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
NPR-17 NPR-20
TABLE OF CONTENTS
w
Group No-Section No.-Page No. Item Groun No-Section No.-Page No.
01 Planned Maintenance Procedures PM-l thru 29 02 Lubrication Charts 03 Battery Service 01-1-l 12-1-1
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 34 Lowering Solenoid Valve 35 Auxiliary Solenoid Valve ( Reach & Tilt Control Valves) 30-5-l 30-3- 1 30-4- 1
04 Multi-Function Control Handle Switches 13-1-1 05 Electric Motor Service -- General 06 Traction Motor Service 07 Pump Motors 08 Auxiliary/Steer Pump Motor Service 09 Contactor Service 10 Electrical Sequence of Operation 16-2-1 16-3-1 16-5-1 16-7-1 17-1-1 19-2-1
36 Reach & Tilt Selector (Solenoid) Valves 30-6- 1 37 Side Shifter Solenoid Control Valve 38 Tilt Cylinder Overhaul 39 Reach Cylinder Overhaul 30-7- 1 32-2-l 32-3-l
11 EV-T15 Solid State Control Status Code 19-3-1 12 Oscillator Card Settings and Tests 19-4-1
40 Upright & Pantograph Remove & Replace and Roller Shim Adjustments 41 Pantograph & Fork Carriage R&R and Roller Shim Adjustments 34-2-l 34-3- 1 34-4- 1 34-5- 1 34-6-l 35-l-l 40-l-l 40-2- 1 40-3-l 34-l-l
13 Steering Control Adjustments (EV-T5PS)19-5-1 14 Wiring Diagrams 15 Directional, Lift & Lower Switches and Transducer Adjustment 16 Periodic Electrical Checks 17 Oscillator Card, Remove & Replace 18 solenoid Control Card Troubleshooting 19 Axle Articulation Adjustment 20 Drive Unit Overhaul 21 Traction Wheel & Tire 22 Caster Wheel & Tire 23 Motor Brake 24 Caster Brake 25 Brake Bleeding Procedure 26 Brake Pedal Adjustment 27 Hydraulic Pressure Checks 28 Hydraulic Sump Tank, Filter and Strainer(s), Service 29 Hydraulic Schematic 30 Hydraulic Pump Overhaul 29-l-l 29-2- 1 29-4- 1 19-7-1 19-8-1 19-10-l lo- 16- 1 20-l-l 20-2- 1 22-l-l 22-2- 1 23-l-l 23-2- 1 23-3-l 23-4- 1 26-l-l 19-6-1
42 Rail Lift Cylinder Overhaul 43 Free Lift Cylinder Overhaul 44 Lift Fork Inspection 45 Lift Chains 46 Load Wheels 47 Specifications 48 Service Weights 49 Lubricants and Shop Supplies
NOTE
Pictorial Indexes are provided on the following four pages. Index ............................ ....Page 6/7
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INDEX
Pictorial Index
Pictorial Index #1 NPR-345
23
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Pictorial Index
INDEX Index 1 of 2 Pictorial Index

Contents
PM Planned Maintenance Procedures ........................... PM-01 thru 29 PM Caster Brake: Adjusting for Lining Wear; When to Replace Brake Linings ........................................................... 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 .............................. 17 Contactors, Control Panel.. ............................................. 19 Electrical Sequence of Operation .................................... 19 Instructions - Status Codes for EV-T15 Control.. ............ 19 Oscillator Card Settings ................................................... 19 Steering Control Adjustments.. ....................................... 19 Wiring Diagrams ............................................................ .16-7-01 thru 12 .17-l-01 thru 09 .19-2-O 1 thru 5 1 .19-3-01 thru 15 19-4-01 thnlo4 .19-5-01 thru 06 19-6-01 thru 03 PM- 16
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
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INDEX
Pictorial Index
Pictorial Index :#2 NPR-345
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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 ........................................... 12 05 05 04 06 02 13 04
40-3-l thru 14
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INDEX
m
Axle Articulation Adjustment Battery Remove & Replace Service Brakes Motor Caster Bleeding Pedal Adjustment Master Cylinder Caster Service Checks Control Panel Contactors Oscillator Card, Remove & Replace Cylinders Tilt Cylinder Overhaul Reach Cylinder Overhaul Rail Lift Cylinder Overhaul Free Lift Cylinder Overhaul Diagrams Electrical Hydraulic Drive Unit Overhaul Lift Chains Inspection Lubrication Remove & Replace Lubrication Charts & Specifications
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Group No-Section No.-Page No.
Ttem Motors
Grout No-Section No.-PaPe No.
20-l-l
General Traction
16-2-1 16-3-1 16-7-1
12-1-1 12-1-1
Auxiliary/Steer Pump Pantograph & Fork Carriage Remove & Replace
34-2- 1 34-2- 1 34-5 1 19-8-1 19-8-1
23-l-l 23-2- 1 23-3-l 23-4- 1 23-4- 1 PM-17
Roller Shim Adjustments Lift Fork Inspection Periodic Electrical Checks Cable & Wire Routing
Planned Maintenance Procedures PM- 1 thru 29 Caster Special Socket Adapter PM-24 Pressure Checks
17-1-1
Steering Lift Circuit
26-l-l 26-l-l 26-l-l 29-4- 1
19-10-l
Auxiliary Reach & Tilt Pump Overhaul
32-2- 1 32-3- 1 34-3-l 34-4- 1
Sequence of Operation Electrical Solid State Control Status Codes (EV-T15) Oscillator Card Settings/Tests 19-3-1 19-4-1 19-2-1
19-6-1 29-2- 1
Steering Adjustments (EV-TSPS) Switches 19-5-1
20-2- 1
Directional, Lift & Lower
19-7-1
Multi-Function Control Handle 13-l- 1 34-6-2 34-6-6 34-6-6 Transducer Adjustment 19-7-1
01-1-l
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INDEX
Upright & Pantograph
Lift Chains Remove & Replace Roller Shim Adjustments 34 - Manual Insert 34-l-l 34-l-l
Valves
Remove & Replace Auxiliary Reach & Tilt Lift Control Lowering Solenoid Auxiliary Solenoid Valve ( Reach & Tilt) Reach & Tilt Selector Side Shifter Solenoid Control 30-5-l 30-6-l 30-7-l 30-l-l 30-2- 1 30-3-l 30-4- 1
Specifications Service Weights
40-l-l 40-2- 1
Lubricants and Shop Supplies 40-3-l Sump Tank Fluid Level

Filter and Strainer(s) 29-l-l 29-l-l
Wheel & Tire

Traction Caster 22-l-l 22-2- 1 35-l-l
Load
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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 A
WARNING
This message is used when a hazard exists which can result in serious personal injury or death, proper precautions are not taken.
if
DANGER
This message is used when an extreme hazard exists.
A
1. 2 3. 4.
WELDING ON TRUCKS
Make sure the truck has no grounds. Disconnect truck battery. Protect electrical wiring and components from weld spatter with a shield. 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.
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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.
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.
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. 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. 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. Improper or careless techniques cause accidents. Dont take chances with incorrect or damaged equipment. Read and understand the procedures for safe operation and maintenance outlined in this manual.
Drive and work safely and follow the safety signs and their messages displayed in the work area, on the truck and in this manual.
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Cautions
GENERAL PRECAUTIONS
Thefollowing list contains general precautions that should be followed when working
on a lift truck.
Service Electric Truck Batteries in a well-ventilated area to avoid the danger of lighting explosive gases, clear of pedestrians and with adequate overhead clearance and on a flat, level surface. Always wear safety glasses for eye protection. 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.
Set the parking brake. Place chocks to the front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement. Use safety stands or blocks whenever a procedure requires you to be under the vehicle. Follow the Safety Instructions outlinedin Group 12, Handling Storage Batteries. Always Discharge the Capacitors prior to working on or around electrical components. Refer to the instructions outlined in Group 19, Discharging Capacitors.
! A
CAUTION
Avoid contact with Battery Acid. The battery contains corrosive acid which can cause injury. Follow the instructions outlined in Group 12 Handling Storage Batteries and those instructions received with your battery and charger.
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Foreword
This Service Publication provides information
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. 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.
Procedures have been made easier to use by

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.
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
Master Parts Book and the Customer Parts Manuals. The manual includes:
P.M.
The technician is cautioned and expected to... ... before beginning to work.
*Take time to completely read (entire) procedures, including any special instructions.
Planned Maintenance Procedures including precautions and safe maintenance recommendations.

01-40
ABOUT PLANNED MAINTENANCE The Planned Maintenance Procedures

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. 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.
Service specifications, adjustments, maintenance and overhaul procedures including lubrication charts, recommended lubricants and service weights, etc.
General and detailed service and repair procedures are outlined (as required) for each
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
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Foreword
An effective PM program should incorporate

two basic phases:
~
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.
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
being determined by operating conditions.
NOTE
Records will tell you how often PM
should be done.
l
Refer to the Operators Manual, located on the truck, for additional information on the operation, care and maintenance of your truck.
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.
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.
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Planned Maintenance Procedures
The Planned Maintenance Procedures Outlined on 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. 5. Lubrication. Each catagory is preceded with a summary of the inspections, checks, tests, etc., that should be performed in each catagory. 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.
P.M. CHECK SHEET

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
1. Visual Inspection
(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.
Code
$ =
1 O.K.
O.K. I
X = Adjust (Not P.M.)
Potential r = Repair or Replace ~~~~~~~~ s = Requires Shop Repair .....:.:.:.:.:.:.:.:.:., ..:.:.:.:.:.:.:.:.:.:.:.:.:.:.: ..v.:. .(.,.,.(.(.,.,.,.,.,. .,.,. .,. .,.,. .,.
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Visible frame damage. Tire Wear and/or lodged foreign objects in tire tread and/or badly darnaged side walls. Overhead Guard for security of mounting (loose or missing fasteners) and damage. Visible fluid leaks. Presence and condition of covers, pads, floor mat, decals and truck data plate. Safety Screen and/or Glass for security of mounting and damage. Visible signs of wear and/or damage to upright. Load Back Rest for security of mounting and damage. Check that ground chain link is touching the floor.
Visual Inspection
1. Insuect Batterv Plugi BzTruck Receutacle
l
Battery Plug 7
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. loaded terminals in the truck and check the battery plug or pitted terminals should be check sheet.
Truck
tsconnect Batterv and check Spring Loaded Terminals
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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. mounting and damage.
4. Check safety screen and/or glass for security of .

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.
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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 & Tire
Wheel & Tire
Fastener Tightening Sequence
D
B G E TORQUE
F A
FASTENERS TO: 124 - 139 LB. FT. (168 - 188 N*M)

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Planned Maintenance
Procedures
Check Mullti-Function operation.
control for freedom of
Check brakes. Check hour meter. Check steering. Check control plugging. Check acceleration.
Check battery connection. Check horn.
Check key switch and dash display. Check upright operation.

l
Check speed limit switch operation.
Operational Tests
a. Check Controls
NOTE
Move control through all functions checking for freedom of movemenet.
Battery connector should be disconnectedandkey switch turned OFF before making these checks.
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.
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b. Check horn to be sure it operates.
c. Turn key switch ON.
Check the Diamostic Disdav & Kev Switch

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. 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.
Digital Readout
\
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.
Battery Symbo
Wrenchkymb
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PM-6
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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. 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.
ReachControl
Tilt Control !SideShift Control
(Optional)
Watch the upright to make sure it operatessmoothly between the free lift and rail lift stages.
. 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.
Multi-Function Control Handle Switch Buttons
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
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h. Check Steerin . While moving the truck at a slow rate of speed in a forward direction of travel, turn hand wheel slowly both clockwise and counterclockwise while listening for unusual steering noise. The steering should be smooth without hesitation. 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
j. .
Check Controlled Plwwing (BrakiwI Operate truck at a slow speed in a forward direction of travel. Reverse direction of travel. The truck should slow down to a smooth 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
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.
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.
1. Check Srxed Limit Switch Oneration

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.
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.
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PM-8
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Planned Maintenance Procedures CLEANING
Battery Compartment. Lower Compartment. Drive Motor and Steer Motor. Brake Components. Axle Mounting.
Caster Wheel and Brake. Hydraulic Compartment. Pump Motor. Control Compartment. 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
l
WARNING
When cleanina with cornDressed 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.
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
Dee 94

a. Remove Batterv
l
WARNING
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.
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.
Remove fasteners securing the side cover to the truck. Lift cover off truck.
Remove fasteners securing floor plate to truck. Lift floor plate upward and over the brake pedal.
Open Access Door. Loosen door fasteners until the door is free to open exposing internal components.
PM-l 0 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM-587
Dee 94

c. Discharm? the CaDacitors
. .
Be sure the battery is unplugged. Discharge capacitors using a 100 ohm, 10 watt resistor connected between the Positive and Negative power terminals on the Transistor Control. Hold theresistorinplacefor2 seconds
before removing. A
CAUTION
Using a shorting device without a resisfor/oadcould cause damage to the control.
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

.
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
SM-587
Planned Maintenance
Procedures
Brake Line Retainers (Bracket and Fastener)
I I
Artkula ting
Axle
Brake ComnonentS
l
Air clean master cylinders located beneath the brake pedal. Blow off the brake lines in the operators compartment. 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.
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.
SM-587
Copyrighted Material PM-1 3 Intended for CLARK dealers only Do not sell or distribute
Dee 94
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.
...... .>>F.. . . . . .. .. . . . . . . . . . . .. . . ..~.~...... :~:~:::::jj,::~.~.~.~.::::~.~~.~:~:~
. ...... ..................... ...._. ,... .. .. .. .. .:.:.~,.:.:.:.:.:.:.:.:.:.:.:.: ..:.:.:,:,: . . . . . . ......................,.. ....,...... . . .. ..,... . . . . . . . . .,.,.,.(.,.,.,.(.,.(.,.,.,~,.,.,. . . . . . . . .,.,.,.....,.,.,.,...,.,...,.,., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..,. ... .,..., . ..... .. .. ..,.,.,.,.,.,.,.,.,.,........... .,.,.,.,.,.,.,.(.,.,.,.....,... ,..., :.: .,.,.,.(.,.,.,.,.(.,.,.........,. ,.... .,.,.,.,.,.,.,.,.,.......,... f::::::::~:~:::::::::::~:~:~:~~:$~:~:~: ,...:... ........... .:.:.:.:.~j::::jjjj::j)j:.:.:.:.: . . . . . . . . ,.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,. ,.. .. .. .. .. .. . . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. . .,. ,.,.... .. .. .. .. .. . ,.. .. .. . .,.,.,..
V Grease Fitting ::::::::i:i:i:i:i:l:~:~:~:~:~:::~:~:~~:~ . . . . . . . . . . . . . . . . .. .. .. ..:. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .

:::::::::::::::::::::::::::i:::.:;:~:~:~:~
iiiliii:i:i:i:i:i:i:i:i:i:ijii:i:,i:i:
Truck Frame ::::::::::::::::: ::::::::::::::::: ::::::::::::::::: :jj j:i:jj:: ::::::::::::::::: i;;;;>:;i;;;;;;;; .y>;:::::,::: .:~l.,\di:;j .....
Dee 94
SM-587

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 <u,_/
. .
. .
k. Check Brake Sm-iw Len&h

l
Measure the distance between the inside of one washer to the inside of the opposite washer (as shown here). If spring length is not as specified, an adjustment must be made. 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

AdiustinP for LininP Wear When to ReDlace Brake Lininps 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.
Lining Wear Check
Brake
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. Make certain retainer plate is properly located against the brake line fitting. Make certain the retainer plate is tightly secured to the axle frame.
I-
.-
b_
Fa
Dee 94
PM-l 6
SM-587

.
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
Unlock bearing lock nut.
MM_ +-
Lock Nut Lock Washer

l
IMPORTANT Be sure the lock nut is installed with the chamfer side (UP) away from bearing.
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).
%323 &
Thrust Washer
l
Grease Shield bearing Cone Bearing Cup Axle Frame
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 Check, adjust and lubricate axle trunnion bearings every P.M.. Refer to Lubrication in Group 01.
Thrust Bearing
Mounting Spindle
SM-587
Copyrighted Material PM-l 7 Intended for CLARK dealers only Do not sell or distribute
Dee 94

Hvdraulic Comnartmen$
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.

Remove the brushes and inspect them for wear. Refer to the Brush Inspection Chart in Group 16. 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. Reinstall brushes and brush cover (if applicable). 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
SM-587
Planned Maintenance
Contactors
Procedures
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.

. .
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.
Jeer

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. Note condition on P.M. Check List. 1. Fastener 2. Bracket 3. Connector 4. Clamp
. . . . . .
* .
5. Fitting 6. Cotter Pin 7.

Dee 94 PM-20 SM-587
Chain Anchor Pin

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
Fork
SM-587
Dee 94
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
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.
l
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
PM-22
AllLiftChainsmustbeadjustedtoproperlength and equal tension as outlined on the following pages.

SM-587
Dee 94

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

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.
Weldment
Spherical Bushing
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
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 pasteof 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.
Dee 94
Planned Maintenance Procedures Lift Chain Adjustment

Step 1: Adjustment Check
l
Step 2: Adjustment Procedure

1. Loosen jam nut on each chain anchor. 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. 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. 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.
With the upright fully lowered, check to see if the inner rails protrude l/8 inch above the intermediate rails (both sides). If they do, check tension of both chains on the longest span. Chain tension should be the same. If the above checks are as specified, the Inner Rail Chains do not require adjustment. Check the carriage chains as outlined on the following 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 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.)
Dee94
PM-24
SM-587
Planned Maintenance Procedures Carriage Chains

l
Step 4: Adjustment Procedure

1. Loosen jam nut on each chain anchor. 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. 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. 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.
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. Ifclearance is as specified, check tension of both chains on the longest span. Chain tension should be the same.
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.
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
Dee 94
Planned Maintenance Procedures Carriage Stop - to - Upright Stop

IMPORTANT
The carriage stop must not be allowed to contact the upright rail stop under any circumstances during normal operation. Step 6: Adjustment Procedure
Loosen jam nut on each chain anchor. 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.
CAUTION
Make sure there is adequate overhead clearance. 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. 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 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.)
Dee 94
SM-587
Planned Maintenance
Procedures
1. use nrotectivelubrication fluid. Clark Part Number 1803827. to coat terminals of followirw 111119s;
l
EV-T15 EV-TSPS
DashDisplay
A,B,Y and 2 Plugs (OSC or Traction Control Card) PL4 Plug Plug PL - DP Plug Wire Spades 10 & 1OC and 12 & 12B Wire Terminals 13 (or 13B) and 26
Key SwitchTerminals HornTerminals
Relay Terminals (for optional equipment only)
2. Check Contactor Tips for the following:

l
Cleanliness Wear 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.

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

l
Meter should register 20,000 ohmsor greater

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

when measured between any EV-T15 control power terminal and truck frame.
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.
SM-587
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 . . .
l
. . . 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
are tight without disturbing the spring preload adjustment.
Brake Cylinder A-+Dee 94 PM-28
INSTALL NEW BRAKE LININGS when the brake arm moves to within l/8inch of the boot.
SM-587
Planned Maintenance Every 1,000 Operating Hours

Check and Adiust the Followina:
l
Procedures
Forward & Reverses Switches Lift & Lower Switches Transducer

Multi-Function
NOTE
RefertoGroup 19,Section 7ofthismanualforspecific procedures.
Forward Switch Reverse Switch
Transducer
&I Lubrication
Refer to Lubrication
Chart(s) in
Grow 01. Section 1 for all reauired lubrication Doin@ and fluids,
J
N<-
Upright & Pantograph
Hose Sheaves Lift Chains
Breather,
Control Handle Gears & Spring
Hydraulic Filter Sump Tank & Strainer Brake Reservoir -1 Motor Brake Linkage A Drive Unit Pivot Bearing Drive Unit Crankcase Drive Unit Wheel Bearings
Steer Shaft & U-Joints
Caster Pivot Bearings I Load Wheel
Caster Axle Bearings Caster Brake Linkage Axle Pivot Block SM -587
Dee 94
CLARKM$z;-ia;Handling
Section 1 Lubrication Chart & Illustrations
GROUP01
NPR-345
Lube Chart & Specifications
SM-587
Copyrighted Material 01-1-l Intended for CLARK dealers only Do not sell or distribute
Dee 94
GROUP 01
Lubrication Chart Key
Lubrication
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.
L18l L2
NLGI #I Grade
Clark Spec. MS-107B
L3
NLGI #2 Grade
Clark Spec. MS-107C
Ir
General Purpose Grease with EP additive
L4
NLGI #2 Grade
Clark Spec. MS-107D
General Purpose Grease with EP and Moly additives
Cold Storage Applications
w Temp Grease
ML-G-23827A
L5
MOCO loo0
@ L6 B
AMOCO 1000 or equivalent Clark Part No. 886399
Chain & Cable Lubricant
Clark Part No. 885385
l-case of 24 one qt. cans
L7
Clark Part No. 885382 l-caseof 6 one gal. cans Hydraulic Fluid
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
Cold Storage Applications
::+.,. m:: :::::::::::::::::::::::
Royce 717 or equivalent
Ef?I
.:.:::::::::::,:.~
MIL-F-17111
Hydraulic Fluid
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.
L8 L9
Special Grease
DOT 3
Acheson Gredag 2230 Dow Coming Assy Paste Texaco Texclad 2 or equivalent
A specially formulated (tacky) grease with excellent adherence capabilities.
Dee 94
01-l-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
SM-587
Lubrication Chart
GROUP 01
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
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: All Power Cable ConnectionS
l
A,pply to electrical
CC 2nnections
All Motor Cable Connections.

All Control Panel Cable Connections.
any time ley are disconected. Note: Reaulybeforemakinrrthe Dnnection.
All Screw-On Tme Wire Terminals

l
All Card retainer screws. Motor Ground Wire (both ends), see below. Reverse Alarm (if so equipped). Strobe Light Connections (if so equipped).
Ground Wire Apply to wire connections any time they are disconnected. Note: ReaDplybeforemakingthe
c;I
Pump Motor
Dee 94
01-l-4
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.
l l
General Note for Part Numbers: 1803827& 2802295. Apply to electrical connections any time they are disconnected. Note: Reauplvbeforemakinethe connection.
Drive Control (EV-T15). Steer Control (EV-TSPS). PL and DP plug connections.
IMPORTANT Avoid direct spraying on contactor tips.

l
Power Cable Connections. A
CAUTION
Cover all prior to
Do not spray motor brushes

and commutator. motor openings spraying.
l
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 Key Switch terminals. Heater Thermostat (Cold Storage). Them0 stat located on contactorpanel.
Electrical Options (Spray all connections).

l
Forward Pointing Head Lights (terminals). Strobe Light (terminals) Reverse Alarm terminals (if applicable). Any and all switches used on the option(s).
Aux. Motor
SM-587
Copyrighted Material 01-l-5 Intended for CLARK dealers only Do not sell or distribute
Dee 94
GROUP 01
Lubrication - Cold Storage

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

(spray threaded area only). See below.
Motor brake adjustment linkages,

springs and bleeder screw (donot spray directly into the bleeder screw). See
Threaded Areas
Dowel Pin Retainers on pantograph. There are nine (9) pins total.
Caster brake adjustment linkages,

springs and bleeder screw (do not spray directly into the bleeder screw). See above.
Dee 94
01-l-6
SM-587
Lubrication
- Cold Storage COLD STORAGE LUBRICATION
GROUP 01
Hydraulic
Sump Tank Fluid which meets ML-F- 17 111. (Royce 7 17 or equivalent)
Specifications: Use Hydratic

.
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
-
B , \ -T-
Grease Fittings Sr>ecifications: Use an extreme low temperature aircraft quality grease meeting ML-G-23827A, product. Temperature range: - 100 to +250F. or equivalent
Refer to Lubrication for remainder of instructions
Chart on Page 3
and time intervals.
SM-587
Dee 94
GROUP 12 SECTION 1 Battery

Contents
Battery Service Area .................................................................. Handling Storage Batteries ........................................................ Battery Removal & Installation ......................................................... Battery Maintenance ......................................................................... Battery Installation ........................................................................... Battery Records ................................................................................ 12-1-3 & 4 12-1-3 & 4 12-1-5 12-1-6 12-1-7 12-1-8
, ....
,
(....i .- .._.___ _ :::;.y

;Y
BATTERY SERVICE
nnrr
L.
I..
._._., ,<\
~.
D
-.&.._..~.-;.. -.
,.,
Y\
Remove all jewelery before working on the truck
Dee 94
GROUP 12
BAllERY
A
FLUSH IMMEDIATELY
WARNING
ACID
SULFURIC
THE BATTERY CONTAINS
CAUSE INJURY. IF ACID CONTACTS ASSISTANCE.
ACID WHICH CAN YOUR EYES OR SKIN, WITH WATER AND GET MEDICAL
CORROSIVE
Disconnect battery before handling electrical components. Polarity must be correct to prevent damage.
1147748
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
BAmERY
BATTERY HANDLING
Change or service batteries only in an area designated for this purpose.
l
GROUP 12
-..__.+ 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.
DANGER
Explosive gas is always present around batteries, especially when they are being charged. The following should be adhered to.
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 Long shirt sleeves. Gaunlet gloves.
A
THE BAlTERY
WARNING - SULFURIC ACID
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
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
BATTERY
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
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.
sulated Spreader Bar
Typical lllustratior
If the battery does not have a cover of its own, cover it with a non-conductive material such as plywood-
Plyw~
(Non-Conductive
Cover)
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
SM-587
BATTERY
Battery Removal
1. Move truck to the designated battery service area. 2. Turn key switch OFJ? and disconnect battery. Key Switch Off
GROUP 12
Brake Applied
Battery Disconnected
.
3. Remove battery retainer plate. 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
Removing
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
Chain/ Container 4
attaching lifting device.

l
An overhead hoist (of sufficient lifting capacity,

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 Vywood or Heavy Cardboard F
---I=
../ .... lad

:A = ---_
-ze
-_
SM-587
Copyrighted Material 12-l -5 Intended for CLARK dealers only Do not sell or distribute
Dee 94
GROUP 12
Battery Vents
l
BATTERY
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
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. After washing battery, thoroughly rinse with clear cold water.
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.
Consult
your battery vendor.
Battery Charging
Follow theinstructions suppliedby theBattery Charger Vendor.
Battery Maintenance
To obtain maximum performance and battery life, the instructions supplied by your Battery Vendor should be adhered to.
Battery Electrolyte
l
Always use a carboy tilter or siphon when handling battery electrolyte. 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
SM-587
BATTERY
Clean Battery Compartment
l
GROUP 12
Clean Battery Compartment
Using baking soda and water solution, clean the walls and floor of the compartment. Rinse with clear water.
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
Air Hose
Blow off the compartment walls and floor with an air hose. Allow to air dry.
REPLACEMENT BAlTERlES
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.
1
.P,...
Fl sawa
::,..
&
Water Solution
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. Install battery retainer. Remove non-conductive material from battery. Connect battery to truck.
SM-587
Dee 94
GROUP 12
KEEPING BAlTERY RECORDS
Records should be kept to get the best service out of your battery and truck.
BATTERY
BAllERlES
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.
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.
spec@ica-
HOW TO GET MAXIMUM LIFE OUT OF YOUR BAITERY

.
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.
.
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. 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. 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.
Thepilotcellshould be changed occasionally to distribute any electrolyte loss over the battery when taking readings.
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..
.
Charging Time. Keep an accuraterecordof the

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.
. . . . .
Visually Inspect for loose terminal connections 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
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\\> Harness
so-7
Lift/Lower Switch
sq7
~,
SM-587
Dee 94
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
Reach, Tilt & Aux. Switches
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.
2. Carefully pull wires taugt but not so tight as to
Multi-Function
Control
cause damage to the connections. Place housing into handle (heel side).
3. Carefully push wires into their retainer slots ...
... using a blunt instrument so as not to damage wire insulation. 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
If disconnected,
CAUTION
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
SM-587
Switches 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.
GROUP 13
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.
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.
Adjustor Bolt
L Washer
GROUP 13
Switches
-#oG ml -Y
I I I Il-
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 3-Wires Each Side
Horn Switch
tioned with all hidden under
Dee 94
13-l-4
SM-587
Transducer, F & R Switches TRANSDUCER, FORWARD AND SWITCHES Forward and Reverse Switch Remove & Replace
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.
GROUP 13
Transducer Installation
l
Install new transducer to the transducer plate. Install transducer and transducer plate assembly to bracket. Route the transducers 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.
Two adjustable switches mounted
Switch Removal
l
Disconnect switch harness assembly Plug PL-8 (to be removed) from the main wire harness Socket SO-8. Refer to illustration on page 1. 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).
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
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
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
SM-587
GROUP 16
Motors
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.
WARNING
........
........ :.: ........ :.:~:::::::::::::::::. ..................................... . . .. . . . . . . . . . . . . . . . . ..j.....:~:::::~::::::.
. . . . . . . . . . . . ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
Remove all Jewelry working on truck.
before
:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
..:.:.:.:.:.:.:.:.:.:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
:.:.:.:.:.:.:.:.:.:.....~.......:.:~.~.:~~~.:.:.~.:.!.:.:.~.:.:.~.~.:.:.:.:.~.~.:.:~.~~.~ :: :::: ::::::::< ..............
..
Always wear Safety Glasses
DischargetheCaDacitorsbeforeworkinpontruck
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.
WARNING
unplugged.
SM-587
16-2-2
Dee 94
Motors
GROUP 16 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: Park truck safely. Fully lower upright. Apply parking brake. Turn key switch OFF. Disconnect battery from truck recepatacle. it is recom-
The presence of any oil on or near motor could indicate either bad bearings or leaking hydraulic system. Determine cause and repair problem before extensive motor damage occurs.
Motor Insulation
If a reduction in motor performance has been noted, it may be due to breakdown in motor insulation causing internal grounding or a short circuit. Failures of motor insulation are due to:
l
Discharge capacitors, see page 2.

