Montacargas SERVIS MANUAL SM-616

TMG 12-25
TMG13-20X
EPG 15-18
SERVICE MANUAL
TMG 12-25
RATED CAPACITY : 1250 – 2270 KG
EPG 15-18
RATED CAPACITY : 1500 – 1800 KG Part No. 8026067
Book No. SM-616
REV. 2
Dec. 2002
Manufactured by #40–1, Ungnam-Dong,

Changwon-City, Kyungnam,
Copyrighted Material Korea
Intended for CLARK dealers only
Do not sell or distribute
REVISION HISTORY
Dec. 2002
When new or revised information is published to Mark Indication Action required
update this manual the action to be taken with the
❍ Page to be newly added Add
pages is indicated in the table.
● Page to be replaced Replace
Pages not marked are not currently revised, but are
included for page numbering continuity. ( ) Page to be deleted Discard
Revision Revision Revision Revision

Mark Page number Mark Page number Mark Page number Mark Page number
SA-1-1 12-1-8 ❍ 13-1-37 ❍ 13-3-26
SA-1-2 ➀ ❍ 13-1-38 ❍ 13-3-27
SA-2-1 13-1-1 ❍ 13-1-39 ❍ 13-3-28
SA-2-2 ● 13-1-2 ➁ ❍ 13-1-40 ❍ 13-3-29
SA-2-3 ● 13-1-3 ➁ ❍ 13-1-41 ❍ 13-2-30
SA-2-4 ● 13-1-4 ➁ ❍ 13-1-42 ❍ 13-3-31
SA-3-1 ● 13-1-5 ➁ ❍ 13-1-43 ❍ 13-3-32
SA-3-2 ● 13-1-6 ➁ ❍ 13-1-44 ❍ 13-3-33
● 13-1-7 ➁ ❍ 13-1-45 ❍ 13-3-34
PS-1-1 ● 13-1-8 ➁ 13-2-1 ❍ 13-3-35
PS-1-2 ● 13-1-9 ➁ 13-2-2 ❍ 13-3-36
● PS-1-3 ➀ ● 13-1-10 ➁ 13-2-3 ❍ 13-3-37
❍ PS-1-3-1 ● 13-1-11 ➁ 13-2-4 ❍ 13-3-38
PS-1-4 ● 13-1-12 ➁ 13-3-1 ❍ 13-3-39
PS-1-5 ● 13-1-13 ➁ ● 13-3-2 ➁ ❍ 13-3-40
PS-1-6 ● 13-1-14 ➁ ● 13-3-3 ➁ ❍ 13-3-41
PS-2-1 ● 13-1-15 ➁ ● 13-3-4 ➁ ❍ 13-3-42
PS-2-2 ● 13-1-16 ➁ ● 13-3-5 ➁ ❍ 13-3-43
PS-2-3 ● 13-1-17 ➁ ● 13-3-6 ➁ ❍ 13-3-44
PS-2-4 ● 13-1-18 ➁ ● 13-3-7 ➁ ❍ 13-3-45
PS-2-5 ● 13-1-19 ➁ ● 13-3-8 ➁ ❍ 13-3-46
PS-2-6 ● 13-1-20 ➁ ● 13-3-9 ➁ ❍ 13-3-47
PS-2-7 ● 13-1-21 ➁ ● 13-3-10 ➁ ❍ 13-3-48
PS-2-8 ● 13-1-22 ➁ ● 13-3-11 ➁ ❍ 13-3-49
PS-2-9 ● 13-1-23 ➁ ● 13-3-12 ➁ ❍ 13-3-50
PS-2-10 ● 13-1-24 ➁ ● 13-3-13 ➁ ❍ 13-3-51
● PS-2-11 ➀ ● 13-1-25 ➁ ● 13-3-14 ➁ ❍ 13-3-52
PS-2-12 ● 13-1-26 ➁ ● 13-3-15 ➁ ❍ 13-3-53
PS-3-1 ❍ 13-1-27 ● 13-3-16 ➁ ❍ 13-3-54
PS-3-2 ❍ 13-1-28 ● 13-3-17 ➁ ❍ 13-3-55
❍ 13-1-29 ● 13-3-18 ➁ ❍ 13-3-56
12-1-1 ❍ 13-1-30 ● 13-3-19 ➁ ❍ 13-3-57
12-1-2 ❍ 13-1-31 ● 13-3-20 ➁ ❍ 13-3-58
12-1-3 ❍ 13-1-32 ● 13-3-21 ➁ ❍ 13-3-59
12-1-4 ❍ 13-1-33 ● 13-3-22 ➁ ❍ 13-3-60
12-1-5 ❍ 13-1-34 ● 13-3-23 ➁ ❍ 13-3-61
12-1-6 ❍ 13-1-35 ❍ 13-3-24 ❍ 13-3-62
12-1-7 ❍ 13-1-36 ❍ 13-3-25 ❍ 13-3-63
SM 616, Dec ’02 ➁ Copyrighted Material REVISION HISTORY - 1

REVISION HISTORY
Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision
number number number number
❍ 13-3-64 16-5-8 19-3-5 19-4-28 ➀
❍ 13-3-65 13-3-6 19-4-29 ➀
❍ 13-3-66 17-1-1 13-3-7 19-4-30 ➀
13-4-1 ➀ 17-1-2 19-3-8 19-4-31 ➀
13-4-2 ➀ 17-1-3 19-3-9 19-4-32 ➀
13-4-3 ➀ 17-1-4 19-3-10 ❍ 19-4-33
13-4-4 ➀ 19-3-11 19-5-1
● 13-4-5 ➁ 19-1-1 19-3-12 19-5-2
● 13-4-6 ➁ ● 19-1-2 ➀ 19-3-13
13-5-1 19-1-3 19-3-14 20-1-1
13-5-2 19-1-4 ❍ 19-3-15 20-1-2
13-5-3 19-1-5 ❍ 19-3-16 20-2-1
13-5-4 19-1-6 ❍ 19-3-17 20-2-2
19-1-7 ❍ 19-3-18 20-3-1
16-1-1 19-1-8 ❍ 19-3-19 20-3-2
16-1-2 ➀ 19-2-1 ❍ 19-3-20 20-4-1
16-1-3 ➀ 19-2-2 19-4-1 20-4-2
● 16-1-4 ➀ 19-2-3 19-4-2 ➀ 20-5-1
16-2-1 19-2-4 19-4-3 ➀ 20-5-2
16-2-2 19-2-5 19-4-4 ➀ 20-5-3
16-2-3 19-2-6 19-4-5 ➀ 20-5-4
16-2-4 19-2-7 19-4-6 ➀ 20-5-5
16-3-1 19-2-8 19-4-7 ➀ 20-5-6
16-3-2 19-2-9 19-4-8 ➀ 20-5-7
16-3-3 19-2-10 19-4-9 ➀ 20-5-8
16-3-4 19-2-11 19-4-10 ➀ 20-5-9
16-3-5 19-2-12 19-4-11 ➀ 20-5-10
16-3-6 19-2-13 19-4-12 ➀ 20-5-11
16-4-1 19-2-14 19-4-13 ➀ 20-5-12
16-4-2 19-2-15 19-4-14 ➀ 20-5-13
● 16-4-3 ➀ 19-2-16 19-4-15 ➀ 20-5-14
16-4-4 19-2-17 19-4-16 ➀ 20-5-15
16-4-5 19-2-18 19-4-17 ➀ 20-5-16
16-4-6 19-2-19 19-4-18 ➀ 20-5-17
16-4-7 19-2-20 19-4-19 ➀ 20-5-18
16-4-8 19-2-21 19-4-20 ➀
16-5-1 19-2-22 19-4-21 ➀ ● 22-1-1 ➁
● 16-5-2 ➀ 19-2-23 19-4-22 ➀ 22-1-2
16-5-3 19-2-24 19-4-23 ➀ 22-2-1
16-5-4 19-3-1 19-4-24 ➀ ● 22-2-2 ➀
16-5-5 19-3-2 19-4-25 ➀ 22-2-3
16-5-6 19-3-3 19-4-26 ➀ ● 22-2-4 ➀
16-5-7 19-3-4 19-4-27 ➀ 22-2-5
2 - REVISION HISTORY Copyrighted Material SM 616, Dec ’02 ➁

REVISION HISTORY
Revision Revision Revision Revision

Mark Page number Mark Page number Mark Page number Mark Page number
22-2-6 ● 25-4-2 ➀ 25-13-3 32-3-1
22-2-7 ● 25-5-1 ➀ 32-3-2
22-2-8 ● 25-5-2 ➀ 29-1-1 32-3-3
22-2-9 25-5-3 29-1-2 32-3-4
22-2-10 ● 25-5-4 ➀ ● 29-1-3 ➀ 32-4-1
25-5-5 ● 29-1-4 ➀ 32-4-2
23-1-1 25-5-6 ● 29-1-5 ➀ 34-4-3
23-1-2 25-5-7 29-1-6 34-4-4
23-2-1 ❍ 25-5-8 ● 29-1-7 ➀
23-2-2 ❍ 25-5-9 ❍ 29-1-8 ● 34-1-1 ➁
23-3-1 ❍ 25-5-10 ❍ 29-1-9 ● 34-1-2 ➁
23-3-2 ❍ 25-5-11 29-2-1 ● 34-1-3 ➁
23-3-3 ❍ 25-5-12 29-2-2 ● 34-1-4 ➁
23-3-4 ❍ 25-5-13 ● 29-2-3 ➀ 34-1-5
23-3-5 ❍ 25-5-14 29-2-4 ● 34-1-6 ➁
23-3-6 ❍ 25-5-15 29-3-1 34-2-1
23-4-1 ❍ 25-5-16 29-3-2 ● 34-2-2 ➁
23-4-2 ❍ 25-5-17 29-3-3 ● 34-2-3 ➁
23-4-3 ● 25-6-1 ➀ 29-3-4 34-2-4 ➀
23-4-4 25-6-2 29-4-1 34-3-1 ➀
23-5-1 25-6-3 29-4-2 34-3-2 ➀
23-5-2 25-6-4 29-4-3 ● 34-3-3 ➁
23-6-1 ● 25-6-5 ➀ 29-4-4 34-3-4 ➀
23-6-2 25-6-6 29-5-1 ● 34-3-5 ➁
23-6-3 25-6-7 ● 29-5-2 ➀ ● 34-3-6 ➁
23-6-4 25-6-8 29-5-3 ● 34-3-7 ➁
● 25-7-1 ➀ 29-5-4 ● 34-3-8 ➁
● 25-1-1 ➀ 25-7-2 29-5-5 34-3-9 ➀
● 25-1-2 ➀ 25-7-3 29-5-6 ● 34-3-10 ➁
● 25-1-3 ➀ 25-7-4 29-6-1 ● 34-4-1 ➁
● 25-1-4 ➀ ● 25-8-1 ➀ 29-6-2 ● 34-4-2 ➁
● 25-2-1 ➀ 25-8-2 29-6-3 ● 34-4-3 ➁
25-2-2 ❍ 25-9-1 29-6-4 ● 34-4-4 ➁
● 25-3-1 ➀ ❍ 25-9-2 29-6-5 ● 34-4-5 ➁
25-3-2 ❍ 25-10-1 29-6-6 ● 34-4-6 ➁
25-3-3 ❍ 25-10-2 29-6-7 ● 34-4-7 ➁
25-3-4 ❍ 25-10-3 29-6-8 ● 34-4-8 ➁
25-3-5 ❍ 25-11-1 ● 34-4-9 ➁
25-3-6 ❍ 25-11-2 32-1-1 (34-4-10)
25-3-7 ❍ 25-11-3 32-1-2 ● 34-5-1 ➁
25-3-8 ❍ 25-12-1 32-2-1 ➀ ● 34-5-2 ➁
25-3-9 ❍ 25-12-2 32-2-2 ● 34-5-3 ➁
25-3-10 ❍ 25-13-1 32-2-3 ● 34-5-4 ➁
25-4-1 ❍ 25-13-2 32-2-4 34-5-5 ➀
SM 616, Dec ’02 ➁ Copyrighted Material REVISION HISTORY - 3

REVISION HISTORY
Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision
number number number number
● 34-5-6 ➁
● 34-6-1 ➁
34-6-2 ➀
34-6-3 ➀
34-6-4 ➀
● 34-6-5 ➁
● 34-6-6 ➁
34-6-7 ➀
● 34-6-8 ➁
34-7-1 ➀
● 34-7-2 ➁
34-7-3 ➀
34-7-4 ➀
34-8-1 ➀
34-8-2 ➀
34-8-3 ➀
● 34-8-4 ➁
● 38-1-1 ➁
38-1-2
● 38-2-1 ➀
● 38-2-2 ➀
● 38-3-1 ➀
38-3-2
38-4-1
● 38-4-2 ➁
40-1-1
● 40-1-2 ➁
● 40-1-3 ➁
40-1-4 ➀
40-1-5
40-1-6
40-1-7
40-1-8
40-2-1
● 40-2-2 ➁
● 40-2-3 ➁
● 40-2-4 ➀
● 40-2-5 ➁
40-2-6
40-3-1
40-3-2
4 - REVISION HISTORY Copyrighted Material SM 616, Dec ’02 ➁

Arrangement and Use of this Manual
Clark arranges parts and service procedures by standard- You can quickly locate a specific point in the manual by
ized Groups. In this manual, Groups are similar to “Chap- using the headers and footers that appear on every Sec-
ter.” Groups are listed I the table of contents on the next tion page. The following illustration points out these
page. areas.
Each Group begins with a table of contents that shows the
Sections contained within the Group. Lengthy Sections Group ID Group ID
also begin with a table of contents showing the topics
contained within the Section.
Each Group and Section has an identifying name and
number, or “ID.” Page ID Page ID
Each page also has a unique ID. The page ID consists of
three numbers separated by hyphens, year/month and the Section ID Manual ID Section ID
revision number. The three numbers represent the Group
number, the Section number, and the page number. For
example, “00-1-2” on the lower corner of the page indi- This manual is intended for the use of trained service
cates Group 00, Section 1, Page 2. The year/month repre- personnel. Please read Group SA, “Safe Maintenance,”
sent the issued or revised one such as April 98. The revision and the Operator’s Manual before working on or operat-
number indicates the revised frequency such as ➀, ➁ .... If ing the truck.
not depicted, the page has not been revised.
Contents-ii Copyrighted
© Copyright Clark Material Material
Handling Company 2001 SM 616, Sep ’02
CONTENTS
Contents by Group and Section

(Alphabetical listing of contents appears on next page.)
Contents are listed here by Group number and name followed by Section number and name:
SA SAFE MAINTENANCE 4. Brake Removal and Replacement

1. Safety 5. Parking Brake R&R and Adjustment
2. Lifting, Jacking, and Blocking 6. Brake Overhaul
3. Towing
25/26 STEER SYSTEM
PS PERIODIC SERVICE 1. Specifications and Description
1. Maintenance Schedules 2. Troubleshooting
2. Planned Maintenance 3. Column Removal and Replacement
3. PM Inspection Form 4. Relief Pressure Check and Adjustment
12 BATTERY 5. Steering Gear Overhaul
1. Battery Service 6. Steer Axle Service
7. Steer Cylinder Overhaul
13 WIRING, SWITCHES, AND INSTRUMENTS 8. Steer Pump Overhaul
1. Schematic Diagrams
2. General Electrical Service Tips 29/30 HYDRAULIC SYSTEM
3. Wiring and Cables 1. Specifications and Description
4. Switches and Sensors 2. Fluids and Filters
5. Instrument Panel 3. Troubleshooting
4. Pressure Checks and Adjustments
16 ELECTRIC MOTORS 5. Main Pump Removal and Overhaul
1. Specifications and Description
6. Main Control Valve Removal and Overhaul
2. Troubleshooting
3. Drive Motors Overhaul 32 TILT CYLINDERS
4. Lift Pump Motor Overhaul 1. Specifications and Description
5. Steering Pump Motor Overhaul 2. Checks and Adjustments
3. Removal and Installation
17 CONTACTORS 4. Overhaul
1. Specifications and Overhaul
34 UPRIGHTS
19 MOTOR CONTROLS 1. Upright Specifications and Description
1. Specifications and Description
2. Trouble shooting
2. Sequence of Operations
3. Upright Inspection
3. Handset Operation
4. Carriage and Upright Roller Clearance
4. Diagnostic Status Codes Checks and Shim Adjustment
5. Controllers Removal and Replacement 5. Cylinder Removal, Shimming, Overhaul and
20 DRIVE AXLE Replacement
1. Specifications and Description 6. Upright Chain Inspection, Adjustment and
2. Fluid Check and Change Installation
3. Troubleshooting 7. Fork and Carriage Removal and Installation
4. Drive Axle Removal and Installation 8. Upright Removal and Replacement
5. Drive Axle Overhaul 38 COUNTERWEIGHT AND CHASSIS
22 WHEELS AND TIRES 1. Specifications and Description
1. Specifications and Description 2. Counterweight Removal and Installation
2. Wheels & Tires Mounting and Maintenance 3. Overhead Guard Removal and Installation
4. Floor Plate, Seat, and Seat Deck R&R
23 BRAKE SYSTEM
1. Specifications and Description 40 SPECIFICATIONS
2. Fluid Check, Fill, and Bleed 1. Nameplate and Decals
3. Pedal and Master Cylinder Removal, Replace- 2. Specifications
ment, and Adjustment 3. Hydraulic Fitting Tightening Procedure
SM 616, April ’98 Copyrighted Material Contents-iii

Alphabetical Listing of Topics
(Contents are listed by order of Group and Section numbers on previous page.)
Contents are listed here by topic followed by the Group#-Section# the topic appears in:
Battery Service ......................................................... 12-1 Lift Pump Motor Overhaul ....................................... 16-4
Brake Fluid Check, Fill, and Bleed ......................... 23-2 Maintenance Schedules ........................................ PM-1
Brake Overhaul ........................................................ 23-6 Motors Specifications and Description ................. 16-1
Brake Removal and Replacement .......................... 23-4 Motors Troubleshooting .......................................... 16-2
Brake System Specifications and Description ...... 23-1 Nameplate and Decals ............................................. 40-1
Carriage and Upright Roller Clearance Checks and Overhead Guard Removal and Installation ........... 38-3
Shim Adjustments .................................................... 34-1 Parking Brake R&R and Adjustment ...................... 23-5
Column Removal and Replacement .................. 25/26-3 Pedal and Master Cylinder R&R and Adjustment . 23-3
Contactors ................................................................ 17-1 Planned Maintenance ............................................ PM-2
Contactors Specifications and Description .......... 17-1 PM Inspection Form ............................................... PM-3
Controllers Removal and Replacement ................. 19-5 Safety ....................................................................... SA-1
Controllers Specifications and Description .......... 19-1 Schematic Electrical Diagrams ............................... 13-1
Counterweight Removal and Installation ............... 38-2 Seat and Seat Deck Removal and Replacement ... 38-4
Counterweight Specifications and Description .... 38-1 Sequence of Operations .......................................... 19-2
Cylinder Removal, Shimming, Overhaul, and Specifications and Description ......................... 25/26-1
Replacement ............................................................. 34-5 Specifications for Entire Truck ............................... 40-2
Diagnostic Status Codes ......................................... 19-4 Steer Axle Service ............................................... 25/26-6
Drive Axle Fluid Check and Change ...................... 20-2 Steer Cylinder Overhaul ..................................... 25/26-7
Drive Axle Overhaul ................................................. 20-5 Steer Pump Overhaul ......................................... 25/26-8
Drive Axle Removal and Installation ...................... 20-4 Steering Gear (Valve) Overhaul ......................... 25/26-5
Drive Axle Specifications and Description ............ 20-1 Steering Pump Motor Overhaul .............................. 16-5
Drive Axle Troubleshooting .................................... 20-3 Steering Relief Pressure Check and Adjust ..... 25/26-4
Drive Motors Overhaul ............................................ 16-3 Switches and Sensors ............................................. 13-4
Electrical Service Tips ............................................. 13-2 Tilt Cylinders Checks and Adjustments ................ 32-2
Floor Plate Removal and Replacement .................. 38-4 Tilt Cylinders Overhaul ............................................ 32-4
Fork and Carriage Removal and Installation ......... 34-7 Tilt Cylinders Removal and Installation ................. 32-3
Handset Operation ................................................... 19-3 Tilt Cylinders Specifications and Description ....... 32-1
Hydraulic Control Valve Overhaul ..................... 29/30-6 Towing ...................................................................... SA-3
Hydraulic Fitting Tightening Procedure ................. 40-3 Troubleshooting ......................................... 25/26-2/34-2
Hydraulic Fluids and Filters ............................... 29/30-2 Upright Chain Inspection, Adjustment
Hydraulic Pressure Checks and Adjustments . 29/30-4 and Installation ......................................................... 34-6
Hydraulic Lift Pump Overhaul ............................ 29/30-5 Upright Inspection ................................................... 34-3
Hydraulic Specifications and Description ........ 29/30-1 Upright Removal and Replacement ....................... 34-8
Hydraulic System Troubleshooting ................... 29/30-3 Upright Specifications and Description ................. 34-1
Instrument Panel ...................................................... 13-5 Wheels & Tires Mounting and Maintenance .......... 22-1
Jacking and Blocking ............................................. SA-2 Wheels & Tires Specifications and Description .... 22-1
Lift Chain Inspection and Service Guidelines ....... 34-2 Wiring and Cables .................................................... 13-3
Contents-iv Copyrighted Material SM 616, April ’98

GROUP SA
GROUP SA
SAFE MAINTENANCE
Safety ............................................................................... Section 1
Lifting, Jacking, and Blocking the Truck ..................... Section 2
Towing.............................................................................. Section 3
SM 616, April ’98 Copyrighted Material Safe Maintenance

NOTES:
Safe Maintenance Copyrighted Material SM 616, April ’98

Group SA, Safe Maintenance
Section 1. Safety
Safety Signs and Messages Safe Maintenance Practices

Safety signs and messages in this manual and on the lift The following instructions have been prepared from cur-
truck provide instructions and identify specific areas where rent industry and government safety standards applicable
potential hazards exist and special precautions should be to industrial truck operation and maintenance. These rec-
taken. Be sure you know and understand the meaning of ommended procedures specify conditions, methods, and
these instructions, signs, and messages. Damage to the accepted practices that aid in the safe maintenance of in-
truck, death, or serious injury to you or other persons may dustrial trucks. They are listed here for the reference and
result if these messages are not followed. safety of all workers during maintenance operations. Care-
fully read and understand these instructions and the spe-
cific maintenance procedures before attempting to do any
NOTE
repair work.
This message is used when special informa-
tion, instructions or identification is re- When in doubt of any maintenance procedure, please con-
quired relating to procedures, equipment, tact your local Clark dealer.
tools, pressures, capacities, and other spe- 1. Powered industrial trucks can become hazardous if
cial data. maintenance is neglected. Therefore, suitable mainte-
nance facilities, trained personnel, and procedures
IMPORTANT must be provided.
This message is used when special precau-
2. Maintenance and inspection of all powered industrial
tions should be taken to ensure a correct
trucks shall be done in conformance with the
action or to avoid damage to, or malfunc-
manufacturer’s recommendations.
tion of, the truck or a component.
3. A scheduled planned maintenance, lubrication, and
inspection program shall be followed.
CAUTION
This message is used as a reminder of safety 4. Only trained and authorized personnel shall be permit-
hazards that can result in personal injury ted to maintain, repair, adjust, and inspect industrial
if proper precautions are not taken. trucks. Work should be performed in accordance with
the manufacturer’s specifications.
5. Properly ventilate work area, vent exhaust fumes, and
WARNING
keep shop clean and floor dry.
This message is used when a hazard exists
that can result in injury or death if proper 6. Avoid fire hazards and have fire protection equipment
precautions are not taken. present in the work area. Do not use an open flame to
check for level or leakage of fuel, electrolyte, oil, or
coolant. Do not use open pans of fuel or flammable
DANGER cleaning fluids for cleaning parts.
This message is used when an extreme haz-
ard exists that can result in injury or death 7. Before starting work on truck:
or serious injury if proper precautions are a. Raise drive wheels off of floor and use blocks or
not taken. other positive truck positioning devices.
b. Disconnect battery before working on the electri-
cal system.
The above terms have been adopted by Clark Material
Handling Company. The same terms may be used in differ- 8. Before working on engine fuel system of gasoline- or
ent context in service literature supplied directly or indi- diesel-powered trucks, be sure the fuel shut-off valve
rectly by vendors of truck components. is closed.
9. Operation of the truck to check performance must be
SM 616, April ’98 Copyrighted Material Safety • SA-1-1

conducted in an authorized, safe, clear area. or defective parts.

