I 12

SM-587

-

TB6b

-20

26

20

TB,r

-13

13

26-

65 _-_-+,2

v..!FEKH 55 .................._.... 55 ..... ....... .+,, 0__.____._...... TILT ; hTBl0 45 -45 P ._............. 28 . .._.................. 28 . . . . . . . . . . . . . ;.eT66

lo-$.

,

TM-

TBI,

13

It.

lo-

,,___________,o

TBIS

35 ...... ....... &,a

. . .._.................

lo-

12

+

5

lo-~5

2

lop4 _____+..S?

s1

16

18 . . . 5*

.y

. .

. . .

5*

frTB6

. . . . . .j.rT85

13 SOLEmID FUNCT!ON Cama

____.+....?... . -58 . . ..i 10_/?...S? ........ 36 ...................... 36 .............i_9TB, s5 , 0 __t/\ .___.___.___.._ 46 .......f ............. 48 .............;+,3 :................. .. 10_v4 ...S6 ... ... ...... 46 .......i I

L12

l2

t0R%‘flTCH ,&)5z_33 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

&&

OPERATIONAL Solenoid

SEQUENCE

#13

Functions

The Solenoid Function Control card in conjunction with the EV-TSPS steer control and the EV-T15 control provides for lift, lower, extend, retract, tilt and side shift function control and for lift interrupt. A.

In Operational Sequence #3, closing the key switch applied battery positive to terminal TB-15 of the solenoid control. The solenoid control is connected to battery negative through the #13 wire at terminal TB-1.

B.

The EV-T15 control card will supply a voltage signal from terminal PA-2 through wire #26 to terminal TB-7 of the solenoid control indicating the battery status.

Notes

LED #2 (RH5) of the solenoid lift interrupt Is activated.

C.

The solenoid control will not allow any solenoid functions to operate if any of the following checks are not satisfied:

control

will

be

turned

'ON'

if

the

1) Checks for open hydraulic function switch inputs when the key switch is first closed. Terminal TB-10 through terminal TB-14 of the solenoid control must be at 0 volts. Note: fault

LED #1 exists.

(RH4)

of

the

solenoid

control

will

be

turned

'ON'

if

2) Continuously checks for invalid switch inputs. If both the up and down switches are closed at the same time or if more than one of the tilt, reach or aux 2 (side shift) switches are closed at the same time. Note: fault

LED #1 exists.

(RH4)

of

the

solenoid

control

will

be

turned

'ON'

if

3) Checks for open solenoid and contactor coils or wires anytime that the For solenoid multi-function control handle is in hydraulic function neutral. coils connected in parallel, both coils must be open to be detected as a fault. Terminals TB-3, TB-4, TB-5, TB-6 and TB-8 must be battery volts. Note: fault

LED #2 exists.

(RH5)

of

the

solenoid

control

will

be

turned

'ON'

if

4) Checks for shorted drivers anytime that the multi-function control handle is in hydraulic function neutral. Terminals TB-3, TB-4, TB-5, TB-6 and TB-8 must be battery volts for fault not to exist. Note: LED be turned

Note:

#1 (RH4) and LED #2 (RH5) fault exists. 'ON' if

of

the

solenoid

the hydraulic control switches If any of are closed the control will the key switch, seconds of closing functions to operate. solenoid

control

will

within 1.5 not allow any

Voltages Present: A. B. C.

Battery positive at TB15, Battery negative at TBl. Approximately 10 volts. See explanations l-4 above.

Rev Aug 94

19-02-34 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

SAll-ERY

b-w<

r2 2 STEER .cxx WITCH

2FU

24/36

I FU

VOLTS

...........................6

t

r-d 12

SWITCH

12

10

I

i

12

10

10

12

10

10

,...................................................................... ACCELERATOR ---

li

24 -24 41-41

12

12

to-=5 12

I

5

<

-.._

A.. lo-

IlLl

12

lo-----vh __.______..,o __________.,o

SM.587

-

___._.,,4._-5-7-

I

45

-45

, 0 _$...!

12

I

,,._?.p~._.,, ......... ______.___.,o -.-.- + w._____65 _________65 ..I-0 . . .RZACH ,n--__r . . . . . . . . . . . c* . . . . . . . . . 13

........__ 28 _____.____............ 26 Sl

. . ..56

I

16

16 .

. ..t’.

. . . .

56

..5a . ..i , 0 _$ ....s3 ............ 3a ...................... 38. , 0 _&..SS ........ 48 .......T .......... 48, , 0 _$ ...S6 ...._....... 4a .......i I _..___p...%?_.

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

13-

Rev Aug 94

OPERATIONAL

SEQUENCE

#14

Lift

A.

Pulling the multi-function control lever towards the operator will close the up switch. With the up switch closed, battery positive will be applied to terminal TB-14 of the solenoid control through wire #5.

B.

When the solenoid control senses battery positive at terminal TB14, it will complete the circuit from the pump contactor coil to battery negative through wire #28 at terminal TB-8.

C.

This will energize the pump contactor coil and in turn, 'close the normally open tips.

D.

Battery positive will be applied to terminal PY-13 of the EV-T15 control card through wire #61. This signal will keep the internal hour meter energized during lift operation.

E.

Current will now flow from battery positive, through the 1FU fuse, the now closed pump contactor tips to the pump motor and back to battery negative. The interaction of magnetic energy between the armature windings and the field coils will cause the pump motor armature to rotate. As the armature rotates, it in turn will rotate the hydraulic pump which will supply oil flow to the main hydraulic lift valve. As the operator pulls farther back on the multi-function control lever, the spool valve is opened and diverts the oil to the lift cylinders causing them to extend and raise the forks.

HYDRAULICS:

F.

When the multi-function control lever is returned to neutral, the up switch will open removing battery positive from terminal TB-14 of the solenoid control. The pump contactor will open and the hydraulic pump motor will coast to a stop.

Voltages Present: A. B. C. D. E. F.

Battery positive. 1.2 volts. Battery positive. Battery positive. Battery positive at the S terminal, battery negative at the A terminal. 0 volts at TB-14 and battery positive at TB-8.

Rev Aug 94

19-02-36 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

r2 2 2FU

24/36

STEER

VOLTS

cacti

t 12

ir 10 50

12

61

r

12

1IO

12

10

12

10

1 61

ACCELERATOR 7-i 7

H-T -12-12-12

/.Ry$q

2

12

i0

LT...; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . :

10

10

t-

10

2

12y-q-13J

2

VAL

24-24

i'"2

m*;

30

301

"

41-41

i.PBG

w9*;

40

40-

15-15

*IA

61 13

ISW SWITCH 12

10

12

PM.

44-13 SL-2 PA4..~........,._.34 .."__~_,....13

6

;*m

PAS,&--___.54

j.,,

PA3 ..~.........._.____.20 ........................2 o ........................

6

0

15 15

*

15

"

*F

0

-_.

--_--___--

SL-3 ____k____,3__________

-_. i

PA2 *

27-27+FS4

*R

;

i'T83

lB-157~62

;

26

26

23-23 1

10

1:

. . . . . . . . . . . . . . . . . . . . .

20

.. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

___________,o

______,4,..S?......56

.. . ..f-..'..'.. 5*

.__________,o

_____+...%....56

.. . ..i

, 0 -&..S?........ , 0 _&.S5

10_+ -12

SW587

.___.._._i..T85

36 ...................... 36 .............~.. T6, ___._._._.46 .".."f""""""' 46 .............+

:........................

...S6 ........... 48 .....__. i 12

-

I

KX=iNSWlTCH

19-262-37 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

CI m

Rev Aug 94

OPERATIONAL

SEQUENCE

#15

Lower A.

Pushing the multi-function control lever away from the operator will close the down switch. With the down switch closed, battery positive will be applied to terminal TB-13 of the solenoid control through wire #35.

B.

When the solenoid control senses battery positive at terminal TB13, it will complete the circuit from the Sl (lower) solenoid coil to battery negative through wire #18 at terminal TB-6.

C.

This will energize the Sl solenoid and in turn, open the oil's path. As the multi-function control lever is pushed HYDRAULICS: further away from the operator, the spool valve will be opened and allow oil to flow from the lift cylinders, through the Sl lower valve and the spool valve to the hydraulic sump tank. The cylinders will retract and the forks will lower.

D.

When the multi-function control lever is returned to neutral, the down switch will open removing battery positive from terminal TB13 of the solenoid control. The Sl solenoid will open to close hydraulic oil's path.

Note

EV-T15 will not record operating time on the : The The hour meter internal hour meter for lower function. will accumulate hours independent of lower function, if of the motors is operating while performing lower any function.

Voltages Present: A. B. C. D.

Battery positive. 1.2 volts. Battery volts across the solenoid coil. 0 volts at TB-13 and battery positive at TB-6.

Rev Aug 94

19-02-38 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

r2 2

t 24136

2

VOLTS

ZEER

_

I CKX

2FU

WITCH

WNPMOTOR

61-

61

f t 12

T50

2

c 2

i-l0

12

10

12

12

1

r*i i”do

mER~q~~’ i 1’

50

-

50

50

IC

:....._..__._............. 4” “D ~ ~ ! I 2 0

............

50-

c

10

2

10

10

2

10

10

2

EG

h..

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . .

. . . . . . . . . .

. . . .

. .

. . . . . . . . . . . . .

.

ACCELE,A?”

f.y%?q ‘2~~q-“-

12-12-12 12

10

;

;

r

2

2 *I.

10 10

”

” AIA

/1

2

24 -24 41-41

$Fa2

;*Pm

PB3 -i

30

Pm.:

40

1:II-I

___

15-15yTTB2

. . . ..‘- . . . . .

12

1)

, 0 ~_$

+, ....s ........ 38 .................... . .~a.___._.......

13

. . . . . . . f . . . . . . . . . . . . . 4a . . . . . . . . . . . . . +.T63

, 0 -$

:........................

...S6 ............4a ........! I

SM-587

H;)RN SWITCH Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

131

Rev Aug 94

OPERATIONAL Reach

/

SEQUENCE

#16

Retract

A.

Depressing and holding the reach button on the side of the multifunction control lever will close the reach switch. With the reach switch closed, battery positive will be applied to terminal TB-11 of the solenoid control through wire #55.

Note:

The reach reach/retract

B.

When the solenoid control senses battery positive at terminal TB11, it will complete the circuit from S3 (aux) solenoid coil to battery negative through wire #38 at terminal TB-4.

C.

This will energize the S3 solenoid coil and in turn, open the oil path to reach cylinders.

D.

Still holding the reach switch closed and pulling the multifunction control lever towards the operator will close the up switch or pushing the multi-function control lever away from the operator will close the down switch. With the up switch or the down switch closed, battery positive will be applied to terminal TB-14 or TB-13 of the solenoid control through wire #5 or wire #35.

switch must operation.

be

held

closed

during

the

entire

Voltages Present: A. B. C. D.

Rev

Battery positive. 1.2 volts. Battery voltage across the S3 solenoid coil. Battery positive.

Aug94

19-02-40 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

r2 2

f

2

STEER

ILOCK

2FU

SWITCH _.

r 12

r

BPS-TP

ir

I I

2

PSNEG

.12 Y

SEN-

wEY 8WITCH

r

_

10

2

yE&

-50

-10

12

10

I-w 10

12

10

10

12

10

2

2

Piipi2

Pi

Pi6 pi5

50

4PL5 T

STEER _Flx

4PL1 t

4PL6 ?

+r

.^

4PL3 1

4PL4 I

4PL2 !

I)1loj”

:......~c ........3c ...........

.

,

..1.........

,

5oA

I 51

I= 10

" ,.IA *L

41-41 24-24

ids2 :*I?36

lo-l0+TB4

ERAKE EiWITCH

+33

15-15

10

PY8 l : .w.;

30 40

40 30

61

PY13 .

;

61

PM.

f

44-13

SL-1 SL-2 .,,...-...___13

P,4.)..&...._.34

15-15iTw

SL-3

6

6

8

8 r_

27-27+Pe4

12

il 2 0

ACCELERATOR r-i 7

I-t 12 10

12

16x7 t

gz$

i

12

Pi3

c_____________________________-_

; . TB5 PA5cf______ 54 _______.,Q 186

p*3

PAZ

..j . . . . . . . . . . . . . . . . 2.

:

26

.._._...................

2.

__________

___.

__- _______ ___. .. . . . . . . . . . . . . . . . . . . . . .

261

1:3

10

I

/,P

10

"

10

""

,o _@

S'

18

...S6 ........... 48 .......i 12

SM-587

113

28~T88

20

I

HORNSWITCH Copyrighted Material 19-&41 Intended for CLARK dealers only Do not sell or distribute

c=L mm

,,'i Rev

Aug 94

OPERATIONAL Reach

/

SEQUENCE Retract

#16

(Continued)

E.

When the solenoid control senses battery positive at terminal TB14 or TB-13 and also at terminal TB-11, 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.

F.

When the EV-T5PS steer control senses the signal at terminal 4PL2, it will turn ON the steer motor at maximum speed.

G.

When the EV-T15 control senses the signal at terminal PA-3, it accumulates hours on the internal hour meter during the reach operation.

H.

When the multi-function control lever is returned to neutral and the reach switch is released, 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.

J.

After a short time delay the solenoid control will remove the voltages from the 53 solenoid coil and the signal from terminal TB-9 of the solenoid control. The S3 solenoid will open to close hydraulic oil's path from the reach cylinders. The EV-T5PS steer control will reduce the steer motor speed to idle speed or coast to a stop. The EV-T15 control card will stop accumulating time on the internal hour meter because of reach/retract operation.

Note

internal hour meter will accumulate hours : The EV-T15's independent of reach/retract function, if the steer reach function. while performing is operating motor

Voltages Present: E. F.

G. H. J.

10 - 12 volts on wire #20. NA 10 - 12 volts. 0 volts. Battery voltage.

Rev Aug 94

19-02-42 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

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

OPERATIONAL

SEQUENCE

#17

Tilt

A.

Depressing and holding the tilt button on the side of the multifunction control lever will close the tilt switch. With the tilt switch closed, battery positive will be applied to terminal TB-10 of the solenoid control through wire #45.

Note:

The tilt switch tilt operation.

B.

When the solenoid control senses battery positive at terminal TB10, 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.

C.

This will energize the S3, S5 and S6 solenoid coils and in turn, open the oil path to tilt cylinder.

D.

Still holding the tilt switch closed and pulling the multifunction control lever towards the operator will close the up switch or pushing the multi-function control lever away from the operator will close the down switch. With the up switch or the down switch closed, battery positive will be applied to terminal TB-14 or TB-13 of the solenoid control through wire #5 or wire #35.

must

be

held

closed

during

the

entire

Voltages Present: A. B. C. D.

Battery positive. 1.2 volts. Battery voltage across the solenoid coils. Battery positive.

Rev Aug 94

1g-02-44 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

r2 2

24136

SEER

_ax

2FU

VOLTS

_

s

/I

SWITCH

P\ PS-IC

PUM'PTOR

61

61

611 61

t 12

li

10

6'1

r10c

12

10

10

12

10

10

~ 61'

2

FKE

12

10

10

61

ttH-12-12-12 II

t-2

2

12cnx-13_J II

.EVT!..S.CARD.. i .F%, TBI. i

2

10

" *L

24-24

;*PEt2

10

" ,IA

41-41

i*m

lo-10+TB4

PYB . WI3

29-

I

I

30

Pl33.j

;

40 61

-61

/ SL-1 1:

1'0

15-15

j . T03

15-15yTB2

6

i . TBS

6

6-6 27-27-a

+

T86

PI%.

j

44-13

pA4..;

. . . . . .. . .

34

.,....-_..__.,

54

SL-3 ___-____,3__________

,,,+____

3

PM.

:

20

20

PAZ.

:

26

261

10

1

SM-587

SL-2

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

_________.

.___ .___

OPERATIONAL Tilt

SEQUENCE

#17

(Continued)

E.

When the solenoid control senses battery positive at terminal TB14 or TB-13 and also at terminal TB-10, 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.

F.

When the EV-T5PS steer control senses the signal at terminal 4PL2, it will turn ON the steer motor at maximum speed.

G.

When the EV-T15 control senses the signal at terminal PA-3, it accumulates hours on the internal hour meter during the tilt operation.

H.

When the multi-function control lever is returned to neutral and the tilt switch is released, 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.

J.

After a short time delay the solenoid control will remove the voltages from the S3, 55 and S6 solenoid coils and the signal from terminal TB-9 of the solenoid control. The S3, S5 and S6 solenoids will open to close hydraulic oil's path from the tilt cylinder. The EV-TSPS steer control will reduce the steer motor speed to idle speed or coast to a stop. The EV-T15 control card will stop accumulating time on the internal hour meter because of tilt operation.

Note

EV-TlS's internal hour meter will accumulate hours : The if the steer motor is of tilt function, independent function. while tilt performing operating

Voltages Present: E. F. G. H. J.

10 - 12 volts at terminal 4PL2. NA 10 - 12 volts. 0 volts. Battery voltage.

Rev Aug 94

19-02-46 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

BATTERY

r2 2

bWlk-<( STEER

24/36

1FU

VOLTS

s

/I

2FU

i%H L

t 12

r/

lJ----EFl

i

I

WM'PMOTOR w" 61-

1’61

R-1050

12

ZTCH

12

lb

10

50

11 12

rlo 10

I10

12

10

10

_d ’ ’ L.YG .i r-3

Rx

5

G

g

g . . . . . . . . . . . . . . . .~

T_Fm

12

10

i

: . . . . . . TR? . . . . . . :

,

ai

lo-i-

10

1.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . :

ACCELERATOR --.-_

1lJ-1()wm

10

PYt3 _:6,

i3

61 SL-1

& 112

SM-587

12

HORNSWITCH

19-262-47 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

-

mw

Rev Aug 94

OPERATIONAL

SEQUENCE

#I8

Side

Shift

(Optional)

A.

Depressing and holding the side shift button on the side of the multi-function control lever will close the side shift switch. With the side shift switch closed, battery positive will be applied to terminal TB-12 of the solenoid control through wire #65.

Note :

The entire

B.

When the solenoid control senses battery positive at terminal TB12, 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. It will also complete the circuit from S7 and S8 (side shift) solenoid coils to battery negative through wire #58 at terminal TB-5.

C.

This will energize the S3, 55 and S6, and S7 and S8 solenoid coils and in turn, open the oil path to side shift cylinder.

D.

Still holding the side shift switch closed and pulling the multifunction control lever towards the operator will close the up switch or pushing the multi-function control lever away from the operator will close the down switch. With the up switch or the down switch closed, battery positive will be applied to terminal TB-14 or TB-13 of the solenoid control through wire #5 or wire #35.

side shift switch must operation. side shift

be

held

closed

during

the

Voltages Present: A. B. C. D.

Battery positive. 1.2 volts. Battery voltage across the solenoid coils. Battery positive.

Rev Aug 94

19-02-48 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

l-27 2

2 STEER LOCK SWITCH

2FU

t 12

2

rd

24/36

1 FU

^

2

611

61

rr 1050

SWITCH

10

PuwIwroR ”

-p+61

12

12

VOLTS

10

SM-

L l L 1 1 1 PM PU PLl PI.2 FL6 PL5 r____-_______________‘-_________-

+_

;4PL7 ,PLS I? T

4PL6 T

4PL1 iPL3 T 1

STEER 4PL. 7

4PL2 1

50

1A T2

.............................................

61

ACCELERATOR --‘*7

I

12

I

10

24 -24 41-41 BFlAK!Z

I

61

SWITCH SL-1 12

10

15-15

-

44-13 SL-2 ___&____13

---------.

.__

SL-3 ___-____13

---------.

.__

23 -23

1:

SM-587

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

,,‘i

Rev Aug 94

OPERATIONAL

SEQUENCE

#18

(Continued)

Side

shift

E.

When the solenoid control senses battery positive at terminal TB14 or TB-13 and also at terminal TB-12, 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.

F.

When the EV-T5PS steer control senses the signal at terminal 4PL2, it will turn ON the steer motor at maximum speed.

G.

When the EV-T15 control senses the signal at terminal PA-3, it accumulates hours on the internal hour meter during the side shift operation.

H.

When the multi-function control lever is returned to neutral and the side shift switch is released, 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.

J.

After a short time delay the solenoid control will remove the voltages from the S3, S5 and S6, and S7 and S8 solenoid coils and the signal from terminal TB-9 of the solenoid control. The S3, S5, S6, S7 and S8 solenoids will open to close hydraulic oil's path from the side shift cylinder. The EV-T5PS steer control will reduce the steer motor speed to idle speed or coast to a stop. The EV-T15 control card will stop accumulating time on the internal hour meter because of side shift operation.

Note

internal hour meter : The EV-T15's independent of side shift function, is operating while performing side

will accumulate hours if the steer motor shift function.

Voltages Present: E. F. G. H. J.

10 - 12 volts at terminal 4PL2. NA 10 - 12 volts. 0 volts. Battery voltage.

Rev Aug 94

19-02-50 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

t-2

2

STEER

24/36 VOLTS

1FU

s

/I

2FU

%ki

FuwmToR -4

P\

Sl-

,

ri

t 12

r-r 10 50

10

10

12

ETCH

12

50

rlo c

12

10

10

12

10

10

NZG

I

Fa

12

10

2

3

ACCELERATOR -->-: 12-12-12

13-

12 EVTl5CARD ~"""""".."...""~

2 t 12

10

I3FlAKE ,3WlTCb 12

10

2

TBI cf

2*=1

-10

Y AL

24-24

$PB2

PB3.i

-10

" AlA

41-41

;*pB6

PW

lo-_10+m

-10

30

30-

:

40

40-

PY13 .

;

61

61-------t

PA6.

;