l l
(1) contamination (2) mechanical factors
Motdr Cleanliness
Electric motors should be kept clean at all times to prevent shorting, minimize wear, and for best cooling. Wipe off all dust, dirt, oil, water, etc., 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.
(3) high temperatures
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.
SM-587
16-2-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
Dee 94
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. 2. Discharge the capacitors. Refer to Group 19. 3. Disconnect power cables from all motor termill&.
Motors
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. 3. Disconnectpowercablesfrommotorterminals. 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
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.
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
Dee 94
Motors
GROUP 16 BRUSH AND COMMUTATOR INSPECTION
The key to planned maintenance of the brush and commutator is recognizing the undesirable brush and commutator conditions. If this is done, corrective action can be taken before a major component is damaged beyond serviceability. The brushes and commutator should be inspected for even wear and good commutation. Good Commutation: Poor Commutation: or coloring A dark uniform coloring pattern at the brush wearing surface. The surface of the commutator appearing rough, pitted, scored signs of burning or heavy arcing between bars. The pattern will be:
. . . . Streaky film with commutator Bar edge burning. Uneven film. Carbon dust bridging between bars wear.
Different Grade Brushes; When the brushes being fitted are of a different grade from those
previously by the previous used, then it is advisable to remove the film left grade brushes.
This film removal should be done by scouring with a strip of abrasive cloth (do not use emery cloth) while the armature is rotating. Do not finish with a lapped, highly polished surface. A surface will help moderately abraded commutator the new brushes to run in and the commutator will acquire more readily the film appropriate to the new brush grade.
Operating Conditions
Operating environment of lift truck motors varies widely: The following recommendations should be applied as actual conditions dictate. Normal Service: Basically an eightSevere Service: Extended operating hour day of indoor hours, or constant usmaterial handling. age. Extreme Service: Dusty or Sandy Locations Cement Plants Lumber Mills
SM-587 16-2-5 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
Flour Mills Coal Dust Areas Stone-Crushing Areas

Dee 94
GROUP 16
General Brush & Commutator Inspection
1. Remove brush cover(s) and remove brushes from brush holders. Clean brushes and holders. Check brush holders for damage. 2. Inspect condition of brushes. Remove each brush from brush holder and inspect brushes and commutator for worn condition and uneven wear. 3. Clean commutator surface. Wipe commutator with a dry, lint-free cloth.
Motors
7. Check brush shunt for good contact with
brush holder. Be sure shunt is not damaged or burned since this may cause brush spring to carry current and lose tension.
8. Clean and check brush box and connector

screws. Tighten if loose. Be sure brush box shunt connection is tight.
9. If brushes do not need to be replaced, and

commutator is in good condition, install brushes and brush springs into brush holders.
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.
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.
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 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.
J
Shunt-\
f-Cross
Connector
Box
Pressure Spring --+\A
I~rBrush
T!/
1 .I Brush BoxBrush I
Retainer Screw
CBrush Box p_ Brush 1 II I III
AI
Hammer Plate FJI-2
6rus.h BOB Retainer Screw
Observe how brushes are assembled in brush holders, and position of brush lead (pigtail). New brushes must be installed in same manner.
rypical lllustation
Dee 94
16-2-6
SM-587
Motors
GROUP 16
Brush Inspection Chart

REPLACE BRUSH
-i
IF SPRING TENSION
IS NOT THE SAME SPRINGS.
FOR EACH BRUSH, REPLACE
REPLACE PIGTAIL
BRUSH IF IS LOOSE
IF BRUSH PIGTAIL IS LOOSE AT THE BRUSH HOLDER TIGHTEN SCREW.
IN THE BRUSH.
REPLACE
BRUSHES
WHEN WORN TO
Dee 94
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
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 \\
IL
2
Wire Harness
TM-
:;:>g#:; :::::::::::::::: ::: j::::::::::: :::::::::::::::: :::::::::::::::: y::::::::::::: :::::::::::::::: :::::::::::::::: :::::::::::::::: :::::::::::::::: y:::::::::::::
?.Z.W:
IJ 1 Torque
------__-Drive Motor Cable Fasteners to: 150 Ib.in. (I 6.9 N*m)
Torque Cable Guide Nut to 100 Ib.in. (11.3 Nom)
Al
Dee 94
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
SM-587
GROUP 16
Motors
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
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 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: Dusty or Sandy Location Cement Plants Lumber Mills

Dee 94
Flour Mills Coal Dust Areas Stone-Crushing Areas

SM-587
GROUP 16
Motors
1. Remove brushes.
3. Remove four screws from drive end head.
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
Motor Housing
Armature Assembly
Drive End Head
SM-587
16-3-4
Dec94
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. Remove bearing from head. Remove the drive end head retaining bolts or screws, itnecessary. Remove the drive end head (the bearing may or may not remain on the shaft). Pull the armature assembly from the housing and field coil assembly. If the bearing remained on the armature shaft, remove bearing from shaft with a bearing puller. When a puller is used, protect the end of the armature shaft with a nut or a thick flat washer. If theshaft, or spline is damaged when removing the end head, the armature or the drive spline usually has to be replaced. Use caution and do
not damage the armature.
IJ
GROUP 16
YJ
II
Ventilating Fan
l
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
l
If the bearing remained in the end head, remove bearing from end head. On some motors the bearing is retained with a snap ring. Remove the snap ring, then press the bearing out of the end head.
Use a hammer and chisel or drift punch to drive spline out of shaft.
Dee 94
SM-587
GROUP 16
Component Inspection & Trouble Shooting
Motors
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
The
Streaky film with commutator wear. Bar edge burning. Uneven film. Carbon dust bridging between bars.
Drive End Head

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

1. Check bearing recess for any signs of wear.
Brushes should be inspected for uneven wear and signs of overheating, i.e.
l
Discolored brush shunts Discolored brush springs. Refer to the Brush Chart on page 16-3-11.
2.
Check brush holder insulation for cracks or any signs of burning.
3. Check brush holders and springs for wear.
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
Armature
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.
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.
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.
Brush and Commutator The brushes and commutator should be inspected for
even wear and good commutation. Good Commutation: A dark uniform coloring pattern at the brush wearing surface. Poor Commutation: The surface of the commutator appearing rough, pitted, scored or signs of
SM-587
16-3-6
Dec94
Motors
4. Standard Winding Armatures are tested on a growler (see illustration below) using a steel strip or hacksaw blade to locate any shorted
GROUP 16
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.
Hacksaw Blade
Check the condition of all insulation. If the insulation on the field coils appears blackenedor charred, the serviceability of the coils is questionable. Burned or charred insulation is a result of coil overheating due to overloading conditions, groundedor shortedcoil windings. Check condition of all other insulation such as brush rigging, under coil connections and around terminal studs.
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.
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.
Dee 94
SM-587
GROUP 16
FRAME AND FIELD SERVICE NOTES If the inside of the motor is exceptionally dirty and
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. 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.
Motors
REASSEMBLY
Reassembly is the reverse of disassembly.
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. 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 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
When changing brushes

When changing brushes the commutator serviced as follows:
l
must be
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
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.
After field coil installation, connect the solder joint making sure the solder is flowing properly to avoid a cold soldered joint.
Pole Shoe Screw Removal & Installation (Field Coil Removal & Installation)
SM-587
Dee 94
Motors
24-Volt Motor Specifications
GROUP 16
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 Weight (Approx.): 43 lbs. (19.51 kg)
Internal .
Bearings are sealed and lubricated with high temperature grease for the life of the bearing.
Motor Insulation
l
Armature components, Class H Commutator components, Class H
Commutator Servicing Diameters

l
ROTATION: REVERSIBLE C.W.D.E. Forward Vehicle Direction
MaximmDiameter, NEW 2.92

Minimum Diameter for RESLOTTING: 2.80 Min. Diameter for REPLACEMENT: 2.75
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 1.OVolts @ 7 1 Amps
Dee 94
Grade: H803
Motor Brush
SM-587
GROUP 16
36-Volt Motor Specifications
Motors
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 Weight (Approx.): 43 lbs. (19.51 kg) Internal Bearings are sealed and lubricated with high temperature grease for the life of the bearing.
Fsulation
l
Armature components, Class H

Commutator components, Class H
ROTATION: REVERSIBLE C.W.D.E.
CommutatorServicing Diameters
Maximum Diameter, NEW:
Minimum
Forward Vehicle Direction

2.92
I
Diameter for RESLOTTING:
2.80 2.75
Min. Diameter for REPLACEMENT:
C.C.W.D.E. Reverse Vehicle Direction
Brush Data
l
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 5)
Max. Force per Worn Brush 12 oz. (340 5)
BrushDrop 1.0 Volts @ 71 Amps
Grade H803
Motor Brush
SM-587
16-3-l
Dee 94
GROUP 16
REPLACE
BRUSH
IF SPRING TENSION
II
I
I
REPLACE
BRUSH IF OIL SOAKED 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
COMMUTATOR
SURFACE MARKINGS
SURFACES
SATISFACTORY
LIGHT TAN FILM over entire commutator

swfoc* ohen is one of many normal condtionl machine. seen on (I well-functioning
MOlYLED
SURFACE
with random film pot-
BLOT nl0t.d
BAR-MARKING, on bon to numb.l
o sfiihdy in o d&k
do&f panem per dot.
HEAVY
FILM
cpn oppeor
over entire commute-
tam is pmbabfy most heqwdy
obrmed
fffm, pppmn
preo of efficient and normal tar and, if uniform,
condition of rommutatorr
in
industry.
of condumm
b quite occ.ptobfc.
WATCH
FOR
THESE
DANGER
SIGNS
STREAKING beg8nnmg
on the commutator of s*rios
swfoce sipnols Ihe to Ihe carbon muses.
THREADING
to rwnfocing --\ .
al
tommutm~r whh
firmlims
rowIts
GROOVING by abrasive phere.
b o mechanical condition cowed motwiol form, in the brush or otmoraction. start corrective
met01 nand*r
whan lxmsiva
mudnansfnoccum
h usually kodr bwsh weor.
brush. Check the chart below
for possible
of commutotw
and mpid
lf grooves
COPPER mattiol,
DRAG,
on obnormol covu
build-up
of commutator of bar. Conif not hked.
PlYCH
BAR-MARKING
produces
bw
w burn...
spots
.-
HEAVY
SLOT
BAR-MARKING edgo to number
con
involve bar. Pot-
forms most often at Iroiling +* bui ton flashover
on lh* commutota ingr equolr
surfor*.
The number of pohr
of these morkon the motor.
atching of hailing tern b r&ted
of rommutotor
dition is rare
half or all 410 numbw
of conductors per dot.
Carbon Products General Electric Company East Stroudsburg. Pa. 18301
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 I Bearing .;-.
17
Name Plate 0 0
Snap -t 112-l 3 UNC-2B A Mounting Bracket 3/8-24 UNF-2B -1
Dee 94
SM-587
GROUP 16
Motors
WARNING
Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris remo2ed with air pressure can cause injury.

Pointer
SM-587
16-5-2
Dee 94
Motors
GROUP 16
GENERAL
Routine Maintenance Schedule with Recorded Findings is the best way to reduce costly shut-downs and repair of equipment during operating hours The goal of any maintenance program, long-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:
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 ..
pull armature out of housing.
Disassembled
T Bearing
View
Bearing
Field Coils & Pole Shoes
Housing Commutator
SM-587
End Head
16-5-4
Drive End Head
Dee 94
Motors
ELECTRIC PUMP MOTORS
GROUP 16
Disassembly
l
Remove the cover band (if so equipped) from the commutator end of the motor. Use a brush hook to reach into the motor and lift the brush springs. Pull the brushes out of the brush 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. 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.
rush I prin! s
c-
Dee 94
SM-587
GROUP 16
l
Motors
burning or heavy arcing between bars. coloring pattern will be: Streaky film with commutator wear. Bar edge burning. The
Drive End Head

l
1. Check bearing recess for any signs of wear. 2. Checkmountingholesforanystrippedorcrossed threads or broken studs.
0. Uneven fti.
l
Carbon dust bridging between bars.
Commutator End Head

1. Check bearing recess for any signs of wear.
l
Discolored brush shunts Discolored brush springs. Refer to the Brush Chart on the following pages.
2.
Check brush holder insulation for cracks or any signs of burning.
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.
NOTE
Armature
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.
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.
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.
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
Dee 94
Motors
4.
GROUP 16
Frame and Field Assembly
l
Standard Winding Armatures are tested on a growler (see illustration below) using a steel strip or hacksaw blade to locate any shorted
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
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.
Switch
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.
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.
Dee 94
Copyrighted Material 16X3-7 Intended for CLARK dealers only Do not sell or distribute
SM-587
GROUP 16
FRAME AND FIELD SERVICE NOTES If the inside of the motor is exceptionally dirty and
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. 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.
Motors
REASSEMBLY
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. 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
l
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
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

l
must be
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 field coil installation, connect the solder joint making sure the solder is flowing properly to avoid a cold soldered joint.
Pole Shoe Screw Removal & Installation (Field Coil Removal & Installation)
SM-587
16-5-8
Dee 94
GROUP 16
24-Volt Pump Motor Specifications
l
Frame Size: 6.5 (165.1 mm) Diameter 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.
Motor Insulation
l
Armature components, Class H Commutator components, Class H
.Commutator Servicing Diameters

l
Maximum Diameter, NEW
2.92 2.80 2.75
Minimum Diameter for RESLOTHNG: Min. Diameter for REPLACEMENT:
Circuit and Rotation

l
Single Rotation CCWDE, + to Battery Negative, to Battery Positive.
Brush Data
l
1 Brush per Holder 4 Brushes per Motor Max. Length of Worn Brush 0.42 (10.67 mm) Length 11.13(28.7n
Min. Force per New Brush 29 oz. (825 gm)
n> 7
Max. Force per Worn Brush 12 oz. (340 gm)
Brush Drop 1.0 Volts @ 71 Amps
Grade: H803
Motor Brush
Copyrighted Material 1 C-5-9 Intended for CLARK dealers only Do not sell or distribute
SM-587
Dee 94
GROUP 16
36-Volt Pump Motor Specifications
Motors
l
Frame Size: 6.5 (165.1 mm) Diameter 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.
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 l
Maximum Diameter, NEW:
2.92
Minimum Diameter for RESLOITING: 2.80 Min. Diameter for REPLACEMENT: 2.75
Brush Data
l
Length -6 1.13(28.7mm)
Max. Force per New Brush 29 oz. (825 gm)
BrushDrop 1.0 Volts @ 71 Amps
Grade
H803
Motor Brush
16-5-l 0 Dee 94
SM-587
Motors
GROUP 16
REPLACE
BRUSH
v
CHECK TENSION OF EACH SPRING
IF SPRING TENSION
REPLACE PIGTAIL
BRUSH IF IS LOOSE
IN THE BRUSH.
0.42" 1
REPLACE HERE. BRUSHES WHEN WORN TO
NEW BRUSHES
Dee 94
SM-587
GEA-7

COMMUTATOR
SURFACE
MARKINGS
SATISFACTORY
SURFACES
LIGHT TAN FILM ov.r entire commutator

surfoc* is one of many ohen nomwl conditions machine. seen on a well-funaioning
MOYYLED condition
SURFACE mod
wf+ft mndom film patfmqwn+fy observed in industry.
SLOT IAR-MARKING,
fib,
a sfiphdy darker
a dafinih panem par Jo+.
HEAVY or.0
FILM
<on oppeor
ov.r
weire
+em is probably
appmm onbanin
+o numkr
of efficient and normal
commvto-
of commu+q+orr
nl.a+ed
of <onduc+urI
+or and, if uniform,
is quite accep+abfc.
WATCH
FOR
THESE
DANGER
SIGNS
STREAKING on the ~ornrn~t~+or wrbre begmmng

of r.riow m.+al nondw for brush, Check the chart b4o.v
sign&
the
YHREADING whan lxcwsiw
of tommu+~+or me+ol hondw
with occur.
fine liner roruhs h usually fwdr brush wear.
GROOVING by abrasive
is o mechanical condition caused material form, in the brush or o+mos_ action. s+w+ correc+iw
to the carbon
possible cousm.
+o resurfacing of ~ommu+a+w and rapid
pherm. If grooves
COPPER mottiol, din
DRAG,
on abnomwl
build-up Rashorn
of comnw+&o~ if no+ &ted.
PIYCH
BAR-MARKING
+x&w
bw of p&r
or burn... of +ft.s,
spo+s mark-
--
HEAVY nching
SLOT
BAR-MARKING edge lo numbw
can
involve
forms mos+ okm
01 boiling edgo of bar. Con-
on +fw commu+a+or wfoc*. ings wuofs
The numbw
of hailing
of ~ommu+a+or bar. Potof conductors per Jo+.
is ram
but can couw
half or all +fta numk
on +fw motor.
+em is r&+ed
Carbon Products General Electric Company East Stroudsburg. Pa. 18301
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 Kit
01
Armature Shafi Bearing
Brush Cover
Dee 94
SM-587
GROUP 16
Motors
AWARNING
Wear eye protection and protective clothing when drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.

Pointer
SM-587
Dee 94
Motors
GROUP 16
GENERAL
Routine Maintenance Schedule with Recorded Findings is the best way to reduce costly
shut-downs and repair of equipment during operating hours The goal of any maintenance program long-lifeand trouble-freeoperations is related to the time spent making inspections and correcting minor problems as they occur. 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: 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:
Operating environment of lift truck motors varies widely: The service frequency shah
depend upon the severity of operating conditions.
w
Normal Service: Basically an eighthour day of mostly indoor or out door material handling.
Severe Service: Extended
operating hours, or constant usage.
Extreme Service:
Chemical Processing Freezer Operation
ProcessingPlants (Poultry, Meat)
Dee 94
SM-587
GROUP 16
Motors
+r 1 --_-, Name plate
Br,ush Cover f
Matching half of coupler attaches to hydraulic pump
Dee 94
Motors
AUXILIARY/STEER
GROUP 16
MOTORS (PERMANENT MAGNET TYPE)
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.
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 2 Read the nameplate to become familiar with the motor, especially the rated voltage. Try to turn the shaft by hand. Keep motor leads separated while doing this. If the shaft turns freely go to item 3. If the shaft wont turn, proceed to item 2A.
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.
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
Ammeter
PoDwce r SUPPlY
Dee 94
SM-587
GROUP 16
MOTOR DISASSEMBLY Care must be taken when the permanent magnet
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
. .
Motors
Disconnect brush assembly lead. Lift brush assembly from brush holder.
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. 8. Scribe a match mark on drive end cover and housing. . Remove drive end (pump mounting) cover. Using a pry bar, carefully pry on cover to loosen. Tap lightly on pry bar, if necessary.
CAUTION
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. 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 1. Loosen and remove clamping screw in brush cover band. 2. Remove brush cover band segments by prying coverpins out of engagement in motor housing. 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.
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). 11. Pull armature out of assembly in one quick motion.
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. 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. 12. Remove commutator end cover. . Remove and save bearing spring washer fi-on the cover bore.
NOTE Observe how brushes are assembled in brush holders. Note position of the brush lead (shunt). 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.
16-7-6
SM-587
Dee 94
Motors
GROUP 16
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
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
End Bearing
Dee 94
Copyrighted Material 1 S-7-7 Intended for CLARK dealers only Do not sell or distribute
SM-587
GROUP 16
Motors
Drive End Head

1. Check bearing recess for any signs of wear. 2. Checkmountingholesforanystrippedorcrossed threads or broken studs.
l
burning or heavy arcing between bars. coloring pattern will be: Streaky film with commutator wear. Bar edge burning. Uneven film. Carbon dust bridging between bars.
The
l.
l
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 Discolored brush springs. Refer to the Brush Chart on the following pages.
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, 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.
Armature
1. Check security of fan. 2. 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
Dee 94
Motors
4.
GROUP 16
NOTE
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.
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 .
Hacksaw Blade
Jre
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.
Lights
L- Switch
WHEN CHANGING BRUSHES

Growler
NOTE

l
must be
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.
stator
1. Check magnets to be sure they are securely mounted and have no cracks.
REASSEMBLY
Dee 94
Copyrighted Material 16-7-g Intended for CLARK dealers only Do not sell or distribute
SM-587
GROUP 16
24-Volt Auxiliary/Steer Pump Motor Specifications
Motors
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 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. Grade: M-8 Magnets
l
4-Magnets
4 Poles
MotorInsulation
l
Armature components, Class H Commutator components, Class H.

l
Circuit and Rotation


l
2.92 2.80 2.75
Minimum Diameter for RESLOTTING: Min. Diameter for REPLACEMENT:
++
--
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 1.0 Volts @ 71 Amps
SM-587 16-7-l 0
Grade: H803
Motor Brush
Dee 94
Motors
36-Volt Auxiliary/Steer Pump Motor Specifications
GROUP 16
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
l
A coupler is used to connect the motor to the pump. One half the coupler attaches to the motor and the other half to the pump. Circuit and Rotation
l
Insulation
l
Armature components, Class H Commutator components, Class H 2.92

. . .
Minimum Diameter for RESLOTTING: 2.80 Min. Diameter for REPLACEMENT: 2.75
Brush Data
.
l
,
Width 0.812 (20.8 mm)1
Max. Force per New Brush 29 oz. (825 gnI)
Brush Drop 1.0 Volts @ 71 Amps
Grade HO03
Motor Brush
Dee 94
SM-587
GROUP 16
Motors

I I
REPLACE
BRUSH
IF SPRING TENSION
REPLACE
BRUSH IF OIL SOAKED
REPLACE PIGTAIL
BRUSH IF IS LOOSE
IN THE BRUSH.
0.42" 1
REPLACE HERE. BRUSHES WHEN WORN TO
NEW BRUSHES
SM-587
16-7-l
Dee 94
GEA-7053

COMMUTATOR
SURFACE
MARKINGS
SATISFACTORY
SURFACES
LIGHT ohen
TAN
FILM over entire commutator normal conditions machine.
MOTTLED condition
SURFACE of
with random film patobserved
SLOT related
BAR-MARKING, on bon to number
a slightly darker in a definite pattern
HEAVY
FILM
con appear
over entire commute-
surface is one of many
tern is probably
most frequently
film, appears
areo of efficient and normal tar and, if uniform,
seen on a well-fundioning
of conduc+ors per slot.
is quite acceptable.
WATCH
FOR
THESE
DANGER
SIGNS
STREAKING beginning
on the oxnmutctor of serious metal below
surface signals the to the carbon causes. for possible
THREADING
of commutator
with
fine lines resuhs brush wear.
GROOVING by abrasive phere.
is a mechanical moteriol
condition cowed or otmosqction.
trander
when excessive metal transfer occurs. h usually leads to resurfacing of commutator and rapid
in the brush
brush. Check the chart
If grooves
form, star+ corrective
COPPER
DRAG,
on abnormal
build-up
of commutator if not checkd.
PITCH
BAR-MARKING
produces
low
or burned
spots
--
HEAVY
SLOT
BAR-MARKING
can
involve bar. Pot-
mote&al, forms most ohen at hailing dition is rare
edge of bar. Con-
on the ~ommutotor
surface. The number
of these mark-
etching of trailing edge
of commuta+or
but can cause Rashover
ings equals half or all the number
of poles on the motor.
tern is related to number
of conductors per slot.
CAUSES OF POOR COMMUTATOR CONDITION .a,+* cgn..,ir. Onion. Tk .+I. MaInO in. F...q., hOI i~pw+on o+ commwt* WVdicot. som. p0.dL.l. em... d++I. rmditions. or.. <an worn yw Wk. on* o+ m. obon tkprop., pmdunir. m~innnar.. .ondition. an d.*.lopinQ so h7t ou can Mk. ,~rrinp
Carbon Products General Electric Company Copyrighted East Stroudsburg, Pa. 18301
Material Intended for CLARK dealers only Do not sell or distribute
Cl!!JRK
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
Dee 94
GROUP 17
Contactors
r ---------sclE%v-
Lock Washer Bolt
I I
l------_--
Q%J- Lock Washel 2.7 Washer 8
-I
Insulator
(If
Conductor
* =;5
&
f Spring-&
Support
L -----
Bracket
(Not Serviceable)
Coil
Base
Forward
Dee 94
Reverse Contactors
17-l -2 SM-587
Contactors
Forward / Reverse Contactor
GROUP 17
WARNING
Disconnect battery before working on contactor 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
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. eroded surfaces. Look for evidence of tip welding. Inspectforevidenceof any contaminants on tips (paint, dirt, paper or cloth material, etc.) which would impair operation.
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. 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. 15. Pull insulator and core bushing from core. 16. Remove armature core with spring from bottom of support and remove support from vice. 17. Remove Bracket (D) from coil and base. 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.
Dee 94
2. Inspect contact tips. Look for any worn or
. .
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:

1. Disconnect power cables from contactors. Removebolts with washers, lockwashers and spacers from contacts. Move power cables out of the way. 2. Disconnect connecting buss bars from contacts. 3. Disconnect wiring from contactor coil terminals. 4. Remove mounting bolts securing Forward & ReverseContactorAssembly tothecontrolpanel base plate that is attached to the truck. Remove assembly fi-om truck. 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
GROUP 17 r
--------me
Contactors
Lock Washer Bolt
s Lock Washer .z 7 Washer E3

l----------
Conductor
p--
Insulator
L-_-_--l
Bracket
(Not Serviceable)
Coil
Base
Forward
Reverse Contactors
SM-587
Contactors
Forward / Reverse Contactor-continued22. Inspect spring seats for damage (cracks, breaks,
etc.). Replace damaged parts with new.
GROUP 17
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
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.
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.
24. Inspect coil for damage.

IMPORTANT The coil has four blind alignment
30. Now locate the Forward Contactor Support and

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.
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.
Inspect alignment holes to be certain they are perfectly round and not egg shaped (damaged). Inspect coil terminals for damage. Replace damaged parts with new ones.
. .
31. Now locate the Reverse Contactor Support and

Movable Contact Assembly over its bracket.
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.
Again, be certain the armature tabispointing inward toward the center of the contactor base. 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. Dee 94
SM-587
GROUP 17
Contactors
-r __---- --
Lock Washer Bolt GQ- Lock Washe g 7 WasheN 8
Conductor III!
Insulator
k+ m
Fastener Lock Washer Insulator Contact Spring Seat
Bracket
(Not Serviceable)
Forward
Dee94
Reverse Contactors
17-l -6 SM-587
Contactors
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
GROUP 17
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
Dee 94
GROUP 17
Contactors
&-Lock
_ockWasher Spring Seat
Nut Washer
----
Insulator
I
I I I I I I I I I
tT---g-Spring
k
-Armature
Base
Assembly
I I I I
I
Retainer
L -----
I-A, Line & Pump Contactors
Dee 94
17-1-8
SM-587
Contactors
I-A, Line & Pump Contactors
GROUP 17
7. Remove lock nut, contact set, insulating washer
and spring fi-om armature stem. Be careful not to disassemble or loose other parts under contact tips on armature assembly.
WARNING
Disconnect battery before working on contactor tips. Before attempting to disassemble a contactor to mstall a new contace set, carefully observe
ti
8. Install spring, washer, new contact set onto stem

and secure with lock nut.
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. 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.
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
2. Inspect contact tips. Look for any worn or
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.
. .
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:

1. Loosen andremove two cover moun ting screws securing cover to coil frame. Observeposition of
positive (+) murking on the cover.

2. Removecover.Besure
to note locationofspring seat and spring under cover.
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
Dee 94
MaterialHandling CMRU Company
Group
SECTION 2 ELECTRICAL SEQUENCE OF OPERATION
19
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 and
CONTROL AUXILIARY CONTROL CONTROL
HYDRAULIC ACCESSORY
Rev Aug 94
19-02-2
SM-587
r-
I f);
I j
;
li
12
12
12 ..
..............
12
..................
..................
...........................................
................... 2 .................... 2 .................... * ..............)* pB,

I 12
EVT 15 CARD .: :......................
TB,
..... .... ......