10. Before starting to drive truck: 19. Modifications and additions that affect capacity and
a. Be in operating position with seat belt fastened. safe truck operation must not be done without the
manufacturer’s prior written approval. Capacity, op-
b. Be sure parking brake is engaged. eration and maintenance instruction plates, tags, or
c. Put direction control in neutral. decals must be changed accordingly. This is an OSHA
d. Start engine. requirement.
e. Check functioning of direction and speed con- 20. Care must be taken to assure that all replacement parts,
trols, steering, brakes, warning devices, and any including tires, are interchangeable with the original
load handling attachments. parts and of a quality at least equal to that provided in
the original equipment. Parts, including tires, are to be
11. Before leaving truck
installed per the manufacturer’s procedures. Always
a. Stop truck. use genuine CLARK or CLARK-approved parts.
b. Put directional control in neutral. 21. Use special care when removing heavy components
c. Apply the parking brake. from the truck, such as counterweight, seat deck,
d. Stop the engine by turning off the key switch. upright, etc. Be sure that lifting and handling equip-
ment is of the correct capacity and in good condition.
e. Put upright in vertical position and fully lower the
Also, this removal may upset the stability of the truck.
forks or attachment.
The frame must always be safely blocked for major
f. Put blocks at the wheels if truck is on an incline. component removal.
12. Brakes, steering mechanisms, control mechanisms,
warning devices, lights, governors, guards, safety de- NOTE
vices, and frame members must be carefully and regu- You should also be familiar with additional
larly inspected and maintained in a safe operating operating and maintenance safety instruc-
condition. tions contained in the following publica-
13. Special trucks or devices designed and approved for tions:
hazardous area operation must receive special atten-
tion to ensure that maintenance preserves the original,
ASME B56.1 - 1988: Operator Control-Industrial Tow Trac-
approved, safe-operating features.
tors (Safety Standard For Powered Industrial Trucks). Pub-
14. Fuel systems must be checked for leaks and condition lished by: American Society of Mechanical Engineers, Three
of parts. Extra special consideration must be given in Park Avenue, New York, NY10016.
the case of a leak in the fuel system. Action must be
NFPA 505-1982: Fire Safety Standard for Powered Indus-
taken to prevent the use of the truck until the leak has
trial Trucks: Type Designations, Areas of Use, Mainte-
been corrected.
nance and Operation. Available from: National Fire
15. The truck manufacturer’s capacity, operation, and Protection Assoc., Inc., Batterymarch Park, Quincy, MA
maintenance instruction plates, tags, or decals must be 02269.
maintained in legible condition.
General Industrial Standards, OSHA 2206: OSHA Safety
16. Batteries, motors, controllers, limit switches, protec- and Health Standards (29 CFR 1910), Subpart N-Materials
tive devices, electrical conductors, and connections Handling and Storage, Section 1910.178 Powered Indus-
must be inspected and maintained in conformance trial Trucks. For sale by: Superintendent of Documents,
with good practice. Special attention must be paid to U.S. Government Printing Office, Washington, DC 20402.
the condition of electrical insulation.
17. To avoid injury to personnel or damage to the equip-
ment, consult the manufacturer’s procedures in replac-
ing contacts on any battery connection.
18. Industrial trucks must be kept in a clean condition to
minimize fire hazards and help in the detection of loose
SA-1-2 • Safety Copyrighted Material SM 616, Jul ’01

Section 2.
Lifting, Jacking, and Blocking
Raising Drive Wheels ..................................................................................................................... 2
Chaining the Upright in Raised Position ..................................................................................... 2
Raising Rear of Truck ................................................................................................................... 3
Raising Entire Truck ..................................................................................................................... 4
Shipping Tie-Down Instructions ................................................................................................... 4
WARNING
Lifting or jacking any large piece of equipment such as a fork truck
presents obvious hazards. It must be done with great care and fore-
thought. Consult the truck weight information in Group 40, Specifica-
tions, to ensure that your lifting equipment is of adequate capacity.
SM 616, April ’98 Copyrighted Material Lifting, Jacking, and Blocking • SA-2-1
7. Check for safe clearance between drive wheels, block

CAUTION and floor.
To perform these service procedures, first:
8. Check the stability of the truck. Be sure that the blocks
• Park truck on a level surface. are located securely under the frame before operating
• Put the upright in a vertical position and the drive motor or working on truck.
lower the carriage fully down.
9. Lower the drive wheels to the floor by reversing this
• Return control handle to neutral and turn procedure.
key switch OFF. • Turn key switch ON.
• Tilt upright fully back.
WARNING • Turn key switch OFF.
Defective equipment can cause accidents. 10. Remove the blocks from under the frame and upright
All tools and lifting equipment must be in rails.
good condition, meet the load capacity
requirements and have OSHA labels when
required. Tools with defects can fail, causing Chaining the Upright in Raised Position
severe injury or death.
This procedure provides safe clearance for access from the
front of truck to components on or near the drive axle.
1. Park truck safely.
Raising Drive Wheels 2. Put blocks at front of and rear of drive wheels.
This procedure uses the upright to lift the drive wheels off 3. Raise upright carriage.
the floor.
4. Chain the center inner rail tie bar to the top outer rail tie
1. Park the truck safely. bar as shown.
2. Turn key switch ON. Tilt the upright fully back.
3. Put a solid 100 x 100 mm (4 x 4 inch) hardwood block
under the front section of each upright rail. Put a
3–6 mm (0.125–0.250 inch) steel plate on top of each
block.
4. Tilt the upright fully forward. This will raise the
drive wheels off the floor.
Triple Stage Uprights: Chain the center intermediate

rail tie bar and the lower inner rail tie bar to the top
outer rail tie bar.
Blocking a Typical Upright

5. Block the truck under the frame behind the drive 5. Reverse the procedure to remove the chains.
wheels with solid blocking.
WARNING
6. Turn key switch OFF.
Keep hands, tools, etc. out of upright.
SA-2-2 • Lifting, Jacking, and Blocking Copyrighted Material SM 616, April ’98
Raising Rear of Truck

The truck may be raised at the rear by jacking and blocking 4. Jack up one side of the truck about 50 mm (2 in) and
under the frame just beyond the counterweight.. put a block under the frame to hold that elevation. Then
Refer to truck data plate for truck weights. move the jack to the other side and jack and block it.
Continue to alternate the procedure from side to side,
increasing elevation not more than 50 mm (2 in) each
WARNING time. Raise the truck no higher than necessary to
perform the maintenance work.
An incorrectly installed counterweight can
move or fall unexpectedly. NEVER LIFT Make sure the left and right sides of the truck are finally
OR BLOCK A TRUCK USING THE blocked in a level working position.
COUNTERWEIGHT. Failure to follow
procedures outlined in this manual can result
in injury or death.
1. Park truck safely.

2. Put blocks at front and rear of drive wheels.
CAUTION
If possible, remove the battery from truck
to reduce weight for added safety and ease
of jacking.
3. Put a floor jack under the frame just beyond the

counterweight.
WARNING
Never lift the truck by the counterweight.
CAUTION
Before performing any maintenance work,
check the truck for stable condition on the
blocking by determining that it will not rock
on blocks.
5. When maintenance work is completed, lower the rear

of truck to the floor by reversing the above procedure
and lowering each side of the truck 50 mm (2 in) at a
time:
• Put jack under frame and raise truck.
• Carefully remove blocks and lower truck.
• Remove jack and blocks from drive wheels.
NOTE
If there is insufficient clearance
under frame for your jack, the truck
may first be driven onto shims, such
as 25 x 150 x 300 mm (1 x 6 x 12 in)
pieces of board, to increase the truck
frame under-clearance.
SM 616, April ’98 Copyrighted Material Lifting, Jacking, and Blocking • SA-2-3
Raising Entire Truck CAUTION

Refer to truck data plate for truck weights. Before performing any maintenance work,
check the truck for stable condition on the
1. Park truck safely. Lower upright fully. If necessary, blocking.
drive truck onto boards to increase under-clearance.
WARNING 7. When maintenance work is completed, lower the en-
SIDE-TO-SIDE TIPOVER. When jacking tire truck to the floor by reversing this procedure.
side of truck, be sure upright is lowered fully. Lower the truck one side at a time, while carefully
Do not raise one side of the truck more than removing the blocks. Be sure no tools or equipment are
about 50 mm (2 in) higher than the other, to under the truck or wheels.
avoid tipping truck over laterally.
NOTE
END-TO-END TIPOVER. If the upright and Depending on jack height, shims under the
drive axle are removed while the truck is tires may be needed for clearance to allow
blocked up, the truck will tip backward due to removal of jack.
the heavy counterweight. Upright and
counterweight must both be removed before
attempting to raise the truck for drive axle
removal. The back of the truck must be
supported by blocking under the steer axle to
prevent movement. Shipping Tie-Down Instructions
If the counterweight is removed while the truck 1. Front of Truck
is up on blocks, the weight of the upright and
drive axle will cause the truck to fall forward. a. With Upright and Carriage Installed
• Lower the carriage fully.
2. Put the jack under side frame, near the center of the truck.
• Put a tie-down (e.g., chain) between the carriage
IMPORTANT fork bars.
Be sure to put the jack squarely and fully
under the main side structure of the frame.
3. Carefully raise the truck one side at a time, only as high
as necessary to do the maintenance work, and not more
than 150 mm (6 in) total.
4. Put blocks under the side frame, at each side of the jack.
Spread the blocks close to the steer and drive wheels
for maximum stability.
5. If using one jack, lower the truck onto the blocks and
move the jack to the opposite side. Repeat the lifting
procedure.
6. Put the same size blocks under each side of the truck so
it will be leveled.
b. Without Upright and Carriage Installed
• Put a chain across the truck floor plate. Protect
truck from chain damage by using covered chain
or protective material under the chain at contact
points.
2. Rear of Truck
• Attach the tie-down to the toe-pin in top of coun-
terweight.
SA-2-4 • Lifting, Jacking, and Blocking Copyrighted Material SM 616, April ’98
Group SA, Safe Maintenenance
Section 3. Towing
If your truck is disabled but can be moved freely on its own NOTE
wheels without further damage, use the following proce- DOT-approved towing equipment is avail-
dures to tow the truck safely to a repair area. able from your Clark dealer.
WARNING 6. Release the parking brake on the towed vehicle. Place

It is important for your safety and to the directional control lever in neutral.
care of your lift truck to use the proper 7. Tow the disabled truck backwards. An operator must
equipment and carefully follow these rec- be on the disabled truck.
ommendations for safe towing.
Do not tow a lift truck if there is a problem CAUTION
with the brakes or tires, or if the steering The power steering and braking will not
cannot be operated. operate on the disabled truck. The steering
handwheel will be difficult to turn and the
Do not tow the disabled truck up or down
service brakes will require additional pedal
ramps or steep inclines.
force.
Do not attempt to tow the disabled truck if
traction or weather conditions are poor. 8. Tow the truck slowly. Careful towing is necessary to
prevent injury to personnel or damage to the disabled
1. Be sure to apply the parking brake or block the drive truck. The truck should be towed at a speed of less than
wheels on the disabled truck while working around it. 8 kph (5 mph, or a moderate walking speed) with a
2. When possible, raise the carriage (forks) on the dis- driver in place and steering the disabled truck.
abled truck 300 mm (12 in) from the floor or ground. IMPORTANT
Secure the carriage on the upright with a chain. Do not lift the disabled truck or any wheels
3. Use a truck for towing that is of equal or larger capacity off the floor while the truck is being towed.
than the disabled truck. Carry a partial load on the tow 9. Park the disabled truck in authorized areas only. Fully
truck for improved traction. lower the forks on the floor, leave the directional
4. Check that the counterweight bolts on both trucks are control in neutral, turn the key switch to OFF, and
in place and properly torqued. These bolts are made of engage the parking brake. Remove the key and, when
special, high-tensile steel and are not commercially necessary, block the wheels to prevent the truck from
available. When necessary, replace these bolts only rolling.
with a genuine Clark replacement part.
5. Use an approved, solid metal tow bar with towing WARNING
couplers that connect to the towing pins in the counter- Always engage the parking brake when
weights. parking a lift truck. The truck can roll and
cause injury or death to personnel near it.
Direction of towing for distances of

300 meters (325 yards) or less.
Solid-matal
tow bar
Partial
load
Disabled truck with Tow truck moving at 8 kilome-

driver in place to steer. ters-per-hour (5 mph) or less.
SM 616, April ’98 Copyrighted Material Towing • SA-3-1

SA-3-2 • Towing Copyrighted Material SM 616, April ’98

GROUP PS
GROUP PS
PERIODIC SERVICE
Maintenance Schedule .................................................... Section 1
Planned Maintenance Program .................................... Section 2
The PM Inspection Form ............................................... Section 3
SM 616, April ’98 Copyrighted Material Periodic Service

GROUP PS
NOTES:
Periodic Service Copyrighted Material SM 616, April ’98

Group PS, Periodic Service
Section 1.
Maintenance Schedule
“Periodic Service” and “Planned Maintenance” ........................................................................ 2
Determining Maintenance Intervals ............................................................................................ 2
Service Chart/Lubrication Points ................................................................................................. 3
Recommended Periodic Service Schedule ................................................................................... 4
SM 616, April ’98 Copyrighted Material Maintenance Schedules • PS-1-1

“Periodic Service” and “Planned Determining Maintenance Intervals

Maintenance” Time intervals on the charts on the next four pages and
elsewhere in this manual relate to truck operating hours as
The term “periodic service” includes all maintenance tasks
recorded on the hourmeter, and are based on experience
that should be performed on a regularly scheduled basis.
Clark has found to be convenient and suitable under normal
The term “Planned Maintenance” indicates a formalized operation. Standard operating condition classifications are:
program of basic inspections, adjustments, and lubrica-
Normal Operation: Eight-hour material handling, mostly
tions that the Clark service organization provides custom-
in buildings or in clean, open air on clean, paved surfaces.
ers at a prescribed interval, usually 50-250 hours. The
recommended basic “Planned Maintenance” procedure is Severe Operation: Prolonged operating hours or constant
given in Section 2 of this Group. usage.
The current Section,“Maintenance Schedules,” specifies Extreme Operation:
all maintenance tasks—including Planned Maintenance • In sandy or dusty locations, such as cement plants,
tasks—that should be performed periodically, and sug- lumber mills, and coal dust or stone crushing sites.
gests intervals at which they should be performed.
• High-temperature locations, such as steel mills and
foundries.
• Sudden temperature changes, such as constant trips
from buildings into the open air, or in refrigeration
plants.
If the lift truck is used in severe or extreme operating
conditions, the maintenance intervals should be shortened
accordingly.
IMPORTANT
MAINTENANCE INTERVALS. If the lift
truck is used in severe or extreme operat-
ing conditions, the maintenance intervals
should be shortened accordingly.
Since the operating environments of lift
trucks vary widely, the above descriptions
are highly generalized and should be ap-
plied as actual conditions dictate.
PS-1-2 • Maintenance Schedules Copyrighted Material SM 616, April ’98

Service Chart/Lubrication Points

A decal, similar to the illustration below, is located on the underside of the seat deck. This decal is a basic guide to periodic
maintenance intervals and tasks. A more detailed chart is supplied on the next page.
TMG Service Chart

Every 8 - 10 hours or daily
Every 50 - 250 hours or monthly
Every 450 - 500 hours or every 3 months
Every 2000 hours or every year
Upright Rollers Load Backrest

Extension, Forks
Transaxle
Lift Chains C C Fluid
Brake Operation
Tilt Cylinder Pins E
Lube B
Brake Linings
Overhead Guard
Mounting Bolts All Wheel Lugs
Axle Mounting Instruments,

& Fasteners
Hydraulic Oil
Filter
* Meters, Lights
Directional,
Speed Control
Drive Motor
*
Lift, Tilt, Aux.
Brushes Operation
Steer Motor Steering
Brushes Operation
Battery Cables Hydaulic Sump
& Receptacles A A Oil
Battery Load Hydraulic Sump
Test Breather
Lift Motor Warning
Brushes
Ground and
Static Chain
* D
Devices, Horn
Controller
Y Plug
Battery Terminals, Tire / Wheel
Electrolyte Level Condition
Steer Axle Steer Axle Wheel

Linkage B B Bearings
Counterweight Overall Visual
Fasteners Check
Check / Lubricate Change or Replace Clean / Air Clean

Monitor Indicator Lights (if equipped)
A - Hydraulic Oil
Check / Air Clean
B - MP Grease
Check
C - Transaxle Fluid
* and Service as Required
D - Electrical Connector E - Brake Fluid
Clark # 1800236 NLG # 2 Clark # 2776236 Grease Clark # 2824625 Dot 3
SM 616, Dec ’02 ➀ Copyrighted Material Maintenance Schedules • PS-1-3

Service Chart/Lubrication Points

A decal, similar to the illustration below, is located on the underside of the seat deck. This decal is a basic guide to periodic
maintenance intervals and tasks. A more detailed chart is supplied on the next page.
EPG15-18 Service Chart

Every 450-500 hours or every 3 months
Load Backrest
Upright Rollers Extension, Forks
Transaxle
Lift Chains C Fluid
Brake Operation
Tilt Cylinder Pins
Lube
Brake Linings
Overhead Guard
Mounting bolts All Wheel Lugs
Axle Mounting Instruments,

& Fasteners Meters, Lights
Drive Motor Directional,
Brushes Speed Control
Hydraulic Oil Lift, Tilt, Aux.
Filter Operation
Steering
Operation
Battery Cables Hydaulic Sump
& Receptacles A Oil
Battery Load Hydraulic Sump
Test Breather
Lift Motor Warning
Brushes Devices, Horn
Ground and Tire / Wheel
Static Chain Condition
Battery Terminals, Steer Axle Wheel
Electrolyte Level Bearings
Steer Axle Control Card
Linkage
Fasteners Check
Check / Lubricate Change or Replace Clean / Air Clean

Monitor Indicator Lights (if equipped)
Check / Air Clean
A - Hydraulic Oil B - MP Grease

Check
C - Transaxle Fluid
* and Service as Required
D - Electrical Connector E - Brake Fluid
Clark # 1800236 NLG # 2 Clark # 2776236 Grease Clark # 2824625 Dot 3
PS-1-3-1 • Maintenance Schedules Copyrighted Material SM 616, Dec ’02

Recommended Periodic Service Schedule

This chart lists maintenance tasks that should be done periodically, the suggested time intervals, and the service manual
Group in which the task is covered. Refer to Operator’s Manual for Daily Checks.
Every 450- Every 900- Every 2000

Every 500 Hours 1000 Hours Hours
TASKS 1st 50 Hours 50-250 Hours (or 3 months) (or 6 months) (or 1 year)
Group PS - Periodic Maintenance
Perform Planned Maintenance
inspections, lubrications, and •
adjustments
Group 12 - Battery
Battery electrolyte level - check/add •
Battery load voltage test •
Battery terminals/cables - •
clean/tighten
Group 13 Wiring and Instruments
Hourmeter - check •
Lamp check - at start-up •
Wiring harness - inspect • •
Instruments/accessories
Group 16 - Electric Motors
Drive motor brushes - check/air •
clean
Lift pump motor brushes - check/air •
clean
Steer pump motor brushes - check/air •
clean
Group 17 -Contactors
Contactor tips - check/air clean
Group 19 - Motor Controls
Display - check display for error •
codes
Controller - air clean •
Controller connectors - check and •
lubricate
Group 20 - Drive Axle
Air vent - inspect, clean or replace •
Axle mounting bolts - •
inspect/tighten
Pressure checks •
Fluid change - drain/fill •
Fluid filter - replace • •
Fluid level/condition - check/sample • •
Group 22 - Wheels And Tires
Wheel mounting bolts - tighten • •
Tire pressure/condition - check • •
Group 23 - Brakes
Operation - check •
Service brake - check wear •
Brake lines - check • •
Parking brake - check/adjust • •

Every 450- Every 900- Every 2000

Every 500 Hours 1000 Hours Hours
TASKS 1st 50 Hours 50-250 Hours (or 3 months) (or 6 months) (or 1 year)
Group 25/26 - Steer Axle and Lines
Power steering relief pressure - check •
Steer axle mounting - inspect •
Steer wheel and trunnion bearings - •
check
Steer wheel and trunnion bearings - •
lubricate/adjust
Steering cylinder seals - check •
leakage
Steering linkage - lubricate •
Group 29/30 - Hydraulic Lift System
Hydraulic fluid level/condition -
check/sample •
Hydraulic fluid change - drain/fill •
Hydraulic filler screen - clean •
Hydraulic fluid filter - replace • •
Hydraulic tank breather - • • •
clean/replace
Control valve linkage - check/clean
Hydraulic system relief pressure - •
test/adjust
Group 32 - Tllt Cylinders
Tilt cylinder adjustment - •
check/adjust
Tilt cylinder drift - test •
Tilt cylinder mounting - •
check/tighten
Tilt cylinder rod ends - •
check/tighten/lubricate
Tilt cylinder rod/seals - check for •
leaks
Group 34 - Upright, Lift Cylinders, Carriage, Forks
Carriage and lift chain - lubricate •
Carriage chain condition - •
inspect/adjust
Forks, latches, stop pin - •
inspect/check wear
Lift chain condition - inspect/adjust •
Load backrest •
Upright cylinder/mounting - •
inspect/tighten
Upright lift cylinder downdrift - test •
Upright rollers - check •
Upright trunnion bolts - tighten •
SM 616, April ’98 Copyrighted Material Maintenance Schedules • PS-1-5


Section 2.
The Planned Maintenance Program
This Section defines a set of basic service procedures, known as the “Planned
Maintenance Program,” and describes a systematic approach for performing them.
Introduction to Planned Maintenance ......................................................................................... 2