44+13d

l

I -15

+TEn

15-15

-15

pn4hf______.34

___sl;r__',3__________

__-_

-152-e

PA5c;______.54

___-___.,3__________

____

-15 "7

-15

F

~~~~,~~~~:

::r-_i

R

-15

10

;sMYp&;ggr

j3

j3

26

2o

13

10 10 __________,O

.__________,. _____+_%____sB --13

10

SM-587

II”

10 10

l2

&&/ITCH

,&$_5, Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

&

131

Rev Aug 94

CMRIC

Material Handling Company

EV-Tl5 SM-587

19-03-O 1

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

Sept 93

STATUS CODE

-01

brake

No

switch

MEMORY RECALL

inp~ESCR’PT’oN

No

CIRCUIT

Traction

SYMPTOM Forward or reverse contactor will not pick up. EVT 15 CARD 2

POSSIBLE *Defective

CAUSE

KEy SWITCH

brake switch or no brake line pressure.

2

9 PBl

c /

- Check brake switch to insure proper closure. *Open circuit between

battery

positive

and terminal

TB3.

BRAKE SWlTCH c /-a

- Check for loose connections or broken wire between brake switch and terminal TB3. - Check for loose connections or broken wire between key switch and positive side of the brake switch. *Defective

10

10 -4

TB4

15

15 -q

TB3

I-

brake system.

- Check that the brakes are releasing and no air in the brake system.

STATUS

INDICATION

CRITERIA

This Status Code will be displayed when TB3 is less than 50% battery volts.

- Check for hydraulic leaks in the brake system. - Check for mechanical interference

in the foot pedal

assembly.

STATUS

CODE

-02

MEMORY RECALL

DESCRIPTION Forward directional

switch is closed on initial power up.

CIRCUIT SYMPTOM

No Traction

EVT 15 CARD

Forward contactor will not pick up, static return to off (SRO) lock out.

2

2 -4

PBI

10

lo --.

TB4

15

15 -4

TB3

15

15 --.

TB2

-4

TB5

SWITCH

4-

POSSIBLE

CAUSE

*Forward directional switch closed on initial power up (closure of battery receptacle, key switch or brake switch). -

Return directional forward direction.

t

handle to neutral and then select

*Forward directional switch is welded closed or misadjusted to be held closed. -

15 J-6

Replace or adjust forward directional switch to insure that it opens when directional handle is returned to neutral.

P

*Short circuit between TB2 and TB5.

STATUS

- Disconnect wire #6 from TB5 and check for short circuit between TB2 and wire #6. *Defective

oscillator

INDICATION

CRITERIA

This Status code will be displayed when voltage at TB5 is greater than 60% battery volts at initial power up.

card.

- Disconnect wire #6 at TB5. Measure voltage at TB5, should be less than 60% of battery volts.

SM-587

19-03-02

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

Sept

93

STATUS

CODE

-03

MEMORY RECALL

DESCRIPTION Reverse directional

switch

is closed on initial power up.

No

CIRCUIT SYMPTOM

Reverse contactor lock out.

will not pick up,

Traction

EVT 15 CARD

static return to off (SRO)

2

2 -4

PBI

10

10 --.

TB4

15

15 -4TB3

SWITCH

+ POSSIBLE

CAUSE

*Reverse directional switch closed on initial power up (closure of battery receptacle, key switch or brake switch). -

k

Return directional handle to neutral and then select reverse direction.

*Reverse directional be held closed.

switch is welded closed or misadjusted

to

15

15 --s

-Replace or adjust reverse directional switch to insure that it opens when directional handle is returned to neutral.

STATUS

- Disconnect wire #8 from TB6 and check for short circuit

-4

TB6

INDICATION

CRITERIA

This status code will be displayed when voltage at TB6 is greater than 60% battery volts at initial power up.

between TB2 and wire #8. oscillator

TB2

i

*Short circuit between terminals TB2 and TB6.

*Defective

15 -4 REV

card.

- Disconnect wire #8 at TB6. Measure voltage at TB6, should be less than 60% of battery volts.

STATUS CODE

-06

MEMORY RECALL

DESCRIPTION Accelerator input voltage is below threshold or REV directional switch closes.

before the FWD

No

CIRCUIT SYMPTOM

ACCE!_ERAKR

--------“I

Forward or Reverse contactor will not pick up.

13 -

-1s+-&; EVT 15 CAR0 TBl

POSSIBLE

Traction

L--_

.-A 29kci!!r

CAUSE

*Accelerator (transducer / pot) is misadjusted or defective. Status code disappears when directional handle is moved away from neutral to close directional switch.

swrr~ -/L

- Check accelerator input voltage at terminal TBl, should be approximately 3.7 volts with directional Adjust or replace accelerator. *Defective -

directional

handle in neutral.

switch.

LLI

TB5

15--/;---6

TB6

Check forward or reverse switch to insure closure when direction is selected.

)Open circuit between directional switch(s) and battery or between directional switch(s) and TB5 or TB6.

positive

- Check all control wires and connections shown in Figure.

SM-587

15d---6

STATUS

INDICATION

CRITERIA

This status code will be displayed when voltage at TB5 and TB6 are less than 60% of the battery volts, and TBl is less than 2.5 volts.

19-03-03

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

Sept

93

STATUS

MEMORY RECALL

DESCRIPTION

CODE

Accelerator

-07

input voltage

too high.

CIRCUIT SYMPTOM

POSSIBLE misadjusted

Traction

ACCaEFATcFl

Forward or Reverse contactor picks up but control will not operate when control handle is moved toward high speed or status code -07 is displayed then disappears when the vehicle starts to accelerate. *Accelerator

No

EVT,5cA;‘* *

13 -

L---

TBl

_.1 29 G!!-

CAUSE

or defective.

swrrcH -I,

- Input voltage at TBl should be less than 3.8 volts. Adjust or replace accelerator to insure that the voltage at TB1 will vary from 3.8 volts to less than 0.2 volts when the control handle is moved into high speed. *Open circuit between

battery

negative

and TBl. :-;1

Check for broken wires or loose connections or open accelerator / voltage supply in the circuit shown in figure. - Check for broken wire or loose or corroded connection at WHT / BROWN wire to terminal PZl.

-

*Short circuit from battery

positive

15---p;----6

TBS

15~-----8

TB6

STATUS

INDICATION

CRITERIA

This status code will be displayed when the accelerator voltage at TBl is higher than 3.8 volts.

to TBl.

input

- Disconnect wire #29 from TBI and measure voltage at wire #29 to negative. Should be zero volts for potentiometer type and less than 3.8 volts for transducer type accelerator.

STATUS

CODE

-08

DESCRIPTION Accelerator input voltage too low on power up after initial key switch closure or on re-closure of brake switch with sufficient time delay to initiate SRO checks.

SYMPTOM

MEMORY RECALL CIRCUIT

No Traction

ACCELERATOR r.._.._.._..-._.._.._..~

Forward or Reverse contactor does not pick up.

I i

-12

13 -

EVT 15 CARD

POSSIBLE *Accelerator

misadjusted

CAUSE

TBl

or defective.

.

- Check accelerator input voltage at TBl, should be approximately 3.8 volts with handle in neutral. replace accelerator. *Short circuit between

battery

negative

Adjust or

and TBl.

- Disconnect wire #29 from TBl.

For transducer, check for open circuit voltage from wire #29 to battery negative. Should be greater than 3.0 volts. When potentiometer is used, resistance should be greater than 4.7K ohms. Replace.

STATUS *Defective

oscillator

card.

- Disconnect wire #29 from TBl.

Measure voltage from TBl to negative. Voltage should be greater than 4.5 volts, if not replace oscillator card.

SM-581

INDICATION

CRITERIA

This status code will be displayed when the accelerator input voltage at TBl is less than 3.0 volts and either the battery receptacle or key switch has been opened.

19-03-04

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

Sept 93

STATUS

CODE

-09

DESCRIPTION Both Forward and Reverse directional the same time.

switches

are closed at

MEMORY RECALL

bb

1

CIRCUIT SYMPTOM

Traction

EVT 15 CARD

Forward or Reverse contactor will not pick up. BRAKE SWITCH

POSSIBLE *Forward or Reverse directional adjusted to be held closed.

CAUSE switch welded closed or mis-

I,

- Replace or adjust directional

switches to insure that they open when control handle is returned to neutral.

*Short circuit between

battery positive

- Disconnect wires #6 and #8 from TB5 and TB6 and check wires for short circuit to positive side of directional switches. *Defective

oscillator

and TB6. Voltage should be less than 60% of battery volts, if not replace oscillator card.

CODE

-e

TB5

REV 15----lt-8-~~~6

-_

STATUS

card.

- Disconnect wires #6 and #8 and measure voltage at TB5

STATUS

15 d-6

and TB5 and / or TB6.

INDICATION

CRITERIA

This status code will be displayed when voltage at TB5 and TB6 are greater than 60% of battery volts at the same time.

MEMORY RECALL

Battery vo,tstoo,o~ESCR~PT~oN

-15

CIRCUIT SYMPTOM

No Traction

EVT 15 CARD

Forward or Reverse contactor will not pick up. +I1

POSSIBLE *Discharged

CAUSE

battery.

f

- Check battery for proper open circuit voltage as outlined in figure and charge battery if required. *Defective

BA-TTERY

battery.

Nominal Battery Volts

I

<

- Check each battery cell for proper voltage, should be greater than 1.95 volts per cell. *Incorrect

oscillator

Replace or repair battery.

1

24

23.4

36

35.1

card adjustment. T

- Check function #15 for proper adjustment for battery being used. Adjust to proper settings (22 - 26 for 24 volt battery and 34 - 38 for 36 volt battery). *Bad wire / connection

on terminal

Should be greater than 1.95 volts per cell. replace wire or connection.

STATUS

i

INDICATION

CRITERIA

This status code is displayed when the battery volts are less than 1.95 volts per cell at initial start up. (See table in above figure.)

PBl.

- Check voltage from terminal PBl to battery negative.

sM-587

Minimum Limit Volts 0 1.95VICell

Repair or

19-03-05

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

Sept

93

STATUS

Battery vo,tstoohigDhESCR’PT’ON

CODE

MEMORY RECALL CIRCUIT

No Traction

SYMPTOM Forward and Reverse contactor will not pick up.

POSSIBLE *Incorrect

oscillator

CAUSE

Maximum Limit Volts

Volts

@I 2.4 V / Cell

card adjustment.

- Check function 15 for proper adjustment for battery

BATTERY

being used. Adjust to proper setting (22 - 26 for 24 volt battery and 34 - 36 for 36 volt battery). *Battery

Nominal Battery

over charged

or incorrect

battery

24

28.8

36

43.2

used.

- Check battery for proper open circuit voltage per table in figure. If voltage excessive, check battery charger for proper output voltage. *Open current sensor wire circuit.

STATUS

INDICATION

CRITERIA

This status code is displayed when the battery volts are greater than 2.40 volts per cell at initial start up. (see table in above figure.)

- Check for loose plug or pin or corrosion at terminal PZ12 on the oscillator card.

- Check for broken wire (green wire) at weld to current sensor and along length of wire.

STATUS

CODE 1

-17

i

1 MEMORY

DESCRIPTION Invalid

card

type

selection.

SYMPTOM Forward or Reverse contactors will not close.

POSSIBLE

CAUSE

*Invalid card type selection.

- Check function #17 for proper card type. Adjust to proper setting (22 - 24).

STATUS

INDICATION

CRITERIA

This status code is displayed when the card type selection value is set to an invalid number.

5x-587

19-03-06

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

Sept 93

STATUS

DESCRIPTION

CODE

Forward

or Reverse

contactor

coil

current

MEMORY RECALL

low.

No

CIRCUIT SYMPTOM Forward or Reverse contactor will not pick up. Status code may alternate between code 23 and code 24. Complete checks for code 23, if the problem is not found, perform check for code 24.

POSSIBLE -Defective

F or R contactor

BRAKE

Traction

EVT 15 CARD

t

CAUSE

coil circuit.

- 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. Repair or replace.

I---

I--

- Remove plug B. Check ohmic value from PB4 to positive side of F coil. Value should be lo-14 ohms. Make same check for R coil. If value not correct, replace coil.

F

15 -,/-27

_

4 PB4

15 +L23

-

4 PB5

- Check for open circuit between positive side of F or R contactor coil and terminal TB2. Repair. *Defective

oscillator

card.

STATUS

- Check for status code in both directions of truck operation. If status code 23 is present in both directions, continuity OK and checks for status code #24 OK, then replace oscillator card.

STATUS

CODE

-24

INDICATION

CRITERIA

This status code is displayed when the current draw in the forward or reverse contactor coil circuit is less than 100 mA.

DESCRIPTION T2 voltage

too

low.

(Less

than

88%

of battery

No

volts). I

CIRCUIT

Traction

SYMPTOM Control does not operate. Status code may alternate between code 23 and code 24. Complete checks for 24, if the problem is not found, perform code 23 checks.

POSSIBLE

CAUSE

*Defective F or R contactor. - F or R power tips fail to close because: 1) Welded normally closed power tips. 2) Binding contactor tip or armature assembly. 3) Defective F or R contactor coil. (See status code 23) 4) Loose contactor coil assembly. a) Coil not locked into position. *Open motor circuit - 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. Gpen circuit in the T2 sensing circuit. - Check for broken wire (Blue wire) or loose or corroded connection and / or terminal at T2. Repair or replace. - Check for loose or corroded connection at plug or pin at terminal PZ9. . Repair or replace. *Defective oscillator card. - If above checks are OK and checks for status code #23 are OK, then replace card.

w-587

19-03-07

BRAKE SWITCH

1,

I

STATUS

INDICATION

CRITERIA

This status code is displayed when T2 voltage is less than 88% of battery volts and the F and R driver is energized.

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

Sept 93

STATUS

CODE

-26

DESCRIPTION Shorted

coil

driver

for

Line

contactor

SYMPTOM Forward or Reverse contactor will not pick up.

EVT 15 CARD

t

jKc/

SWITCH

POSSIBLE *Defective

I

CAUSE

coil driver internal to oscillator

card.

- Replace oscillator card.

10 -&

STATUS

24

INDICATION

This status code is displayed contactor coil driver.

STATUS

CODE

-27

----j--o

132

CRITERIA

when there is a shorted Line

DESCRIPTION Oscillator

Card

power

supply

is less than

14 Volts. I

CIRCUIT

1Traction

SYMPTOM Forward or Reverse contactors open and close, then can only be closed by opening and closing the key switch.

POSSIBLE *Discharged

CAUSE

battery.

- Check battery to insure proper state of charge.

Voltage may be dropping below 14 volts at terminal PBl when one of the motors is under load. Charge the battery.

*Loose connection

at terminal

PBl.

- Insure that the wire connection at terminal PBl is tight and

EVT 15 CARD

not corroded.

STATUS *Defective

oscillator

card.

INDICATION

This status code is displayed supply is less than 14 volts.

CRITERIA

when the oscillator card power

- Replace oscillator card.

SM-581

19-03-08

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

Sept 93

STATUS

DESCRIPTION

CODE

-41

-

Open Thermal

Protector

or Control Over Temperature.

MEMORY RECALL

No

Cl RCU IT

Traction

SYMPTOM 6 ..-..,,7‘_“_“_.._“_, r”-“--” I ITP 1 \ 1 I

Reduced or no power to traction motor in control range.

I i

I

POSSIBLE *Open thermal

protector

I I i I I I I I i.-..--.-.-.-..-.-.._.._.._I

CAUSE

circuit.

- Check for loose or corroded connection or broken wire between: VI0 wire at thermal protector and PZ2. WHTNIO wire at thermal protector and PZ5. Repair or replace as necessary. *Defective

thermal

protector

Q 2 5 3

(part of transistor).

0 PZ5

- Disconnect wires from PZ2 and PZ5. At room temperature (25 C or 75 F) measure resistance between VI0 and WHTNIO wires. Replace transistor if ohmic value is greater than 1300 ohms. control

0 5 0 PZ2

STATUS

OSCILLATOR CARD TCONNECTCR

INDICATION

CRITERIA

This status code is displayed when the voltage and PZ5 is greater than 1.8 volts.

is in thermal cut-back.

between PZ2

- Allow control to cool, status code should disappear. Review duty cycle, application, motor current, brake drag and ambient temperature etc.

STATUS

MEMORY RECALL

DESCRIPTION

CODE

-42

Motor

current

sensor

input

missing.

No

CIRCUIT

Traction

SYMPTOM No power to traction motor in control range.

SENSOR 0; POSSIBLE Qpen

~2 .

-

CAUSE

sensor wire circuit to PZ12.

EVT 15 CARD

- Check for loose or corroded connection at terminal PZ12.

v l

- Check for loose connection or broken wire (green wire)

Pi!12

at weld on current sensor and along length of wire. *Defective

oscillator

card.

- Check for voltage between terminal PY7 and negative with motor not operating. oscillator card.

If greater than 1.6 volts, replace

STATUS

INDICATION

CRITERIA

This status code is displayed when voltage between PY7 and negative is greater than 1.6 volts with no current flowing in the motor circuit.

SM-587

19-03-09

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

Sept 93

STATUS

DESCRIPTION

CODE

Motor current

-43

sensor

MEMORY RECALL L Cl RCU IT

input missing.

No Traction

A

SYMPTOM No power to traction motor in control range.

POSSIBLE Qpen

CAUSE

sensor wire circuit to PZ13.

EVT 15 CARD

- Check for loose or corroded connection at terminal PZ13.

7

- Check for loose connection or broken wire (yellow wire) at weld on current sensor and along length of wire. *Defective

oscillator

+ PZ13

card.

- Check for voltage between terminal PY7 and negative with motor not operating. If less than 0.84 volts, replace oscillator card.

STATUS

INDICATION

CRITERIA

This status code is displayed when voltage between PY7 and negative is less than 0.84 volts with no current flowing in motor circuit.

STATUS

MEMORY RECALL

DESCRIPTION

CODE

Transistors

-44

did not turn OFF properly.

CIRCUIT SYMPTOM

POSSIBLE *Transistors

..-. .-..-.._.. -._, r iiy --i i I ‘--&-’ s 1 I I

,‘2

i

j

Traction

I

r”-“-“-’

I

Forward or Reverse contactors open and close, then can only be closed by opening and closing the key switch.

Yes

q,NG

CAUSE

defective.

- Check for open circuit or loose or corroded connection between the transistors and terminal PZ4 (red wire).

- Turn-off time for transistors is out of specification. field test is possible.

No

!.._.._.._.._.~~~._.._.._.._.._~ @ . j l pz9 PZ4

Replace transistors.

EVT 15 CARD

STATUS

INDICATION

CRITERIA

This status code is displayed when, during control operation, the transistors fail to turn OFF. Voltage from T2 to battery negative as measured at terminal PZ9 is less than 12% battery volts.

~~-587

19-03-10

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

Sept 93

STATUS

CODE

-45

MEMORY RECALL

DESCRIPTION Transistors

did not turn

ON properly

CIRCUIT SYMPTOM

-._, I-“-“-‘-. .._. ._.._.._.. I f 4.4 3; --J

Forward or Reverse contactor will open and close, then open and then can only be closed by opening and closing the key switch.

I I i

T*

‘--&J

s

YeS Traction

A

1 N33

POSSIBLE *Defective

transistor

CAUSE

circuit.

- Check for open wire (red wire) or loose connection between the transistor and terminal PZ4.

Repair or replace.

- Check for corrosion on plug / pin at terminal PZ4. Repair or

L.._.._.._.._.~._.._.._.-.-! P

replace.

- Check for open wire (blue wire) or loose connection at

PZ9

terminal T2 (#3 REC power terminal). Repair or replace.

. PZ4

EVT 15 CARD

- Check for corrosion on plug / pin at terminal PZ9. Repair or replace.

STATUS *Defective

This-status ON.

transistors.

INDICATION

code is displayed

CRITERIA

when the transistors

fail to gate

- Intermittent or open transistor gate.

Field test may or may not show defect. Replace transistors after above checks show no problem found.

STATUS

CODE

-46

MEMORY RECALL

DESCRIPTION Look

ahead

test for T2 volts.

(Less

than

12% of battery

I%

volts.)

CIRCUIT SYMPTOM

‘A-t/

A

.

Forward or Reverse contactor will not pick up.

Traction

0

r-..-_...__.&.-._.._.._,

POSSIBLE *Defective

.

CAUSE

I

1A contactor.

- Check for welded 1A contactor power tips. *Defective

f =

transistor.

- Check for shorted transistors. *Defective

oscillator

I

7

:___-..-,,,.G__,~_i .I ._.-4. _--_.~_-_-: JG i :“--’

! I

!

l.._.._..__x!?__.-.-.-._: R

Replace transistors.

j - PZ9

card.

. PZ4

E’.‘T 15 CARD

- Check for 1A contactor coil being energized due to shorted driver. Replace oscillator card.

STATUS

INDICATION

This status code is displayed than 12% of battery volts.

SM-587

19-03-11

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

CRITERIA

when the voltage at T2 is greater

Sept

93

STATUS

CODE

-48

l-

DESCRIPTION Look ahead test for T2 volts

(Greater

than

88% battery

MEMORY RECALL

No

volts) Cl RCU IT

Traction

SYMPTOM

Fg;

Forward or Reverse contactor will not pick up.

POSSIBLE *Defective

forward

or reverse

CAUSE contactor.

- Check for welded forward or reverse contactor power tips.

- Check for sluggish operation of forward or reverse contactor. *Defective 3 REC circuit.

- Check for shorted 3 REC. - Check for shorted 3 REC snubber (23 REC). *Defective

oscillator

STATUS

INDICATION

This status code is displayed than 88% of battery volts.

card.

CRITERIA

when the voltage at T2 is greater

- Check for Forward or Reverse coil being energized due to shorted driver.

STATUS

Replace card.

CODE

-50

DESCRIPTION volts low after Line contactor

Capacitor

closes.

MEMORY RECALL CIRCUIT

No Traction

SYMPTOM Forward or Reverse contactor picks up. operate.

POSSIBLE *Defective

Control does not

CAUSE

Line contactor.

- Check for open line contactor power tips and / or contamination.

Repair or replace.

- Check for adjustment of steer interlock switch holding Line contactor power tips open. Readjust.

- Check for loose or open connection in cables from battery positive to contactor panel positive. Repair or replace.

- Check for loose or open connection in bus bars from 1FU power fuse to Line contactor power tips. Repair. *Defective

1FU power fuse.

- Check power fuse for open circuit. Replace.

34-587

STATUS

INDICATION

CRITERIA

This status code is displayed when capacitor volts are less than 85% battery volts at initial start up.

19-03-12

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

Sept 93

STATUS

DESCRIPTION

CODE

Capacitor

-51

volts

low before

Line

contactor

MEMORY RECALL

closes

No

(precharge).

Cl RCU IT

Traction

SYMPTOM Line Contactor does not close.

POSSIBLE

CAUSE

*Defective capacitor. - Check capacitor bank per component checking section. - Check for loose or open connections in capacitor circuit. *Misadjusted / defective steer interlock switch. - Check to insure that the steer interlock switch closes after the line contactoh power tips close. Repair or replace. -Defective steer control. - Disconnect the positive cable and 4PL plug from the steer control. If status code disappears, repair steer control. -Open circuit in capacitor precharge circuit. - Check for loose connection or broken wire (WHT) at #3 REC heat sink or along the length of the wire. - Check for loose or corroded connection at terminal PZ14. - Check for loose connection or broken wire (BLACK) at 1 FU power fuse or along the length of the wire. - Check for loose or corroded connection at terminal PBl. *Unsuppressed voltage spikes. - Check that any and all coils, including horns, that are present on the truck have the proper voltage suppression. - Check that the static drag chain is present on the truck and dragging on the floor so that it keeps static electricity from building up in the truck.

STATUS

STATUS

INDICATION

CRITERIA

This status code is displayed when capacitor volts are less than 85% battery volts at initial start up.

DESCRIPTION

CODE

Transistors

-53

fail to turn OFF during

plugging

cycle.

Yes

CIRCUIT

Traction

SYMPTOM Forward or Reverse contactor opens and closes, then opens and can only close by opening and closing the key switch.

POSSIBLE

CAUSE

*Open T2 circuit. - Check for short from terminal negative.

PZ9 (blue wire) to battery

- Try to operate in opposite direction.

If status code -44 does not appear, check for open motor circuit or intermittent directional contactor power tips. Repair or replace.

*Transistors

defective.

- Turn-off time for transistors are out of specification. field test is possible.

No

Replace transistors.

STATUS

INDICATION

This status code is displayed OFF during plug cycle.

- Check for open circuit or loose or corroded connection

CRITERIA

when the transistors

fail to turn

between the transistors and terminal PZ4 (red wire).

34-587

19-03-13

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

Sept

93

STATUS

CODE

-54

DESCRIPTION Shorted

F, R or 1A contactor

No

coil driver. I

CIRCUIT

Traction

SYMPTOM Control will not operate

POSSIBLE *Defective

oscillator

CAUSE

card.

- Replace oscillator card.

STATUS

INDICATION

CRITERIA

This status code is displayed when either the forward, reverse or 1A contactor coil driver is shorted internal to the oscillator card.

STATUS

CODE

-57

DESCRIPTION Current

sensor

input

voltage

polarity

check.

SYMPTOM Forward or reverse contactors open and close, then can only be closed by opening and closing the key switch.

SENSOR POSSIBLE *Unsuppressed

voltage

A2

CAUSE

spikes.

*~-------

- Check that any and all external coils that are present on the truck have the proper voltage

EVT 15 CARD

t

suppression.

- Check that the static drag chain is present on the truck and dragging on the floor so that it keeps static electricity from building up in the truck. *Reversed yellow and green current sensors wires (if wires are reversed, truck will not run at all).

- 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. Insure that the yellow wire, at the sensor, is at battery positive.

STATUS

INDICATION

CRITERIA

This status code is displayed when the voltage input to terminal PZl2 is positive in relationship to terminal PZ13.

*Reversed power cable connection. - Insure that the battery negative cable connects to the panel NEG terminal and the motor A2 cable connects to the panel A2 terminal.

SM-587

19-03-

4

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

Sept 93

STATUS

CODE

-99

MEMORY RECALL

DESCRIPTION Maintenance

Reminder

code.

CIRCUIT

bb Traction

SYMPTOM status code is displayed for about 3 seconds when key switch is first turned ON. Truck may run at a reduced speed and status code -99 will flash on the display. -99

POSSIBLE

-99

CAUSE

Truck has accumulated the number of hours as preset in functions #19 and #20. Perform required PM maintenance and reset functions 19 and 20 to next desired maintenance hour number. Note:

Amount of travel speed reduction setting of function #21.

is determined

by the

The EVlOO / EV-T15 handset is required for all function setting changes.

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.

r

STATUS

CODE

Blank

MEMORY RECALL

DESCRIPTION No display

on Dash Display

or Handset.

CIRCUIT

No Traction

SYMPTOM Display screen on dash display or handset is blank.

EVT 15 CARD

POSSIBLE *Positive

or negative

CAUSE

control voltage

2

missing. .r SWITCH

Insure that with the key switch ON, voltage is present between terminals PBl (positive) and PZl (Negative). - Check for broken wire(#2) or loose or corroded connection from power fuse to terminal PBl. - Check for open or intermittent key switch. - Check for broken wire (#lo) or loose or corroded connection from key switch to terminal TB4. - Check for broken wire (WHT / BROWN) or loose or corroded connection from key switch to terminal PZl. -

loose connections between each wire between the ‘Y’ plug and dash display / handset. *Defective

PBI

PZl

if

10

lo -4TB4

L

*Open circuit between oscillator card ‘Y’ plug and dash display or handset.

- If truck does run but no display, check for open circuit or

2

F

STATUS

INDICATION

CRITERIA

This indicates a lack of voltage to the oscillator card and / or dash display. Battery voltage must be present between terminals TB4 and PZl of the oscillator card when the key switch is turned ON.

dash display / handset.

- Replace dash display / handset.

SM-587

19-03-15

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

Sept 93

Cl!!lRKWl;&r&:Handling

GROUP 19

Section 4 Oscillator Card Settings

Typical Illustration

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

GROUP 19

Oscillator Card

AWARNING Drive wheel must be off the floor before any adjustments are made. Raise rear of truck and block it on both sides.

Typical Illustration

Remove all Jewelry working on truck. Sep 93

A

before

Always wear Safety Glasses

1942

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

SM-587

EV-T15 Settings

GROUP 19 NPR (24 Volt Truck) EV-T15 Card Factory Settings

hnction Factory Setting

Actual Value

Description

No.

Speed Limit C/A

F03

Creep Speed Controlled Acceleration & 1A Tiie

006-008 090-110 006-008

0.6 - 0.8 Sec. 7.7% - 8-3% -

F04

Current Limit

218-222

-

F05

Plugging Distance (Current)

135-145

655 - 687 Amps

F06

1A Drop Out

255

F07

Plug % On Time Adjustment

35-40

Function Disabled -

FOS

N/A N/A

N/A N/A

N/A Speed Limit 1 Speed Limit 2

N/A 154-156

N/A N/A -

000-001

Function Disabled

Speed Limit 3

000-001

Function Disabled

Internal Resistance Compensation Battery Volts

026 024

0.88 Volts Drop

F16 F17

Pedal Position Plug

095-105 022-024

F18 F19

Steer pump Time Delay Maintenance Hours (l=l hour)

F20

FOl F02

F09 FlO Fll F12 F13 F14 F15

Card Type Selection

N/A

24 Volts Std. C/L w/Speed Limit

001-003

l-2 Set 50 hours

Maintenance Hours (l=lOO hours)

050 002

F21

Maintenance Speed Limit

000-001

Function Disabled

F22

N/A 005 000-001

N/A -

F24

N/A Speed Limit JR Compensation Speed Limit Comp Start

F25

N/A

N/A

N/A

F26

N/A

N/A

N/A

F27

N/A Last Fault Flag

N/A 016-030

N/A Next Fault Location

F23

F28 SM-587

19-4-3

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

200 hours

Function Disabled

Dee 94

EV-T15 Settings

GROUP 19

NPR (36 Volt Truck) EV-TIS Card Factory Settings Function Description

No.

Factory Setting

Actual Value

FOl

Speed Limit C/A

011-015

1.24 - 1.36 Sec.

F02

Creep Speed

F03 F04 F05

Controlled Acceleration & 1A Time Current Limit

045-055 008-011 218-222

6.35% - 6.65% 0.856 - 1.024 Sec. -

Plugging Distance (Current)

150-160

-

1A Drop Out Plug % On Time Adjustment

255 35-40

Function Disabled -

N/A

N/A

N/A

F09 FlO Fll

N/A

N/A

Fll Fl2

Speed Lit l(271 MPH & above) Speed Limit 2 Speed Limit 3

N/A N/A 157-159 169-171 000-001

F06 F07 F08

N/A Speed Limit 1 (up to 270 MPH)

N/A -

F14

Internal Resistance Compensation (up to 270 MPH)

020

Function Disabled Function Disabled 1.14 Volts Drop

F14

Internal Resistance Compensation

026

0.88 Volts Drop

F13

000-001

(271 MPH & above) F15

Battery Volts

036

F16

Pedal Position Plug

095-105

36 Volts -

F17

Card Type Selection

022-024

Std. C/L w/Speed Limit

F18

001-003

1-2 Set

F19

Steer pump Time Delay Maintenance Hours (l=l hour)

50 hours

F20 F21

Maintenance Hours (l=lOO hours) Maintenance Speed Limit

050 002 000-001

Function Disabled

F22

N/A Speed Limit IR Compensation

N/A 005

N/A -

Speed Limit Comp Start

000-001

Function Disabled

F25

N/A

N/A

N/A

F26

N/A

N/A

N/A

F23 F24

Dee 94

19-4-4

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

200 hours

SM-587

~;t$h\Handling ELRRIC

GROUP 19

Section 5 Steering Control Adjustments EV-T5PS Contents

SM-587

Preparation and Safety .......................................................................

19-5-2

Adjustment Steps 1 - 3 .......................................................................

19-5-3

Adjustment Steps 4 - 5 ....................................................................... Adjustment Steps 6 - 7 .......................................................................

19-5-4 19-5-5

Adjustment Step 8 .............................................................................

19-5-6

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

Dee 94

Steer Control

GROUP 19 A

WARNING

Drive wheel must be off the floor before any adjustments are made. Raise rear of truck and block it on both sides.

Typical Illustration

Remove all Jewelry working on truck.

Dee 94

A

before

19-5-2

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

Always wear Safety Glasses

SM-587

Steering EV-TSPS

GROUP 19 SC-POS

Steer Control Adjustments 1. Turn key switch ON and step on brake pedal. 2. TurnMaxSpeedtrimpotfullyclockwise(CW).

Maximum Speed Trim Pot

Current Compensation

Steer Control

rypical Illustratiotl

SC-POS 3. Turn Steer Comp trim pot fully clockwise 0%.

Steering Compensation Trip Pot

Steer Compensation Current Compensation

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

Steering EWT5PS

GROUP 23

SC-POS 4.

Turn Current Comp trim pot fully counterclockwise (CCW).

Steer Compensation

Current Compensation Trim Pot

Current Compensation

Steer Control

lypical Illustration

5. Measure

SC-POS motor out voltage between M+ and

M- power terminals on steer control.

Steer Compensation Current Compensation

II

III

-------------_____

L-l

I l-l

Steer Control Dee 94

19-5-4

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

SM-587

Steering EWT5PS

GROUP 19 SC-POS

6. Turn Idle Speed trim pot until motor output voltage is: 9.2 +/-0.2 (24~VoltTruck) 13.6 +/-0.2 (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.

SM-587

19-5-5 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Steering EV-TSPS

GROUP 23

SC-POS 8. Turn Current Comp trimpot clockwise (CW) until motor output voltage is:

12.4 +/-0.2 (24-Volt Truck) 17.5 +/-0.2 (36-Volt Truck)

M+

Steer Compensation

Current Compensation Trim Pot

Current Compensation

Steer Control

rypical Illustration

9. Remove blocking and lower truck to ground.

Typical Illustration

Dee 94

19-5-6

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

SM-587

Wl~~;~~Handling Cl!!lRK

GROUP 19 Section 6 Wiring Diagrams NPR-345

WY SM-587

19-6-lMaterial Copyrighted Intended for CLARK dealers only Do not sell or distribute

TypicalIkstrario~~

Aug 93

Wiring Diagram Battery

Steer Lock Switch \

Accelerator

1

,

1

J

PYl3 PM PM16-=6

10

10

10

10-1k6

6

1oyi=.!&26 ,___~~~~~~~.lO~~~~~~

.-r-w,_

66

10

. .P

10

*6l .67

~~~~~~~~~~.lo-~~~~-~L-----.

~-~~_~~~~~.lo-~~---~PL----.~-~~r m 10 .62 I 10 .. s . 10 rm

ckukMuterialHMdlingco.

SL-l_

6L-2 ~~~.24~~-~~n~~~

PA6r

---.64-----d-B,

PA3

W

13 12 ____a__ 12-m-----* W

28-

l87*

-28 -20

w

-13

13

lm.

.lBll

46

lT8l0

26

26

l TB6

16

16

-46 TnT

I44

61

OTB14 Tm*

26-*l813 66mm--w-m--w-66-w..m2

lo-Q=!&6 10-I

llB16

81

*TM

61)“‘~_““~_~___..~

Horn Switch NPR 15D.17,20.22

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

..P

Q-

: . .

_ -

6

d b

I

b! L Copyrighted Material

%

Intended for CLARK dealers only Do not sell or distribute

P c%-

GROUP 19 Section 7 Forward & Reverse Switches, Up (Lift )& Down (Lower) Switches and Transducer Adjustments Contents Safety................................................................................................ 19-7-2 Switch Adjustments ..... .......... ................................ .... .. .............. ........ 19-7-3 Transducer Adjustment ......................... ............ ................................. 19-7-4 Forward, Reverse Switch Voltage Check & Adjustments ......... .......... 19-7-7

Multi-Function Qble

,~

-

Control Hand

Clamp Tilt and Auxiliary Switches +

guide

x

Markmg Tape

Clamps, Cable Guides and Marking Tapes:

Switch Side) -)e’

IMPORTANT Cables must be positioned with all tape markers aligned with or hidden under clamps or guides. SO-G Latch plug number with socket number c PL-9

jefore making a connetion. If you do not, Aectrical shorts and possible damage to equipment may result. See below.

Arrows must face in direction shown Switch

SM-587

p$TT%F

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

-

Control Handle

GROUP 19 A

WARNING

Drive wheel must be off the floor before any adjustments are made. Raise rear of truck and block it on both sides.

Remove all Jewelry working on truck.

Dee 94

A

before

19-7-2

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

Always wear Safety Glasses

SM-587

Control Handle

GROUP 19

Forward, Reverse, Up (Lift) & Down (Lower) Switch Adjustment Objective: Switch must fullv actuate when the roller is at the hiah noint of the cam. 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.

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 ...... switch arm just touches the switch

plunger

with the arm roller in contact with the cam ‘Just Touch”

surJace, refer to example. The adjusbnent ismude with the adjusting screw of each switch. Do not over adjust.

m

r Up (Lift) Switch

Up and Down Switch Adjustment 1. 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, is just touching but not depressing the switch plunger that is under the lever. 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. Tighten the Cam Low Profile

switch mounting bracket screws iust enough to allow the bracket to be moved "LID“and “down” bv hand but not so loose that the bracket will move on its own.

2. Adjust each switch, with the screw adjuster, so Reverse Suritch s’cre

that the switch plunger is being fullv deuressed when the switch lever roller is on the high hartof the cam. (The switch lever will be parallel to the switch body.) Do not adjust to the point where

the switch lever is being bent. IMPORTANT: do not adjust the switch operating (turn on) point with the switch screw adjuster. 3. Set the truck up in operational condition

Truck Condition 0

Truck on blocks, drive wheels off floor.

l

Upright fully lowered.

l

Key switch “off ‘.

l

Battery “unplugged”.

SM-587

(battery plugged in, key switch ON, no load on the forks and drive wheels off floor).

4. Loosen the switch mounting bracket screw on the UP (Lift) switch end. Move the up switch end of the bracket “up” or “down” as needed to operate the lift pump at a point just before the 19-7-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Control Handle

GROUP 19 lift valve starts metering hydraulic flow to the cylinder. Tighten the bracket screw described in Step 1. 5. Loosen the switch mounting bracket screw on theDOWN switch end. Move thedown switchend of the bracket “up” or “down” as needed to operate the lower solenoid valve at a point just before the lift valve starts metering flow from cylinder. Tighten the bracket screw. 6. Check that the adjustments of both switch plungers are operating as set in Step 2. If they are not, repeat Step 2.

7. Recheck the UP (Lift) and DOWN CLowerl switch actuation noints. If the lift pump and lowering solenoid valve come on at the proper time, proceed to Step 7. If one or both do not, repeat Steps 4,5 and 6. This may be necessary because the adjustment of the UP (or Down) switch is changing slightly as you are performing the adjustment to the DOWN (or Up) switch. 8. Securely tighten the switch mounting bracket screws without distrubting adjustmenta.

TRANSDUCER ADJUSTMENT Step 2 l

Measure accelerator voltage at wire #29 on terminal TE31 of traction control oscillator card and battery negative. #I 3 Battery Negative -,

A

TBl’ lwl

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

Control Handle

GROUP 19

Lock Nut

l

TLUTI key switch ON. DO NOT STEP ON BRAKE PEDAL.

l

Loosen Lock Nut holding transducer to mounting plate.

Sep 4 l

Measure voltage between wires #29 and #13. A

CAUTION

To prevent damage to wiring: Loosen wires #29 & #13 by pulling them part way thru cam “slot”.

Usinczthe bodv of the transducer, slowly rotate body clockwise and then counterclockwise by hand (voltage will increase and decrease as the body is rotated). Do not rotate the body to the extent thal wires are pulled out (or damaged). Stop rotation when voltage registers between 3.50 and 3.75 volts. This is know as the “neutral point” OI maximum accelerator voltage position. Note when in this position the wire harness will be on the toI

Transducer Wire Harness

1 Transducer Body

SM-587

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

Dee94

Control Handle

GROUP 19 itep 5 l

.

With transducer at the “neutral point”, tighten Lock Nut securing transducer in position.. Verify acceleratorvoltageis between 3.50 and 3.75 volts and, any handlemovement (in either direction) results in reducing accelerator volts.

Lock Nut

Step 6 l

Move handle to maximum forward and maximum reverse direction positions. Verify accelerator volts are less than 0.20 volts.

r /

Forward Switch

Dee 94

19-7-6

Reverse Switch

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

SM-587

Control Handle

GROUP 19

=ORWARD AND REVERSE SWITCH ADJUSTMENT

Step 7 l

Disconnect connectors SO-8 and PL-8. NOTE

Forward and reverse switch voltages should be measured between wire #6 and wire #8 (alternately) on terminals TB-5 and TB-6 (on traction control oscillator card) and battery negative, see below.

Battery Negative

TB6 Wire #F TB5_ Wire #6

SM-587

T2

.lsdII

Capacitor

19-7-7

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

Dee 94

Control Handle

GROUP 19 Step 8 l

Step on brake pedal. Measure directional switches and accelerator voltages at wire #6, wire #8 and wire #29 with respect to battery negative (wire #13). Battery Negative --, k-

m

n Capacitor

l-l-l-

TB6 7 Wire #8 \ TB5 Wire #6 ’

TBI _/ Wire #29

/

Step 9 .

Move control handle to neutral position,seeoppositeillustration.Directional switch voltage at wire #6 and wire #8 must be zero (0). If voltage at one and/or both wires is battery volts, turn the “adjustment screw(s) as required to open (deactivate) the forward and/or reverse switches. NOTE

Adjusting the screw counterclockwise will operate the switch closer to neutral position of the control handle. Adjusting the screw clockwise operates switch further away from neutral position. Dee 94

ww

19-7-a Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Control Handle ForwardandReverse

GROUP 19 Switch Adjustment-continued.

Step IO l

Move control handle extremely slowly to operate the forward switch. When switch oper-

ates, hold handle in this position. l

l

Now, verify forward switch voltage is battery volts (measure voltage at wire #6). Monitor and note “specific accelerator voltage” corresponding to forward switch operating position. This accelerator voltage (wire #29) must be between 3.40 and 3.60 volt.

Forward Switch

Step 11 l

Move control handle extremely slowly to operate the reverse switch. When switch oper-

ates, hold handle in this position. l

l

Now, verify forward switch voltage is battery volts (measure voltage at wire #S). Monitor and note “specific accelerator voltage” corresponding to reverse switch operation position. This accelerator voltage (wire #29) must be between 3.40 and 3.60 volts.

Reverse Switch

SM-587

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

Dee 94

Control Handle

GROUP 19 Step 12

To adjust actuation (operating) positions of Forward and/or Reverse Switches: l

Rotate the adjustment screw(s), as required to obtain “specific accelerator voltage” of 3.40 to 3.60 volts corresponding to the actuation positions of both switches. The voltage measure at the “actuation moment “of each switch must be 3.40 - 3.60 volts (+O.OSvolts apart maximum).

Reverse Switch AdJustmentScrew

Forward Switch Adjustment Screw

Step 13 l

Dee 94

Plug in connectors.

19-7-l

0

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

SM-587

GROUP 19 Section 8 Periodic Electrical Checks Contents Preparation ..................... ................................................................... 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

Periodic Electrical Inspection

GROUP 19 1. Move truck to service area. . Park truck on a flat level surface. .

Extend pantograph.

.

Fully lower pantograph.

.

Tilt forks forward until fork tips touch the floor.

2. Turn key switch off. l

Remove key.

l

Disconnect truck battery.

3. Remove Front Console Cover .

Remove fasteners securing 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.

Dee94

19-8-2

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

Front Console\ Cover \ SM-587

Periodic Electrical lnpsection .

GROUP 19

Remove console cover from truck.

4. Discharge the CaDacitors

Discharge Capacitors

.

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 SCR control. 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. A WARNING Discharging the capacitors without using specified resistor could cause serious injury to yourself and bystanders.

SM-587

19-8-3

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

Dee94

Periodic Electrical Inspection

GROUP 19

Electrical Inspections IMPORTANT Connector Plugs and Receptacles are permanently labeled with the proper PL (Plug) and SO (Socket/Receptacle) number for easy identification.

A

CAUTION

Match the plug number with the appropriate receptacle number before making a connection. If you do not, electrical shorts and possible damage to the equipment may result. i.e., Plug #PL-6 plugs into pin socket SO-6. etc.

IMPORTANT Tape Markers are used to correctly position each wire harness and electrical cable on the truck. When correctly installed, the tape marker will be hidden by the mounting clamp (guide). Be sure to follow the instructions, where notedinthis manual, when installing a wire harness or electrical cables. If you do not, ossible shorts and equipment damage may result.

s must face in direction shown. -

L-Tape Marker

(Stamping: DT06-6P)

I

PL-6 Plug

Pin(s)

(Used on Wire Harness’s and Power Cables)

(Stamping: DT06-6S

Torque specifications (where noted) for mounting hardware, clamps, etc., must be adhered to or equipment damage may result.

Special Instructions have been illustrated to show proper installation of multiple cable and wire connections. If the instructions are not specifically followed, possible electrical shorts and control damage may result. Assemble Front-to-Front ;semble Back-to-Back TC-NEG. Cable (Pump Motor “A”) TC-NEG. Cable (BAT.NEG.) TC-NEG. Cable (Steer Control Neg.) ire 13C & 13D (Main Harness)

EXAMPLE

e 13B (Main Harness)

Dee94

19-8-4 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Periodic Electrical

lnpsection

GROUP 19

Power Cables l

l

Cables having small cuts in the casing may be repaired with electrical tape.

r

Repairable Damage

{n\

Cables having damage as shown in illustration below should be removed immediately and replaced with new. Be certain the replacement cable is the exact same length, size and has the proper connector. Make absolutely certain the cable end is properly crimped and its connection properly torqued upon installation.

Power Cables having small

Everycableand wiring harness on this truck is manufactured to an exact specification. A shorter cable or harness will not fit. If either a harness or cable is routed improperly, it will not fit. Subsequently, electrical shorts and damaged components may result if the replacement part is the wrong one, or if it is routed incorrectly.

Cable unfit for further service.

Broken Wires -I

SM-587

19-8-5

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

Dee94

Periodic Electrical Inspection

GROUP 19

IMPORTANT Improperly Torqued Fasteners Can Cause Damage l

Use an appropriate wrench and tighten all fasteners to the torque specified in the following inspection procedures.

Typical Inch Pound Torque Wrench

Pointer

Typical Foot Pound Torque Wrench

Scale

Pivoted Handle

Pointer

19-8-6

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

SM-587

Periodic Electrical lnpsection

GROUP 19

Assemble Front -

Torque to: 100 lb. in.

TC-NEG. Cable (Steer Control Negative)

Buss Bar

Wire 13C & 13D (Main Harness) e 138 (Main Harness) 1 \

\

-TC-P

able (or) . Wire Harness

L

5iiiiir 5ii?

Cable, (Pump Motors) /

Torque to: 100 lb. in. (11.3 N-m)

/

m

Clamp

IMPORTANT

lamps must be lositioned so al

Terminal Barrels must face opposite each other.

-APE MARKERS ,re aligned witk lr hidden under 3e clamps 01 ,lamp guides.

A!

CAUTION

Wire harness, clamps (guides) and terminal connections must be installed exactly as shown. If they are not installed as illustrated here, you may shorts and experience component damage.

ressure

Cables & Wiring l

l

l

l

SM-587

19-8-7

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

Make sure wire connections are secure. Check wiring for damage. Replace as required. Check harness clamp/guides for security of mounting. Be certain the clamps and harness are installed as shown. Be certain power cables are tight and installed properly as illustrated here. Dee94

Periodic Electrical Inspection

GROUP 19 26

20

20A

5

Solenoid Control Card

IO

134568

I 13C

l

l

I 48

I 38

I 58

I I8

II

I I I I I I I\

28

45

Check steering control connection PL-4 to be sure it is securely ;ougged in and theat the wiring is in good condition. Be certain all terminal connections are tight and properly installed on the solenoid control card.

Dee 94

I2

19-8-8

55

cy

65

35

IOC

IOE

IOF

Q Main Harness

I l

Be certain the steering control and control card are securely mounted.

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

SM-587

Periodic Electrical

GROUP 19

Checks

NOTE Connect PL-DP to Display Unit prior to assembling to bracket.

l

l

l

l

l

Check Key Switch for security of mounting. Inspect wires 12 & 12B and 10A & 10 for security of mounting and damage. Check the display unit for security of mounting and damage. Inspect wire PL-DP for security of mounting and damage. Check plugs, sockets and wiring for damage. Replace damaged components with new.

Inspect Plug & Socket Wires for damage, cuts (exposed wire). Repair or replace damaged wires.

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

Periodic Electrical Checks

z

GROUP 19

-Clamp or

6

hrkrng

Guide

Tape

Clamps, Cable Guides and Marking Tapes: IMPORTANT Cables must be positioned with all tape markers aligned with or hidden under clamps or guides.

Multi-Function Control Handle

l

l

Inspect wire and harness clamps for security of mounting. Make sure the harness Marking Tape is in alignment with or covered by the clamp. This assures the harness is correctly positioned. Inspect the multi-function control handle for damage. The handle has two halves. Check to be sure thefasteners on the switch and heel sides of the handle are secure.

damage and proper installation. Refer to following page for detailed drawings. . Inspect wiring for damage (cuts, etc.). Repair or replace as required. . Report condition on the PM check sheet and give to the designated authority. .

/ l

l

l

l

Plug (or Socket) Housing

Inspect handle switches for damage (Reach, Tilt, ALIX.).Replace any that are damaged. Check the handle mounting bracket for security of mounting. The bracket must be adjusted so the handle is vertical and in line with the hydraulic control valves. Make certain the mounting bolts are tight. Check security of all mounting fasteners (bolts, screws and C-rings). Replace any that are missing or damaged.

Seal should be pressed flush with housing.

Inspect all connectors (plugs and sockets) for

Dee 94

19-8-l 0

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

SM-587

Periodic Electrical Checks

GROUP 19

IMPORTANT

Typical Panel xeptacle & PI Assembly

Firmly push plug into socket until latch “clicks” locking the two components together.

Ass$mbly

Rubber Seal

----r

IMPORTANT

1

I End Seals must be 1 1 firmlysaatedwithin 1 I theassembly hous- I ’ ing. L ----i

Pin

E~8rvq30@

Retainer Plate (light orange)

rypical Illustration

The electrical connectors on this truck are equipped with rubber seals to protect them from water and condensation. There is a seal at each end (wire end) of the connector. The plug is equipped with a seal and retainer plate, see above. There is a pin retainer plate in the socket sub-assembly. l

Check seals for damage that would make them unfitforfurther service(cuts, etc.). Make certain

the end seals are seated flush with the end of the connector housing. l

The retainer plates snap into place to secure the pins and their sockets. Check the plates for damage and security of mounting.

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

Periodic Electrical Checks

GROUP 19 l

Assemble

Back -t

TC-NEG. Cable

l

TC-NEG. Cable Steer Control Negative

Make certain connections are made as illustrated or possible electrical shorts and component damage Ifanyconnectionsare found to be loose, be 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. Cables must

ue to: 100 lb. in.

Torque.yut to: 100 lb. in. -4 (11.3

N-m)

_\1

,

Guides and Markin! IMPORTANT Cables must be positioned

so all tape markers are aligned with or hidden under clamps or guides.

Dee 94

19-8-l 2

Cables

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

mIlnt

he

rmltd

ac

chnwn

SM-587

Periodic Electrical Checks

GROUP 19

Inspect power cable connections on the drive motor and the contactor panel for damage and security of

l

mounting. Replace damaged parts. Tighten connections to the torque specified.

rorque Cable Mounting Nuts to: 100 Ib.in. (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.

/”

‘Q../ Torque Motor Cable Fasteners to: 150 Ib.in. (16.9 N-m)

Cables must be routed as shown.

19-B-l 3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Periodic Electrical Checks bsemble

-

Front-to-Front

-%

c

Rttrs

I

Rar

,
/‘sJ..

_

Pa”e,

TC-NEG. Cable (Pump Motor “A”)

b

_

GROUP 19

TC-NEG. Cable (BAT.NEG.)

TC-NEG.

7ack-to-Back

SC-POS. _

LTorque

L

hire

F

13C & 13D (Main Harness)

to: 100 lb. in. (11.3 Nom)

Control Panel

0

r.

Typical Illustration

Cables must be installed as shown

.

security of mounting. Replace damage parts. Tighten connections to the torque specified.

Inspect power cables on the control panel and the power steering (aux.) motor for damage and

Dee 94

19-8-14

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

SM-587

Periodic Electrical Checks

GROUP19 Assemble Front-to-Front Assemble

-

hw-

A

TC-NEG. Eable (Pump Motor “A”)

-%

CAUTION

Cables, Wiring and Terminal Connections must beinstalled as shown. If they are not, you may experience electrical shorts and component damage.

TC-NEG. Cable (BAT.NEG.

TC-NEG. Cable (Steer Control Neg.)

13C & 13D (Main Harness)

CP-FU tF%

Wire 138 (Main Harness)

LTorque

to: 100 lb. in. (11.3 Nom)

A t

Inspect connections for damage and security of mounting. Replace damaged parts. Torque fasteners to specifications listed. Torque all connections to 100 lb.in\TC-NEG (Bat. Neg.) (11.3 N*m)unless otherwise specified.

1r Cables must be routed as shown.

SM-587

19-8-l 5 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Periodic Electrical Checks l

GROUP 19

Install truck battery. Refer to Group 12 for installation and safety instructions.

Tvoical Illustration

Protective Cover Cardboard

A

WARNING

The battery contains corrosive acid which can cause injury. If acidcontactsyoureyesorskin, flush immediately with water and get medical assistance. Do not smoke or allow open flame near the battery. Explosive gas is always present around batteries.

l

or Plywood)

// f A& I

Install battery retainers.