----41
24
. . . . . . . . . . . . . ;..+
Fp86
0 ..,...........
+XE
, ;
t..........,
0
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . .._.........
m4
py,3
_.;
. . . . . . . . . . . . . . . . . 6,
. .
. . . . . . . . . . . . . ..___....
6,
. . . . . . . . . . . . . . . . . . . . . . . . j__,
SWITCH>;,
12
. . . . . . . . . . . . . . . . . . 2, ~15~------+
G 1111111111111111__11I
.. . . . . . . . . . . . . ..____...
R 23 ------23
10
12
. . . . . . . . . . . .. .. . . . . . . , lo-45
.. . . . . . . . . . . . . . . . . . . . . . 45 . . . . . . . . . . . . .. . . . . . .. . ; cT810
_NO,D
18 a ,. . . . . ./.z FUNCTICN CcnrrRcc
HYDRAULIC FUNCTION CONTROL
12 . ..,. . . . . -... .,O . ..,. . . . . . . . .,O _..___.____.._......., l2 I I . . .. . . . .+...%. . . .. . . . .,&..??... _.:I . ..58
. . . _.. . . . . ., 58 ,. . ..i ._.__.____._..........
... .
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. 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. 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. 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.
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. if the 1C volts. It for about battery is capacitors is normal 2 seconds initially
B.
C.
D.
Note:
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.
equipped with potentiometer Trucks positive connection. battery will not have
Note:
F.
The Negative circuit to the accelerator will be completed through wire #13 to the control panel NEG cable terminal. 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.
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.
G.
H.
J.
Battery Positive is supplied through wire #2, control fuse 2FU and wire #12 to the key switch.
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
SM-587
r2
24/M VOLTS
P_
............................................... ................................
PS-IC
6,
...................
i
......................
i
i30
:......................... 20 .............. . i ;............. 40.. .......................... .
i
;3 304b
i
;O 61
iL---f._
2-2-2 . . . . . . . . . . . . . . . . . 24 IA
,
s-L29
._,30 .. .._........_..........~ 0 .............
_...., 0 . . . . . . . . . . . . . +-c 10 -/*

0 ......................................
j-----
PB6
0 .................. ,
pyo
q, .: .....
JlG
i
...........
j
.
...4
........................
...................
o ..............
i.*
TO4
py,3
61
61
5 ...................................... , 5 .................. i.. ....... ,5

............... %. ............... . 5 .................. 6-----6
................ 4.. ........ , 5 .............. ,,A!. ................ 8 27 ................... ..................
, 5 ............. {.*m3 ,5
............. j.* TB.2
; * TBS 6 ............... 27 .............. i.* T86 I.* p&(
, 3 ........................ ........... PA6 ,.j................. ,4 ......... +-+. ........

pA,,_;.
,,,+_____ PA3 -.I.. ...............
SL-1
34
54
.....
Sk2 SL-3
......
. 3 __________I____
................. 2 o ........................ 26.. ........ . t.. i, j ....
___+.&.____,3
2 o ........................ 26 .......................
PAZ -_I.. ..............
23 -23
*Fe5
iP,y
py5 y---y
P,M P;3 Pi! : :
:.+ . . . . . . . . . . . . t . . . . . ;_;
26
20
.13
. . . . . . . . . . . . . . ..___...............
0 .._.___...............,, 5
0 . . . . . ..___...i.<TB,s
m,
. ..___..........
26
. . . .._........._......
26
.........
; oTB,d
TBge;
..20
.__._.................
20
;._ . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . &d&%...,, +______---,O_____+ 1 AUX2 a.----__65
. . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . +.Ta,a _--_-----65-----~~T~,~ . . . . . . . . . . . . .._____... 55 45 ._........... +T6,, ; ST010
,B,
. . . . . . . . . . . . . . . . . , 3 . . .. . . . . . . . . . . . . . . .. .. , 3
.J- + .__._........_. RZbCH 55 0 . . . . . . . . . . . . _L * 1 lo-45 TILT
& _________....__..__......., 0 . . . . . . . . . . . . . \/: ,2 i

; _.,_ _ _... __._ . . .,
P . . . . . . . . . . . . . . . 26 .._................... s1 16
. _,58
26 ______...._.. +a 16
jlTB6
10--x+
SOLEN3lD FUNCTION axrFcL
0 _.._ _ _... .,,4...??...
__ _ ..?. . . . . ., 56
.+,S
{ _... . ..,. . . . . . . . _,O I , 2
. . . ..,. .,p._.??.._.
..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 Switch
#3
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.
Status voltage battery be displayed Code -15 or -16 will is less than or higher than the function #15. voltage setting, if the battery preprogrammed
Note:
B.
The negative circuit to the solenoid control will be completed through wire #13 at terminal TB-1 of the Solenoid Control card. 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. The closing of the line contactor power tips will release the steer lock switch. (close)
C.
D.
E.
The closure of the steer lock switch will supply battery positive through wire #SO to terminal 4PLl of the EV-TSPS steer control. The negative circuit to the steer control will be completed through the internal black wire connected to the PS-NEG terminal. 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.
F.
G.
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
SM-587
BATTERY
._
1 FU 2FU
l_,.
._
24/36 VOLTS
61
12 10
l-l0
12 10
10
2 lx6
!O 61
12 10
12 10
w:
10 2 10
................. .E?.................... ........................ . ...........
yfxI-;=.i
12v13J
1 1 ;
p@j ,.; ............ .... . 3. ............... .. ...... 30 .. .... ......i 41-41---+ 10-10 pB6 PW *: 40 40:
10 cI_y* 10
IA
6 1 ...................... 6, SL-1 4 4 ....... .iw& ....... 13 PA4,.j .. . . .. . . .34

PA+____
.....1 ......................_;
15 ...................................... , 5 t ......... 15
i--_l5A
.... .... .... ... .. , 5
-i_
5 .... .... ... ...... , 5 .............j.* TB* ...... .. .. ...._ FwD ___.____.___.., 6-6
iaT
. . . .-.... . .,a ,. . . . . . .iSL-3 54 ---..?a&.___., 3 . . . . . . . . . .t.
.. ..
*_I .__..._.......... 20 ................._..... 2. .....................f * .................. B...............i.* TB6 pAa ;......... 1fj ..............F!0 ........_..._.... -_I ..... .......... 26 ...._._.______.____.... 26 ......... 27 ............_...2..............i.* pB4 ,,A* i .____..._., 5 ..............\ $7 ......._......... R :15 ,-p 23 -23 Ii
10 26 ~ 2; 13
*lo-k5 L-lo
----,(,---
_i., AUXZ--es 6. ____ ,(,,-a lo1 0 ._\fi
-- ..._.................. 55 .............;.<Tf,,, * ...FEPCH ... .. .... .. 55 J._ TILT i_ TBtO 45 -45

. . . . !! . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . &TO8
.
E\...%..
..............
5
j*TBM TB8 *.
26
.....................
.26
........
.A
................
-13 0
20
.....................
.20
......................
...................... 35 .............i. :*,,I,~

-________
-13
65 -----;+TBZ
B I
1;
10
10---G ---,
16
16
:*TB6
_____,
1 i
112
. .,58 . ..?. . . . 56 . . ..,.. .j.<785 0 ___>p...%. . ..58 . . ..i s3 10 $ .._.___..._..... 38 ...____.___...._...... 38 .............+,,
46 .......0 .... ... ...... 46 .. .......... .;.+TBa
SOLENOID NNCTKMl Oa-rRu
1o
,&s6________. 4; ___..__. i
12
,~
:.......................;
Aug 94
SM-587
H3RN SWITCH Material Copyrighted Intended for CLARK dealers only Do not sell or distribute
OPERATIONAL Close the Key
SEQUENCE
#3
Switch
(Continued)
H.
The EV-T15 control card checks the battery condition by checking the battery volts between terminal PB-1 and battery negative. If the battery is not discharged, the card will supply a voltage signal from terminal PA-2 through wire #26 to terminal TB-7 of the Solenoid Control. The closure of the line contactor power tips will keep the 1C capacitors charged to battery volts. The BV-T15 control card will monitor the capacitor charge on the white wire at terminal PZ-14.
Status Code -50 will be displayed if the capacitor voltage does not remain above 85% battery volts after the line contactor closes.
J.
K.
Note:
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. 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.
M.
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
SM-587
BATTERY r2 2 2FU P \... . .. . .. . .. . . .. . . . .. . . . . . . . . . PS-IC 61
*HIwe
24136 VOLTS S FUM?hKITORA
:::::::::::%;:I PS-TP
I
I PSNEG
10
50 SrE ER ... . TRAN>CUXR m : s; . -.,
:......................... 2(J............ ............................ i .....................
61
t
2
$FlELd
-12-12~12
EVT 15 CARD :. ............. . ..: -2 AL 10 10 -/% IA 24-----24 41-4, lo-lO+TB4 -----j-p86 2 2 j .PB1 TBI . ; 29-
A i ; .PE* pwc.j................ 3. _....____...............~~............

pyg *.; . .._________.._._ 4. ,....................... PY13 0 4. 61 . . . . . . . . . . . . . . . . . . ..
3RAK!z
10
61
f .. . . .. . . , 5 . . . . . .. . . . . . . f-15-z
_ ....................... , 5
6-6
. . .. . . . . . . . . . . .. .
. .. . . .. . . .J4 _..__.QPQ_...__l 3 ---------, 5 ..__......... j.. TB2 pAd._j ; * TM

,,+_____ 54 SL-3 ___+.+.___.,3 . . . . . . . . . .
F y . . . . . . . , 5 . . . . . . . . . . . . . . ,, A. . . . . . . . . . . . . . . . . . . . -15 -+R
2,
. . . . . . . . . .._......2.
. . . . . . . . . . . . . i.*
p+s
26y
80
81
82
13
83
26
10 ,o-Es 1o ~_~...,5 -I AUX2 b------65
10
10 ---+TBlS~ 5 j-b TB14 Two TBlC

_..20
26
-26
.._...................
2.
. . . . . . . . . . . . . . . .._.....
. . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . &,3 ---------65-----~rTB,2 . . . . . . . . . . . . . . . . . . . . . . 55 45 ._.___................ . . . . . . . . . . . . . f.cTB,, ;snwo
12 ___________,O_____+ ,O_, lo10 12 ___________,O lO----v~
-13
13
-J--w * . . . . . . . . . . . . . . 55 1. TILT -45 P \h .._._._..._..... 28 s1 18
28 . . . . . . . . . . . . . ;.oTBa 18 j*TBs SOLENOID FUNCTION a?NTRci.
li
12
I r
112
. -58 . . ..-. . . . 58 . . . . .j..T& ___________,o______+?.? . ..58 . ..i s3 10_$. ...__......_...38 ...................... 38 .............&TB4 55 , ,, _~/_..__._........ 48 .......f ............. 48 .............+,a :.. . . ........... ... ...; S6 , 0 _v4 .__..._........ 48 . . . . . . . i II
_____+...S.?... 12l
1;
131
SM-587
HORN SWITCH I&-09 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
Rev Aug 94
OPERATIONAL Steering Function
SEQUENCE
#4
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'. Current flows from the battery, through the line contactor, current sensor, steer motor armature, transistor and back to battery negative. 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. 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. When the gate voltage to the transistor is removed, the transistor turns 'OFF'. 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. 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.
C.
D.
E.
F.
G.
H.
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.
standing on from the Steer Motor
Rev Aug 94
19-02-10
SM-587
r2 2 2FU
STEER
SXK SWITCH _,
t 12
rI
12
ITCH
12
-10
12
c
10
10 10 10
12
12
1 12
-t
c
-1
10 0 -/+ 10
LL
24-24 IA 41-41
i.F-32
R4KE 0 PITCH>!<
12
, 0 _,
o+
30/ 30 *.!................ 4. .............___.__..... 4o ..................i ; * PB6 pyo Tm py,3*.I.................61 .............___._...... 6, .....................

Fwrj
+. .............__. &++;...... , 3 ...................... , 5 ................. , 5 _._____._____~.~ 44 ._...... m3 p*G ~.________ , 5 ......~............................... .-.....,..,34 5 . m2 PA4,.j ~...___.._ , 5 . ...""..""._..&...'............... . . . . . . . . . . . . . . . . , 5 ________.._._~..
6------6
SL-1
. . . iy3 __.... 13 ___________-"___.,3_________

. . . . . . . . . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . .
; * TB5
.. . . . .. . . . .. . . .
pA5+______
PA3 *_; . . . . . . . . . . . . . . . .
54
2.
f______.__.,
5 . . ..__....... i ~~~~~~~__.~ 5 . . . . . . . . . . . . .
4% . . . . . . . . . . . . . . . . . .
. . . . . . . . .. . . . .. . . .. 6
i.&TB6
m
$
R
.__.__..._.__.___2,
.____._.._.._.._..2,
. . . . . . . . . . . . . i.*
PA2
26
26
,5w&
23-23
$iEf$-l
12
60
61
62
13
63
1
26
10 lo-L5 10_Jne??L35 12 ___________,O_____ , 0 _, ,0-G-GE45
10
lo+TBl5 5 +oT014
TB7. TBOb TBl.
-20 -13
26
2620 13
. . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . +B,3 ^t AUX2 _* +______65-----____ 66 ____+,2
IFEACH *_..__._.......'55 . . .. . . .. . . .. . .. . . . . . . . 55 . . . . . . . . . . ...& TB,,
i_cTBlO 45 P , 0 _--L/c...............26 . .. . . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . ...+
I?
12 ___________,O ____-______,O 12
.saENOlD
10-k s1 16 56 16 . . . ..+.._...._. 56 VT= . ... .. . ..~.r~~ ______,,4.__5?..._., FUNCTDN Cm-ma
I r
112
______+.%.....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 13 1
1:
SM-587
KIRNSWITCH
Rev
Aug 94
OPERATIONAL
SEQUENCE
#4
Steering
Function
(Continued)
J.
Current will continue to flow from battery positive through PS 1c capacitor to battery negative during the transistor's OFF-time This current will charge the capacitor back to battery voltage 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. 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. highest demand.
RPM
K.
Note:
When more then one signal is present, the demand signal has the- priority on ON-time
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). 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. 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. EV-T5PS card will send the steer control to The EV-T15 control card display a Status that the steer control
M.
N.
P.
Removal of the signal from the Steer Transducer (stop turning the steer tiller) will cause the EV-T5PS control and the Steer Motor to shut OFF in 2-3 seconds.
Voltages Present: J. K. L. M. N. P. Battery voltage across the capacitors. NA NA NA Battery Negative NA
Rev Aug 94
19-02- 12
SM-587
r2 2 2FU
1 FU
MC .I )R '+m *.
TPS-TP m s
6:l
12
r-i
12 SWITCH 10 10
6'1
12
rlo c
10
IO
10
*#,L
IA
24-24 41------41
;.Paz ;*Pm fci
pw
*.~.__._..__........ 30 . . . . .._......._..___...3 0 .._..._...;
t=
10 -$
pys ,_.~-~..40*'-'--'40.-'~~
.
+---15A 6------6
lbTB5 PAS*:------
54
^-
_.,
.................
...
2..0 ............... 8 ................... i......... .15.............. B............... i.. TB6 PA3 _.I.. ............... 2o ..................... ...2 0 ........................
F f___._.,l 5 ................. 27 .................. ................... . 7 .............. ..*pB4 PM* : 26 261
li
1;
10 lo-+=----5
10 Ls?3??!...35
10
lO+TBl5
Te.7.
26
28-
;o TOI4
T80.
. . . . . . . . . . . .. . . . . 2. ._..__._.........._2 0 . .. . .. . . . . . . . . . . . . . . .. . -13 13
. . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . .;.*TB,3
TlJ,,
.___________lO_____ lo----+-, lo-
AUX2 _,,b______65
_.i.s
_________
65
_____+2
.,_____.___.._...5 5 . . . . . . . . . . . . . . .._._... 5 5 _.._____.....~.~ TB(, d._ TILT -45 P 45

+%TEWJ
1,, _\/..
12 10 -4%
_____._........ 28 ..........__.__.___... 28 .............j.+TBa s1

18 "'"r'..."'. 18 58 ;+T86 . . . . . .i .(TBS
,,___________10_____+..??,_...58 ',___________lO 12
SOLENOID FUNCTION CONTROL
______~~...~.*.,.....5* . ... . . 1 0 -,r....s3 . . . . . . . . . . .38 . . . . . . . . . .. . . .. . . .. . . . 38 . .. . . .. . .. . ..~.~ TB4 . . .. . ..y........48 . . . . .. . . . . ...& T&, .___..._i 12 K................... I HORNSWITCH 131 Rev
s5 1 0 -~~,...............48 S6 1 0 -+._.___..____.4* 12
SM-587
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. 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. 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)
B.
C.
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.
The battery state of charge is displayed positive number dependent on the battery the LED above the battery symbol will be as a 3 digit and condition, 'ON'.
Note:
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. The E!V-T5PS steer control will turn on the steer motor at idle speed (825 - 875 RPM).
F.
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
SM-587
2FU
mER ax SWITCH
IFU
24/36 VOLTS
WM'PM3TORA f..!u
. .. . .. . .. . . . . .. . . .. . . . .. . . . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . ..*.~~~..... ,...................................... <\
12
ri
12 %TCH 10
t 12
r-r 1050
12
rlo
c
10 10 10 Rx 10 2 ACCELERATOR 7-T 7
12
10
12
10
li
12
..._............_.2.
23----23
12
, 0 -s??!K..35 12 ,___________,O ,O_, lo,O_$ 12 ,,___________,o ,.______--___,o 12 lo-$ lo-~ _____+..?.? _____+..S.?.._. _____ e-i_ AUX2 d b______65 IFEACH 0 . . ..__......._. 55
. . .. . . . . . . . . . . . . . . . . .. 35 . . . . .._.....+. T6,3 ^________ 66 _____+Ta,s ..___........ +,(f
=I*13 j i
13
. . . . . . . . . . . . . . . . . . . . . 55
J_e TILT ;-%Ttm 45 -45 P . .._........_.. 26 ..__._..._..._.__..... 26 ______....... +a s1 .,.... 16 56 ..66 ..__.? _._...... . ..:
___..__._____......... 38 . . . . . . . . . .._.
16 56
; *Tm .. . . . . . . /..TBS
/ i
SOLENOID FUNCTKN
icxzsrrm
_~ s3 ,_.._...._______ 38 n.25 ..........
j.+T&4
;+ TB3 :....................... . 131
46 ....... y.. ........... 48 ....... .1
46 .............
t-10-
10 _v4
S6 ...............
SM-587
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. 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)
B.
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.
If battery and TB-6 at (Status Code voltage the same -09) is applied the time, to both terminals TB-5 control will be shut OFF.
Note:
D.
This will energize the forward contactor coil and in turn, open the normally closed contactor tips and close the normally open tips. 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.
E.
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
SM-587
r2 EER _ax SWITCH
I FU
.. ..
BATTERY >wilc-<c 24136 VOLTS
2FU
12
ri
12 ETCH
I-f10 50
10
12 10
rlo c
10 10
12 10
12 10
10
13
li
10
EVTl5CARD __.. ........ ............! 10 10 -/IA
*,L
24 -24 41-41
;*Fw frm
Pea.; PY8
l
30
40
12
__________+___
15 15 REV xs . ... .............. *F * 6-6 ................... 27-27
__________e___
.......................I
t-
15 15
12
li 1
1 I
26 2b
OlSPlAY\
WI
Dpz
:
,.i
.+82
; ::
,311
,a-,3
._
-82
_^
-1
TB7.
I
I
I
I
10 lo-k5
,o_,++%?%..~~
\Dp5 10
i&+-+83-83,,~TB15
-20 -13
26
261 20 13
5
. . .._.................
j eTB14
Tw*
35 ....... .... ..+B,3 _____+TB,2
12
TBI.
,___________,O
AUX2 _-_-_.a 1- -______65_-----_-_65 ,O-----L lo1 ,, _$
IFEACH * .......... .... 55 . ..... ............. .. 55 .............&TO,, _J_ TILT ;*TBiO 45 -45 P . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . j.oTW s1 ,a j+T*6 . . ., 58 . . .. . . ./.rTBs 10 SOLENOID FUNCTION aavrROL
12 ,p___________,~ ,,___________,O 12
10-h _____+...??.,. ______+.?8
. .,58 ._. ..?. .

...___.5 8 .. __.i
SM-587
, 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. Status Code less than 88% A signal -24 will battery be displayed volts. if T2 voltage is
Note:
B.
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.
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. 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. 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. The interaction of magnetic energy between the motor fields and the armature causes the armature to rotate.
D.
E.
F.
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
SM-587
2FU
-;t
Bu(
t
92
t
93
T 50
t 30
I 40
!I
20 6'1
a, 91
10
rlo
10
_~2+#+~---13EVIlSLAHU
1 ) ]
24-24
l5-15yTe2 6 6
PM,.;_.,......_.34
...__i~3...___13 __________ .___

___-____,3__________
: . TB5
pA5+_____
54
.___
6 . . .._........__.._. 6 ___.______.__..~. TB6 27-27+m
PA3 ..;.................20 .__..__.................2 o ,....................... PA2
26
I--_ 5-A
12
26~
23-23
10 lo-=5 ,O _++?w. 12 ,,___________,O_____ lolo-
10
10 5
; .TB15 Twc
; *TB14 lBBS m, c
-20 -13
26
35 . . . . . . . . .._........... 35 ..__.._._....j.* Ta,$ _.i_ AUX2 4 b_-_---65~----____ 65-w--+(2
1-H '.....______._..55 . .. . . . .. .. . . . . . . . . . . . 5 5 _.._.........+ TB,, 45 j* TBlO lb SoLEralD FUNCTKN
_i.. TILT -45 P 1 0 _&_.___.__......26
. .. . . . . . . . . . . . . . ..____ 26 ._..........+ TBB
12
12
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
SM-587
d i-cm
Rev
Aug 94
OPERATIONAL Turning A.
OFF
SEQUENCE
the
#S
Capacitor Charging and Flyback
Transistors,
The control now removes the gate voltage and the transistors turn 'OFF'. 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. 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. 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.
B.
C.
D.
Voltage Sequence: Too quick to measure.
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 purpose voltage 'OFF'. of the spikes
when
Note:
#23
REC created
is
by
to filter the the #3 REC turning
Rev Aug 94
19-02-20
SM-587
r2T 2 2FU
2 STEER k%
1 FU
24/36
VOLTS _ WMMOTOR
12
r-i
12 SWITCH 10 10 10 10 10
I 12
ri 105(
10
5(
12
rlo -l-P
2 2
12
12 ACCELERATOR --.Y
t 12
lb
EIRAKE 8iWITCH
E
10 1 0 -/? 10 IA b
*L
24 -24 41-41 lo-lo+T84
--+a ------+Pfs
P83.: PY8 .
30
301 40 --I 6
40
py,3 *./ . . . . . . ..___._....61 ,.......................
, ......................
12
10
_____
12
10
10 10-9-5 ,,~._.___~:.~...35 12 _-________,o lolo,0-/t 10-----u __________,o __________,o ______+.5? ______p...?? _. _----+ _.i_ AUX2 b______65
10
104TB15
TB7* ;oTBM TBS*
: ;
20
20 13
. . . . .._.._.__......... 35 . . . . . . . . . . . . . j.+TB,S _________ 65 _____+,2
my13
..I- * . . .FEPCH . . . . . . . . . . . . 55 .._____.___.__.__......5 5 . . . . . . . . . . . . . +l,, A -45 P ._.._.____.....28 s1 16 .._._. 56 . . . 56

38 . ..__.._._.._.........
TILT
45
28 . . . . . .. . .. . . .
j.%TBlO
;.eTBB
13
16-----f+TB6 . . . .+. . . . . . . ..i

...................... 38 ............. j.+,,.,
j ;
56
. . . . . .i.<T85
SOLENOID FUNCTtCN ;ccNTRoL
O-
fi.... s.. ......

........... 5 .S6 ...........
13
, 0 -&..S , 0 -v4..
112
46 ..... ..?. ............ .4a ........ 12
46 .............
j.eT83
I
-
:. ...................... . 1
d 13-
SM-587
HORN SWITCH w-2d2-21 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
i-cm
Rev Aug 94
OPERATIONAL
Accelerator, Turning
SEQUENCE
#9
and Pulse Monitor Trip (PMT)
Thermal
Protector
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
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. 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.
Even at reduced current the truck should be able 1A contactor operation. limit during thermal to reach sufficient cutback, speed for
B.
Note:
C.
When the transistors are turned ON, the #3 REC stops conducting. 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. The control AGAIN' mode exists. To closed with 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.
D.
E.
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
SM-587
r2 2 2FU
24/36
VOLTS _ PUMtvKITOR **.a
SEER
LCCK SWITCH
........................................ r
P L PS-3REC
---a.....~ --..................................................................... 1
................... ps-ic. 6, ........................... . , ................................. , ................... .
12
ri
12 ETCH 10
t li
R-10 50
10
10
50
Es_
$y.
50 50
$ 1
501
1ri;;
:......?n ...................
2 0
.. . . . . . . . . . .
12
rl c
10
11
I
2
24-24
10
15-15 l5-_15iT62 6 6
;*m
PA6 +..... p*4 *_I. . .
1.3......_................. i......... _..__., 3 _____-____+____ . . . . .34 . . 0s.e

. . . . . . . . . . 44 SL-2 54 SL-3 ___-____13 .. . . . . . . . . . . . . . . . . . . . . . . 2. 261 _--______+___ .. . . . . . . . . . . . . . . . . . . . . . . j
SL-1 . . . . . . . . . u*- . . . . . . . . .
TBS TB6
p+_____
6 . . . . . . . . . . . . . . . . . . . 6 .. . . .. . . .. . . . . . $ 27-27-m
p*3 ._; . . . . . . . . . . . . . . . . . 2. PAZ
26
2 10
10
10
1o+m5
Tw.
26 20
26 20 ___ 13
I
12
10-x5
;*TLw
l-60, 781-13
; ;
...................... 35 .............+J,3
65 _____+,2
*........___.... 55............_.......... 55 .............i.<TB,, ; *-WI0 45 ....._._.......____... 26 .............+,?,~

12 16 56 ;-* 1% . . . . . . j.rT65
13
; so!_EtalD i FUNCT!CN
;coMRoL
12
...._____.__.____.._.. 38 .............i.+W
._v4 . . . . . . . . . . . . . . . 46 12 13 Rev
-587
I-iORN SWITCH Copyrighted Material 19-2d2-23 Intended for CLARK dealers only Do not sell or distribute
Aug 94
OPERATIONAL
IA
SEQUENCE
#10
Contactor
Operation
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. 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. 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. 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. 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. 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.
The EV-T15 1~ will not cut-back. has close a built if the in thermal control is hold-off in severe feature. thermal
The transistor
B.
C.
D.
E.
F.
Note:
Voltages A. B. C. D. E. F.
Present:
0.5 volts or less. NA NA lo-13 volts across the contactor coil Battery volts across the drive motor. NA
terminals.
Rev Aug 94
19-02-24
SM-587
r2 2
24/36
VOLTS
2FU
. .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . ..
.................. ps_,c .......... 6, ...........................

I 61
PSBREC t 12
12
rd
12 SWITCH 10 10
II
II
1.
IPS-TP
STEER
,,Q'
I.
92
93
50
io
40
20
12
r10L
10 10
12
10
12
la
61
I-t 12
ia
24 -24 41-41 LRME WITCH 10-10 401
.............. ... ... 6 , ......................