PM Intervals ..................................................................................................................................... 2
The PM Form ................................................................................................................................... 2
The Basic PM Procedures ................................................................................................................ 2
Truck Location and Parking ............................................................................................................. 2
External Inspection ........................................................................................................................ 3
Decals ............................................................................................................................................... 3
Fittings and Fasteners ...................................................................................................................... 3
Overhead Guard and Chassis ........................................................................................................... 3
Lights and Safety Devices ............................................................................................................... 3
Leaks ................................................................................................................................................ 3
Carriage, Load Backrest, and Upright ............................................................................................. 3
Forks ................................................................................................................................................ 4
Wheels and Tires .............................................................................................................................. 4
Operational Checks ....................................................................................................................... 4
Operator’s Environment ................................................................................................................... 4
Service and Parking Brake (Initial Check) ...................................................................................... 5
Dash Display and Safety Lock-Outs ................................................................................................ 5
Steering (Initial Check) .................................................................................................................... 5
Hydraulic System ............................................................................................................................. 6
Carriage, Upright, and Sideshifter ............................................................................................ 6
Control Levers .......................................................................................................................... 6
Horn, Lights, and Alarms ................................................................................................................ 6
Traction and Braking System .......................................................................................................... 7
Brakes ....................................................................................................................................... 7
Controlled Reversal .................................................................................................................. 7
Acceleration .............................................................................................................................. 7
Turning ..................................................................................................................................... 8
Internal Inspection ......................................................................................................................... 8
General Checks ................................................................................................................................ 8
Fluid and Filters ............................................................................................................................... 8
Battery .............................................................................................................................................. 9
Air Cleaning the Truck ............................................................................................................... 10
Minor Adjustments Covered by PM .......................................................................................... 10
Switch Adjustments ....................................................................................................................... 10
Parking Brake Adjustment ............................................................................................................. 10
Racking Adjustments ..................................................................................................................... 10
Chain Adjustments ......................................................................................................................... 10
Missing or Loose Fasteners ........................................................................................................... 10
Chassis Lubrication ..................................................................................................................... 11
Drive Axle Lubrication .................................................................................................................. 11
Upright and Tilt Cylinder Lubrication ........................................................................................... 11
Steer Axle Lubrication ................................................................................................................... 11
Critical Fastener Torque Checks ............................................................................................... 12
Wrapping Up the PM .................................................................................................................. 12
Clean Up ........................................................................................................................................ 12
Test the Truck ................................................................................................................................ 12
Report the PM ................................................................................................................................ 12
SM 616, April ’98 Copyrighted Material Planned Maintenance • PS-2-1

Introduction to Planned Maintenance

A program of regular, routine inspections, lubrication, and The PM procedure, in outline form, is as follows:
other service tasks is important for the long life and trouble- 1. External visual checks. Perform these as you walk
free operation of the lift truck. around the truck with it turned off.
The Clark service organization offers customers a formal- 2. Operational checks. Perform these while operating
ized program—called Planned Maintenance, or PM—for the truck.
performing these tasks. 3. Internal visual checks. Perform these after removing
the floor board and cowl cover.
PM Intervals 4. Air cleaning internal components. Do this while
The PM inspections, adjustments, and lubrications are typi- performing the previous step.
cally performed on each covered truck at 50-250 hour 5. Critical fastener torque checks.
intervals. (See Section 1, in this Group about defining 6. Minor adjustments and repairs you found in your
service intervals.) inspection.
7. Fluid level checks and fill.
The PM Form
8. Chassis lubrication.
As an aid to service technicians performing and document-
9. Final clean up.
ing PM inspections, Clark has prepared a “Planned Mainte-
nance Report” form. A copy of this form is inserted in 10. Reporting your results to the responsible party.
Section 3 of this Group.
We recommend that you use this form as a checklist and to Each of these steps is explained in detail beginning on
make a record of your inspection and truck condition. This the next page.
record can be used to inform the owner of needed repairs
and help establish the optimal PM intervals.
CAUTION
When you have finished the PM inspections, be sure to give • Do not make repairs or adjustments un-
a copy of the report to the person responsible for lift truck less authorized to do so.
maintenance.
• Disconnect the battery before you work
on electrical components.
• Always wear safety glasses.
The Basic PM Procedures • Wear a safety (hard) hat in industrial
The basic PM procedure is to perform checks first, repairs plants and in special areas where protec-
and adjustments last. As you go through each step of the tion is necessary or required.
PM, you should note all your findings on the PM report • Remove all jewelry (watch, rings, brace-
form. lets, etc.) before working on the truck.
The PM report form serves as a record of what you did in
the PM and what further service needs to be performed.
“Further service” consists of any repair, adjustment, in-
spection, or lubrication that you discovered during the PM Truck Location and Parking
or any periodic service procedure that is due but not cov- Before starting the external inspection, make sure the truck
ered by the PM agreement). is parked on a clean, level surface. Fully lower upright,
You should consult the previous PM report forms, periodic turn truck off, and engage the parking brake.
service chart, and truck hour meter to determine what If it is necessary to drive the truck to a suitable inspection
periodic service is due. List the service due on the new PM location, perform the initial braking and steering checks,
form. given later in this Section, as you begin to move the truck.
To perform the operational checks, the truck must be where
there is sufficient clearance to raise the upright and room to
maneuver the truck at full speed without endangering per-
sonnel, equipment, or materials.
PS-2-2 • Planned Maintenance Copyrighted Material SM 616, April ’98

External Inspection CAUTION

Walk around the truck and take note of any obvious dam- HYDRAULIC FLUID PRESSURE. Do not
age and maintenance problems, as follows: use your hands to check for hydraulic leak-
age. Oil may be hot or under pressure. Fluid
Decals under pressure can penetrate your skin and
cause serious injury.
Check to be sure all capacity, safety, and warning plates
and decals are attached and legible.
NOTICE
Do not operate a lift truck with damaged Carriage, Load Backrest, and Upright
or missing decals and nameplates. Replace
(See Group 34 for more detailed inspection procedure.)
them immediately. They contain important
information. See Group 40 for decal loca- Inspect the welds on the carriage, load backrest, and up-
tions. right for cracks. Be sure that the mounting fasteners are in
place and tight.
Fittings and Fasteners Overhead
Guard
Make sure that fittings and fasteners are present, in usable
condition and fully fastened. Critical fastener torque checks
should be performed later--when making minor adjust- Upright
ments and repairs. Rails
Overhead Guard and Chassis Load

Backrest
Be sure that the overhead guard and any other safety de-
vices are in place, undamaged, and attached securely. In-
spect welds and structural members for cracks or other Carriage
damage.
Forks
Lights and Safety Devices
Check safety devices, such as lights, horn, and audible
alarms, to make sure they are securely attached and have on
visible damage.
Inspect the upright assembly: rails, carriage rollers, load
backrest, lift chains, and lift and tilt cylinders. Look for
Static Chain obvious wear and maintenance problems and damaged or
Look under the truck to missing parts. Check for any loose parts or fittings. Check
make sure the static chain for leaks, any damaged or loose rollers and rail wear (metal
contacts the floor and is not flaking).
excessively worn or loose. Carefully check the lift chains for wear, rust and corrosion,
See Group 13 for more in- cracked or broken links, and stretching. Check that the lift
formation. and carriage chains are correctly adjusted to have equal
tension and that the tops of the rails are within 4 mm (1/8 in)
Leaks of each other.
Look under the truck and Check that the lift chain anchor fasteners and locking means
on the chassis, uprights, and exposed hoses for any signs of are in place and tight. Be sure all safety guards and chain
external leakage: brake fluid, drive axle oil, and hydraulic retainers are in place and not damaged.
fluid, and battery fluid. Inspect the carriage stops and cylinder retainer bolts. Check
When you suspect hydraulic oil leaks and loose fittings, all welded connections.
DO NOT USE BARE HANDS TO CHECK. Inspect all lift line hydraulic connections for leaks. Check
the lift cylinder rods for wear marks, grooves and scratches.
Check the cylinder seals for leaks.

Forks Check all wheel lug nuts or bolts to be sure none are loose
or missing. Have missing bolts or lug nuts replaced and
Inspect the load forks for cracks, breaks, bending, and tightened to correct torque as explained in Group 22.
wear.
WARNING
HEEL WEAR. If the fork blade at the heel
is worn down by more than 10 percent, the
load capacity is reduced and the fork must
be replaced.
6.4 mm
(0.25 in.) max. WARNING
Heal Wear Check tire pressure from a position facing
the tread of the tire, not the side. Use a
A long-handled gauge to keep your body
away. If tires are low, the tire may require
removal and repair. Incorrect (low) tire
Tip Height
pressure can reduce truck stability. See
Difference
“Specifications” in Group 22 for proper
10% of “A” is max.
wear allowed
inflation pressure.
Operational Checks
Be sure that:
Fork • Truck is parked on a level surface.
Bending • Key switch is off.
• Parking brake is applied.
• Directional control is in "N" (neutral).
Y • Battery is connected.
X
Operator’s Environment
X must be less than 25.4 mm (1 in) when measured at Sit in the operator’s seat and make sure the seat is secure
Y height of 46 cm (18 in). and that the seat adjustment mechanism operates properly.
Measure fork bending with a T-square and wood bock as With the key switch off, check that travel and load handling
shown above. capability, dash display, lights, and alarms are all disabled.
Inspect the fork latches to ensure that they are in good Handwheel
condition, operate freely, and lock correctly. See Group 34
for more details on inspection procedures, including use of
fork wear gage.
Control
Wheels and Tires Levers
Check the condition of the drive and steer wheels and tires.
Remove objects that are embedded in the tread. Inspect the
tires for excessive wear or breaks or "chunking out.”
Seat
Pedals
Adjustment

Check that the steering wheel is tight and rotates smoothly Continue this test by selecting reverse before releasing the
and adjusts for tilt properly. Check the control levers and parking brake. The error code -03 should display and the
foot pedals to make sure they are securely mounted, oper- drive and steer pump motors should be locked out.
ate freely, and return to neutral when released. Perform an Place the direction control in neutral and release the park-
additional visual inspection of the upright and overhead ing brake. The numerical display should now show the
guard from the seated position battery status (normal condition). The battery must be
recharged if the reading is less than 20 (percent). The truck
Service and Parking Brake (Initial Check) will not function if the reading is less than 9.
Push the brake pedal down fully and hold. The brakes Apply the parking brake
should apply before the pedal reaches the floorplate. If the
See Groups 13 and 19 for detailed descriptions of all
pedal continues to creep downward, report the failure
display light functions and status error codes.
immediately. Do not operate the truck until the brakes
are repaired.
Operate the parking brake to make sure that it is securely
mounted and that it applies, catches, and releases properly. Steering (Initial Check)
Apply the parking brake. Turn the key switch on. Key switch is still on. Put the truck in neutral and release
the parking brake. Put the direction control in forward then
turn the steering handwheel clockwise until the steering
Dash Display and Safety Lock-Outs hits its stop. Then turn the handwheel counterclockwise
As you turn the key switch on, check the instrument and count the revolutions before the steering hits its stop.
display. All indicator lights should come on for a 2-second There should be 4.5 revolutions from stop to stop. Return
lamp check. The seat belt prompt light should remain on the steer wheels to the straight-ahead position.
for 4 seconds, accompanied by the high-pitched seat-belt The steering system components should operate smoothly
alarm. The parking brake light should remain on (if the when the steering handwheel is turned. If the truck has the
brake is set) and the numerical display should read -01 to on-demand steering option, the steer pump motor should
indicate that the parking brake is set. come on only when you turn the wheel.
(If any other error codes display or indicator lights identify Hard steering, excessive play (looseness), or unusual sounds
a problem, note the condition for further service action.) when turning indicates a need for detailed inspection and
service as described in Group 25/26.
Parking Brake
Light
Seat Belt Light

If the truck has a steering system fault, take the truck
out of service until it is repaired.
Numerical
Display
With the parking brake set, the drive motor and the steer-
ing pump should not function. Test this feature by de-
pressing the pedal and by turning the handwheel.
Place the direction control in forward and then release the
parking brake. The numerical display should now read “-
02” to indicate that you have not consciously selected a
direction after parking. The drive motor and the steering
pump should not function during this error condition.

Hydraulic System The basic adjustment procedure is described later in

this Section. Detailed upright checks and adjustments
Next you will test the hydraulic control levers and load are described in Group 34.
handling mechanism.
CAUTION
CAUTION Be sure that there is adequate overhead
Check for sufficient clearance above and clearance before raising the upright.
in front of the upright before operating the
control levers. 2. Pull back on the lift control lever and raise the carriage
to full height. Watch the upright assembly as it rises.
All movements of the upright, fork carriage, and lift
Control Levers
chains must be even and smooth, without binding or
With the parking brake still on, check each control lever in jerking or making “clunking” noises.
both directions to see that it works as follows:
Watch for chain wobble or looseness; the chains
• Lever has freeplay: You can move the lever slightly should have equal tension and move smoothly with-
without having an effect. The hydraulic pump motor out noticeable wobble.
does not start and the load handling mechanism does
not move; for instance, the carriage does not lower or Release the lever.
lift. The basic chain adjustment procedure is described
• Lever has lag: You can move the lever slightly more later in this Section. Detailed chain inspection and
and the pump motor starts without causing lift, tilt, or adjustment procedures are in Group 34.
sideshift to occur. (Lowering occurs without the pump
motor starting.)
• Lever actuates load handling function: You can move
the lever slightly more and lift, lower, tilt, or sideshift
occur slowly in the appropriate direction
• Lever accelerates load handling function: You can
move the lever further to increase the speed at which
lift, lower, tilt, or sideshift occur.
Lift
If the maximum fork height cannot be reached, this
Tilt indicates there is low oil level in the hydraulic sump
or severe binding within the upright.
Aux
3. Push forward on the lift control lever. Watch the
upright as it lowers. If you suspect a problem with
lifting or lowering speeds, refer to Group 34 to diag-
nose the problem.
Carriage, Upright, and Sideshifter
4. Check sideshifter action by pushing forward and
With the parking brake still on, make sure load handling backward.
mechanism performs all functions smoothly, fully, and
responsively:
1. Pull back on the tilt control lever and hold until the
Horn, Lights, and Alarms
upright reaches the full back tilt position. Push forward
on the lever to tilt it forward. Return the upright to the Test the horn and headlights and other safety devices be-
vertical position and release the lever. Repeat these fore moving the truck. Check backup alarms and lights and
actions as you observe. all other safety equipment as you drive the truck in the
• If there is excessive play between rails and chan- following steps.
nels, upright adjustment is required.
• If there is racking, adjustment of the cylinder rod CAUTION
yokes or shims is required. (“Racking” is when the If the service brake, parking brake, or in-
extension of the two tilt cylinder rods is unequal.) terlock is not operating properly, take the
truck out of service until it is repaired.

Traction and Braking System on a grade and apply the parking brake. The parking
brake should hold a lift truck with rated load on a 15%
Next, drive the truck to test the braking, accelerating, turn-
grade. Also, when travelling at full speed, application
ing and reversing.
of the parking or service brake should stop the truck in
WARNING one truck-length.
Fasten your seat belt before driving the
truck. ON
NOTE
After you move the truck, you can check
OFF
where the truck was parked to see if there
are any leaks.
Brakes
Make sure that the truck is on a level surface, the travel area
is clear in front of and behind the truck, the parking brake is
released, the direction control is in neutral, and the key Controlled Reversal
switch is on. The numerical display should show battery Accelerate to a slow speed and reverse the direction control
condition with the parking brake off. without applying the foot brake. Truck should slow to a
1. Move the direction control lever from neutral to forward.
2. Check brakes at creep speed: Release the brake pedal
and depress the accelerator pedal to obtain slow for-
ward speed. Apply the brake pedal to ensure that the
brakes are sufficient to stop the truck. Pedal should feel Forward
firm and drive motor should cut off before brakes Neutral
apply.
Reverse
Service
Brake
Accelerator
smooth stop then accelerate normally in the opposite direc-
tion.
Repeat in both directions at various speeds.
Acceleration
After checking to see that you have a clear path, check
3. Check brake pedal freeplay: Travel again and gently acceleration from a stand still condition. Drive the truck in
depress the brake the brake pedal. The pedal should a straight line at a high rate of speed. Acceleration should
drop a very slight distance before the brakes begin to be smooth and without hesitation. Listen for unusual drive
apply. train noise. Repeat in opposite direction.
4. Check brakes at full travel speed: Depress and release The accelerator pedal must move easily and smoothly
the brake pedal several times while driving the truck. throughout the acceleration stroke and return without bind-
The brakes should bring the truck to a smooth stop ing. There should be no restriction to movement on accel-
without pulling, squealing, or shuddering. Drive motor eration or deceleration.
should cut off before brakes apply.
5. Check brake holding capability and adjustment: Park
the truck on a grade and depress brake pedal. The brake
should hold a lift truck with rated load on a 15% grade.
6. Check the function of the parking brake: Park the truck

Turning 3. Apply the parking brake, put the truck in neutral, and
turn off the key switch.
1. Drive the truck in a straight line. The truck must travel
without drifting to either side. 4. Open the seat deck and remove the floorboard and
cowl cover as described in Group 38.
2. Drive slowly (creep speed) through
a series of full right and left turns.
Check steering response and General Checks
smoothness of operation. Look for:
• The turning effort must be the • Pinched wires
same in either direction. You
should hear the power steer- • Frayed or broken cables
ing pump operate over relief • Dirty or loose electrical connections
when in a full turn. • Loose or bent linkage pins
• The drive motor control sys- • Signs of excessive wear or damage to linkages, hinges,
tem employs a speed differ- hoses, lines, clamps, and fittings
ential between the left and
• Leaks, (often indicated by dust or dirt built up) from
right motors to facilitate turn-
pumps, steering gear, and reservoirs and plumbing
ing. If this system is malfunc-
tioning steering can be diffi- • Loose or damaged fasteners and motor mounts.
cult and wheels can make
scrubbing noises. Fluid and Filters
Refer to Group 26 for steer system troubleshooting infor-
mation. IMPORTANT
Carriage must be fully lowered and up-
right in vertical position before you check
Internal Inspection hydraulic fluid.
The internal inspection involves accessing the truck’s in-
ner compartments, inspecting the various electrical and
hydraulic components, and checking fluid levels.
Brake Fluid
You can perform much of the inspection as you air clean
the truck, which is described later in this Section. Using a flshlight, check brake fluid reservoir through
inspection window. Fill to full mark, if low, with DOT 3
CAUTION BRAKE FLUID. See Group 23 for procedure.
Remove all jewelry (watch, rings, brace-
let, neck chains, etc.) before working on
electric trucks. Severe burns can result
from contact with electrical circuits.
Proceed as follows:
1. Park the truck on a level surface.
IMPORTANT
Fully lower carriage and place upright in
vertical position.
2. Discharge the capacitors:
a. Turn off the key, put the direction control in Brake Fluid Level
neutral, and set the parking brake. Inspection Window
b. Disconnect the battery connector.
c. Turn the key switch on.
d. Bleed off the charge by honking the horn until the
sound dies away.

Hydraulic Fuid and Filters

Remove dipstick and check hydraulic fluid level. Top off
if below full mark as described in Group 29.
Consult the periodic service chart (or service decal) to
determine if it is time to replace the sump cap filter and/or
spin-on hydraulic filter. If they are due, their replacement
is considered part of the PM.
Hydraulic Filter
Hydraulic
Fluid
Dipstick
Sump Cap
Breather Filter
Controller Connectors
Pull connectors PL-3 and PL-5 and lubricate terminals with
Clark Electrical Connector Grease, part # 2819910.
Make sure all connections are tight.
PL-3 PL-5
Battery
Inspect the battery for any damage, cracks, leaking condi-
tion, etc. If the terminals are corroded, clean and protect
them with CLARK Battery Saver (available from your
Clark dealer).
Check six cells with your hydrometer as desribed in Group
12. A consistent reading among the six cells indicates the
battery is probably in good condition.
Perform the battery load test described in Group 12.

Air Cleaning the Truck Minor Adjustments Covered by PM

You must air clean the truck as you perform the internal As you performed your inspections, you noted all needed
inspection described earlier in this Section. adjustments and repairs on the PM report form. Some of
these items may be outside the scope of the PM and should
CAUTION
be reported for additional service. At this point in the PM,
Wear suitable eye protection and protec-
however, you should perform certain adjustment and re-
tive clothing.
pairs, if needed. These include:
CAUTION
Battery must be disconnected and capacitors Switch Adjustments
discharged before inserting air wand into If any action that is triggered or indicated by a switch does
truck compartments.
not occur at the right instant, check the switch adjustment.
IMPORTANT To adjust the switch, slightly loosen the mounting screws
and slide the switch to appropriately advance or retard the
No item of PM is more important than air
point at which the switch trips. Retighten the screws. If
cleaning the motors.
switch or circuitry is defective, report this on the PM form
Use an air hose with special adapter or extension that has a as a further needed repair.
control valve and nozzle to direct the air properly. Use
clean, dry, low-pressure compressed air. Restrict air pres- Parking Brake Adjustment
sure to 30 psi (207 kPa), maximum. (OSHA requirement).
Use air pressure to: Adjust the parking brake at the caliper end. Loosen the
jamb nut and turn the adjusting nut to increase (or de-
• Blow air into all motor openings from various angles
crease) the slack in the cable. Tighten the jamb nut.
to remove dust.
• Blow off all switches, contactors, motor controls, and The brake caliper should be fully released when the park-
all compartment walls. ing brake handle is in the off position and should be fully
applied when the handle is fully back.
• Air-clean the upright assembly, drive axle, steering
axle, steering cylinder. See Group 23 for detailed procedure.
If air pressure does not remove heavy deposits of grease,

oil, etc., it may be necessary to use steam or liquid spray Racking Adjustments
cleaner. DO NOT clean electrical components with steam. Racking adjustments are part of the PM. To eliminate
racking on back tilt, add or remove shims as explained in
Group 34. For forward racking adjustment, adjust rod end
mounting yokes as described in Group 34.
Chain Adjustments
With the upright fully lowered, the tops of the upright rails
should be flush with each other within 4 mm (1/8 in).
Paired chains should have equal tension. Fork heels should
rest 13 to 38 mm (0.5 to 1.5 in) off ground.
Check for chain stretch with chain ruler as described in
Group 34.
Basic chain adjustment procedure: With upright and car-
riage fully lowered, loosen jamb nut on chain anchor,
loosen adjusting nut, and turn adjusting nut to obtain cor-
rect length/tension. Tighten jamb nut.
See Group 34 for detailed procedure.
Missing or Loose Fasteners

Replace/tighten missing or loose fasteners during the PM.
This incudes bolts, cotter pins, cable ties, and so on.

Chassis Lubrication Upright and Tilt Cylinder Lubrication

Lubrication requirements are given on the truck’s service Clean the fittings and lubricate the tilt cylinder rod end
decal (which is shown in Section 1 of this Group.) bushings (forward end). Clean the fittings and lubricate the
tilt cylinder base rod end bushings (rear end). Clean and
At each PM, check the drive axle fluid and grease the
lubricate the upright trunnion bushings.
fittings at the upright pivot points and steer wheel.
Consult the service decal or periodic service chart to iden-
tify other lubrications that are due (for example, wheel
bearings) and report these on the PM form. Grease
Fitting
Be sure to clean the grease fittings before lubricating.
Remove the excess grease from all points after lubricating.
Lubricate miscellaneous linkage as needed.
Drive Axle Lubrication

Grease
WARNING Fitting
To access the drive axle raise and block
the upright using safe procedures described Grease
in Section 2, “Lifting and Jacking Proce- Fitting
dures of Group 2, “Safe Maintenance.”
Check the drive axle fluid level with:
• Truck on a level surface.
• Oil at operating temperature.
1. Remove the fluid level inspection/fill plug located in
the front surface of each drive unit housing (two
places).
2. The oil level is correct (FULL) when it is within
13mm (0.5 in) of the lower edge of the inspection plug Steer Axle Lubrication
opening. Pivot the drive wheel to gain access to the grease fittings.
3. IMPORTANT: Add recommended fluid only, as Grease with lubricant specification NLG # 1.
indicated on service decal.
After adding oil to the drive axle, wait several minutes
until the oil has distributed evenly throughout the unit,
and check for correct oil level. DO NOT OVERFILL.
4. Inspect each fill plug for damage. Replace as neces-
sary.
TMG Steer Axle Grease Fittings.

Locate two fittings by pivoting wheel.
Fill Plug Drive Axle (Front View) Fill Plug
5. Install and tighten the plugs.