I Retainer -

l

Connect battery to truck receptacle.

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

Battery

~;$ria\Handling El!!YRK

GROUP 19

Section 10 Oscillator Card Remove & Replace

/ J

SM-587

19-10-l

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

Dee 94

Oscillator Card

GROUP 19

Truck Preparation l

Turn key switch OFF.

l

Disconnect truck battery.

l

Remove console cover.

l

Discharge capacitors.

A

A

Removeall Jewelry before working on truck.

Dee 94

19-l o-2

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

Always wear Safety Glasses

SM-587

Oscillator Card R&R

GROUP 19

Oscillator Card Removal Disconnect Plugs Disconnect PL-8 from SO-8. Disconnect SO-10 fron n PL-10.

Tilt and Auxiliary Switches

Disconnect SO-7 from PL-7. Disconnect SO-9 from

so-9 PL-9

Remove Switch Actuator Remove Nut (A), see below.

l

Pull Switch Actuator (l3) from control and move downward on the plastic wire looms. This is to prevent component damage when pivoting control out of the way.

l

Remove Nuts (A) from control handle bracket, see above.

l

/I

A

CAUTION

Switches may be damaged if the Switch Cam is not removed. Be very careful when removing cam that you do not damage the switches.

SM-587

Bracket Switch Cam-

1

Fastener-

II UP (Lift) & Down (Lower) Switches

19-10-3

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

Dee 94

Oscillator

GROUP 19 Remove Card l

Installation

Using a 8 rnxn socket and a 6-inch extension, remove upper and lower mounting bolts securing card to panel.

l

Disconnect plugs from card.

l

Remove wiring from ‘II3 l-TB6.

l

Remove card from truck.

Card R&R

*

Installation is the opposite of removal.

r

Mounting Screew

TBl - TB6

-

Dee 94

19-l o-4

Mounting SC&w”

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

’

SM-587

El!!flRIC

Wl;;;;;\Handling

GROUP 19

GROUP 19, Section 16 Solenoid

Control

Card Trouble

Shooting

(Vol ta,oe Checks)

Voltage Data Sheet ..................... .. ..,.. .. .. .. .. ..... .. ., .. ... .. .. .. .. .. ... .. .. .... ... .. .. .. .. .. 19-16-2 RH5 Voltage Checks ............... ................. ..... ..................... ....... ................ 19- 16-3 RH4 Volatge Checks ............... ...... .. ... .. .. ., ... .. .. . ... .. .. ... ... . .. .. ..... .. .. . ... ... .. .. .. . 19-16-4

Indicator Lights (Leds) It is normal for the indicator

lights (leds) to” flicker” when the different hydraulic switches are activated. This does not indicate a problem. There is a problem, however, when one or both lights illuminate with no “flicker” (a solid glow). Refer to the procedures on the

Solenoid Control Card

Top View

SM-587

19-16-l

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

Aug 94

Trouble Shooting

GROUP 19

-1OA

Output

5011 Amp

+lOA

Zero Ohms

: Common

Battery Negative

n

Wire

arness

Solenoid

Aug 94

T.B.

Control Card

indicator 19-16-02 SM-587

lo

Lights (LEDS)

\ J

19-l 6-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Trouble Shooting

GROUP 19 NPR-345 Trouble Shooting Solenoid Control Card IMPORTANT

ItisnormalfortheIndicatorLights~EDs),seeoppositeillustration, to “flicker” when any part of the hydraulic system is put into use. This does not indicate a problem. There is a problem, however, when one or both lights illuminate with “no flicker”.

All Hydraulic Functions Disabled: Check Indicator 1. l

Lights (RH4 & RHS)

Open door on Solenoid Control Card and check to see if the indicator lights (leds) are illuminated. Both Lights “ON” (RH4 & RH5) If both lights are illimunitated, the Solenoid Card is defective and should be replaced with a new one.

l

RH4 Light “ON” (Key Switch “ON” and all Hydraulic Switches Open.) Checkforshorted switchorwire tocorosponding temlinal with avolt-ohm meter, seeopposite illustration. 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:

l

Meter shoul read:

TBlO-

wire#m

ov

TBll-

Wire#55

ov

TB12- Wire#65

ov

TB13- Wire#35

ov

TB14- Wire#5

ov

If there is any voltage present at any of these checks, there is a short in the switch and/or wire. Repair or replace as required.

RH5 Light “ON” (Key Switch “ON” and all Hydraulic Switches Open.) Check for open solenoid or wires to corresponding terminals shown below: Connect RED (+) to:

Meter shoul read:

TB3 - Wire #48

Battery Positive - 24 or 36 Volts

TB4 - Wire #38

Battery Positive - 24 or 36 Volts

TB6 - Wire #18

Battery Positive - 24 or 36 Volts

TB8 - Wire #28

Battery Positive - 24 or 36 Volts

TB5 - Wire #58

*Battery Positive - 24 or 36 Volts

If voltage is other than specified at any of these checks, the solenoid is defective or there is a open in the wiring. Repair or replace as required.

*only when truck is equipped with side shift function. Otherwise meter should register:

- 0 Volts - continued next page -

SM-587

19-16-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Aug 94

Trouble Shooting

GROUP 22

SO// Amp

+lOA

-

13

-

48

-

38

-

58

Zero Ohms

18 -2628 -2oSELECTOR Common _

nr

nr

-

45

-

55

-

65

+

n1

._c - -..-

B

_?A -5-

Battery Negative

35 10

Solenoid Control Card

Indicator Lights (LEDS)

Aug 94

19-l 6-4 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

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.)

l

RH5 Light “ON” TB7

- Wire #26

10 to 12 Volts - Battery Charged indicating the Solenoid Card is receiving BDI Signal from the EV-T15 Oscillator Card. 0 Volts means - Battery is below 80% Discharge and must be taken out of service and “fully” charged or replaced if defective.

)

RH4 & RH5 Lights “OFF” Connect RED (+) to:

Meter shoul read:

TBl

Battery NEG. (0 V)

- Wire#13

TB15 - Wire #lO

Battery Charged

Battery POS. (24 or 36 V)

When Installing a New Solenoid Control Card Refer to the following page. NPR-345

Solenoid Control Card

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

Trouble Shooting

GROUP 22 NEW SOLENOID CONTROL CARD INSTALLATION When Installing a New Solenoid Control Card: IMPORTANT l

Remove “Jumper

Plug JP2” ... if the truck is equipped with 2nd Auxiliary function.

See illustration below.

NOTICE l

If you have a truck without side shift function and the “Jumper Plug JP2” is removed, you will experience the following conditions: -The hydraulic system will fail to function .. . there will be no hydraulics at all. -The RI35 Indicator Light (LED) will be “ON”.

l

If you have a truck equipped with side shift function and the “Jumper Plug JP2” is in place, the following conditions will exist: -The monitoring function of the card for side shift solenoid circuit will not work.

-However, the side shift circuit will be operable.

Jumper Plug JP2

-

Remove JP2 when truck is equipped with Side Shift Function.

IMPORTANT When replacing plug, be certain it is installed -, correctly as shown.

NPR-345

\

Solenoid

Control

Card

against board.

Aug94

19-16-6

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

SM-587

M$d$pk&Handling CLqRIC

GROUP 20

Section 20 Axle, Articulartion Adjustment Contents Illustration . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .... . .. . .. .. .. . . ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 20-l-2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . .. . . .. . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l-3

rC-----

Articulating Axle

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

Mounting Block

Axle

GROUP 20

Dee 94

20-l-2

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

SM-587

Axle

GROUP 20

Truck Preparation 1. Park truck on a flat level surface. 2. Retract and fully lower pantograph. 3. Place forks in forward tilt. 4. Turn key switch OFF. 5. Remove floor plate. 6. Open rear door. NOTE

Batteryshouldbeinthetruckwhen checking or adjusting axle articulation.

\

Check Adjustment Bolts

Floor Plate /

of Axle Stop

1. Check clearance between stop bolt and axle at Point “A”, refer to illustration on page 2. l

Clearancemay bechecked by using a 9/32”twist drill. The drill should just fit between the bolt head and the top of the axle housing.

2. Check clearance at Point “B” using a 5/16”twist drill. If adjustment is required, loosen adjustor set screw and rotate adjustor in direction necessary to obtain proper adjustment. Tighten set screw to secure stop bolt in the adjusted position.

SM-587

20-I-3

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

WI 6”

Dee 94

CLqRRlVl;~;;h\Handling

GROUP 20 Section 2 Drive Unit Contents

Lubrication ........................................................................................ 20-2-3 Removing the Top of the Gear Unit ................................................... 20-2-4 Dismantling the Housing Lid ............................................................. 20-24 Dismantling the Crown Gear and Wheel Shaft ................................... 20-2-5 Dismounting the Outer Race .............................................................. 20-2-5 Dismounting the Inner Race .............................................................. 20-2-5 Dismounting the Helical Spur Gear and the Conical Pinion Shaft.. ... ..20-2- 6 Mounting the Gear Unit - General Remarks ....................................... 20-2-7 Measuring the Assembly Dimension of the Conical Pinion Shaft ..... ..20-2- 8 Preassembly of the Conical Pinion Shaft ............................................ 20-2-8 Preassembly of the Wheel Shaft ......................................................... 20-2-g Preassembly of the Wheel Shaft Bearing in the Housing ................... .20-2-g Setting the Circumferential Backlash ............................................... 22-2-10 Checking the Tooth Pattern .............................................................. 22-2-10 Setting the Conical Pinion Shaft, Helical Gear, and Bearing Cle a. ....22-2-12 Mounting the Conical Pinion Shaft .................................................. 22-2- 12 Mounting the Wheel Shaft ............................................................... 22-2-14 Mounting the Housing Lid ............................................................... 22-2-16 Mounting the Top of the Gear Unit .................................................. 22-2- 17 Special Tools ................................................................................... 22-2-18

Drive Motor Removal

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

C=RnlIP _.I__.

3fl

Drive Unit

I_

A

WARNING

Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.

Remove all Jewelry before working on truck.

Use a Torque Wrench to tighten Terminal Connections. Typical Foot Pound Torque Wrench

Pivoted

Pointer

Dee94

20-2-2

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

SM-587

GROUP 20

Drive Unit

First 500 Oueratiw Hours

Refer to the Lubrication Chart in Group 01 of this manual. Fii unit to bottom of level plug opening with the drive unit in the vertical position.

Change oil after fust 500 hours of operation or ( 6 ) months , whichever comes first.

INSTRUCTIONS FOR REPAIR

LUBRICATION

Fverv 2000 Oueratiw Hour3 After initial 500 hours, change oil after 2000 hours of operation or once a year, whichever comes f?rst. Use AMOCO 1000 or equivalent.

General Before disassembling the drive unit, drain the transmission fluid. l

\

Level Plus

SM-587

Place transmission on a clean work surface.

Seal

Drain Plug

lbp3

20-2-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Drive Unit

GROUP 20 Dismantling the gear unit Removing the top of the gear unit (300) from the basic gear unit (100).

1. Remove the screws (402/404/406). Loosen the top of the gear unit by tapping lightly (e.g., with a plastic hammer) and lift it off.

Dismantling the housing lid (134).

1. Remove the screws (135), loosen the lid by tapping lightly, and lift off.

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

Drive Unit

GROUP 20

Dismantling the crown gear (104) and wheel shaft (119) 1.

Fasten special tool “A” (see page 18) with screws (135) to housing. If the conical pinion shaft (104) is dismantled as well, 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).

2.

Hold the wheel shaft tight and remove the screw (129). Remove washer (128) with shims (130- 133) and bind them together with a wire or the like. NOTE

Surface X of the wheel shaft is used for setting the wheel shaft bearing and must not be damaged. 3.

Insert a g-mm diameter punch into the threaded hole of the wheel shaft and drive to dismantle the wheel shaft.

4.

The wheel bolts (120) can be removed by pressing them out when the wheel shaft is dismantled

5.

Take the crown gear out of the gear unit.

Dismounting the outer race (122), shims (124-127), radial sealing ring (102). 1.

Dismount the outer race (122 inside) by lightly tapping with a copper punch or the like. Make sum not to damage the shims. Bind the outer race and the shims together with a wire or the like and place them with the crown gear,

2.

Pry out the sealing ring, dismount the outer race (122 outside) by lightly tapping with a copper punch or the like, and place the outer race with the wheel shaft.

Dismantling the inner race. 1.

The inner race should be dismantled only if the bearings am damaged and have to be replaced. If a new wheel shaft or a new set of bevel gears is mounted, new bearings must be fitted.

2.

To dismantle the inner race, cut open the bearing cage and extract the inner race via the small bearing collar using the extractar.

SM-587

20-2-5 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Drive Unit

GROUP 20 Dismounting the helical spur gear (201) and the conical pinion shaft (104). 1.

Unscrew the hex nut, dismount the helical spur gear using the extractor, and drive out the conical pinion shaft (e.g., using a copper punch).

2.

Remove the top inner race (112) and place it with the helical spur gear. Press the lower inner race (105) with spacer bushing (111) off the conical pinion shaft using the special tool “B” (see page 18) and place them with the conical pinion shaft.

3.

Dismount the top outer race (112) by lightly tapping with a copper punch or the like. Make sure not to damage the shims (114-l 17). Bind the outer race and the shims together with a wire or the like and place them with the inner race or the helical spur gear.

4.

Dismount the bottom outer race (105) by lightly tapping with a copper punch or the like. Again make sure nottodamagethe shims (107-l lO).Bindtheouterraceandtheshims togetherandplacethemwiththeinner race or the conical pinion shaft and the spacer bushing.

Dee 94

20-2-6 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Drive Unit

GROUP 20

Mounting the gear unit General remarks Before mounting the gear unit, the following points should be noted: Clean all parts carefully and remove all traces of sealing compound. Check all parts for wear, damage and cracks and replace them if necessary. Hone the sealing surfaces with an oil stone or a smooth-cut file. Wheel set components such as helical spur gears should be replaced in pairs, helical gears must be replaced in pairs. It is recommended

to always replace seals and radial seal rings whenever repairs are made.

Cleaned anti-friction bearings should be lubricated before being mounted. For sealing, use only elastic non-hardening sealing compound (e.g., Loctite 574).

SM-587

20-2-7 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Drive Unit

GROUP 20 Mounting the basic gear unit (100) Measuring the assembly dimension of the conical pinion shaft (104) 1.

Insert special tool “D” (see page 19) into the bearing borehole of the housing and measure dimension F.

The housing dimension E is determined addcording to the following formula: E=L-F+22.5

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.

Press the inner race (105) carefully with special tool “C”(see page 18) up to the limit stop.

Dee 94

20-2-8 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SW587

Drive Unit

GROUP 20

PI-e-assemblyof the wheel shaff (119) 1.

Apply Loctite 242 to the knurled portion fo wheel bolt (120) and press into the holes providedon the flange of the wheel shaft.

2.

Rush the Nilos ring (121) onto the wheel shaft up to its stop at the flange.

3.

Using special tool “H” (see page 20), press inner race (122) onto the wheel shaft up to the stop.

4.

Grease the inner race of the taper roller bearing on the wheel shaft (cavities between rollers and cage and between cage and Nilos ring; use Shell Alvania R3 or a grease of identical composition and specification).

Pre-assembly of wheel shaft bearing in the housing (101) 1.

Apply Loctite 575 to the sealing ring (102) at its outside diameter and mount it using special tool “E” (see page 19); the open side of the ring must point to the inside of the gear unit.

2.

Applu Lock 19).

3.

Insert the outer race (122 outside) into the housing and insert the outer race (122 inside) with shims (124 127) for the preliminary setting.

242 to the Gamma ring (103) and press it onto the housing using special tool “E” (see page

IIE"

@.

inside

SM-587

Dee 94

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

Drive Unit

GROUP 20

Setting the circumferentail backlash on the crown gear (104) and checking the tooth pattern 1.

Press the inner race (122) onto the crown gear using the special tool “H” (see page 20).

2.

Insert the crown gear (101) into the housing.

3.

Push in the pre-assembled wheel shaft and use special tool “J” (see page 20) to pull together the crown gear and the washer (128) until the bearing clearance is approximately zero.

4.

For measuring the circumferential backlash at the crown gear, secure the conical pinion shaft against turning, e.g., with a wooden wedge.

5.

The circumferential backlash is corrected by adjusting with shims (124-127).

6.

Admissible circumferentail backlash 0.1-O. 15 mm (0.004 - 0.006”).

Checking the tooth pattern NOTE

For checking the tooth pattern it is necessary to apply a thin coat of marking ink to 3-4 tooth flanks of the crown gear. 1.

Mesh the coated tooth flanks several times with the conical pinion. The pattern will show better if the conical pinion is slightly braked while in mesh. Compare the pattern obtained with the “Mounting guideline” below.

2.

If a correction is necessary, its direction is indicated by the “Mounting guideline”.

3.

Secure the hex nut (118) by staking.

-

Correct pattern adjustment

Tooth pattern on the ring gear

by

changing the mounting di-

Defective patterns Concave Flank

ITY

1 Convex Flank

Setting instructions

mensions in direction of arrow

Pattern at tip

marked

Pattern at root

sions +_A a, and (‘.A, or

mounting

dimen-

backlash S,). The mounting dimensions

may only

Note fig. 1 & 2

Dee 94

20-2-l

0

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

SM-587

Drive Unit

GROUP 20

wooden wedge circumferential

backlash

O.lOjO.15

SM-587

Dee 94

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

Drive Unit

GROUP 20

Setting the conical pinion shaft (KM), helical gear (201) and setting the bearing clearance 1.

Position the shims (107- 110) according to instructions on page 8 and insert the outer race (105) into the housing (101).

2.

Insert the previously mounted conical pinion shaft.

3.

Using the special tool “F’ (see page 19), apply a light pre-stress to the conical pinion shaft via the housing towards the stop.

Adjustment of bearing clearance. 1.

The thickness of the top shims (114- 117) to be fitted can now be determined on the basis of the following

dimensions: c=

Distance between spacer bushing/conical pinion shaft and contact of outer race.

S=

Distance between surface of outer race and surface of inner race. NOTE

If the outer race is higher than the inner race (dimension as shown in detail “Z”), dimension X is determined

as follows: Shim thickness X = C - S - 0.02 If the outer race is lower than the inner race, dimension X is determined as follows: Shim thickness X = C + S - 0.02 2.

Insert the shims and the top outerrace. Fit the inner race by tapping onto the pinion shaft using special tool “G”(seepage19).Placethehelicalspurgear(201)ontotheconicalpinionshaftandscrewthehexnut(l18). Hold the helical spur gear tight using the special tool (see illustration) and torque the nut to 60 + /- 5 Nom (44+/- 3.7 ft-lb.). After checking the tooth pattern the shaft nut is locked by staking.

Checking the bearing clearance of the pinion shaft 1.

Mark the measuring point on the helical spur gear with a grease pencil.

2.

Press the conical pinion shaft downwards by hand, while turning it serveral times through approximately 180”. Adjust the dial gauge to zero at the measuring point.

3.

Pull the conical pinion shaft upwards via the helical spur gear, turning it as described above, and hold it steady at the measuring point.

4.

Read the bearing clearance off the dial gauge. Allowable clearance: O-0.05 mm (O-0.002”). NOTE

When taking this measurement it is important to turn the shaft several times so as to align the rollers in the taper roller bearing.

Dee 94

20-2-l 2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Drive Unit

detail

GROUP 20

,. Z

’

Dee 94

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

Drive Unit

GROUP 20 Mounting the wheel shaft (119), crown gear (104), and setting the bearing clearance. 1.

Use special tool “J” (see page 20) to pull together the mounted wheel shaft and crown via washer (128): Torque to 10 Nom (7.4 ft-lb.) = approximately 5000 N bearing pm-stress

2.

When doing so, turn the wheel shaft several times tin both directions to enable the bearing rollers to align themselves.

3.

Measure dimension “Y” via the hole of special tool “J” (see page 20).

4.

Shim thiclcness “X” = Y - washer thickness of auxiliary unit.

5.

Unscrew special tool “J” (see page 20) and remove.

6.

Insert shims in accordance with dimension “X”.

7.

Apply Loctite 242 to screw (129) and pull together the previously mounted wheel shaft and crown gear via the washer (128). Tightening torque MA = 110 Nom (81 ft-lb.) +/- 10%. NOTE

A direct check of the bearing pre-stress as not set is hardly possible. When checking according to the measu.ring method described above, there should be no measurable bearing clearance. Nevertheless, it should still be possible to rotate the wheel shaft easily by hand.

Dee 94

20-2-l 4 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 20

Drive Unit

SM-587

20-2-l 5 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Drive Unit

GROUP 20 Mounting the housing lid (134)

1. Coat the housing lid with loctite 574 and fit into position. Apply Loctite 242 to screws (135) and fasten. Torque to 9.5 Nom (7 ft-lb.)

NOTE If the basic gear unit is stored as an assembly group, e.g., for standby purposes, it should be

suitably protected against corrosion and be packaged accordingly. Conservation can be carried out, e.g., by filling the unit with oil and draining it afterwards. A closed plastic cover is sufficient to package the unit for storage. Dee 94

20-2-l 6 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

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.

Insert dowel pins (401) into the basic gear unit in such a way that they project from the sealing surface by about 3 mm - l/8”).

2.

Coat the sealing surface of the top of the gear unit with Loctite 574 and place it onto the basic gear unit.

3.

Screw in bolts (402 and 404).

4.

Tighten bolts (402/406) with ti tightening torque of 23 N*m (17 ft-lb.).

5.

Tighten bolts (404) with tightening torque of 46 N*m (34 f&lb.).

Dee 94

SM-587

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

Drive Unit

GROUP 20

SDecial Tool “A” 1

I !

A

1 HFK 250/300

HFK 200

180

1

210

B

167

178

C

152

165

46

0

1302

E

1

1 HFK 400/500 I

65 1692

0.2

0.2

F

so,+s.z

4820.2

G

21

42

k3.2

H

I

28

J

I

20.2

46

I

I

R90

R95

K

43

68

L

19 7s”

o( dent-h)

618

707

I 1

1 I

8

30 7o” 618

708

1

618

709

1

Special Tool “B” Od

HFK 200 30-0.2

00

67.5

Jdcnt-Nr.

618

HFK 250/300

HFK 400/500

35.SQ.2

40.5’0.2

79.5 710

618

711

79.5 618

712

Special Tool ” C” HFK400/500 00 0d

HFK 28.2200 23+O.2

L min. {dent-Nr.

Dee 94

95

618

713

f HFK 26'0.2 250/300

3oj;O.I

31.2

-2

170

17s

618

7lL

618

'F-F3

715

20-2-I 8 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Drive Unit

GROUP 20 Special Tool “D”

HFK

0D L’

Ident-Nr. *

rated

200

HFK

46,5

fl--L-?~

250/300

HFK

51.5

55

63,5

67.5

618.716

400/500

77s

618.717

_I&

Id

618.718

W

dimension

Y

-< II

-2

Actual dimension marked on bushing

Special Tool “E”

pdent-Nr.1

618.722

1

618.723

1

618.724

]

Special Tool “F”

manufactured from M 12 x L DIN 933 1779-1

Teil

Teil

1

2

,”

Special Tool “G” ,

23-0.2

26+0.2

HFK400/500 30.5'0.2

mm. L

35

35

35

Ident-Yr.

618.840

618.841

618.842

HFK 200 0d

SM-587

HFK250/300

20-2-l 9 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

--.

Dee 94

Drive Unit

GROUP 20 Special Tool “H” ~1 l

NennmaQ

Special Tool “I” f7.2’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

Drive Unit

GROUP 20

Special Tool “K”

HFK

0d

300

1

HFK 400

136

140

A

13.7+0,l

14,7+o;l

Ident-Nr.

450 685

450 688

28

Ir

max. 270

SM-587

20-2-21

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

Dee 94

Drive Unit

GROUP 20 DRIVE UNIT

-I--

303

407 408

304

402

Upper Half Dee 94

20-2-22 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Drive Unit

SM-587

GROUP 20

20-2-23 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

IVl~leri-i~Handling El!‘YRK

GROUP 22

Section 22 Traction Wheel & Tire Contents Preparation ....................................................................................... Illustrtion, exploded view .................................................................. Pressing Tire ....................................................................................

.22-l-3 22-l-2 .22-l-3

Tracti

SM-587

22-l-l

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

Dee 94

Tires

GROUP 22 Fastener Tightening Sequence

Tir

Wheel

Torque Fasteners to: 124 - 139 Ib.ft. (168 - 188 Nom)

Wheel & Tire A

Drive Unit

Dee 94

22-l -2

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

SM-587

Tires

GROUP 22

Truck Preparation 1. Park truck on a flat level surface. 2. Retract and fully lower pantograph. 3. Place forks in forward tilt. 4. Turn key switch OFF and disconnect battery.

truck

5. Elevate and block rear of truck. 6. Remove wheel fasteners 7. Remove wheel assembly.

-

-_

_ - -

Replacing Traction Wheel Tire 1. A sleeve slightly smaller in diameter than the wheel with a depth larger than the wheel should be used when pressing on a new tire, see opposite illustration.

of truck using hardwood (oak) blocks.