SL-1 .._..... iyi .,... . . . . . . . , 3 . .._.___________.___... 3 _________
15-15
i;;lj . . ..__. ___.,3 2.
___+a# ,% _.._._..._........ . . . . . . . .. . . .. . . .. . .
___-___-__ . . . . . . . . . . . .. . . . . . . . . .
.. . . . . . .._..............
261
26
13
10 lo-=5 10_+&?z?i..35 12 .__________,O ,0-I lo,O_,,/% 12 _ ,__________,O lo----y4 ______,k...? . . 1 _____ * -L AUX2 o______65
10
1o+T615 5 :oTFm
m7c
-----20 -13
26
2620 13
2
TBoaTB1r
. . . . . . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . +j,3 __---_--65 55 ____+6,* . . . . . . . . . . . . j.*Ts,, ;*TBIO . . . . . . . . . . ;.,T@
* . . .-Ii . . . . . . . . . . . 55 ,......................
TILT -455-45 P .__.._.....____ 26 . . . . . . . . . . . . . . . . . . . . 26 Sl 18 16
SOLENOID
j*T66 FUNCTtCN CCNFRCL
1
13 13 Rev
12
. _.58 . . ..f. . . . . 56 . . . . . .j.rTf,5 .__________,o______p..-s?.... ..58 .. . ..i .__ 36 _..................... 10 -&..S? .____ 36 .............j..$Tw 10-$ ...s5 ............ 46 .......f ............. 48 .............j.qTB3
,0.-v4 . . .S6 . . . . . . . . . . . 46 .. . . . . . . i -I 12 i. . . . . . . . . . . . . . . . . . . . . .
112
SM-587
I-DRN SWITCH 19-2052-25 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
d m
131
Aug 94
OPERATIONAL Plugging
SEQUENCE
#11
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. While the handle is in it's neutral position, both the directional switches are open. The control stops functioning because the voltage has been removed from terminal TB-5 of the EV-T15 control card. The forward and IA contactor coils are de-energized and the contactor tips return to their normal position, opening the drive motor circuit.
B.
C.
D.
Note:
The
truck
will
be
coasting
forward.
Rev Aug 94
19-02-26
SM-587
r2 2 2FU ( ret
24/36 I FU ,...................................... r ;i P \ . . . .._........................ ps_,c
VOLTS PUwmoR . . . . . (YiA .. . . .. . . . . . . .. . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .s.>W-k 6, . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,
..
1 8
t 12
61
12
10
ro
c
10 10 m 10 2 -12-12-12
h-J
23 REC DRIVEMOTOR A2%1 R I:
12
10
12
10
8.l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
lo
61
ACCELERATOR ___EVT15CARD :. ....................... 12+$f#-13--l 2930 301 40
: 1
13
li
,n
I I
1-2
2 24 -24
2----+al ;.pen
TB1 . ;
Pm.;
--I;
..;
...................... -;
---p
61
;.
TB3
TBP
,--@ ._......____.......
c ,.; ....._.......... . . . . . . . . . ** . . . . . . . . . , SL-2 p$$, 9.;... . . .. . . .3$ . . . .- . . . . ,

44
SL-1
3 3
........................f... .. . ___-_--___;_ .__ .__ __________;_

. . . . . . . . . . . . . . . . . .. . . .
P,+______
54
SL-3 ___-*9___.,3 . . . . . . . . . . . . . . . . . . . . . 2.
12
13
10 lo-E5 10~.w._QY...35 12 ___________,o ,9-, ,o-G-d=-45

, 0 _# ._.............
10 5 TTB14
TB7. TBo* TBI.
-20 -13
26
2620 13
2
. . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . &TB,3 _____+,* . . . . . . . . . . . . . ;.* TO,,

j.%TBlO . . . . . . . . . . . . . j.oT,M
_----e
-I b______65_________65 AUX2 -J-Faux * . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . . . . . . . . . . 55 45 P

26 . . . . . . . . . . . . . . . . . . . . . . 26
13 SOLENOID FUNCTKZN mRcc
12 ______-____,O ___________,O 12
Sl lo- _____+.. _____+..??.._. , 9 --+...s3 , 0 .___+.s5 ,O __/*\
16 . . . ..L. . . . . . . . ..:
16 56
; *KM t.. . . . .+
s7 . . . . ..56 _.56
..__._..... 36 . . . . . . . . . . . . . . . ..___.. 36 . . . . . . . . . . . . . j..,TBa _..__._.._ 46 .._....? . . . . . . . . . . . . . 46 __.__.___._.. j_+TBJ . . .S6 . . . . . . . . . . . 46 .. . . . ...! I :___. _... . . . . . . . . . . . . .
SM-587
l2
wFz-w,TcH ,&_*7 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
H3R\l
SEQUENCE (continued)
#ll
E.
The operator moves the multi-function control handle through neutral to reverse, closing the reverse directional switch. With the 6 of the has been neutral. over. 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
F.
G.
The control now completes the circuit from the reverse contactor coil to battery negative through wire #23 at terminal PB-5 of the EV-T15 control card. 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. The control now gates ON the transistors.
H.
J.
Rev Aug 94
19-02-28
SM-587
2 2FU
l-27
STEER Loa< SWITCH
1FU P
24/3i
VOLTS
. . . . . . . . . . . . . . . . . . . . . .. .. . . . .. . . .. . . . ../....................................................................... 61 61
12
ri
12 ETCH 10
t 12
rr 1050
12
rlo
c
10 10 10 10
61
li
1 IO
6i
12
IO 1
BRAKE SWITCH
10 lOLL5
,o_+..-_~...35
10
lo+ 5
..____________.__.....~~...__.___.___
TB15 ;-a TB14

;.*TB,3
m7TBs* m,-
26
26-
. . .._.__._......__.*O ________________._______) . . . . . . . . . .. . . .. . 2. . -13 13
12
,,___________lO_____ , 0 -, 10iTILT45
1-
AUX2 +______65
___-_____
65
_____+,2
IFEACH . . . . . . . . . ...+ TB, , 0...............55 . . . . . . . . .. . .. . .. .. . . ...5 5 . 45 i-%TBlO 1 SOLENOID FUNCTlON cm-r&a_
, 0 .-\/:
12
,,___________jo
28 .............+LB ...P .._......... 28 ..._______._._........

s1 16
._.56 . . . ..?. . . . .
10----v'\
_____+._57...
16 56
:eT86
. . . . . .;.<TB5
,,_________-_10______+..S.?...._.56 12 10 -h...SB , 0 _\/,...S5
. . . ..i
_ __....... 36 . . . . . . . . . . . . . . . ..__... 36 ._..........+ TB, . . . . ..f............. . . . . .. . . . .46 . 46 .. . .. . . .. . . ..~.~ TB3 . . .. . ...! :......................
S6 1 0 ~~4...~~..~~~~....4*
I
& l3 Re
SM-587
II*
l2
HOFiiiWITCH ,9$&g Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
; I Aug 94
SEQUENCE (continued)
#ll
As the transistors
the forward
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. 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.
The plugging distance can be controlled by changing the position of the multi-function (regulating) control handle (accelerator).
L.
Note:
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. 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.
N.
Rev Aug 94
19-02-30
SM-587
2413.6 VOLTS 2FU STEER _CCK SWITCI 1 FU
PSBREC t n 10 5 PS-POS mm
61
I
PSNEG
12
r-i
12 SWITCH 10 10
12
roc
10 3 30 40 20 6:l 13
-2 -10 -10 3M WITCk -10 3 -15 /,L ,IA "
2 24-24 41-41-p 10-10
2 +mt jrm?
TBI 0; PB3.: pyo.j
2930 40 30 40....._..__......'._.6 , .. . . . . . . . . . . . . . . . .. . ..
15-15 -15 6 y
i . -ma
TB2 ;.TBS I*~06
SL-1 PA6 *_+........___. 44 "'."...g&"'""
3 .. . . . . . . . . . . . . . . . . . .. .
pnr..~............34 _..__.e...o..,..__13 -__------. pA5+______.54 ___s~-___,3_________.
-15 -15 -15 " *F
6-6 27-27+P84 23 -23
. . . . . . . . . . . . . . . . . .. .. . PA3 ._~_____........_._.20 ._._____.__....._.__....2 o . PM*: 26
261
,R Y
-62 -63
10 lo-L5
10
10 5
; .T81.5 lB7.
;DTB . . . . . . . . . . . . . &,a _____ +2 TBa* lB1.
-20
26
26 20
, o _$..-:_~._.35
___________,O ----AUX2 4L +______65
...................... 35
_________ 65
* . . . . . . . ..__.... 55 . . . . . . . . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . +,, lO----+J_ TILT i sTB10 45 lo-45 P , 0 _,,,L.............. 26 . . .._................. 26 . . . . . . . . . . . ..~ TB8 104% " 16 la 56
IP SOLENOID FUNCTlON Cm-rRcc
; **I36
. . . . . .j .(TB~
___________,o_____.+...S? .. . ..sa . .. . . . .
___________,o ______+.%...56 1 0 _bh...s3........ lo. . . ..i
36 _____..___.._......... 36 . . .. . . .. . . . ..~+ To,
13
/Lss..__.. 46 . . .. ...f............. 46 . . . . . . . . . ...+ TB3 . . . .. ...1 - I 12 !..................... Km 13A Rev
S6 , 0 __+___________..46 112
SM-587
K)RN SWITCH w-2052-31 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
Aug 94
OPERATIONAL Travel Speed
SEQUENCE Limit
#12
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. 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. 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. If
the the Note:
B.
C.
Note:
'Speed Limit C/A' is set the 'C/A', the truck will normal normal C/A rate.
the to speed limit the normal
at a lower value always accelerate
than at
When revert
switch is re-closed operation and speed.
the
truck
will
Voltages Present: A. B. C. Battery negative. Approximately 6 volts. NA
Rev Aug 94
19-02-32
SM-587
r2 2 2FU
STEER LCCX SWITCH
24/36 VOLTS _ WtvPPMOTOR
12
rd
12 SWITCH 10
t 12
n10 50
I\
_JPS-TP
TFI s PSNEG
61
1 3 3040
n--l
..................................................................:
ACCELER4TOR --7 12-12-12 2 24 -24 41-41
13 3040
15-15+T~2 6 6 27-27-m 6 0
i . TM
PA, ..; .. . . .. . . 34 . . . ._....., SL-3

pns,+_____.54 ___-____,3
3 - --------______----
;-TM
PA3..I . ...... ..... .... 2. .__..................... 2. ............... ... ... ... PAZ
26
261
13
10 lo-~5
,0__-&.~...35
10
10+
5
. . .._.................
TBIS
TMTB6b
-20 -13
26
2620 13
TBI,
35 ...... ....... &,a 65 _-_-+,2
12
TB,r
,.___________,o lololo-$.
_----
_.i_ AUX2 + b______65_-__-____ It.
v..!FEKH 55 .................._.... 55 ..... ....... .+,, 0__.____._...... TILT ; hTBl0 45 -45 P ._............. 28 . .._.................. 28 . . . . . . . . . . . . . ;.eT66 s1 18
. . . 5* .y . . . . .
13 SOLEmID FUNCT!ON Cama
12
,
,,___________,o
lop4
_____+..S?
16 5*
frTB6
. . . . . .j.rT85
,,_______-___,(I 12
SM-587
L12
____.+....?... . -58 . . ..i 10_/?...S? ........ 36 ...................... 36 .............i_9TB, s5 , 0 __t/\ .___.___.___.._ 46 .......f ............. 48 .............;+,3 :................. .. 10_v4 ...S6 ... ... ...... 46 .......i I
l2
t0R%flTCH ,&)5z_33 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
&&
OPERATIONAL Solenoid
SEQUENCE Functions
#13
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. 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. LED #2 (RH5) of the solenoid lift interrupt Is activated. control will be turned 'ON' if the
B.
Notes
C.
The solenoid control will not allow any solenoid functions to operate if any of the following checks are not satisfied: 1) Checks for open hydraulic function switch inputs when the key switch is first closed. Terminal TB-10 through terminal TB-14 of the solenoid control must be at 0 volts. 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 #1 (RH4) and LED #2 (RH5) fault exists. 'ON' if of the solenoid control will
Note:
the hydraulic control switches If any of are closed the control will the key switch, seconds of closing functions to operate. solenoid
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
SM-587
SAll-ERY r2 2 2FU STEER .cxx WITCH
b-w<
I FU 24/36 VOLTS
...........................6
12
r-d
12 SWITCH 10
12
10
10
12
10
10
,. .....................................................................
ACCELERATOR ---
li
24 -24 41-41
12
12
to-=5
12
,,._?.p~._.,, ......... ______.___.,o -.-.- + w._____65 _________65 ..I,n--__r 0 . . .RZACH . . . . . . . . . . . c* . . . . . . . . .

A.. lo< -.._
IlLl
-45
45
I
13
, 0 _$...!
12 __.______..,o __________.,o 12 lo-----vh
___._.,,4._-5-7-
........__ 28 _____.____............ 26
Sl 16
. . ..56 . . ..t. . . . .
16 56
..5a . ..i , 0 _$ ....s3 ............ 3a ...................... 38. , 0 _&..SS ........ 48 .......T .......... 48, , 0 _$ ...S6 ...._....... 4a .......i I
_..___p...%?_.
SM.587
13-
Rev Aug 94
OPERATIONAL Lift
SEQUENCE
#14
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. 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. This will energize the pump contactor coil and in turn, 'close the normally open tips. 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. 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.
HYDRAULICS:
B.
C.
D.
E.
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.
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
SM-587
r2 2 2FU
STEER cacti
24/36
VOLTS
t 12
ir 10 50
12
61
12
1 IO
r
1 61
12
10
12
10
LT...; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . :
12
H-T
-12-12-12 10 10
ACCELERATOR 7-i 7
i0
61 13
/.Ry$q 2 24-24 41-41 2 i'"2 i.PBG m*; w9*;
12y-q-13J
VAL
" *IA
30 40
301 40-
t-
10
ISW SWITCH 12 10 15-15 lB-157~62 6 15 15 15 * " *F *R 0 27-27+FS4 23-23 1 1: 6 0 ;*m j.,, i'T83 PM. 44-13 SL-2 PA4..~........,._.34 .."__~_,....13 PAS,&--___.54
--_--___--
-_. -_. i
SL-3 ____k____,3__________
PA3 ..~.........._.____.20 . . . . . . . . . . . . . . .. .. . . . . . . 2o . . . . . . .. . . . . . . .. . . . . . . . . PA2 *
26
26
12
10
. . . . . . . . . . . . . . . . . . . . .
20
.. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
___________,o .__________,o
______,4,..S?......56 _____+...%....56 , 0 -&..S?........ , 0 _&.S5
. . . ..f-..'..'.. 5* . . . ..i
.___.._._i..T85
36 . . . . . . . . . . . . . . . . . . . . . . 36 . . . . . .. . . .. ..~.. T6, ___._._._.46 .".."f""""""' 46 . . . . . . . .. ....+
10_+
-12
...S6 ........... 48 .....__. i

12 -
:........................ I CI m Rev Aug 94

KX=iNSWlTCH
SW587
OPERATIONAL Lower A.
SEQUENCE
#15
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. 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. 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.
B.
C.
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.
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.
Note
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
SM-587
r2 2 2FU
t 2 24136 VOLTS _ WNPMOTOR
I CKX
ZEER WITCH
61
61-
f
t 12 2 T50
12
10
i-l0
c
2 c 10 2 10 2 10 2
50
mER~q~~ i 1
50 50 IC 50-
r* i ido
:....._..__._............. 4 D ~ ~ ! I
2 0
............
EG
12
10
12
10
h..
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . .
. . . . .
. . . . . . . . . .
. . . .
. .
. . . . . . . . . . . . .
ACCELE,A?
12-12-12
12 10
f.y%?q 2~~q-2
PB3 -i
/1
1:II-I
2
*I.
30 40
10 10
AIA
24 -24 41-41
;*Pm
$Fa2
Pm.:
15-15yTTB2
___
. . . ..- . . . . .
12
1)
, 0 ~_$ , 0 -$
.___._....... +, ....s ........ 38 .................... . .~a

. . . . . . . f . . . . . . . . . . . . . 4a . . . . . . . . . . . . . +.T63
13
...S6 ............4a ........!

I
:........................
131
SM-587
H;)RN SWITCH Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
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.
The reach reach/retract switch must operation. be held closed during the entire
Note:
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. This will energize the S3 solenoid coil and in turn, open the oil path to reach cylinders. 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.
C.
D.
Voltages Present: A. B. C. D. Battery positive. 1.2 volts. Battery voltage across the S3 solenoid coil. Battery positive.
Rev
Aug94
19-02-40
SM-587
r2 2 2FU
I LOCK
STEER SWITCH _.
r 12
ir 2
BPS-TP
I I
PSNEG
12
r
10
.12
Y SENPi3 Pi
Piipi2
4PL6 ?
Pi6 pi5
4PL1 t 4PL3 1 4PL4 I 4PL2 !
w EY WITCH 8
i 10 2
STEER
_Flx
c_____________________________-_
16x7 t
4PL5 T
yE&
gz$
50
+r
5oA
I)1lo j
:......~c ........3c ...........
il
2 0 .
..1.........
12
-10 I-w 10 2
-50
.^
12
10
10
I 51
12
10
ACCELERATOR r-i 7
I-t 12 10
I=
10 ERAKE EiWITCH
" ,.IA *L
41-41 24-24
ids2 :*I?36
PY8 l : .w.;
30 40
40 30
lo-l0+TB4
PY13 .
61 SL-1 44-13
61
12
10
15-15 15-15iTw 6 8 27-27+Pe4 6 8 r_
+33
PM.
P,4.)..&...._.34
SL-2 .,,...-...___13 SL-3
__________
___.
; . TB5 PA5cf______ 54 _______.,Q

186 p*3 ..j . . . . . . . . . . . . . . . . 2. .._._................... 2.
__- _______ ___.

.. . . . . . . . . . . . . . . . . . . . . .
PAZ
26
261
12
10
1:3
10 10
"
/,P S'
20 18
28~T88
113
""
,o _@ SM-587
...S6 ........... 48 .......i

12
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. When the EV-T5PS steer control senses the signal at terminal 4PL2, it will turn ON the steer motor at maximum speed. When the EV-T15 control senses the signal at terminal PA-3, it accumulates hours on the internal hour meter during the reach operation. 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. 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.
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
F.
G.
H.
J.
Note
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
SM-587
OPERATIONAL
Tilt
SEQUENCE
#17
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.
The tilt switch tilt operation. must be held closed during the entire
Note:
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. This will energize the S3, S5 and S6 solenoid coils and in turn, open the oil path to tilt cylinder. 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.
C.
D.
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
SM-587
r2 2 2FU
SEER
24136
VOLTS
_ax
/I
P\ PS-IC 61
s
61
PUM'PTOR
SWITCH
611
61
t 12
li
10
6'1
12
10
r10c
10 10 2 ~ 61'
12
10
FKE
12
10
10
61
ttH-12-12-12
II t-2
2 10 10 " *L " ,IA 24-24 41-41
lo-10+TB4
.EVT!..S.CARD..
2
i .F%, TBI. i
;*PEt2 Pl33.j PYB . WI3
12cnx-13_J II
2930
i*m
40 61 SL-1
-61
/
1: 1'0 15-15
15-15yTB2 j . T03 PI%. pA4..; j . . . . . .. . .
44-13
34
SL-2
3 _________.
.,....-_..__.,
.___ .___
6 6-6 27-27-a
6 +
i . TBS
T86
,,,+____
54
:
SL-3 ___-____,3__________ 20 261
PM.
20 26
PAZ.
10
SM-587
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. When the EV-T5PS steer control senses the signal at terminal 4PL2, it will turn ON the steer motor at maximum speed. When the EV-T15 control senses the signal at terminal PA-3, it accumulates hours on the internal hour meter during the tilt operation. 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. 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.
EV-TlS's internal hour meter will accumulate hours : The if the steer motor is of tilt function, independent function. while tilt performing operating
F.
G.
H.
J.
Note
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
SM-587
BATTERY
r2
2 2FU STEER i%H L 1FU /I
bWlk-<(
24/36 VOLTS
WM'PMOTOR w" 61-
lJ----EFl
161
12
r/
12 ZTCH lb rlo 10 I10 10 10 10 10
t 12
R-1050
10
50
11 12
12
Rx
12
1.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . :
ACCELERATOR --.-_
_d
L.YG .i
r-3
5 G i g : . . . . . . TR? . . . . . . :
g . . . . . . . . . . . . . . . .~
T_Fm
lo-i-
ai
i3
10
1lJ-1()wm
PYt3 _:6,
61 SL-1
& 112 12
SM-587
HORNSWITCH
mw
Rev Aug 94
OPERATIONAL Side A. Shift
SEQUENCE (Optional)
#I8
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. The entire side shift switch must operation. side shift be held closed during the
Note :
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. 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. 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.
C.
D.
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
SM-587
l-27
2 2FU 2 STEER LOCK SWITCH 1 FU 24/36 VOLTS ^ PuwIwroR
-p+61
61
611
12
rd
12 SWITCH 10 2
t 12
rr 1050
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 4PL. 7 4PL2 1
STEER
+_
10
50
1A T2
.............................................
ACCELERATOR --*7
61
12
10
24 -24 41-41 BFlAK!Z SWITCH SL-1 61 I
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 Side E. shift
SEQUENCE
#18
(Continued)
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. When the EV-T5PS steer control senses the signal at terminal 4PL2, it will turn ON the steer motor at maximum speed. 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. 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. 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.
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.
F.
G.
H.
J.
Note
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
SM-587
2 2FU
t-2
STEER %ki 1FU /I P\
24/36 VOLTS
s -4
FuwmToR
Sl-
12
ri
12 ETCH 10 10 10
t 12
r-r 10 50
10
10
50
12
rlo c
10 10
NZG
12
Fa
12
2 ACCELERATOR -->-: 12-12-12 EVTl5CARD ~"""""".."...""~ 2 2 24-24 41-41 lo-_10+m 2*=1 $PB2
;*pB6
3 13-
12 TBI cf
PB3.i PW
l
t 12
10
-10 -10 I3FlAKE ,3WlTCb -10
Y AL
30
: ;
304061-------t
" AlA
40 61
PY13 .
I
-15 -15 -152-e -15 -15 -15 "7 F R ~~~~,~~~~: ::r-_i 15-15 +TEn
PA6. ; 44+13d
12
10
pn4hf______.34 PA5c;______.54
___sl;r__',3__________ ___-___.,3__________
__-_ ____
10
;sMYp&;ggr
j3
j3
26
2o
10 10 __________,O
13
.__________,. _____+_%____sB --10 13
SM-587
II
10 10
l2
,&$_5, Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
&&/ITCH
&
131
Rev Aug 94
CMRIC
EV-Tl5
SM-587 19-03-O 1 Sept 93
STATUS CODE
-01
No
brake
switch
inp~ESCRPToN
MEMORY RECALL CIRCUIT
No
Traction
SYMPTOM
Forward or reverse contactor will not pick up. EVT 15 CARD 2 2 9 PBl
POSSIBLE
*Defective
CAUSE
brake switch or no brake line pressure.
KEy SWITCH /
- Check brake switch to insure proper closure.

*Open circuit between battery positive and terminal TB3. BRAKE SWlTCH c /-a 10 10 -4 TB4
- 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 brake system.
15 I-
15 -q
TB3
- 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
assembly. in the foot pedal
STATUS
CODE
DESCRIPTION
Forward directional switch is closed on initial power up.
-02
POSSIBLE
No
Traction
SYMPTOM
Forward contactor will not pick up, static return to off (SRO) lock out.
SWITCH 2 2 -4
EVT 15 CARD PBI
4-
CAUSE
10 lo --. TB4
*Forward directional switch closed on initial power up (closure of battery receptacle, key switch or brake switch).
-
Return directional forward direction.
handle to neutral and then select
t
15 15 15 -4 15 --. TB3 TB2 TB5
*Forward directional switch is welded closed or misadjusted to be held closed.

-
Replace or adjust forward directional switch to insure that it opens when directional handle is returned to neutral.
15 J-6 P
-4
*Short circuit between TB2 and TB5.
STATUS
INDICATION
CRITERIA
- Disconnect wire #6 from TB5 and check for short circuit

between TB2 and wire #6. *Defective oscillator card.
This Status code will be displayed when voltage at TB5 is greater than 60% battery volts at initial power up.
- Disconnect wire #6 at TB5. Measure voltage at TB5,

should be less than 60% of battery volts.
SM-587
19-03-02
Sept
93
STATUS
-03
CODE
DESCRIPTION
Reverse directional switch is closed on initial power up.
No
Traction
SYMPTOM
Reverse contactor lock out. will not pick up, static return to off (SRO)
2 2 -4
EVT 15 CARD PBI
+ POSSIBLE CAUSE
*Reverse directional switch closed on initial power up (closure of battery receptacle, key switch or brake switch).
-
SWITCH
10
10 --.
TB4
Return directional handle to neutral and then select reverse direction. switch is welded closed or misadjusted to
k 15
15 REV
15 -4TB3
15 -4 TB2
*Reverse directional be held closed.
-Replace or adjust reverse directional switch to insure that it opens when directional handle is returned to neutral. *Short circuit between terminals TB2 and TB6. i
15 --s
-4
TB6
- Disconnect wire #8 from TB6 and check for short circuit

between TB2 and wire #8. *Defective oscillator card.
STATUS
INDICATION
CRITERIA
This status code will be displayed when voltage at TB6 is greater than 60% battery volts at initial power up.
- Disconnect wire #8 at TB6. Measure voltage at TB6, should

be less than 60% of battery volts.
STATUS CODE
DESCRIPTION
Accelerator input voltage is below threshold or REV directional switch closes. before the FWD
-06
No
Traction
SYMPTOM
Forward or Reverse contactor will not pick up.
EVT 15 CAR0 TBl
ACCE!_ERAKR
--------I -1s+-&;
L--_ .-A kci!!r 29 13 -
POSSIBLE
CAUSE
swrr~ -/L
*Accelerator (transducer / pot) is misadjusted or defective. Status code disappears when directional handle is moved away from neutral to close directional switch.
- Check accelerator input voltage at terminal TBl, should be

approximately 3.7 volts with directional Adjust or replace accelerator. *Defective
-
handle in neutral.
15d---6 15--/;---6 TB5 TB6
directional
switch.
LLI
Check forward or reverse switch to insure closure when direction is selected. positive
)Open circuit between directional switch(s) and battery or between directional switch(s) and TB5 or TB6.
STATUS
INDICATION
CRITERIA
- Check all control wires and connections shown in Figure.
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.
SM-587
19-03-03
Sept
93
STATUS
CODE
DESCRIPTION
Accelerator input voltage too high.
-07
POSSIBLE
*Accelerator misadjusted
No
Traction
SYMPTOM
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.
ACCaEFATcFl 13 -
EVT,5cA;* *
TBl
L---
_.1 29 G!!-
CAUSE
swrrcH -I,
or defective.
- 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
15---p;----6 15~-----8
TBS TB6
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. positive to TBl.
STATUS
INDICATION
CRITERIA
input
*Short circuit from battery
This status code will be displayed when the accelerator voltage at TBl is higher than 3.8 volts.
- Disconnect wire #29 from TBI and measure voltage at wire

#29 to negative. Should be zero volts for potentiometer type and less than 3.8 volts for transducer type accelerator.
STATUS
-08
CODE
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.
No
Traction
SYMPTOM
Forward or Reverse contactor does not pick up. -12 EVT 15 CARD
ACCELERATOR r.._.._.._..-._.._.._..~
I
i
13 -
POSSIBLE
*Accelerator misadjusted
CAUSE
or defective. Adjust or
TBl
- Check accelerator input voltage at TBl, should be

approximately 3.8 volts with handle in neutral. replace accelerator. *Short circuit between battery negative 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.
INDICATION
CRITERIA
- Disconnect wire #29 from TBl.
Measure voltage from TBl to negative. Voltage should be greater than 4.5 volts, if not replace oscillator card.
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.
SM-581
19-03-04
Sept 93
STATUS
CODE
DESCRIPTION
Both Forward and Reverse directional the same time. switches are closed at
-09
POSSIBLE
*Forward or Reverse directional adjusted to be held closed.
MEMORY RECALL
1
bb
Traction
CIRCUIT SYMPTOM
EVT 15 CARD
Forward or Reverse contactor will not pick up. BRAKE SWITCH
CAUSE
switch welded closed or mis-
I,
- Replace or adjust directional
switches to insure that they open when control handle is returned to neutral. battery positive and TB5 and / or TB6. -_ 15 d-6 REV 15----lt-8-~~~6 -e TB5
*Short circuit between
- Disconnect wires #6 and #8 from TB5 and TB6 and check

wires for short circuit to positive side of directional switches. *Defective oscillator card.
STATUS
INDICATION
CRITERIA
- Disconnect wires #6 and #8 and measure voltage at TB5

and TB6. Voltage should be less than 60% of battery volts, if not replace oscillator card.
This status code will be displayed when voltage at TB5 and TB6 are greater than 60% of battery volts at the same time.
STATUS
CODE
Battery vo,ts too,o~ESCR~PT~oN
-15
SYMPTOM
Forward or Reverse contactor will not pick up. +I1

EVT 15 CARD
No
Traction
POSSIBLE
*Discharged battery.
CAUSE
f Nominal Battery Volts Minimum Limit Volts 0 1.95VICell
- Check battery for proper open circuit voltage as outlined in figure and charge battery if required. *Defective battery. Replace or repair battery.
BA-TTERY
<
24 1 T i 36 23.4 35.1
- Check each battery cell for proper voltage, should be

greater than 1.95 volts per cell. *Incorrect oscillator card adjustment.
- 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 PBl. Repair or
STATUS
INDICATION
CRITERIA
- Check voltage from terminal PBl to battery negative.

Should be greater than 1.95 volts per cell. replace wire or connection.
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.)
sM-587
19-03-05
Sept
93
STATUS
CODE
Battery vo,ts toohigDhESCRPTON
No
Traction
SYMPTOM
Forward and Reverse contactor will not pick up. Nominal Battery Maximum Limit Volts @I 2.4 V / Cell
POSSIBLE
*Incorrect oscillator
CAUSE
Volts
card adjustment.
- Check function 15 for proper adjustment for battery

being used. Adjust to proper setting (22 - 26 for 24 volt battery and 34 - 36 for 36 volt battery). *Battery over charged or incorrect battery used.
BATTERY
24 36
28.8 43.2
- 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
- Check for loose plug or pin or corrosion at terminal

PZ12 on the oscillator card.
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 broken wire (green wire) at weld to current

sensor and along length of wire.
STATUS
CODE 1
DESCRIPTION
Invalid card type selection.
1 MEMORY
-17
*Invalid card type selection.
SYMPTOM
Forward or Reverse contactors will not close.
POSSIBLE
CAUSE
- 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
Sept 93
STATUS
CODE
DESCRIPTION
Forward or Reverse contactor coil current low.
No
Traction
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. BRAKE t
EVT 15 CARD
POSSIBLE
-Defective F or R contactor
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.
- 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.
I---
F _ 4 PB4 4 PB5
15 -,/-27 15 +L23
I--
- Check for open circuit between positive side of F or R

contactor coil and terminal TB2. Repair. *Defective oscillator card.
STATUS
INDICATION
CRITERIA
- 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.
This status code is displayed when the current draw in the forward or reverse contactor coil circuit is less than 100 mA.
STATUS
CODE
DESCRIPTION
T2 voltage too low. (Less than 88% of battery volts).
I
-24
POSSIBLE
No 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.
CAUSE
BRAKE
SWITCH
*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.
1,
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.
w-587
19-03-07
Sept 93
STATUS
CODE
DESCRIPTION
Shorted coil driver for Line contactor
-26
POSSIBLE
*Defective - Replace oscillator card.
SYMPTOM
jKc/
CAUSE
card. coil driver internal to oscillator
EVT 15 CARD SWITCH
I
DESCRIPTION
power supply is less than
10 -&
24
----j--o
132
STATUS
INDICATION
CRITERIA
This status code is displayed contactor coil driver.
when there is a shorted Line
STATUS
CODE
-27
POSSIBLE
*Discharged battery.
Oscillator
Card
14 Volts.
I
CIRCUIT SYMPTOM
1 Traction
Forward or Reverse contactors open and close, then can only be closed by opening and closing the key switch.
CAUSE
- 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 not corroded.
at terminal
PBl.
- Insure that the wire connection at terminal PBl is tight and
EVT 15 CARD
STATUS INDICATION CRITERIA
*Defective
oscillator
card.
This status code is displayed supply is less than 14 volts.
when the oscillator card power
- Replace oscillator card.
SM-581
19-03-08
Sept 93
STATUS
-
-41
CODE
DESCRIPTION
Open Thermal Protector or Control Over Temperature.
MEMORY RECALL Cl RCU IT
No
Traction
SYMPTOM
Reduced or no power to traction motor in control range. 6 ..-.. ,,7 ___..__, r--- I ITP 1 \ 1 I
I I i
POSSIBLE
*Open thermal between: protector circuit.
CAUSE
I I i I I I I I i.-..--.-.-.-..-.-.._.._.._I
- Check for loose or corroded connection or broken wire

VI0 wire at thermal protector and PZ2. WHTNIO wire at thermal protector and PZ5. Repair or replace as necessary. *Defective thermal protector (part of transistor). Q 2 5 3 0 PZ5
0 5 0 PZ2 OSCILLATOR CARD TCONNECTCR
- 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 is in thermal cut-back. duty cycle, application, motor current, brake drag and ambient temperature etc.
STATUS
INDICATION
CRITERIA
between PZ2
This status code is displayed when the voltage and PZ5 is greater than 1.8 volts.
- Allow control to cool, status code should disappear. Review
STATUS
-42
CODE
DESCRIPTION
Motor current sensor input missing.
No
Traction
SYMPTOM
No power to traction motor in control range.
SENSOR 0;
POSSIBLE
Qpen
~2 .
EVT 15 CARD
CAUSE
sensor wire circuit to PZ12. v
- Check for loose or corroded connection at terminal PZ12. - Check for loose connection or broken wire (green wire)
at weld on current sensor and along length of wire. *Defective oscillator card. If greater than 1.6 volts, replace
Pi!12
- Check for voltage between terminal PY7 and negative with

motor not operating. oscillator card.
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
Sept 93
STATUS
CODE
DESCRIPTION
Motor current sensor input missing.
-43
POSSIBLE
Qpen
MEMORY RECALL L Cl RCU IT A
No
Traction
SYMPTOM
No power to traction motor in control range.
CAUSE
EVT 15 CARD
7 + PZ13
sensor wire circuit to PZ13.
- Check for loose or corroded connection at terminal PZ13. - Check for loose connection or broken wire (yellow wire)
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. 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
CODE
DESCRIPTION
Transistors
-44
POSSIBLE
*Transistors defective.
did not turn OFF properly.
Yes
Traction
SYMPTOM
Forward or Reverse contactors open and close, then can only be closed by opening and closing the key switch.
I ,2
i
r---
..-. .-..-.._.. -._, r iiy --i i I --&- s 1 I I
q,NG
CAUSE
- 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. Replace transistors.
No
!.._.._.._.._.~~~._.._.._.._.._~ @ . j l pz9 PZ4 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
Sept 93
STATUS
CODE
DESCRIPTION
Transistors did not turn ON properly
-45
POSSIBLE
*Defective transistor circuit.
YeS
Traction
SYMPTOM
Forward or Reverse contactor will open and close, then open and then can only be closed by opening and closing the key switch. T*
I I i
-._, I----. .._. ._.._.._.. I f 4.4 3; --J --&J s 1
N33
CAUSE
- Check for open wire (red wire) or loose connection

between the transistor and terminal PZ4. replace. Repair or replace. L.._.._.._.._.~._.._.._.-.-! P PZ9 . PZ4
- Check for corrosion on plug / pin at terminal PZ4. Repair or - Check for open wire (blue wire) or loose connection at
terminal T2 (#3 REC power terminal). Repair or replace.
- Check for corrosion on plug / pin at terminal PZ9. Repair or

replace.
EVT 15 CARD
STATUS
*Defective transistors. This-status ON.
INDICATION
CRITERIA
fail to gate
code is displayed
when the transistors
- Intermittent or open transistor gate.
Field test may or may not show defect. Replace transistors after above checks show no problem found.
STATUS
CODE
DESCRIPTION
Look ahead test for T2 volts. (Less than 12% of battery
-46
POSSIBLE
*Defective 1A contactor.
I%
Traction
volts.)
SYMPTOM
A-t/
r-..-_...__.&.-._.._.._,
CAUSE
.
I
:___-..-,,,.G__,~_i .I ._.-4. _--_.~_-_-: JG i :--
- Check for welded 1A contactor power tips.