EPG 15-18 Steer axle grease fittings
’98➀
April’02
SM 616, Dec Copyrighted Material Planned Maintenance • PS-2-11
Critical Fastener Torque Checks Wrapping Up the PM

For safety, maintain correct torque on all fasteners of com-
ponents that directly support, handle, or control the load Clean Up
and protect the operator. Before closing up the truck, wipe up any spilled fluids and
Check torque of critical items, including: hand prints you may have left.
• Drive axle mounting After closing up the truck, wipe off any handprints, drips,
• Drive and steer wheel mounting spills, or other blemishes caused by the PM. It’s a good
practice to leave the truck looking noticeably better than
• Counterweight mounting
when you started.
• Overhead guard mounting
Clean up any spills or debris you left on the floor or other
• Tilt cylinder mounting and yokes surfaces.
• Upright mounting and components.
Critical fastener torque specifications are given in the gen- Test the Truck
eral specifications Section of Group 40.
Operate the truck one last time to ensure that you identi-
fied all problems and that your repairs/adjustments were
successful.
Report the PM
Finish filling out your PM form, making sure you noted
everything you checked, all the problems you found, and
all the items you adjusted or repaired.
Take the PM form to the person responsible for lift truck
maintenance, present your results, discuss any problems,
and point out where further service is needed.

Section 3.
The PM Inspection Form
As an aid to service technicians performing and document- Use this form as a checklist, and make a record of your
ing PM inspections, Clark has prepared an Electric Truck inspection and truck condition. Note the special coding
Planned Maintenance Report form. (Sample appears on the system for indicating the importance of needed repairs and/
next page.) or adjustments.
SM 616, April ’98 Copyrighted Material The PM Inspection Form • PS-3-1

ELECTRIC TRUCK C O.K. 3 = O.K.
O Potential x = Adjust (Not P.M.)
PLANNED MAINTENANCE REPORT D r = Repair or replace
Urgent
CUSTOMER E s = Requires shop repair
DATE HOUR METER
DATE LAST P.M. HRS. LAST P.M.
MODEL& SERIALNO. CUST. P.O. NO.

ATTACHMENTNO.
AUTHORIZED SIGNATURE INSPECTOR SPECIALINSTRUCTIONS
A. TEST DRIVE MACHINE 16MOTORS 23BRAKE SYSTEM 34UPRIGHT-CARRIAGE

a. Drive Train Noise a. Drive Motor Condition a. Check for Leakage a. Security of Mounting
b. Steering Operation Brush Wear b. Cylinder Fluid Level b. Roller Condition/Clearance
c. Service Brake Operation Commutator Condition c. Clean Vent Cap c. Chain and Anchor Condition
PS-3-2 • The PM Inspection Form

d. Speed Control b. Pump Motor Condition d. Pedal Free Travel d. Chain Adjustment
Creep Speed Brush Wear e. Pedal Drift e. Latch and Stop Condition
1A Operation Commutator Condition f. Cylinder Mounting f. Cylinder Condition

e. Plugging & Directional Control c. Steer Motor Condition g. Service Brake Wear/Adjustment g. Forks, Locks, Stops
f. Return to Neutral Brush Wear h. Parking Brake Wear/Adjustment h. Rail Condition
g. Hydraulic System Operation Commutator Condition i. Brake Line/Cable Condition i. Trunnion Ring Condition
h. Pedal Pads & Linkages
i. Parking Brake Operation 19ELECTRICAL TESTS 26STEER AXLE 34LOAD BACK REST
j. Seat Brake Operation a. Ground Tests a. Security of Mounting a. Condition
(if equipped) b. Cable and Terminal Condition b. Axle Stop Adjustment b. Security of Mounting
k. Pedestrian Warning Devices c. Wire Harness Condition c. Drag Link Adjustment
(if equipped) d. Speed Pot Test d. Articulation Stops 35LIFT LINKAGE (POW)
l. Emergency Reverse Switch e. Contactor Assemblies e. Check Wheel Bearings a. Security of Mounting
(Powrworker) f. Contactor Tip Condition b. Linkage Condition
g. Service Brake Switch Operation 26STEERING SYSTEM c. Linkage Adjustment
01CLEANING & LUBRICATION h. Park Switch Operation a. Check for Leakage d. Load Wheel Bearings
Copyrighted Material
a. Air Clean ruck
T i. S.R.O. b. Oil Level - Condition

b. Air Clean Electrical Control j. P.M.T. c. Security of Mounting 38SHEET METAL & CWT
c. Air Clean All Motors k. Speed Limit Switches d. Tilt Column Operation a. Decals-Missing/Condition

d. Lubricate rTuck l. Steering Switches b. Data Plate Condition
m.Hydraulic Valve Switches 29/30 HYDRAULIC SYSTEM c. Seat Mounting and Operation
12 BATTERY AND CABLES * n. Drive Motor Cur
rent (Amps) a. Check for Leakage d. Seat Belts (If Equipped)
a. Cable Condition * o. Pump Motor Cur rent (Amps) b. Fluid Level - Condition e. Door and Deck Latches
b. Fluid Level * p. Steer Motor Cur
rent (Amps) c. Clean/Replace Breather f. C/W Mounting Bolts
c. Battery Load Test * d. Replace Filter g. Tethers (If Equipped)
d. Battery Retention/Stops 20DRIVE AXLE e. Linkage Adjustment h. Slip Resistance Surfaces
e. Specific Gravity * a. Differential Fluid Level f. Hose Condition
f. Receptacle Condition b. Clean Air Vent g. Lift Speed (In./Sec.) 39OVERHEAD GUARD
g. Battery Connector Condition c. Security of Mounting No Load a. Condition
h. Battery Disconnect Operation d. Check Wheel Bearings Full Load b. Security of Mounting
h. Drift Test (In./Min.)
13GAUGES-LIGHTS-INDICATORS 23WHEELS AND TIRES Lift Cylinder 53 ATTACHMENTS
a. Hour Meter Operation a. Tighten Mounting Bolts Tilt Cylinder a. Mounting Bolts
b. Gauges - All Operate b. Tire Condition b. Leakage
c. Lights - All Operate c. Drive 32TILT CYLINDERS c. Operation
d. Wiring Condition d. Steer a. Check for Leakage
e. Horn e. Load b. Cylinder Rod Condition
f. Lift Interr upt f. Caster c. Mounting Security/Torque
g. Operation of Accessories g. Tire Pressur
e d. Tilt Cylinder Adjustment (Racking)
SM 616, April ’98

* SEE MAINTENANCE INTERVAL IN P.M.A. MANUAL
59-760-0723 September 96
GROUP 12
GROUP 12
BATTERY
Battery Service ................................................................ Section 1
SM 616, April ’98 Copyrighted Material Battery

GROUP 12
NOTES:
Battery Copyrighted Material SM 616, April ’98

Group 12, Battery
Section 1.
Battery Service
Battery Handling ............................................................................................................................ 2
Battery Removal ............................................................................................................................ 3
Battery Maintenance ..................................................................................................................... 4

Maximum Battery Life .................................................................................................................... 4
Battery Vents ................................................................................................................................... 4
Battery Cleaning .............................................................................................................................. 5
Battery Charging .............................................................................................................................. 5
Battery Electrolyte ........................................................................................................................... 5
CleanBattery Compartment ............................................................................................................. 5
Replacement Batteries ..................................................................................................................... 5
Battery Installation ........................................................................................................................ 5
Keeping Battery Records .............................................................................................................. 6
Battery Tests ................................................................................................................................... 6

Specific Gravity Test ....................................................................................................................... 6
Load Test ......................................................................................................................................... 6
Connector, Negative Terminal, and Static Chain Installation .................................................. 7
SM 616, April ’98 Copyrighted Material Battery Service • 12-1-1

Group 12, Battery
Battery Handling
CAUTION DANGER
Remove all jewelry (watch, rings, bracelets, Explosive gas is always present around
etc.) before working on electrical systems. batteries, especially when they are being
Severe burns can result from contact with charged.
electrical circuits.
• No smoking allowed in the charging area.
WARNING
Battery service must be done by trained per- • Battery electrolyte must never be checked
sonnel. Battery acid can cause severe burns with an open flame.
and injury. Do not smoke or have open flames • Open flame, sparks, or electric arcs must
around batteries. never be allowed in the battery charging
area.
WARNING
• The battery contains corrosive sulfuric
Electric truck batteries are heavy and awk- acid which can cause injury. If acid con-
ward to handle. On charge, they give off tacts your eyes or skin, flush immediately
hydrogen and oxygen which, in certain con- with water and get medical assistance.
centrations, are explosive. Electric truck bat-
teries are also costly, so before you remove,
service, or install a truck battery, consult BAT-
TERY MANUFACTURER for more recom-
mendations and instructions on handling and
charging batteries. Carefully read and follow
recommendations and instructions.
Change or service batteries only in an area designated for
this purpose. Refer to page 4 for additional information.
• Be sure this area has provisions to flush and neutralize
acid spillage.
• Be certain the area has proper ventilation to ventilate
fumes from charging batteries.
Persons maintaining batteries must wear protective cloth-
• Check to see that there is fire protection. Fire extin- ing such as:
guishers should be properly maintained and located in
designated areas. • Face and head shields
• Long shirt sleeves
• Gauntlet gloves
• Rubber apron
Fire Extinguisher
Wash Stand
BATTERY
NO SERVICE
AREA
SMOKING
Vent Fan
12-1-2 • Battery Service Copyrighted Material SM 616, April ’98

Group 12, Battery
DANGER
Be sure the battery service area is equipped with material Never lay tools or other metal objects on a
handling equipment designed for the purpose of removing battery. Metal objects contacting battery
and replacing batteries, such as a conveyer or overhead terminals will cause short circuits. The
hoist equipped with safety hooks. shorted circuits could ignite battery fumes
and cause the battery to explode.
IMPORTANT
To prevent side forces from damaging the
battery, the distance between the lifting
hooks (of the spreader bar) must be ad-
justed to the same dimension as measured
between the battery lifting eyes. Make sure
the lifting hooks are the correct size to fit
the lifting eyes of the battery.
• When using an overhead hoist, be sure to use an
insulated spreader bar or similar lifting device.
• 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 with a non-
conductive material, such as plywood, as shown be-
low.
• If the battery does not have a cover of its own, cover it
with a non-conductive material such as plywood. Battery Removal
1. Move truck to the designated battery service area.
Overhead Hoist
Safety Hook
CAUTION
SAFE PARKING. Before working on truck:
• Park truck on a hard, level and solid sur-

face, such as a concrete floor with no gaps
or breaks.
• Put upright in vertical position and fully
lower the forks or attachment.
Safety • Put all controls in neutral. Turn key
Insulated switch OFF and remove key.
Chain Hooks
Spreader Bar
Container • Apply the park brake and block the
wheels.
Lifting 2. Turn key switch OFF and disconnect battery.
Eyes
Plywood
Battery Disconnected

Group 12, Battery
3. Lift and latch seat deck to access battery. could ignite battery fumes, causing the battery to
explode.
4. If the battery to be handled is uncovered, cover battery
with a non-conductive material (plywood, heavy card- • Maintain good battery cable connections.
board, etc.) prior to removal from truck. • Check power cables and wiring for damage that can
cause premature drainage of the battery.
IMPORTANT • Do not overcharge a battery.
Do not wash battery in truck. • Do not undercharge a battery.
• Follow the instructions provided by the supplier(s) of
the battery and battery charging equipment.
CAUTION
An overhead hoist of sufficient lifting capac- • Maintain accurate battery records. If battery troubles
ity (refer to “Weights” in Group 40) should be occur, these records will help you and your battery
used to lift battery. The safety hooks of the representative determine the nature of the problem.
insulated spreader bar should be attached to
the lifting eyes provided in the battery casing.
Battery Vents
5. Be sure battery is covered. Attach lifting device. Lift • When Charging Batteries: The vent caps must be
and remove battery. kept in place to avoid electrolyte spray. Care must be
taken to assure that vent caps are functioning. The
vents must be open to allow the battery to breathe.
Battery Maintenance The battery cover must be removed/opened to dissi-
pate heat and explosive gas.
NOTE • When Cleaning Batteries: The vent caps must be
To obtain maximum performance and battery tightly in place.
life, follow the instructions supplied by your
battery vendor.
Industrial batteries are used to supply the electrical power
to operate an electric industrial truck. Their voltage de-
pends on the number of individual cells they contain. There
are approximately two 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. Only use batteries that comply with factory
specifications as to size and capacity.
Maximum Battery Life Keep Vents Holes Clear

• Do not add acid to a battery. Only qualified battery
representatives should determine if this is necessary.
• When lifting a battery, use a lifting device designed
for this purpose.
• Check the electrolyte level after placing a battery on
charge. The electrolyte level in a battery should be
slightly below the lower lip of the filling hole vent.
Do not overfill. Overfilling 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

Group 12, Battery
Battery Cleaning Clean Battery Compartment

The easiest and most satisfactory method of cleaning a • Using baking soda and water solution, clean the
battery is to wash it with a low-pressure cold water spray. walls and floor of the compartment. Rinse with clear
The battery top can also be washed with a baking soda water.
solution and rinsed with clear water. • Blow off the compartment walls and floor with an air
hose. Allow to air-dry.
IMPORTANT WARNING
• Remove battery from truck before wash- Wear eye protection and protective clothing
ing. when cleaning or drying with compressed
• Vent caps must be free of obstruction and air. Reduce air pressure to 207 kPa (30 psi).
Debris removed with air pressure can cause
in good condition.
injury.
• Battery top should be clean and free of
cracks or breaks.
• Battery terminals must be clean and sol-
idly mounted.
• Damaged batteries should be repaired or
replaced. Consult your battery vendor.
• Check to be sure all vent caps are tight before washing

the battery.
• Fill a bucket with cold water. Add a box of baking
soda to the bucket. Stir the solution until dissolved. Replacement Batteries
Keep this solution around the battery service area at
all times.
• After washing battery, thoroughly rinse with clear CAUTION
cold water. Use a battery properly sized to the dimen-
sions of the battery compartment. Batter-
ies too small can shift and cause damage to
Battery Charging
the truck or injury to the operator or by-
Follow the instructions supplied by the battery charger standers.
vendor. Only use batteries that comply with fac-
tory recommendations as to size and ca-
pacity.
Battery Electrolyte
• Check with battery manufacturer’s documentation be-
fore working on battery electrolyte. Battery Installation
• Always use a carboy tilter or siphon when handling If the battery is uncovered, cover the battery with a non-
battery electrolyte. conductive material (i.e., plywood, heavy cardboard, etc.)
• When mixing electrolyte, always pour acid into water prior to installation.
– NEVER pour water into acid. Pouring water into • Using an overhead hoist and insulated spreader bar,
acid will cause a dangerous chemical action or splash. lift battery into battery compartment.
• Install battery retainer, if applicable.
• Remove non-conductive material from battery.
• Connect battery to truck.

Group 12, Battery
Keeping Battery Records Battery Tests

Records should be maintained to get the best service out of
your battery and truck. NOTE
Use both tests described here.
These records should contain:
• Test Date. Each test should be dated for future refer-
ence and comparison.
Specific Gravity Test
• Specific Gravity and Temperature Readings. Each Test at least six cells across battery with a temperature-
battery cell should be checked and recorded before corrected hydrometer (see chart). Battery is fully charged
and after charging. The specific gravity reading of the when the reading falls in the 1.280 to 1.300 range. If the
electrolyte, calculated using a multiplier to account difference between cells is more than .015, battery needs
for the ambient temperature, should not be less than maintenance.
1.260. If below 1.250, the battery should be re-
charged and tested. SPECIFIC GRAVITY TEST
• Variation Between Each Cell Tested. The variation
SPECIFIC GRAVITY STATE OF CHANGE
in specific gravity reading between cells should not
be greater than 15 points (0.015). If readings are 1.260–1.300 100% CHARGED
greater, there are defective cells.
1.230–1.250 75% CHARGED
1.200–1.220 50% CHARGED

NOTE
The pilot cell should be changed occasionally 1.170–1.190 25% CHARGED
to distribute any electrolyte loss over the bat- 1.140–1.160 VERY WEAK
tery when taking readings.
1.110–1.130 DISCHARGED
• Load Voltage Tests should be performed and re-
corded indicating the condition of a battery while it is
The battery specific gravity is an indication of the battery’s
performing work.
state of charge. You can determine the specific gravity of
• Actual Operating Hours of the Battery. Record the the electrolyte solution in a battery with an hydrometer. If
actual time the battery is in use before putting it on the state of charge is low, the hydrometer will read low. If
charger. the state of charge is high, the hydrometer will read high.
• Charging Time. Keep an accurate record of the For, example a reading from:
actual time the battery is on charger. After each
charge, check to see if the battery is fully charged. • 1.260 to 1.300 indicates a fully-charged battery.
Test the battery before placing it back into service. • 1.200 to 1.220 indicates a battery is in a discharged
Record these results. condition and cannot give satisfactory service.
• Visually Inspect for loose terminal connections or
posts, a cracked case, damaged cell covers (vent caps), Load Test
or excessive corrosion. This data should be noted to
help determine work environment and possible trouble Put the main hydraulic system into tilt by-pass while read-
areas. ing battery volts with a voltmeter.
Battery needs recharge or repair if voltage drops below
80% of the rated voltage of the battery.
Minimum acceptable readings:
• 36 volt battery: 28.8 volts
• 48 volt battery: 38.4 volts

Group 12, Battery
Connector, Negative Terminal, and Static Chain Installation
NOTE
See Group 13 for cable and wiring routing
and connection illustrations.
Static Chain: Chain must make good contact with the floor Negative Terminal: Connections must be tight and free
to ensure proper grounding of the truck. Replace or adjust from corrosion. Cables must not be frayed or cracked.
chain as follows: Batterry: Connectors must be clean, securely mounted,
New Chain: Fasten at third link. tight-fitting, and show no cracking.
Worn Chain: Fasten at first link.

Group 12, Battery

GROUP 13
GROUP 13
WIRING, SWITCHES, AND INSTRUMENTS
Electrical Diagrams ........................................................ Section 1
General Electical Service Tips ....................................... Section 2
Wiring and Cables .......................................................... Section 3
Switches and Sensors ...................................................... Section 4
Instrument Panel ............................................................ Section 5
SM 616, April ’98 Copyrighted Material Wiring, Switches, and Instruments

GROUP 13
NOTES:
Wiring, Switches, and Instruments Copyrighted Material SM 616, April ’98

Group 13, Wiring, Switches, and InstrumentsM
Section 1
Electrical Diagrams
Circuit Schematic Diagram
SM 616, April ’98 Copyrighted Material Electrical Diagrams • 13-1-1

Group 13, Wiring, Switches, and Instruments
TMG(For USA)
13-1-2 • Electrical Diagrams Copyrighted Material SM 616, Dec ’02 ➁

TMG(For USA)
SM 616, Dec ’02 ➁ Copyrighted Material Electrical Diagrams • 13-1-3

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

Wiring Diagrams

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(Except USA)
SM 616, Dec ’02 Copyrighted Material Electrical Diagrams • 13-1-27

TMG(Except USA)
13-1-28 • Electrical Diagrams Copyrighted Material SM 616, Dec ’02

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

EPG


NOTE :
Group 13, Electrical System Copyrighted Material SM 616, Dec ’02 ➁

Section 2.
General Electrical Service Tips
Safe Preparations
2. Discharge the capacitors:
• Turn the key switch to OFF.
Off
• Disconnect the battery.
• Turn the key switch to ON.

On
1. Move truck to service area:

• Park truck on a flat level surface.
• Fully lower upright. • Operate the horn to drain voltage from the
• Tilt forks forward until fork tips touch the floor. capacitors. Horn sound dies out when ca-
pacitors are discharged.
SERVICE AREA
3. Disable the truck:

• Turn the key switch to OFF.
• Remove key.
• Make sure battery is disconnected.
SM 616, April ’98 Copyrighted Material General Electrical Service Tips • 13-2-1
Checking Power Cables

Every cable and wiring harness on this truck is manufac- it will not fit. Subsequently, electrical shorts and damaged
tured to an exact specification. A shorter cable or harness components may result if the replacement part is the wrong
will not fit. If either a harness or cable is routed improperly, one, or if it is routed incorrectly.
Cables having damage as shown in illustration be-

low should be removed immediately and replaced
with new. Be certain the replacement cable is the
exact same length, size and has the proper connec-
tor. Make absolutely certain the cable end is prop-
erly crimped and its connection properly torqued
upon installation
Cuts
Damaged Casing
Power cables having small cuts

may be repaired with electri-
cal tape. Break
Broken Wires
Repairable Damage Cable Unfit for Further Service
Typical
Torquing Fasteners Foot Pound Pivoted
Torque Wrench Handle
Scale
Socket
IIIII
Improperly torqued fasteners can cause

IIIIIIIIIIIIIIIIIIII
damage
Use an appropriate wrench and tighten all
fasteners to the torque specified in the
IIII
following inspection procedures. Head Force or Pull

Pointer
Typical Torque Wrench
13-2-2 • General Electrical Service Tips Copyrighted Material SM 616, April ’98
Connecting and Mounting Components
Tape markers are used to correctly position each Connector Plugs and Receptacles are permanently
wire harness and electrical cable on the truck. When labeled with the proper PL (Plug) and SO (Socket/
correctly installed, the tape marker will be hidden Receptacle) number for easy identification.
by the mounting clamp (guide). Be sure to follow
Match the plug number with the appropriate recep-
the instructions, where noted in this manual, when
tacle number before making a connection. If you do
installing a wire harness or electrical cables. If you
not, electrical shorts and possible damage to the
do not, possible shorts and equipment damage may
equipment may result. i.e., Plug #PL-6 plugs into pin
result.
socket #SO-6, etc.
Pin Lock (Arrows must point in direction shown.)
Tape Marker
SO-6 Socket
Clamp
(and/or Guide)
Markers on Wire Harnesses and Power Cables Pin(s)

PL-6 Plug
Example of Pin Lock Plug and Socket

Multiple cable and wire connections must be
connected as illustrated or electrical shorts and
control damage may result.
Terminal Barrels
Must Face Oppo-
site Each Other
Assemble
Back to Front Buss Bar
Barrel
Barrel
Multiple Connections
SM 616, April ’98 Copyrighted Material General Electrical Service Tips • 13-2-3
Firmly push plug into socket until

latch "clicks" locking the two com-
ponents together.
There is a moisture-resistant seal at each wire-
end of the connector and between the plug
and socket.
Check seals for damage that would make Latch et
ck
them unfit for furtherservice (cuts, etc.). Make So
certain the end seals are seated flush with the
end of the connector housing. Make certain End seals g
the plug and socket latchtightly to each other.
must be firmly Plu
Seal(s)
seated within
the assembly
hous-ing.
Seals and Latch
Retainer plates snap into place to secure the pins and their
sockets.
Check the plates and seal for damage and secure mounting.
Retainer Plate (light orange)

Rubber Seal (dark orange)
So
cke
t
tch
La
g
Plu
Pin Retainer Plate (orange)
Retainer Plates
13-2-4 • General Electrical Service Tips Copyrighted Material SM 616, April ’98
Group 13, Wiring, Switches, and InstrumentsM
Section 3
Wiring and Cables
The following illustrations depict wiring

and cable routing and connections for
standard trucks and main accessory har-
ness.
SM 616, April ’98 Copyrighted Material Wiring and Cables • 13-3-1

TMG(For USA)
13-3-2 • Wiring and Cables Copyrighted Material SM 616, Dec ’02 ➁

TMG(For USA)
SM 616, Dec ’02 ➁ Copyrighted Material Wiring and Cables • 13-3-3

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(For USA)

TMG(Except USA)
13-3-24 • Wiring and Cables Copyrighted Material SM 616, Dec ’02

TMG(Except USA)
SM 616, Dec ’02 Copyrighted Material Wiring and Cables • 13-3-25

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

TMG(Except USA)