Press Direction

:g#;:;:

~~~;~~~,~q .

2. Install wheel fasteners and torque them to 124 139 lb.ft. (168 - 188 N*m). Fasteners must be

...‘.‘.:.:+. ::::::::.:+:.

:::::::::::::::

;:{:;:;:$;:s:. .:.:.:.:.:::::: ::::::::::+:. v...: ,.... ,: :K::.:::::::.

::::::::::::::: ::::::::::::::: ::::::::::::::: :::::::::::::::

tightened using diagonal sequence shown in illustration on page 2.

.A.....

:::::::::::::::

;$$$g ‘.‘...y.:+:

‘:~$$:~:~:

~

. . .. . .

:F::::::::::;: ::::::::3>3 :::;::::,:.:.:, :::::::::::::::

::::::::::::::: ::::::::::::::: ::::::::::::::: :::::::::::::::

press

~

‘:jjjjjjjjj

Old Tire

Table

SM-587

22-l-3

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

Dee94

CLSRKlflfx&$Handling

GROUP 22

Section 2 Caster Wheel & Tire Contents Preparation ........................................................................................ Illustrtion, exploded view .................................................................. Pressing Tire ..................................................................................... Bearing Adjustment Procedures .........................................................

SM-587

22-2-l

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

22-2-3 22-2-2 22-2-3 22-2-4

Dee 94

Tires

GROUP 22

Refertoadjustmentprocedures and torque specifications outlined on Page 4 in this section.

Nut 1 Chamfer’

Wheel & Tire Assembly

Dee 94

22-2-2

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

SM-587

Tires

GROUP 22

Truck Preparation 1. Park truck on a flat level surface. 2. Retract and fully lower pantograph. 3. Place forks in forward tilt. 4. Turn key switch OFF and disconnect battery.

truck

5. Elevate and block rear of truck. 6. Remove hub cap from caster wheel and loosen nut. 7. Block the brake pedal in the down position to release the caster brake. 8. Remove caster wheel assembly. _

Replacing Caster Wheel Tire

of

truck

using

1. 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. 2. The thin lipped section of the caster wheel must be protected during handling and pressing. Ensure that the tire is seated evenly on the wheel before starting to press.

Press D,irection #

4

3. Inspect bearings for further serviceability. If the bearings areunfit for further service, they should be replaced. Refer to Group 25 for overhaul procedures. 4. If the bearings are fit for further service, then install wheel assembly and adjust bearings as outlined on the following page. NOTE Reused bearings should bewashed in a non-flammable cleaning solution and dried. New or cleaned bearings must be carefully packed with wheel beating grease prior to reassembly.

SM-587

22-2-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Tires

GROUP 22

Check Caster Wheel Bearings Refer to Group 01 for proper lubrication.

IMPORTANT Be sure the “chamfer ” side of nut is installed toward wheel bearing. Refer to opposite

illustration. Adjustment l

Chamfer To Face Inward

Spin wheel when torquing nut to specifications.

This is to insure proper seating of the wheel bearings. l

l

Using a torque wrench and the special tool shown below, torque the bearing nut to 300 lb.in. (33.9 N*m) while spinning the wheel. Loosen nut and then retorque to 25 lb. in. (2.82 Nom) while spinning the wheel.

The wheel should spin freely, yet not have more than 0.006” end play after adjustment. l

Tighten nut (do not loosen nut) to the first available locking tab of the lock washer. Bend lockwasher “tab” into nut slot to secure adjustment. Install hub cap. Special (Socket Type) Adapter

Applications: Used to torque 24H Nuts. May be purchased from most engine or auto parts stores.

Dee 94

22-2-4

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

SM-587

GROUP 23 Section 1 Brake, Motor Contents Motor Brake Service.. .......................................................................

.23-l-2

Brake Adjustment.. ........................................................................... Final Brake Adjustment Specifications .............................................

.23-l-5 .23- 1-8

Caster Brake (Refer to) ..................................................................... Brake Bleeding Procedures (Refer to) ................................................

23-2- 1 23-3- 1

Brake Pedal Check and Adjustment (Refer to) ...................................

23-4- 1

Brake System The brake system consists of a brake mounted on top of the drive motor and a brake mounted in the caster wheel assembly. Both brakes are spring applied and hydraulically released by a brake pedal and two master cylinders. The caster brake service procedures are covered in Section 2 of this manual. Brake Bleeding Procedure is covered in Section 3 and Brake Pedal Check and Adjustment Procedure is covered in Section 4 of this manual.

Drive Motor

SM-587

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

Brakes

GROUP 23 Motor Brake Service

A!

Brake Pressure

CAUTION

Park truck on a level surface and chock wheels. NOTE

only be necessary to do the following two steps thecomplete brake assembly is to be removed

It will

l

l

if

Disconnect wiring from brake pressure switch. 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.

Loosen clamp (A) and pull hose (B) downward approximately 1 - inch on pump elbow. Tighten clamp (A).

l

Remove brake drum nut from motor shaft.

Dee94

23-1-2

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

SM-587

Brakes

.

l

l

GROUP 23

Depress brake pedal and place a block on the pedal to retain it in the down position. Doing so will release brake shoe pressure against the brake drum.

Now lift brake drum from motor shaft and brake assembly. Bring drum to a vertical position and remove it as shown here.

L

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

Brakes

GROUP 23 If brake assembly is to be serviced in the truck: l

Replace old shoes and spring with new ones as required

times.

If the brake assembly had to be removed from the truck for service, then complete the following steps. l

l

’

IMPORTANT Ao~lv Anti-Seize. Cla P&t No. 1802307 tb motor shaft, bore and threads before assembling drum nut.

Locate assembly onto drive motor as shown below. Apply general Purpose Threadlocker, Clark Part No. 1802300 to the mounting bolt threads and install bolts finger tight. Tighten bolts to soecifications using the diagonal sequence (A thru D) shown below.

Torque nut to: 170 - 190 Nom (125140 Ibf.ft.)

Replace old shoes and springs with new ones as required. NOTE Prior toinstally brake drum, check brake cylinder mounting bolts for proper torque.

l

Apply Anti-Seize, Clark Part No. 1802307 to motor shaft, bore and threads. Now install the drum, key andnut. Torque to specification shown above. Torque bolts to: 20 - 25 Nom 1 (177 - 221 Ibf. in.)

IMPORTANT w

v

l

Reconnect pressure switch wiring

l

Replace hydraulic hose and retighten.

l

Release pedal and remove blocking.

Install bolts using General Purpose Threadlocker, Clark Part No. 18Oi300 to bolt threads. Torque bolts to: 20-25 Nom (177-221 Ibf. in.)

Drive Motor

Dee 94

23-1-4

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

SM-587

Brakes

GROUP 23

Brake Adjustment

l

Step 1 l

l

Pull boot from cylinder exposing the cylinder piston and rod end, see below.

Loosen and back-off jam nut (1) freeing brake arm, see below. Loosen nuts (2 & 3). Rotate them inward several turns. Now loosen nut (4) releasing spring pressure.

Step 2 l

Rotate actuating rod counterclockwise while holding nuts (1,2, 3 & 4). Rotate rod outward until piston is fully released (there must be some gap between rod end and piston). Brake are must

be fleeto move in either direction.

IMPORTANT The brakearm must beallowed to “float” until adjustment is made.

l

l

Now depress brake pedal several times to move piston outward until it is flush with housing Pedal will become very firm. Do not force pedal down. While holding light pressure on pedal, loosen bleeder to allow pedal to be depressed to the floor. Do not release brake pedal. Tighten bleeder.

Typical Illustration

SM-587

23-1-5

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

Dee 94

Brakes

GROUP 23 Step 3 l

Now, while holding nuts (2 thru 4) screw rod clockwiseuntilitjust touches thecylinderpiston. You can do this visually or by feel.

. Measure amount of rod protruding beyond the back of the plate as shown below. l

Release brake pedal.

. Now, screw rod inward l/4 of an inch while holding nut (4). This willmove thepistoninward l/4 of an inch.

Typical Illustration

Step 4 l

l

Next, install the boot.

l

0 While holding arm in neutral (brake released), tighten nut (1) against arm . .. finger tight.

Tvnienl llhxtratinn

Next, tighten nut (2) against arm ... finger tight. Using two wrenches, securely tighten both nuts

with&t moving brake are &t-of neutral.

Secure Adjustment

23-1-6

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

SM-587

Brakes

GROUP 23 Step 5 l

Fkeload brake spring. Tighten nut (4) against the spring washer, as shown, until spring length is 44.5 mm (l-3/4”). Measurement should be taken from the inside of spring washer to inside of spring washer as shown below.

Typical Illustration

Step 6 l

Using two wrenches, tighten jam nut (3) while holding nut (4) to secure adjustment. Make

certain jam nut is tightened securely without disturbing the spring preload adjustment.

Typical Illustration

SM-587

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

Brakes

GROUP 23

Brake

Pressure Spring

Final Adjustment Specification Cooling Plate must

I

Drive Motor

Typical Illustration

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

in place at all times to provide required

El!!RKM$&ri;\Handling

GROUP 23 Section 2 Caster Brake Contents

Truck Preparation . .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .... . ... .. .. .. .. .. .. .. .. . .. .. .. . .. .. .. .. . 23-2-2 Service Procedure . .. .. .. .. .. .. .. .. .. .. .. .. . ... .. . . .... . . .. .. .. .. .. .. .. .. .. .. .. . . .. ... . .. .. .. .. . 23-2-2 Slave Cylinder Remove & Replace . .. .. ... . .... .. .. . . .. .. .. .. .. .. .. .. . ... ... . .. .. .. .. . 23-2-5 Brake Backing Plate Remove & Replace . .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 23-2-5 Brake Arm and Brake Shoe Installation . .. .. .. .. .. . .. .. . ... . .. .. .. .. .. ...I.......... 23-2-6 23-2-7 Caster Wheel Brake Linkage Installation ,.......................................... Caster Brake Adjustment . .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. 23-2-8 Bleeding Brake System (Refer to) . .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. . 23-3-l Brake Pedal Check and Adjustments (Refer to) . .. .. . ... .. .. .. .. .. .. .. .. . . .. .. .. . 23-4- 1

Brake System The brake system consists of a brake mounted on top of the drive motor and a brake mounted in the caster wheel assembly. Both brakes are spring applied and hydraulically released by a brake pedal and two master cylinders. The motor brake service procedures are covered in Section 1 of this manual. Brake Bleeding Procedure is covered in Section 3 and Brake Pedal Check and Adjustment Procedure is covered in Section 4 of this manual..

Caster Assembly

SM-587

23-2-l

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

Dee 94

Brakes

GROUP 23 Caster Brake Service Truck Preparation l

l

l

To service the caster brake, the truck should be elevated so the caster wheel just clears the floor. This allows rotation of the caster providing access to each side of the assembly. rear of truck farenough to allow rotation of the caster assembly.

Elevate

Place oak blocks beneath frame (as shown) on each side of truck.

Typical Illustration

Block Truck 2-inches off floor.

Typical Illustration

Remove Access Cover l

Remove two bolts and cover from caster assembly.

Brake Spring Release spring application pressure and remove spring. Loosen and back off jam nut (1). Slowly rotate nut (2) away from the spring until thecasterwheelis free torotate. Remove nut and spring.

Caster Assembly ypical Illustration

Dee 94

23-2-2

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

SM-587

Brakes

GROUP 23

Disconnect Rods & Remove Brake Arm 2. Remove retainer pins and clips (1) securing the spring and slave cylinderrod

to the brake arm.

3. Remove clip lock (2), loosen brake arm clamping bolt (3) and remove brake arm.

Adjusting for Lining Wear When to Replace Brake Linings As brake Iiningswear, the brake arm will move inward toward the caster “weldment”. When the armiswithin3/16ofaninchfi-omthisweldment, move arm 1-spline away from weldment.

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

Brake Arm

Expose Brake Assembly 4. Remove caster wheel exposing the brake assembly. The brake assembly does not have to be removed to replace the brake shoes.

SM-587

23-2-3

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

Dee 94

Brakes

GROUP 23 5. Remove old brake shoes. Spring @

~’ f$$s

-y;

I

Retainer Ring c

6. Remove shoe actuating shaft. Clean the shaft and bore in backing plate.

NOTE Go to Step 7 if the Slave Cylinder

or Brake Backing Plate does not require service.

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

SM-587

Brakes

GROUP 23

SLAVE CYLINDER If the cylinder needs to be replaced: Disconnect brake line fitting at cylinder. Loosen and remove cylinder mounting bolts. Remove slave cylinder. Remove cylinder push rod fkom cylinder. Replace cylinder with a new one. Tightenmountingboltsfingertight.Donot

torque

bolts at this time. Connect brake line fitting.

1 Tightening Sequence BRAKE BACKING PLATE If the brake assembly was removed: Install the backing plate (less brake shoes) aligning bolt holes in plate with those in the caster housing. Install the six mounting bolts using General

PurposeLockthreader,ClarkPart No. 1802300 on bolt threads. Tighten the bolts to a torque of 240-300 lbs. in. Bolts must be tightened in the sequence shown here.

SM-587

23-2-5

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

Dee 94

Brakes

GROUP 23

7. Sparingly grease the cam shaft and bore with Moly grease. 8. Install cam shaft through bore. 9. Install brake shoes.

Brake Shoe & Lining

&+*

Clip Lock

Typical Illustration

10. With brake arm held parallel to weldment, move arm 1-spline away from weldment as shown. l

Install clip lock over arm and onto cam shaft.

l

Secure arm to shaft with clamping lock bolt.

Move Arm 1-Spline as shown

Typical Illustration

Dee 94

23-2-6

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

SM-587

Brakes

GROUP 23

11. Install caster wheel . Replace shaft seal with a new one. .

Repack wheel bearings with lubricant recommended in GROUP 01.

.

Install

.

Install bearing locking washers and nut lock over shaft. Install chamfer toward wheel.

.

Tighten nut lock to the first available locking tab. lock in place using tabs on lo&washer.

wheel being careful not to damage seal.

Typical Illustration

12. Install spring and cylinder rods to brake arm and secure with retaining pins and clips.

Typical Illustration

SM-587

23-2-7

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

Dee 94

GROUP 23 13. Align push rod and slave cylinder. l

l

Rod and cylinder must be parallel with one another. Loosen mounting bolts and locate cylinder so it is absolutely parallel with the push rod. The tighten bolts finger tight. Now, torque bolts to 240 - 300 lb. in. without moving cylinder and rod out of alignment.

Typical Illustration

14. Adjust brake spring length. l

l

Using wrench, thrn nut (1) against washer until 2-l/4” (57.2 mm) can be measured between inside of one washer to the inside of opposite washer. After obtaining correct spring adjustment, use a second wrench and tighten jam nut (2) against nut (1) without disturbing spring adjustment.

Typical Illustration

Dee 94

23-2-8

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

SM-587

Brakes

GROUP 23

15. Install cover and secure with the two bolts previously removed

NOTE

Check brake pedal up-height for correct adjustment.Refer to section 4.

Typical

SM-587

23-2-9 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Material Handling Cl!!lRK Company

GROUP 23

Section 3 Brake Bleeding Procedure Contents Bleeding the Brake ............... ............................ ........ .................. ....... 23-3-2

Brake System

-

Bleeder Screw

Bleeder Screw

Drive Motor

NOTE

&!.?a :3

It is not necessary to remove the cover to bleed the caster brake.

-3,

3

\

\ :>

---

/

i; /

c:

--

SM-587

23-3-l

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

Dee 94

Brakes

GROUP 23 Pump Brake Pedal

Keep Reservoir *

filled wi ith fluid.

Master Cylinder(s)

Bleeder Valves

SlavXylinder (Caster Brake)

Bleeding Brake System Manual Method (as illustrated)

l

Fill the brake reservoir full of brake fluid. Keep full during bleeding operation. l

Wipe bleeder valve(s) with a clean cloth. Be

sure debris is removed prior to attaching a bleeder hose to the valve. l

l

Using a brake line hose (or a clear plastic hose), place one end over the bleeder valve of the cylinder to be bled. Place opposite end of hose into a clean, glass jar filled part way with brake fluid. Be sure end of hose remains submerged in brake fluid during bleeding operation or air will be drawn into the brake system during the bleeding operation. Depress andrelease brake pedal several times. On the last stroke, hold pedal in the down position, open the bleeder valve allowing air to escape into the jar of fluid. Close bleeder.

Dee 94

l

Repeat above (checking reservoir fluid level frequently) until air bubbles cease to appear in the glass jar. Go to the next cylinder and bleed in the same manner described. Once the system has been bled, check the brake reservoir to be sure it is full.

IMPORTANT Check to be sure the brakes release when the pedal is depressed. If they do not, then the pedal up height should be adjusted. Refer to Group 23, Section 4.

Pressure Bleeder Method Empty reservoir to l/4 full. Attach pressure bleeder to motor brake bleeder valve. Turn on pressure bleeder. Open bleeder valve. Let fluid flow into reservoir until it is nearly full. Shut off bleeder valve. Shut off pressure bleeder. Repeat at caster brake bleeder valve.

23-3-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

$at&rfi\Handling Cl!“lRK

GROUP 23

Section 4 Brake Pedal Adjustment Contents Brake Pedal Check and Adjustments . . ... .. .. . ... . ... .... . . .. .. .. .. .. .. .. . .. . .. .. .. .. . 23-4-2

*

SM-587

Master Cylinder(s)

23-4-l

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

Dee 94

Caster Brake

GROUP 23

Typical Illustration

Brake System Pedal Up-Height Adjustment

rBrake Pedal

Measure the distance between the floor plate and the bottom edge of the brake pedal as shown below. If measurement is not as specified, then an adjustment should be made at the brake master cylinder(s). See opposite illustration.

Adjusting Pedal Up-Height l

l

Using two wrenches, hold piston rod(s) and loosen jam nut(s). Rotate piston rod(s) until correct adjustment is accomplished. Tighten jam nut after making adjustment.

IMPORTANT Be absolutely certain that both cylinders are adjusted evenly. Check by lifting pedal full up and individually check piston for even tension. If one is loose, adjustment is not even. Correct adjustment as required. Again, be certain to secure adjustment with jam nut(s).

/

Master Cylinder

ADJUSTING

NOTE

Checkthat both brakesrelease with pedal down. If not, further brake pedal height adjustment may be necessary.

PEDAL UP-HEIGHT

-Pedal Up-Height

MEASURING

112.5

PEDAL UP-HEIGHT

114.0

mm (4-7/l 6”) to mm (4-l/2”) Floor Plate

*

Dee 94

Master Cylinder(s)

23-4-2

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

SM-587

WIRU

lVi;$Dri;/Handling

GROUP 26

Section 1 Hydraulic Pressure Checks Lift, Steering, Auxiliary, Reach & Tilt Side Shift (if so equipped)

NPR-345

Remove Cover for access to: Press4 re Check Connections

Fork

Open Door for access to Auxiliary Pump Relief Valve

SM-587

26-l -1

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

Dee 94

Hydraulic Pressure Checks

GROUP 26

Test Port 1 Auxiliary, Reach &Tilt, Steering and Side Shift (if so equipped) pressure test port.

l

Test Port 2 Refer to Group 30 for Lift Circuit Relief Valve check and adjustment procedures.

l

IMPORTANT: Check system pressure with the hydraulic fluid at operating temperature ... 110 to 130”F.

(Clark Part No. 1800106)

be checked with a Mica Quudrigage or with a conventional pressure gauge having a scale of 0 to 3OOOpsi.

HYDRAULIC PRESSURE CHECKS Check Relief Valve Setting for the Auxiliary, Reach, Tilt, Steering and Side Shift (if so equipped) Circuits. NOTE The therelief valve for these circuits is located in the auxiliary pump. Refer to illustration on Page 3. 1. Open truck door. 2. Remove console cover. 3. Remove cap from test port #l, see above.

5. Attach adaptor to test port #l. 6. Turn key switch ON. 7. System relief setting may be checked by actuating the Multi-Function Control to place the pantograph forks in full reach, tilt, or side shift (if so equipped) position. Hold control in the fully actuated position. When the system operates over relief, immediately read the pressure gauge and then release control. Do not operate

4. Connect Adaptor (see above) to pressure gauge. Notice: The hydraulic relief valve setting may

Dee 94

26-l-2

system over relief any longer than it takes to read the pressure gauge.

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

SM-587

Hydraulic

Pressure Checks

GROUP 26

Relief Valve Adjustment If adjustment is required, follow the procedures listed here. If adjustment is not required go to Step 3.

1. Remove cap covering the adjustor. 2. Rotate adjustor CLOCKWISE to increase pressure and COUNTERCLOCKWISE to decrease pressure. Adjust the relief valve to operate between 1550 and 1650 psi. Once adjustment has been attained, install and securely tighten cap to secure adjustment. 3. Install console cover and close door. NOTE

Relief valve(s) are factory preset and shouldnotrequire adjustment. However, if adjustment is required, do not exceed specified setting.

elief Valve Sub-Assembly Spring(s) I

Relief Valve Configuration may vary with pumps.

Auxiliary SM-587

Pump

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

Hydraulic Pressure Checks

GROUP 26

Test Port 1 l

Refer to Group 26 for Auxiliary, Reach & Til Steering and Side Shift (if so equipped) pressur check and adjustment procedure.

Port 2 Lift Circuit pressure test port.

IMPORTANT: Check system pressure with th hydraulic fluid at operating temperature: 110 to 130” F.

HYDRAULIC PRESSURE CHECKS

5. Attach adaptor to test port #2.

Check Lift Control Circuit Relief Valve Setting. NOTE

The relief valve is located at the top/rear of the lift control valve. Refer to illustration on Page 3.

6. Turn key switch ON. 7. Move the Multi-Function Control to elevate upright to full maximum lift. Hold control in the fully actuated position. When the system operates over relief, immediately read the pressure gauge and then release control. Do not operate

1. Open door.

system over relief any longer than it takes to read the pressure gauge. Turn key switch

2. Remove console cover.

OFF.

3. Remove cap from test port #2, see above.

If adjustment is required, refer to the adjustment procedures next page.

4. Connect adaptor (see above) to pressure gauge. The hydraulicreliefvalvesetting may be checked with a Mica Quadrigage or with a conventional

If adjustment is correct, refer to S tep 6 next page.

pressure gauge haveing a scale of 0 to 3000 psi. Dee 94

26-l-4

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

SM-587

Hydraulic

Pressure Checks

GROUP 26

Relief Valve Adjustment 1. Loosen lock nut securing the adjustor (see below). 2. Rotate adjustor CLOCKWISE to increase pressure and COUNTERCLOCKWISE pressure.

to decrease

Adjust the relief valve to operate between 2650 and 2750 psi.

4. Once adjustment has been attained, turn key switch OFF. 5. Now, using two wrenches, hold adjustor and tighten lock nut to secure adjustment. 6. Install console cover and close door.

NOTE

Relief valve(s) are factory preset and should not require adjustment. However, if adjustment is required,

do not exceed specified setting.

Adjustor ‘-1

SM-587

26-l-5

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

Dee 94

Material Handling

CORK

GROUP 29

Company

Section 1 Hydraulic Sump Tank Filter and Strainer Drain, Clean and Refill

NPR-345

Open rear door to expose sump tank

SM-587

29-i-l

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

Dee 94

Hydraulic System

GROUP 29 A

WARNING

Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is normally adequate.

A

CAUTION

Cleanliness is of extreme importance. Before disconnecting the hydraulic components, clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system.

A

WARNING

When usina air pressure to clean off truck: Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.

Removeall Jewelry before working on truck. Always Wear

Safety Glasses

Dee 94

29-l -2

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

SM-587

Hydraulic System

GROUP 29

HYDRAULIC SYSTEM SERVICE Drain Hydraulic Sump Tank IMPORTANT All cylinders should be fully retracted. Be sure: .

Truck is on alevel surface. Set the parking brake. Place chocks to the front and rear surfaces of the tires to provide restraint from inadvertent vehicle movement.

.

Upright is fully lowered and pantograph retracted.

.

Forks are in full forward tilt and the side shifter (if so equipped) is shifted fully to the right.

.

Power key switch is OFF. (Key should be removed from switch.)

1. Loosen and pull hose clamp downward on hose, see opposite illustration. 2. Place a shop cloth behind hose and fitting. Pull hose free of fitting using the cloth to retard fluid leakage.

A

CAUTION

Protect drive motor and brake assembly from any oil spill.

3. Place end of hose into a 10 gallon container and allow the sump tank to drain. Sump capacity is approximately 8 gallons.

10 Gallon Capacity SM-587

29-l -3

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

Dee 94

Hydraulic System

GROUP 29 4. Place a clean plastic parts bag over end of hose. .

Secure bag with hose clamp.

.

Tie hose to filter mounting bracket so it is out of the way.

5. Place a container beneath hose and tube (18~ 2). Loosen hose clamp (4). Pull hose free of tube (5). Place end of hose into container and allow fluid to drain. .

Loosen clamp (3) and pull hose free of sump outlet allowing remainder of fluid to drain from sump tank.

.

Loosen clamp (6) and pull hose from pump fitting.

.

Set tube with hoses andfittings to one side. Place clean plasticparts bagsover hose ends to prevent dirt from entering hoses and tubes.

Dee 94

29-1-4

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

SM587

Hydraulic System

GROUP 29

6. Remove strainer (7) from sump outlet and allow remainder of fluid to completely drain from sump tank.

7. Remove fill breather cap and strainer from sump filler tube. 8. Flush sump tank with two or three quarts of hydraulic fluid. .

Remove pan and dispose of used fluid in approved manner.

9. Wash both tank strainers in a Stoddard type cleaning solvent and allow to air dry. 10. Inspect breather cap for further serviceability. 11. Install strainers, hydraulic tube and lines. .

Secure hoses with clamps.

SM587

29-l-5

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

Dee 94

Hydraulic System

GROUP 29 Using a filter wrench or a strap wrench, loosen and remove the spin-on type filter cartridge. Discard old cartridge and gasket.

Check Ground Wire to be sure it

13. Clean gasket surface on the filter base, see white arrows. 14. Apply a light film of fluid to the new gasket. .

Locate gasket on cartridge as shown.

15. Install cartridge to filter base. Hand tighten until gasket is seated. .

Then Tighten l/2 to 3/4 additional turn.

16. Fill hydraulic sump tank with hydraulic fluid recommended in Group 01. .

Check fluid level as outlined on the following page.

Dee 94

29-l -6

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

SM587

Hydraulic System

GROUP 29

Check Sump Tank Fluid Level IMPORTANT All cylinders should be fully reacted. Be sure: l

Upright is fully lowered.

l

Forks are in full forward tilt.

l

If so equipped, side shifter is shifted fully to the right.

Multi-Function Control Handle

Refer to Group 01 for recommended Hydraulic Fluid(s).

l

l

l

Fluid level should be at the full mark on the sump tank. If it is not, add fluid until it is. Use Hydraulic Fluid recommended in Group 0 1. Purge air from the hydraulic system. Operate the hydraulic controls through their cycle several times forcing air from the lines into the sump tank. Check sump fluid level again. Add fluid as necessary to bring fluid level to the full mark on the sump tank.

SM587

29-l-7

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

Dee 94

El!BRIC

Material Handling company

GROUP 29

Section 2 Hydraulic Schematic NPR-345

w SM-587

29-2-l Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Typical Illustration

Aug 93

Hydraulic Schematic

----_-__1 P -v-e

I 2gfi$s’

A I

valve

(

~----------~-i

I

I_

-4

_s_-____

Aux Control

I-

L

T 2

Al IS vl

1

Lift 3

Sl

L”Gzo’

Front Buikhead Plate of Truck ReachIIin Selector Valve

Reach Cylinders

I

I

r-i------i’Lz----F”_l____; mli2Y!~ I

b---a

-------

: :

I : I-

I L

i!l

Mateftal Handling Co.

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

Lift

inder

Flay ?!. imiter

valves

NPR 150,17,

20, -

1

i _

GROUP 29 Section 4 Hydraulic Pump Overhaul Contents Disassembly ..................................................................................... .29-4-3 Parts Inspection ................................................................................ .29-4-3 Reassembly ...................................................................................... .29-4-5

SM-587

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

Hydaulic Pump

GROUP 29 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 Intended for CLARK dealers only Do not sell or distribute

SM-587

Hydraulic

Pump

GROUP 29

DISASSEMBLY

l

Preparation for Disassembly Overhaul pump only in a clean, dust-free location, using clean tools and equipment. Dirt or grit will damage the highly machined surfaces and will result in leakage or premature failure of the pump.

A

NOTE Allreferencenumbersrefertoitems illustrated in the illustrations on the opposite page.

4. Holding shaft end down, remove rear cover (3). Dowel pins (7) may remain either with the body or with the rear cover.

2. On models with splined drive shaft, proceed to Step 3. On models with keyed drive shaft, remove drive key (11) from drive shaft. Using a file or stone, remove any burrs from shaft end or key way. NOTE During disassembly, take special note of the wear patterns on the wear plate (8), thrust plate (6) and body (14). The large port in the rearcover (34) always corresponds to the inlet side of the pump. The inlet side can be further identified by the gear contact pattern in the body (gear) bore. The wear plate (8) will have a somewhat heavier wear pattern on the inlet side. The thrust plate (6) will also have a pattern than can be established for reassembly. Also note that the long journal of the driven gear (13) is toward the front of the pump.

NOTE

Cover seal (5) and thrust plate (6) may or may not remain with rear cover. Should they remain with the body, remove seal and lift out thrust plate before proceeding. 5. Lift out driven gear (13), drive gear (12), and wear plate (8). 6. Invert pump body with shaft seal up. Remove shaft seal (10) by prying it out with a large screwdriver. .A

CAUTION

Care should be taken not to damage (gouge) the shaft seal bore, because this will result in shaft seal leakage.

Parts Inspection 1. Wash all parts and dry thoroughly with a clean lint free cloth.

3. Separate rear cover (3) Ii-om body (14) by supportingpump,shaftendup,onmountingflanges andpressing on drive shaft end in arbor press, or tap drive shaft with a plastic mallet. Use one

hand tosupport rear cover from underneath, since cover and internal parts will drop suddenly when dowels are disengaged. SM-587

CAUTION

At no timeshould screwdrivers be inserted further into pump body more than the depth of the relieved areas. Any burr must be removed from the body (14) and/or cover (3) after thisoperationtoassureagood seal between body and cover.

Pump Disassembly

1. Clean outside of pump in a S toddard type cleaning solvent and dry thoroughly.

An alternate method of removing the rear cover is to pry simultaneously with two large screwdrivers in the relieved areas between body and cover.

2. Inspect wear plate (8) and thrust plate (6). Replace if scoring or uneven wear is observed. NOTE Somewhat heavier wear pattern is normal on the lowpressure (inlet) side of the plates (6 & 8). However, there should be no heavy scoring in this area.

29-4-3

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

Dee94

Hydaulic Pump

GROUP 29

Gear Face a

(:3C)

Do Not Force Seal below surface

; ; II

Bronze Face Tot-ward Gears --(6)

High Pressure Side Pressure Loading Seal (15)

Wear Plate (8)

Dow Pjn (7) -Bolt

(1)

Seal (5)

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

SM-587

Hydraulic

Pump

GROUP 29 2. Invert body so that gear boresare up. Install wear plate (8) in bottom of bore, making sure that pressure loading seals (9 & 15) are positioned properly in seal grooves and installed against bottom of bore surface. Ensure outside of “w” seal is exposed to the discharge pressure. (Or legs of “W” seal pointing toward the suction

3. Remove pressure loading seal (15) and seal (9) from wear plate. The seals may be two-piece or one-piece design. In either case, discard old seal or seals. All replacement seals are two-piece design and should be installed into groove. See circled view in exploded parts illustration on opposite page. The seal should extend a minimum of 0.005” (0.127 mm) beyond surface of wearplate. Do not push seals below wear plate

PO@. 3. Lubricate the bushings in body (14) and wear plate (8) with SAE 10 engine oil.

surface at any point. 4. Inspect bushings in body and cover. Replace cover or body if bushings are heavily scored or burned.

4. Apply Lubriplate or equivalent to outer surface of drive shaft in installation sleeve. (Sleeve I.D. should be slightly larger than the O.D. of the shaft.)

5. Inspect gear journals and faces. Replace if faces or journals are scored or worn.

5. Lubricate rear gear faces and journals with S AE 10 engine oil and install thrust plate (6) in its original position, bronze face toward the gears.

6. Inspect body for wear and scoring. If gear contact wear on low pressure side (inlet) exceeds 0.005” (0.127 mm) depth, replace body. If the body is usable lightly remove/wipe burr with suitable de-burring tool.

6. Apply a small amount of grease to rear cover seal (5) and install seal into groove.

Pump Reassembly

7. Lubricate bushings in rear cover (3) with SAE 10 engine oil.

Cleanliness is of extreme importance. Prevent dirt or foreign matter from entering hydraulic system.

8. Position pump with shaft end down. Match scribe marks on cover and body and install

1. Place body (14) on flat plate with shaft seal bore up. Install new shaft seal (10). Press seal into bore until it is to approximate depth shown below. (The outside diameter of the sleeve should be slightly smaller the outside diameter of the shaft seal.) l

Pack the area between the double lip of the seal with Lubriplate or equivalent grease.

cover. 9. Install cap screws (1) and washers (2) finger tight. Torque bolts to: 34 - 38 lb.ft. 10. On models equipped with keyed drive shaft, install drive key (11). 11. Check that drive shaft turns with adjustable wrench without evidence of mechanical bind. *Sleeve wall thickness should be approximately 0.25 mm (0.010”).

.ess

I-Mounting

Face

rShaft Seal -ing Bear -J \ /&_JGearlShaft

..-J--j\

-+ .. . ..V.C_

-_Ekl.52 Figure 1

SM-587

Installation *Sleeve

mm (l/l 6”)

Figure 2

Figure 3

29-4-5

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

Dee94

CUIRK~;~pri-i~Handling

GROUP 30

Section 1 Hydraulic Control Valves and Solenoid Control Valves Remove & Replace Contents Truck Preparation . .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. . ... .. .... .. . . .. .. .. .. .. .. .. . .. . .. .. .. .. . 30-l-2 Control Linkage . . . ., . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30- l-5 Removal of Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30- l-6 Lift, Auxiliary, Reach & Tilt Control Valves . .. .. .. .. .. .. .. .. . ... . . .. .. .. .. .. . ... . 30-l-8 Flow Regulator.. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .30- l-9 Auxiliary and Lowering Solenoid Valves ... .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 30-l- 10 Reassembly Suggestions . .. .. .. .. .. .. ... . .. .... .. ... . .. ... . .. .. .. .. .. .. .. .. . . ... . .. .. .. . .. 30-l-13 Hydraulic Tube Installation . .. .. .. .. .. .. .... .. ... . .... .... .. .. .. .. .. .. .. .. . . .. .. 30-l-13 & 14 7

Lift

I I

Aux Solenoid

Aux

I

Valve

Solenoid Valve

Typical Illustration

SM587

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

Dee 94

GROUP 30

Hydraulic Valve r

1. Move truck to service area. l

Park truck on a flat level surface.

l

Extend pantograph.

l

Fully lower pantograph.

l

Tilt forks forward until fork tips touch the floor.

A

\... ,, j .\ : :, ,j @ v

WARNING

When usina air pressure to clean off truck: Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury

Typical Illustration

Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is normally adequate.

I

Q:: :

‘.:.. . ..

Remove all Jewelry before working on truck.

Always wear Safety Glasses

,.>;.F?+., i”h. ;..‘....Y L ;;:.F’ ,,+Y -.c’

2. Turn key switch off. l

.

Remove key. &connect truck battery.

l-

3. Remove Front Console Cover

Typical Illustration

.

Remove fasteners securing 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.

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

/i

Hydraulic Valve .

GROUP 30

Remove console cover from truck. Refer to opposite illustration.

4. Open Access Door .

Remove door latch bolt.

.

Remove bolt securing left overhead guard leg to the overhead guard.

.

Open door. NOTE

TheFrontHipPadmayberemoved for easier access to components.

Typical Illustration

5. Discharge the CaDacitorS l

l

Discharge Capacitors

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 solid state control panel. Hold the resistorinplacefor two ( 2 ) seconds before removing. A

CAUTION

Using a shorting device without a “~esisfor/oad”could cause damage to the control.

A

WARNING

Discharging the capacitors without using specified resistor could cause serious injury to yourself and bystanders.

SM587

\

unplugged.

)

Typical Illustration

30-l -3

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

Dee 94

Hydraulic Valve

GROUP 30

/d

CAUTION

Cleanliness isof extremeimportance. Beforedisconnecting hydrauliccomponents, clean exterior of plumbing, valves and compartment to prevent dirt and foreign matter from entering hydraulic system. Immediately cap fittings as lines are removed to prevent fluid leakage and contamination. Lowering Solenoid Valve Lift Control Valve

Aux Reach & Tilt Valve

ux Solenoid Val

Viewed from Right Rear Comer of truck.

Twical

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

illustration

Hydraulic Valve

GROUP 30

Step 1 A

CAUTION

Switches may be damaged if the Switch Cam is not removed. Be very careful when removing cam that you do not damage the switches.

0

Remove Switch Cam. Loosen and remove fastener, see above. Carefully pull switch cam away from bracket and switches.

Step IA

i /-

‘.:j::

\+

‘.::I., “::$:,

‘.j$, Truck Mounting Bracket

r

&&Control

Mounting Pin

Linkage

Control Linkage 0 Remove retainer from each lever mounting pin. l Push pins free of valve spools and control linkage.

SM587

30-l-5

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

Dee 94

Hydraulic Valve

GROUP 30

Lowering Solenoid Valve.

Disconnect Lift Line from valve and tee fitting.

- Bulkhead Fittings

.

Retu

Disconnect Disconnect

Dee 94

Return Line from lift valve. Return Line from Aux. Sollenoid

Valve.

Disconnect Disconnect

Tube #l from Aux Valve and Bulkhead Tube #2 from Aux Valve and Bulkhead

30-l -6 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fitting. Fitting.

SM587

Hydraulic Valve

GROUP 30

Dismnect Tube #I from the Lowering Solenoid Valve and Flow Regulator. Disconnect Tube #2 from the Aux Solenoid Valve and the Lift Valve.

Aux Soienoid Valve

Disconnect Tube #1 and #2 from P.S. Control and Aux. Solenoid Valve.

SM587

30-l-7

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

Dee94

Hydraulic Valve

GROUP 30 Step 8 Tag each tube upon removal.

2 \

,

‘\JT

\I a\ve

Tag and disconnect Tube #I and #2 from control valves.

Step IO

Remove Auxiliary Control Valve.

Remove Lift Control Valve

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

Hydraulic Valve

GROUP 30

Step 11

\ * )

Flow Regulator r--------7

I.Jc’ L

Remove Flow Regulator from valve.

Typical Illustration

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

Hydraulic Valve

GROUP 30 Step 12

-

---

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

Hydraulic Valve

Step

GROUP 30

13

Nuts

1

Lowering Solenoid

Aux Solenoid Valve e

nting Bolts <\

Remove nuts from mounting bolts. Lift retainer plate from bolts. Lift aux solenoid valve from bolts.

Typical illustration

SM587

30-l -11

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

Dee 94

Hydraulic Valve

GROUP 30 Step 14

Loosen nut and back off several turns. Slide bolt and valve free of bracket.

V&e

S8nrfce ProcedUreS are covered in the following sections. Refer to the appropriate section.

30-2-l 30-3-l 30-4-l 30-5-l

Auxiliary Reach & Tilt Control Valve Lift Control Valve Lowering Solenoid Valve Auxiliary Solenoid Valve

Note:

The following valves are located on the Pantograph and include remove and replace procedures.

30-6-l 30-7-l

Reach & Tilt Solenoid Valve Side Shifter Solenoid Valve Typical Illustration

Dee 94

30-l -12

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

SM587

Hydraulic Valve

GROUP 30

REASSEMBLY SUGGESTIONS Mounting the Lift and Tilt Control Valve Assemblies

Hydraulic Tube Installation 1. Lubricate all O-rings slightly with hydraulic fluid.

IMPORTANT

1. Initially, tighten the valve mounting bolts only finger tight. Do not tighten them at this time. -