*Defective transistor. Replace transistors. f =
! I
- Check for shorted transistors.

l.._.._..__x!?__.-.-.-._: R
j - PZ9
. PZ4
- Check for 1A contactor coil being energized due to

shorted driver. Replace oscillator card.
E.T 15 CARD
STATUS
INDICATION
CRITERIA
This status code is displayed than 12% of battery volts.
when the voltage at T2 is greater
SM-587
19-03-11
Sept
93
STATUS
l-
-48
CODE
DESCRIPTION
Look ahead test for T2 volts
(Greater than 88% battery
No
Traction
Fg;
volts)
SYMPTOM
POSSIBLE
*Defective tips. forward or reverse
CAUSE
contactor.
- Check for welded forward or reverse contactor power - 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 card. Replace card.
STATUS
INDICATION
CRITERIA
This status code is displayed than 88% of battery volts.
when the voltage at T2 is greater
- Check for Forward or Reverse coil being energized due to

shorted driver.
STATUS
-50
CODE
DESCRIPTION
Capacitor
volts low after Line contactor
closes.
No
Traction
SYMPTOM
Forward or Reverse contactor picks up. operate. Control does not
POSSIBLE
*Defective Line contactor.
CAUSE
- 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.
STATUS
INDICATION
CRITERIA
- Check power fuse for open circuit. Replace.
This status code is displayed when capacitor volts are less than 85% battery volts at initial start up.
34-587
19-03-12
Sept 93
STATUS
CODE
DESCRIPTION
Capacitor (precharge). volts low before Line contactor closes
-51
Line Contactor does not close.
No
Traction
SYMPTOM
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
INDICATION
CRITERIA
This status code is displayed when capacitor volts are less than 85% battery volts at initial start up.
STATUS
CODE
DESCRIPTION
Transistors fail to turn OFF during plugging cycle.
-53
POSSIBLE
*Open T2 circuit.
Yes
CIRCUIT SYMPTOM
Traction
Forward or Reverse contactor opens and closes, then opens and can only close by opening and closing the key switch.
CAUSE
PZ9 (blue wire) to battery
- Check for short from terminal negative.
- 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. defective. No Replace transistors.
*Transistors
- Turn-off time for transistors are out of specification.

field test is possible.
STATUS
INDICATION
CRITERIA
fail to turn
- Check for open circuit or loose or corroded connection

between the transistors and terminal PZ4 (red wire).
This status code is displayed OFF during plug cycle.
when the transistors
34-587
19-03-13
Sept
93
STATUS
CODE
DESCRIPTION
Shorted F, R or 1A contactor coil driver.
I
-54
Control will not operate
No CIRCUIT
Traction
SYMPTOM
POSSIBLE
CAUSE
- 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
DESCRIPTION
Current
sensor input voltage polarity check.
-57
POSSIBLE
*Unsuppressed voltage spikes.
SYMPTOM
Forward or reverse contactors open and close, then can only be closed by opening and closing the key switch.
SENSOR
CAUSE
*~------suppression.
A2
EVT 15 CARD
- Check that any and all external coils that are present on
the truck have the proper voltage
- 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. *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.
STATUS
INDICATION
CRITERIA
This status code is displayed when the voltage input to terminal PZl2 is positive in relationship to terminal PZ13.
SM-587
19-03-
Sept 93
STATUS
CODE
DESCRIPTION
Maintenance Reminder code.
-99
-99
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.
POSSIBLE
CAUSE
Truck has accumulated the number of hours as preset in functions #19 and #20. Perform required PM maintenance and reset functions 19 and 20 to next desired maintenance hour number. Note: Amount of travel speed reduction setting of function #21. is determined by the
-99
STATUS INDICATION CRITERIA
This status code is displayed when the number of accumulated truck hours exceeds the preset maintenance hours as set in function #19 and #20.
The EVlOO / EV-T15 handset is required for all function setting changes.
STATUS
CODE
DESCRIPTION
No display on Dash Display or Handset.
Blank
POSSIBLE
*Positive
-
No
Traction
SYMPTOM
Display screen on dash display or handset is blank.
EVT 15 CARD
CAUSE
missing. .r SWITCH f
or negative
control voltage
PBI
PZl
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. *Open circuit between oscillator card Y plug and dash display or handset.
i-
10
lo -4TB4
STATUS
INDICATION
CRITERIA
- If truck does run but no display, check for open circuit or

loose connections between each wire between the Y plug and dash display / handset. *Defective dash display / handset.
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.
- Replace dash display / handset.
SM-587
19-03-15
Sept 93
Wl;&r&:Handling Cl!!lRK
GROUP 19
Section 4 Oscillator Card Settings
GROUP 19 AWARNING
Drive wheel must be off the floor before any adjustments are made. Raise rear of truck and block it on both sides.
Oscillator Card
Remove all Jewelry working on truck. Sep 93
before
A
1942
SM-587
EV-T15 Settings
GROUP 19 NPR (24 Volt Truck) EV-T15 Card Factory Settings
hnction No. FOl F02 F03 F04 F05 F06 F07 FOS F09 FlO Fll F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28
SM-587
Description Speed Limit C/A Creep Speed Controlled Acceleration & 1A Tiie Current Limit Plugging Distance (Current) 1A Drop Out Plug % On Time Adjustment N/A N/A N/A Speed Limit 1 Speed Limit 2 Speed Limit 3 Internal Resistance Compensation Battery Volts Pedal Position Plug Card Type Selection Steer pump Time Delay Maintenance Hours (l=l hour) Maintenance Hours (l=lOO hours) Maintenance Speed Limit N/A Speed Limit JR Compensation Speed Limit Comp Start N/A N/A N/A Last Fault Flag
19-4-3
Actual Value 006-008 090-110 006-008 218-222 135-145 255 35-40 N/A N/A N/A 154-156 000-001 000-001 026 024 095-105 022-024 001-003 050 002 000-001 N/A 005 000-001 N/A N/A N/A 016-030
Factory Setting 0.6 - 0.8 Sec. 7.7% - 8-3% 655 - 687 Amps Function Disabled N/A N/A N/A Function Disabled Function Disabled 0.88 Volts Drop 24 Volts Std. C/L w/Speed Limit l-2 Set 50 hours 200 hours Function Disabled N/A Function Disabled N/A N/A N/A Next Fault Location
Dee 94
GROUP 19
Function No. FOl F02 F03 F04 F05 F06 F07 F08 F09 FlO Fll Fll Fl2 F13 F14 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26
Dee 94
EV-T15 Settings
NPR (36 Volt Truck) EV-TIS Card Factory Settings

Description Speed Limit C/A Creep Speed Controlled Acceleration & 1A Time Current Limit Plugging Distance (Current) 1A Drop Out Plug % On Time Adjustment N/A N/A N/A Speed Limit 1 (up to 270 MPH) Speed Lit l(271 MPH & above) Speed Limit 2 Speed Limit 3 Internal Resistance Compensation (up to 270 MPH) Internal Resistance Compensation (271 MPH & above) Battery Volts Pedal Position Plug Card Type Selection Steer pump Time Delay Maintenance Hours (l=l hour) Maintenance Hours (l=lOO hours) Maintenance Speed Limit N/A Speed Limit IR Compensation Speed Limit Comp Start N/A N/A
19-4-4
Actual Value 011-015 045-055 008-011 218-222 150-160 255 35-40 N/A N/A N/A 157-159 169-171 000-001 000-001 020 026 036 095-105 022-024 001-003 050 002 000-001 N/A 005 000-001 N/A N/A
Factory Setting 1.24 - 1.36 Sec. 6.35% - 6.65% 0.856 - 1.024 Sec. Function Disabled N/A N/A N/A Function Disabled Function Disabled 1.14 Volts Drop 0.88 Volts Drop 36 Volts Std. C/L w/Speed Limit 1-2 Set 50 hours 200 hours Function Disabled N/A Function Disabled N/A N/A
SM-587
~;t$h\Handling ELRRIC
GROUP 19
Section 5 Steering Control Adjustments EV-T5PS

Contents
Preparation and Safety ....................................................................... Adjustment Steps 1 - 3 ....................................................................... Adjustment Steps 4 - 5 ....................................................................... Adjustment Steps 6 - 7 ....................................................................... Adjustment Step 8 ............................................................................. 19-5-2 19-5-3 19-5-4 19-5-5 19-5-6
SM-587
Dee 94
GROUP 19 A WARNING
Steer Control
before
A
19-5-2
Dee 94
SM-587
Steering EV-TSPS Steer Control Adjustments

1. Turn key switch ON and step on brake pedal. 2. TurnMaxSpeedtrimpotfullyclockwise(CW).
GROUP 19
SC-POS
Maximum Speed Trim Pot
Current Compensation
rypical Illustratiotl
Steer Control
SC-POS
3. Turn Steer Comp trim pot fully clockwise 0%.
Steering Compensation
Trip Pot
Steer Compensation Current Compensation
Steer Control
GROUP 23
4.
Steering EWT5PS SC-POS
Turn Current Comp trim pot fully counterclockwise (CCW).
Steer Compensation
Current Compensation Trim Pot
lypical Illustration
Steer Control
SC-POS
5. Measure
motor out voltage between M+ and
M- power terminals on steer control.
Steer Compensation Current Compensation
II
III L-l
-------------_____ l-l
Steer Control
Dee 94
19-5-4 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
Dee 94
GROUP 23
8. Turn Current Comp trimpot clockwise (CW) until motor output voltage is:
Steering EV-TSPS
SC-POS
12.4 +/-0.2 (24-Volt Truck) 17.5 +/-0.2 (36-Volt Truck)
M+
Steer Compensation
Current Compensation Trim Pot
rypical Illustration
Steer Control
9. Remove blocking and lower truck to ground.
Dee 94
19-5-6
SM-587
Wl~~;~~Handling Cl!!lRK
GROUP 19 Section 6 Wiring Diagrams NPR-345
WY
SM-587 19-6-l Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
TypicalIkstrario~~
Aug 93
Steer Lock Switch \
Wiring Diagram Battery
Accelerator
PYl3 PM PM16-=6
PA6r PA3
I44 W -28 -20

-13
81
61
SL-l_
6L-2 ~~~.24~~-~~n~~~
13 12 ____a__ 12-m-----* W
---.64-----d-B,
10 10-1k6 1oyi=.!&26 ,___~~~~~~~.lO~~~~~~ lo-Q=!&6 10-I 10 10 ~~~~~~~~~~.lo-~~~~-~L-----. -46 TnT . .P *6l .67 .-r-w,_
10
10 6
llB16
l87* lm.
28w
13
OTB14 Tm*
26-*l813 66mm--w-m--w-66-w..m2 66 46 26 16 61)~_~_~___..~ 26 16 .lBll lT8l0 l TB6 *TM
~-~~_~~~~~.lo-~~---~PL----.~-~~r m 10 .62 I 10 .. s . 10 rm
Horn Switch
NPR 15D.17,20.22
ckukMuterialHMdlingco.
..P
Q-
: . .
_ -
d
b
I
b! L Copyrighted Material
P c%-
Intended for CLARK dealers only Do not sell or distribute
GROUP 19 Section 7 Forward & Reverse Switches, Up (Lift )& Down (Lower) Switches and Transducer Adjustments
Contents Safety ................................................................................................ 19-7-2 Switch Adjustments ..... .......... ................................ .... .. .............. ........ 19-7-3 Transducer Adjustment ......................... ............ ................................. 19-7-4 Forward, Reverse Switch Voltage Check & Adjustments ......... .......... 19-7-7
Multi-Function
Qble ,~
Control Hand
Tilt and Auxiliary Switches +
Clamp guide
Markmg Tape Switch Side) -)e
Clamps, Cable Guides and Marking Tapes: 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

jefore making a connetion. If you do not, Aectrical shorts and possible damage to equipment may result. See below.
c PL-9
Arrows must face in direction shown

Switch
p$TT%F
-
SM-587
GROUP 19 A WARNING
Control Handle
before
A
19-7-2
Dee 94
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. 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.
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 upor downrelative 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 scre
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
l
Truck on blocks, drive wheels off floor. Upright fully lowered. Key switch off . Battery unplugged.
(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
SM-587
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.
Control Handle
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 -,
TBl lwl
Oscillator Card
Control Handle
GROUP 19
Lock Nut
TLUTI key switch ON. DO NOT STEP ON BRAKE PEDAL.
Loosen Lock Nut holding transducer to mounting plate.
Sep 4
l
Measure voltage between wires #29 and #13.

A thru cam slot.
CAUTION
To prevent damage to wiring: Loosen wires #29 & #13 by pulling them part way Usinczthe bodv of the transducer, slowly rotate body clockwise and then counterclockwise by hand (voltage will increase and decrease as the body is rotated). Do not rotate the body to the extent thal wires are pulled out (or damaged).
Stop rotation when voltage registers between 3.50 and 3.75 volts. This is know as the neutral point OI maximum accelerator voltage position. Note when in this position the wire harness will be on the toI
Transducer Wire Harness
1
Transducer
Body
SM-587
Dee94
GROUP 19
itep 5
l
Control Handle
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.
Forward Switch
r
/ 19-7-6
Reverse Switch
Dee 94
SM-587
Control Handle =ORWARD AND REVERSE SWITCH ADJUSTMENT
GROUP 19
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
T2
.lsdII
Capacitor
SM-587
19-7-7
Dee 94
GROUP 19
Step 8
l
Control Handle
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 --, km
n
Capacitor TB6 7 Wire #8 \ TB5 Wire #6 l-l-l-
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 Switch Adjustment-continued.
GROUP 19
Step IO
l
Move control handle extremely slowly to operate the forward switch. When switch oper-
ates, hold handle in this position.

l
Now, verify forward switch voltage is battery volts (measure voltage at wire #6).
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
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
Dee 94
GROUP 19
Step 12
Control Handle
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.OS volts apart maximum).
Forward Switch Adjustment Screw
Reverse Switch AdJustmentScrew
Step 13
l
Plug in connectors.
Dee 94
19-7-l
SM-587
GROUP 19 Section 8 Periodic Electrical Checks

Contents Preparation ..................... ................................................................... 19-8-2 Inspections . .. ...... ............ .......................................... ................ .... ..... 19-8-4
Remove all Jewelry before working on truck
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.
Periodic Electrical Inspection
2. Turn key switch off.

l
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.
Front Console\ Cover \
SM-587
Dee94
19-8-2
Periodic Electrical lnpsection

.
GROUP 19
Remove console cover from truck.
4. Discharge the CaDacitors .

.
Hold the resistor in place for 2 seconds before removing. A CAUTION Using a shorting device without a resistorloadcould cause damage to the control. A WARNING Discharging the capacitors without using specified resistor could cause serious injury to yourself and bystanders.
SM-587
19-8-3
Dee94
GROUP 19
IMPORTANT
Connector Plugs and Receptacles are permanently labeled with the proper PL (Plug) and SO (Socket/Receptacle) number for easy identification.
Electrical Inspections
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.
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.
s must face in direction shown.
LTape Marker
(Stamping: DT06-6P)
PL-6 Plug
(Stamping: DT06-6S
Pin(s)
(Used on Wire Harnesss and Power Cables)
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) e 13B (Main Harness)
EXAMPLE
Dee94
SM-587
Periodic Electrical Power Cables

l
lnpsection
GROUP 19
Cables having small cuts in the casing may be repaired with electrical tape. 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.
Repairable Damage
{n\
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.
Power Cables having small
Cable unfit for further service.
Broken Wires -I
SM-587
19-8-5
Dee94
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.
Pointer
Typical Foot Pound Torque Wrench
Scale
Pivoted Handle
Pointer
19-8-6
SM-587
Periodic Electrical lnpsection

Assemble Front -
GROUP 19
Torque to: 100 lb. in.
TC-NEG. Cable (Steer Control Negative) Wire 13C & 13D (Main Harness) e 138 (Main Harness)
Buss Bar
1 \
able (or) . Wire Harness
-TC-P
5iiiiir 5ii?
Clamp IMPORTANT
Cable, (Pump Motors) /

/
Torque to: 100 lb. in. (11.3 N-m)
lamps must be lositioned so al
m
! A CAUTION Cables & Wiring
l
-APE MARKERS
,re aligned witk lr hidden under 3e clamps 01 ,lamp guides.
Terminal Barrels must face opposite each other.
ressure
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.
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
SM-587
19-8-7
GROUP 19
26 20

20A 5
Solenoid Control Card
134568
IO
II
I2
I 13C
I 48
I 38
I 58
I I8
28
I I I I I I I\
45 55 65 35 IOC IOE
IOF
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.
l
cy
Q
Main Harness
I Be certain the steering control and control card are securely mounted.
Dee 94
19-8-8
SM-587
GROUP 19
Periodic Electrical
NOTE Connect PL-DP to Display Unit prior to assembling to bracket.
Checks
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.
Periodic Electrical Checks
GROUP 19
Clamps, Cable Guides and Marking Tapes: IMPORTANT

Cables must be positioned with all tape markers aligned with or hidden under clamps or guides.
z
6 hrkrng
-Clamp or Guide
Tape
Multi-Function Control Handle
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. 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. Inspect all connectors (plugs and sockets) for
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.
/ .
Plug (or Socket) Housing
Seal should be pressed flush with housing.

19-8-l 0 SM-587
Dee 94
GROUP 19
Typical Panel xeptacle & PI Assembly

IMPORTANT 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)
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 l
the end seals are seated flush with the end of the connector housing. The retainer plates snap into place to secure the pins and their sockets. Check the plates for damage and security of mounting.
Check seals for damage that would make them unfitforfurther service(cuts, etc.). Make certain

l
GROUP 19
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
Assemble
Back -t
TC-NEG. Cable TC-NEG. Cable Steer Control Negative

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

so all tape markers are aligned with or hidden under clamps or guides.
Cables must be positioned
Cables
mIlnt
he
rmltd
ac
chnwn
Dee 94
19-8-l 2
SM-587
GROUP 19
l
Inspect power cable connections on the drive motor and the contactor panel for damage and security of
mounting. Replace damaged parts. Tighten connections to the torque specified.
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

bsemble Front-to-Front
GROUP 19
Rttrs Rar
/sJ..
,<I
Pae,
-%
b c
_ 7ack-to-Back TC-NEG.
TC-NEG. Cable (Pump Motor A) TC-NEG. Cable (BAT.NEG.)
SC-POS.
_ L hire 13C & 13D (Main Harness)
LTorque
to: 100 lb. in. (11.3 Nom)
Control Panel
r.
Cables must be installed as shown

security of mounting. Replace damage parts. Tighten connections to the torque specified.
SM-587
Inspect power cables on the control panel and the power steering (aux.) motor for damage and
Dee 94
19-8-14
GROUP19
Assemble Front-to-Front Assemble -% TC-NEG. Eable (Pump Motor A) TC-NEG. Cable (BAT.NEG.
CAUTION
hw-
TC-NEG. Cable (Steer Control Neg.)
Cables, Wiring and Terminal Connections must beinstalled as shown. If they are not, you may experience electrical shorts and component damage.
13C & 13D (Main Harness) Wire 138 (Main Harness)
CP-FU tF%
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

l
GROUP 19
Tvoical Illustration
Install truck battery. Refer to Group 12 for installation and safety instructions.
Protective Cover
Cardboard or Plywood)
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.
// f A&
I
Install battery retainers.
I
Retainer -
Battery
Connect battery to truck receptacle.
~;$ria\Handling El!!YRK
GROUP 19
Section 10 Oscillator Card Remove & Replace
/
J
SM-587
19-10-l
Dee 94
GROUP 19
Oscillator Card
Truck Preparation
l
Turn key switch OFF. Disconnect truck battery. Remove console cover. Discharge capacitors.
Removeall Jewelry before working on truck.
A
19-l o-2
Dee 94
SM-587
Oscillator Card R&R Oscillator Card Removal

Disconnect Plugs
Disconnect PL-8 from SO-8. Disconnect SO-10 fron n PL-10. Disconnect SO-7 from PL-7. Disconnect SO-9 from
Tilt and Auxiliary Switches
GROUP 19
so-9 PL-9
Remove Switch Actuator

l
Remove Nut (A), see below. 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. Remove Nuts (A) from control handle bracket, see above.
Bracket Switch Cam1
Fastener-
/I
CAUTION
II
UP (Lift) & Down (Lower) Switches
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
19-10-3
Dee 94
GROUP 19
Remove Card
l
Oscillator
Installation
*
Card R&R
Using a 8 rnxn socket and a 6-inch extension, remove upper and lower mounting bolts securing card to panel. Disconnect plugs from card. Remove wiring from II3 l-TB6. Remove card from truck.
Installation is the opposite of removal.
Mounting Screew
TBl - TB6
Mounting SC&w
Dee 94
19-l o-4
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)

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
It is normal for the indicator
Top View
SM-587
19-16-l
Aug 94
GROUP 19
Trouble Shooting
-1OA
Output
5011 Amp
+lOA
Zero Ohms
: Common
Battery Negative
Wire
arness
lo
T.B.
Solenoid
Control Card
indicator
19-16-02 SM-587 \ J
Lights (LEDS)
Aug 94
19-l 6-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
SM-587
Trouble Shooting
NPR-345 Trouble Shooting Solenoid Control Card
IMPORTANT
GROUP 19
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.
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: TBlOTBllMeter shoul read:
wire#m
Wire#55
ov
ov ov ov ov
TB12- Wire#65 TB13- Wire#35 TB14- Wire#5

l
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: TB3 - Wire #48 TB4 - Wire #38 TB6 - Wire #18 TB8 - Wire #28 TB5 - Wire #58 Meter shoul read: Battery Positive - 24 or 36 Volts Battery Positive - 24 or 36 Volts Battery Positive - 24 or 36 Volts Battery Positive - 24 or 36 Volts *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
Aug 94
GROUP 22
Trouble Shooting
SO// Amp +lOA
13 48 38 58
Zero Ohms
18 -2628 -2oSELECTOR
Common _
nr
nr
Battery Negative
45 55 65 35 10
n 1
- -..-
._c
_?A
-5-
Indicator Lights (LEDS)
Aug 94
19-l 6-4
SM-587
Trouble Shooting
Lift Function ONLY Disabled
GROUP 19
(The remainder of the Hydraulic Functions should be operable.)

(Key Switch ON and all Hydraulic Switches Open.)
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: TBl - Wire#13 Meter shoul read: Battery NEG. (0 V) Battery POS. (24 or 36 V)
Battery Charged
TB15 - Wire #lO
When Installing a New Solenoid Control Card Refer to the following page.
NPR-345
GROUP 22
NEW SOLENOID CONTROL CARD INSTALLATION When Installing a New Solenoid Control Card: IMPORTANT
l
Trouble Shooting
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.
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

IMPORTANT
When replacing plug, be certain it is installed -, correctly as shown.
Remove JP2 when truck is equipped with Side Shift Function.
NPR-345 Solenoid Control Card
against board.
Aug94
19-16-6
SM-587
M$d$pk&Handling CLqRIC
GROUP 20
Section 20 Axle, Articulartion Adjustment

Contents
Illustration . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .... . .. . .. .. .. . . ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 20-l-2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . .. . . .. . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l-3
rC-----
Mounting Block
Articulating Axle
GROUP 20
Axle
Dee 94
20-l-2
SM-587
Axle 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
GROUP 20
Batteryshouldbeinthetruckwhen checking or adjusting axle articulation.
Floor Plate /
Check Adjustment Bolts
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 9/32twist 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 5/16twist 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.
WI 6
SM-587
20-I-3
Dee 94
lVl;~;;h\Handling CLqRR
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
C=RnlIP
_.I__.
I_
3fl
Drive Unit
WARNING

Typical Foot Pound Torque Wrench
Pivoted
Pointer
Dee94
20-2-2
SM-587
Drive Unit LUBRICATION

First 500 Oueratiw Hours Change oil after fust 500 hours of operation or ( 6 ) months , whichever comes first. 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.
GROUP 20
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.
INSTRUCTIONS FOR REPAIR General

Before disassembling the drive unit, drain the transmission fluid.
l
Place transmission on a clean work surface.
Seal
Level Plus
lbp3
Drain Plug
SM-587
20-2-3
Dee 94
GROUP 20
Dismantling the gear unit
Removing the top of the gear unit (300) from the basic gear unit (100).
Drive Unit
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.
Drive Unit
Dismantling the crown gear (104) and wheel shaft (119)
1.
GROUP 20
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). 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
2.
Surface X of the wheel shaft is used for setting the wheel shaft bearing and must not be damaged. 3. 4. 5. Insert a g-mm diameter punch into the threaded hole of the wheel shaft and drive to dismantle the wheel shaft. The wheel bolts (120) can be removed by pressing them out when the wheel shaft is dismantled 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, 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.
2.
Dismantling the inner race.