EPG

EPG

EPG

EPG

EPG

EPG

EPG

EPG

EPG

EPG

EPG

EPG

EPG

EPG

EPG

EPG

EPG

EPG

ghreews asfdsafsd afdsfds
Section 4.
Switches and Sensors
Accelerator Control Switch ........................................................................................................... 2

Description ....................................................................................................................................... 2
Adjustment ....................................................................................................................................... 2
Brake Switches ............................................................................................................................... 3

Service Brake Switch Description ................................................................................................... 3
Service Brake Switch Adjustment ................................................................................................... 3
Parking Brake Switch Description ................................................................................................... 3
Parking Brake Switch Adjustment ................................................................................................... 3
Direction Control Switches ........................................................................................................... 4

Description ....................................................................................................................................... 4
Adjustment ....................................................................................................................................... 4
Lift and Tilt Pump Switches ......................................................................................................... 4

Description ....................................................................................................................................... 4
Adjustment ....................................................................................................................................... 4
Steer Angle Sensor ......................................................................................................................... 5

Description ....................................................................................................................................... 5
Check and Adjustment ..................................................................................................................... 5
Voltmeter Method ..................................................................................................................... 5
Handset Monitor Mode Method ............................................................................................... 5
Steer Angle, Voltage Input, and Control Action Graph ........................................................... 6
SM 616, April ’98 Copyrighted Material Switches and Sensors • 13-4-1

Accelerator Control Switch
Description Adjustment
The accelerator control is operated by the accelerator foot 1. Loosen four fasteners at A and B on illustration.
pedal to send a signal for power demand to the control.
2. Depress pedal to floor mat and hold.
At the start, the accelerator control is stroked (by the action
of the accelerator pedal), and in turn sends a signal to the 3. Position switch so that push rod is fully pushed in and
motor control, requesting it to produce longer electrical that roller is centered on top of disc.
pulses to the motor, which in turn will supply more power 4. Tighten fasteners as indicated on illustration.
to the drive train.
Trouble with the accelerator control is normally investi-
An internal spring returns the control to start position. gated in conjunction with the motor control. Refer to Group
The accelerator is an integral unit and is not serviceable. 19 for proper procedure.
Opening of the unit will void the warranty.
Accelerator
Pedal
Roller Disc
Accelerator
Control Switch
A
B
Torque:
8-10 N•m Torque
(71-88 in-lb) 20-25 N•m
(177-221 in-lb)
13-4-2 • Switches and Sensors Copyrighted Material SM 616, April ’98

Brake Switches
Service Brake Switch Description Parking Brake Switch Description

The foot brake switch is on the frame under the dash panel. The parking brake switch is mounted to the hand brake
The switch operates when it is released by the brake pedal assembly. The brake handle center pin depresses the switch
lever during braking. Depressing or releasing the switch when the hand lever is not applied. This depressing of the
operates two sets of contacts that alternate from open to switch closes the contacts.
closed to cut power to the drive motors and activate the When the parking brake is applied, it releases the switch,
auto-regen function. allowing the contacts to return their normally open posi-
IMPORTANT tion. This open circuit signals the controller to disable the
The switch must cut electrical current to drive motors.
the drive motor before the brakes apply. IMPORTANT
Otherwise, excessive lining wear will result The switch must cut electrical current to the
and the drive motor will overheat. drive motor before the brakes apply. Other-
wise, excessive lining wear will result and
Service Brake Switch Adjustment the drive motor will overheat.
Adjust the switch so that it “clicks” just before the end of
pedal “freeplay” (the lag between pressing the brake and Parking Brake Switch Adjustment
operating the master cylinder, covered in Group 23). Ad- 1. Turn key switch OFF.
just switch as follows.
2. Loosen parking brake switch mounting screws.
3. Adjust position of switch so that there is contact with
2. Make sure freeplay is properly adjusted as described in the center pin and the switch actuates (clicks) just as
Group 23. the parking brake lever is fully released.
3. Loosen brake switch mounting screws. 4. Tighten mounting screws.
4. Rotate switch against pedal until switch trips. (A click 5. Check operation of switch before truck is returned to
can be heard.) Tighten mounting screws. service.
5. Check operation of switch by depressing brake pedal.
Switch should actuate just before the end of freeplay
(at which time you feel resistance in the pedal caused
by the master cylinder beginning to operate.)
Parking Brake Switch
Service Brake Switch
SM 616, April ’98 Copyrighted Material Switches and Sensors • 13-4-3

Direction Control Switches Lift and Tilt Pump Switches
Description Description
These switches are normally open. When the directional The pump control switches are mounted on brackets at the
control lever is placed in the FWD or REV detent, the valve spools and they are normally open. Movement of the
proper switch is actuated (closed), its contacts close, and valve spools from the neutral position trips the switches
a signal current passes to the drive motor controller, and closes their contacts. Current flow through the con-
which controls the rotational direction of the drive mo- tacts enables the lift pump motor to run.
tor.
The FWD and REV switches are located at the base of Adjustment
the directional control lever. They are actuated by a cam
on the directional control lever. 1. Turn key switch to the OFF position.
2. Loosen switch mounting screws.
Adjustment 3. Adjust switch to activate after spool moves from
neutral.
4. Tighten mounting screws.
2. Loosen FWD and REV switch mounting screws.
3. Adjust position of FWD switch so it actuates when IMPORTANT
directional control lever is in forward detent. Adjust Upon moving a control lever, the pump
REV switch so it actuates when directional control motor should start immediately, and the
lever is in reverse detent. hydraulic function should begin.
4. Tighten mounting screws.
5. Check operation of switch before truck is returned to
5. Check operation of switches before truck is returned service.
to service.
13-4-4 • Switches and Sensors Copyrighted Material SM 616, April ’98

Handset Monitor Mode Method
Steer Angle Sensor (Detailed handset operation instructions are in Group 19.)
Description
Place the handset into the Monitor mode (Function 25) and
The steer angle sensor is mounted atop the steer axle trunnion view RAM location 95, which is turn angle volts, by using
assembly. This device helps the drive motor controllers gener- the following steps:
ate an efficient speed differential between the two drive mo-
1. Make sure the steer wheel is pointing straight ahead (0°
tors when the truck is turning.
turn angle) and connect the battery.
The steer angle sensor is a potentiometer that translates the 2. Push CONT 10. This activates Function 25.
angle of rotation of the steer angle into a voltage level read by
both the left and right controls at P12. When the steer wheel is 3. Adjust handset to 95. This specifies the RAM location
straight ahead (0° turn angle) the input voltage at each control to look at.
should be 2.15 volts. As the vehicle turns left, this input 4. Push STORE. This accesses the specified RAM loca-
voltage decreases. As the vehicle turns right, the input voltage tion.
increases. 5. Push ESC and hold for 2 seconds. This displays the
The graph on the next page outlines the input voltages, the Angle value stored in RAM location 95.
actions of the controls, and the corresponding turn angle of the Handset should read 110. If it does not, skip step 6 and
steer wheel. For example, assume the truck makes a left turn go to step 7.
from the 0° to 90° steer wheel position. In the first 16° of travel
6. ESC from Monitor mode and then reset Function 25 to
(2.15 to 1.90 volts), there is no change to inside wheel speed.
0 using the same procedure as outlined above.
Between 16° (1.9OV) and 66° (1.10V), the inside motor
reduces its speed proportionally from top speed at 16° to creep To adjust the sensor:
speed at 66°. (Also available are two vehicle speed limit 7. Loosen the potentiometer locknut and turn the poten-
enable points during the transition from 16° to 66°. Speed limit tiometer body until the handset reads 110.
1 can be enabled at 41° and speed limit 2 can be enabled at 8. Lock down the potentiometer shaft and turn the steer
60°.) Between 66° and 71° the inside wheel is in a free wheel wheel all the way to the left turn stop, the reading
mode. As the steer reaches the 71° point, the inside wheel is should be 37 or less. Turn the wheel to the right turn
programmed to reverse and accelerate proportionally in the stop, the reading should be 183 or greater. (See graph
opposite direction. Above 86° is over-travel for the turn angle on next page.)
potentiometer.
9. After adjusting the potentiometer, ESC from Monitor
Check and Adjustment mode and then reset Function 25 to 0 using the same
procedure as outlined above.
CAUTION
Before any adjustments are done, safely jack
up the truck, block the drive wheels off the
floor, and discharge the capacitors as de-
scribed in Group SA.
Use one of the following methods to adjust the steer angle
sensor:
Voltmeter Method
1. Attach a voltmeter, positive to P12 (pot white wire 19A)
and negative to battery P20 (pot orange wire 13A).
2. Turn the steer wheel straight ahead (0° turn angle).
3. Connect the battery and turn the key switch on.
4. Voltage should read 2.05 to 2.25 volts. If it does not
loosen the locknut on the potentiometer and turn the
potentiometer body until the voltage reads 2.05 to 2.25
volts. Then tighten the locknut on the potentiometer
shaft.
6. Turn the steer wheel all the way to the left turn stop, the
voltage should be 0.72 volts or less. Turn the wheel to the
right turn stop, the voltage should be 3.53 volts or greater.
SM 616, Dec ’02 ➁ Copyrighted Material Switches and Sensors • 13-4-5

TMG EPG 15-18

Assemble the center of
magnet to be alligned with
the edge of sensor.
Steer Sensor
Steer Angle To Wires
Potentiometer 13A and A B
Magnet
19A
View A
19
13
Locknut
A B C D E 21 View B
Steer Sensor (IN PUT)
(OUT PUT)
1.24~ 4.5V
3.02V
OUTPUT
3.02V
Proportionally
reduces the speed
of the right motor
as steeer angle
incresses
2.04V
No speed change
2.15V
No speed change
1.90V
Proportionally
Steer Angle, Voltage Input, and Control Action Graph reduces the speed
of the left motor
as steeer angle
incresses
After adjusting the potentiometer as described on the 1.24V
previous page, you can check potentiometer voltage out-

put levels and controller responses over the entire turning MAGNET
POSITION
range against the graph below. LEFT TURN RIGHT TURN
TMG In put : 4.5V(check the input voltage between wire #13

and wire #21 of sensor.)
Out put : 1.24~3.02V(check the output voltage between
wire #13 and wire #19 of sensor.)
The graph outlines the input voltages, the actions of the

controls, and the corresponding turn angle of the steer
wheel.
13-4-6 • Switches and Sensors Copyrighted Material SM

SM616,
616,Dec ➁
’02’98
April
Section 5.
Instrument Panel
Dash Display
Spacer
Horn
Torque:
2.8-5.6 N•m
(25-50 in-lb)
SM 616, April ’98 Copyrighted Material Instrument Panel • 13-5-1

Dash Display
The Dash Display provides the operator with an easily understandable,
visual feedback of the status of the truck and its system components.
3 5
10
4 6
7 9
Standard Display 8
1. Pump Motor Brush Wear 5. Planned Maintenance

Indicator (optional) 6. Numeric Display
2. Drive Motor Brush Wear 7. Hour Meter Status
Indicator (optional) 8. Service Status
3. Seat Belt Alert 9. Battery Status
4. Park Brake 10. Accessory Switches (lights, etc.)
13-5-2 • Instrument Panel Copyrighted Material SM 616, April ’98

Command System Display (Option)

The Command System Display provides the operator with an easily under-
standable, visual feedback of the status of the truck and its system compo-
nents. The operator can also select/change vehicle operating characteristics.
5 1 2 3 4 14
15
16
13
6 9 17 18
24 10 19
7 22
11
8 21
12 20
23
Command System
1. Pump Motor Over Temperature (Opt) 13. Performance Selector Button

2. Pump Motor Brush Wear (Opt) 14. Battery Level (high)
3. Pump Control Over Temperature (Opt) 15. Battery Level (med)
4. Planned Maintenance 16. Battery Level (low)
5. Drive Motor Over Temperature (Opt) 17. Seat Belt Alert
6. Drive Motor Brush Wear (Opt) 18. Park Brake
7. Traction Control Over Temperature (Opt) 19. Numeric Display
8. Drive Motor Overload 20. Hour Meter Status
9. Performance Mode 1 21. Service Status
10. Performance Mode 2 22. Battery Status
11. Performance Mode 3 23. Stored Status Code Button
12. Performance Mode 4 24. Accessory Switches (Lights, etc.)
SM 616, April ’98 Copyrighted Material Instrument Panel • 13-5-3

NOTE
Use the Operator manual for instructions
on changing performance characteristic via
the Clark Command Display.
Pump Motor Temperature: (Optional) The sym- Pump Control Temperature: (Optional) The sym-
bol is displayed to "alert" of pump motor temperature bol is displayed and "-141" status code appears on
exceeding the design limits. Do not use truck. Allow numeric display to "alert" of main transistor on pump
pump motor to cool until after symbol turns "OFF". control exceeding allowable design limits. Do not use
Pump Motor Brush Wear: (Optional) The symbol truck. Allow control to cool until symbol turns "OFF".
is displayed to warn one or more of the pump motor Call Service.
brushes are worn beyond allowable length. Do not Traction Control Temperature: (Optional) The
use truck. Call service to replace brushes. symbol is displayed and "-41" status code appears on
Drive Motor Brush Wear: (Optional) The symbol numeric display to "alert" of main transistor on trac-
is displayed to "alert" of drive motor temperature tion control exceeding allowable design limits. Do
exceeding the design limits. Do not use truck. Allow not use truck. Allow control to cool until symbol turns
drive motor to cool until after symbol turns "OFF". "OFF". Call Service.
Seat Belt: At start up this symbol displays along with Drive Motor Overload: This symbol will come on
an audio alarm for 4 seconds. This display reminds when the drive motor is stalled or overloaded. The
you to fasten your seat belt. numeric display will show a status code "-82" - "-83"
when this occurs.
Parking Brake: The symbol is displayed and "-01"
status code appears on the numeric display when Drive Motor Temperature: (Optional) The symbol
parking brake is applied. Release parking brake to is displayed to "alert" of drive motor temperature
operate truck. exceeding the design limits. Do not use truck. Allow
motor to cool until after symbol turns "OFF".
Planned Maintenance: This symbol is displayed
and "-99" status code appears on the numeric display Performance Selector Button: Used in conjunction
when the key switch is turned "ON" and trucks with stored status code access button to select one of
operating hours exceed pre-programmed hours for the four available pre-programmed sets of perfor-
planned maintenance. The symbol is a reminder only mance characteristics of the truck. (See Operator
and will turn "OFF" after 4 seconds and display will manual.)
return to normal operation. The truck shall be inop- Stored Status Code Button: Used in conjunction
erative while this symbol is displayed. Call Service. with performance selector button to retrieve the fail-
Hour Meter: This symbol identifies the number ure history. (Up to 16 status codes with associated
displayed on numeric display as truck and/or pump state of battery and truck operating hours).
motor (optional) operating hours. The symbol is
displayed for 4 seconds to 8 seconds when the key Battery Level: Graphical display
switch is turned "OFF". showing state of charge.
Service Status: "-01 through -03," "-06 and -08" are
usually operator fault codes, and can be corrected by
as explained in "Section 5, Operating Procedures." If
you see any other codes displayed, the truck needs to
be serviced. Performance Mode Levels: Se-
Battery Status: If this symbol displays, the numeric lected level of operating character-
display shows the percentage of usable charge re- istic of the truck from the 4 avail-
maining on the battery. able sets of pre-programmed oper-
ating characteristic.
13-5-4 • Instrument Panel Copyrighted Material SM 616, April ’98

GROUP 16
GROUP 16
ELECTRICAL MOTORS
Specifications and Description ...................................... Section 1
Inspection and Troubleshooting .................................... Section 2
Drive Motors Overhaul .................................................. Section 3
Lift Pump Motor Overhaul............................................ Section 4
Steer Pump Motor Overhaul ......................................... Section 5
SM 616, April ’98 Copyrighted Material Electrical Motors

GROUP 16
NOTES:
Electrical Motors Copyrighted Material SM 616, April ’98

Group 16, Electrical Motors
Section 1.
Motors Specifications and Description
Specifications .................................................................................................................................. 2
Drive Motors ................................................................................................................................... 2
General ...................................................................................................................................... 2
Insulation .................................................................................................................................. 2
Brush Data ................................................................................................................................ 2
Lift Pump Motor .............................................................................................................................. 2
General ...................................................................................................................................... 2
Insulation .................................................................................................................................. 2
Brush Data ................................................................................................................................ 2
Steering Pump Motor ....................................................................................................................... 3
General ...................................................................................................................................... 3
Insulation .................................................................................................................................. 3
Brush Data ................................................................................................................................ 3
Descriptions and Locations ........................................................................................................... 4

Drive Motors ................................................................................................................................... 4
Lift Pump Motor .............................................................................................................................. 4
Steering Pump Motor ....................................................................................................................... 4
SM 616, April ’98 Copyrighted Material Motors Specs & Description • 16-1-1
Specifications
Drive Motors Lift Pump Motor
General General
Type: Shunt wound Type: Shunt wound
Frame Size: 168.2 mm (6.625 in) diameter Frame Size: 170.2 mm (6.7 in) diameter
Weight (Approx.): 26.8 kg (59 lb) Weight (Approx.): 36.2 kg (80 lb)
Internal Bearings: On commutator end only. Bearings are Internal Bearings on Pump End Commutator End: Bearings
sealed and lubricated with high-temperature grease for the are double sealed and lubricated with high-temperature grease
life of the bearing. for the life of the bearing.
Rotation: Reversible; CW for forward travel; CCW for Rotation: Reversible; CCW, viewed from drive end
reverse travel when viewed from drive end. Terminal Nut Torque: 8-10 N•m (71-88 in-lb)
Terminal Nut Torque: 8-10 N•m (71-88 in-lb)
Insulation
Armature Armature Components: Class H
Resistance at Terminals: 0.0097 Ohms at 25˚C (77˚ F) Field Components: Class H
Insulation: Class H
Brushes
Fields
Grade: CM880
Resistance at Terminals: 0.52 Ohms at 20˚C (68˚ F)
Quantity: 1 Brush per holder; 4 brushes per motor
Insulation: Class H
Length of New Brush: 33.02 mm (1.30 in)
Width of New Brush: 31.50 mm (1.24 in)
Brushes
Thickness of New Brush: 15.90 mm (1.13 in)
Grade: CM8100
Maximum Length of Worn Brush: 15.75 mm (0.62 in)
Maximum Force per New Brush: 1077 g (38 oz)
Minimum Force per Worn Brush: 454 g (16 oz)
Brush Drop: 1.5 Volts @ 300 Amps
Thickness of New Brush: 12.70 mm (0.50 in.)
Maximum Force per Worn Brush: 907 g (32 oz)
Brush Drop: 0.4 V+ .00444I Volts
Width
Length
Thickness
Brush Dimensions Terminology
16-1-2 • Motors Specs & Description Copyrighted Material SM 616, April ’98
Steer Pump Motor
General
Type: Permanent magnet field
Frame Size: 165.1 mm (6.5 in) diameter
Weight (Approx.): 15.4 kg (34 lb)
Internal Bearings on Pump End Commutator End: Double-
sealed and lubricated with high-temperature grease for the
life of the bearing.
Insulation
Armature Components: Class H
Field Components: Permanent magnet
Brushes
Thickness of New Brush: 9.3 mm (0.368 in)
Minimum Force per Worn Brush: 454 g (16 oz)
Brush Drop: 0.05 Volts @ 29 Amps
SM 616, April ’98 Copyrighted Material Motors Specs & Description • 16-1-3
Descriptions and Locations Lift Pump Motor

The truck has four electric motors: The pump motor drives the main hydraulic pump and
• Two identical traction motors remains off except when the load handling cylinders are
being actuated.
• One main hydraulic pump motor
The motor is controlled by the pump contactor or by an
• One steer pump motor.
electronic control option. The motor is equipped with stan-
dard winding connections and meets latest revision of UL
Drive Motors 583.
The two drive motors are shunt-wound type with Class H
insulation and a radial cooling fan. One motor drives the Steering Pump Motor
left traction wheel, the other the right. The electronic
control system varies the speeds of the two motors The permanent magnet motor differs from conventional
independently to accommodate cornering. DC motors in that the field winding has been replaced with
ceramic magnet pole pieces. Do not impact, drop or
The exterior connections are easily accessible from the squeeze the motor. This can damage the ceramic pole
top of the motor where they are protected from external pieces, making motor unfit for use.
damage. The brushes are accessible and can be changed
easily with battery removed from the truck. The motor is equipped with standard winding connections
and meets latest revision of U.L. 583.
This motor is equipped with standard winding connec-
tions and meets latest revision of UL 583.
EPG 15-18
TMG
Drive Motor Drive Motor
Steer Motor
(with pump)
Lift Motor (with pump)
(USA ONLY)
16-1-4 • Motors Specs & Description Copyrighted Material SM616,

SM 616,Dec
April ➀
’02’98
Section 2. Motors Inspection and Troubleshooting

Prolonged operation at excessively high temperatures will
Inspection Procedures cause insulation to become brittle and crack, leading to
The brushes and commutator should be inspected for even premature failure. The insulation condition can be judged
wear and good commutation at every PM. both visually and by test measurement. Regular, periodic
measurements of insulation resistance can give a useful
Before performing these service procedures: indication of the rate of insulation deterioration.
• Park truck safely.
A sudden drop or consistent trend toward low values of
• Fully lower upright. insulation resistance gives evidence that insulation is dete-
• Apply park brake. riorating and that failure may be imminent.
• Turn key switch OFF.
• Disconnect battery from truck receptacle. Using a 500-Volt Megger
• Discharge capacitors by turning the key switch to This test may be made with motor in the truck.
ON for 10 seconds and operating horn until sound 1. Disconnect battery from truck receptacle.
dies away,
2. Disconnect power cables from motor terminals.
• Turn key switch OFF and remove the key.
3. Connect one lead of the 500-volt megger to any motor
terminal.
Motor Cleanliness NOTE
Electric motors should be kept clean at all times to prevent Test ALL terminals individually or by in-
shorting, minimize wear, and optimize cooling. terconnecting with jumper wires.
• Wipe off all dust, dirt, oil, water, etc., from outer 4. Connect other lead to motor frame. Apply voltage.
surface of motor. Resistance should measure at least 1,000,000 ohms
• Remove any debris from cooling air vents and around (1 megohm).
motor frame to prevent overheating.
5. If less than 1 megohm is measured, air-clean motor and
• Air-clean (blow out) motors using clean, dry (mois- repeat test. If air cleaning does not make an improve-
ture-free) compressed air at 207 kPa (30 psi) maxi- ment, the motor will have to be removed and disas-
mum air pressure. Air-clean all inner areas around sembled for a closer inspection.
commutator and brushes, including cooling air vents
and fan.
Using a Simpson 260-6p Volt-Ohmmeter (VOM) or
The presence of any oil on or near motor could indicate Equivalent Calibrated on the Rx10,000 Scale
either bad bearings or leaking hydraulic system. Determine
cause and repair problem before extensive motor damage This test may be made with motor in the truck.
occurs. 1. Disconnect battery from truck receptacle.
2. Disconnect power cables from motor terminals.
Motor Insulation Tests
3. Connect the positive lead of the VOM to all terminal
Reduced motor performance may be due to a breakdown in studs of test motor. Use jumper wires to connect motor
motor insulation, causing internal grounding or a short terminals.
circuit. NOTE
Failure of motor insulation can be due to: Test ALL terminals individually, or joined
together, as noted.
• Contamination
• Mechanical factors 4. Connect VOM negative lead to motor frame. Resis-
tance should measure at least 1,000,000 ohms (1 me-
• High temperatures
gohm).
Contamination includes dirt, moisture, oily vapors, metal
5. If less than 1 megohm is measured, air-clean motor and
chips, carbon dust from brushes, etc.
repeat test. If air cleaning does not make an improve-
Mechanical factors include shock, vibration, over speed, ment, the motor will have to be removed and disas-
etc. sembled for a closer inspection.
SM 616, April ’98 Motors Inspection and Troubleshooting • 16-2-1