O-ring Face Seal Fittings Check to be sure the O-ring face seal is lubricated, seated and properly retainedin fitting groove, see below. If the seal is missing or not fitted properly in its groove, the connection will leak.

2. Insert control linkage into slot of each valve spool. l

Insert l/4-inch rod through the holes provided in the slotted end of each valve spool. This is to temporarily hold linkage in place within the in slots.

3. Realign the multi-function instructed in Group 13.

control handle as

2. Align the tube, or hose nut to the mating fitting (or align the fitting to the port) and check to see that the threads seat properly ... tighten finger tight .. . until it stops turning whilemoving fitting (or nut) lightly side to side to prevent cocking, or thread damage.

4. Now, tighten valve mounting bolts. 5. Remove l/4-inch rod and install linkage mounting pins and retainers. l

Usiw finger tins only, lightly snug fitting (or nut) with a wrench until it bottoms out on the seat or port.

Tube or Hose Fitting

SM-587

Connector

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

Dee 94

Hydraulic Valve

GROUP 30 3. Using a pen or marker,

STEP 1

mark a line on the nut and extend onto the adapter (or connector) as shown. 4. Holdconnector withone wrench and tighten the cap with a second wrench. l

rl

-!

c

II

1

Assembly Instructions for Fittings equipped with O-Ring Face Sea/s

Rotatenutjustoneflatas shown.

STEP 2

Tighten

One (1) Flat

I I

from finger tight (bottomed out) position using second wrench.

Initial osition

-

IMPORTANT Hold connector with one wrench while tightening the nut with a second wrench, see above. 30-l -14

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

SM-587

M$d$;\Handling CLqRK

GROUP 30

Section 2 Auxiliary, Reach & Tilt Control Valve

Contents Valve Cut-A-Way with Specifications .............................................. Disassembly ...................................................................................... Cleaning, Inspection and Reassembly ................................................

.30-2-2 30-2-3 30-2-4

Lowering Solenoid Valve Lift Control Valve

Viewed from Right Rear Comer of truck.

_

Typical illustration

SM587

30-2-l Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Hydraulic Valve

GROUP 30 Breather

7

AUX VALVE - SIDE VIEW

Plug

Torque to: 8 - 10 Lb. Ft. (10.8 - 13.6 N-m)

r

(Must be open at all times.)

-Bushing

\

/

LSpacer

Ls2asher !- Body

-

Cap

Torque

to’. 20 - 25 Lb. Ft. (27.1 - 33.9 N-m)

I_

O-Ring

Tvoical Illustration

AUX VALVE - TOP VIEW

l

Flow Rate : 3 Gal / min. (11.4 Lhnin) Typical Illustration

Dee94

30-2-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM587

Hydraulic Valve

GROUP 30 Port

PlUCJ Torque to: 8 - 10 Lb. Ft. (10.8 - 13.6 Nam)

Typical Illustration

Cap

Disassembly 1. Placevalve assembly in avise with softjaws, do not over tighten, and remove the spool cap. 2. Remove spool from valve body as shown.

Torque to: 20 - 25 Lb. Ft. (27.1 - 33.9 Nom)

4. Remove wiper seal from valve body. Discard the seal. 5. Remove port plug and O-ring. Discard the Oring.

A CAUTION Be extremely careful when removing spool and O-rings from valve body. Do not scratch, nick or m ar the spool or the body bore. To do so will make the valve unfit for further service. NOTE Do not remove spring retainer ring unless the spring is broken and needs to be replaced 3. Using a brass tool similar to that shown, carefully remove spool O-rings from valve body bore. Discard the O-rings. SM587

30-2-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Brass Tool Typical Illustration

Dee94

Hydraulic Valve

GROUP 30 Cleaning and Inspection l

Wash all parts in a Stoddard type cleaning solvent and place them on a clean surface for inspection. Inspect the cap breather to be sure it is not obstructed with dirt, paint or debris. Be certain all foreign matter has been removed from the spool and valve body. Air dry parts

A

WARNING

AIR PRESSURE Wear eye protection

and protective clothing when cleaning or drying with air pressure. Reduceair pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury. l

l

Discard all old seals and the spool wiper ring. Inspect valve spool and bore for burrs and scoring. Use a light to inspect the body bore. Look for loose chrome plating, cracks or other damage caused by foreign material in the hydraulic system. If scoring is not deep enough to cause objectionable leakage, the surfaces can be stoned or polished with a crocus cloth. Be careful when polishing that you do not remove the chrome plating. Any surface having deep cuts, nicks or scratches make the part unsuitable for further service and the valve should be replaced. The spool and body are a matched set and cannot bereplaced as indivudal parts.

8 - 10 lb.ft.

Valve Reassembly l

Port Plug-

Lubricate all parts with clean hydraulic fluid to facilitate reassembly andprovide initial lubrication.

O-Ring

(10.8 - 13.6 N*m)

Port Plug l

l

Install a new O-ring on the port plug and screw the plug into the appropriate port - finger tight. Torquetheplug

Dee94

to: 8- lOlb.ft. (10.8 - 13.6Nem)

30-2-4

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

SM587

Hydraulic Valve

GROUP30

Valve Spool l

l

l

Spool flush with back side of “groove”.

Install O-ring into cap end ov valve. Insert clevis end of spool into the back end of valve body bore. Push spool inward until it is even with the back side of the seal “groove” located at the front of the valve body bore. See opposite illustration. Pinch lubricated O-ring (as shown) so it can be inserted into the groove. Let loose of O-ring.

Typical Illustration

l

l

Using brass tool as shown, carefully seat the Oring completely into groove. Now, slowly rotate spool (as required) pushing spool until it is through O-ring.

Carefully seat O-ring.

Typical illustration

l

l

l

Continue to move spool until the spring bushing is seated in the valve bore. Body

Install spool cap and torque to 20 - 25 lb.ft. Install wiper.Using a sleeve with an O.D. slightly smaller than the O.D. of the wiper seal, tap the seal inward until seal is flush with the outside of the body.

Typical Illustration

SM587

30-2-5

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

Dee 94

Hydraulic Valve

GROUP 30 Pklg

Torque to: 8

- 10 Lb. Ft. (10.6 - 13.6 Nom)

open at all times.)

-Bushing

/

-

LSpacer ~s~asher Cap

Torque to: 20 - 25 Lb. Ft. (27.1 - 33.9 Nem) Typical Illustration

Spool Spring Assembly

If the spool spring assembly was disassembled for parts replacement, lubricate the parts with clean hydraulic fluid. Install bushing over spool and into body. Install spring over spacer. Place washer over end of spool. Now, install the spacer with the spring onto the valve spool and secure components in position with the retainer ring. Install cap and torque to: 20 - 25 lb.ft. (27.1- 33.9 Nom). Typical Illustration L

Dee94

30-2-6

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

SM587

Hydraulic Valve

GROUP 30

Check Sump Tank Level l

l

Fluid level should be at the full mark on the sump tank. If it is not, add fluid until it is. Use Hydraulic Fluid per Clark Specification MS68. Now, purge air from the hydraulic system. Operate the hydraulic controls through their cycle several times forcing air from the lines into the sump tank.

Multi-Function Control Handle

l

Check sump fluid level again. Add fluid as necessary to bring fluid level to the full mark on the sump tank.

\

‘\ 7-ypical Illustration

L

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

“\

Clark Part No.885385 Hydraulic Fluid

Dee 94

GROUP 30 Section 3 Lift Control Valve Contents Specifications ............................................................................

.30-3-2 & 3

Pilot Operated Relief Valve Assembly with Schematic ..................... .30-3-5 Cut-A-Way View of Valve ................................................................ Lift Control Valve ...................................................................... Valve Disassembly ............................................................................ Valve Reassembly ..........................................................................

30-3-6 30-3-7 & 8 30-3-g .30-3-10

Lowering Solenoid Valve Lift Control Valve

Aux Reach & Tilt Valve

Viewed from Right Rear Comer of truck. SM587

30-3-l Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Hydraulic Valve

GROUP 30 1. Move truck to service area. l

Park truck on a flat level surface.

l

Extend pantograph.

l

Fully lower pantograph. Tilt (if so equipped) forks forward until fork tips touch the floor.

l

A

WARNING

When usina air oressure to clean off truck: Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is normally adequate. Remove all Jewelry before working on truck. @

Always wear Safety Glasses

2. Turn key switch off. .

Remove key.

.

Disconnect truck battery.

3. Remove Front Console Cover .

Remove fasteners securing 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.

Dee94

Front Console

Cover 30-3-2

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

\ SM587

Hydraulic Valve

/@ Q

GROUP 30

e

4. Remove Side Cover .

Remove fasteners seuring side cover to truck.

.

Lift cover off truck.

5. Dischawe the CaDacitorq

ide Cove

Discharge Capacitors

.

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 SCR control. Hold the resistor in place for2 seconds before removing. A

CAUTION

Using a shorting device without a “~esisforload”couid cause damage to the control.

A

WARNING

Discharging the capacitors without using specified resistor could cause serious injury to yourself and bystanders.

SM587

30-3-3

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

Dee 94

Hydraulic Valve

GROUP 30

Torque to: 8 - 10 Ib.ft. (11 - 14 N*m) After Setting Relief

Screw TorqueDrive to: 20 - 35 lb.ft. (41- 47 N*m)

11

Relief Valve Adjustor 2650 - 2750 PSI (183 - 190 bar) @ 8.5 GPM (32.2 l/min)

f? : Liquid Lock Threads1 4 s,,,,,

NOTE

Spool and Body are a matched set and cannot bepurchasedseparately.

Dee 94

T 30-3-4

Torque to: 2 - 3 Ib.ft. (3 - 4 N*m)

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

SM587

Hydraulic Valve

SM587

GROUP30

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

Hydraulic Valve

GROUP 30

r-Washer

Load Check Poppet 1

Spacer

I

O-Ring 1

O-Ring

Return Spring

Liquid Lock Threads ue to: 2 - 3 Ib.ft. (3 - 4 N-m)

Dee94

30-3-6

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

SM587

GROUP30

Hydraulic Valve

Spring T

I

LIFT CONTROL VALVE

Reassembly

Load Check Valve

Lubricate the poppet and spring with clean hydraulic fluid.

Disassembly l

l

l

Remove hex plug. Remove spring and poppet. If poppet is to be used again, care must be taken not to damage it. Remove O-ring from hex plug. Discard O-ring.

Inspection l

l

Install poppet into cavity center. Next insert spring into poppet hole. Lubricate new O-ring withclean hydraulic fluid. Install O-ring onto hex plug. Take care not to cut or over-stretch the O-ring.

Clean all parts in a Stoddard type cleaning solvent and allow to air dry.

Install plug (finger tight) into valve body over poppet and spring.

Inspect poppet for scratches or nicks. If found, replace poppet with a new one.

Torque hex plug to 30 - 35 lb.ft. (41 - 47 N*m).

SM587

30-3-7

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

Dee 94

Hydraulic Valve

GROUP 30 O-Ring I 7

O-Ring

To remove (or install) Screw “A”, you must keep valve spool from 2 rod as shown. rntntinn ‘3 -.--

(Washer)

m

h’yw’u

w-w..

.

. . . .rw.w_

,

Torque to: 2 - 3 Ib.ft. (3 - 4 N-m)

Dee94

30-3-8

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

SM587

Hydraulic Valve

GROUP 30 Cleaning and Inspection

Valve Disassembly Ceanliness is of extreme importance. Before disconnecting hydraulic components, clean exterior of plumbing, valves and compartment to prevent dirt and foreign matter from entering hydraulic system. Immediately cap fittings as lines are removed to prevent fluid leakage and contamination. End Cap Removal l

l

l

Remove both mounting screws securing end cap to valve body using a Phillips screwdriver. Insert a rod with an O.D. only slightly smaller than the hole in the end of the valve spool. Too small a diameter rod will cause damage to the spool cross hole bore. Retain spool with rod and using a standard type screwdriver, remove screw (A).

Wash all parts in a Stoddard type cleaning solvent. Be certain all foreign matter has been removed from the spool and valve body. Air dry parts. Discard all seals, spool seals and springs. Reassemble only with new seals and springs. Inspect the surface of the spool and body bore for cuts, scratches, nick etc. Examine the spool. Look for loose chrome plating, cracks or other damage caused by foreign material in the hydraulic system. Use a light to inspect the spool bore in the valve body. Nicks on the spool can be removed with a crocus cloth. Any surface having cuts or scratches makes the part unsuitable for further service and the valve should be replaced. The spool and body are a matched set and cannot be replaced as individual parts.

NOTE

This may require heavier than normal forces since the screw has been installed using loctite. l

Remove spacer, spring and washer.

Spool and Seal Removal l

Remove spool from valve body. A

CAUTION

Be extremely careful when removing spool and Orings from the valve body. Do not scratch, nick or mar thespool or the body bore. To doso,will make the valve unfit for further service. l

Using a brass tool similar to that shown, carefully remove O-rings from valve body bore. Discard these seals.

A

WARNING

AIR PRESSURE

Wear eye protection and protective clothing when cleaning or drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury. SM587

30-3-g

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

Dee 94

Hydraulic Valve

GROUP 30 Valve Reassembly

Flush with Back Side of Groove

Spool and Seals 1. Lubricate valve spool and a new O-ring with clean hydraulic fluid. 2. Carefully insert spool into the bore at the cap end of the valve body. 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. 3. Next, pinch (as shown) a new lubricated O-ring so it can be partially inserted into the groove. 4. Using a brass tool, completely push the O-ring into the groove. Be extremelycarefulthatyoudo not damage (cut or nick) the O-ring during installation.Be extremelycarejidthatyoudo not damage the body bore. To do so will make the assembly unfitfor service. 5. Now, slowly rotate the spool while gently moving it on through the front O-ring. Continue to push the spool inward until the end of the spool is flush with the inside edge of the grove located at the cap end of the valve. 6. Lubricate and install a new O-ring into this groove. Follow the same procedure described in Steps 3 & 4. 7, After the O-ring is installed, use the procedure previously described and push the spool back through the valve and the newly installed Oring. Continue this process until the end of the spool is flush with the casting at cap end of body. End Cap Assembly (Refer to Illustrationon Page 8) 1. Install washer onto the end of the valve spool. 2. Insert the spacer into the spring. 3. Place one drop of Loctite onto the threaded end of Screw “A”.

4.

Install Screw “A” through the spacer(andspring) into the base end of the spool finger tight.

5. Position rod (described in “Disassembly”, on page 8 & 9) into the hole of the spool. 6. Hold rod and spool from turning and using a flat bladed screwdriver, securely tighten Screw “A’. Check Spring Operation .

Push down on Screw “A”. The spring should compress and upon releasing the screw, the spring should return to its original position.

.

Apply a mediumcoating of lubricant (Lubriplate or equivalent) to the spring and spacer.

7. Sparingly apply Loctite to the threads of both end cap mounting screws. 8. Align the “mounting holes” of the end cap with those in the valve body. Install mounting screws finger tight. Now tighten screws to specifications. Torque Screws to:

IMPORTANT

2 - 3 lb.ft. (3 - 4 Nom)

Threads of Screw “A and those in the valve spool should be free of dirt and grease before applying Loctite and assembling the components. Sparingly apply Loctite to the screw threads. Too much Loctite could hamper proper operation.

9. Install port plugs into valve openings until such time as the valve is installed onto the truck.

Dee 94

0

30-3-l

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

SM587

Ma~pri-i~Handling Cl!!!!RK

GROUP 30

Section 4 Lowering Solenoid Valve Contents Specifications, Wamings and Caution . .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. . ... .. .. .. .. . 30-4-2 Hydraulic Schematic . .... . ... . ... . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. ... ... .. .. 30-4-3 Disassembly .. . .. .. .. .. ... . .. .. .. . . .. ... . .. . ... .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .. .. .. .. .. .. .. . 30-4-4 Reassembly . .. .. .. .. .. .. .. .. .. ... . ... .. . .. .. .. .. . ... . ... .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. ... .. . .. .. 30-4-5 Installation Notations (refer to Section 1 for Removal Instructions) . ...30-4-5

Lift Control Valve

Aux Reach & Tilt Valve

Typical Illustration

SM587

Viewed from Right Rear Comer of truck. 30-4-l

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

Dee 94

Solenoid Valve

GROUP 30 A

WARNING

Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is normally adequate.

A

CAUTION

Cleanliness is of extreme importance. Before disconnecting the hydraulic components, clean exterior of plumbing and solenoid valve to prevent dirt and foreign matterfromentering hydraulic system.

A

WARNING

When using air pressure to clean off truck: Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.

Removeall Jewelry before working on truck. Always Wear

Safety Glasses

Dee 94

30-4-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM587

Solenoid Valve

GROUP 30

LOWERING SOLENOID VALVE Description A solenoid-operated, 2-way, normally closed, poppet-type, screw-in hydraulic cartridgevalve, designed to function as a load-holding or blocking

IMPORTANT Coil must be installed with the lettering side out as shown here.

Valve. \/

Operation When de-energized, the solenoid valve acts as a check valve, allowing flow from 1 to 2, while blocking flow from 2 to 1, see below. When energized the poppet lifts to open the 2 to 1 flow path. In this mode, flow is also allowed from 1 to 2.

Toraue: 5 Ib.ft. (6.8 Nom) max.

twist counterclockwise 180” and release. In this position the valve will remain open. To return to normal operation, push button in, twist clockwise 180’ and release. Override will be detented in this position. Torque: 35 Ib.ft.

1 I ---

I II 1

-+ -J

io II

li II

2

p-1 ----- 4 II 1’ ‘I

I

----

L__,__

0

$

1

Rated Flow: 114 L/MIN (30 G.P.M.) Rated Pressure: 24132 kPa (3500 PH.) Minimum Pull-in Voltage: 85% of nominal @ 20685 kPa (3000 PSI). Typical Illustration

SM587

30-4-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee94

Solenoid Valve

GROUP 30 ACAUTION

Retainer Nut

Thevalvestemisveryfragile. Beverycareful when handling the valve that you do not dent or bend the stem.

L

Manual Override Control Torque: 5 Ib.ft. (6.8 Nom) max.

Over torquing the coil nut or Over torquing the valve at installation will cause damage to the valve. Torque: 35 Ib.ft. (47.4 NVTI)9.

-----

Va’ve BodyT-

1

Lead Wires-,,

(I) O-Ring

Back-Up Ring (3) L__//-(21

O-Ring

ACAUTION Valve is not serviceable. not take apart.

A

Do

CAUTION

Cleanliness is of extreme importance. Before disconnecting the hydraulic components, clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system. Wire Leads

DISASSEMBLY l

Remove nut and coil from solenoid valve stem.

l

Remove solenoid valve from valve body.

l

Remove fittings from valve body.

l

Cleaning & Inspecting Solenoid l

Wash all parts but the coils in a Stoddard type cleaning solvent.

Dee94

l

l

Wipe all parts dry with a clean lint-free cloth. Allow components to airdry beforereassembly. Replace al seals with new ones. Inspect wire leads and plugs for further serviceability. Replace defective parts.

30-4-4 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM587

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. Be certain to tighten coil retainer nut to 5lb. ft. (6.8 Nom) maximum. If you overtighten the nut damage to the valve stem will result.

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.

REASSEMBLY

INSTALLATION

Lubricate all parts in clean hydraulic fluid prior to installation. Reassemble only with new seals. Install large O-ring (1) into it’s groove being verycarefulthatyoudonotnickorcuttheO-ring making if unfit for service as it will leak. Install O-ring (2) and backup ring (3) as shown on opposite page. Again, be very careful you do not nick or cut the O-rings or leakage will occur. Install solenoid valve into body bore. Be certain solenoid valve is tightened securely to the body. Torque to 36 ft lb (47,4 N*m). Install coil onto valve stem. Position the coil to allow easy connection of the electrical plugs as shown in above illustration.

IMPORTANT Inspect hoses, hydraulic connections and their seals for damage. Replace defective parts. Prior to attaching hose ends and connections to the fittings on the solenoid valve, clean and lubricate them with new hydraulic fluid. Remove caps just prior to installation.

When Mounting Solenoid Valve:

Install coil retainer nut and torque to 5 ft lb (6-8 Nom)

l

Align valve body “slot” with mounting bolt on truck. Locate valve over bolt and install retainer nut finger tight. Refer to Section 1.

Install hydraulic fittings install finger tight. SM587

30-4-5

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

Dee94

Solenoid Valve

GROUP 30 When Connecting Hydraulic Plumbing: l

l

l

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. Tighten valve body mounting nuts securely. Now go back and securely tighten each hydraulic connection. Tighten coil retainer nut. Connect coil plugs to their receptacles in the wire harness.

IMPORTANT Allelectricalplugsandtheirreceptaclesarematched labeled for easy connection. Check to be sure each plug and receptacle match before attempting to make connections. l

l

Dee 94

Check wire harness clamps for security of mounting. Be certain the harness is in good condition and that it is routed properly. Replenish hydraulic system. Refer to instructions in Section 1.

30-4-6 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM587

Handling CORKMaterial Company

GROUP 30

Section 5 Auxiliary Solenoid Valve (Reach and Tilt Control) Contents Specifications, Warnings and Caution ......................................... .. ..... 30-5-2 Hydraulic Schematic , . . . , . . , . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. .. . . .. . . . . . . . . . . . . .. . . 30-5-3 30-5-4 Disassembly . . . . . . . . . . . . . . . . . . . . . ,. . . ..,.........,................................................ Reassembly ... ...... .................................................. .... .... ................ .... 30-5-5 Installation Notations (refer to Section 1 for Removal Instructions) .... 30-5-5

Lowering Solenoid Valve Lift Control Valve

ux, Reach & Tilt Control Valve

11Auxiliary

Typical Illustration

SM587

Solenoid

Valve 11

Viewed from Right Rear Comer of truck. 30-5-l

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

Dee 94

Solenoid Valve

GROUP 30 A

WARNING

Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is normally adequate.

A

CAUTION

Cleanliness is of extreme importance. Before disconnecting the hydraulic components, clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system.

A

WARNING

When usina air Dressure to clean off truck: Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.

A

CAUTION

Cap all ports to prevent dirt and foreign debris from entering assembly.

Always Wear

Remove all Jewelry before working on truck.

Dee 94

Safety Glasses

30-5-2

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

SM587

Solenoid Valve

GROUP 30

AUXILIARY SOLENOID VALVE 0 IQ

IMPORTANT All wiring, plugs and receptacles are labeled for easy identification. Be

careful when making connections. You will experience shorts and component failure if the wiring, (harness routing) plugs,and receptacles are not correctly installed.

1

Torque: Slb.ft. (6.8 N*m) Max. -

orque: 35 lb.ft. (47.4 N*m) Max I

_-I

--

--

Hydraulic Schematic Rated Flow: 114 L/MIN (30 G.P.M.) Rated Pressure: 20685 kPa (3000 P.S.I.) -ypical Illustration

Minimum Pull-in Voltage: 85% of nominal @ 20685 kPa (3000 p-s-i.).

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

Solenoid Valve

GROUP 30 O-Ring(s) /-

Typical Cartridge Kit

-ypical Illustration

Disassembly l

Unplug Coil S3 from wire harness.

res 10K & IOL

* Remove nut and coil from solenoid valve. l

Remove solenoid valve from valve body.

l

Remove fittings from valve body.

Cleaning & Inspection Wash all parts except coils in a Stoddard type cleaning solvent. Wipe coils with a clean cloth. Wipe all parts dry with a clean lint-free cloth. Allow components to airdry before reassembly. Replace all seals with new ones. Inspect wire leads and plugs for further serviceability. Replace defective parts .Use Service Parts Kit(s). Inspect wire leads and plugs for further servicability. If damaged, replace the coil. Dee 94

l

I Body @I

L

30-5-4

l- -----

1rypical Illustration

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

SM587

Solenoid Valve

GROUP 30

REASSEMBLY A

Wires 1OL & 10M

CAUTION

Cleanliness is of extreme importance.Before disconnecting the hydraulic components, clean exterior of plumbing and solenoid valve to prevent dirt and fqreign matter from entering hydraulic system.

Wires 10K & 1

Take particular care not to damage the coil stem. l

l

l

Lubricate all parts in clean hydraulic fluid prior to installation. Use only new seals. Install large O-ring into it’s groove being very careful that you do not nick or cut the O-ring making if unfit for service as it will leak.

When Mounting Solenoid Valve: l

When Connecting Hydraulic Plumbing:

Install three O-rings and six backup rings as shown on opposite page. Again, be very careful you do not nick or cut the O-rings or leakage will

l

OCCUT, l

l

l

l

Install solenoid valve into body bore. Be certain solenoid valve is torqued correctly to the body.

l

Next, install coil over solenoid valve. Installcoilretainernut N*m).

and tighten to5 lb.ft. (6.8

INSTALLATION

l

IMPORTANT Inspect hoses, hydraulic connections and their seals for damage. Replace defective parts.

Tighten valve body mounting nuts securely. Now go back and securely tighten each hydraulic connection.

Connect coil plugs to their receptacles in the wire harness.

IMPORTANT All electrical plugs and their receptacles are matched labeled for easy connection. Check to be sure each plug and receptacle match before attempting to make connections.

Prior to attaching hose ends and connections to the fittings on the solenoid valve, Clean and lubricate them with new hydraulic fluid.

SM587

Be certain valve fittings and hose ends are clean and in proper alignment and then install each one finger tight until1 all connections have been made..

A CAUTION Be certain coil is positioned so wire leads may be connected to the harness leads without causing damage to wiring.

Lubricate fittings with clean hydraulic fluid and install them finger tight to the valve body.

Remove caps just installation.

Align valve body “slots” with mounting bolts on truck.Locatevalveoverboltsandinstallretainer nuts finger tight. Refer to Section.

l

prior to 30-5-5

Check wire harness clamps for security of mounting. Be certain the harness is in good condition and that it is routed properly.

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

Dee 94

Solenoid Valve

GROUP 30

Wires 1 OK & 1 OL

resulting in possible shorts and com-

r

Check Sump Tank Level l

l

l

Fluid level should be at the full mark on the sump tank. If it is not, add fluid until it is. Use Hydraulic Fluid per Clark Specification MS68. Now, purge air from the hydraulic system. Operate the hydraulic controls through their cycle several times forcing air from the lines into the sump tank. Check sump fluid level again. Add fluid as necessary to bring fluid level to the full mark on the sump tank.

Multi-Function Control Handle

Use .

..-_I

I22 MS68 \ Typical lllustratior

jpical

Illustration

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

“1

Clark Part No.885385 Hydraulic Fluid

C19RK

Material Handling Company

GROUP 30

Section 6 Reach & Tilt Selector Valve Contents Truck Preparation ............... .. .................................... .................... ..... 30-6-2 Discharge Capacitors ... .............. .................................. .. .................. .. 30-6-3 Hydraulic Plumbing Diagram ........................................................... . 30-6-6 Specifications and Hydraulic Schematic ............. ...........I........ ........... 30-6-6 Location and Mounting Illustration ... ................ ...............I...... ........... 30-6-9 Removal, Disassembly & Reassembly . .......... .................................... 30-6-9

SM-587

30-6-l

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

Dee 94

Selector Valve

GROUP 30 1. Move truck to service area. .

Park truck on a flat level surface.

.

Extend pantograph.

.

Fully lower pantograph.

.

Tilt (if so equipped) forks forward until fork tips touch the floor.

2. Turn key switch off. l

Remove key.

l

Disconnect truck battery.

3. Remove Front Console Cover .

Remove fasteners securing 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. Refer to opposite illustration. Front Console

Cover Dee 94

30-6-2

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

\ SM-587

Selector Valve

GROUP 30

4. Open Access Door .

Remove door latch bolt.

.

Remove bolt securing left overhead guard leg to the overhead guard.

.

Open door. NOTE TheFrontHipPadmayberemoved for easier access to components.

5. Dischawe the Car>acitoq

Discharge Capacitors

.

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 solid state control panel. Holdthe resistorinplacefor two (2 ) seconds before removing. A

CAUTION

Using

a shorting device without a “resisforload”could cause damage to the control.

A

WARNING

Discharging the capacitors without using specified resistor could cause serious injury to yourself and bystanders.

SM-587

30-6-3

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

Dee 94

Selector Valve

GROUP 30

A

WARNING

Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is normally adequate.

A

CAUTION

Cleanliness is of extreme importance. Before disconnecting the hydraulic components, clean exterior of plumbing and solenoid valve to prevent dirt and foreign matterfromentering hydraulic system.

A

WARNING

When usina air Dressure to clean off truck: Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury. -

Removeall Jewelry before working on truck. Always Wear

Safety Glasses

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

Selector Valve

Selector

GROUP 30

Valve

(Reach & Tilt) Valve

Mounting

Fastener

Pantograph

IMPORTANT ROUTE HOSING AS SHO

Grease Fitting

WARNING Place a 4x4 support between front and rear members of pantograph (as shown). This is to prevent “retraction” of the pantograph when disconnected from the upright.

BEFORE

SM-587

WORKING

ON PANTOGRAPH,

BE CERTAIN IT IS BLOCKED

30-6-5

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

AS SHOWN.

Dee 94

Selector Valve

GROUP 30

o-Ringport For. Tilt (S.S.Right) o-RingPODReach, Pantograph #5 SAE o-Ring POTRetract, Pantograph #5 SAE

#4 SAE

o-Ringport Retract, Pantograph o-Ringport Reach, Pantograph ~4 SAE o-Ring port Back Tilt (S.S.LA)

#5 SAE

#5 SAE

#6SAEO-RingPort(ConnectstoAuxContmlValve

Hydraulic Circuit Typical Illustration

u* = s5

(Vl)

S6 (172) s5

(Vl)

S6 (172)

Counterbalance Valves

s5

=

Solenoid Valve

S6

=

Solenoid Valve

C2 Port

=

Back Tilt or Side Shift Right control circuit

C4 Port

=

Forward Tilt or Side Shift Left control circuit

Cl Port

=

Reach (Pantograph) control circuit

C3 Port

=

Retract (Pantograph) control circuit

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

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

Selector Valve

GROUP 30

7. Removevalve from the pantograph. Place components on a clean work bench.

REACH 81TILT SELECTOR VALVE

A

WARNING

DISASSEMBLY

Be sure pantograph is blocked as illustrated on page 5.

l

REMOVAL

l

Remove coils and solenoid valves S5 & S6 from valve body. Remove both counterbalance valves fromvalve body.

A

WARNING

NOTE It will not be necessary to separate the valve bodies unless there was leakage between the two. If the valve was leaking between the bodies, then remove four l/4-20 screws and separate the bodies. Discard the six O-ring seals located between the bodies.

Hydraulic lines may have trapped pressure. “Crack” fittings to release pressure before disconnecting.

A

WARNING

When trapped pressure is relieved, the pantograph may settle. Beware.

Cleaning l

1. Loosen guard mounting bolts and remove guard. 2. Unplug connectors #l from coil S6 and unplug connectors #2 from coil S5. 3. Remove fasteners #4 from clamps #3. Move wiring out of the way.

l

l

WashallpartsexceptthecoilsinaStoddardtype cleaning solvent. Wipe coils with clean cloth. Wipe all parts dry with a clean lint-free cloth. Allow components to airdry before reassembly. Replace all seals with new ones. Be sure to use a brass tool when removing seals.

4. Tag hoses and disconnect h ydraulic connections #5 and #8 from valve “A”. Remove hoses 6,7, 9 & 10 from each reach cylinder. Cap all hose ends. A CAUTION Residual pressure will be pressent when disconnecting lines. Use caution when disconnecting fittings. 5. Tag tubes and disconnect fittings #ll & #12 from bottom side of valve “A”. Cap both hose ends. 6. Remove both mounting fasteners from pantograph frame “B” and valve “A”. .

Dee 94

30-6-8

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

SM587

Selector Valve

GROUP 30

Solenoid Valves

es

Cleanliness is of extreme importance. Before disconnecting hydraulic components, clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system

SM587

30-6-9

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

Dee 94

Selector Valve

GROUP 30

Typical Cartridge Kit

rypical Illustration

REASSEMBLY

Receptacle Leads

Lubricate all parts in clean hydraulic fluid prior to installation. 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. Install O-ring and backup ring as shown above. Again, be very careful not to nick or cut the Orings or leakage will occur. Install the solenoid valves into their respective bores in the valve body. Be certain the solenoid valve is torqued correctly to the body. Next, install the coil over the solenoid valve. Install coil retainer nut and torque to 251b. ft. (33.9 N*m)maximum. This will allow thecoil to be correctly positioned at time of installation to the truck. Dee94

30-6-l

Torque: 5 Ib.ft. *6.8 N-m) Max. Torque: 25. Ib.ft. (33.9 N-m) Max.

0

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

SM587

Selector Valve

GROUP 30 A

CAUTION

Cleanlinessisof extremeimportance. Before dis-connecting the hydraulic components, If thevalve has been tampered with 9c 1eanexteriorof plumbing and solenoidvalve itmustbereplaced with anew one. to prevent dirt and foreign matter fr entering hydraulic system.

(NON-ADJUSTABLE)

- Back-Up Kings

INSTALLATION

REASSEMBLY l

l

l

l

Typical lllustratio

Lubricate all parts in clean hydraulic fluid prior to reassembly. Use only new seals1 Install large O-ring into it’s groove being very careful not to nick or cut the O-ring making if unfit for service or it will leak. Install O-rings and backup ringsas shown above. Again, be very careful not to nick or cut the Orings or leakage will occur. Install the counter balance valves into their respective bores in the valve body. Torque them to 35 lb.ft. (47.4 Nom) to valve body.

SM587

30-6-l 1

IMPORTANT Inspect hoses, hydraulic connections and their seals for damage. Replace defective parts. Wipe hose ends and connections clean prior to installing them to the solenoid valve. Remove hose caps just prior to installation.

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

Dee 94

Selector Valve

GROUP 30 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

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

SM587

Selector Valve

GROUP 30

Mounting Selector Valve 1. Position valve to the pantograph frame aligning holes in frame with those in the valve. Refer to opposite illustration.

A

Replenish hydraulicfluid in the sump tank before putting the truck into service.

2. Install mounting fasteners finger tight. Do not

tightenfasteners until after the hydraulic hoses are installed.

Connecting Hydraulic Plumbing 3. Remove cap, hose tag and then install connection #l 1 to valve finger tight.

CAUTION

The system must be purged of air before putting truck back into service or damage to the hydraulic system may result. 9. Install and tighten clamp bolts #M.

4. Remove cap, hose tag and install #12 connection finger tight. 4. Install connections #5 and #8. Then install connections #6,7,8,9 & 10 to the reach cylinders finger tight. 5. Now, securely tighten each hydraulic connection to the valve body and the reach cylinders. IMPORTANT Be sure the hoses are routed correctly before attempting to connect them to the valve. Refer to page 5 for correct routing.

Installing clamps, connect wire plugs, tighten nuts and bolts. 6. Next, be sure the valve guard is located properly and securely tighten both solenoidvalvemounting bolts. 7. Install wire clamps #3 with bolts #4. 8. Connect coil plugs to their receptacles. IMPORTANT All electrical plugs and their receptacles are matched labeled for easy connection. Check to be sureeachplugandreceptaclematch before attempting to make connections.

SM587

30-6-I 3

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

Dee 94

EllFlRH

Material Handling Company

GROUP 30

Section 7 Side Shifter Solenoid Control Valve (Optional Equipment) Contents .30-7-2 Truck Make Ready ........................................................................... 30-7-4 Removal ............................................................................................ Specifications and Hydraulic Schematic.. ................................... .30-7-5 & 6 .X&7-7 Disassembly and Reassembly ........................................................... Installation ........................................................................................ Hose Routing ....................................................................................

SM587

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

30-7-8 30-7-g

Dee 94

Solenoid Valve

GROUP 30 1. Move truck to service area. l

Park truck on a flat level surface.

l

Extend pantograph.

l

Fully lower pantograph.

l

Tilt (if so equipped) forks forward until fork tips touch the floor.

Typical Illustration

2. Turn key switch off., * Remove key. l

Disconnect truck battery.

Dee 94

30-7-2

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

SM587

Solenoid Valve

GROUP

30

Typical Illustration

SM587

30-7-3

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

Dee 94

Solenoid Valve

GROUP 30 Removal Refer to Illustration on opposite page. l

Unplug connectors from S7 coil.

l

Unplug connectors from S8 coil.

l

Tag each hose as to its location.

l

Disconnect hydraulic connections Vl, V2, C6, C5, C2 and C4 from the side shift selector valve.

A

AWARNING When usina air Dressure

CAUTION

to clean off truck:

Hydraulic lines may be under pressure. “Crack” fittings slowly. l

Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.

Cap each hose when disconnected.

NOTE There will be some fluid

l

l

Always Wear

leakage upon disconnectin g each fitting. Place a rag beneath the fitting to be removed. Remove mounting fasteners securing the selector valve to the pantograph.

Remove all Jewelry before working on truck.

Remove valve and place on a clean work bench. Refer to page 7 for valve service instructions.

A

l

l

Replace all O-rings with new ones. Inspect hoses and connections for further serviceability.

A

CAUTION

Cleanliness is of extreme importance. Before disconnecting the hydraulic components, clean exterior of plumbing and solenoid valve to prevent dirt and foreign matterfromentering hydraulic system.

Replace defective parts.

Dee 94

WARNING

Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is normally adequate.

Pages 6 & 8 provide diagrams and hydraulic schematic. l

Safety Glasses

30-7-4

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

SM587

Solenoid Valve

GROUP 30

Solenoid Valve

S8

. ~--~--_-_-_---_rxrr~~~

Top

[ j r

_-_-_-I

c2

#5 SAE O-Ring Port

c4

#4 S AE O-Ring Port

C5

#I4SAJZO-Ring Port

?&I SAE O-Ring Port

v2

##4SAE O-Ring Port

Solenoid Valve

I

I

j t

C6

C6 ##4SAE O-Ring Port Vl

view

. ...

Vl

f

NOTE Refer to Hydraulic Schematic on the next page. Fmnu

SM587

30-7-5 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Back

Dee 94

Solenoid Valve

GROUP 30

Hydraulic Schematic

4

Hydra-

_-._

Vl

........... ......... c2

c4

Hydraulic Circuit

0*

...........

0**

...............

..........

tv2

C6

J ______-___r-_l---I-

_I_

.

.

.._-_.....

Schematic

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

Side Shift Cylinder

Solenoid Valve

GROUP 30

Typical Cartridge Kit

jlpical Illustration

Disassembly l

Remove nut and coil from each solenoid valve.

l

Remove both solenoid valves from valve body.

Receptacle Leads

Torque nuts 8 - IO lb. ft. (11 - 14 Nom)

Cleaning & Inspection Wipe coil(s) clean using aclean shop rag. Inspect wire leads for damage. Wash hydraulic components in a Stoddard type cleaning solvent and wipe dry with a clean shop rag. Discard old seals. Replace defective parts Use Service Parts Kits.

r.....‘......<

22

f-l1

r

------

.. .. .. .. .. .. .. .. . .. .. 11..

Coil j

Reassembly l

l

l

Lubricate seals, valves and body in clean hydraulic fluid. - Retainer Nut

Install seals and backup rings as shown above. Becarefil that you do not nick or cut seals upon installation. Install cartridge valve into valve body and torque to 8 - 10 lb. ft. (11 - 14 N*m). 30-7-7

l-

----

-l

r Body--l -ypical Illustration

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

Dee94

Solenoid Valve

GROUP 30 Installation

I

Mount Selector Valve l

Line up mounting holes in selector valve with those in mounting bracket. Install fasteners finger tight. (see below)

Install Hoses l

Wipe hose ends and connections clean. Remove hose caps just prior to installing connection to valve. Be certain all connections are tight.