1. 2. 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. To dismantle the inner race, cut open the bearing cage and extract the inner race via the small bearing collar using the extrac tar.
SM-587
Dee 94
GROUP 20
Dismounting the helical spur gear (201) and the conical pinion shaft (104).
1.
Drive Unit
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). 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. 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. 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.
2.
3.
4.
Dee 94
SM-587
Drive Unit 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.
GROUP 20
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
Dee 94
GROUP 20
Mounting the basic gear unit (100)
Measuring the assembly dimension of the conical pinion shaft (104)
1.
Drive Unit
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.
20-2-8 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SW587
Dee 94
Drive Unit
GROUP 20
PI-e-assemblyof the wheel shaff (119)

1. 2. 3. 4. Apply Loctite 242 to the knurled portion fo wheel bolt (120) and press into the holes providedon the flange of the wheel shaft. Rush the Nilos ring (121) onto the wheel shaft up to its stop at the flange. Using special tool H (see page 20), press inner race (122) onto the wheel shaft up to the stop. 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. 2. 3. 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. Applu Lock 19). 242 to the Gamma ring (103) and press it onto the housing using special tool E (see page
Insert the outer race (122 outside) into the housing and insert the outer race (122 inside) with shims (124 127) for the preliminary setting.
IIE"
@.
inside
SM-587
Dee 94
GROUP 20
Drive Unit
Setting the circumferentail backlash on the crown gear (104) and checking the tooth pattern 1. 2. 3. 4. 5. 6. Press the inner race (122) onto the crown gear using the special tool H (see page 20). Insert the crown gear (101) into the housing. 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. For measuring the circumferential backlash at the crown gear, secure the conical pinion shaft against turning, e.g., with a wooden wedge. The circumferential backlash is corrected by adjusting with shims (124-127). 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. If a correction is necessary, its direction is indicated by the Mounting guideline. Secure the hex nut (118) by staking. ITY
2. 3.
Tooth pattern on the ring gear Defective patterns Concave Flank
Correct pattern adjustment
by Setting instructions
changing the mounting dimensions in direction of arrow
1 Convex Flank
Pattern at tip
marked
mounting
dimen-
Pattern at root
sions +_ A a, and (.A, or backlash S,). The mounting dimensions may only
Note fig. 1 & 2
Dee 94
20-2-l
SM-587
Drive Unit
GROUP 20
wooden wedge
circumferential backlash O.lOjO.15
SM-587
Dee 94
GROUP 20
Drive Unit
Setting the conical pinion shaft (KM), helical gear (201) and setting the bearing clearance 1. 2. 3. Position the shims (107- 110) according to instructions on page 8 and insert the outer race (105) into the housing (101). Insert the previously mounted conical pinion shaft. 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= S= Distance between spacer bushing/conical pinion shaft and contact of outer race. 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. 2. 3. 4. Mark the measuring point on the helical spur gear with a grease pencil. 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. Pull the conical pinion shaft upwards via the helical spur gear, turning it as described above, and hold it steady at the measuring point. 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
SM-587
Drive Unit
GROUP 20
detail
,. Z
Dee 94
GROUP 20
Mounting the wheel shaft (119), crown gear (104), and setting the bearing clearance.
1.
Drive Unit
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. 3. 4. 5. 6. 7.
When doing so, turn the wheel shaft several times tin both directions to enable the bearing rollers to align themselves. Measure dimension Y via the hole of special tool J (see page 20). Shim thiclcness X = Y - washer thickness of auxiliary unit. Unscrew special tool J (see page 20) and remove. Insert shims in accordance with dimension X. 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
SM-587
Drive Unit
GROUP 20
SM-587
Dee 94
GROUP 20
Mounting the housing lid (134)
Drive Unit
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. 2. 3. 4. 5. 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). Coat the sealing surface of the top of the gear unit with Loctite 574 and place it onto the basic gear unit. Screw in bolts (402 and 404). Tighten bolts (402/406) with ti tightening torque of 23 N*m (17 ft-lb.). Tighten bolts (404) with tightening torque of 46 N*m (34 f&lb.).
SM-587
Dee 94
GROUP 20
Drive Unit
SDecial Tool A
I !
1 A B C 0 E F G HFK 200
1 HFK 250/300
180 167 152 46 1302
so,+s.z 0.2
1 HFK 400/500 I
210
1
I
178 165 65 1692 4820.2 42 I

20.2 0.2
21
k3.2
H
J K L o(
I
I
28 R90 43 19 7s 618 707
46 R95 68 30
I
8
dent-h)
I 1
7o 618 708
618
709
Special Tool B
Od 00 Jdcnt-Nr. HFK 200 30-0.2 67.5 618 710 618 HFK 250/300 35.SQ.2 79.5 711 618 HFK 400/500 40.50.2 79.5 712
Special Tool C
HFK400/500 00 0d HFK 28.2200 23+O.2
f HFK 26'0.2 250/300

31.2
3oj;O.I
'F-F3
-2
17s
L min. {dent-Nr. 618
95
170
713
618
7lL
618
715
Dee 94
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
fl--L-?~
HFK 400/500 63,5 77s
HFK
200
HFK
250/300 51.5 67.5
0D
L
46,5 55
Ident-Nr. *
618.716
618.717
618.718
Id
W
_I&
Y
rated
dimension
-< II
-2
Special Tool E
Actual dimension marked on bushing
pdent-Nr.1
618.722
618.723
618.724
Special Tool F
manufactured from M 12 x L DIN 933 1779-1
Teil
Teil
Special Tool G
,
0d mm. L Ident-Yr. HFK 200 HFK250/300
23-0.2
35
26+0.2
35 618.841
HFK400/500 30.5'0.2 35 618.842
--.
618.840
SM-587
20-2-l 9
Dee 94
GROUP 20
Special Tool H ~1
l
Drive Unit
NennmaQ
Special Tool I
f7.2O.:
Special Tool J
hex nut M 12 DIN 934 headless screw M 12 55 DIN 939
Dec94
Drive Unit
GROUP 20
Special Tool K
HFK
300
HFK 400 140 14,7+o;l 450 688
0d
A Ident-Nr.
136 13.7+0,l 450 685
28 max. 270
Ir
SM-587
20-2-21
Dee 94
GROUP 20
DRIVE UNIT
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
GROUP 20
SM-587
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
Dee 94
GROUP 22
Fastener Tightening Sequence
Tires
Tir
Wheel
Torque Fasteners to:

124 - 139 Ib.ft. (168 - 188 Nom)
Wheel & Tire A
Drive Unit
Dee 94
22-l -2
SM-587
Tires 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. 5. Elevate and block rear of truck. 6. Remove wheel fasteners 7. Remove wheel assembly. truck
GROUP 22
_ - -
-_
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. 2. Install wheel fasteners and torque them to 124 139 lb.ft. (168 - 188 N*m). Fasteners must be
.....:.:+. ::::::::.:+:.
of truck using hardwood (oak) blocks.
Press Direction
~~~;~~~,~q .
::::::::::::::: ::::::::::::::: ::::::::::::::: :::::::::::::::
:::::::::::::::
:g#;:;:
:::::::::::::::
tightened using diagonal sequence shown in illustration on page 2.
;:{:;:;:$;:s:. .:.:.:.:.:::::: ::::::::::+:. v...: ,.... ,: :K::.:::::::.

.A.....
::::::::::::::: ::::::::::::::: ::::::::::::::: :::::::::::::::
:F::::::::::;: ::::::::3>3 :::;::::,:.:.:, :::::::::::::::
. . .. . .
;$$$g
....y.:+:
:~$$:~:~:
press
:jjjjjjjjj
Old Tire
Table
SM-587
22-l-3
Dee94
lflfx&$Handling CLSRK
GROUP 22
Section 2 Caster Wheel & Tire

Contents
Preparation ........................................................................................ Illustrtion, exploded view .................................................................. Pressing Tire ..................................................................................... Bearing Adjustment Procedures ......................................................... 22-2-3 22-2-2 22-2-3 22-2-4
SM-587
22-2-l
Dee 94
GROUP 22
Tires
Refertoadjustmentprocedures and torque specifications outlined on Page 4 in this section.
Nut 1 Chamfer
Wheel & Tire Assembly
Dee 94
22-2-2
SM-587
Tires 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. 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. truck
GROUP 22
Replacing Caster Wheel Tire

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. 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.
of
truck
using
Press D,irection
#
SM-587
Dee 94
GROUP 22
Tires
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
Chamfer To Face Inward
l
Spin wheel when torquing nut to specifications.
This is to insure proper seating of the wheel bearings.

l
Using a torque wrench and the special tool shown below, torque the bearing nut to 300 lb.in. (33.9 N*m) while spinning the wheel. 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
SM-587
GROUP 23 Section 1 Brake, Motor

Contents
Motor Brake Service.. ....................................................................... Brake Adjustment.. ........................................................................... Final Brake Adjustment Specifications ............................................. Caster Brake (Refer to) ..................................................................... Brake Bleeding Procedures (Refer to) ................................................ Brake Pedal Check and Adjustment (Refer to) ................................... .23-l-2 .23-l-5 .23- 1-8 23-2- 1 23-3- 1 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
GROUP 23
Motor Brake Service ! A
Brake Pressure
Brakes
CAUTION
Park truck on a level surface and chock wheels. NOTE

It will
only be necessary to do the following two steps thecomplete brake assembly is to be removed
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).
Remove brake drum nut from motor shaft.
Dee94
23-1-2
SM-587
Brakes
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.
GROUP 23
If brake assembly is to be serviced in the truck:
l
Brakes
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
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. Replace old shoes and springs with new ones as required. NOTE Prior toinstally brake drum, check brake cylinder mounting bolts for proper torque.
Torque nut to: 170 - 190 Nom (125140 Ibf.ft.)
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.)
Reconnect pressure switch wiring Replace hydraulic hose and retighten. Release pedal and remove blocking.
IMPORTANT
w v
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
SM-587
Brakes Brake Adjustment

Step 1
l
GROUP 23
l
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.
Pull boot from cylinder exposing the cylinder piston and rod end, see below.
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
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.
be fleeto move in either direction.
IMPORTANT
The brakearm must beallowed to float until adjustment is made.
SM-587
23-1-5
Dee 94
GROUP 23
Step 3
l
Brakes
. Measure amount of rod protruding beyond the back of the plate as shown below.
l
Now, while holding nuts (2 thru 4) screw rod clockwiseuntilitjust touches thecylinderpiston. You can do this visually or by feel.
Release brake pedal.
. Now, screw rod inward l/4 of an inch while holding nut (4). This willmove thepistoninward l/4 of an inch.
Step 4
l
Next, tighten nut (2) against arm ... finger tight. Using two wrenches, securely tighten both nuts
Next, install the boot.
0 While holding arm in neutral (brake released), tighten nut (1) against arm . .. finger tight.
with&t moving brake are &t-of neutral.
Tvnienl llhxtratinn
Secure Adjustment
23-1-6
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.
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.
SM-587
GROUP 23
Brakes
Brake
Pressure Spring
Final
Adjustment Specification
Cooling Plate must
in place at all times to provide required
Drive Motor
El!!RKM$&ri;\Handling
Section 2 Caster Brake
Contents
GROUP 23
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
Dee 94
GROUP 23
Caster Brake Service
Truck Preparation
l
Brakes
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.
Elevate
rear of truck farenough to allow rotation of the caster assembly.
Place oak blocks beneath frame (as shown) on each side of truck.
Block Truck 2-inches off floor.
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
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
Dee 94
GROUP 23
5. Remove old brake shoes.
Spring @ ~ f$$s
-y;
Brakes
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.
SM-587
Brakes 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
GROUP 23
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
Dee 94
GROUP 23
Brakes
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
10. With brake arm held parallel to weldment, move arm 1-spline away from weldment as shown.
l
Move Arm 1-Spline as shown
Install clip lock over arm and onto cam shaft. Secure arm to shaft with clamping lock bolt.
Dee 94
23-2-6
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
wheel being careful not to damage seal.
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.
12. Install spring and cylinder rods to brake arm and secure with retaining pins and clips.
SM-587
23-2-7
Dee 94
GROUP 23
13. Align push rod and slave cylinder.
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.
14. Adjust brake spring length.

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.
Dee 94
23-2-8
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
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
&!.?a
:3 -3,
NOTE
\ :>
----
i; /
It is not necessary to remove the cover to bleed the caster brake.
c:
SM-587
23-3-l
Dee 94
GROUP 23
Pump Brake Pedal
Brakes
Keep Reservoir
* Master Cylinder(s) filled wi ith fluid.
Bleeder Valves
SlavXylinder (Caster Brake)
Bleeding Brake System

Manual Method (as illustrated)
Fill the brake reservoir full of brake fluid. Keep full during bleeding operation.
l 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.
Wipe bleeder valve(s) with a clean cloth. Be
sure debris is removed prior to attaching a bleeder hose to the valve.

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.
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.
SM-587
Dee 94
$at&rfi\Handling Cl!lRK
GROUP 23
Section 4 Brake Pedal Adjustment

Contents
Brake Pedal Check and Adjustments . . ... .. .. . ... . ... .... . . .. .. .. .. .. .. .. . .. . .. .. .. .. . 23-4-2
Master Cylinder(s)
SM-587
23-4-l
Dee 94
GROUP 23
Brake System
Pedal Up-Height Adjustment
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.
Caster Brake
rBrake Pedal
Adjusting Pedal Up-Height

l
Using two wrenches, hold piston rod(s) and loosen jam nut(s). Rotate piston rod(s) until correct adjustment is accomplished. 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).
NOTE
Master Cylinder
ADJUSTING PEDAL UP-HEIGHT
Checkthat both brakesrelease with pedal down. If not, further brake pedal height adjustment may be necessary.
MEASURING PEDAL UP-HEIGHT
-Pedal Up-Height
112.5
114.0
mm (4-7/l 6) to mm (4-l/2) Floor Plate
Master Cylinder(s)
Dee 94
23-4-2
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
Dee 94
GROUP 26
l
Hydraulic Pressure Checks

Test Port 1
Auxiliary, Reach &Tilt, Steering and Side Shift (if so equipped) pressure test port.
Test Port 2
l
Refer to Group 30 for Lift Circuit Relief Valve check and adjustment procedures.
IMPORTANT: Check system pressure with the

hydraulic fluid at operating temperature ... 110 to 130F.
(Clark Part No. 1800106)
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. 4. Connect Adaptor (see above) to pressure gauge. Notice: The hydraulic relief valve setting may
be checked with a Mica Quudrigage or with a conventional pressure gauge having a scale of 0 to 3OOOpsi.
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
system over relief any longer than it takes to read the pressure gauge.
Dee 94
26-l-2
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
GROUP 26
l
Hydraulic Pressure Checks

Test Port 1
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 Check Lift Control Circuit Relief Valve Setting.
NOTE
5. Attach adaptor to test port #2.

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
The relief valve is located at the top/rear of the lift control valve. Refer to illustration on Page 3. 1. Open door.
system over relief any longer than it takes to read the pressure gauge. Turn key switch
OFF. If adjustment is required, refer to the adjustment procedures next page. If adjustment is correct, refer to S tep 6 next page.
2. Remove console cover. 3. Remove cap from test port #2, see above. 4. Connect adaptor (see above) to pressure gauge.
The hydraulicreliefvalvesetting may be checked with a Mica Quadrigage or with a conventional pressure gauge haveing a scale of 0 to 3000 psi. Dee 94
26-l-4
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. Adjust the relief valve to operate between 2650 and 2750 psi. to decrease
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
Dee 94
Material Handling
CORK
Company
GROUP 29
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
Dee 94
GROUP 29
A WARNING
Hydraulic System
Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is normally adequate.
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.
WARNING
When usina air pressure to clean off truck:

Removeall Jewelry before working on truck. Always Wear
Safety Glasses
Dee 94
29-l -2
SM-587
Hydraulic System HYDRAULIC SYSTEM SERVICE Drain Hydraulic Sump Tank

IMPORTANT All cylinders should be fully retracted. Be sure:
.
GROUP 29
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.
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
Dee 94
GROUP 29
4. Place a clean plastic parts bag over end of hose. .
.
Hydraulic System
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
SM587
Hydraulic System
6. Remove strainer (7) from sump outlet and allow remainder of fluid to completely drain from sump tank.
GROUP 29
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
Dee 94
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
Hydraulic System
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
SM587
Hydraulic System Check Sump Tank Fluid Level

IMPORTANT All cylinders should be fully reacted. Be sure:
l
GROUP 29
Upright is fully lowered. Forks are in full forward tilt. If so equipped, side shifter is shifted fully to the right.
Refer to Group 01 for recommended Hydraulic Fluid(s).
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
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
Aug 93
Hydraulic Schematic
----_-__ 1
P
-v-e
i _
~----------~-i Aux Control
A
I
(
I 2gfi$s
valve
I_
_s_-____
-4
I-
Al IS vl
Front Buikhead Plate of Truck ReachIIin Selector Valve
T
2 Lift 3 LGzo
Sl
Reach Cylinders
r-i------iLz----F_l____;
mli2Y!~
-------
b---a
:
:
I
L
I
: I-
i!l
Flay ?! . imiter
Lift
inder
valves
Mateftal Handling Co.
NPR 150,17,
20, -
GROUP 29 Section 4 Hydraulic Pump Overhaul

Contents Disassembly ..................................................................................... .29-4-3 Parts Inspection ................................................................................ .29-4-3 Reassembly ...................................................................................... .29-4-5
SM-587
GROUP 29
Outlet
Hydaulic Pump
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
SM-587
Hydraulic
Pump
l
GROUP 29
An alternate method of removing the rear cover is to pry simultaneously with two large screwdrivers in the relieved areas between body and cover. A
DISASSEMBLY 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.
CAUTION
Pump Disassembly
NOTE Allreferencenumbersrefertoitems illustrated in the illustrations on the opposite page. 1. Clean outside of pump in a S toddard type cleaning solvent and dry thoroughly. 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. 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
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. 4. Holding shaft end down, remove rear cover (3). Dowel pins (7) may remain either with the body or with the rear cover.
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. 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. Dee94
hand tosupport rear cover from underneath, since cover and internal parts will drop suddenly when dowels are disengaged.
SM-587
29-4-3
GROUP 29
Hydaulic Pump
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)
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 PO@. 3. Lubricate the bushings in body (14) and wear plate (8) with SAE 10 engine oil. 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. 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. Apply a small amount of grease to rear cover seal (5) and install seal into groove. 7. Lubricate bushings in rear cover (3) with SAE 10 engine oil.
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
surface at any point.

4. Inspect bushings in body and cover. Replace cover or body if bushings are heavily scored or burned. 5. Inspect gear journals and faces. Replace if faces or journals are scored or worn. 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.
Pump Reassembly
Cleanliness is of extreme importance. Prevent dirt or foreign matter from entering hydraulic system.
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
8. Position pump with shaft end down. Match scribe marks on cover and body and install
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).
Pack the area between the double lip of the seal with Lubriplate or equivalent grease.
.ess
I-Mounting
Face
rShaft Seal -ing Bear -J \ /&_JGearlShaft
..-J--j\
-+ .. . ..V.C_
Installation *Sleeve
-_Ekl.52 Figure 1 Figure 2
mm (l/l 6) Figure 3
SM-587
29-4-5
Dee94
~;~pri-i~Handling CUIRK
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
I I
Lift
Aux
Aux Solenoid
Valve
Solenoid Valve
SM587
30-l-l Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
Dee 94
GROUP 30
1. Move truck to service area.
l
Hydraulic Valve
r
Park truck on a flat level surface. Extend pantograph. Fully lower pantograph. Tilt forks forward until fork tips touch the floor.
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 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.

l
,.>;.F?+., ih. ;.. L ;;:.F ,,+Y ....Y -.c
\... ,, j .\ : :, ,j @ v
I
Q:: :
/i
. :.. . ..
Remove key. &connect truck battery.
l-
3. Remove Front Console Cover . . .
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.
5. Discharge the CaDacitorS

l
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/oadcould cause damage to the control.
WARNING
\ unplugged. )
SM587
30-l -3
Dee 94
GROUP 30
Hydraulic Valve
/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
illustration
Hydraulic Valve Step 1 A CAUTION
GROUP 30
Switches may be damaged if the Switch Cam is not removed. Be very careful when removing cam that you do not damage the switches.
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
Mounting Pin
&&Control Control Linkage 0 Remove retainer from each lever mounting pin. l Push pins free of valve spools and control linkage.
Linkage
SM587
30-l-5
Dee 94
GROUP 30
Hydraulic Valve
Disconnect Lift Line from valve and tee fitting.
Lowering Solenoid Valve.
- Bulkhead Fittings
Retu
Disconnect Disconnect
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
Fitting. Fitting.
Dee 94
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
Dee94
GROUP 30
Step 8
Tag each tube upon removal.
Hydraulic Valve
2
\ ,
\I a\ve
\JT
Tag and disconnect Tube #I and #2 from control valves.
Step IO
Remove Auxiliary Control Valve.
Remove Lift Control Valve
Hydraulic Valve
GROUP 30
Step 11
\ * )
Flow Regulator r--------7
I.Jc L
Remove Flow Regulator from valve.
GROUP 30
Step 12
Hydraulic Valve
---
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
Hydraulic Valve
GROUP 30
Step
13
Nuts
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
Dee 94
GROUP 30
Step 14
Hydraulic Valve
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.
Auxiliary Reach & Tilt Control Valve Lift Control Valve Lowering Solenoid Valve Auxiliary Solenoid Valve The following valves are located on the Pantograph and include remove and replace procedures. Reach & Tilt Solenoid Valve Side Shifter Solenoid Valve
30-2-l 30-3-l 30-4-l 30-5-l Note:
30-6-l 30-7-l
Dee 94
30-l -12
SM587
Hydraulic Valve REASSEMBLY SUGGESTIONS Mounting the Lift and Tilt Control Valve Assemblies
1. Initially, tighten the valve mounting bolts only finger tight. Do not tighten them at this time. -
GROUP 30
Hydraulic Tube Installation
1. Lubricate all O-rings slightly with hydraulic fluid.
IMPORTANT
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. control handle as
3. Realign the multi-function instructed in Group 13.
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.
l
4. Now, tighten valve mounting bolts. 5. Remove l/4-inch rod and install linkage mounting pins and retainers.
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
Connector
SM-587
Dee 94
GROUP 30
3. Using a pen or marker,
Hydraulic Valve
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
STEP 1
-!
II
rl
Assembly Instructions for Fittings equipped with O-Ring Face Sea/s
Rotatenutjustoneflatas shown.
STEP 2
Tighten
One (1) Flat

from finger tight (bottomed out) position using second wrench.
I I
Initial
osition
IMPORTANT Hold connector with one wrench while tightening the nut with a second wrench, see above.
30-l -14 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
SM587
30-2-l Copyrighted Material Intended for CLARK dealers only Do not sell or distribute
Dee 94
GROUP 30
7
Hydraulic Valve
AUX VALVE - SIDE VIEW r
-Bushing
Plug Torque to: 8 - 10 Lb. Ft. (10.8 - 13.6 N-m)
Breather
(Must be open at all times.)
LSpacer
Ls2asher
!- Body
I_
O-Ring
Cap
Torque
to. 20 - 25 Lb. Ft. (27.1 - 33.9 N-m)
Tvoical Illustration
AUX VALVE - TOP VIEW
Flow Rate : 3 Gal / min. (11.4 Lhnin)

Dee94
SM587
Hydraulic Valve
GROUP 30
Port PlUCJ Torque to: 8 - 10 Lb. Ft. (10.8 - 13.6 Nam)
Cap
Torque to: 20 - 25 Lb. Ft. (27.1 - 33.9 Nom)
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. 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
4. Remove wiper seal from valve body. Discard the seal. 5. Remove port plug and O-ring. Discard the Oring.
Brass Tool
Dee94
GROUP 30
Cleaning and Inspection
l
Hydraulic Valve
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
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
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.
Port Plug8 - 10 lb.ft. (10.8 - 13.6 N*m) O-Ring
Valve Reassembly
l
Lubricate all parts with clean hydraulic fluid to facilitate reassembly andprovide initial lubrication.
Port Plug
l
Install a new O-ring on the port plug and screw the plug into the appropriate port - finger tight. Torquetheplug to: 8- lOlb.ft. (10.8 - 13.6Nem)
Dee94
30-2-4
SM587
Hydraulic Valve
Valve Spool
l
GROUP30
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.
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.
Continue to move spool until the spring bushing is seated in the valve bore. 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.
Body
SM587
30-2-5
Dee 94
GROUP 30
Pklg open at all times.)
Hydraulic Valve
Torque to: 8
- 10 Lb. Ft. (10.6 - 13.6 Nom)
-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).
L
Dee94
30-2-6
SM587
Hydraulic Valve Check Sump Tank Level

l
GROUP 30
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.
\
L
7-ypical Illustration
Clark Part No.885385 Hydraulic Fluid
Dee 94
GROUP 30 Section 3 Lift Control Valve

Contents
Specifications ............................................................................ Cut-A-Way View of Valve ................................................................ Lift Control Valve ...................................................................... Valve Disassembly ............................................................................ Valve Reassembly .......................................................................... .30-3-2 & 3 30-3-6 30-3-7 & 8 30-3-g .30-3-10 Pilot Operated Relief Valve Assembly with Schematic ..................... .30-3-5

SM587 30-3-l Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Dee 94
GROUP 30
l
Hydraulic Valve
Park truck on a flat level surface. Extend pantograph. Fully lower pantograph. Tilt (if so equipped) forks forward until fork tips touch the floor.
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. @
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.
30-3-2
Front Console
Cover
\
SM587
Dee94
Hydraulic Valve
4. Remove Side Cover . .
Remove fasteners seuring side cover to truck. Lift cover off truck.
/ @ Q
e
GROUP 30
ide Cove
5. Dischawe the CaDacitorq . .
Hold the resistor in place for2 seconds before removing. A
CAUTION
Using a shorting device without a ~esisforloadcouid cause damage to the control.
WARNING
SM587
30-3-3
Dee 94
GROUP 30
Hydraulic Valve
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)
NOTE
Spool and Body are a matched set and cannot bepurchasedseparately.
f : Liquid Lock Threads1 ? 4 s,,,,,

T
30-3-4
Torque to: 2 - 3 Ib.ft. (3 - 4 N*m)
Dee 94
SM587
Hydraulic Valve
GROUP30
SM587
GROUP 30
Hydraulic Valve
Load Check Poppet 1
r-Washer
Spacer
O-Ring
O-Ring 1 Return Spring
Liquid Lock Threads ue to: 2 - 3 Ib.ft. (3 - 4 N-m)
Dee94
30-3-6
SM587
Hydraulic Valve
GROUP30
Spring T
LIFT CONTROL VALVE
Load Check Valve

Disassembly
l
Reassembly Lubricate the poppet and spring with clean hydraulic fluid. 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. Install plug (finger tight) into valve body over poppet and spring. Torque hex plug to 30 - 35 lb.ft. (41 - 47 N*m).
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
Clean all parts in a Stoddard type cleaning solvent and allow to air dry. Inspect poppet for scratches or nicks. If found, replace poppet with a new one.
SM587
30-3-7
Dee 94
GROUP 30
O-Ring I 7 O-Ring
Hydraulic Valve
To remove (or install) Screw A, you must keep valve spool from 2 rod as shown. rntntinn 3 -.--
(Washer)
hywu
w-w..
. . . .rw.w_
Torque to: 2 - 3 Ib.ft. (3 - 4 N-m)
Dee94
30-3-8
SM587
Hydraulic Valve 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
GROUP 30
Cleaning and Inspection
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.
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).
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.
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
Dee 94
GROUP 30
Valve Reassembly
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.
IMPORTANT
Hydraulic Valve
Flush with Back Side of Groove
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: 2 - 3 lb.ft. (3 - 4 Nom) 9. Install port plugs into valve openings until such time as the valve is installed onto the truck.
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.
Dee 94 30-3-l
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

30-4-l
SM587
Dee 94
GROUP 30
A WARNING
Solenoid Valve
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.
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.
Safety Glasses
Dee 94
SM587
Solenoid Valve 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
GROUP 30
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 ---
II I
1
io
II
li II
-+ -J
p-1 ---- 4 II
1
I
L__,__
---0
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).
SM587
Dee94
GROUP 30
ACAUTION
Thevalvestemisveryfragile. Beverycareful when handling the valve that you do not dent or bend the stem. 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. Retainer Nut L
Solenoid Valve
Manual Override Control Torque: 5 Ib.ft. (6.8 Nom) max.
-----
Lead Wires-,,
Vave BodyT-
(I) O-Ring
Back-Up Ring (3) L__//-(21
O-Ring
ACAUTION
Valve is not serviceable. not take apart. 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. Remove solenoid valve from valve body. Remove fittings from valve body.
l
Wipe all parts dry with a clean lint-free cloth. Allow components to air dry beforereassembly. Replace al seals with new ones. Inspect wire leads and plugs for further serviceability. Replace defective parts.
SM587
Cleaning & Inspecting Solenoid

l
Wash all parts but the coils in a Stoddard type cleaning solvent.
Dee94
Solenoid Valve A CAUTION
GROUP 30
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
Lubricate all parts in clean hydraulic fluid prior to installation. Reassemble only with new seals. Install large O-ring (1) into its 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. Install coil retainer nut and torque to 5 ft lb (6-8 Nom) Install hydraulic fittings install finger tight. SM587
INSTALLATION 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:

l
Align valve body slot with mounting bolt on truck. Locate valve over bolt and install retainer nut finger tight. Refer to Section 1.
30-4-5
Dee94
GROUP 30
When Connecting Hydraulic Plumbing:
l
Solenoid Valve
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
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.
Dee 94
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
ux, Reach & Tilt Control Valve
11 Auxiliary
30-5-l
Solenoid
Valve 11
SM587
Dee 94
GROUP 30
A WARNING
Solenoid Valve
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.
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.
CAUTION
Cap all ports to prevent dirt and foreign debris from entering assembly.
Always Wear
Safety Glasses
Dee 94
30-5-2
SM587
Solenoid Valve
GROUP 30
AUXILIARY SOLENOID VALVE 0 IMPORTANT

All wiring, plugs and receptacles are labeled for easy identification. Be
IQ
careful when making connections. You will experience shorts and component failure if the wiring, (harness routing) plugs,and receptacles are not correctly installed.
1
I
Torque: Slb.ft. (6.8 N*m) Max. -
orque: 35 lb.ft. (47.4 N*m) Max
_-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.).
GROUP 30
O-Ring(s)
/-
Solenoid Valve
Typical Cartridge Kit
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. 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 air dry 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
I
Body @I
l- -----
rypical Illustration 1
30-5-4
SM587
Solenoid Valve REASSEMBLY A CAUTION
GROUP 30
Wires 1OL & 10M
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. Take particular care not to damage the coil stem.
l
Wires 10K & 1
Lubricate all parts in clean hydraulic fluid prior to installation. Use only new seals. Install large O-ring into its groove being very careful that you do not nick or cut the O-ring making if unfit for service as it will leak. 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
OCCUT,
When Mounting Solenoid Valve:

l
Align valve body slots with mounting bolts on truck.Locatevalveoverboltsandinstallretainer nuts finger tight. Refer to Section.
When Connecting Hydraulic Plumbing:

l
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.. Tighten valve body mounting nuts securely. Now go back and securely tighten each hydraulic connection. A CAUTION Be certain coil is positioned so wire leads may be connected to the harness leads without causing damage to wiring.
Install solenoid valve into body bore. Be certain solenoid valve is torqued correctly to the body. Next, install coil over solenoid valve. Installcoilretainernut N*m). and tighten to5 lb.ft. (6.8
Lubricate fittings with clean hydraulic fluid and install them finger tight to the valve body.
INSTALLATION 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 installation.
SM587
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.
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.
Dee 94
GROUP 30
Solenoid Valve
Wires 1 OK & 1 OL
resulting in possible shorts and com-
Check Sump Tank Level

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.
Use . ..-_I
I22 MS68 \
Typical lllustratior jpical Illustration 1
Clark Part No.885385 Hydraulic Fluid
C19RK
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
Dee 94
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.
Selector Valve
2. Turn key switch off.

l
Remove key. Disconnect truck battery.
3. Remove Front Console Cover

. .
Remove console cover from truck. Refer to opposite illustration.

Front Console
Cover Dee 94 30-6-2
\ 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 . . 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
a shorting device without a resisforloadcould cause damage to the control.
Using
WARNING
SM-587
30-6-3
Dee 94
GROUP 30
Selector Valve
WARNING
CAUTION
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.
-
Safety Glasses
Selector Valve
GROUP 30
Selector
Valve
Valve Mounting Fastener
(Reach & Tilt)
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
WORKING
ON PANTOGRAPH,
BE CERTAIN IT IS BLOCKED
AS SHOWN.
SM-587
30-6-5
Dee 94
GROUP 30
Selector Valve
o-Ring port For. Tilt (S.S.Right) o-Ring POD Reach, Pantograph #5 SAE o-Ring POT Retract, Pantograph
#5 SAE #4 SAE
#5 SAE
#5 SAE
o-Ring port Retract, Pantograph o-Ring port Reach, Pantograph ~4 SAE o-Ring port Back Tilt (S.S.LA)
#6SAEO-RingPort(ConnectstoAuxContmlValve
Hydraulic Circuit
* = u
s5 =
Counterbalance Valves Solenoid Valve Solenoid Valve Back Tilt or Side Shift Right control circuit Forward Tilt or Side Shift Left control circuit Reach (Pantograph) control circuit Retract (Pantograph) control circuit
S6
s5 (Vl) C2 Port C4 Port Cl Port C3 Port
=
= = = =
S6 (172)
s5 (Vl)
S6 (172)
Selector Valve
GROUP 30
Over torquing the coil nut or the valve at
9&10-
A Selector Valve
B Pantograph Frame C Reach Arms D Carriage Frame
GROUP 30
REACH 81TILT SELECTOR VALVE
Selector Valve
7. Removevalve from the pantograph. Place components on a clean work bench.
A
REMOVAL A
WARNING
DISASSEMBLY
l
Be sure pantograph is blocked as illustrated on page 5.
Remove coils and solenoid valves S5 & S6 from valve body. Remove both counterbalance valves fromvalve body. 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.
WARNING
Hydraulic lines may have trapped pressure. Crack fittings to release pressure before disconnecting.
WARNING
When trapped pressure is relieved, the pantograph may settle. Beware.
Cleaning
l
WashallpartsexceptthecoilsinaStoddardtype cleaning solvent. Wipe coils with clean cloth. Wipe all parts dry with a clean lint-free cloth. Allow components to air dry before reassembly. Replace all seals with new ones. Be sure to use a brass tool when removing seals.
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. 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
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
Dee 94
GROUP 30
Selector Valve
REASSEMBLY
Lubricate all parts in clean hydraulic fluid prior to installation. Install large O-ring into its 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
Receptacle Leads
Torque: 5 Ib.ft. *6.8 N-m) Max. Torque: 25. Ib.ft. (33.9 N-m) Max.
30-6-l
SM587
Selector Valve A (NON-ADJUSTABLE) CAUTION
GROUP 30
Cleanlinessisof extremeimportance. Before dis-connecting the hydraulic components, If the valve has been tampered with 9c 1eanexteriorof plumbing and solenoidvalve itmustbereplaced with anew one. to prevent dirt and foreign matter fr entering hydraulic system.
- Back-Up Kings
Typical lllustratio
REASSEMBLY
l
INSTALLATION
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.
Lubricate all parts in clean hydraulic fluid prior to reassembly. Use only new seals1 Install large O-ring into its 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. 30-6-l 1
SM587
Dee 94
GROUP 30
Valve Mounting Fastener
Selector Valve
Nui
A Solenoid Valve
B Pantograph Frame C Reach Arms D Carriage Frame
Typical lllustratior
Dee 94
30-6-q 2
SM587
Selector Valve Mounting Selector Valve

1. Position valve to the pantograph frame aligning holes in frame with those in the valve. Refer to opposite illustration. 2. Install mounting fasteners finger tight. Do not A
GROUP 30
CAUTION
Replenish hydraulicfluid in the sump tank before putting the truck into service. 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.
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. 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
Dee 94
EllFlRH
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 .................................................................................... 30-7-8 30-7-g
SM587
Dee 94
GROUP 30
l
Solenoid Valve
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., * Remove key.

l
Disconnect truck battery.
Dee 94
30-7-2
SM587
Solenoid Valve
GROUP
30
SM587
30-7-3
Dee 94
GROUP 30
Removal
Refer to Illustration on opposite page.
l
Solenoid Valve
Unplug connectors from S7 coil. Unplug connectors from S8 coil. Tag each hose as to its location. Disconnect hydraulic connections Vl, V2, C6, C5, C2 and C4 from the side shift selector valve.
AWARNING
When usina air Dressure
CAUTION
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. Always Wear
Hydraulic lines may be under pressure. Crack fittings slowly.

l
Cap each hose when disconnected.
NOTE There will be some fluid
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 valve and place on a clean work bench. Refer to page 7 for valve service instructions. Pages 6 & 8 provide diagrams and hydraulic schematic.
Safety Glasses
WARNING
Replace all O-rings with new ones. Inspect hoses and connections for further serviceability. Replace defective parts.
CAUTION
Dee 94
30-7-4
SM587
Solenoid Valve
Solenoid Valve
GROUP 30
S8
.
~--~--_-_-_---_rxrr~~~
Top
view
_-_-_-I
[ j r
Solenoid Valve
j t
c2 c4
#5 SAE O-Ring Port #4 S AE O-Ring Port
C5
#I4SAJZO-Ring Port
C6
. ... f
C6 ##4 SAE O-Ring Port Vl

v2
?&I SAE O-Ring Port

##4 SAE O-Ring Port
Vl
NOTE Refer to Hydraulic Schematic on the next page. Fmnu Back
SM587
Dee 94
GROUP 30
Solenoid Valve
Hydraulic Schematic
Hydra-
Vl
Hydraulic Circuit
tv2
..........
........... .........
...........
_-._
c2
* 0
...............
c4
** 0
C6
J
______-___r-_l---I_I_ . . .._-_.....
Schematic
Side Shift Cylinder
* 0
Return to VI/C2/SS Circuit
** u
Return to V2/C4/S6 Circuit
30-7-6
Solenoid Valve
GROUP 30
jlpical Illustration
Disassembly
l
Remove nut and coil from each solenoid valve. Remove both solenoid valves from valve body.
Torque nuts 8 - IO lb. ft. (11 - 14 Nom)

r...........<
Receptacle Leads
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.
f-l1
------
.. .. .. .. .. .. .. .. . .. .. 11..
22
j
Coil
Reassembly
l
Lubricate seals, valves and body in clean hydraulic fluid. 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
- Retainer Nut
lr
----
-l
Body--l
Dee94
GROUP 30
Solenoid Valve
Installation
Line up mounting holes in selector valve with those in mounting bracket. Install fasteners finger tight. (see below)
Mount Selector Valve

l
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
SM587
Solenoid Valve
GROUP30
Important
Route Hosing As Show
Side Shift Cylinder Grease XT/ Reach & Tilt Solenoid Valve $$#!p&&
Greast Fitting
I
Grease Fitting
SM587
30-7-g
Dee 94
Cl!!IRIC
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
GROUP 32
Tilt Cylinder
Air Hose
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.
before
WARNING
is
Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation normally adequate.
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 Preparation Cleaning & Inspection Suggestions

l
GROUP 32
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.
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
Dee94
GROUP 32
Tilt Cylinder Split Retainer Ring
Disassembly
(Refer to illustration above.)
are free of cylinder housing. Remove gland.
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. 1. Placecylinder in avise equipped with softjaws. Do not over-tighten - distort barrel
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. 3. Remove outer O-ring and backup ring from the gland assembly. 4. Discard seals, wiper and backup rings.
2. Push piston rod all the way into cylinder. 3. Using a narrow blade screwdriver, remove the
split type retainer ring.
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.
Piston Rod & Piston

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.
SM-587
8. Using screwdriver, carefully lift end of shear

ring from its 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
Tilt Cylinder 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.
GROUP 32
8. Using a torque wrench and the l-l/S socket,

torque nut to: 201 to 2301b.ft. (273 - 312 N*M). 9. Now, lubricate piston and piston rod with clean hydraulic fluid 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.
Reassembly
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. 4. Place a plastic parts bag over the threaded area of the piston rod (to protect seal). Slide a new Oringoverthebagandintothegrooveinthepiston rod.
Gland Assembly
1. Lubricate new seals, wiper ring and gland assembly with clean hydraulic fluid.
5. Remove bag and install piston onto rod. Carefully slide piston over the O-ring and up against rod shoulder.
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..
6. Install nut onto rod finger tight against the

piston.
7. Install the 12 to 15 inch rod back into the hole

provided in the piston rod.
SM-587
32-2-5
Dee 94
GROUP 32
Back-Up Ring O-Ring-,
Tilt Cylinder
1 r
Split Retainer Ring -Nut
lRod
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 its groove. 10. Next, pull piston rod out as far as it will come. This will position the gland so the retainer ring groove is located above the cylinder housing. 11. Lubricate a new O-ring and place it over the gland and into the housing on top of the gland.
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 its groove in the gland assembly. Be sure it is completely seated in its 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.
Dee 94
32-2-6
SM-587
Tilt Cylinder Check Sump Tank Level

l
GROUP 32
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.
SM-587
32-2-7
Dee 94
~z$e;;k&Handling EMIRK
GROUP 32
Section 3 Reach Cylinder Overhaul

Contents 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
Safety ................................................................................................
)_
0
0 JQ
,==z\
I, II
II II II Ii
II II II
Ii
SM-587
32-3-l
Dee 94
GROUP 32
Reach Cylinder
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.
before
WARNING
is
Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation normally adequate. A
CAUTION
Cleanlinessisofextremeimportance. Beforedisconnecting hydrauliccomponents, clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system. Cap all ports (after overhaul) until assembly is ready for installation.
Dee 94
32-3-2
SM-587
Reach Cylinder Preparation Cleaning & Inspection Suggestions

l
GROUP 32
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 Stoddard type cleaning solvent should be used to wash the cylinder.
Soft Fiber Brush
Nut Rod En d
Cylinder Piston Rod
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
Dee 94
GROUP 32
:::. [ii
Reach Cylinder
a,
.:: Y:..
,:,,,:C.~.../ ..,; f,
.::
ii;
v.:..:.; ,:,:.. :....
,.:::z
Anchor End
Piston Seals1
1 I I {
flllTop View11
Energizer, I LSdf-Alionino
Rod End
Piston
SealShear Ring I
I-
Snap Ring
Disassembly
(Refer to illustration
above.)
Gland Assembly
1. Remove wiper ring. 2. Remove seal from inner groove. Becareful that you do not nick or scratch innersurfaceof gland assembly. 3. Remove outer O-ring and backup ring from the gland assembly. 4. Discard seals, wiper and backup rings.
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. 1. Placecylinder in aviseequipped with softjaws. Do not over tighten - distort barrel.
2. Push piston rod all the way into cylinder. 3. Using snap ring pliers, remove snap ring from
cylinder gland.
Piston Rod & Piston

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.
4. Remove washer. 5. Using a bronze drift, gently tap gland assembly

into cylinder housing clear of the shear ring.
6. Using screwdriver, carefully lift end of shear

ring from its groove. Be carefulyou do not nick or scratch the piston rod or cylinderbore
2. Remove nut from piston rod and remove holding rod.
3. Pull piston free of rod. 4. Remove O-ring from rod. 5. Remove seal ring (Glyde Ring@) and the energizer from piston.
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. 8. Pull outward on piston rod until rod and gland
are free of cylinder housing. Remove gland.
6. Discard O-ring, sealing ring (Glyde Ring@) and

energizer. Always install new seals.
Dee 94
32-3-4
SM -587
Reach Cylinder 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. 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. 5. Inspectsurfacesofthepistonandpistonrod to be sure they are clean, smooth and free of damage.
GROUP 32
Bushing
Grease Fitting
Reassembly
Piston Rod & Piston
1. Lubricate all parts with clean hydraulic fluid. 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.
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.
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. Dee94
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

hydraulic fluid. SM-587
GROUP 32
Reach Cylinder
Wiper
lTypical Illustration
Piston
Seal -I Shear Ring -_I
l-
Snap Ring
7.
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. 14. Install a new snap ring into its groove in the gland assembly. Be sure it is completely seated in its groove. 15. Install jam nut and rod end in 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.
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 groove. Be sure the shear ring is fully seated in its groove. 10. Next, pull piston rod out as far as it will come. This will position the gland so the retainer ring groove is located above the cylinder housing.
Dee 94
SM-587
Reach Cylinder Check Sump Tank Level

l
GROUP 32
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.
I-
SM-587
32-3-7
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
GROUP 34
PANTOGRAPH REMOVAL Preparation
NOTE
Upright
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
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
SM-587
Upright R&R
GROUP 34
t 4J
Upright Pantograph Lift Chain
6. Remove two bolts (1) from cable retainers (2). 7. Remove front and rear retainers. 8. Disconnect electrical plug (3). 9. Remove both harness clamp bolts (4). 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
11. Remove cotter pins (6). 12. Remove chain anchor pins (7) securing the lift chains to the carriage chain anchors.
NOTE
Lift Chains may be disconnected at the Primary Cylinder Piston Head (see next page) or from the carriage as shown here.
34-l -3
Dee 94
GROUP 34
Upright R&R
Cylinder Piston Head II))
Chain Anchor --Bw
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
SM-587
Upright
GROUP 34
I . . ; i . . . . . . . . . .
13
Hooks
F .
Raise both inner and intermediate rails until the inner rail channels are clear of the carriage rollers.
1 Hardwood (Oak) Blocking
13. Using a 5ton chain hoist, attach hoist to the
.4. Raise both inner and intermediate rails until the
inner and intermediate rail assemblies, see illustrations above. Be sure hoist is equipped with
safety hook(s).
SM-587
inner rail channels clear the carriage rollers.
34-l -5
Dee 94
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.
NOTE
Upright
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
Fully lower intermediate & inner rails Disconnect hoist safety hook from lifting device
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 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
GROUP 34
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
34-l -7
Dee 94
GROUP 34
Upright
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
Dee94
34-l -8
SM-587
Upright
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.
GROUP 34
7. Remove fasteners securing safety screen to the upright. 8. Remove screen and set to one side.
SM-587
34-l -9
Dee 94
GROUP 34
Upright
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.
WARNING
Make certain upright lift cylinders are fully lowered before disconnecting hydraulic lines. 10. Disconnect the bulkhead fittings, see illustration below and on the following pages.
IMPORTANT
Cap all Hydraulic Fittings upon removal of tubing.
Cbnnections
\ !Pl
Y\i
\\
Dee94
34-l
-10
SM-587
Upright
GROUP 34
.I
Bulkhead Fitting