Brush and Commutator Maintenance on commutator.
The key to planned maintenance of the brush and commu- 4. Check appearance of commutator surface where
tator is recognizing undesirable brush and commutator con- brushes ride. Inspect commutator bars for burned,
ditions. If this is done, corrective action can be taken damaged, or raised areas. The best signs of good
before a major component is damaged beyond serviceabil- commutation are a dark brown, highly-polished com-
ity. The brushes and commutator should be inspected for mutator and uniform, glossy brush-wearing surfaces.
even wear and good commutation. 5. Measure and record the brush length at each inspec-
Good Commutation: The brush wearing surface has a tion. The record will verify amount of brush wear and
dark uniform coloring pattern. indicate if there is enough brush length remaining until
next scheduled inspection.
Poor Commutation: The brush wearing surface appears
rough, pitted, or scored, or signs of burning or heavy arch- 6. Brushes must be replaced when worn to approximately
ing between bars are present. The coloring pattern exhib- half of original length.
its:
IMPORTANT
• Streaky film with commutator wear.
• Bar edge burning. New brushes must be of same size and equal
or better grade (material specification) as
• Uneven film.
replaced brushes.
• Carbon dust bridging between bars.
Brushes should be inspected for uneven wear and signs of Observe how old brushes are assembled in
overheating: brush holders and position of brush lead
(pigtail). New brushes must be installed in
• Discolored brush shunts. same manner. (See motor overhaul Sections
• Discolored brush springs. for illustrations.)
Refer to the Brush Inspection Chart at the end of this
section. 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.
Brush and Commutator Inspection
8. If brushes do not need to be replaced and commutator
1. Remove brush cover(s). Remove brushes from brush is in good condition, install brushes and brush springs
holders. Clean brushes and holders. Check brush hold- into brush holders.
ers for damage. 9. If brushes are to be replaced, the motor should be
removed from the truck, disassembled and the arma-
2. Inspect brushes and commutator for worn condition
ture turned. The commutator can usually be cleaned up
and uneven wear.
with a very light cut, if done every time the brushes are
3. Clean commutator surface. Wipe commutator with a replaced. Check mica and undercut as necessary. This
dry, lint-free cloth. DO NOT use lubricant or solvent light cut will true any high bars and will assure proper
life of new brushes.
Retainer Cross
Brush Shunt Screw, Connector Screw IMPORTANT
Shunt Always replace both brushes and springs.
Pressure
Spring Brush Box Do not use old springs with new brushes. Be
Retainer sure brush spring is correctly placed on
Screw
brush holder and that brush is free to slide
Commutator
in brush box.
Brush Box Brush Box
Brush Brush 10. Clean and check brush box and connector screws.
Brush Box Tighten if loose. Be sure brush box shunt connection
Retainer is tight. Install brush cover on motor case.
Screw
Hammer 11. Check and tighten all motor bolts. Check lower nut on
Plate each terminal post. It should be installed finger-tight,
Pigtail then tightened another 1/4 turn with a wrench.
16-2-2 • Motors Inspection and Troubleshooting

Copyrighted Material SM 616, April ’98
Brush Inspection Chart
BRUSHES WORN REPLACE BRUSH

UNEVEN IF
CHIPPED
CHECK TENSION BROKEN

OF EACH SPRING
IF SPRING TENSION IS NOT THE SAME

REPLACE BRUSH IF OIL SOAKED
FOR EACH BRUSH, REPLACE SPRINGS.
REPLACE BRUSH IF IF BRUSH PIGTAIL

PIGTAIL IS LOOSE IS LOOSE AT THE
IN THE BRUSH. BRUSH HOLDER –
TIGHTEN SCREW.
NOTE
REPLACE BRUSHES
WHEN WORN TO
Brush dimensions are
HERE. on page 1 of this Sec-
tion.
NEW BRUSHES
SM 616, April ’98 Motors Inspection and Troubleshooting • 16-2-3

16-2-4 • Motors Inspection and Troubleshooting

Section 3.
Drive Motor Overhaul
Drive Motor Removal and Installation ........................................................................................ 2
Drive Motor Exploded View ........................................................................................................ 3
Drive Motor Disassembly .............................................................................................................. 4
Drive Motor Components Inspection ........................................................................................... 6
Drive Motor Assembly .................................................................................................................. 6
CAUTION
Before working on truck:
1. Park truck on a hard, level and solid

surface, such as a concrete floor with
no gaps or breaks.
2. Put upright in vertical position and
fully lower the forks or attachment.
3. Put all controls in neutral. Turn key
switch OFF and remove key.
4. Apply the park brake and block the
wheels.
5. Disconnect battery.
6. Turn key on. Sound horn until sound
dies away to discharge the capacitors.
SM 616, April ’98 Copyrighted Material Drive Motor Overhaul • 16-3-1

Drive Motor Removal and Installation

1. Tilt the steering column fully forward and remove the
floor plate.
2. Disconnect battery and remove all electrical cables
from the motor. Tag cable terminals to aid in reinstal-
lation. Position cables out of the way of motor removal. NOTE
3. Remove the battery. When removing or installing cables to mo-
tor, hold the terminal’s lower nut with a
4. Remove bolts holding motor to axle. Have drain pan in wrench while turning the upper fastening
place to catch axle oil. nut with another wrench.
5. Lower motor onto floor.
6. Jack up and block the rear of the truck high enough to
slide motor from under truck.
7. Reinstall in reverse order. Use new O-ring, coated with
drive axle fluid. New motors may have a plastic
packing around the input shaft. Remove and discard
this packing prior to motor installation.
8 Check and fill drive axle oil as described in Group 20.
Drive Axle
Torque:
70- 80 N•m
(52- 59 ft-lb)
O-ring
Drive Motors
16-3-2 • Drive Motor Overhaul Copyrighted Material SM 616, April ’98

Drive Motor Exploded View

Typical Construction Illustrated
Bearing Retainer Screws
Frame Assembly Commutator End Frame End

Mounting
Conductors, Brush Holder to A1&A2 Bolts
Brush Terminal Parts

Brush Access
Brush Cover
Brush Holder
Assembly*
Housing
Field
Terminal Field Coil Set
Parts
Main Pole
Field Terminal
Posts
Bearing
Bearing Retainer
Pole Mounting Screws Armature Assembly

Fan
Frame-Drive End
Frame to Housing Mounting Bolts
Oil Seal
*NOTE
See page 5 for close-up view
of brush holder assembly.

Drive Motor Disassembly NOTE

Drive motor weighs approximately 107 kg
(235 lb).
1. Remove O-ring seal on mounting flange pilot.
4. Remove cover band.
5. Loosen bolts attaching drive end frame to motor hous-

2. Fasten a lift chain to end frame. Make sure that bolts
ing (yoke).
holding chain to motor are tightened fully against
chain links to avoid bending bolts. 6. Put an identification match mark on both end frame
and housing to assure proper location when assebling
NOTE motor.
If motor does not have tapped holes in end Lift drive motor off blocks about 25 mm (1 in) and tap
bell for attaching lift chain, use nylon slings on end frame uniformly about its outer periphery with
of correct capacity or similar means to posi- a soft-faced hammer to separate drive end frame from
tion motor as described below. motor housing.
3. Upend drive motor and set it on fan end using blocks to

support end bell.
Refer to exploded view on page 3.

7. Remove commutator end motor frame.

NOTE
8. Carefully remove brushes. Check brush holder for cracks Be sure brush spring is correctly placed on
and damage. Replace brushes and brush springs. brush holder and that brush is free to slide
in brush box.
See Section 2 for bush inspection instruc-
tions.
9. Lift housing assembly off armature assembly and store 10. Lift armature assembly off drive end frame.
in a safe place. 11. Remove and discard commutator end bearing from
armature assembly.
NOTE
Make sure bearing puller is positioned to
pull on innner race of bearing.
Replace all bearings when overhauling mo-
tor.
12. Remove oil seal from end frame and discard it.

Drive Motor Components Inspection Drive Motor Assembly

1. Carefully inspect all components of motor for wear, Refer to exploded view on page 3.
evidence of damage from overheating, rust or corro-
1. Install new bearing on commutator end of armature.
sion, excessive buildup of dirt or contaminants and
for any other damage that would impair operation. Use a socket or a tubular driver of correct size that
fully contacts inner race to install.
2. Discard all bearings and oil seals and replace with
new.
3. Examine brush boxes for evidence of wear, arcing or
external damage. Make sure connections are solid
andtight.
4. Examine commutator for evidence of excessive wear,
eroded surfaces, raised commutator bars, excessive
heat build-up or any visible damage that would impair
operation. º
Turn commutator if necessary. The commutator can
usually be cleaned up with a very light cut, if done
each time the brushes are replaced. Check mica and
2. Install new seal in drive end frame. Make sure seal is
undercut as necessary. This light cut will true any
fully seated in bore.
high bars and will assure proper life of new brushes.
Put a coating of petroleum jelly on seal lips.
5. Discard brushes and replace with new.
3. Put drive end frame on supporting blocks and insert
6. Examine field windings making sure that insulation is
armature assembly into frame. Be very careful not to
in place and not damaged (no exposed surfaces). Look
damage sealing lips of oil seal as shaft is inserted.
for any evidence of arcing or of excessive heat build-
up. 4. Use a chain hoist to lift drive motor housing assem-
bly and lower it over armature assembly. Make
7. Examine ventilating fan for any evidence of damage.
sure alignment marks made earlier are matched.
If dirty, carefully clean surfaces.
5. Install and tighten mounting bolts attaching end frames
to housing.
6. Use a chain hoist to upend motor and lay it on its side.
7. Install new drive motor seal (O-ring) on transmission
mounting pilot using reverse of procedure given on
page 2.
Jam Nut
Nut
Flat Washer Lock Washer
Housing
Insulating Bushing Insulators
Flat Washer
Terminal Stud
Terminals Connection Torque: 8-10 N•m (71-88 in-lb). Hold lower nut with a
wrench when tightening jam nut.

Section 4.
Lift Pump Motor Overhaul
Lift Pump Motor Exploded View ................................................................................................. 2
Removal .......................................................................................................................................... 3
Installation ...................................................................................................................................... 3
Disassembly .................................................................................................................................... 4
Inspection ........................................................................................................................................ 5
Reconditioning ............................................................................................................................... 5
Assembly ......................................................................................................................................... 6
SM 616, April ’98 Copyrighted Material Hydraulic Pump Motor Overhaul • 16-4-1
Lift Pump Motor Exploded View
Bearing
Field Coil Set
Terminal Kit Retainer
Bearing Frame
Fan
Washer
Brush Access
Cover Coupling
Fastener Bearing
Brush Kit
Armature
CAUTION
Before working on truck:

surface, such as a concrete floor with
no gaps or breaks.
2. Put upright in vertical position and
fully lower the forks or attachment.
wheels.
5. Disconnect battery.
6. Turn key on. Sound horn until sound
dies away to discharge the capacitors.
16-4-2 • Hydraulic Pump Motor Overhaul Copyrighted Material SM 616, April ’98
Removal Installation
Usually pump and motor are removed as an assembly. Normal practice is to install pump and motor as an assem-
bly.
1. Disconnect motor cables from motor.
Refer to pump section for instructions of installation of
2. Cover all drive moptor openings to protect from oil.
pump on motor.
3. Remove hydraulic lines from pump and cap ends.
1. Position pump and motor assembly on truck. Install
4. Remove fasteners clamping the motor. Remove pump and tighten fastener to a torque of 40-45 N•m (30-33
and motor assembly from truck. ft-lb).
5. Remove fasteners attaching pump to motor. Lift off 2. Install hydraulic lines on the pump.
pump.
3. Install motor cables on correct motor terminals.
4. Install battery.
TMG
EPG 15-18
TMG13-20x
EPG15-18
Edge of
Mounting
Bracket
125 mm
(4.9 in) Position end of motor
from edge of mounting
bracket as shown.
SM 616, Dec ’98➀

April’02 Copyrighted Material Hydraulic Pump Motor Overhaul • 16-4-3
Disassembly
NOTICE
If brushes have not been removed
before disassembling motor, brushes 4. Use an impact tool to loosen (and also to torque at
must be lifted off commutator and assembly) mounting screws in drive end frame.
held in raised position. This is done
by lifting brush spring off end of
brush and moving spring to one side
of brush which traps or “locks”
brush in place.
1. Put match mark on each end frame of motor and extend

mark onto body. This will assure exact alignment of 5. Use same procedure to remove screws in brush end
frames for assembly of motor. frame.
2. Remove plastic brush covers.

3. Remove brushes.
6. Remove brush end frame.
7. Remove drive end frame and armature assembly from
body.
NOTE
Drive end frame and armature
assembly can be removed first (for
inspection of commutator and
bearings).
8. If necessary, remove (separate) drive end frame and 1. COMMUTATOR END FRAME. Check brush holder
bearing assembly from armature. insulation and wiring for cracks or any signs of burning.
This is usually done by using a hydraulic press to force Check brush holders for wear, and check bearing recess
armature out of drive end bearing. for signs of wear.
If a press is not available, it can be removed by careful use 2. DRIVE END FRAME. Check for cracks or other
of a puller. damage. Check bearing recess and snap ring groove for
any signs of wear.
If this is method used, use care not to apply excessive or
concentrated loads to aluminum end frame. 3. BEARINGS. Check bearings by turning them with
fingers. If bearing has binding, gritty effects, excessive
NOTE looseness, wobble, or turns very freely, it should be
The ventilation fan is not normally replaced.
removed. If it is to be removed, it 4. ARMATURE. Check windings, commutator connec-
can be removed by using heat very tions and commutator bars for any signs of burning or
carefully to expand it and allow it to looseness. Check commutator for worn condition, ex-
be pulled off without damage. cessive carbon build-up in undercuts between bars, and
excessive runout. If brushes are to be replaced, the
9. To remove fan, use a puller over fan and against end of motor should be removed from the truck, disassembled
armature shaft. Exert a small pressure against fan. Use and the armature turned. The commutator can usually
a propane torch to heat hub of fan around shaft. be cleaned up with a very light cut if done every time
the brushes are replaced. Check mica and undercut as
When fan becomes loose (will be indicated by becoming necessary. This light cut will true any high bars and will
loose on puller) it should be removed as quickly as pos- assure proper life of new brushes. Refinish commuta-
sible. tor surface if pitted or excessively worn. Check shaft
After removal, clean shaft surface of armature. bearing journals and internal spline for wear.
10. Install new fan on shaft making sure it is tight fit. 5. MOTOR BODY (Frame and Field Assembly). Inspect
all insulation for burned, blackened or charred areas.
Use Loctite Retaining Compound 40 or equivalent applied
Check coil connections and terminal studs.
to inside of fan hub.
6. COOLING FAN. Inspect for broken or loose sections.
Inspection
After motor has been disassembled, all components should
be cleaned and inspected for wear and damage. Reconditioning
Thoroughly clean all components, except bearings and ar-
1. COMMUTATOR REPAIR. Check commutator condi-
mature with a good grade petroleum-base cleaning solvent
tion for carbon build-up in undercuts between commu-
and then dry using compressed air.
tator bars and for excessive wear and runout before
The armature should be blown off with compressed air to proceeding further with disassembly. If necessary, or if
remove brush dust and dirt from around commutator and brushes are to be replaced, commutator should be re-
windings. Bearings should be wiped with a clean cloth. moved, turned and re-undercut.
After cleaning and drying, inspect all components for prob-
lem areas that will require reconditioning.
2. BEARING REPLACEMENT. Remove bearing from Assembly

drive end frame.
The bearing is retained with a snap ring. Remove 1. Press drive end frame assembly onto armature shaft until
internal snap ring from groove in frame at end of bear- bearing inner race is firmly seated against shoulder on
ing, then press bearing out of frame. shaft.
Install new bearing by pressing on outer race of bearing to Section showing shaft in place against bearing.
force it into bore until it is firmly seated against shoulder.
Install snap ring to retain it.
NOTE
Install bearing on shaft by pressing
on bearing inner race.
DO NOT PRESS OR USE FORCE

AGAINST DRIVE END FRAME.
2. Install armature and drive end frame assembly into

motor body.
Align match marks on end frame and motor body.
NOTE
Do not reuse bearings but replace
with new.
3. If necessary, remove bearing from commutator end of

armature shaft by using a bearing puller.
Protect end of armature shaft with a nut or thick flat
washer.
Be careful not to damage commutator bars.
3. Install drive end frame mounting screws and tighten
lightly to temporarily hold assembly. Tighten alter-
nately to assure good mechanical alignment.
4. Install bearing spring (end thrust) washer into bearing
bore in commutator end frame. Use thin film of grease
to hold in place.
4. Install new bearing on armature shaft by pressing inner

race of bearing firmly against shoulder on shaft.
5. BEARING LUBRICATION. Replacement bearings are
packed with lubricant and need no further lubrication.
NOTE
If brushes are installed, raise all
brushes to locked position.
5. Assemble commutator end frame over bearings on ar-

mature until it joins motor body.
Be sure bearing spring washer has remained in place.
Make sure match marks are aligned.
6. Install commutator end mounting screws and tighten
lightly to hold assembly temporarily. Tighten fasteners
alternately to assure good mechanical alignment.
7. Fully tighten drive end frame mounting screws using
impact tool set.
8. Use same tool set and procedure to tighten mounting
screws in commutator end frame.
9. If brushes were not removed (replaced), set brushes to
final (lowered) position, by moving brush springs to top
of each brush.
10. If brushes were removed, install new brushes and brush
springs by:
a) Inserting brushes in holder with lead wire in same
position as when removed and make sure brush is
free in holder.
b) Connect brush leads to correct terminals.
c) Install new brush spring clip on top of each brush.
Jam Nut
Nut
Flat Washer Lock Washer
Housing
Flat Washer
Terminal Stud
Section 5.
Steering Pump Motor Overhaul
Steer Pump Motor Removal and Installation ............................................................................. 2
Troubleshooting Prior to Disassembly ......................................................................................... 2
Steer Pump Motor Exploded View ............................................................................................... 5
Brush Removal and Inspection .................................................................................................... 5
Motor Disassembly ........................................................................................................................ 5
Armature Removal ........................................................................................................................ 6
Motor Inspection ............................................................................................................................ 6
Armature and Bearing Repair ...................................................................................................... 7
Bearing Lubrication ...................................................................................................................... 7
Motor Assembly ............................................................................................................................. 7
SM 616, April ’98 Copyrighted Material Steering Pump Motor Overhaul • 16-5-1
CAUTION Steer Pump Motor Removal and

Park truck safely before beginning work: Installation
1. Disconnect and remove battery.
1. Park truck on a hard, level, and solid
surface, such as a concrete floor with no 2. Apply parking brake.
gaps or breaks. 3. Remove bolts holding front battery plate amd lay plate
2. Put upright in vertical position and fully back to access motor.
wheels.
5. Disconnect the battery.
6. Turn key on and operate horn until the
sound dies off to discharge the capaci-
tor.
4 It is normal to remove pump and motor as a unit.

Disconnect motor leads and move them out of way.
5. First, protect motor openings from leaking fluid. Then
remove hydraulic hoses from pump and cap ends.
6. Remove motor mounting bolts .
7. Remove pump and motor from truck.
8. Reverse procedure to install motor. Tighten mounting
fasteners to 40-45 N.m (30-33 ft-lb). Tap in front bat-
tery plate fsteners with a hammer.
Steer Pump
Torque:
40-45 N•m Steer Pump Motor
(30-33 ft-lb)
(TMG For USA)
16-5-2 • Steering Pump Motor Overhaul Copyrighted Material SM616,

SM 616,Dec
April ➀
’02’98
Troubleshooting Prior to Disassembly

1. Read the nameplate to become familiar with the motor motor leads on the power supply for a longer time. If
- especially the rated voltage. the motor sounds normal, go to step 4. If the motor
sounds noisy, it should be disassembled. (See proce-
2. Try to turn the shaft by hand. Keep motor leads
dure in this section.)
separated while doing this. If the shaft turns freely, go
to step 4. If the shaft won’t turn, proceed to step 3. 4. Connect an ammeter in the circuit as shown below.
With rated voltage applied and the shaft running free,
3. The shaft could be tight for a number of reasons. This
the ammeter should read less than 20% of the name-
check is to determine if the tightness is of a temporary
plate full load current, indicating the original problem
nature only.
is external to the motor. A higher ammeter reading
Obtain a power source to produce the rated voltage. indicates a faulty armature.
DO NOT make a permanent connection. Touch the
motor leads quickly to the power supply - just long
enough to observe if the shaft turns. If it turns, hold the
Ammeter
A
DC
DC
Power
Motor
Supply
V Voltmeter
Steer Pump Motor Exploded View
CAUTION
The permanent magnet motor differs from con-
ventional DC motors in that the field winding
has been replaced with ceramic magnet pole
pieces. Do not impact, drop or squeeze the
motors. This can damage the ceramic pole
pieces, making motor unfit for use.
Stator
Terminal Kit
Bearing
Armature
Bearing
Drive End
Frame
Fastener
Terminal Kit
Commutator End Frame

Fastener
Spring Washer
16-5-4 • Steering Pump Motor Overhaul Copyrighted Material SM 616, April ’98
6. When reassembling motor, replace brushes and brush

Brush Removal and Inspection springs (complete set), as needed, by reversal of above
1. Loosen and remove clamping screw in brush cover procedure
band. NOTE
If brushes have not been removed before
disassembling motor, brushes must be
raised off commutator and held in “locked
position.” This is done by moving brush
spring clip from top of brush and placing it
against side of brush to hold (lock) brushes
in a raised position in brush holders.
2. Air clean inside of motor around brushes and commuta- Motor Disassembly
tor, using dry (moisture-free) compressed air.
IMPORTANT
NOTE Do not place stator ring (motor housing) in
any mechanical holding device (e.g., vise)
Observe how brushes are assembled in
during disassembly or assembly operation.
brush holders and position of brush lead
Permanent distortion or other damage will
(shunt). New brushes must be installed in
result. With motor disassembled, care must
same manner.
also be taken not to drop stator ring assembly,
3. Brushes should be removed, as follows: since it can be distorted. Motor may be held
by clamping on mounting bracket.
a) Remove brush spring clip from its mounting on top of
brush assembly. Use a brush hook to reach into motor NOTE
and lift brush springs. Before disassembling motor, note if there
are match marks on stator assembly hous-
b) Disconnect brush assembly lead. ing and commutator cover. If marks are
c) Lift brush from brush holder. not visible, use a scribe tool to make match
marks. These marks will be used at assem-
4. Remove any carbon dust or dirt from brush assembly. bly.
IMPORTANT
Permanent magnet motors should be dis-
assembled only in a clean area free of fer-
rous (iron/steel) metal chips..
1. Remove brush cover band.
2. Remove brushes and brush springs.
IMPORTANT
If brushes are left installed, raise all brushes
to locked position.
5. Inspect condition of brushes.