Connect Coils Plug connectors to S8 and S7 coils. See illustration at left. .

Tighten all mounting fasteners.

.

Install guard.

Mounting Fasteners

IMPORTANT All Wiring, Plugs and Receptacles arelabeledfor easy identification. You

Side

must install cables and wiring exactlly as shown or you will experience shorts and component failure. Side Shift Selector Valve

II Mounting Bracket

Dee 94

30-7-8

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

SM587

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

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

Dee 94

Cl!!IRIC

Material Handling Company

GROUP 32

Section 2 Tilt Cylinder Overhaul Contents Safety ............................................................................................... .32-2-2 Preparation Cleaning and Inspection suggestions ............................... 32-2-3 Disassembly ...................................................................................... 32-2-4 Cleaning & Inspection ....................................................................... 32-2-5 Reassembly ................................................................................ 32-2-5 & 6 Sump Tank Fluid Level ..................................................................... 32-2-7

Models Equipped with

Side Shift

SM-587

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

1

Tilt Cylinder

GROUP 32

Air Hose

A

WARNING

When using air pressure to clean off truck: Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to30 PSI (207 kPa). Debris removed with air pressure can cause injury.

Remove all Jewelry working on truck.

Always wear Safety Glasses

before

A

WARNING

Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation normally adequate.

A

is

CAUTION

Cleanlinessisof extreme importance. Before disconnecting hydrauliccomponents, clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system. Typical Illustration Dee 94

32-2-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Tilt Cylinder

GROUP 32

1

Preparation Cleaning & Inspection Suggestions l

l

l

The exterior surface of a cylinder should be thoroughly washed before disassembly. A soft fiber brush should be used to remove debris and foreign objects from grooves and threaded areas, etc. 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.

l

l

l

Threaded area of piston rod should be examined for damage, stripping or marring after removal of rod end and jam nut. The bushing in rod end should be inspected for further serviceability. All foreign objects should be removed from between threads on the piston rod, in the nut and rod end. Any part unfit for further service should be replaced with a new Pm*

SM-587

32-2-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee94

Tilt Cylinder

GROUP 32

Split Retainer Ring

Disassembly

are free of cylinder housing. Remove gland.

(Refer to illustration above.)

Wash exterior of the tilt cylinder in a Stoddard type cleaning solvent before disassembly. Use a brush to remove grease and grime from the cylinder tube, anchor and rod ends. Remove rod end and jam nut.

Gland Assembly 1. Remove wiper ring. 2. Remove seal from inner groove. Be careful that you do not nick or scratch inner sutiace if gland assembly.

1. Placecylinder in avise equipped with softjaws. Do not over-tighten - distort barrel

3. Remove outer O-ring and backup ring from the gland assembly.

2. Push piston rod all the way into cylinder. 3. Using a narrow blade screwdriver, remove the

4. Discard seals, wiper and backup rings.

split type retainer ring.

Piston Rod & Piston

4. Remove washer. 5. Remove white backup ring. 6. Remove O-ring. 7. Using a bronze drift, gently tap gland assembly into cylinder housing clear of the shear ring.

8. Using screwdriver, carefully lift end of shear ring from it’s groove. Becareful you do not nick or scratch the piston rod.

9. With a pair of pliers, carefully pull shear ring from cylinder tube. Again, be carejXyou do not nickor scratch the piston rod. Discard the shear ring. 10. Pull outward on piston rod until rod and gland Dee 94

32-2-4

1. Insert a 12 to 15 inch holding rod into the hole provided just below threaded area of piston rod, see arrow (4) above. Now install a l-l/S” socket onto the piston rod nut. 2. Remove nut from piston rod while holding retainer rod. 3. Pull piston free of piston rod. 4. Remove O-ring from piston rod and discard. 5 Remove sealing ring (Glyde Ring@) and the ’ energizer from piston. Use care not to nick or scratch piston surfaces. 6. DiscardO-ring, sealing ring (Glyde Ring@) and energizer. Always install new seals.

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

SM-587

Tilt Cylinder

GROUP 32

Cleaning & Inspection 1. Discard old seals, wiper and shear ring. 2. Wash all parts in a Stoddard type cleaning solvent and dry with a clean lint free shop rag. 3. Inspect cylinder mounting bushings for damage. Both the rod and anchor ends have two bushings each end. If they are unfit for further service, they may be pressed out and new bushingspressedin. New bushings should be pressed flush with outer surface of the anchor and rod ends. Refer to opposite illustration. 4. Inspect threaded parts for damage. Examine cylinder barrel for scoring, nicks or scratches. A crocus cloth may be used to clean up light scratches, etc. Be car@2 not to remove the chrome plating when polishing surface. Replace all damaged or unserviceable parts. 5. Inspect surfacesofthepistonandpistonrod to be sure they are clean, smooth and free of damage.

8. Using a torque wrench and the l-l/S” socket, torque nut to: 201 to 2301b.ft. (273 - 312 N*M).

Reassembly

9. Now, lubricate piston and piston rod with clean hydraulic fluid

Piston Rod & Piston 1. Using only new seals and O-rings, lubricate all parts with clean hydraulic fluid.

2. Lubricate and install the square energizer ring into the groove in the piston. Refer toillustration on opposite page.

3. Lubricate and install the Glyd Ring@ over the energizer. Be careful that you do not nick or cut the seals making them unfit for service.

10. Startpistonintocylindertube whilegentlypushing and rotating piston rod until piston and seal have passed the shearring groovein the cylinder tube. Be careful you do not damage seal. 11. Shovethepistonrodallthewayintothecylinder tube until it bottoms.

Gland Assembly

4. Place a plastic parts bag over the threaded area of the piston rod (to protect seal). Slide a new Oringoverthebagandintothegrooveinthepiston rod.

5. Remove bag and install piston onto rod. Carefully slide piston over the O-ring and up against rod shoulder.

6. Install nut onto rod finger tight against the

1. Lubricate new seals, wiper ring and gland assembly with clean hydraulic fluid.

2. Install the inner seal, with the sealing lip faced inward, into the gland groove. Becareful that you do not cut or nick the sealing lip upon installation. 3. Install a new wiper ring into the gland. 4. Lubricate and install a new backup ring into the outer groove on the gland..

piston.

7. Install the 12 to 15 inch rod back into the hole provided in the piston rod. SM-587

32-2-5

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

Dee 94

Tilt Cylinder

GROUP 32 Back-Up Ring O-Ring-,

1 r

Split Retainer Ring -Nut

lRod

Typical Illustration

5. Lubricate and install a new O-ring in the grove next to the backup ring. Note position of backup and o-ring per above diagram. 6. Place a plastic parts bag over the threaded end of the rod (to protect seals) and carefully slide the gland over the rod and into the cylinder housing. 7. Push gland as far as it will go into the housing. 8. Insert the open end of a new shear ring into the cylinder housing while pushing on the ring with your fingers. Push ring inward as far as you can. 9. Now, using a bronze punch, gently tap ring the rest of the way into the tube and groove. Be sure the shear ring is fully seated in it’s groove.

12. Lubricate a new backup ring and place it over the

O-ring just installed. 13. Install the washer over the gland and next to the backup ring previously installed. 14. Install a new split retainer ring into it’s groove in the gland assembly. Be sure it is completely seated in it’s groove. 15. Install jam nut and rod end to the same location it was when removed from the piston rod. 16. Cap cylinder ports until such time as the cylinder is installed in the truck.

10. Next, pull piston rod out as far as it will come. This will position the gland so the retainer ring groove is located above the cylinder housing. 11. Lubricate a new O-ring and place it over the gland and into the housing on top of the gland.

Dee 94

32-2-6

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

SM-587

Tilt Cylinder

GROUP 32

Check Sump Tank Level l

l

Fluid level should be at the full mark on the sump tank. If it is not, add fluid until it is. Use Hydraulic Fluid per specifications in Group 01. Now, purge air from the hydraulic system.

Operate the hydraulic controls through their cycle several times forcing air from the lines into the sump tank.

Multi-Function Control Handle

l

Check sump fluid level again. Add fluid as necessary to bring fluid level to the full mark on the sump tank.

SM-587

32-2-7

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

Dee 94

EMIRK~z$e;;k&Handling

GROUP 32

Section 3 Reach Cylinder Overhaul Contents Safety ................................................................................................

32-3-2 Preparation Cleaning and Inspection Suggestions .............................. .32-3-3 Disassembly ...................................................................................... 32-3-4 Cleaning & Inspection ...................................................................... .32-3-5 Reassembly ................................................................................ 32-3-5 & 6 Sump Tank Fluid Level .................................................................... .32-3-7

)_ 0

0 JQ ,==z\

SM-587

32-3-l

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

I,

II

II II II Ii

II II II

Ii

r

Dee 94

Reach Cylinder

GROUP 32

A

WARNING

When usina air Dressure to clean off truck: Wear eye protection and protectiveclothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.

Remove all Jewelry working on truck.

Always wear Safety Glasses

before

A

WARNING

Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation normally adequate. A

is

CAUTION

Cleanlinessisofextremeimportance. Beforedisconnecting hydrauliccomponents, clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system. Cap all ports (after overhaul) until assembly is ready for installation.

Dee 94

32-3-2

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

SM-587

Reach Cylinder

GROUP 32

Preparation Cleaning & Inspection Suggestions l

l

The exterior surface of a cylinder should be thoroughly washed before disassembly. A soft fiber brush should be used to remove debris and foreign objects from grooves and threaded areas, etc. -

l

A Stoddard type cleaning solvent should be used to wash the cylinder.

Soft Fiber Brush

Nut Rod En d

Cylinder Piston Rod

l

l

l

Threaded areas should be examined for damage, stripping or marring after removal of rod end and jam nut. The bushing in rod end should be inspected for further serviceability. All foreign objects should be removed from between threads on the piston rod, in the nut and rod end. Any part unfit for further service should be replaced with a new Part*

SM-587

32-3-3

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

Dee 94

Reach Cylinder

GROUP 32

a, ,:,,,‘:C’.‘~‘.‘.‘./ ..,; ‘f,

0

:::.

[ii

.:: Y:..

.::

ii;

,.:::z’

v.:..:.;,:,:.. :....

F

Anchor End

Piston Seals1

Energizer, ILSdf-Alionino

I

1 I

Seal-

Piston

Shear Ring -

Disassembly

(Refer to illustration

{

I

I

I-

flllTop

View11

Rod End

Snap Ring

Gland Assembly

above.)

1. Remove wiper ring.

Wash exterior of the reach cylinder in a S toddard type cleaning solvent before disassembly. Use a brush to remove grease and grime from the cylinder tube, anchor and rod ends.

2. Remove seal from inner groove. Becareful that you do not nick or scratch innersurfaceof gland assembly.

1. Placecylinder in aviseequipped with softjaws. Do not over tighten - distort barrel.

3. Remove outer O-ring and backup ring from the gland assembly.

2. Push piston rod all the way into cylinder.

4. Discard seals, wiper and backup rings.

3. Using snap ring pliers, remove snap ring from

Piston Rod & Piston

cylinder gland.

into cylinder housing clear of the shear ring.

1. Insert a 12 to 15 inch holding rod into the hole provided just below threaded area of piston rod. Now install a 1-l/8” socket onto the piston rod nut.

6. Using screwdriver, carefully lift end of shear

2. Remove nut from piston rod and remove hold-

4. Remove washer. 5. Using a bronze drift, gently tap gland assembly

ring from it’s groove. Be carefulyou do not nick or scratch the piston rod or cylinderbore

ing rod.

3. Pull piston free of rod.

7. With a pair of pliers, carefully pull shear ring from cylinder tube. Again, becarefil you do not nick or scratch the piston rod or cylinderbore. Discard the shear ring.

4. Remove O-ring from rod.

8. Pull outward on piston rod until rod and gland

6. Discard O-ring, sealing ring (Glyde Ring@) and

are free of cylinder housing. Remove gland.

Dee 94

32-3-4

5. Remove seal ring (Glyde Ring@) and the energizer from piston. energizer. Always install new seals.

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

SM -587

Reach Cylinder

GROUP 32

Cleaning & Inspection 1. Discard old seals, wiper and shear ring. 2. Wash all parts in a Stoddard type cleaning solvent and dry with a clean lint free shop rag. 3. Inspect cylinder mounting bushing for damage. If it is unfit for further service, it may be pressed out and new bushing pressed in. A sleeve to fit over spherical inner bushing will be needed. Do not press out by pressing on the inner bushing.

Bushing

4. Inspect threaded parts for damage. Examine cylinder barrel for scoring, nicks or scratches. A crocus cloth may be used to clean up light scratches, etc. Be careful not to remove the chrome plating when polishing surface. Replace all damaged or unserviceable parts.

Grease Fitting

5. Inspectsurfacesofthepistonandpistonrod to be sure they are clean, smooth and free of damage.

Reassembly Piston Rod & Piston 1. Lubricate all parts with clean hydraulic fluid.

2. Lubricate and install the square energizer ring into the groove in the piston. Refer to illustration on previous page.

3. Lubricate and install the GlydeB over the energizer. Be careful not to nick or cut the seals making them unjit for service.

4. Place a plastic parts bag over the threaded area of the piston rod (to protect seal). Slide a new Oring over the bag and into the groove in the rod.

5. Remove bag and install piston onto rod. Carefully slide piston over the O-ring and up against rod shoulder.

6. Install nut onto rod finger tight against the piston.

7. Install the 12 to 15 inch rod into the hole provided just below threaded area of piston rod.

8. Using a torque wrench, torque nut to: 115 to 132 lb.ft. (156 - 179 N*m).

9. Now, lubricate piston and piston rod with clean

10. Start piston into cylinder tube while gently pushing and rotating piston rod until piston and seal have passed the shear ring groove in the cylinder housing. Becarefulyou do not damage seal. 11. Push the piston rod all the way into the cylinder Housing until it bottoms.

Gland Assembly 1. Lubricate new seals, wiper ring and gland assembly with clean hydraulic fluid. 2. Install the inner seal, with the sealing lip faced inward, into the gland groove. Be careful not to cut or nick the sealing lip upon installation. 3. Install a new wiper ring into the gland. 4. Lubricate and install a new backup ring into the outer groove on the gland.. 5. Lubricate and install a new O-ring in the grove next to the backup ring as shown in illustration on opposite page.. 6. Place a plastic parts bag over the threaded end of the rod (to protect seals) and carefully slide the gland over the rod and into the cylinder housing.

hydraulic fluid. SM-587

32-3-5 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee94

Reach Cylinder

GROUP 32

Wiper

l-

Seal -I

Piston

l-

Snap Ring

Shear Ring -_I

Typical Illustration

Push gland into the thousing until it is clear of shear ring groove.

11. Lubricate and install the washer over the gland next to the housing.

8. Insert the open end of a new shear ring into the cylinder housing while pushing on the ring with your fingers. Push ring inward as far as you can.

14. Install a new snap ring into it’s groove in the gland assembly. Be sure it is completely seated in it’s groove.

9. Now, using a bronze punch, gently tap ring the rest of the way into the groove. Be sure the shear ring is fully seated in it’s groove.

15. Install jam nut and rod end in the same location it was when removed from the piston rod.

7.

10. Next, pull piston rod out as far as it will come. This will position the gland so the retainer ring groove is located above the cylinder housing.

Dee 94

16. Cap cylinder ports until such time as the cylinder is installed in the truck.

32-3-6 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Reach Cylinder

GROUP 32

Check Sump Tank Level l

l

Fluid level should be at the full mark on the sump tank. If it is not, add fluid until it is. Use Hydraulic Fluid per specification listed in Group 01. Now, purge air from the hydraulic system. Operate the hydraulic controls through their cycle several times forcing air from the lines into the sump tank.

Multi-Function Control Handle

l

Check sump fluid level again. Add fluid as necessary to bring fluid level to the full mark on the sump tank.

SM-587

I-

32-3-7

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

Dee 94

lVlz$?;~%&Handling CUFIRIC

GROUP 34

Section 1 Upright & Pantograph Remove & Replace Roller Shim Adjustments Contents Pantograph ....................................... ............ ........................ ............ . 34-l-2 Upright ....................................... .................. .................................... . 34-l-7 Cables, Hose & Chain Sheaves ............. .............................. .. .......... . 34-1-18 Pantograph Carriage Rollers ............................................................ 34-l-23 Upright Rollers ................................. .................................. .............34- l-29

Overhead Guard \

Upright

Pantograph & LBR

SM-587

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

Dee 94

Upright

GROUP 34 PANTOGRAPH REMOVAL Preparation 1.

Move truck to service area. NOTE

Iftheupright is to be removed, a 5ton chain hoist equipped with safety hooks is required. Upright weights are provided in Specifications, Group 40 of this manual. l

Be sure truck is parked on a flat level surface.

2. Fully extend pantograph. l

l

Lower the pantograph onto hardwood (oak) blocks as shown. Place a support (2 x 4 or 4 x 4) between the front andrearmembersofthepantograph (asshown). Thisistopreventthepantographfromretracting when disconnected from the upright and hydraulic plumbing.

3. Now, actuate the lowering control long enough for the primary cylinder to collapse providing some slack in the lift chains. Release control. 4. Turn key switch off. l

Remove key from switch.

5. Disconnect truck battery at the battery disconnect lever.

Wear Safety Glasses

Remove jewelery before working on truck

Dee 94

34-1-2

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

SM-587

Upright R&R

t 4J

GROUP 34

Upright Pantograph

Lift Chain

\

6. Remove two bolts (1) from cable retainers (2).

11. Remove cotter pins (6).

7. Remove front and rear retainers.

12. Remove chain anchor pins (7) securing the lift chains to the carriage chain anchors.

8. Disconnect electrical plug (3). 9. Remove both harness clamp bolts (4).

NOTE

10. Disconnect hydraulic hoses from tube connections (5) using two wrenches. One wrench to hold the tube connection(s) while loosening the hose connection(s). There will be some hydraulit fluid leakage upon disconnecting fittings. SM-587

34-l -3

Lift Chains may be disconnected at the Primary Cylinder Piston Head (see next page) or from the carriage as shown here.

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

Dee 94

Upright R&R

GROUP 34

Cylinder Piston Head II))

Chain Anchor --Bw

Typical Illustration

NOTE

Carriage chains may be disconnected at the primary cylinder. l

Remove cotter pins and anchor pins securing lift chains to the chain anchors. Remove lift chains one at a time from the chain anchors. IMPORTANT Once a lift chain has been disconnected, lay it over the pantograph. Then, using wire, tie the chain end to the LBR. This will keep the chains out of the way and from falling to the ground.

Dee 94

34-l -4

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

SM-587

Upright

GROUP 34

I . . ; i . . . . .. .. . .

13

F .

Hooks

Raise both inner and intermediate rails until the inner rail channels are clear of the carriage rollers.

I

1 Hardwood (Oak) Blocking

1

13. Using a 5ton chain hoist, attach hoist to the

inner and intermediate rail assemblies, see illustrations above. Be sure hoist is equipped with

.4. Raise both inner and intermediate rails until the

inner rail channels clear the carriage rollers.

safety hook(s). SM-587

34-l -5

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

Dee 94

Upright

GROUP 34 15. Move truck away fi-om pantograph just far enough to allow the intermediate and inner rails to clear the pantograph. 16. Completely lower the intermediate and inner rail assemblies. 17. Disconnect chain hoist and move truck away from pantograph.

l

NOTE

If the upright or rail lift cylinders are to be removed, refer to the following pages. The free lift (center) cylinder may be removed without removing the upright.

Backup truck just enough to to provide clearance between pantograph and upright rails INRails

a

Fully lower intermediate & inner rails

l

Disconnect hoist safety hook from lifting device

l

Move truck away from pantograph 1 1

Hardwood (0ak)Blocking Dee 94

34-l -6 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Upright

GROUP 34

UPRIGHT REMOVAL Preparation NOTE If the pantograph has not been removed, refer to pages 2 thru 6 for removal instructions. Pantograph must be removed from upright before attempting to remove upright. 1. Turn key switch off. l

Remove key from switch.

2. Disconnect truck battery at the battery disconnect. 3. Remove battery from truck. Refer to Group 12.

Wear Safety Glasses

Remove jewelery before working on true

Cleanliness is of extreme importance. Before disconnecting hydraulic components, exterior surfaces to prevent dirt and foreign mater from entering the hydraulic system.

SM-587

L

34-l -7

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

Dee 94

Upright

GROUP 34

Typical Illustration

4. Remove Console Cover, see above. Remove fasteners securing cover to truck. Remove cover. Open rear door.

5. Remove Center Pad, see below. Loosen bolts located beneath the pad at the lower edge. Lift pad upward and remove from truck.

Hook(s) I’ Center Pad

3i0tf L.H. Side

“S Etsoo Center Hanger

Typical Illustration

Dee94

34-l -8

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

SM-587

Upright

GROUP 34

6. Overhead Guard Removal .

Attach lifting straps to all four comers of the overhead guard (as shown).

.

Connect straps to a chain hoist equipped with a safety hook.

.

Adjust hoist to support overhead guard upon removal of mounting bolts.

.

Remove upper and lower mounting bolts securing legs to overhead guard..

.

Remove mounting bolts securing the overhead guard to the upright, see arrows.

.

Remove and set the overhead guard to one side.

7. Remove fasteners securing safety screen to the upright. 8. Remove screen and set to one side.

SM-587

34-l -9

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

Dee 94

Upright

GROUP 34

Typical Illustration

beneath frame on both sides of truck -- just behind the Butriggers.

9.

Elevate and support each side of truck with suitable hardwood (Oak) blocking, see above.

A

WARNING

Make certain upright lift cylinders are fully lowered before disconnecting hydraulic lines. 10. Disconnect the bulkhead fittings, see illustration below and on the following pages.

IMPORTANT Cap all Hydraulic Fittings upon removal of tubing.

Cbnnections

Dee94

\ !Pl

Y\i

\\

34-l

-10

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

SM-587

GROUP 34

Upright

Typical illustration

.I

Bulkhead Fitting

T”

Fitting Connecti

11. Disconnect hydraulic tube from lift valve and “T” fitting (at the bulkhead fitting), see above. 12. Disconnect hydraulic tube with 7”’ fitting from lowering solenoid valve and bulkhead fitting, see below.

SM-587

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

I

Dee 94

Upright

GROUP 34 13. Disconnect hydraulic tubing from the auxiliary valve and the bulkhead fittings. l

l

Hydraulic Connections

Dee 94

\

y

Cap each tube to prevent dirt and foreign debris from entering. Be sure all bulk head fittings are capped.

\

34-l -12

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

SM-587

GROUP 34

Upright 14. Disconnect Electrical plugs and tie them out of the way with a tie wrap, as shown below.

Rail Cylinder

SM-587

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

Dee 94

Upright

GROUP 34

2 1. Move upright away from the truck so it may be lowered to the floor.

IMPORTANT Chain all three rails together at the upper tie bars so they do not move independently. See below.

LiftingStraps ChZns

15. Place lifting straps beneath the upper tie bars of the outer, intermediate and inner rail assemblies (one strap at each side of upright as shown here). Connect strap ends to the chain hoist. Be certain the hoist is equipped with a safety hook.

16. Actuate lift hoist until straps are taunt. You will want enough strap tension to support the upright after it is disconnected from the truck.

17. Loosen the upper (four) capscrews (1). These are accessible from the front of the truck. NOTE The upper bolts (1) are torqued

to: 200 lb.ft. (lightly oiled)

18. Loosen retainer bolts (2). These are accessible from within the battery compartment. NOTE The lower bolts (2) are torqued

to: 375 lb.ft. (lightly oiled)

19. Remove retainer bolts (2). 20. Remove capscrews (1). NOTE

Some trucks will be equipped with spacer blocks. These blocks will drop free upon removal of the upright. Be certain the blocks are installed when reassembling the upright to the truck. Dee 94

34-1-14 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Upright

GROUP 34

Outrigger(s)

d

Inner Rail Assembly

t

Floor

22. Next, using hardwood (oak) blocks, space them equally on the floor to support the upright (as shown above). The upright should be lowered ‘\\ onto the blocks (truck side facing downward) outriggers pointing upward. This will allow the rail assemblies to be pulled out of the outer rail assembly providing access to rail rollers and secondary cylinders. A Be careful hoses.

CAUTION not to damage

Rail Cylinders Pulling the inner and intermediate rail assemblies part way out of the top of the outer rail assembly will allow removal of the secondary cylinders. The rail cylinders must beremoved to adjust or replace the lower rail rollers.

Rollers & Shims Access to the rollers and their shims is accomplished by pulling the rail assemblies part way outthebottomoftheouterrail assembly after the rail cylinders have been removed.

SM-587

34-1-15

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

Dee 94

Upright

GROUP 34 !3. Loosen and then remove hydraulic fittings at the base of the L.H. and R.H. Rail Lift Cylinders. Discard old O-ring seals. Use new seals at time of installation.

24. Remove snap ring located at the base of eacl cylinder, see below.

Outrigger 7

Inner Rail Assembly

Rail Assembly t

;semblv

L-

Oak Blockinae

Floor Typical Illustration

Dee94

34-1-l

6

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

SM-587

Upright

GROUP 34 25. Remove the external snap ring from the top of each piston rod. 26. Remove washer from each rod. 27.

Support the cylinders, and move the rails outward far enough to allow removal of the cylinders. NOTE

Each cylinder is equipped with a weldment near the top end of the barrel assembly. This weldment fits over an alignment pin that is part of the upright. Move cylinder off pin and out of upright.

A

WARNING

Rail cylinders weigh between QQQ and ooo pounds each. Exercise care when removing a cylinder from the upright.

Rail Cylinder

SM-587

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

Dee 94

Upright

GROUP 34 Cable, Hose & Chain Sheaves Remove snap rings (6) and sheaves (5). Remove screws (4) securing mounting plates to block (16) and remove assembly from block. Remove pin (15) and block (16) from cylinder rod. Loosen and remove nuts (l), bolts (3), and spacers (2).

16

Disassemble assembly. Replace any damaged components. Installation is the reverse of removal.

7

Free Lift Cylinder Cylinder l

l

l

5 6

8

Remove cotter pins (7), jam nuts (1 l), nuts (lo), centering bushings (9). Remove chain anchors and lift chains (items 8 & 13). Remove snap ring (14). Lift cylinder off centeringpin (12) andout of upright. Installation is the reverse of removal. NOTE Free

Lift Cylinder may beremoved

with upright attached to truck.

A

WARNING

Free Lift Cylinder weights between ooo and ooo pounds. Excercise care when removing cylinder from upright.

r t

Inner Rail Assembly

Floor

Dee 94

34-1-18

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

SM-587

Upright

GROUP 34 Cable, Hose & Chain Sheaves

Nut (1) -

+-

Screw (4)

Block (11

Secures Block to Cylinder Rod Sheave (5)

SM-587

34-l-19

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

Dee 94

Upright

GROUP 34 Cable and Chain Sheaves Removal l

Loosen andremoveretainerbolt

l

Remove washer, sheaves and spacer.

l

Replace damaged components.

Installation is the reverse procedure of removal.

from stub shaft.

rmediate Rail Assembly Chain Sheave

13ait I

Dee 94

34-l -20

Intermediate Rail

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

SM-587

Upright

GROUP 34

Inside Spanner Tool

Outside Spanner Tool

SM-587

34-1-21

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

Dee 94

Upright

GROUP 34

Carpenter Square

Dee 94

34-1-22

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

SM-587

Upright

GROUP 34 Pantograph Assembly

SM-587

34-1-23

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

Dee 94

Upright

GROUP 34

Inner Rail Assembl

t

Floor

PANTOGRAPH CARRIAGE ROLLERS The clearance between the upright innerrails and the pantograph carriage rollers must be checked and adjusted.

(Checks and Adjustment) NOTE Roller Clearance Check and Adjustment may be accomplished with upright mounted to the truck or removed and laying on the floor as shown above.

Spanning Inner Rail Assembly 1. Span inner rail with inside spanner tool. l

l

Find the smallest distance between the rails. After finding the smallest distance, place a roller shim between the spanner tool and the inner rail. Then lock tool in position.

Inner Rail

Step 1 Span Rail

i

to find narrowest point.

Step2 Insert

Dee94

34-l -24

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

SM-587

GROUP 34 Outside Spanning Tool

Inside Spanning Tool

2. Set outside spanning tool to match the adjusted inside spanning tool. 3. Lock the outside spanning tool in the adjusted position. 4. Span upper carriage rollers at their outer most camber point. Add or remove shims at roller shaft to match tool size. 5. Center carriage rollers by counting the total of shims used on both right and left upper rollers and then dividing them in half. .

Place half the total on the right and half on the left roller shaft. If there was an odd number of shims, install the odd shim on the right roller shaft. IMPORTANT When upright is fully extended, the upper carriage rollers extend beyond the inner rail assembly. To allow therollers toretract smoothly back into the rail, one shim should be removed from each side.

6. Installuppercarriagerollers and securely tighten the Allen head retaining bolts.

SM-587

34-l-25

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

Dee 94

Upright

GROUP 34 7. Span center carriage rollers at their outer most camber point. Add or remove shims at roller shaft to match tool size.

Carriage Rollers

8. Center carriage rollers by counting the total of shims used on both right and left center rollers and then dividing them in half. l

Placehalfthetotalontherightandhalfontheleft roller shaft. If there was an odd number of shims, install the odd shim on the right roller shaft.

9. Place square at the outer most camber of the centerandlowerrollers. Holdsquare tight against rollers and take the following measurements. l

l

Measure the distance between the top of the square and straight edge at point (A). Take a measurement at point (B). These measurements should be the same. If they are not, add or remove shims from the lower roller shaft until distance measured at each point is equal.

Dee 94

34-l -26

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

SM-587

Upright

GROUP 34

10. Spanlower rollers. Addor subtract shims to (the roller that has not been squared)match the size of the outside spanning tool.

Spanning Lower Carriage Rollers

11. Now check and adjust rollers on opposite side of carriage. Place square at the outer most camber of the center and lower rollers. Take measurements as before. This side will be square within l/32”; if not, return to Step 9 and repeat procedure. Make certain rollers are centered as previously describbed.

SM-587

34-l -27

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

Dee94

Upright

GROUP 34 12. The top carriage rollers are checked last. Remember that the top carriage rollers extend out of the inner rails when the pantograph carriage is fully elevated. To make re-entry of these rollers into the inner rails easier, additional clearance is required for the top carriage rollers. (Refer to steps 4,5 & 6). l

l

l

l

Place the square directly through the centers of the rollers as shown in opposite illustration. See if a l/32” roller shim will fit between the outer most camber of the roller and the square. There must be some clearance between the square and the side surface of the top roller. This clearance should not exceed l/32” or one shim. If adjustment is necessary, remove Allen screw and roller. Add or remove shim as necessary to acquire correct adjustment. Install Allen screw and check adjustment again.

13. Check opposite upper roller in the same manner, adjust if necessary. NOTE

Upper Rollers only are retained with Allen head screw. Center and lower rollers are always captive within the upright rails.

Dee 94

34-l-28

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

SM-587

Upright

GROUP 34

The triple stage upright, as the name implies, has three sets of upright rails. The rails are identified as: .

Outer Rails

.

Intermediate Rails

.

Inner Rails

The upright is equipped with 8 rollers. This diagram shows the position of therollers within the triple stage upright.

When the free lift (center) cylinder is fully extended, the pantograph carriage elevates through what is called “free lift” portion of upright travel. Just beyond themaximumfi-eeliftposition, therollerson top ofthe carriage are visible as they extend out the top of the inner rails. SM-587

As the free lift cylinder fully extends, the rail lift cylinders and lift chains elevate the intermediate and inner rails to maximum fork height.

Therearefourrollers that workbetweentheouterrails and the intermediate rails. Four more rollers work between the intermediate rails and inner rails. The pantograph has six rollers that work within the inner rail. The top two are retained by Allen screws.

34-l -29

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

Dee 94

Upright

GROUP 34

Uprights are not manufactured with rails parallel.

Upright Rails to Rollers The following procedure explains how to: l

l

lst-Measure rail-to-roller clearance. 2nd-Adjust rail-to-roller clearance.

34-l-30

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

GROUP 34 Triple Stage Upright

mmmmm

m m

c

3

Point of Roller Contact.

IMPORTANT

With age and wear, clearance between upright rails can increase and cause excessive looseness between rails and rollers. Upright rollers become worn, rail surfaces wear, and stress relieving due to handling of heavy loads over a period of time may cause slight dimensional changes between upright rails. The white arrows show clearance between rails and rollers. The dotted lines indicate roller operating channels. A roller clearance inspection should be performed if, during an operational check of the upright, you note excessive looseness or binding between rail sets, or if scoring is evident on the rails. Properroller clearance should be maintained because the system is designed to nest the rails snugly while providing smooth extensions.

SM-587

34-1-31

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

Dee 94

Upright

GROUP 34

usec-&Imp to force rollers to one side. Torque on C-Clamp shouldnotexteed 20 Ib.ft.

Shim Check

Roller

L

ii’.‘.:.:.:.:.:.:.):.:.:.:.:.:

\ .,.,.,.,.,.,.,.,.,.(,.,.

::::::“a:::::::~:::::::~.~:~.~:~:~:~:~:~:~~:~:~ :.:.:i...A.... . . ...... . ,. ,.

,.

I

Point of roller contact.

I

/

Inner Rail

t

Floor

Dee 94

34-l

-32

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

SM-587

Upright

GROUP 34 Checking roller clearances: Evaluation of shim requirements generally dictates that a specific roller is acceptable until 0.040” clearance is exceeded, meaning adjustment requires one standard l/32” shims toreducerail-to-rollerclearance to proper tolerances.

CAUTION Watch for overhead clearance when extending upright.

A

ROLLERS SHOULD BE ADJUSTED “LINE TO LINE” WITH 0.020” MINIMUM CLEARANCE

WARNING

PINCH POINTS

Adjustmentreference Useextremecarewhenworking on the upright to avoid placing hands or fingers into potential pinch points. Unexpected movement of upright components can cause serious injury

chart when usingfeelergauges.

IFeeler 1 Gauge will Step; Gauge I pass / not uass

1 l.020” 2

Roller Clearance Inspection

3

Before checking roller clearance, place the intermediate rail approximated 6 inches outof the outer rail and the inner rail approximately 6 to 12 inches out of the intermediate rail as illustrated on opposite page. If the upright is mounted and you are elevating the rails hydraulically, the inner rail will automatically assume it’s correct position. Note the procedure for checking clearance is basically the same whether the upright has been removed or is mounted on the truck.

I

PASS

I

Shimmed

I

check with al

not nass

I Yes

;.050”

PASS

’

I.080” I

not pass

I No, add

I soso”

PASS

1

I

1.120” I

notpass

Shim

I Correctlv I

1.050” I ;

1

I 1

I

I

0

check with a’

I

I

1

check with al

I No, add

There are two methods covered, one is using a pry bar to position rails and rollers and the other is using a Cclamp. If the upright is mounted to the truck, the use of an approved safety platform or step ladder is recommended when making inspections and checking clearances at the upper levels. If the upright has been removed and placed flat on the floor, proper blocking of hard wood (oak) or steel

supports must be used to keep the upright horizontal with thejloor. This is especially important when fully extending the intermediate and inner rails.

SM-587

34-l-33

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

Dee 94

Upright

GROUP 34 When using a pry bar: l

C-Clamp Method

Insert pry bar between the outer and intermediate rail on the right side (as shown on page 32). Pry with moderate pressure moving intermediate and inner rails left at top end of upright.

l

l

l

Using a 0.020” feeler gauge, see if you can insert the shim between the roller and rail. There is to be some clearance but it is not to exceed0.040”. If the space between roller and rail will accommodate two or more shims, record the number of shims that will fit in the open space between rail and roller. Refer to chart on page 33. Now pry the intermediate rail away from the inner rail. Check clearance between the intermediate rail roller and the inner rail. Record the number of shims to be used on the outer and intermediate rails opposite the rollers checked.

Install C-Clamp at the location shown in the illustration on page 32. It may be necessary to use a block on the inside of the channel rail as shown. Tighten C-Clamp to displace roller clearanceon that side of the upright. Now, check roller clearance on opposite side of upright. Using a 0.020 inch feeler gauge, try to insert it between the roller and rail at point of roller contact as shown on opposite page. If a 0.020” will pass between roller and rail, and 0.040” will not fit between rail and roller, it is correctly adjusted. If the clearance exceeds 0.040”, refer to the chart on page 33. Record the number of shims to be used on the outer and intermediate rails opposite the rollers checked.

IMPORTANT

There is to be some clearance but it should not be less than 0.020” or more than 0.050”.

Dee 94

34-1-34

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

SM-587

Upright

GROUP 34 Checking Lower Rollers Now check the lower rollers in the same manner as you did for the upper rollers. l

Record the number of shims to be used on the outer and intermediate and inner rails opposite the rollers checked.

$T

C-Clamp

Bottom

Roller

View Check

Feeler Gauge

r

Point of roller contact

Inner Rail

Intermediate Rail t

Floor

SM-587

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

Dee 94

Upright

GROUP 34

Checking Upper Rollers with Upright Extended approximately one half of maximum lift. Check roller clearance in this area using the same procedure as before. Record the number of shims to be used on the outer and intermediate and inner rails opposite the rollers checked.

l

Top View

I

7

Rail

Roller

‘/

I

Shim Check

ROLLERS SHOULD BE ADJUSTED “LINE TO LINE” WITH 0.020” MINIMUM CLEARANCE

Adjustmentreferencechartwhenusingfeelergauge: ) Feeler

Stepl Gauge 1 ’ .020” .0.50” 2 / ,050” 1.080” 3 i .080” ’, .120”

Dee 94

34-l -36

)

Gauge will

i

PASS

1

not pass

j PASS 1 not pass

i

I Q check with a I Correctly

pass I not pass i

Shimmed

i

0

,; check with a! I 1 1 No, add

1

1 Yes

PASS

1

check with al

fnotpass

1

Noadd 3

1

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

f

2