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
Dee 94
GROUP 34
13. Disconnect hydraulic tubing from the auxiliary valve and the bulkhead fittings.
l
Upright
Cap each tube to prevent dirt and foreign debris from entering. Be sure all bulk head fittings are capped.
Hydraulic Connections
Dee 94
34-l -12
SM-587
Upright
14. Disconnect Electrical plugs and tie them out of the way with a tie wrap, as shown below.
GROUP 34
Rail Cylinder
SM-587
Dee 94
GROUP 34
Upright
2 1. Move upright away from the truck so it may be lowered to the floor.
IMPORTANT
LiftingStraps ChZns
Chain all three rails together at the upper tie bars so they do not move independently. See below.
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) Inner Rail Assembly
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
Dee 94
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.
Upright
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
Dee94
34-1-l
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.
WARNING
Rail cylinders weigh between QQQ and ooo pounds each. Exercise care when removing a cylinder from the upright.
Rail Cylinder
SM-587
Dee 94
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). Disassemble assembly. Replace any damaged components. Installation is the reverse of removal. 16
Upright
5 6 7
8
Free Lift Cylinder Cylinder

l
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.
WARNING
Free Lift Cylinder weights between ooo and ooo pounds. Excercise care when removing cylinder from upright.
r
t
Inner Rail Assembly
Floor
34-1-18 SM-587
Dee 94
Upright Cable, Hose & Chain Sheaves
GROUP 34
Nut (1) -
+-
Screw (4)
Block (11
Secures Block to Cylinder Rod Sheave (5)
SM-587
34-l-19
Dee 94
GROUP 34
Cable and Chain Sheaves
Removal
l l l
Upright
Remove washer, sheaves and spacer. Replace damaged components.
Loosen andremoveretainerbolt
from stub shaft.
Installation is the reverse procedure of removal.
rmediate Rail Assembly Chain Sheave
13ait I
Intermediate Rail
Dee 94
34-l -20
SM-587
Upright
GROUP 34
Inside Spanner Tool
Outside Spanner Tool
SM-587
34-1-21
Dee 94
GROUP 34
Upright
Carpenter Square
Dee 94
34-1-22
SM-587
Upright
GROUP 34
Pantograph Assembly
SM-587
34-1-23
Dee 94
GROUP 34
Upright
Inner Rail Assembl
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
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
to find narrowest point.
i
Step2
Insert
Dee94
34-l -24
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
Dee 94
GROUP 34
7. Span center carriage rollers at their outer most camber point. Add or remove shims at roller shaft to match tool size. 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
Upright
Carriage Rollers
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
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
SM-587
Upright
10. Spanlower rollers. Addor subtract shims to (the roller that has not been squared)match the size of the outside spanning tool.
GROUP 34
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
Dee94
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
Upright
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
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
As the free lift cylinder fully extends, the rail lift cylinders and lift chains elevate the intermediate and inner rails to maximum fork height. The upright is equipped with 8 rollers. This diagram shows the position of therollers within the triple stage upright. 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.
Dee 94
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
34-l -29
GROUP 34
Upright
Uprights are not manufactured with rails parallel.
Upright Rails to Rollers

The following procedure explains how to:
l
lst-Measure rail-to-roller clearance. 2nd-Adjust rail-to-roller clearance.
34-l-30
GROUP 34
Triple Stage Upright
mmmmm
m m
c
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
Dee 94
GROUP 34
Upright
usec-&Imp to force rollers to one side. Torque on C-Clamp shouldnotexteed 20 Ib.ft.
Shim Check
Roller
ii..:.:.:.:.:.:.):.:.:.:.:.:
::::::a:::::::~:::::::~.~:~.~:~:~:~:~:~:~~:~:~
:.:.:i...A.... . . ...... . ,. ,. ,.
\ .,.,.,.,.,.,.,.,.,.(,.,.
Point of roller contact.
Inner Rail
Floor
34-l -32 SM-587
Dee 94
Upright
GROUP 34
Checking roller clearances:
CAUTION
Watch for overhead clearance when extending upright.
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.
ROLLERS SHOULD BE ADJUSTED LINE TO LINE WITH 0.020 MINIMUM CLEARANCE
WARNING
PINCH POINTS Useextremecarewhenworking on the upright to avoid placing hands or fingers into potential pinch points. Unexpected movement of upright components can cause serious injury
Adjustmentreference
chart when usingfeelergauges.

I
IFeeler 1 Gauge will Step; Gauge I pass / not uass
Shimmed
Shim
1 l.020
2 ;.050
PASS not nass PASS not pass PASS notpass
I Correctlv I
I
check with al
1.050 I
;
I Yes
I I
I
I I
1
check with a
I.080 I
I No, add
Roller Clearance Inspection

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 its correct position. Note the procedure for checking clearance is basically the same whether the upright has been removed or is mounted on the truck. There are two methods covered, one is using a pry bar to position rails and rollers and the other is using a 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
I soso
check with al
1.120 I
I No, add
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
Dee 94
GROUP 34
When using a pry bar:
l
Upright
C-Clamp Method
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.
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.
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.
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
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 View
Check
Roller
Feeler Gauge
Point of roller contact
r
t
Inner Rail
Intermediate Rail Floor

Dee 94
SM-587
GROUP 34
Upright
Checking Upper Rollers with Upright Extended approximately one half of maximum lift.
Check roller clearance in this area using the same procedure as before.
l
Top View
Rail
Roller
Shim Check
Adjustmentreferencechartwhenusingfeelergauge:
) Feeler )
Gauge will
Shimmed Correctly
Stepl Gauge 1 .020 .0.50 2 / ,050 1.080 3 i .080 , .120
pass I not pass

i 1
PASS not pass
I Q check with a I
1 Yes
j PASS 1 not pass

1
, ; check with a! I 1 1 No, add

1 1
PASS
check with al Noadd 3

f 2
fnotpass
Dee 94
34-l -36
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
Adjustmentreferencechartwhenusingfeelergauges
Feeler I i I
Gauge will
1 I
Shimmed
Shim
I I
SteplGauge
lpass / not pass I Correctlv ; PASS
I QJ
1.050 I not pass
I check with a I I I I Yes I
I I
I
Dee 94
SM-587
GROUP 34
Upright
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.
.
Top View
------cf----AL
Rail
,7
r
Roller
Fe&x Gauge
Point of rot ler contact.
-1
Shim Check
I-
IFeeler I SteplGauee 1 j.020

I .050 I
Gauge will / not uass
I I pass
I I I
Shimmed Correctlv
I I
I Q
I
I ,
PASS not pass
check with a i Yes I 0
1
bottom Insde
L
Pry Bar
2 I .050 1 PASS
I checl
1 No, add
I 1
al
1 I I 1 1
f .080
3
1.080
f I I
not pass PASS
check with a
/.120 1 notpass
I
\\ Pry Bar
/
I No, add
Dee 94
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
Intermediate
procedure as before.
l
Top View
j Check ,
Roller
Point of roller contact.
IFeeler
9-9
Gauge will
;-Shimmed
ass / not uass 1 Correctlv
1 , .020
I PASS
I
LQQ
check with a l
I .050" I not uass

Pry Bar
\
I Yes
I 1
2: ;.050" ; PASS I.080" 1 not uass
I I check with a I
No, add
0
1
3 ; .080
PASS
check with a No, add
I .120
I not pass
I I
1 I
SM-587
Dee 94
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. If any of the rollers require adjustment, refer to adjustment procedures on next page.
If the upright roller clearance was checked with
Upright
;nims = u.ubW 1 Etc.
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. .0.040
-
0.060
Rails Extended 6-l 0 inches

Rails Extanded approximately
l/2 wav
34-l -40
Rails extended to within 6-10 inches of maximum fork heiaht

SM-587
Dee 94
Upright 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 itsshaft using a plastic or hard-rubber mallet. Gently tap the roller to seat it evenly and snugly against the shims.
Upper Roller Sets Left Right *
,
GROUP 34
Intermediate Rail
Left @
Left @
i 1
II
Lower Roller Sets Dee94
SM-587
lVl;~;~-i~Handling El!!!!Rl5
GROUP 34
Section 2 Pantograph & Fork Carriage Assembly

Contents Safety and 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
Dee 94
GROUP 34
Pantograph
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.
WARNING
is
Hydraulic fluid is toxic to skin, eyes and respiratory tract. Good ventilation normally adequate.
q?gJ@&
WARNING
WARNING
Always wear Safety Glasses when working on truck.
Dee 94
34-2-2
SM-587
Pantograph Preparation
. . . .
GROUP 34
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
(125 - 140 Ib.ft.)
2. EIevate and Block Pantograph. . .
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
Dee 94
GROUP 34
Standard Models Only
3. .
Pantograph
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
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
SM-587
Pantograph
Side Shift Models Only - continued -
GROUP 34
WARNING
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.
Support forks as fork bar is removed so they cannot fall.
f-ork,Bar
(B) I
Pin
Fork Bar (B)
Connects to Side Shift Cylinder
SM-587
34-2-5
Dee 94
GROUP 34
SERVICING FORK CARRIAGE
Pantograph
Bushings
Dee 94
34-2-6
SM-587
Pantograph SERVICING FORK CARRIAGE
GROUP 34
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
Dee 94
GROUP 34
4. Using a brass drift, drive shaft (4) out of roller (4A) and bell crank.
Pantograph
_.
5. Now, drive shaft (3) outwardfree of bell crank (3A).Remove shaft and bell crank.
:,
:
,
:
.,
., ;
. .
,,
r
,I
,, -
,, ,. . : i
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.
\Shaft
(3)
7.
Installation is the reverse of removal.
Dee 94
34-2-8
SM-587
Pantograph Fork Carriage Removal
GROUP 34
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 Dee 94
GROUP 34
Fork Carriage Removal
Models equipped with Tilt Only
Pantograph
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.
\*
* *\ > *@)I
I
5. Slowly elevate carriage until free of arms. Continue to elevate carriage until lower scissors rollers are free of carriage channels. Then set carriage to one side.
Liftingztraps Safety Hook
Dee 94
34-2-l
SM-587
Pantograph SERVICING PANTOGRAPH ARM ROLLERS

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
GROUP 34
roller and thrust pad without removing scissor assembly from carriage. 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
GROUP 34
\ Inner Arm Pivot Bearings
Upright
Pivot Bearing L Shield
Prepack bearing cup & cone assemblies prior to installation.
Nut (*) Install with chamfer towards nut lock. Torque to: 27 - 41 l N.m (20-30 Ib.ft.
5. Disassemble the outer arm assembly.

6. Replace seals with new ones.
NOTE
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 Check grease fitting for damage and to make certain none are missing.
If the Inner Arm Pivot Bearings need to bereplaced, the pantograph carriage must be removed from the upright. Refer to Group 34, Section 1. 7. Reassemble to the reverse of disassembly. Lubricate parts with clean chassis grease prior to assembly.
IMPORTANT
Prepack bearing cup & cone assemblies prior to installation Dee 94
34-2-l 2 SM-587
lVl;t$;\Handling EMIRK
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
Dee 94
GROUP 34
Lift Cylinder
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.
before
WARNING
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
SM-587
Lift Cylinder Disassembly

1. Wash exterior surface of cylinder thoroughly before disassembly.
l
GROUP 34
Wiper
I
_-; _____--- A I
I
A soft fiber brush should be used to remove debris and foreign objects from grooves and threaded areas, etc. A Stoddard type cleaning solvent should be used to wash the cylinder.
Seal
G3
0
8
Ian
Spring
Plunger
m) GI
Back-Up:
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
SM-587
Dee 94
GROUP 34
r Washer SnaD Ring7 Plunger Spring ---Barrel
Lift Cylinder
7 I r.
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. . . Remove lock washer, back-up ring and O-ring from cylinder gland Remove rod wiper and seal from cylinder gland.
End View
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.
5. Inspectsurfaceofthepistontobesuretitisclean, smooth and free of damage.

l
Replace all damaged or unserviceable parts.
Dee 94
SM-587
Lift Cylinder Reassembly

Piston Rod & Piston
1. Lubricate all parts with clean hydraulic fluid.
GROUP 34
Hydraulic Cylinder Seal Tool
Clark Part No.s: 1801783 and 1801784 Avail from: Central Parts Divn. 7300 South Cicero Ave. Chicago, Ill. 60629
Example
2. Lubricate and install the spring, plunger, washer

and snap ring into base end of the piston rod. Refer to illustration on page 34-3-3.
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
aonot 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.
Dee 94
~#$?ri;\Handling CLSRK
GROUP 34
Section 4 Free Lift Cylinder Overhaul

Contents
Disassembly ...................................................................................... Inspection .......................................................................................... Reassembly ...................................................................................... 34-3-3 34-3-4 .34-3-5
Cylinder Removal Instructions are covered in Group 34, Section 1.
SM-587
34-4-l
Dee 94
GROUP 34
Lift Cylinder
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.
before
WARNING
is
Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation normally adequate.
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
SM-587
Lift Cylinder Disassembly

1. Wash exterior surface of cylinder thoroughly before disassembly.
l
GROUP 34
I
Wiper Scarf Cut Back-Up Ring Seal F3 Q

Install Back-Up & O-Rings as shown.
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. 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
Dee 94
Lift Cylinder Reassembly

Piston Rod & Piston
1. Lubricate all parts with clean hydraulic fluid.
GROUP 34
Hydraulic Cylinder Seal Tool
Clark Part No.s: 1801783 and 1801784 Avail from: Central Parts Divn. 7300 South Cicero Ave. Chicago, Ill. 60629
Example
2. Lubricate and install wear ring onto the piston

rod. Refer to illustration page 34-4-3.
3. Now, 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 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 the piston 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. Set Lock Washer into Grooves provided.
SM-587
34-4-5
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
Dee 94
GROUP00
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.
Component
Inspection
l
Procedure
Set the top jaws by measuring the thickness of

the shank, see Figure 2 (reference measurement). The calipers should be squeezed by hand until the top jaws make contact with both sides of the shank.
IMPORTANT
Fork Wear Calipers

The
forks can be checked for wear by using a
Fork Wear Caliper which is a go-no go gauge that

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.
NOTE
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. Care should be taken when using the calipers to hold them square across the shank or an incorrect reading will be obtained. 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.
l
Fork Wear Calipers (Clark Part No. 1803641)

havetwomeasuringpointsorjaws(Figure page), they are:
l
1,opposite
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 1/2offthefloorasmeasured at the heel of the fork. The area that fork wear usually appears is illustrated in Figure 4.
The
Dee 94
34-5-2
SM-587
GROUP 34
Fork Wear Caliper
Clark Part Number 1803641
Area of Fork Shank to be measured as
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
Dee94
GROUP
00
l
Component
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.
Inspect Fork Condition

l
Inspect forks for cracks, breaks, bending

and wear.
... __..._._.-..._..__._________ ...._ ....~ ......._._ .......__. .. -
3% of B Maximum Difference
+ForkTps
1 Maximum -,
have them bent or damaged, inspected by a trained maintenance person before operating the
Inspect Forks for Twists and Bends

l
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
SM-587
CMRH~de;dx\Handling
Contents
GROUP 34
Section 6 Upright Chain Inspection; Adjustment & Replacement

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
SM-587
34-6-l
Dee94
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:
Chains
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.
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.
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).
Cracked Plates
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).
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
Worn contours and worn sulfates on the outside links or pin heads should not exceed 5% of new link height.
Fatigue cracks generally run from the pin hole toward the edge of the link plate approximately 90 from the line of pull.
G3
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
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.
SM-587
Chains
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.
GROUP 34
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. 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.
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
If lubrication does notloosena tightjoint, thechainmayhave corrosion and rust problems or bent pins and must be replaced.
Chain Length Adjustments
An upright or unexpectedly:
l
WARNING
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.
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. 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).
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
GROUP 34
IMPORTANT
For all chain adjustments:
l
Chains
Triple-Stage Upright (TSU) Chain Length Adjustments

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 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.
IMPORTANT
The carriage stop must not be allowed to contact the upright stop under any circumstance during normal operations.
Dee 94
SM-587
Chains
GROUP 34
IMPORTANT
For all chain adjustments:
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) 34-65 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Dee 94
SM-587
GROUP 34
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
WM.
Chains
General Guidelines
Chain Movement - Make sure that the chain operating path is clear and that the chain articulates freely through its full range of operation. 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. Paint - Make sure the chain does not get painted over at any time. 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.
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 l l l 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. 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): 1. Attach a hoist strap on the carriage of the standard upright or inner rail of the TSU. 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.
Chain Removal and Replacement
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
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. SM-587
Chains
GROUP 34
NOTE
Other Chain Service Notes

.
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.
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. 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.
. 5. Use the steps in reverse order to replace the lift chain

set.
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. 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
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
Axle 2
SM-587
35-1-1
Dee 94
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. Removal 1. Remove snap ring and shim(s) from each axle.
Load Wheels
levate 3-inches and block outrigger here
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. 2. Pull rocker arm shafts out of the wheels and outrigger. 3. Remove load wheels. Inspection 1. Wipe bearings clean. Remove grease, dirt and debris from bearings.
.
4. Install rocker arms. Point on rocker arm must face downward.
IMPORTANT
After load wheels androcker arms are installed, locate a C clamp near the rocker arm pivot pin and tighten slightly. 5. Install snap ring on each rocker arm shaft.
IMPORTANT
Always use new snap rings. Install snap ring so the sharp edge is located away from the rocker arms. 6. Clean any dirt and grime from the grease fittings and grease wheel bearings until the grove between bearings is full.
l
2. Rotate bearing by hand. Note any rough spots while rotating bearing. 3. Examine seals for signs of damage.
Elevate outrigger and remove blocking. Lower outrigger until load wheels are flat on the floor. 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. Installation & Lubrication 1. Install new bearings into wheels. Load Wheel, 1
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
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
Brown 1 Red 2
Example Reference Wiring Schematic

Wire No. 6 is a Solid Blue Wire. Wire No. 13 is a orange wire with a brown stripe. Wire 33 is a solid orange wire.
Grange 3 Yellow 4 Green Blue 5 6
Violet 7 Gray White 8 9
Note
Data listed on the following pages is based on: N-PR-17
NPR-20
3500 lbs (1600 kg) @ 24-inch (600 mm)

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.
GROUP 40
Ikavel Speeds with Capacity Load
N-PR-17 with 170 & 198 MPH Uprights: NPR-20 with 210MFH Uprights
:
Specifications, Truck
5.8 mph 24-Volt Models 5.7 mph 24-Volt Models
6.7 mph 36-Volt Models 6.6 mph 36-Volt Models
navel Speeds without Load

NPR-17 & 20 with all MPH Uprights: 6.3 mph 24-Volt Models 7.2 mph 36-Volt Models
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 120F. when
making test.) NPR-17 with 170 & 198 MPH Uprights: NPR-20 with 210,240,258 making test.) NPR-17 & 20 with all MFH Uprights: 65 fpm 24-Volt Models 95 fpm 36-Volt Models & 270 MPH: 42 fpm 24-Volt Models 40 fpm 24-Volt Models 62 fpm 36-Volt Models 60 fpm 36-Volt Models
Lift Speeds without Load (MS68 Hydraulic Fluid should be at operating temperature 120F when
Lowering Speeds with Capacity Load: Lowering Speeds with out Load: 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.
80 fpm ( all models and uprights) 90 fpm ( all models and uprights)
r
(MS68 Hydraulic Fluid should be at operating temperature 120F. when making test.)
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
SM-587
GROUP 40
r
Fork Stwead
33 Wide Pantograph
1
330.6n-m 13
2
577nx-n 22.73 574.6mn-r 22.62 582.6mm 22.94 703mm 27.68
3
682mm 26.86 677.6nx-n 26.68 677.6mn-1 26.68
4
787mm 31 784mm 30.87
37 Wide Pantograph
330.6mm 13
889mm 35
33 Wide Pantograph with Sideshift Forks 37: Wide Pantograph with Sideshift Forks
482.6mm 19 559mn-l 22
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
Or
Top View
NOTE
All dimensions are in inches unless otherwise specified. NPR- 17 Data is based on 3500 lb. load, 42.0 forks, 198 MFH Upright with no sideshift. NPR-20 Data is based on 4000 lb. load, 42.0 forks, 198 MFH Upright with no sideshift.
SM-587
40-l Material -3 Copyrighted Intended for CLARK dealers only Do not sell or distribute
Dee 94
GROUP 40
A
5232mm 206 5943mIn 234 6248nxn 246 701Omm 276 7468mm 294 7772mm 306
B
4318nx-n 170 5029mn-l 198 5334nxn 210 6096mm 240 6553mm 258 6858mm 270
C
1814kg 40001bs 1814kg 4OOOlbs 1814kg 40OOlbs 1814kg 4OOOlbs 1588kg 35001bs 1361kg 30001bs
D
2260mm 89 2260mm 89 2413mm 95 2718m.m 107 2870mm 113 3022mm 119
E
2209mm 87 2209mm 87 2362mm 93 2667mm 105 2819mm 111
t t
1372mm 54 1524mm 60 1828nx-n 72 1981mm 78 2134nx-n 84
814kg 17951bs 853kg 18801bs 982kg 21651bs 1069kg 23571bs 1108kg 24431bs
449kg 18001bs 449kg 18OOlbs 449kg 18OOlbs 449kg 18OOlbs 449kg 18001bs
297 lmm 117
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
SM-587
Specifications
- Truck
GROUP 40
Refer to Chart o n opposite
page.
1219.18mm (48.00) Load Backrest Extension
........ :...... . +
Pantoiraph Extended
I
..---
Pantograph Retracted
B/C
-e
I .
Roller(s)
...~~ I,.. ,.,.,.,.,.... .. ., ~,.,,..,,...,.,.,.,.,...

:::.!..
x.: .....
..x ;,y ,.,::::~:.,:.:

.I . . . . .
==-I+
. . .
-2
3
..A A.
50.8mm 38.4mm
(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
Overall Dimensions
Specifications
Truck
Ground Clearance minimum with 4 Dia. Load Wheels: Ground Clearance minimum with 5 Dia. Load Wheels: Ground Clearance minimum with 10.5 Dia. Load Wheels: Length to fork face (13.38 & 13.88 Battery Compartment Width):Length to fork tip (16.13 Battery Compartment Width):
1.OO 1.75 1.75 47.9 50.1
Turning Radius:
Outside:(13.38 & 13.88 Battery Compartment Width): Inside: (13.38 & 13.88 Battery Compartment Width): Outside:(16.13 Battery Compartment Width): Inside:(16.13 Battery Compartment Width): Width: 66.5 36.9 68.7 36.9 53.0
Battery Compartment Size

N-PR-17 NPR-17 & 20 NPR-17
Maximum Battery Size

38.69 W, 13.00 L, 31.5 H 38.69 W, 13.50 L, 31.5 H 38.69 W, 15.75 L, 31.5 H
Min. Weight
1400 pounds 1590pounds 1885 pounds
38.75 W x 13.38 L x 32.0 H

38.75 W x 13.88 L x 32.0 H 38.75 W x 16.13 L x 32.0 H
(Maximum size including cover if required)
Battery
T-e - Lead-Acid Canacity (6hr. rate) Maximum: KWH (6hr. rate) Maximum (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
108.5- 24V 25.1 1240 - 24V / 775 - 36V 28.9 - 24V 127.0 - 36V 1395-24V/980-36V. 32.3 - 24V / 34.0 - 36V
NPR-17
Bat. Comnartment Max. Capacity
Max. KWH Rating
Min. Weight lbs.
1400
1590
1885
NPR-20
Bat. Compartment Max. Capacity Max. KWH Rating Min. Weight lbs.
(Battery Compartment Length x Width X Height)
38.75 x 13.88 x 32
1240 - 24V / 775 - 36V 28.9 - 24V / 27.0 - 36V
38.75 x 16.13 x 32
1395 - 24V / 980 - 36V 32.3 - 24V 134.0 - 36V
1590
1885
Steering
Type:
Hydraulic Assist
Turns (Lock to Lock):
4.25
Dee 94
SM-587
SDecifications
Truck
GROUP 40
Mark Rail
Lift Cylinder Downdrift Test

(Make test withfluidMS-68at operatingtemperature 120F.)
Cvlinder drift should not exceed 1.0 inch in a five minute period.
Check drift here
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
Elevate Carriage & Load 1O-l 5 inches and approximately 1 in Back tilt.
Tilt Cylinder Drift Test

(MaketestwithfluidMS-68atoperatingtemperature120F.) Cvlinder drift should not exceed ref. 1 ref. 2 0.040 inch in a five minute period. 0.1 degree in a five minute period.
Pantograph w/ Tilting Carriage
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.
Checking drift at Forks
Elevate carriage and load 12 to 15 inches and place mast in full back tilt postion.
SM-587
40-lMaterial -7 Copyrighted Intended for CLARK dealers only Do not sell or distribute
Dee 94
GROUP 40
Service/Parking Brake(s)
Spring
Specifications
Truck
Applied and Hydraulically Released. Brakes must be capable ofholding truck, with
.:.:,:,::::::
a full rated capacity load on a 15% grade minimum. iI i Brake PedE rPedal
Uo_Heiaht
112.5 mm (4-7/16)
41
Master Cylinder(s)
One cylinder connects to the Motor Brake.
170 - 190 Nom (125~1401bfft)
IMPORTANT Apply 1802397

(Anti-Seize) to motor shaft, bore and Install bolts using Loctite 242 on threads.
20 (177
-
25 Nom 221 Ibf. in.)
Dee 94
SM-587
Sr>ecifications - Truck
GROUP 40
Brake OFF
BrakeON L
BrakeOFF
_____-_
Brake ON
l-
114-
Brake OFF
Cover
must be
in place at all times to provide required
SM-587
Dee94
GROUP 40
Caster Brake
Specifications
Truck
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
Brake Assembly Mounting SDecification

l
Tighten Sequence (Caster Brake Mounting Bolts)

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
Truck
GROUP 40
ELECTRICAL SYSTEM SPECIFICATIONS

Voltage IA Free Wheeling Drive Motor Current Lift Pump Motor @ By-Pass (MS-68 OIL @ 120 F) Steer / Auxiliary Pump Motor @ By-Pass (MS-68 OIL @ 120 F)
Operating Aux Function Operating Steering 95 TO 105 AMPS 95TOll5AMPS 60 TO 70 AMPS 90TOllOAMPS
24V 50 TO 60 AMPS
36V 40 TO 50 AMPS
490 TO 510 AMPS
520 TO 540 AMPS
Ground Tests (New & Used Trucks)
20,000 OHMS MINIMUM
Meter set on Rx10,OOO Scale, measure from Negative battery connector to truck frame.
Solid State Traction Control Specifications

Type System Voltage Low Voltage Cut-Off Accelerator Input Voltage Transistor 24 OR 36 VOLTS D.C. 16 VOLTS D.C. 3.5V TO 0.2V Controlled Thermal Cut-Back 194 F. Solid State
Speed Control 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. 194F.
Solid State Solenoid Control

System Voltage Low Voltage Cut-Off 24 OR 36 VOLTS D.C. 16 VOLTS D.C. Contactor
(
Lift Motor Control Motor Diameters Inches

)
Drive (Traction ) Motor Lift Pump Motor Steer/Auxiliary Pump Motor
6.7 8.0 6.4
SM-587
Dec94
GROUP 40
Hydraulic System Specifications
24 Volt LifI Pump TYPe
Flow (GPM) @RPM @ Pressure (PSI) 6.9 1185 1910
Specifications
Truck
System Voltage Gkar
36 Volt
------I
10.1 1720 2020
1Relief Valve Settinp (PSI)

24 Volt
2650 - 2750 @ 8.5 GPM System Volta e G&r

2.4 2130 1000
Steer /Auxiliary Pump
Type
Flow (GPM)
_ @RPM
-1
2.5 2200 1000
@ Pressure (PSI)
1 Relief Valve Setting (PSI)
1550 - 1650 @ 1.9 GPM
Hydraulic Valve
Lift Control Auxiliary Control

I
I
Filters Suction Strainer
Spool
TYPe
Micron Rating
Cleanable 100 Mesh SS Screen 149 Absolute Cleanable 30 Mesh SS Screen 533 Absolute 10 Micron Cellulose Spin On beta 5=2, beta 13=20, beta 17=75
Fill Strainer
TYpe Micron Rating
Return Line
TYpe beta Rating
Reservoir Breather
TYPe
Micron Rating
___.-
10 Micron Cellulose Push On 10 Nominal
---____ 7.7 -1 MS68
[System Reservoir Capacity (Gallons) Hydraulic Fluid

Dee 94
SM-587
Specifications - Truck
GROUP 40
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)
Brake Assy to Drive Motor Bolts (Diagonal Sequence)240 - 270 lb. in. (27 - 31 N*m)
Brake Drum to Drive Motor Shaft Nut
(125 - 140 lb.ft. (170 - 190 Nom)
Drive Motor Mounting Bolts

25 lb.ft. (34 Nom)
Drive Unit to Axle Mounting Bolts

(Refer to illustration in Group 20, Section 2)
74 - 81 lb. ft. (100 - 110 N*m)
Drive Wheel Mounting Bolts (Diagonal Sequence) -124 - 139 lb.ft. (168 - 188 N*m
Truck to Upright Mounting Bolts w Lower

375 lb.ft. (508 N*m)
Truck to Upright Mounting Bolts w Upper (Refer to illustration in Group 34, Section 1, Page 14) Load Backrest Extension Mounting Bolts
200 lb.ft. (271 N*m)
125 - 140 lb.ft. (170 - 190 Nom)
(Refer to illustration in Group 34, Section 2, Page 3) Oil Filter Assembly

Group 29, Section 1, Page 6. Refer to the instructions found in
Overhead Guard Mounting Bolts
177 to 199 Ib.ft. (240 - 270 N*m)
OHG Leg to Overhead Guard Bolt

30 - 33 lb.ft. (40 - 45 Nom)
OHG Leg to Truck Frame Bolt
75 - 80 lb.ft. (102 - 108 N*m)
SM-587
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
Dee 94
GROUP 40
SERVICE WEIGHTS IN POUNDS
MODEL NPR-17
Specifications
I
UPRIGHT 170
BATTERY COMPARTMENT MINIMUM BATTERY WEIGHT LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT
13.38 1400
13.88 1590
16.13 1885
0 6381 2348
3500 9881 6293
0 6571 2400
3500 10071 6345 3725 3500 10071 6345 3725 3500 10161 6392 3769 3500 10443 6527 3916 N/A
0 6938 2573 1 4365 I 0 6938 2573 4365 0 7029 2621 4407 0 7310 2761 4549 I 0 7505 2856 4649
3500 10438 6501 3937 3500 10438 6501 3937 3500 10529 6550 3979 3500 10810 6689 4120 3300 10805 6559 4245 2800 10392 6044 4347
I
198
I I
4033 0 6381 2348 4033 0 6471 2395 4076 0 6753 2529 4223
3587 1 4171 3500 9881 6293 3587 3500 9971 6340 3631 3500 10253 6475 3778 N/A 0 6571 2400 4171 0 6661 2447 4214 0 6943 2581 4361 I 0 7138 2672 4466 N/A 7224 2716 4508 0
I LOAD
TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT
210
LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT
240
258
I LOAD
0 6948 2620 4328 0 7034 2664 4370
TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT
270
LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT
N/A 7592
0 2902 4690
NOTE:
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
SM-587
Specifications
GROUP 40 SERVICE WEIGHTS IN POUNDS
MODEL BATTERY COMPARTMENT UPRIGHT MINIMUM BATTERY WEIGHT LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT I 13.88 1590
NPR-20 16.13 1885
0 6846 2475 4371
4000 10846 6984 3862 4000 10846 6984 3862 4000 10936 7031
0 7213 2645 4568 I 0 7213 2645 4568 0 7304 2694
4000 11213 7134 4079 4000 11213 7134 4079 4000 11304 7183 4121 4000 11585 7323 4262 3500 11280 6856 4424 3000 10867 6341 4526
170
198
LOAD 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
0 6846 2475 4371 0 6936 2522
210
I
240
4414 0 7218 2656 4561 0 7413 2747
3905 1 4610 3900 11218 7165 4052 N/A 0 7585 2833 4751 0 7780 2928 I 4852 N/A 0 7867 2974 4893
258
LOAD TOTAL WEIGHT FRONT AXLE WEIGHT 1 REAR AXLE WEIGHT LOAD TOTAL WEIGHT FRONT AXLE WEIGHT REAR AXLE WEIGHT
4666 0 7499 2791 4708
270
NOTE:
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
GROUP 40
Specifications
Pantograph Assembly
I
r
Location of:
Pantograph Serial Number
(You must refer to this number when ordering parts for the Pantograph).
Dee 94
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. 1802303 1803252 1803253 1803254 1803255 1803256 1803257 1802308 Gasket Maker Ultra BlueX RTV High Temp Form-A-Gasket-2 Form-A-Gasket- 3 High TackTM CopperCoat Gasket Remover
- continued Dee 94
Size 50 ml. 3.35 oz. 3 oz. 3 oz. .25 pint 6 oz. spray 12 cz.spray 18 oz. spray
Quantity IO/case 12/ease 12/ease 12/ease 12/ease 12/ease 12/ease IO/case
SM-587
40-3-I
GROUP 40
CLARK PRODUCTS -continued ADHESIVE PRODUCTS Part No. 1802306 Size Quantity
Silicone Adhesive Sealant Fast Cure Epoxy Superbonder-Gel Bearing Mount SprayAdhesive Steel and Aluminum Epoxy Loctite Weld Loctite Weld Stick
PRODUCTS
3 oz.
1
IO/case IO/case IO/case IO/case 12/ease

1 /
1803259 1802309 1802304 1803260 1803261 1803262 1803263

CLEANING Part No 1803264
O-4 gm. cups
3 gm. 10 ml. 16 oz.

1 oz.
Pkg
2 oz.
11.8
12/ease oz. 12/ease
Size
Quantity.
Natural BlueTM Natural BlueTM Natural BlueTM Locquic PrimerN Brake and Parts Cleaner EnviroSafeTM B & P Cleaner Carb and Choke Cleaner
4 oz. spray 24 oz.

1
24 / case 12/ease 6 / case

1
1803265 1803266 1803267 1803268 1803269 1803270
gal.
6 oz. spray 20 oz. spray 20 oz. spray 16 oz. spray
/pkg
12/ease 12/ease 12/ease
- continued -
Dee 94
SM-587
GROUP 40
CLARK PRODUCTS -continuedCLEANERING PRODUCTS Part No 1803271 1803272 1803273 1803274 EnviroSafeTM C & C Cleaner EliminatoTMr 11 EnviroSafeTM Degreaser RadiatorCleaner Size 6 oz. spray 20 oz. spray 20 oz. spray 1 qt. Quantity. 12/ease 12/ease 12/ease 12/ease
LUBRICANTS Part No. 1802307 1803275 1803276 1803277 1803278 1803279 1803280 1803281 1803282 1803283 Anti-SeizeTM Super LubeSuper LubeSilicone Lube Water Pump Lube HydraulicJackOil Tune-upGrease Ultra SlickTM Prussian Blue Valve Grind Size 1 lb. can 4.5 oz. spray .25 oz. oiler 16 oz. spray 12 oz. 1 qt. .33 oz. 4 oz. -75 oz. 34 B Quantity IO/case 12/ease 12/ease 12/ease 12/ease
1
/pkg /pkg /pkg /pkg /pkg
continued -
SM-587
Dee 94
GROUP 40
CLARK PRODUCTS - continued THREADLOCKER Part No. 1802300 1802302 1811140 1803258 PRODUCTS Size Quantity
Gen. PurposeThreadlocker Heavy Duty Threadlocker Teflon- Pipe Sealant Form-A-Thread
IO ml. IO ml. 50 ml. .32 syringe
IO/c&e IO/case IO/case 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 1802153 - 1 Qt. Description 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 air cleaners, chain drives, hydraulic systems, and general lubrication service.
Dee 94
40-3-4
SM-587
GROUP 40
Lubricants
Part Number 2776236 - 1 Gal 916027 - 1 Qt Description Transmission Fluid Specifically recommended for Transmission Models:
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 Allison C-3 Catepiller TO-2 International Harvester Hy-Tran B-6 Abex Dennison IV-0 Hydraulic Fluid Specification
Part Number 1801708 - 2 Gal.
Description 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 Navistar B-6 Allis-Chalmers PF821 J.I. Case JlC143, TFD Massey Ferguson 1138 White-Type 56
Part Number 1802536 - 1 Gal.
Description 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
Dee 94
GROUP 40
Part Number 1800236 - 1 Qt.; 1802155 - 1 Gal. Description Hydraulic Fluid
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 1802200 - 1 Qt.; 1802154 -1 Gal.
Description Transmission/Converter Fluid

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 801167 - 1202.; 850487 -1 Gal.
Description Super Heavy-Duty Brake Fluid

Clark Super Heavy-Duty Brake Fluid protects the vital metal and rubber components found in your equipments 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 1802307
Description 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 1803275 - .25 oz.; 1803276 - 4.5 oz
Description Super-lubeSynthetic Lubricant With Teflon

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
SM-587
GROUP 40
Part Number 1803277 Description 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 1803278
Description 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 1803279
Description 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 1803281
Description Ultra SlickTM Engine 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 1800636
Description Ignition Distributor, Cam Lube

A must for long ignition-cam follower life. Cam Lube is a high-temperature which does not conduct electricity. grease
Part Number 617410
Description Lubriplate
A white grease for clutch throwout bearings, Lubriplate withstands high temperatures and increases the life of bearings.
Part Number 886785
Description 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 886396
Description 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
Dee 94
GROUP 40
Part Number 886399 Description Chain and Cable Lubricant
Chain and Cable Lubricant provides constant lubrication by penetrating chain links, andreducesfrictiondragsonsuddenoverloads.It alsopreventsdrippingonsloworidle chains.
Sealants
Part Number 886398 Description Battery Saver
Battery Saver preserves battery power by retarding acid action, preventing corrosion, and sealing vibration cracks.
Part Number 886784
Description 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 1801146
Description 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 1801145
Description 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 1801480
Description GE Silicone
Protects SCRs by weatherproofing solvents. and sealing while resisting chemicals, oils, and
Part Number 1803280
Description Electric Tune-Up Grease

Protects electric connections and wiring from salt, dirt, and corrosion. Extends the life of the bulb sockets. Prevents voltage leaks around any electrical connection. Also prevents spark plugs from fusing to boots. Use in extremely dusty, dirty, or corrosive applications.
Dee 94
SM-587
GROUP 40
Part Number 1802306 Description 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 1802303 Description 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 1802308
Description 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 1803252
Description 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 1803253
Description 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 1803254
Description Form-A-Gasketa No. 2

Slow drying, non-hardening sealant designed for sealing cut gaskets and stamped parts. Allows for easy disassembly if required. Use where sealing is more important than adhesion. Temperature range is - 8.5F to 4ooOF. For valve-cover gaskets and oil-pan gaskets.
SM-587
Dee 94
GROUP 40
Part Number 1803255 Description 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 1803256
Description High TackTM Spray-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 1803257
Description 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 500F. For cylinder head gaskets, carburetor gaskets, exhaust manifold gaskets, and other high temperature applications.
Threadlocks and Threadsealers

Part Number 945945 Description Loctite Nut Lock
LoctiteNutLockturnsordinarynutsintovibration-prooflocknuts. Itreducesassembly costs by eliminating expensive lock nuts and prevents machinery from vibrating loose.
Part Number 1802300
Description 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 1802302
Description 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 1801140
Description 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
SM-587
GROUP 40
Part Number 1803258 Description 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 1802304 Description 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 1802309
Description 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 1803259
Description 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 1803260
Description 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 1803261
Description 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 1803262
Description 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
Dee 94
GROUP 40
Part Number 1803263 Description 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 886397 Description 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 1800330
Description Degreaser
This easy-to-use degreaser is water soluble, safe for paint, and does not rust.
Part Number 1802522
Description 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 1803264 - 4 oz.; 1803265 - 24 oz.;

1803266 - gal.
Description Natural BlueTM Cleaner/Degreaser

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. Description Locquic@ Primer N Degreases oily parts and speeds the curing ofanaerobic products such as threadlockers, pipesealant,bearingmount, andgasketmaker.Recommendedforcoldweatheruseand quick repairs. Use with anaerobic products to speed assembly in all applications.
Part Number 1803267
Part Number 1803268
Description 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
SM-587
GROUP 40
Part Number 1803269 Description Enviro-SafeTM Brake & Parts Cleaner
Environmentally safe formula. Biodegradable natural citrus solvents dissolve and remove oil and grease from brake systems and metal parts. No CFCs or chlorinated solvents. Low toxicity.
Part Number 1803270
Description Carb And Choke Cleaner

Super jet spray quickly cuts and removes grease, gum and varnish from chokes, baffle plates, and carburetor linkages.
Part Number 1803271
Description Enviro-SafeTM Carb And Choke Cleaner

Biodegradable formula safely cleans using citrus solvents. Environmentally - no CFCs or chlorinated solvents. friendly
Part Number 1803272
Description EliminatorTM 11 Engine Degreaser

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 1803273
Description Enviro-SafeTM Cleaner And Degreaser

Biodegradable. Safely removes grease, dirt, and oil with the power of natural citrus solvents.
Part Number 1803274
Description 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 917330 - 7.5 oz.; 917329 - 1 Gal.
Description
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
Dee 94
GROUP 40
Miscellaneous Shop Supplies
Part Number 1800078 Description 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 1803282
Description 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 1803283
Description 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
SM-587

11883734-Clark NPR 17 NPR 20 Forklift Service Repair Workshop Manual Download

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11883734-Clark NPR 17 NPR 20 Forklift Service Repair Workshop Manual Download

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SM-587 NPR 17/20

Pictorial Index #1 NPR-345

INDEX Index 1 of 2 Pictorial Index

Pictorial Index :#2 NPR-345

Index 2 of 2 Pictorial Index

Group No-Section No.-Page No.

Grout No-Section No.-PaPe No.

16-2-1 16-3-1 16-7-1

Auxiliary/Steer Pump Pantograph & Fork Carriage Remove & Replace

34-2- 1 34-2- 1 34-5 1 19-8-1 19-8-1

23-l-l 23-2- 1 23-3-l 23-4- 1 23-4- 1 PM-17

Steering Lift Circuit

26-l-l 26-l-l 26-l-l 29-4- 1

Auxiliary Reach & Tilt Pump Overhaul

32-2- 1 32-3- 1 34-3-l 34-4- 1

Steering Adjustments (EV-TSPS) Switches 19-5-1

Directional, Lift & Lower

Specifications Service Weights

Lubricants and Shop Supplies 40-3-l Sump Tank Fluid Level

Wheel & Tire

This message is used when an extreme hazard exists.

IMPORTANT SAFETY NOTICE

Procedures have been made easier to use by

Tobe better prepared to do the necessaryservice

Planned Maintenance Procedures including precautions and safe maintenance recommendations.

ABOUT PLANNED MAINTENANCE The Planned Maintenance Procedures

The Pictorial Index lists components or systems

of Contents list the pages in this

An effective PM program should incorporate

water levels, lights (if so equipped), instruments and warning devices.

being determined by operating conditions.

Records will tell you how often PM

Planned Maintenance Procedures

P.M. CHECK SHEET

X = Adjust (Not P.M.)

Planned Maintenance Procedures

tsconnect Batterv and check Spring Loaded Terminals

Planned Maintenance Procedures

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

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

Check for Obvious Leakage

Planned Maintenance Procedures

Retorque drive wheel fasteners afterthefirst2OOhoursofoperation.

Wheel & Tire

Wheel & Tire

Fastener Tightening Sequence

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

Check Mullti-Function operation.

control for freedom of

Check battery connection. Check horn.

Check key switch and dash display. Check upright operation.

Check speed limit switch operation.

Move control through all functions checking for freedom of movemenet.

Planned Maintenance Procedures

b. Check horn to be sure it operates.

c. Turn key switch ON.

Check the Diamostic Disdav & Kev Switch

Planned Maintenance Procedures

Multi-Function Control Handle Switch Buttons

Planned Maintenance Procedures

1. Check Srxed Limit Switch Oneration

Planned Maintenance Procedures CLEANING