Remove each brush from brush holder and inspect brushes
and commutator for worn condition and uneven wear, arc-
ing, etc.
Turn commutator if necessary. The commutator can usu-
ally be cleaned up with a very light cut, if done each time
the brushes are replaced. Check mica and undercut as nec-
essary. This light cut will true any high bars and insure
proper life of new brushes.
3. Remove pump drive coupling segment from motor shaft Armature Removal
end.
To avoid damage to either armature or permanent magnets,
4. Loosen motor assembly thru-bolts at commutator-end it is recommended that armature be removed only with
cover. motor housing and armature shaft positioned vertically.
5. Remove thru bolts from assembly.
6. Scribe a match mark on cover and housing, then remove
drive end (pump mounting) cover.
Carefully pry on cover to loosen. Tap lightly on pry
bar, if necessary.
7. The drive end bearing may now be inspected.
NOTE 1. Reassemble either commutator-end cover or drive end

cover to armature shaft and stator housing.
Be sure parts have match marks
before disassembly. 2. Support and hold stator housing firmly on end cover (a
second person is suggested).
8. Remove commutator end cover for inspection of com- 3. Pull armature out of assembly in one quick motion.
mutator and commutator end bearing.
Remove and save bearing spring washer from cover bore. NOTE
9. Carefully inspect commutator-end bearing and commu- It is important that pulling motion on the ar-
tator surface for wear, burning, or other damage. mature be continuous.Do not pull part way
out and release,
If pulling motion is not continuous it will
allow magnets to pull armature back into
stator and cause severe damage.
4. Remove end cover from stator housing.
NOTE ]
It may not be necessary to remove Commutator-end cover with brushes in “locked”
armature, unless other inspection position.
and tests show requirement for
repair or servicing of stator
assembly, armature or bearings. See
Motor Inspection
discussion of procedure below. With motor disassembled, go through following checklist
to locate problem:
A. Bearings - Should spin smoothly and easily, have ample
lubrication and be free of corrosion. Replace bearings
if they are worn out, damaged, or have been removed
from armature shaft.
B. Armature. Check for grounds and shorted turns. Check
commutator for worn condition, excessive carbon build-
up in undercuts between bars, and excessive runout.
Refinish commutator surface if pitted or excessively
worn.
C. Stator. Check magnets to be sure they are securely

mounted.
Motor Assembly
D. Inspect wire harness and all connections on brush 1. Place commutator cover on a work bench with brush
assembly for signs of damage due to overheating. assembly facing upward.
E. Brushes. Remove any carbon dust or dirt from brush

ring assembly. Check brushes for wear and that they NOTE
are free in brush holders. If brushes are installed, raise all brushes to
locked position.
Armature and Bearing Repair
1. Check commutator condition for carbon build-up in

undercuts between bars and excessive wear and runout,
prior to reassembly. If necessary, commutator should
be turned and re-undercut.
2. Remove bearings with a standard ball bearing puller.
Use extreme care not to damage armature with bearing 2. Place bearing spring washer into bearing bore in com-
puller. mutator cover.
NOTE
Do not reuse bearings which have been re-
moved from armature shaft.
3. Take a complete armature assembly, with bearings

installed, and insert comutator end bearing into bearing
Typical view of bearing puller shown. bore of cover.
3. Install new bearings on armature shaft. New bear-
ings should be installed by pressing inner race of
bearing into correct position against shoulder on
armature shaft.
Keep armature assembly in a vertical position.
Bearing Lubrication
Replacement bearings are packed with lubricant during
manufacture and require no further lubrication during life
of bearing.
4. Put complete stator assembly over vertical armature, 7. If brushes were not removed (replaced), set brushes
and into position on commutator cover. to final (lowered) position, by moving brush springs
to top of each brush. If brushes were removed, refer to
step 8, below.
KEEP FINGERS
CLEAR OF THIS
SPACE
CAUTION
Care must be exercised at this point. There 8. Install new brushes by reversing removal procedure:
is a strong magnetic attraction between sta- a) Install brush with lead wires positioned as when re-
tor assembly and armature, which tends to moved.
pull stator assembly rapidly downward. It
is important to have a firm grasp on stator b) Install brush assembly into brush holder. Be sure all
assembly and be sure fingers are free from brushes are free in holder.
space between stator assembly and com- c) Connect brush lead assembly.
mutator cover.
d) Install brush spring clip on top of brush.
5. The stator assembly must be placed in a definite rela-
9. Install brush cover.
tionship with commutator cover in order to obtain a
neutral brush setting. 10. Install pump drive coupling segment.
11. Spin shaft by hand to check if it is free.
Be sure motor leads (if attached) are not touching together.
If leads are touching, a generator action will give effect of
friction in motor.
12. Perform the “no load test” described earlier in this
Section under “Troubleshooting Prior to Disassembly.”
There should be match-marks on both items.

6. Assemble drive end cover in correct relationship. Install
mounting thru bolts and tighten alternately to ensure a Jam Nut
good mechanical alignment. Nut
Do not use hammer or excessive force. Flat Washer Lock Washer
Housing
Flat Washer
Terminal Stud
GROUP 17
GROUP 17
ELECTRICAL CONTACTORS
Contactors ....................................................................... Section 1
SM 616, April ’98 Copyrighted Material Electrical Contactors

NOTES:
Electrical Contactors Copyrighted Material SM 616, April ’98

Group 17, Electrical Contactors
Section 1. Contactors Specifications and Overhaul
Specifications Removal and Replacement

Standard Truck: One line contactor, one main pump 1. Disconnect power cables from contactors. Move power
contactor, one power steering pump contactor. cables out of the way.
Pump Control Option: One line contactor and one power 2. Disconnect connecting bus bars from contacts.
steering pump contactor
3. Disconnect wiring from contactor coil terminals.
On-Demand Steering Option: One line contactor and one
main pump contactor 4. Remove mounting bolts and contactor assembly from
truck.
Mounting Fastener Torque: 8-10 N•m (71-88 in-lb).
5. Reverse procedure for installation.
Torque:
8-10 N•m
(71-88 in-lb)
Line Contactor
Power Steering
Pump Motor
Contactor
Main Pump Motor

Contactor
Standard Contactor Panel Installation. See Group 13 for wiring and bus bar arrangement.
SM 616, April ’98 Copyrighted Material

Contactors Specifications and Overhaul • 17-1-1
Overhaul
WARNING
Disconnect battery before working on 4. Remove the parts in rectangle C for inspection pur-
contactor tips. poses. It is not necessary to disassemble the armature
Before attempting to disassemble a assembly.
contactor to install a new contact set, care- 5. While the contactor is disassembled inspect:
fully observe location and orientation of
each part. • Insulators for cracks and other damage. An insu-
lator found to be cracked or broken should be
Inspection: replaced with a new one.
1. Check armature and movable contacts for freedom of • Springs and spring seats for damage. Replace
movement by depressing movable tips with your fin- damaged parts with new ones.
ger. • Cone-shaped surface of the armature and the
2. Check for any restrictions to movement and for return corresponding surface in the base plate for scoring
of parts by action of the spring. or other damage. Check alignment pin at bottom
of cone for breakage. Also check for broken or
3. Inspect contact tips. Look for any worn or eroded missing aluminum washer that seats against ledge
surfaces. Look for evidence of tip welding. Inspect for at top of cone.
evidence of any contaminants on tips (paint, dirt, paper
• Coil and coil terminals for damage. Replace dam-
or cloth material, etc.) which would impair operation.
aged parts with new ones.
• Do not use sandpaper or file tips. Any damage
must be corrected by tip replacement. IMPORTANT
• Tips must be replaced before they wear through to The coil has alignment holes that must prop-
copper base. erly align with pins in the bracket. Inspect
alignment holes to be certain they are round
To remove and replace contact sets: and not “egg” shaped (damaged).
6. Reassemble the contactors reversing the above steps.
NOTE
On line contactor, remove pump lock switch. Torque each assembly bolt slightly and then move
to the next one until all are fully torqued 1.6 to 2.0
N•m (14 to 18 in-lb).
Torque lock nut 1.6 to 2.0 N•m (14 to 18 in-lb).
7. Move contacts with your finger. Be sure movement is
Pump Lock free of binding and that tips are in correct orientation
Switch
and tips contact correct mating parts.
8. On line contactor only, reinstall pump switch. Depress
contacts again and observe to make sure pump switch
1. Remove lock nut.
“clicks” (activates) before contact tips come together.
2. Remove parts shown in rectangle A, noting the position
and location of each part for proper reassembly.
3. Remove the assembly bolts and remove the parts
shown in rectangle B. Note the size, location, and
orientation of the fixed contacts for reassembly.
17-1-2 • Contactors Specifications and Overhaul

Lock Nut
Lock Washer
Washer
Spring Seat
Spring
Movable
Contact Set
Shim C
Guide Assem-
bly Bolt
Insulator
Armature Assembly
B
Fixed
Contact Set
Spring
Support
Retainer
Coil
Base
Typical Contactor

Contactors Specifications and Overhaul • 17-1-3
17-1-4 • Contactors Specifications and Overhaul

GROUP 19
GROUP 19
MOTOR CONTROLS
Specifications and Description ...................................... Section 1
Sequence of Operations .................................................. Section 2
Handset Operation ......................................................... Section 3
Diagnostic Status Codes ................................................. Section 4
Controllers Removal and Replacement ........................ Section 5
NOTE
WIRING AND CABLES INSTALLA-
TIONS for controllers are illustrated in
Group 13.
SM 616, April ’98 Copyrighted Material Motor Controls

GROUP 19
NOTES:
Motor Controls Copyrighted Material SM 616, April ’98

Group 19, Motor Controls
Section 1.
Specifications and Description
Specifications .................................................................................................................................. 2
Drive Motor Control ................................................................................................................. 2
Lift Pump Motor Control .......................................................................................................... 2
Power Steering Pump Motor Control ....................................................................................... 2
General Description of CTS450 Transistor Motor Controllers ................................................ 3

Motor Characteristics ....................................................................................................................... 3
Solid-State Reversing ...................................................................................................................... 3
Flexible System Application ............................................................................................................ 3
More Features with Fewer Components .......................................................................................... 3
CTS450 Controller Features ......................................................................................................... 4

Performance Features....................................................................................................................... 4
Standard Operation ................................................................................................................... 4
Proportional Operation for Dual Motor Vehicles ..................................................................... 4
Creep Speed .............................................................................................................................. 5
Control Acceleration ................................................................................................................. 5
Current Limit ............................................................................................................................ 5
Regenerative Braking to Zero Speed ........................................................................................ 5
Acceleratore Pedal Position Plug Braking ................................................................................ 5
Brake Pedal Regen Braking ...................................................................................................... 5
Field Weakening ....................................................................................................................... 5
Speed Limits ............................................................................................................................. 5
Ramp Start ................................................................................................................................ 6
Anti-Rollback ........................................................................................................................... 6
Steer Pump Contactor Time Delay ........................................................................................... 6
On-Board Coil Drivers & Internal Coil Suppression ............................................................... 6
System Protective Override ............................................................................................................. 6
Static Return to Off (SRO) ....................................................................................................... 6
Accelerator Volts Hold Off ...................................................................................................... 6
Pulse Monitor Trip (PMT) ........................................................................................................ 6
Thermal Protector (TP) ............................................................................................................. 6
Low Voltage ............................................................................................................................. 6
Diagnostics ....................................................................................................................................... 7
Standard Status Codes .............................................................................................................. 7
Stored Status Codes .................................................................................................................. 7
Hourmeter Readings ................................................................................................................. 7
Maintenance Alert and Speed Limit ......................................................................................... 7
Battery Discharge Indication (BDI) .......................................................................................... 7
Internal Resistance Compensation ............................................................................................ 7
Handset ..................................................................................................................................... 7
RS 232 Communication Port .................................................................................................... 7
Circuit Board Coil Driver Modules .......................................................................................... 8
SM 616, April ’98 Motor

Copyrighted Controls Specifications and Description • 19-1-1
Material
Specifications
Drive Motor Control

Type: GE CTS450 transistorized control providing sepa-
rate excitation of motor fields and armature. One for each
drive motor.
Voltage: 36 or 48 volts
Lift Pump Motor Control

Standard type: Contactor only. (TMG)
Optional type: Transistorized. (TMG)
Voltage: 36/48 volts (TMG)
Voltage: Sevcon pump control 48 volts,
Transistorized (EPG 15-18)
Power Steering Pump Motor Control

Standard Type: Contactor only (See Group 17.)
Optional Type: On-demand transistorized control, 36/48
volt.
19-1-2 • Motor Controls Specifications and Description

Copyrighted Material SM
SM616,
616,Dec ➀
’02’98
April
General Description of CTS450

Transistor Motor Controllers
GE CTS450 transistorized controllers regulate the truck’s
shunt wound drive motors. These controllers separately
excite the motor’s armatures and fields. The following
explains this concept and its benefits.
Motor Characteristics
Series motors produce very high levels of torque at low
speeds. Shunt wound motors provide high efficiency. The
separately excited motor, by independently controlling the
field and armature current, combines the best attributes of By energizing the transistors in pairs, current can be made
both the series and the shunt wound motors. to flow in either direction in the field. The field and
In a shunt motor, the field is connected directly across the armature control circuits typically operate at 12KHz to
voltage source and is therefore independent of variations l5KHz, a frequency range normally above human hearing.
in load and armature current. If field strength is held This high frequency and the removal of directional
constant, the torque developed will vary directly with the contactors provide very quiet vehicle operation.
armature current. If the mechanical load on the motor The line contactor is normally the only contactor required
increases, the motor slows down, reducing the back EMF for the shunt motor traction circuit. This contactor is used
(which depends on the speed, as well as the constant field for both pre-charge of the line capacitors and for emer-
strength). The reduced back EMF allows the armature gency shut down of the motor circuit in case of problems
current to increase, providing the greater torque needed to that would cause a full motor torque condition.
drive the increased mechanical load. If the mechanical
load is decreased, the process reverses. The motor speed
and the back EMF increase, while the armature current and Flexible System Application
the torque developed decrease. Thus, whenever the load Because the shunt motor controller has the ability of
changes, the speed changes also, until the motor is again in controlling both the armature and field circuits indepen-
electrical balance. dently, the system can normally be adjusted for maximum
In the separately excited motor, the motor is operated as a system efficiencies at certain operating parameters. There
fixed field shunt motor in the normal running range. How- are exceptions to every rule, but generally speaking, with
ever, when additional torque is required, for example, to the ability of independent field and armature control, the
climb non-level terrain, such as ramps, the field current is motor performance curve can be maximized by proper
increased to provide the higher level of torque. control application.
Solid-State Reversing More Features with Fewer Components

The direction of armature rotation on a shunt motor is Field weakening with a series wound motor is accom-
determined by the direction in which current flows through plished by placing a resistor in parallel with the field
the field windings. Because of the relatively low current winding of the motor. Bypassing some of the current
requirements of the shunt motor field, only typically about flowing in the field into the resistor causes the field cur-
10% that of the armature current at full torque, it is nor- rent to be less, or weakened. With the field weakened, the
mally cost-effective to replace the double-pole, double- motor speed will increase, giving the effect of "over-
throw reversing contactor with a low power transistor drive". To change the “overdrive speed” it is necessary to
H-Bridge circuit. change the resistor value. Given that control capability of
the shunt field in the separately excited motor is available,
such control capability can be used to vary the strength of
the field current, allowing for an infinite number of "over-
drive" speeds from motor base speed to maximum weak
field. This circuit convention eliminates another contactor
and resistor that would have been with the series motor.

Material
Overhauling speed limit, or downhill speed, will also be Handset or a trimpot. The % ON time has a range of
more constant. By its nature, the shunt motor will try to approximately 0 to 100 percent. The CTS450 controllers
maintain a constant speed downhill. This phenomenon can operate at a constant frequency and the percent on time is
be enhanced by increasing the field strength with the con- controlled by the pulse width of the voltage/current applied
trol. Overhauling load control works in just the opposite to the motor circuits.
way of field weakening. Armature rotation slows as the
current in the field is increased. An extension of this feature
Proportional Operation for Dual Motor Vehicles
is a zero-speed detect feature that prevents the vehicle from
free-wheeling down an incline. If the driver forgets to set A key performance advantage of this control is the ability
the brake, a slow roll speed could be selected to prevent to achieve actual “proportioning” of motor speed. In a non-
high speed roll on a steep grade. proportioning, or single control system, when the vehicle
starts to turn, the outside drive wheel turns in a larger circle
Regenerative braking (braking energy returned to the bat-
than the inside wheel. Depending on the geometry of the
tery) may be accomplished completely with solid state. The
vehicle, at some degree of turn angle, the inside wheel must
main advantage of regenerative braking is increased motor
slow down to prevent scrubbing of the wheel. This is
life. The current in the motor is reduced by 50% or better
accomplished on single control system by disconnecting
during braking while maintaining the same braking torque
the inside motor and letting the wheel "free wheel” or
as electrical braking using a diode clamp around the arma-
“float” at whatever speed is dictated by the outside wheel
ture. The lower current translates into longer brush life and
that is still under power. The main disadvantage to this
reduced motor heating. Again, to accomplish the same
system is that no torque is available on that motor when the
regenerative braking in a series motor system, additional
inside wheel is in the “free-wheel” mode, and performance
components, namely a power diode, current sensor, and
in a turn is reduced. When the steer wheel nears the 90° turn
contactor would be required.
angle, the inside motor is re-connected in the opposite
direction of the outside. At this point, torque is returned to
CTS450 Controller Features the inside wheel and the speed is the same on both motors.
The following defines the features of the controller in With two controls, the speed of each motor can be regu-
regard to perfromance, protection override, and diagnotics. lated independently. The driver controls the speed of the
outside wheel with the accelerator input signal. The inside
wheel speed is controlled by the turn angle of the steer
Performance Features wheel. A potentiometer is attached to the steer wheel in
order to communicate the steer angle to the controllers.
During vehicle manufacture, software selection identifies
Standard Operation
each control for its application as a right or left control. The
The oscillator section of the card has two adjustable fea- controls are physically identical, and it is only software that
tures. With the accelerator at maximum volts, the creep separates a right from a left control or differentiates a
speed can be adjusted by Function 2 of the Handset. The control for a dual motor application from one intended for a
field control feature allows the adjustment of the field single motor vehicle. As the steer reaches some preselected
weakening level in order to set the top speed of the motor. turn angle, approximately 20°, the inside wheel will start to
This top speed function (Minimum Field Current) is en- slow down proportionally to the speed of the outside wheel.
abled when the armature current is less than the value set by This proportional decline will continue on a linear path
function 24 and the accelerator input voltage is less than l until the steer angle reaches another predetermined angle
volt. Top Speed can be adjusted by Function 7 of the of, approximately 65°.
100% 100%
RIGHT MOTOR LEFT MOTOR
Rev • SPEED • Forward
Rev • SPEED • Forward
50% 50%
90˚ 90˚
80˚ 70˚ 60˚ 50˚ 40˚ 30˚ 20˚ 10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚ 60˚ 70˚ 80˚
50% RIGHT LEFT 50%

STEERING ANGLE
TURN TURN
100% 100%
19-1-4 • Motor Controls Specifications and Copyrighted

Description Material SM 616, April ’98
At this point, the wheel will stop, as the steer angle is on-time. Once both of the above conditions have been met,
increased toward the 90° point, the inside wheel will change and regen current limit can no longer be maintained, the
to the opposite direction and start to accelerate proportion- braking function is canceled. The fields will then reverse,
ally in speed. As the steer angle reaches the 90° point the and the control reverts back to motoring. Part of the energy
inside wheel speed will be the same as the outside wheel produced by the motor during regen is returned to the
speed. During this entire turn except for several degrees battery, and part is dumped in the motor as heat.
when the motor was stopped to change direction, torque
was always present on the inside wheel, providing a
smoother ride throughout the turning radius of the vehicle. Acceleratore Pedal Position Plug Braking
Details for adjustment the steer angle potentiometer can be This feature allows control of the Regen distance based on
found in Group 13. accelarator pedal position when there has been a direc-
tional switch change. Pedal position will reduce the plug-
ging current to the value set by this function as the
Creep Speed accelerator is returned to the creep speed position. Maxi-
With the accelerator at maximum volts ( approximately 3.7 mum Regen current is obtained with the accelerator in the
to 3.5 VDC ), the creep speed can be adjusted by Function 2 top speed position. This feature is adjustable by using
of the Handset. At creep speed, the ON time can decrease to Function 16 on the Handset.
approximately 5%, with the OFF time approximately 95%.
At full transistor operation, this condition will be reversed Brake Pedal Regen Braking
(short OFF time, long ON time). This variation of ON and
OFF time of the oscillator varies the voltage applied to the This feature sets or varies the amount of Regen current
motor thereby varying the speed of the motor for a given with Auto-Regen braking feature. The current is set through
load. the use of a switch on the brake pedal to provide Auto-
Regen braking This feature is adjusted through Function
21 on the Handset.
Control Acceleration
This feature allows for adjustment of the rate of time it Field Weakening
takes for the control to accelerate to 100% applied battery
voltage to the motor on hard acceleration. This function allows the adjustment of the field weakening
level in order to set the top speed of the motor. The
function is enabled when the armature current is less than
Current Limit the value set by Function 24 and the accelerator input
This circuit monitors motor current by utilizing sensors in voltage is less than 1 volt. It is important to note that the
series with the armature and field windings. The informa- function is used to optimize motor and control perfor-
tion detected across the sensor is fed back to the card so mance and this setting will be determined by GE and Clark
current may be limited to a pre set value. If heavy load engineers at the time of vehicle development. This setting
currents are detected, this circuit overrides the oscillator must not be changed by field personnel without the per-
and limits the average current to a value set by Function 4 mission of Clark.
and Function 8 of the Handset. The C/L setting is based on
the maximum thermal rating of the control. See current Speed Limits
limit curves for available current and adjustment range.
This feature provides a means to control speed by limiting
motor volts utilizing three adjustable speed limits initiated
Regenerative Braking to Zero Speed by individual limit switches. The NC switches are con-
Slow down is accomplished when reversing direction by nected between input points on the control card and bat-
providing a small amount of retarding torque for decelera- tery negative. The lower motor volt limit always takes
tion. If the vehicle is moving and the directional lever is priority when more than one switch input is open. This
moved from one direction to the other, the regen signal is motor volt limit regulates top speed of the transistor con-
initiated. Once the regen signal has been initiated, the field troller, but actual truck speed will vary at any set point
current is increased. Armature current is regulated to the depending on the loading of the vehicle. Each speed limit
regen current limit as set by Function 9. As the vehicle can be adjustable with the Handset using Functions 11, 12,
slows down, the field current continues to increase, and and 13, for speed limits SL1, SL2, and SL3 respectively.
transistor Q2 begins to chop. The field current will increase SLI is active in all card types and must be disabled with the
until it reaches a preset value set by function 10, and Handset if speed limits are not used.
transistor Q2 on-time will increase until it reaches 100%

Material
Ramp Start
This feature provides maximum control torque to restart a Accelerator Volts Hold Off
vehicle on an incline. The memory for this function is the
directional switch. When stopping on an incline, the direc- This feature checks the voltage level at the accelerator
tional switch must be left in its original or neutral position input whenever the key switch or parking brake switch is
to allow the control to initiate full power when restarted. activated. If the voltage is less than 3.0 volts, the control
The accelerator input will modulate ramp start current. will not start. This feature assures that the control is calling
for low speed operation at start up.
Anti-Rollback
Pulse Monitor Trip (PMT)
This feature provides retarding torque to limit rollback
speed in the non-travel direction when the accelerator The PMT design contains three features which shut down
pedal is released when stopping on a grade or when the or lock out control operation if a fault conditions occurs
brake pedal is released when starting on a grade. This that would cause a disruption of normal vehicle operation:
feature forces the vehicle to roll very slowly down ramp • Look ahead
when accelerator or brake is release. Because the vehicle • Look again
can gain a lot of speed during roll-back, the torque needed
• Automatic look again and reset.
to re-start on the ramp is lower than an unrestricted roll-
back speed. The PMT circuit will not allow the control to start under
the following conditions:
Steer Pump Contactor Time Delay • The control monitors both armature and field transis-
tors at start-up and during running.
This feature provides two options for SP time delay. Op-
tion l provides a 0.5 to 63 second time delayed drop out of • The control will not allow the line contactor to close
the steer pump contactor when the Forward or Reverse at start-up, or will drop it out during running, if either
directional switch is opened This Option 1 is overridden armature or field transistors are defective so as to
by a 1.5 second time delayed drop out whenever the park- cause uncontrolled truck movement.
ing brake switch is opened.
Thermal Protector (TP)
On-Board Coil Drivers & Internal Coil Suppression This temperature sensitive device is internal to the power
Coil drivers for the LINE and SP contactors are on-board transistor (Ql) module. If the transistor’s temperature be-
the control card. These contactors must have coils rated gins to exceed the design limits, the thermal protector will
for the vehicle battery volts. lower the maximum current limit, and maintain the transis-
tors within their temperature limits. As the control cools,
the thermal protector will automatically reset, returning the
System Protective Override control to fun power.
Static Return to Off (SRO) Low Voltage

This inherent feature of the control is designed to require Batteries under load, particularly if undersized or more
drivers to return the directional lever to the neutral posi- than 80 percent discharged, will produce low voltages at
tion anytime they leave the vehicle and return. If the the control terminals. The CTS450 control is designed for
parking brake switch or key switch is opened, the control use down to 50 percent of a nominal battery voltage of
shuts off and cannot be restarted until the directional lever 36-84 volts. Lower battery voltage may cause the control to
is returned to neutral. A time delay of approximately 2 operate improperly. However, the resulting PMT should
seconds is built in to allow momentary opening of the open the Line contactor in the event of a failure.
parking brake switch if a bump is encountered.