SM-587

Upright

GROUP 34 -

Checking Lower Rollers with Upright Extended approximately one half of maximum lift. _..W_A_

*v-I*

~A”--.~~

A._

C...”

.

..“..

procedure as before. l

Record the number of shims to lx used on the miter 2nd intmnwdi~t~ w_.__

.+.._

^...“_-A.“UI.I

mfl inner a .

_.._.

. .

.

railc nnnnci+a ----v -rr .““.LC

the rollers checked.

Top View

Shim Check reeler tiauge

Point of roller contacT

ROLLERS SHOULD BE ADJUSTED “LINE TO LINE” WITH 0.020” MINIMUM CLEARANCE

Adjustmentreferencechartwhenusingfeelergauges ’ Feeler I

i

I

I

Gauge will

Shim

SteplGauge

Shimmed

I

lpass / not pass I Correctlv

’ I I

I QJ

1.050” I not pass

I check with a I I I I Yes I

I

I

; PASS

I I

SM-587

1

34-l -37 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

0

I

I Dee 94

Upright

GROUP 34

Checking Upper Rollers with Upright Extended to within 6” of maximum lift. Now chek roller clerance in this area using the same procedure as before. .

Record the number of shims to be used on the outer and intermediate and inner rails opposite the rollers checked.

Top View

Rail

I

1

------cf----AL

Fe&x Gauge

L

-1

Shim Check

r

ROLLERS SHOULD BE ADJUSTED “LINE TO LINE” WITH 0.020” MINIMUM CLEARANCE

I-

I

SteplGauee 1 j.020” I .050”

1

Pry Bar

Gauge will

I I pass

/ not uass

I

PASS

I ,

not pass

2 I .050” 1 PASS

f .080” 3

1.080”

f I I

I Pry Bar

’ I I

Shimmed

I

check with a i

I I

Correctlv

I Q

Yes

I checl

not pass

1 No, add

PASS

I 1

/.120” 1 notpass \\

Roller

Point of rot ler contact.

IFeeler I

bottom Insde

,7

0

1 I I

1

1

2

al

check with a

I No, add

I

I

/

L

Dee 94

34-l -38Material Copyrighted Intended for CLARK dealers only Do not sell or distribute

SM-587

Upright

GROUP 34 Checking Lower Rollers with Upright Extended to within @‘ofmaximum lift. Now chek roller clearance in this area using the same procedure as before.

Intermediate

Record the number of shims to be used on the outer and intermediate and inner rails opposite the rollers checked.

l

7

Top View ‘j Check

Roller

,

Point of roller contact.

ROLLERS SHOULD BE ADJUSTED “LINE TO LINE” WITH 0.020” MINIMUM CLEARANCE

IFeeler

Gauge will

;-Shimmed

ass / not uass 1 Correctlv 9-9

1 , .020”

I PASS

I .050" I not uass I

Pry Bar \

2: ;.050" ; PASS I.080" 1 not uass

3 ; .080”

I .120”

SM-587

34-l -39 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

;

PASS

I not pass

I

1

i

LQQ

check with a l

I Yes I 1

I I check with a I

0

No, add

1 I

1

check with a

I I

No, add

1

2

Dee 94

Upright

GROUP 34 Determine Number of Shims needed to make roller adjustments Refer to Step 3. Look at the three numbers you have recorded at each roller on the rails. The smallest of these numbers is the total number of shims to be added. A “0” means DO NOT add shims.

;nims = u.ubW 1 Etc.

If any of the rollers require adjustment, refer to adjustment procedures on next page. If the upright roller clearance was checked with

the upright mounted to the truck, and roller adjustment is required, remove the upright as outlined at the beginning of this section. Do not attempt to adjust shims with upright mounted on truck.

Rails Extended 6-l 0 inches

Rails Extanded approximately

Typical Illustration

l/2 wav

Dee 94

34-l -40

.0.040

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

-

0.060”

Rails extended to within 6-10 inches of maximum fork heiaht SM-587

Upright

GROUP 34

Shim Adjustment With the upright laying horizontal on blocking. Expose the rollers by pulling the rails part way out the bottom as shown in opposite illustration. Pull rollers (one set at a time) from their sheaves. Count the number of shims used on each shaft. Add shims as indicated in the roller clearance check. If the check indicates that an even number of shims are needed (2 etc), split the number between the right and left roller. If the check indicates that an oddnumberof shims are needed (1,3 etc), place the odd shim on the right shaft. Always keep the odd number of shims to one side. Your target for adjustment is to have the same number of shims at each roller set (right & left per rail assembly). An odd or extra shim must be placed on the same side as the one before.

,

Reposition eachrolleron it’sshaft using a plastic or hard-rubber mallet. Gently tap the roller to seat it evenly and snugly against the shims. Upper Roller Sets

9

Left Right *

Intermediate Rail

i 1 II

Left @

@

Lower Roller Sets

Typical Illustration

SM-587

Left

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

Dee94

lVl;~;~-i~Handling El!!!!Rl5

GROUP 34

Section 2 Pantograph & Fork Carriage Assembly Contents Safetyand Preparation . .. . . .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. 34-2-2 Remove Forks .. . .. .. . . .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. 34-2-4 Servicing Carriage . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. .. . ... .. .. .. .. .. 34-2-6 Servicing Pantograph Arm Rollers . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 34-2-9

+

Upright ‘oClra..h

kUpright r Inner

Arm

Outer Arm

Servicing the Pantograph The Pantograph Assembly may be serviced while installed in the upright with two exceptions: The carriaee rollers and the inner and outer arm bushinps must be serviced with the pantograph removed from the upright.

Refer to GROUP 34, Section 1 in this manual for adjustment and service procedures. SM-587

34-2-l

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

Dee 94

Pantograph

GROUP 34

A

WARNING

When using air pressure to clean off truck. Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.

A

WARNING

Hydraulic fluid is toxic to skin, eyes and respiratory tract. Good ventilation normally adequate.

is

0

q?gJ@&

A

WARNING

Remove all Jewelry before working on truck.

A

WARNING

Always wear Safety Glasses when working on truck.

Dee 94

34-2-2

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

SM-587

Pantograph

GROUP 34

Preparation .

Move truck to service area.

.

Park truck on a flat level surface.

.

Extend and lower pantograph.

.

Turn key switch OFF.

All Models

1. Remove Load Back Rest Extension . Remove bolts from LBR Extension and lift the extension free of the fork carriage. Bolt -l Torque Specification 17 - 190 Nom

2. EIevate and Block Pantograph.

(125 - 140 Ib.ft.)

.

Turn key switch ON and elevate pantograph approximately 3 to 4 feet.

.

Place oak blocking (hardwood) between pantograph carriage and fround. Lower pantograph until carriage rests on 4x4 blocking as shown here.

.

Tilt forks forward.

.

Turn key switch OFF and remove key.

.

Disconnect truck battery.

Fork Chriage

I II it

as shown. SM-587

34-2-3

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

Dee 94

Pantograph

GROUP 34 Standard Models Only 3.

Remove forks.

.

Remove fork lock pins and snap ring from the fork bar.

.

Now, remove fork bar from carriage and forks. Using a hammer and brass drift, drive the fork bar in direction of arrows until free of carriage and forks.

.

Remove forks.

A WARNING

Support forks as fork bar is removed so they cannot fall.

Side Shift Models Only 3A. Remove Forks. l

l

Snap Ring

Remove snap ring from fork bar (B). Remove fork lock pins from fork guides (C).

Side Shift Cylinde Fork Guide

34-2-4

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

SM-587

Pantograph

GROUP 34

Side Shift Models Only - continued -

A

l

WARNING

Support forks as fork bar is removed so they cannot fall.

l.

l

Drive fork bar (B) in direction of arrows (with a brass drift). When bar (B) is free of carriage, remove forks. Examine bushings in fork guides (C) for damage. If bushings are unfit for further service, install new bushings. Check fork bar (B) for burrs or excessive wear.

f-ork,Bar

(B) I

Pin

Fork Bar (B)

Connects to Side Shift Cylinder

SM-587

34-2-5

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

Dee 94

Pantograph

GROUP 34 SERVICING FORK CARRIAGE

Bushings

Dee 94

34-2-6

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

SM-587

GROUP 34

Pantograph SERVICING FORK CARRIAGE

1. Remove retainer bolt (1 & 2) securing

pivot shafts (3 & 4) in position.

? d.

Remove Roll pin (5) from Tilt Cylinder Rod End Mounting Shaft (6).

3. Using a brass drift, drive shaft (6) out of each bell crank (3A) freeing cylinder rod end from both bell cranks.

Bell Crank (3A) -

SM-587

34-2-7

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

Dee 94

Pantograph

GROUP 34 4. Using a brass drift, drive shaft (4) out of roller (4A) and bell crank.

_.’

:,

5. Now, drive shaft (3) outwardfree of bell crank (3A).Remove shaft and bell crank.

:

. .’

:

.,

‘,

.,

,, ;

r’

’ ,I’

,, -

,, ,. ‘. : i

0

Bushinas

6. Remove old bushings and press in new ones.

NOTE The bell crank with tilt roller (or block) may be removed as a subassembly. Removing shaft (3) will allowbothbellcrank(3A)&roller (4A) to be removed as a subassembly.

7.

Dee 94

\Shaft

(3)

Installation is the reverse of removal.

34-2-8

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

SM-587

Pantograph

GROUP 34

Fork Carriage Removal

Trucks Equipped with

Side Shift

Solenoid Valve

Fork Carriage Removal Side Shift Models Only 1. Remove cover bolts and cover (1).

2. Remove harness clamp (3) 3. Remove both cable and hose covers (4).. 4. Disconnect electrical plugs (2) from their connectors at the solenoid valve.

5. Disconnect hydraulic connections (5) from the solenoid valve. Cap open ports and connections. 6. Move each hose and wiring toward the rear of the pantograph and tie them out of the way at point (6) with tie wraps. SM-587

34-2-9

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

Dee 94

GROUP 34

Pantograph Fork Carriage Removal Models equipped with Tilt Only 1. Remove both cable and hose covers (4), see below. 2. Disconnect hydraulic connection (A) from the tilt cylinder.

All Models 3. Install lifting straps as shown to chain hoist equipped with safety hook. 4. Remove retainer bolts and pins (C) securing scissor arms to the fork carriage.

\*

5. Slowly elevate carriage until free of arms. Con-

* *\

tinue to elevate carriage until lower scissors rollers are free of carriage channels. Then set carriage to one side.

‘> *@)I I

b

Liftingztraps Safety Hook

Dee 94

34-2-l

0

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

SM-587

Pantograph

GROUP 34 SERVICING PANTOGRAPH ARM ROLLERS roller and thrust pad without removing scissor assembly from carriage.

Thrust Pads (Scissor Arm Roller “B or C”) 1. Disconnect reach cylinders. Refer to illustration on opposite page. Remove retainer bolts and pins (item “B”) securing reach cylinders to pantograph arms. 2. Refer to illustration on this page, lift reach arms (A) upward while pivoting arm (B) in direction shown by arrows. This will allow access to arm

3. Inspect the thrust pads for further service as shown below. Pads that are damaged or worn to their wear limit should be removed and new pads installed. 4. Remove Allen screw and pad. Install new pad. Be certain same number of shims are installed on shaft if they were removed.

Scissor Arm Roller “B & C”

When pad is worn near “Flush” with carriage roller, new pads should be installed.

rotating Arm “B” ( as shown) to move km roller upward and out of the carriage channel.

Be extremely careful that you do not “pinch” your hands or fingers. SM-587

34-2-l 1 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Upright

GROUP 34 \

Inner Arm Pivot Bearings

Pivot Bearing L Shield

Prepack bearing cup & cone assemblies prior to installation.

Nut (*) Install with chamfer towards nut lock. Torque to: 27 - 41 lN.m (20-30 Ib.ft.

NOTE

5. Disassemble the outer arm assembly.

If the Inner Arm Pivot Bearings need to bereplaced, the pantograph carriage must be removed from the upright. Refer to Group 34, Section 1.

6. Replace seals with new ones.

7. Wash bearings (cups & cones) in a Stoddard type cleaning solvent. Inspect parts for further serviceability. Replace any part that is nicked or having rough spots in the cones or cups. Cones and cups must be replaced together. Do not install a new cone in an old cup. 6

7. Reassemble to the reverse of disassembly. Lubricate parts with clean chassis grease

Check grease fitting for damage and to make certain none are missing.

prior to assembly.

IMPORTANT Prepack bearing cup & cone assemblies prior to installation Dee 94

34-2-l

2

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

SM-587

EMIRKlVl;t$;\Handling

GROUP 34

Section 3 Rail Lift Cylinder Overhaul Contents Disassembly ...................................................................................... 34-3-3 Inspection ............................................................. ............................. 34-3-4 Reassembly ................................... ...... ...... .. .... .................... .............. 34-3-5

Cylinder Removal Instructions are

Snap Ring -ba

Rail Lift Cylinder --)

\ Alignment Pin

SM-587

34-3-l

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

Dee 94

Lift Cylinder

GROUP 34

A

WARNING

When usina air pressure to clean off truck: Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.

Remove all Jewelry working on truck.

Always wear Safety Glasses

before

A

WARNING

Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is normally adequate.

A

CAUTION

Cleanliness isof extremeimportan ce. Beforedisconnecting hydrauliccomponents, clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system.

Dee94

34-3-2

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

SM-587

Lift Cylinder

GROUP 34

Disassembly 1. Wash exterior surface of cylinder thoroughly before disassembly. l

l

_-; _____--- A I

Wiper

I I

Seal

A soft fiber brush should be used to remove debris and foreign objects from grooves and threaded areas, etc.

, G3

0

Spring

Ian

A Stoddard type cleaning solvent should be used to wash the cylinder. 8

Plunger

Back-Up:

m) GI

1

Soft Fiber Brush

2. Place gland end of cylinder in a vise equipped with soft jaws. Do not over tighten. l

Using a bronze (or brass) drift, unlock the lockwasher fom the gland and the cylinder barrel.

I I

: :

Install i Back-Up & O-Rings

asshown.

Barrel

~

L

SM-587

34-3-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Lift Cylinder

GROUP 34 r Washer SnaD Ring7

Plunger

7 I r.

Spring ---Barrel

Piston Rod

Mounting LRing Groove

Washer L

Split Piston

Bleeder

L u-cup

3. Using a spanner wrench or a bronze (brass) drift, remove gland assembly from cylinder barrel. . .

End View

Remove lock washer, back-up ring and O-ring from cylinder gland

Cylinder Gland

Remove rod wiper and seal from cylinder gland.

4. Pull piston rod from barrel assembly. .

Remove spacer and split piston from piston rod.

5. Remove snap ring, retaining washer, plunger and spring from base end of piston rod.

Cleaning & Inspection 1. Discardold seals, O-rings, back-up rings, wiper and lock washer. 2. Wash remaining parts in a Stoddard type cleaning solvent and dry with a clean shop rag. 3. Inspect threaded parts for damage. 4. Examine the piston rod, inner surfaces of the gland assembly and cylinder barrel for scoring, nicks or scratches. A crocus cloth may be used to clean up light scratches, etc. Be careful that you do not remove the chrome plating when polishing surface.

Dee 94

5. Inspectsurfaceofthepistontobesuretitisclean, smooth and free of damage. l

Replace all damaged or unserviceable parts.

34-3-4 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Lift Cylinder

GROUP 34

Reassembly

Hydraulic

Piston Rod & Piston

Cylinder Seal Tool

Clark Part No.‘s: 1801783 and 1801784

1. Lubricate all parts with clean hydraulic fluid.

Avail from: Central Parts Divn.

2. Lubricate and install the spring, plunger, washer

7300 South Cicero Ave.

and snap ring into base end of the piston rod. Refer to illustration on page 34-3-3.

Chicago, Ill. 60629 Example

3. Lubricate and install spacer onto the piston rod. Refer to illustrtion on page 34-3-3.

4. Now, lubricate and place split piston onto the piston rod. Start piston rod into cylinder barrel and gently push rod inward until it bottoms out.

Be careful that you do not nick or scratch chrome surJace. Gland Assembly 1. Lubricate new seals, wiper ring and gland assembly with clean hydraulic fluid. 2. Install the inner seal into the gland groove. Be certain the sealing lip faces inward. Use tool shown in opposite column. Be carejiil that you

a’onot cut or nick the sealing lip upon installation. 3. Install a new wiper ring into the gland. 4. Lubricate and install a new O-ring and backup ring into the outer groove on the gland. Install lock washer on outside of gland. NOTE

Placing a plastic parts bag over the gland threads when installing the O-ring and back-up ring will help protect parts against damage, cutting, etc. 5. Now, carefully start the gland assembly over the piston rod and screw it into the barrel finger tight. Do not cut or nick sealing lips upon

installation. 6. Using a bronze (or brass) drift, tighten gland against barrel assembly. 7. Next, using drift as shown in opposite illustration, deform lock washer into the grooves provided in both the gland and barrel to securely lock them together. SM-587

34-3-5

Set Lock Washer into Grooves provided.

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

Dee 94

~#$?ri;\Handling CLSRK

GROUP 34

Section 4 Free Lift Cylinder Overhaul Contents Disassembly ......................................................................................

34-3-3

Inspection .......................................................................................... Reassembly ......................................................................................

34-3-4 .34-3-5

Cylinder Removal Instructions are covered in Group 34, Section 1.

SM-587

34-4-l

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

Dee 94

Lift Cylinder

GROUP 34

A

WARNING

When usina air pressure to clean off truck: Wear eye protection and protectiveclothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.

Remove all Jewelry working on truck.

before

Always wear Safety Glasses

A

WARNING

Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation normally adequate.

A

is

CAUTION

Cleanlinessisofextremeimportance. Beforedisconnecting hydrauliccomponents, clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system.

Dee 94

34-4-2

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

SM-587

Lift Cylinder

GROUP 34

Disassembly

I

Wiper

1. Wash exterior surface of cylinder thoroughly before disassembly. l

l

Scarf Cut Back-Up Ring

A soft fiber brush should be used to remove debris and foreign objects from grooves and threaded areas, etc. A Stoddardtypecleaning to wash the cylinder.

Install Back-Up & O-Rings as shown.

Seal F3 Q

solvent should be used

Washer

:

Soft Fiber Brush 2. Place gland end of cylinder in a vise equipped with soft jaws. Do not overtighten. l

Using a bronze (or brass) drift, unlock the lockwasher fom the gland and the cylinder barrel.

I-

SM-587

34-4-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

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

Lift Cylinder

GROUP 34

Reassembly

Hydraulic

Piston Rod & Piston

Cylinder Seal Tool

Clark Part No.‘s: 1801783 and 1801784

1. Lubricate all parts with clean hydraulic fluid.

Avail from: Central Parts Divn.

2. Lubricate and install wear ring onto the piston

7300 South Cicero Ave.

rod. Refer to illustration page 34-4-3.

Chicago, Ill. 60629

3. Now, start piston rod into cylinder barrel and

Example

gently push rod inward until it bottoms out. Be

careful that you do not nick or scratch chrome sueace. Gland Assembly 1. Lubricate new seals, O-rings, back-up rings, wiper ring and gland assembly with clean hydraulic fluid. 2. Install back-up ring and the inner seal into the gland groove. Be certain the sealing lip faces inward. Use tool shown in opposite column. Be

careful that you do not cut or nick the sealing lip upon installation. .

Lubricate and install (large) O-ring into the outer groove nearest top end of gland. NOTE

Placing a plastic parts bag over the gland threads when installing the O-rings and back-up rings will help protect parts against damage, cutting, etc. .

Next, lubricate and install a new back-up ring and O-ring into the outer groove at the base end of the gland.

3. Install a new wiper ring into the gland. 4. Now, carefully place the gland assembly over thepiston rod and, after applying lube to threads, screw it into the barrel finger tight Do not cut or

nick sealing lip(s) upon installation. 5. Using a bronze (or brass) drift, tighten gland against barrel assembly. 7. Next, using drift as shown in opposite illustration, deform lock washer into grooves provided in both the gland and barrel to securely lock them together.

SM-587

34-4-5

Set Lock Washer into Grooves provided.

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

Dee 94

Handling EMRKMaterial Company

GROUP 34

Section 5 Lift Fork Inspection Contents Inspection Procedure ........................................................................ .34-5-2 Fork Wear Caliper .......................................................................... ...34-S-2 For Inspection Illustrations .......................................................... 34-5-3 & 4

Lift Forks Shank

SM-587

34-5-l

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

Dee 94

Component

GROUP00 Inspection

FORK WEAR INSPECTION ITA Recommended Practices for the inspection and repair of Forks on Fork Lift Trucks require that a fork be removed from service when the thickness of the blade has worn by 10% of its original thickness.

l

The calipers should be squeezed by hand until the top jaws make contact with both sides of the shank.

forks can be checked for wear by using a

IMPORTANT

Fork Wear Caliper which is a “go-no go” gauge that

The amount of force used to squeeze the tips of the top jaw against the fork should be very slight as “caliper” distortion can occur if excessive force is used.

will clearly indicate when the fork does not comply with standards, The design of the caliper is based on the assumption that on a new fork, the cross section of the fork arm blade between the end of the taper and the heel is the same as the shank. Because the middle of the shank is not in contact with the top or bottom members of the carriage and therefore not subject to wear, it can be used as a reference point to set the calipers.

Care should be taken when using the calipers to hold them square across the shank or an incorrect reading will be obtained.

NOTE

Once the top (outside) jaws are set to the thickness of the shank, the calipers are then ready to check the blade of the fork.

Fork Wear Calipers (Clark Part No. 1803641) havetwomeasuringpointsorjaws(Figure page), they are:

1,opposite l

l

l

Set the top jaws by measuring the thickness of the shank, see Figure 2 (reference measurement).

Fork Wear Calipers The

Procedure

The outside or top jaws are used to set the calipers. The inside or lower jaws have been fixed at a point on the caliper legs that will always measure 10% less than the reading recorded by the top jaws (Figure 3, opposite page).

Check Fork Blade against Shank Thickness in the area shown in Figure 2. Carefully fit the caliper over the fork blade. Ifthe inside or lower iaws of the calipers pass over the flanks of the fork blade at any point between the end of the taper and the heel of the fork, the forks should be replaced.

Incorrect Readings Incorrect readings may be mistakenly made by accidentally altering the setting of the calipers when laying them down or when checking the blade. If is good practice to recheck caliper setting on the shank

each time before checking a fork blade. Accuracy in caliper measurement depends on the sense of touch. To get a delicate touch of the caliper on the fork, the caliper should be held lightly and not with a “grab grip.” With a little practice the required skills can be easily acquired.

Fork Wear most common cause of fork wear is when the fork is allowed to drag the floor due to misadjusted chains,chainstretch,tirewear,etc.Carriagechainsshould beadjustedso theforkis 1/2”offthefloorasmeasured at the heel of the fork. The area that fork wear usually appears is illustrated in Figure 4. The

Dee 94

34-5-2

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

SM-587

GROUP 34 Fork Wear Caliper

Area of Fork Shank to be measured as

Clark Part Number 1803641

t

f Area of Fork Blade to - be measured for wear.

Figure 2

Figure 3

Cross Section

Figure 4

Fork Blade

Area of Typical Fork Wear

SM-587

34-5-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee94

GROUP

00

Component

Inspect Fork Condition l

The fork top surface should be level and even with each other. The height difference between both fork tips should be no more than 3% of the fork length.

l

Inspect forks for cracks, breaks, bending and wear.

r

3% of “B” Maximum Difference

... __..._._.-..._..__._________ ...._ ....~......._._ .......__. .. -

/

have them bent or damaged, inspected by a trained maintenance person before operating the

1” Maximum ‘-,

Inspect Forks for Twists and Bends l

l

l

+ForkT’ps

Carpenter Square

Place a 2” thick metal block, at least 4” wide by 24” long on the blade of the fork with the 4” surface against the blade. Put a 24” carpenters square on the top of the block and against the shank.

Check the fork 20” above the blade to make sure it is not bent more than 1 inch maximum.

Dee94

34-5-4

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

SM-587

CMRH~de;dx\Handling

GROUP 34

Section 6 Upright Chain Inspection; Adjustment & Replacement Contents

Periodic Inspections .. . ... ... .. .. .. .. .. .. .. ... .. .. ... .. .. .. ... ... .. .. .. .. .. .. .. .. .. .. . .. ... .. . . 34-6-2 Chain Length Adjustments . .. .. .. .. .. .. .. .. ... .. .. ... . ... .. .. .. .. .. .. .. .. .. .. . ... .. .. . . .. . 34-6-3 Triple-Stage Upright (TSU) Chain Length Adjustments . .. .. .. .. .. .. . ... .. .. 34-6-4 Chain Lubrication .. . ... . .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . ... .. .. .... .. .. .. .. .. .. .. .. . . .. .. ... . .. . 34-6-6 Chain Removal and Replacement . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . . 34-6-6 General Guidelines . .. .. .. .. .. .. .. .. .. .. .... .... .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . 34-6-6 Lift Chains . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. . 34-6-6 Primary Cylinder/Carriage Chains (T.SUs) . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 34-6-7 Other Chain Service Notes . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 34-6-7

Primary Cylinder Piston Head 111))

Chain Anchor W

Typical Illustration

SM-587

34-6-l

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

Dee94

Chains

GROUP 34 Periodic Inspections Each 50-250 hours of operation (more frequently in severe or extreme environments), chains should be inspected and lubricated. Inspection should focus on the following:

Elongation When a length of 12.00 inches (305 mm) of a new chain has elongated to a length of 12.360 inches (315 mm), it should be discarded and replaced. It is important to measure the chain in the section that moves over the sheaves becauseit receives themost frequent articulation Measuring the chain near its clevis terminals could give an erroneous reading as it would not have flexed as frequently, if indeed at all, as nearer the middle of the assembly.

allowed to operate in this condition, a pin, or series of pins, canbegin to twist out of a chain resulting in failure. The pin head rivets should be examined to determine if the TEE” flats are still in correct alignment. Chain with rotated/displaced heads or abnormal pin protrusion should be replaced immediately. Do not attempt to repair the chain by welding or driving the pin(s) back into the chain. Once the press fit integrity between outside plates and pins has been altered, it cannot be restored. Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system. Thisconditiondamagesthechainandincreasesfiictional loading, and should be corrected.

Turned pins and abnormal pin protrusion. Chains should be replaced when wear exceeds 3% of the pitch or when I2 inches (305 mm) of chain is stretched 318 inch (IO mm).

Edge Wear Check the chain for wear on the link plate edges caused by running back and forth over the sheave. The maximum reductionofmaterial shouldnotexceed5%.Thiscanbe compared to a normal link plate height by measuring a portion of chain that does not run over the sheave. Distorted or battered plates on leaf chain can cause tight joint and prevent flexing.

k5X

of

The chains should periodically be inspected very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, thechain wouldbereplaced. Itisimportant,however, to determine the causes of the crack before installing new chain so the condition does not repeat itself. . Fatigue Cracking - Fatigue cracks are a result of repeated cyclic loading beyond the chains endurance limit. The magnitude of the load and frequency of its occurrence are factors which determine when fatigue failure will occur. The loading can be continuous or intermittent (impulse load).

G3

H

Worn contours and worn sulfates on the outside links or pin heads should not exceed 5% of new link height.

Turning or Protruding Pins Highlyloadedchainopemtedwithinadequatelubncation can generate abnormal frictional forces between pin and link plates. In extreme instances, the torque could surpass the press fit force between the pins and the outside plates, resulting in pin rotation. When chain is Dee 94

Cracked Plates

Fatigue cracks generally run from the pin hole toward the edge of the link plate approximately 90” from the line of pull.

Fatigue cracks almost always start at the link plate pin hole (point of highest stress) and are perpendicular to the chain pitch line. They are often microscopic in their early stage. Unlike a pure tensile failure, there is no noticeable yielding (stretch) of the material.

34-6-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Chains

l

GROUP 34

Stress-Corrosion Cracking-The outsidelinkplates, which are heavily press fitted to the pins, are particularly susceptible to stress corrosioncracking. Like fatigue cracks, these initiate at the point of highest stress (pin hole) but tend to extend in an arclike path between the holes in the pin plate.

Ultimate Strength Failure This type of failure is caused by overloads far in excessof the design load.

Broken plate caused by overload.

Tight Joints Arc-like cracks in plates are a sign of stress corrosion.

More than one crack can often appear on a link plate. In addition to rusting, this condition can be caused by exposure to an acidic or caustic medium or atmosphere. Stress corrosion is an environmentally assisted failure. Two conditions must be present: a corrosive agent and static stress. In the chain, static stress is present at the pin hole due to the press fit pin. No cyclic motion is required, and the plates can crack during idle periods. The reactions of many chemical agents (such as battery acid fumes) with hardened steel can liberate hydrogen which attacks and weakens the steel grain structure. For this same reason, never attempt to electroplate a leaf chain or its components. The plating process liberates hydrogen, and hydrogen embrittlement cracks will appear. These are similar in appearance to stress corrosion cracks. If a plated chain is required, consult Clark. Plated chains are assembled from modified, individually plated components which may reduce the chain rating. l

Corrosion Fatigue - Corrosion fatigue cracks are very similar (in many cases identical) to normal fatigue cracks in appearance. They generally begin at the pin hole and move perpendicular (90”) to the chain pitch line.

All joints in leaf chain should flex heely. Tight joints resist flexure and increase internal friction, thus increasing chain tension required to lift a given load. Increased tension accelerates wear and fatigue problems.

If lubricationdoes notloosena tightjoint,thechainmayhave corrosion and rust problems or bent pins and must be replaced.

Chain Length Adjustments

A

An upright or unexpectedly: l

l

l

l

l

Corrosion fatigue is not the same as stress corrosion. Corrosion fatigue is the combined action of an aggressive environment and a cyclic stress (not a

static stress alone, as in stress corrosion).

WARNING

l

carriage

can

move

Do not walk or stand under raised forks. Keep clear of load and carriage when making any check or adjustment. Keep your arms and fingers away from moving parts of the upright. Block the carriage or upright when working with the components in a raised position. Do not reach through open areas of the upright. Never attempt to move or align the rails by hand. Use a prybar.

Failure to follow these warnings can result in serious injury. SM-587

34-8-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Chains

GROUP 34 IMPORTANT

Triple-Stage Upright (TSU) Chain Length Adjustments

For all chain adjustments: l

l

l

l

Threaded chain anchors must be left free to pivot in mouting hole. Anchor cotter pin heads must be to the inside of the upright. Torque jam nuts to adjustment nuts to 100-200 Nom (74-l 48 ft-lb). Make sure chain anchors are secured so that no twist is evident in the chains.

Triple-stage uprights use two chain sets; one set for carriage lift and one set for rail lift. Adjustment anchors for the lift cylinder stage are located at the back of the outer rail. Adjustment anchors for the primary lift stage are behind the primary cylinder. Carriage chain anchors are not intended for adjustment. For TSU inner rail lift chains, chain length must be adjusted if the difference between the bottom of the inner rail and the outer rail is greater than 10 mm (0.40 in). For the TSU primary cylinder lift chain, the chain length must be adjusted if: The fork-to-ground clearance is less than 5 mm (0.20 in) or more than 25 mm (1.0 in) when the upright is vertical. The center of the bottom carriage roller comes within 20 mm (.80 in) of the bottom edge of the inner rail. The carriage safety stop hit the inner rail stop at full lift height. To adjust the cylinder lift chains on a TSU use the following illustration and procedures: l

IMPORTANT

l

The carriage stop must not be allowed to contact the upright stop under any circumstance during normal operations.

Dee 94

l

34-6-4 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Chains

GROUP 34 IMPORTANT For all chain adjustments: l

l

l

Threaded chain anchors must be left free to pivot in mounting hole. Anchor cotter pin heads must be to the inside of the upright. Torque jam nuts to adjustment nuts to 100-200 Nom (74-l 48 ft-lb).

. Make sure chain anchors are secured so that no

twist is evident in the chains. Adiust chain length h LTo

inner rail

1. Set the upright in the vertical position. 2. Break the jam nuts loose on the chain anchors. 3. Adjust the chain anchor adjustment nuts until the bottom of the inner rail is within 2.5 mm (0.10 in) of the bottom of the outer rail. To adjust the primary cylinder lift chain on a TSU use the following illustration and procedures:

2. Carriage roller position: a. Raise carriage about 1 m (3.2 ft) and smear a bead of grease on the bottom 75 mm (3 in) of the inner rail in the area of the roller pattern. b. Tilt upright fully back and completely lower. C. Measure the distance from where the center of the bottom carriage roller stopped to the bottom edge of the inner rail. Distance should not be less than 20 mm (0.80 in) or chain length adjustment is required. 3. Carriage stop-to-upright: a. Lift upright to its full height and check for clearance on the carriage safety stop. b. If the carriage stop hits the upright stop, adjust the chain anchor adjustment nuts out until there is at least 3 mm (0.12 in) clearance between the stops.

IMPORTANT The carriage stop must not be allowed to contact the upright stop under any circumstance during normal operations. If all three chain length requirements listed above cannot be met,thetirediametermaybeoutofthedesignrangeallowance. Also, excessive tire wear will decrease carriage stop clearance.

Adjust chain length hereTo carriage

1.

Fork-to-ground clearance: a. Set the upright to vertical position. b. Break the jam nuts loose on the chain anchors. c. Tumthechainadjustmentnutsuntilclearancebetween forks and ground is lo-20 mm (0.40-0.80 in)

SM-587

34-65 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Chains

GROUP 34 General Guidelines

Chain Lubrication Like all bearing surfaces, the precision-manufactured, hardened-steel, joint-wearing surfaces of leaf chain require a film of oil between all mating parts to prevent accelerated

Chain Movement - Make sure that the chain operating path is clear and that the chain articulates freely through its full range of operation.

WM.

Maintaining a lubricant film on all chain surfaces will: Minimize joint wear. Improve corrosion resistance. Reduce the possibility of pin turning. Minimize tight joints. Promote smooth, quiet chain action. Lower chain tension by reducing internal friction in the chain system. Laboratory wear tests show #40 oil to have greater ability to prevent wear than #lO oil. Generally, the heaviest (highest viscosity) oil that will penetrate the joint is best. l

Lubrication - Assure that the chain is well lubricated with the heaviest oil that will penetrate the void between the link plate apertures and the pins.

l

l l

Paint - Make sure the chain does not get painted over at any time.

l

l

Whatever method is used, the oil must penetrate the chain joint to prevent wear. Applying oil to external surfaces will prevent rust, but oil must flow into the live bearing surfaces for maximum wear life. To prepare the chain for oiling, the leaf chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that oil may penetrate the live bearing area.

Protection - Where necessary, as a protection from atmosphere or sliding wear, the chain may be covered with a layer of grease. It should be noted, however, that the grease will have to beremoved at a later date for chain inspection and relubrication. Chain Mountings - Double check to be sure all chain fastening devices are secured and all adjustments have been made to assure uniform loading of multiple chain applications. Check chain anchors and pins for wear, breakage and misalignment. Damaged anchors and pins should be replaced. Sheaves - Sheaves with badly worn flanges and outside diameter should be replaced. This wear may be due to chain misalignment or frozen bearings.

Oil may be applied with a narrow paint brush or directly poured on. Chain should be well flooded to be sure the oil penetrates the joint. In locations difficult to reach, it may be necessary to use a good quality oil under pressure such as an aerosol can or pump pressure spray.

Lift Chains (Standard and TSUs) To remove and replace the lift cylinder and/or carriage chain set on standard and triple-stage uprights (TSU):

Chain Removal and Replacement

A

1. Attach a hoist strap on the carriage of the standard upright or inner rail of the TSU.

WARNING

The procedures for removing and replacing chain set involve hoisting and blocking components. Do not walk or stand under raised forks. Keep your arms and fingers away from moving parts of the upright. Do not reach through open areas of the upright. Failure to follow these warnings can result in serious injury. See “Lifting, Jacking and blocking” for safe blocking procedures. Dee 94

2. Lift the carriage or inner rail slightly to create slack in the chains. Block the carriage or inner rail up for safety. 3. Remove the chain anchor pins on the outer rail and pull the chains off of the sheaves on the inner or intermediate rails.

4. Remove the chain anchor pins from the carriage on the standard upright or the inner rail on the TSU. On the TSU, the inner rails must be lowered to the floor to access the chain anchor pins.

34-6-6 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Chains

GROUP 34 Other Chain Service Notes

NOTE

If a hose adapter is used, the chain sheaves must be loosened and removed to prevent the hoses from stretching when the inner rails of the TSU are lowered to access the chain anchor pins.

.

5. Use the steps in reverse order to replace the lift chain set.

Use lengths of factory assembled chain. Do not build lengths from individual components.

.

Do not attempt to rework damagedchains by replacing only the components obviously faulty. The entire chain may be compromised and should be discarded.

.

Never electroplate assembled leaf chain or its components. Plating will resultin faihrre from hydrogen embrittlement. Plated chains are assembled from modified, individually plated components. Welding should not be performed on any chain or components. Welding spatter should never be allowed to come in contact with chain or components.

Primary Cylinder/Carriage Chains (TSUs) 1. Tilt the upright forward, lower it and completely collapse the primary cylinder to create slack in the chains. The carriage may also be lifted and blocked in position and the primary cylinder completely collapsed to create slack in the chains.

Leaf chains are manufactured exclusively from heat treated steels and therefore must not be annealed. If heating a chain with a cutting torch is absolutely necessary for removal, the.chain should not be reused.

2. Remove the chain anchor pins from the back of the primary cylinder. Pull the chains through the chain sheave and lay over the carriage load backrest. 3. Remove the chain anchor pins from the back of the carriage. 4. Use these steps in reverse order to replace the primary cylinder/carriage chain. Perform the chain length adjustment and chain tension check before returning the truck to service.

SM-587

34-6-7 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

El!!YRK

Material

Company

Handling

GROUP 35 Section 1 Load Wheels Contents

.13- 1-2 Remove & Replace.. ......................................................................... 13-1-2 .......................................................................................... Inspection Installation and Lubrication ............................................................... 13-1-2

Articulating

Always wear Safety Glasses

Remove all Jewelry before working on truck.

SM-587

Axle 2

35-1-1

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

Dee 94

Load Wheels

GROUP 35 LOAD WHEELS Remove & Replace Prenaration 1. Park truck on a flat level surface. 2. Disconnect battery andremove key from switch. 3. Elevate outrigger approximately 3-inches and block in this position.

levate 3-inches and block outrigger here

Removal 1. Remove snap ring and shim(s) from each axle.

4. Install rocker arms. Point on rocker arm must face downward.

IMPORTANT Note the number of shims used on each shaft so that the same number is used at reassembly. These shims are used to properly locate the” load wheel subassembly” so that the wheels do not rub against the outrigger.

After load wheels androcker arms are installed, locate a “C” clamp near the rocker arm pivot pin and tighten slightly.

2. Pull rocker arm shafts out of the wheels and outrigger.

IMPORTANT

3. Remove load wheels.

IMPORTANT

5. Install snap ring on each rocker arm shaft. Always use new snap rings. Install snap ring so the sharp edge is located away from the rocker arms.

Inspection 1. Wipe bearings clean. Remove grease, dirt and debris from bearings. .

2. Rotate bearing by hand. Note any rough spots while rotating bearing.

6. Clean any dirt and grime from the grease fittings and grease wheel bearings until the grove between bearings is full. l

Elevate outrigger and remove blocking. Lower outrigger until load wheels are flat on the floor.

3. Examine seals for signs of damage. Bearing 4. Replace bearings that have rough spots or damaged seals. 5. Examine grease fittings to be sure that they are in place and not damaged.

Load Wheel,

1

Installation & Lubrication 1. Install new bearings into wheels.

IMPORTANT Extruded edge of bearing must face outward. 2. Fill groove between bearings with grease. 3. Locate wheels in outrigger with extruded side (seal side) of bearing facing outward.

Dee94

35-1-2

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

SM-587

~lt&ria:Handling CLSRIC,

GROUP 40

Specif icatio ns N -345 Narrow Aisle Electric Stand-Up Rider Reach Trucks

Wiring is Color Coded Color Code Black

0

Example Reference Wiring Schematic

Brown 1 Red

2

Grange 3 Yellow 4

Wire No. 6 is a Solid Blue Wire.

Green

5

Wire No. 13 is a orange wire with a brown stripe.

Blue

6

Wire 33 is a solid orange wire.

Violet 7 Gray

8

White

9

Note Data listed on the following pages is based on: N-PR-17

3500 lbs (1600 kg) @ 24-inch (600 mm)

NPR-20

4000 lbs (1800 kg) @ 24-inch (600 mm)

198” MPH Upright, with or without sideshift as noted. 42.0” Forks Hvdraulic Performance and Pressure Checks published herein is with Clark MS-68 Hydraulic Fluid @ Operatering Temperature of 120” F.

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

GROUP 40

Specifications, Truck

Ikavel Speeds with Capacity Load N-PR-17 with 170 & 198 MPH Uprights:

5.8 mph 24-Volt Models

6.7 mph 36-Volt Models

NPR-20 with 210MFH Uprights

5.7 mph 24-Volt Models

6.6 mph 36-Volt Models

6.3 mph 24-Volt Models

7.2 mph 36-Volt Models

:

navel Speeds without Load NPR-17 & 20 with all MPH Uprights:

Performance may vary +5% and -10% due to motor and system efficiency tolerance. The performance shown represents nominal values obtained under typical operating conditions.

Lift Speeds with Capacity Load (MS68 Hydraulic Fluid should be at operating temperature 120°F. when making test.) NPR-17 with 170 & 198 MPH Uprights:

42 fpm 24-Volt Models

62 fpm 36-Volt Models

NPR-20 with 210,240,258

40 fpm 24-Volt Models

60 fpm 36-Volt Models

& 270 MPH:

Lift Speeds without Load (MS68 Hydraulic Fluid should be at operating temperature 120°F when making test.) 65 fpm 24-Volt Models

NPR-17 & 20 with all MFH Uprights:

95 fpm 36-Volt Models

Lowering Speeds with Capacity Load:

80 fpm ( all models and uprights)

Lowering Speeds with out Load:

90 fpm ( all models and uprights)

(MS68 Hydraulic Fluid should be at operating temperature 120°F. when making test.) r

Wheels & Tires (Type & Size) Drive/Steer:

13.5 x 5.5” Rubber 13.0 x 5.5” Polyurethane

Nut Toraue: 168 - 188 Nm (124-139 lbf. ft.) Nuts must be tightened using diagonal sequence shown here.

1 Load Tires: Articulated

5 x 3.76” Polyurethane 5 x 3.01” Polyurethane

Single

10.5 x 4.5” Polyurethane

/

Caster (Stabilizer): 8.0 x 4.0” Polyurethane

Dee 94

40-l -2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 40

Specifications, Truck

r Fork Stwead 33” Wide Pantograph

37” Wide Pantograph

33” Wide Pantograph with Sideshift Forks 37: Wide Pantograph with Sideshift Forks

2

3

4

330.6n-m

577nx-n

682mm

787mm

13”

22.73”

26.86”

31”

330.6mm

574.6mn-r

677.6nx-n

784mm

889mm

13”

22.62”

26.68”

30.87”

35”

482.6mm

582.6mm

677.6mn-1

19”

22.94”

26.68”

559mn-l

703mm

22”

27.68”

1

I

5

Reference numbers relate to Adjustment-Pin Holes (l-5), see below.

FORK SPREAD

939.8mm (37’‘)Wide Pantograph 838.2mm (33”)Wide Pantograph

101.6mm (4.00”) y

9

Or

t

Top View

NOTE

All dimensions are in inches unless otherwise specified. NPR- 17 Data is based on 3500 lb. load, 42.0” forks, 198” MFH Upright with no sideshift. NPR-20 Data is based on 4000 lb. load, 42.0” forks, 198” MFH Upright with no sideshift.

SM-587

40-l Material -3 Copyrighted Intended for CLARK dealers only Do not sell or distribute

Dee 94

GROUP 40

Specifications, Truck

A

B

C

5232mm

4318nx-n

1814kg

2260mm

2209mm

206”

170”

40001bs

89”

87”

5943mIn

5029mn-l

1814kg

2260mm

2209mm

1372mm

814kg

449kg

234”

198”

4OOOlbs

89”

87”

54”

17951bs

18001bs

6248nxn

5334nxn

1814kg

2413mm

2362mm

1524mm

853kg

449kg

246”

210”

40OOlbs

95”

93”

60”

18801bs

18OOlbs

701Omm

6096mm

1814kg

2718m.m

2667mm

1828nx-n

982kg

449kg

276”

240”

4OOOlbs

107”

105”

72”

21651bs

18OOlbs

7468mm

6553mm

1588kg

2870mm

2819mm

1981mm

1069kg

449kg

294”

258”

35001bs

113”

111”

78”

23571bs

18OOlbs

D

E

t

t

7772mm

6858mm

1361kg

3022mm

297 lmm

2134nx-n

1108kg

449kg

306”

270”

30001bs

119”

117”

84”

24431bs

18001bs

A B C D E F

Overall height (less load back rest extension) Maximum Fork Height Maximum Capacity @ 600 mm (24 inch) Load Center Overall down height Rail length Maximum Free Lift (Fork Height)

Refer to Dimensional Chart on the opposite page.

Dee 94

40-l -4 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Specifications

GROUP 40

- Truck

Refer to Chart o n opposite

page.

1219.18mm (48.00”) Load Backrest Extension

I

Pantoiraph Extended

........ :...... .

I

+

Pantograph Retracted

I

B/C

-e I .

..---

Roller(s)

-2

...~~ I,.. ,.,.,.,.,.... .. ., ~,.,,..,,...,.,.,.,.,... :::.!..

x.: .....

..x ;,y,.,‘::::~:‘.‘,:.:

==-I+

E

.I

.

.

.

.

.

.

.

.

..A A.

3”

F

1

50.8mm 38.4mm

t

(2.00”) f (1.51

‘I) J

Center of roller to bottom of inner rail. SM-587

40-l -5 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

GROUP 40

Specifications

Truck

-

Overall Dimensions Ground Clearance minimum with 4” Dia. Load Wheels:

1.OO”

Ground Clearance minimum with 5” Dia. Load Wheels:

1.75”

Ground Clearance minimum with 10.5” Dia. Load Wheels:

1.75”

Length to fork face (13.38” & 13.88” Battery Compartment Width):-

47.9”

Length to fork tip (16.13” Battery Compartment Width):

50.1”

Turning Radius: Outside:(13.38” & 13.88” Battery Compartment Width):

66.5”

Inside: (13.38” & 13.88” Battery Compartment Width):

36.9”

Outside:(16.13” Battery Compartment Width):

68.7”

Inside:(16.13” Battery Compartment Width):

36.9”

Width:

53.0”

Battery Compartment Size

Maximum Battery Size

Min. Weight

N-PR-17

38.75” W x 13.38” L x 32.0” H

38.69” W, 13.00” L, 31.5” H

1400 pounds

NPR-17 & 20

38.75” W x 13.88” L x 32.0” H

38.69” W, 13.50” L, 31.5” H

1590pounds

NPR-17

38.75” W x 16.13” L x 32.0” H

38.69” W, 15.75” L, 31.5” H

1885 pounds

(Maximum size including cover if required)

Battery T-e

- Lead-Acid Canacity (6hr. rate) Maximum: KWH (6hr. rate) Maximum

NPR-17 Bat. Comnartment Max. Capacity Max. KWH Rating

Min. Weight lbs.

NPR-20

Dee 94

108.5- 24V 25.1

1240 - 24V / 775 - 36V 28.9 - 24V 127.0 - 36V

1400

1395-24V/980-36V. 32.3 - 24V / 34.0 - 36V

1885

1590

(Battery Compartment Length x Width X Height)

Bat. Compartment Max. Capacity Max. KWH Rating Min. Weight lbs.

Steering

(Battery Compartment Length x Width X Height) 38.75 x 16.13 x 32 38.75 x13.38 x 32 38.75 x 13.88 x 32

Type:

38.75 x 13.88 x 32

I

38.75 x 16.13 x 32 1395 - 24V / 980 - 36V 32.3 - 24V 134.0 - 36V

1240 - 24V / 775 - 36V 28.9 - 24V / 27.0 - 36V

1885

1590

Hydraulic Assist

Turns (Lock to Lock):

40-l -6 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

4.25

SM-587

SDecifications

-

GROUP 40

Truck

Lift Cylinder Downdrift Test (Make test withfluidMS-68at operatingtemperature120’F.)

Cvlinder drift should not exceed

Mark Rail

e

Check drift here

1.0 inch in a five minute period.

Test Load: a capacity load evenly distributed on lift forks. (If a pallet is used, load should not extend beyond pallet. Load should be stacked to provide maximum stability.) Forks must completely engage load and be adjusted as wide as possible to provide even distribution of weight.

-

48 x 48 Pallet

t

Elevate Carriage & Load 1O-l 5 inches and approximately 1’ in Back tilt.

Tilt Cylinder Drift Test Pantograph w/ Tilting Carriage

(MaketestwithfluidMS-68atoperatingtemperature120°F.) Cvlinder drift should not exceed ref. 1

0.040 inch in a five minute period.

ref. 2

0.1 degree in a five minute period.

Test Load: a capacity load evenly distributed on lift forks. (If a pallet is used, load should not extend beyond pallet. Load should be stacked to provide maximum stability.) Forks must completely engage load and be adjusted as wide as possible to provide even distribution of weight.

SM-587

Checking drift at Forks

Elevate carriage and load 12 to 15 inches and place mast in full back tilt postion.

40-lMaterial -7 Copyrighted Intended for CLARK dealers only Do not sell or distribute

Dee 94

GROUP 40

Specifications

-

Truck

Service/Parking Brake(s) Spring

Applied and Hydraulically Released. Brakes must be capable ofholding truck, with

a full rated capacity load on a 15% grade minimum. .:.:,:,::::::

Brake PedEiI i

rPedal

Uo_Heiaht

112.5 mm (4-7/16”)

41

Master Cylinder(s) One cylinder connects to the Motor Brake.

I

170 - 190 Nom (125~1401bfft)

IMPORTANT Apply1802397 (Anti-Seize) to motor shaft, bore and

20 (177

Dee 94

Install bolts using Loctite 242 on threads.

25 Nom 221 Ibf. in.)

-

40-l -8 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 40

Sr>ecifications - Truck

Brake OFF

BrakeON

BrakeOFF

_____-_

L

Brake ON

l-

\

114”-

Cover

Brake OFF

must be

in place at all times to provide required

Typical illustration

SM-587

40-l -9 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee94

GROUP 40

Specifications

-

Truck

Caster Brake

Brake Swing: SDecification l

A correctly adjusted Brake Pressure Spring: 2-l/4-inches as measured between washers (spring in the applied positioned). Refer to opposite illustration. (1) Pressure Spring Adjustor (2) Jam Nut (Locking Nut)

Caster Wheel Assembly

Tighten Sequence (Caster Brake Mounting Bolts)

Brake Assembly Mounting SDecification l

1

Install Capscrews using General Purpose Threadlocker (Clark #1802300) and torque to 25 lb.ft. (34 N*m), using a diagonal tightening sequence shown in opposite illustration.

Dee 94

40-l -10 Material Copyrighted Intended for CLARK dealers only Do not sell or distribute

SM-587

Specifications

GROUP 40

Truck

-

ELECTRICAL SYSTEM SPECIFICATIONS Voltage

24V

36V

IA Free Wheeling Drive Motor Current

50 TO 60 AMPS

40 TO 50 AMPS

Lift Pump Motor @ By-Pass (MS-68 OIL @ 120” F)

490 TO 510 AMPS

520 TO 540 AMPS

95 TO 105 AMPS 95TOll5AMPS

60 TO 70 AMPS 90TOllOAMPS

Steer / Auxiliary Pump Motor @ By-Pass (MS-68 OIL @ 120” F) Operating Aux Function Operating Steering

Ground Tests (New & Used Trucks)

“20,000 OHMS MINIMUM”

Meter set on Rx10,OOOScale, measure from Negative battery connector to truck frame.

Solid State Traction Control Specifications Type System Voltage Low Voltage Cut-Off Accelerator Input Voltage

Speed Control

Transistor 24 OR 36 VOLTS D.C. 16 VOLTS D.C. 3.5V TO 0.2V Controlled Thermal Cut-Back 194” F. Solid State

Solid State Steer Control Specifications Type System Voltage Low Voltage Cut-Off Controlled Thermal Cut-Back

Transistor 24 OR 36 VOLTS D.C. 16 VOLTS D.C. 194°F.

Solid State Solenoid Control System Voltage Low Voltage Cut-Off

Lift Motor Control Motor Diameters

24 OR 36 VOLTS D.C. 16 VOLTS D.C. Contactor

(

Inches

)

Drive (Traction ) Motor Lift Pump Motor Steer/Auxiliary Pump Motor

SM-587

40-l Material -11 Copyrighted Intended for CLARK dealers only Do not sell or distribute

6.7 8.0 6.4

Dec94

GROUP 40

Specifications

-

Truck

Hydraulic System Specifications 24 Volt LifI Pump

TYPe

Gkar

10.1

@RPM

1185

1720

@ Pressure (PSI)

1910

2020

2650 - 2750 @ 8.5 GPM

Steer /Auxiliary Pump

G&r

Return Line

Reservoir Breather

2.4

2.5

@RPM

2130

2200

@ Pressure (PSI)

1000

1000

1550 - 1650 @ 1.9 GPM

/

Lift Control

I

Auxiliary Control

Spool

I

I

TYPe

Cleanable 100 Mesh SS Screen

Micron Rating

149 Absolute

TYpe

Cleanable 30 Mesh SS Screen

Micron Rating

533 Absolute

TYpe

10 Micron Cellulose Spin On

beta Rating

beta 5=2, beta 13=20, beta 17=75

TYPe

10 Micron Cellulose Push On

Micron Rating

10 Nominal

___.-

---____

[System Reservoir Capacity (Gallons)

7.7 -1

Hydraulic Fluid

MS68

Dee 94

‘-1

Flow (GPM)

1Relief Valve Setting (PSI)

Fill Strainer

System Volta e

Type

_

Suction Strainer

------I

6.9

24 Volt

Hydraulic Valve

36 Volt

Flow (GPM)

1Relief Valve Settinp (PSI)

Filters

System Voltage

40-l -12 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 40

Specifications - Truck

Critical Fastener Torque Specifications [Tightening Torque WET, SAE 301 example Artculating.Axle

Mounting Bolts

60 Ib.ft. (81 N*m)

(Refer to illustration in Group 22, Section 1, Page 2)

Articulating Axle Stop Bolt Set Screw

35 Ib.ft. (47 Nom)

(Refer to illustration in Group 20, Section 1, Page 2)

Brake Assy to Drive Motor Bolts (Diagonal Sequence)240 - 270 lb. in. (27 - 31 N*m) (Refer to illustration in Group 23, Section 1, Page 4)

Brake Drum to Drive Motor Shaft Nut

(125 - 140 lb.ft. (170 - 190 Nom)

(Refer to illustration in Group 23, Section 1, Page 4)

Drive Motor Mounting Bolts

25 lb.ft. (34 Nom)

(Refer to illustration in Group 20, Section 1, Page 2)

Drive Unit to Axle Mounting Bolts

74 - 81 lb. ft. (100 - 110 N*m)

(Refer to illustration in Group 20, Section 2)

Drive Wheel Mounting Bolts (Diagonal Sequence) -124 - 139 lb.ft. (168 - 188 N*m (Refer to illustration in Group 22, Section 1, Page 2)

Truck to Upright Mounting Bolts w Lower

375 lb.ft. (508 N*m)

(Refer to illustration in Group 34, Section 1, Page 14)

Truck to Upright Mounting Bolts w Upper

200 lb.ft. (271 N*m)

(Refer to illustration in Group 34, Section 1, Page 14) Load Backrest Extension Mounting Bolts

125 - 140 lb.ft. (170 - 190 Nom)

(Refer to illustration in Group 34, Section 2, Page 3) Oil Filter Assembly

Refer to the instructions found in

Group 29, Section 1, Page 6.

Overhead Guard Mounting Bolts

177 to 199 Ib.ft. (240 - 270 N*m)

(Refer to illustration in Group 34, Section 1, Page 9)

OHG Leg to Overhead Guard Bolt

30 - 33 lb.ft. (40 - 45 Nom)

(Refer to illustration in Group 34, Section 1, Page 9)

OHG Leg to Truck Frame Bolt

75 - 80 lb.ft. (102 - 108 N*m)

(Refer to illustration in Group 34, Section 1, Page 9)

SM-587

40-l Material -13 Copyrighted Intended for CLARK dealers only Do not sell or distribute

Dee 94

M&f?;~-i~Handling C19RK

GROUP 40 Section 2 Service Weights Contents

Service Weights in Pounds . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. . ... .. .. .. .. .. 40-2-2

SM-587

40-2-l

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

Dee 94

GROUP 40

Specifications

SERVICE WEIGHTS IN POUNDS NPR-17

MODEL

I UPRIGHT

170

I 198

210

240

258

270

NOTE:

BATTERY COMPARTMENT

13.38

13.88

16.13

MINIMUM BATTERY WEIGHT

1400

1590

1885

LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT

0

3500

0

3500

0

3500

6381

9881

6571

10071

6938

10438

I LOAD

2348

6293

2400

6345

2573

6501

I

4033

3587 1 4171

3725

1 4365

3937

I

0

3500

0

3500

I 0

3500

6381

9881

6571

10071

6938

10438 6501

TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT

LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT

I LOAD

I

TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT

2348

6293

2400

6345

2573

4033

3587

4171

3725

4365

3937

0

3500

0

3500

0

3500

6471

9971

6661

10161

7029

10529

2395

6340

2447

6392

2621

6550

4076

3631

4214

3769

4407

3979

0

3500

0

3500

0

3500

6753

10253

6943

10443

7310

10810

2529

6475

2581

6527

2761

6689

4223

3778

4361

3916

4549

4120

0

N/A

I 0 7505

3300

N/A

7138

6948

LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT

I 0

10805

2620

2672

2856

6559

4328

4466

4649

4245

0

2800

0

N/A

7034

7224

0

N/A

10392

7592

2664

2716

2902

6044

4370

4508

4690

4347

DATA IS BASED ON 42.0 ID OUTRIGGERS WITH SIDESHIFT. DEDUCT 50 lb FROM TOTAL WEIGHT IF SIDESHIFT IS NOT PRESENT.

24.0 LOAD CENTER. “N/A” _______ DATA NOT AVAILABLE, CONFIGURATION HAS NOT BEEN TESTED” Dee 94

40-2-Z

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

SM-587

Specifications

GROUP 40 SERVICE WEIGHTS IN POUNDS

MODEL

NPR-20 BATTERY COMPARTMENT

UPRIGHT

170

198

I

210

I 240

258

270

NOTE:

13.88

16.13

MINIMUM BATTERY WEIGHT

1590

1885

LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT

0

4000

0

4000

6846

10846

7213

11213

2475

6984

2645

7134

4371

3862

4568

4079

0

4000 10846

I 0 7213

4000

6846

LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT

I

I

I

LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT LOAD TOTAL WEIGHT FRONT AXLE WEIGHT 1 REAR AXLE WEIGHT

I

LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT

11213

2475

6984

2645

7134

4371

3862

4568

4079

0

4000

0

4000

6936

10936

7304

11304

2522

7031

2694

7183

4414

3905 1 4610

4121

0

3900

0

4000

7218

11218

7585

11585

2656

7165

2833

7323

4561

4052

4751

4262

0

N/A

0

3500

7413

7780

11280

2747

2928

6856

I 4852

4424

4666

0

3000

7499

7867

10867

2791

2974

6341

4708

4893

4526

0

N/A

DATA IS BASED ON 42.0 ID OUTRIGGERS WITH SIDESHIFT. DEDUCT 50 lb FROM TOTAL WEIGHT IF SIDESHIFT IS NOT PRESENT. 24.0 LOAD CENTER.

“N/A” _______ DATA NOT AVAILABLE, CONFIGURATION HAS NOT BEEN TESTED” SM-587

40-2-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

Specifications

GROUP 40

Pantograph Assembly

I

Location of: Pantograph Serial Number (You must refer to this number when ordering parts for the Pantograph).

r

Dee 94

40-2-4 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

Handling CORKMaterial Company

GROUP 40

Section 3 Lubricants and Shop Supplies Easy Referene Listing Lubricants ......................... ................ ...... .. .... .... .................................. ................ .. 3 Gasket Materials ................................... .... ........................ .......................... .... ..... 1 Threadlocks and Threadsealers ......................................... ................ ................. 4 Adhesives . .............................................. ........ .... ...................... .. .. .......... ................ 2 Cleaners ......... ................ .................... ................ .. ........................ ............ .............. 2 Detailed Product Descriptions ............................... .... ......................................... 4

These products are available through your local Clark dealer.

GASKET PRODUCTS Part No.

Size

Quantity

1802303

Gasket Maker

50 ml.

IO/case

1803252

Ultra BlueX

3.35 oz.

12/ease

1803253

RTV High Temp

3 oz.

12/ease

1803254

Form-A-Gasket-2

3 oz.

12/ease

1803255

Form-A-Gasket- 3

.25 pint

12/ease

1803256

High TackTM

6 oz. spray

12/ease

1803257

CopperCoat

12 cz.spray

12/ease

1802308

Gasket Remover

18 oz. spray

IO/case

- continued -

SM-587

40-3-I

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

Dee 94

GROUP 40 CLARK PRODUCTS -continuedADHESIVE PRODUCTS Part No.

Size

Quantity

IO/case

1802306

Silicone Adhesive Sealant

3 oz.

1803259

Fast Cure Epoxy

1

1802309

Superbonder-Gel

3 gm.

IO/case

1802304

Bearing Mount

10 ml.

IO/case

1803260

SprayAdhesive

16 oz.

12/ease

1803261

Steel and Aluminum Epoxy

1 oz.

1 /

1803262

Loctite Weld

2 oz.

12/ease

1803263

Loctite Weld Stick

11.8

CLEANING

O-4 gm. cups

oz.

IO/case

Pkg

12/ease

PRODUCTS

Part No

Size

Quantity.

1803264

Natural BlueTM

4 oz. spray

24 / case

1803265

Natural BlueTM

24 oz.

12/ease

1803266

Natural BlueTM

1

gal.

6 / case

1803267

Locquic PrimerN

6 oz. spray

1

1803268

Brake and Parts Cleaner

20 oz. spray

12/ease

1803269

EnviroSafeTM B & P Cleaner

20 oz. spray

12/ease

1803270

Carb and Choke Cleaner

16 oz. spray

12/ease

/pkg

- continued -

Dee 94

40-3-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 40 CLARK PRODUCTS -continuedCLEANERING PRODUCTS Part No

Size

Quantity.

1803271

EnviroSafeTM C & C Cleaner

6 oz. spray

12/ease

1803272

EliminatoTMr 11

20 oz. spray

12/ease

1803273

EnviroSafeTM Degreaser

20 oz. spray

12/ease

1803274

RadiatorCleaner

1 qt.

12/ease

Size

Quantity

LUBRICANTS Part No. 1802307

Anti-SeizeTM

1 lb. can

IO/case

1803275

Super Lube-

4.5 oz. spray

12/ease

1803276

Super Lube-

.25 oz. oiler

12/ease

1803277

Silicone Lube

16 oz. spray

12/ease

1803278

Water Pump Lube

12 oz.

12/ease

1803279

HydraulicJackOil

1 qt.

1

/pkg

1803280

Tune-upGrease

.33 oz.

1

/pkg

1803281

Ultra SlickTM

4 oz.

1

/pkg

1803282

Prussian Blue

-75 oz.

1

/pkg

1803283

Valve Grind

34 B

1

/pkg

continued -

SM-587

40-3-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

GROUP 40 CLARK PRODUCTS - continued THREADLOCKER

PRODUCTS

Part No.

Size

Quantity

1802300

Gen. PurposeThreadlocker

IO ml.

IO/c&e

1802302

Heavy Duty Threadlocker

IO ml.

IO/case

1811140

Teflon- Pipe Sealant

50 ml.

IO/case

1803258

Form-A-Thread

.32 syringe

6 / case

Descriptions, Classifications, Specifications of Lubricants and Shop Supplies The following lists descriptions as well as part numbers of lubricants, sealants, gasket materials, threadlocks and threadsealers, adhesives, cleaners, and miscellaneous shop compounds recommended for servicing Clark industrial trucks. These products are available through your local Clark dealer.

Lubricants Part Number

Description

1802153 - 1 Qt.

Motor Oil lOW30 Clark all-season lOW30 motor oil is unexcelled for keeping Clark engines clean. It protects against formation of sludge, varnish and harmful deposits which cause sluggish performance. Clark premium lOW30 motor oil is made from high-quality solvents and refined neutral stocks and is especially suited for gasoline engines which include emission-control systems. Specially formulated additives prevent rust and provide effective detergent action. This superior oil product meets API service classifications SE, SD, SC, SB, CC, CB, CA andmilitary specification MILL-46152 and exceeds hUL-L-2104B.

1802152 - 1 Qt.

Motor Oil Extra-Duty

30W

Clark extra-duty 30W motor oil was developed for the lubrication of gasoline, diesel, Ll?G, and natural-gas engines for which MIL-L-2140B products are recommended. This oil also meets or exceeds API service class CD, CC, CB, CA, and SB. Clark 30W oil may be used in stationary, automotive, fzum, and marine-engine service use. It is especially effective wherever the use of heavy-duty motor oil is recommended. Suitable for oil-bath aircleaners, chain drives, hydraulic systems, and general lubrication service.

Dee 94

40-3-4

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

SM-587

GROUP 40 Lubricants Part Number

Description

2776236 - 1 Gal

Transmission Fluid Specifically recommended for Transmission Models:

916027 - 1 Qt

H2OO,H210andH211 HR500 and HR600 TA-12 and TA-18 This product provides proper frictional characteristics, superior wear protection for gears, excellent water tolerance to avoid excessive foaming and rusting within the system, good filterability, and low temperature fluidity. These fluids meet CMHC MS-276A and the requirements for the following: John Deere Quatt-ol Q-41

Catepiller TO-2

Allison C-3

International Harvester Hy-Tran B-6 Abex Dennison IV-0 Hydraulic Fluid Specification

Part Number

Description

1801708 - 2 Gal.

Special Purpose Transmission/Hydraulic Fluid Increased demands for performance and protection of fluids used in equipment with common hydraulic and transmission oil reservoirs have brought about thedevelopment of Clark SpecialPurposeTransmission/HydraulicFluid. This qualityproductmeets the service-refill requirements for the following tractor manufacturers: John Deere J20A, 303

J.I. Case JlC143, TFD

Navistar B-6

Massey Ferguson 1138

Allis-Chalmers PF821

White-Type 56

Part Number

Description

1802536 - 1 Gal.

High-Performance Transmission Fluid Clark High-Performance Transmission Fluid is made of selected, highly-refined base oils blended with a specially-balanced additive combination. This product has outstanding high-temperature oxidation resistance, dispersancy, and detergency. It provides anti-corrosion and rust protection, and is compatible with the various automatic transmission components such as elastomeric seals andplastic parts. Its high-viscosity index permits use over a wide temperature range by providing excellent lowtemperature fluidity while retaining desired viscosity in high-temperature conditions. This fluid meets all of the requirements of the GM DEXTRON specification. It is recommended for use in all types of automatic transmissions for which DEXT.RON products are required.

SM-587

40-3-5

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

Dee 94

GROUP 40 Part Number

Description

1800236 - 1 Qt.;

Hydraulic Fluid

1802155 - 1 Gal.

Clark premium anti-wear hydraulic fluid is tailored to meet the special requirements of Clark hydraulic systems. Clark hydraulic fluid will not oxidize to form sludge and guards against rust by plating all metal parts with a film that is impervious to moisture. It stands up to high-heat ranges and pressures andprotectsprecision-tunedparts against abnormal wear. Above all, it is compatible with the chemistry of the seals, packings, and hoses so it cannot cause deterioration of these vital components. Every hydraulic fluid formulated for Clark hydraulic systems must pass strict tests complying with Clark specification MS-68 which calls for an anti-wear additive plus many other properties. This fluid also meets the stringent requirements of the Denison HF-2 and Lee Norse lOO-1 specifications.

Part Number

Description

1802200 - 1 Qt.;

Transmission/Converter Fluid

1802154 -1 Gal.

Clark transmission-converter fluid is compounded with the special properties required for Clark torque converters and automatic transmissions. This superior fluid has been developed to meet General Motors’ DEXTRONII specifications and equals or exceeds all requirements for Type A Suffrx A automatic-transmission oil. Genuine Clark transmission-converter fluid flows freely in low temperatures, yet resists high temperatures, pressure, and oxidation while preventing corrosion and seal deterioration.

Part Number

Description

801167 - 1202.;

Super Heavy-Duty Brake Fluid

850487 -1 Gal.

Clark Super Heavy-Duty Brake Fluid protects the vital metal and rubber components found in your equipment’s brake system. It is non-corroding and lubricates all metal parts while keeping the rubber parts from shrinking or becoming brittle. To insure quality performance, Federal regulations VV-H-9 1Oa Amendment I and SAE specifications70R1,70R3,andJ70BaresurpassedbyClarkSuperHeavy-DutyBrakeFluid.

Part Number

Description

1802307

Anti-SeizeTM Lubricates to protect against galling, pitting, and corrosion on equipment subject to temperature extremes (up to 2OOOOF)or in corrosive applications. Assures easy disassembly of components. Use for wheel lug nuts and fasteners, upright and frame mounting bolts and in corrosive environments.

Part Number

Description

1803275 - .25 oz.;

Super-lubeSynthetic Lubricant With Teflon

1803276 - 4.5 oz

Multipurpose lubricant for machinery and equipment. Compatible with other lubricants and is safe on metal, rubber, plastics, wood, leather and painted surfaces. For cables, hinges, locks, linkages, gears, and pulleys.

Dee 94

40-3-6

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

SM-587

GROUP 40 Part Number

Description

1803277

Silicone Spray Lubricant Stops friction and squeaks. Silicone formula does not attract dirt or dust. Protects and renews rubber mountings, bushings and weather-stripping. Prevents deterioration due to sunlight. Use to lubricate door locks and rubber moldings for doors or windows.

Part Number

Description

1803278

Water Pump Lube And Radiator Anti-Rust Lubricates to prevent squeal and pump corrosion in the engine cooling system. Disperses rust. Protects metal parts with a corrosive resistant film.

Part Number

Description

1803279

Hydraulic Jack Oil Improves lubrication in all types of hydraulic units. Prevents rust and sledge build-up. Contains anti-oxidant, anti-rust and anti-wear additives to maximize service life. Use in bottle jacks, arbor presses, Port-A-Powers, and hand pallet trucks.

Part Number

Description

1803281

Ultra SlickTMEngine Assembly Lube Proper lubrication of metal mating surfaces is essential prior to starting anew or rebuilt engine. Ultra Slick has superior adhesion to component surfaces to prevent scuffing and galling during initial startup. Use on engine bearings, camshafts, lifters, valves, guides, and rocker-arm shaft assemblies.

Part Number

Description

1800636

Ignition Distributor, Cam Lube A must for long ignition-cam follower life. Cam Lube is a high-temperature which does not conduct electricity.

Part Number

Description

617410

Lubriplate

grease

A white grease for clutch throwout bearings, Lubriplate withstands high temperatures and increases the life of bearings.

Part Number

Description

886785

Spray Lube Spray Lube is easy to apply to open gears and reaches hard-to-get places. It acts as a rust preventive and does not drip off.

Part Number

Description

886396

Innerslide Lubricant This lubricant is a “dripless” grease, ideal for sliding tandems and fork trucks. Cuts greasing time, prevents rust, and provides constant lubrication to minus 60” F.

SM-587

40-3-7 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

GROUP 40 Part Number

Description

886399

Chain and Cable Lubricant Chain and Cable Lubricant provides constant lubrication by penetrating chain links, andreducesfrictiondragsonsuddenoverloads.It alsopreventsdrippingonsloworidle chains.

Sealants Part Number

Description

886398

Battery Saver Battery Saver preserves battery power by retarding acid action, preventing corrosion, and sealing vibration cracks.

Part Number

Description

886784

Spray - Kote Spray-Kote renews, insulates, and protects. It seals electrical wires and keeps them pliable while preventing rust and corrosion. Resists extreme heat or cold and requires no pre-cleaning before use.

Part Number

Description

1801146

MS 180 Freon Degreaser Non-flammable and non-conductive, MS 180 Freon Degreaser is ideal for SCR controls and panels, harness plugs for electrical wiring, and SCR terminal strips.

Part Number

Description

1801145

Conquer-3 Conquer-3 is a water dispersive and corrosion preventive that protects against oxidation. It displaces water and moisture, even from wet insulation, and leaves a protective film. Excellent for protecting SCR control panels

Part Number

Description

1801480

GE Silicone Protects SCR’s by weatherproofing solvents.

Part Number

Description

1803280

Electric Tune-Up Grease

and sealing while resisting chemicals, oils, and

Protects electric connections and wiring from salt, dirt, and corrosion. Extends the life of the bulb sockets. Prevents voltage leaks around any electrical connection. Also prevents spark plugs from fusing to boots. Use in extremely dusty, dirty, or corrosive applications.

Dee 94

40-3-8 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 40 Part Number

Description

1802306

Silicone Adhesive Sealant General purpose, clear RTV indoor/outdoor sealant. Seals, bonds, mends, and secures glass, metal, plastics, fabrics, vinyl, and weather-stripping. Protects electrical wiring. Waterproof and flexible. Seal windows, electrical connections, vinyl tops, and seams.

Gasket Materials Part Number

Description

1802303

Gasketmaker Flexible, non-corrosive gasketing material for use on rigid machined flanges with less than .OlO” (.25 mm) gap. Use where “anaerobic” (cures in the absence of air) gaskets are specified. Seals transmission cases, transaxle castings, waterpumps, andotherrigid covers and plates.

Part Number

Description

1802308

Gasket Remover Quickly removes baked-on gaskets and all types of gasket adhesives. Prepares metal parts for new gaskets and assembly. For all metal parts.

Part Number

Description

1803252

Ultra Blue@ High performance, oil resistant RTV silicone. Low odor, low volatility. Eight times more flexible than cork/composite gaskets and three times more oil resistant than other silicones. Forms in-place gaskets on valve covers, oil pans, intake manifold and seals, timing covers, water pumps, and thermostat housings. Use as a gasket dressing to upgrade conventional metal and pre-cut gaskets.

Part Number

Description

1803253

Hi-Temp RTV Silicone For very high temperature applications. Replaces cut gaskets. Makes reliable formedin-place gaskets that resist cracking, shrinking, and migrating caused by thermal cycling. The temperature range is - 75’ F to 650° F. Form in-place gaskets on valve covers, oil pans, intake manifolds and seals, timing covers, water pumps, and thermostat housings. Use to coat pre-cut gaskets to increase reliability.

Part Number

Description

1803254

Form-A-Gasketa No. 2 Slow drying, non-hardening sealant designed for sealing cut gaskets and stamped parts. Allows for easy disassembly if required. Use where sealing is more important than adhesion. Temperature range is - 8.5’F to 4ooOF. For valve-cover gaskets and oil-pan gaskets.

SM-587

40-3-9 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

GROUP 40 Part Number

Description

1803255

Form-A-Gasket@No. 3 Slow drying, non-hardening, brush-top sealant for close fitting machine surfaces. Temperature range -659 to 400’ F. Use for sealing hoses and as a cut gasket dressing.

Part Number

Description

1803256

High TackTMSpray-A-Gasketa Fast drying adhesive for holding gaskets in place during assembly and sealing. Remains effective under extreme temperature of - 65’ F to 4500 F. Holds and seals all felt, cork, metal, paper, rubber, and asbestos gaskets.

Part Number

Description

1803257

Copper Spray-A-Gasket@ Fast drying, metallic-copper sealant helps dissipate heat, prevents gasket burnout and improves heat transfer. Fills minor surface irregularities and seals instantly. Temperature range - 50° F to 500°F. For cylinder head gaskets, carburetor gaskets, exhaust manifold gaskets, and other high temperature applications.

Threadlocks and Threadsealers Part Number

Description

945945

Loctite Nut Lock LoctiteNutLockturnsordinarynutsintovibration-prooflocknuts. Itreducesassembly costs by eliminating expensive lock nuts and prevents machinery from vibrating loose.

Part Number

Description

1802300

General Purpose Threadlocker For locking and sealing smaller (l/4”-3/4”; 6- 18 mm) threaded fasteners that will require removal. Blue in color. For valve cover bolts, water pump bolts, oil pan bolts, or rocker-arm adjustment nuts.

Part Number

Description

1802302

Heavy Duty Threadlocker For locking and sealing heavy-duty, large, orperrnanent threaded assemblies. Use with large studs and fasteners (3/g”- 1”; 9-24 mm). Red in color. Use on cylinder block studs, ring gear bolts, frame bolts, and upright mounting bolts.

Part Number

Description

1801140

Pipe Sealant With Teflona Seals plugs and tapered pipe threads instantly. Will not shrink or dry out and will not shred to contaminate systems. For pipe plugs above l/8” (3 mm), water pump plugs, fuel fittings, coolant fittings, hydraulic system fittings.

Dee 94

40-3-l 0 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 40 Part Number

Description

1803258

Form-A-Thread@ Makes reliable, permanent thread repairs without drills, taps, tools or inserts. Restores worn, stripped, or damaged threads; effective up to 128 ft-lb of torque. Use for intake manifold bracket fasteners, threads, water pump bolt threads, or front cover bolt threads.

Adhesives Part Number

Description

1802304

Bearing Mount “Anaerobic” adhesive helps restore the fit between replacement bearings in worn housings or worn shafts. Fills clearance to .OOS (.015 mm) and will disassemble. Mounts and retains ball bearings in housings or on shafts, roller bearings, plain bearings, and bushings.

Part Number

Description

1802309

SuperbonderR Revolutionary thick no-run formula developed specifically for making fast heavy duty repairs. For metal, plastic, rubber, leather, paper, wood or cork. Use to repair broken or loose trim, dash panels, seat cushions.

Part Number

Description

1803259

Fast Cure Epoxy 45 Easy to use pre-measured epoxy mixer cups. Ideal for bonding glass, plastics, rubber, and metal. Bonds in 5 15 minutes. Useon loose trim, broken grilles, casting cracks, and holes.

Part Number

Description

1803260

Spray Adhesive Dries clear with superior bonding strength. For permanent or repositionable applications. Resists water, humidity, and heat. Used for attaching cloth, carpeting, sound insulation, and floor coverings.

Part Number

Description

1803261

Steel And Aluminum Epoxy Grey epoxy adhesives for metals, concrete, and many plastics. When cured, can be drilled, sanded, threaded, or filed. Resistant to fuels and solvents. Fills gaps and bonds trim. Use on casting cracks and holes, auto trim, and ornaments.

Part Number

Description

1803262

Loctite Weld - An Alternative To Welding A 15minute, 2-part adhesive and tiller system that eliminates the need for welding or brazing. Once cured, it can be drilled, sanded, filed, or painted. Use on aluminum, steel, brass, bronze, casings, stampings, etc. Over 3000 psi shear strength.

SM-587

40-3-l 1 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

GROUP 40 Part Number

Description

1803263

Loctite Weld Stix SimilartoLoctite Weldonly inpre-measuredribbons. Sets in 5 minutes andcures fully in 1 hour. Fills gaps to 2” (50 mm) and is ideal for under water applications. Use on aluminum, steel, iron, wood, glass, masonry, ceramic, gas tanks, oil pans, and most plastics.

Cleaners Part Number

Description

886397

Penetrating Oil An easy-to-use penetrating oil that cuts rust, paint, and grease and is effective on hot surfaces. Saves time, labor, and broken parts; contains Moly.

Part Number

Description

1800330

Degreaser This easy-to-use degreaser is water soluble, safe for paint, and does not rust.

Part Number

Description

1802522

Brake Cleaner This brake cleaner provides fast, complete cleaning, removing oil, dirt, and grease, leaving no film. It is non-flammable and can be used on brake parts, and electrical and ignition accessories. An effective, thorough, safe, and economical parts cleaner.

Part Number

Description

1803264 - 4 oz.;

Natural BlueTMCleaner/Degreaser

1803265 - 24 oz.; 1803266 - gal.

General purpose, biodegradable, cleaner for removing grease, grime, oil, and mildew, food or other stains from any washable or metal surface. Non-toxic, non-corrosive, U.S.D.A.-authorized, contains no butyl. Dilutes with water. Great for pressure washers and steam cleaners. Also cleans engine parts, floors, porcelain and more.

Part Number

Description

1803267

Locquic@ Primer N Degreases oily parts and speeds the curing of“anaerobic” products such as threadlockers, pipesealant,bearingmount, andgasketmaker.Recommendedforcoldweatheruseand quick repairs. Use with anaerobic products to speed assembly in all applications.

Part Number

Description

1803268

Brake dz Parts Cleaner Quickly dissolves and removes oil, grease, brake fluid, and oxidized oils. Dries fast without leaving a residue and is non-corrosive.

Dee 94

40-3-l 2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587

GROUP 40 Part Number

Description

1803269

Enviro-SafeTMBrake & Parts Cleaner Environmentally safe formula. Biodegradable natural citrus solvents dissolve and remove oil and grease from brake systems and metal parts. No CFC’s or chlorinated solvents. Low toxicity.

Part Number

Description

1803270

Carb And Choke Cleaner Super jet spray quickly cuts and removes grease, gum and varnish from chokes, baffle plates, and carburetor linkages.

Part Number

Description

1803271

Enviro-SafeTMCarb And Choke Cleaner Biodegradable formula safely cleans using citrus solvents. Environmentally - no CFC’s or chlorinated solvents.

Part Number

Description

1803272

EliminatorTM11 Engine Degreaser

friendly

Quickly dissolves and removes grease, oil, and dirt from all types of equipment. Cleans iron, steel, aluminum, magnesium, and copper. Not harmful to metal, rubber, plastics, or concrete. Rinses off easily with water.

Part Number

Description

1803273

Enviro-SafeTMCleaner And Degreaser Biodegradable. Safely removes grease, dirt, and oil with the power of natural citrus solvents.

Part Number

Description

1803274

Heavy Duty Radiator Cleaner Removes rust and scale from automotive and industrial engines, radiators and water jackets. Cleans and unclogs steam cleaner and pressure washer coils. Safe for aluminum.

Part Number

Description

917330 - 7.5 oz.; 917329 - 1 Gal.

Natural Citrus Hand Cleaner An environmentally safe hand cleaner that harnesses the cleaning power of natural citrus extracts rather than petroleum solvents. Formula tackles the toughest dirt and leaves hands clean and fresh smelling. Fortified with lanolin, aloe, and jojoba oils for skin care.

SM-587

40-3-l 3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Dee 94

GROUP 40 Miscellaneous Shop Supplies Part Number

Description

1800078

Belt Dressing Thetractive qualities of this belt dressing on flat,round, and V-belts can increase power by 50% without collecting dirt For use on truck, auto, farm, and industrial machinery.

Part Number

Description

1803282

Prussian Blue Aids precision fitting of machined surfaces. Locates high spots on bearings, valves, gears, and other close-to-tolerance components. Non-drying and easy to clean-up.

Part Number

Description

1803283

Valve Grinding Compound Aids valve grinding and seating operations to remove burrs, surface defects, carbon, gum, and corrosion. Can be used for lapping and grinding chromium. Mixes with water to form an easy-to-use paste.

Dee 94

40-3-l 4 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM-587