Diagnostics Battery Discharge Indication (BDI)

The control detects the system’s present operating status Provides accurate battery state of charge information and
and can be displayed to either the Dash Display or the passive and active warning signals to the vehicle operator.
Handset. There are currently over 65 status codes that are Features and functions:
available with CTS450 systems using Traction and Pump
• Displays 100 to 0 percent charge.
controls.
• Display blinks with 20% charge. Disables pump cir-
cuit with 10% charge.
Standard Status Codes
The CTS450 control has over 65 Status Codes that assist Internal Resistance Compensation
the service technician and operator in trouble shooting the
vehicle. If mis-operation of the vehicle occurs, a status This feature is used when the Battery Discharge Indicator
code will be displayed on the Dash Display for vehicles so is present. Adjustment of this function will improve the
equipped, or by plugging the Handset into the logic card’s accuracy of the BDI.
“Y plug” location and then reading the status code.
With the status code number, follow the procedures out- Handset
lined in Section 4, “Diagnostic Statues Codes,” Section to This is a multi-functional tool used with the LX ZX and
determine the problem and a solution. CTS450 Series GE solid state controls. The Handset (Clark
Note: The Status Code Instruction Sheets do not cover all part #915374) consists of a Light Emitting Diode (LED)
possible causes of a display of a Status code. They do display and a keyboard for data entry. The handset cord
provide instructions for checking the most direct inputs that (Clark part #1804205) is also needed.
can cause status codes to appear. Features and functions:
• Monitor existing system status codes for both trac-
Stored Status Codes tion and pump controls. Monitor intermittent random
This feature records the last 16 stored status codes of each status codes.
control that have caused a PMT controller shut down and/ • Monitor battery state of charge, if available.
or disrupted normal vehicle operation. (PMT type faults are • Monitor hourmeter reading on traction and pump
reset by cycling the key switch). These status codes, along controls. Monitor or adjust the control functions.
with the corresponding BDI and hourmeter readings can be
accessed with the Handset.
RS 232 Communication Port
Hourmeter Readings This serial communication port can be used with Clark
Command Dash Displays to allow changes to vehicle oper-
This feature will display the recorded hours of use of the ating parameters by the operator.
traction and pump control to the Dash Display each time
the key switch is turned off.
Clark Command Dash Display Option
Maintenance Alert and Speed Limit The Clark Command Dash Display Option allows the op-
erator to select the best vehicle performance for changing
This feature is used to display Status Code 99 and/or acti- factory (task) conditions. There are four “operator interac-
vate a speed limit when the vehicle operating hours match tion modes” that can be selected by depressing a push
the hours set into the maintenance alert register. This fea- button on the dash display.
ture is set with the Handset using Functions 19, 20, and 21.
The operator is alerted that maintenance on the vehicle is From the Dash Display, the operator may select any of four
required. pre-set interactive modes consisting of four Controlled
Acceleration levels, four Field Weakening levels and four
Speed Limits. These interactive modes are pre-set using
the Handset (Functions 48-62). This feature allows the
operator to select the best vehicle performance for chang-
ing factory (task) conditions.

Material
Circuit Board Coil Driver Modules

Coil drivers are internal to the control card, and are the
power devices that operate the Line and SP contactor coils.
On command from the control card, these drivers initiate
opening and closing of the contactor coils. All driver mod-
ules are equipped with reverse battery protection, so that if
the battery is connected incorrectly, the contactors cannot
be closed electrically.

Section 2.
Sequence of Operations
Sequence #1: Normal Off State ..................................................................................................... 2
Sequence #2: Connecting the Battery .......................................................................................... 4
Sequence #3a: Closing the Key Switch ........................................................................................ 6
Sequence #3b: Closing The Key Switch ....................................................................................... 8
Sequence #4: Park Brake & Static Return to Off (SRO) Checks ............................................ 10
Sequence #5: Selecting a Direction & Energizing the PS Contactor....................................... 12
Sequence #6: Turning on the Traction Controls ....................................................................... 14
Sequence #7: Brake Pedal Regen ............................................................................................... 16
Sequence #8a: Regenerative Braking (Plugging) ...................................................................... 18
Sequence #8b: Regenerative Braking (Plugging) ...................................................................... 20
Sequence #9: Steer Potentiometer Operation ............................................................................ 22
SM 616, April ’98 Copyrighted Material Sequence of Operations • 19-2-1

Sequence #1: Normal Off State
This standard TMG schematic is shown with all switches and contactors in their normal OFF position. No
circuits are operating. The four basic areas of the circuitry are identified.
POWER This area includes the contactor tips, motor cables, buss bars, motors and traction
controls.
DIRECTIONAL This area includes the forward and reverse switches, 1MS switch, foot brake & park
brake switches.
SPEED This area includes the accelerator, steer angle potentiometer and its input into the
controls.
ACCESSORY This area includes the horn, horn switch, hydraulic switches dash display, pump
driver and key switch.
19-2-2 • Sequence of Operations Copyrighted Material SM 616, April ’98

BATTERY
30 30
2
L PUMP LOCK SWITCH
32 32
2 PS PS POWER STEER MOTOR
2FU P PUMP MOTOR

FU2 POS 500 A
1FU
500
15
CTS-450 CTS-450
POWER
Master Slave
12 A1 LA1 RA1 A1
S1 LS2 POS POS RS1 S1
A FIELD FIELD
A
2 32 30
S2 LS1 RS2 S2
NEG NEG PD
12 A2 LA2 RA2 A2
3
KEY 1
SWITCH LEFT DRIVE MOTOR RIGHT DRIVE MOTOR 2
NEG
2 2 2
50
MASTER
2 2 LP1 LP10 50
12
13
10 10 LP2 ACCELERATOR
LP7
SPEED 2
13
10 L 24 LP17
29
10
PS 60 LP18
STEER ANGLE
FWD
6 LP4 LP9 21 13 13
PARK
BRAKE REV DIRECTIONAL SWITCH
SWITCH
8 LP5 29 SLAVE 2
RP7 30
10 RP1
7 31 31 LP14
LP12 19 19 RP12
LP21 49 RP10
38 15 LP3 LP15 23 RP16

1MS
FOOT LP16 27 LP15
ACCELERATOR
BRAKE
6 8 15 LY5 LY12 LP6 7 7 RP6
7 SWITCH
12
31 DIRECTIONAL 15 15 RP3
13
7 7
8 8 RP5
6 6 RP4
31 31 31 RP14
10 10 10 RP2 RY12
81 80 30
7 82
10
15 12 5 82
7 6
10 20 23 13 13
DASH DISPLAY
10 FILTER 28
LIFT
10
10 TILT
28
28 28 30
ACCESSORY 30
12
AUX 1
10 28 P 13
10 AUX2 28 HORN
12 25 13
HORN SWITCH
Sequence #1. Normal Off State

A. Releasing the park brake lever closes the Park Brake Switch supplying battery positive volts to:
Sequence #2: Connecting the Battery
A. Battery positive is applied:

- to the Line Contactor.
- thru wire #2
to LP1 and RP1 of the Traction Controls.
thru the Fuse (FU3) to the Key Switch and to the Horn Button.
B. Battery negative is applied:

- to the “NEG” connections of each traction controls.
- thru wire #13
to terminal #3 of the Pump Driver (PD).
to the Accelerator Control.
to the Steer Angle Potentiometer.
to wire #23 of the Dash Display.
to the negative terminal of the Horn.
The internal capacitors of each Traction Control are charged in about 2 seconds.
NOTE
A Status Code “51” displays if the internal capacitors of each Traction Control do not charge to above
85% battery volts. It is normal for a Status Code “51” to be intermittently displayed for about 2
seconds during the charging time, when the battery is initially plugged in.
C. The Horn is operated by pushing on the Horn Button which supplies battery voltage from wire #12 through
the Horn Button contacts, through wire #25 to the positive terminal of the horn.
Voltages Present:
A. Battery Positive Volts
B. Battery Negative Volts
C. Battery Positive Volts on wire #25 and the Horn positive terminal

BATTERY
A
2
L PUMP LOCK SWITCH
30
32
30
32
A 3FU POS
2FU
500 P A PUMP MOTOR
1FU
500
15
CTS-450 CTS-450
Master Slave
12 A1 LA1 RA1 A1
A FIELD FIELD A
2 32 30
S2 LS1 RS2 S2
NEG B NEG PD
12 A2 LA2 RA2 A2
3
KEY
SWITCH
1 B
LEFT DRIVE MOTOR RIGHT DRIVE MOTOR 2
NEG
2 2 2
50
A A MASTER
2 2 LP1 LP10 50
12
13
2
B
10
L LP17
LP7 29 13
24
PS 60 LP18
10
STEER ANGLE
FWD B
6 LP4 LP9 21 13 13
PARK
SWITCH
8 LP5 29 SLAVE 2
RP7 30
10 RP1
7 31 31 LP14
LP12 19 RP12
19
RP10
A
LP21 49
38 15 LP3 LP15 23 RP16
1MS
FOOT LP16 27 RP15
ACCELERATOR
BRAKE LP6 7 7 RP6
6 8 15 LY5 LY12
7 SWITCH
12
31 13
15 15 RP3
7 7
8 8 RP5
6 6 RP4
31 31 31 RP14
10 10 10 RP2 RY12
81 80 30
7 82
10
15 12 5 82
7 6
10 20
DASH DISPLAY B 23 13 13
FILTER
10 28
10 LIFT 28
TILT
12 10 28 28 30 30
10 AUX 1 28 P 13
10
AUX2
28 A C HORN B
12 25 13
HORN SWITCH
Sequence #2. Connecting the Battery

Sequence #3a: Closing the Key Switch
A. Closing the Key Switch supplies battery volts through wire #10 to:
-LP2 and RP2 of the traction controls.
-the Line Contactor Coil positive terminal.
-Power Steer (PS) Coil positive terminal.
-the Park Brake (PB) switch common terminal.
-Dash Display terminal #20.
-all hydraulic control valve switches.
The battery volt input at the Dash Display terminal #20 signals the Display “Self Test,” all indicator lamps
turn ON for approximately 2 seconds, and the Seat Belt Warning Buzzer & Indicator Lamp turn ON for 8
to 10 seconds.
NOTE
Status Code “15” or “16” displays if the battery voltage is less than or greater than the battery voltage
setting pre-programmed in Function 15.
B. The Traction Controls send data signals through wires #80,81 & 82 to the Dash Display to turn “ON” all
the segments of the digital readout. If all segments are operating correctly the display should read “8888”
for about 2 seconds.
C. The Traction Controls senses the lack of battery volts at terminals LP6 & RP6 indicating that the Park
Brake switch is open (park brake set). The control signals the dash to display a “-01” indicating to the
operator that the Park Brake is set. The Traction Controls will not operate until the Park Brake is released
(park brake switch open) to prevent damage to the motors or brakes.
NOTE
The Wrench Symbol turns “ON” anytime a status code is displays.
D. The Dash Display also senses the lack of battery volts at terminal #6 indicating that the Park Brake is set
(park brake switch open). The Dash Display turns “ON” the Park Brake indicator lamp. (CONTINUED
ON PAGE 9).
NOTE
If the trucks hourmeter reading exceeds the pre-programmed reminder hours (Functions 19 & 20) the
controls signal the dash to turn “ON” the Maintenance Reminder indicator lamp and display a -99
status code for 4 seconds. The Traction Controls are disabled while the -99 status code is being
displayed.
Voltages Present
A. Battery Positive Volts
B. N/A
C. 0 Volts
D. 0 Volts

BATTERY
30 30
L PUMP LOCK SWITCH
32 32
2
2FU P PUMP MOTOR

3FU POS 500 A
1FU
15 500
CTS-450 CTS-450
Master Slave
12 A1 LA1 RA1 A1
A FIELD FIELD
A
2 32 30
S2 LS1 RS2 S2
NEG NEG PD
12 A2 LA2 RA2 A2
3
KEY 1
NEG
A 2 2 2
50
MASTER
2 2 LP1 LP10 50
12
13
ACCELERATOR
10 10 LP2 A 2
10
L LP17
LP7 29 13
24
PS
A 10 60 LP18
STEER ANGLE
FWD
6 LP4 LP9 21 13 13
PARK
SWITCH
8 LP5 29 SLAVE 2
RP7 30
10 RP1
7 31 31 LP14
LP12 19 19 RP12
LP21 49 RP10
38 15 LP3 LP15 23 RP16
1MS RP15
FOOT LP16 27
ACCELERATOR
BRAKE LP6 7 7 RP6
7 SWITCH 6 8 15 LY5 LY12
12
31
C 13
15 15 RP3
7 7
8 8 RP5
6 6 RP4
31 31 31 RP14
10 10 10 RP2 RY12
7 D
81 80
B A 82
30
10
15 12 5 82
7 6
10 20 A DASH DISPLAY 23 13 13
10 FILTER 28
LIFT
10 28
10 TILT 28 30 30
A
12
AUX 1
28
10 28 P 13
AUX2
10 28 HORN
12 25 13
HORN SWITCH
Sequence #3a. Closing the Key Switch

Sequence #3b: Closing The Key Switch
E. If the internal capacitors of both controls are charged, the Master control completes the circuit thru wire
#24 at terminal LP17 to negative. This energizes the Line Contactor Coil and closes the Line Contactor
Power Tips.
F. The closure of the Line Contactor Power Tips supply both Traction Controls with battery positive to
operate the Traction Motors.
G. The closing of the Line Contactor Tips releases (opens) the pump interlock switch. This switch ensures
that a hydraulic function will not operate until the Line Contactor is closed.
H. The Traction Controls monitors the battery condition. If, the controls determine the battery has sufficient
charge, the Master Control supplies a voltage thru wire #50 to terminal #1 of the Pump Driver turning the
driver “ON” providing battery negative on terminal #3 to wire #32.
J. The closure of the pump interlock switch supplies battery negative from Pump Driver terminal #3 thru
wire #32 to wire #30 to the Pump Contactor Coil negative terminal.
NOTE
Status code -50 displays if the capacitor voltage of each control does not remain above 85% battery
volts after the Line Contactor closes.
Voltages Present:
E. Approximately 10 to 13 volts across the Line Contactor Coil
F. Battery Volts across the Positive & Negative terminals of each Traction Control
G. N/A
H. 1.75 to 6 volts on wire #50
J. Battery Negative Volts on wire #30 & #32

BATTERY
L PUMP LOCK SWITCH

30 30
2 32 32
G
2 F PS PS POWER STEER MOTOR
2FU P PUMP MOTOR

FU2 POS 500 A A
1 1FU
500 A
5
A
CTS-450 CTS-450
Master Slave
12 A1 LA1 RA1 A1
A FIELD F FIELD
A
2 32 30
S2 LS1 RS2 S2 J
NEG NEG PD
12 A2 LA2 RA2 A2
3
KEY 1
H NEG
2 2 2
50
MASTER H
2 2 LP1 LP10 50
12
13
2
L
E LP7 29 13
10 24 LP17
10
PS 60 LP18
STEER ANGLE
FWD
6 LP4 LP9 21 13 13
PARK
SWITCH
8 LP5 29 SLAVE 2
RP7 30
10 RP1
7 31 31 LP14
LP12 19 19 RP12
LP21 49 RP10
38 15 LP3
LP15 23 RP16
1MS
FOOT ACCELERATOR LP16 RP15
27
BRAKE
6 8 15 LY5 LY12 LP6 7 7 RP6
12 7 SWITCH
31 13
15 15 RP3
7 7
8 8 RP5
6 6 RP4
31 31 31 RP14
10 10 10 RP2 RY12
81 80 30
7 82
10
15 12 5 82
7 6
10 20 23 13 13
DASH DISPLAY
10 FILTER 28
LIFT
10 28 J
10 TILT 28 30 30
12 28
10
AUX 1
28 (-)
HORN SWITCH P 13
10 AUX2 28 HORN
12 25 13
Sequence #3b. Closing the Key Switch.

Sequence #4: Park Brake & Static Return to Off (SRO) Checks
A. Releasing the park brake lever closes the Park Brake Switch supplying battery positive volts to:
-the Forward & Reverse Directional switch common terminals.
-to the Foot Brake switch thru wire #38 to the 1MS switch.
-to the Traction Controls terminals LP6 & RP6.
-to the Dash Display terminal #6. (the Park Brake Indicator Lamp now turn OFF)
B. Battery positive volts are supplied through wire #7 to the dash display on terminal 6. The park brake
indicator now turns off.
C. Battery positive volts are also supplied to terminals LP6 & RP6 of the CTS-40 Master and Slave controls.
The -01 status code on the display is now replaced with the battery state of charge display or some other
status code.
D. Battery positive volts are also supplied to the common terminals of the F & R directional switches and to
the 1MS switch through the normally closed contacts of the brake pedal switch through wire #38.
E. The controls will not allow the truck to start until the following SRO checks are satisfied:
1) Terminals LP6 & RP6 of the CTS-450 Master and Slave controls must be at battery positive voltage.
(Status code -01 if at 0 volts)
2) Checks for open F & R switch inputs, terminals LP4, RP4, LP5 and RP5 must be 0 volts for at least 1
second after voltage is applied to terminals LP6 & RP6. (Status code -02 or -03)
3) Checks for open 1MS switch input, terminals LP3 & RP3 must be 0 volts for at least 1 second after
voltage is applied to terminals LP6 & RP6.
4) Checks the accelerator input voltage at terminals LP7 & RP7. Must be greater than 2.5 volts. (Status
code -06).
NOTE
The CTS-450 controls repeat the SRO checks anytime the park brake switch is opened for more than 2
seconds.
F. If all the above SRO checks are satisfied, the CTS-450 controls send a signal to the dash display to show
the battery state of charge.
NOTE
The battery state of charge is displayed as a 3 digit number changing as the battery is discharged. The
battery symbol indicator is on in this mode.
Voltages Present:
A. Battery positive volts
B. Battery positive volts
C. Battery positive volts
D. Battery positive volts
E. See explanation 1 through 4 above
F. Data signals, cannot be measured.

BATTERY
30 30
2
L PUMP LOCK SWITCH
32 32
PS PS POWER STEER MOTOR

2
2FU P PUMP MOTOR
3FU POS 500 A
1FU
500
15
CTS-450 CTS-450
Master Slave
12 A1 LA1 RA1 A1
A FIELD FIELD
A
2 32 30
S2 LS1 RS2 S2
NEG NEG PD
12 A2 LA2 RA2 A2
3
KEY 1
NEG
2 2 2
50
MASTER
2 2 LP1 LP10 50
12
13
2
L LP7 29 13
10 24 LP17
E
10
PS 60 LP18
STEER ANGLE
A FWD
6 LP4 LP9 21 13 13
PARK
SWITCH
LP5 29 SLAVE 2
8
E
10
D RP7 RP1
30
7 31 31 LP14
LP12 19 19 RP12
38 LP21 49 RP10
15 LP3
LP15 23 RP16
1MS
FOOT ACCELERATOR RP15
LP16 27
BRAKE
7 SWITCH 6 8 15 LY5 LY12 LP6 7 7 RP6
12
31 C C 13
15 15 RP3
7 7
8 RP5
E
8
6 6 RP4
31 31 31 RP14
10 10 10 RP2 RY12
81 80 30
7 82
10
B 15 12 F 5 82
7 6
10 20 23 13 13
DASH DISPLAY
10 FILTER 28
LIFT
10 28
10 TILT 28 30 30
12 28
AUX 1
10 28 P 13
10 AUX2 28 HORN
12 25 13
HORN SWITCH
Sequence #4. Park Brake & Static Return to Off (SRO) Checks

Sequence #5: Selecting a Direction & Energizing the PS Contactor
A. Moving the directional lever to forward closes the forward switch. The forward switch supplies battery
positive volts, through wire #6 to terminals LP4 & RP4.
NOTE
The CTS-450 Master & Slave controls now make a series of start up checks to ensure proper operation.
If a fault is detected the appropriate status code displays and the Traction Controls are disabled.
B. When the Traction Controls senses battery positive at terminals LP6 ,RP6, LP4, RP4 and 0 volts at LP5 &
RP5, it completes the circuit from the power steer coil to negative through wire #60 at terminal LP18 of the
Master control.
NOTE
If battery voltage is applied to both the F & R control inputs LP4, LP5 & RP4, RP5 at the same time, the
controls are shut OFF. This indicates that both the F & R directional switches have been closed (Status
code -09).
C. This energizes the power steer contactor coil and in turn, close the normally open contactor tips.
D. The power steer motor now operates because current flows from battery positive through the steer motor
and to battery negative. (Note: Permanent Magnet Motor)
NOTE
The traction controls now begin to accumulate the running hours of the truck because the power steer
motor is now running. The traction controls record the running time in Seconds, Minutes and Hours
but the time is displayed only in full 1 hour increments.
Voltages Present:
A. Battery positive
B. 10 to 13 volts across the PS contactor coil
C. Battery positive
D. Battery volts across the PS motor

BATTERY
30 30
2
L PUMP LOCK SWITCH
32 32
PS
C
2 PS POWER STEER MOTOR
2FU P PUMP MOTOR

3FU POS 500 A
1FU
D
15 500
CTS-450 CTS-450
Master Slave
12 A1 LA1 RA1 A1
A FIELD FIELD
A
2 32 30
S2 LS1 RS2 S2
NEG NEG PD
12 A2 LA2 RA2 A2
3
KEY 1
NEG
2 2 2
50
MASTER
2 2 LP1 LP10 50
12
13
2
L LP7 29 13
10 24 LP17
A PS
10 60 LP18 B STEER ANGLE
FWD
PARK
6 LP4 A LP9 21 13 13

SWITCH
8 LP5 29 SLAVE 2
RP7 30
10 RP1
7 31 31 LP14
LP12 19 19 RP12
LP21 49 RP10
38 15 LP3
LP15 23 RP16
1MS
27
BRAKE
6 8 15 LY5 LY12 LP6 7 7 RP6
12 7 SWITCH
31 13
15 15 RP3
7 7
8 8 RP5
6 6 RP4 A
31 31 31 RP14
10 10 10 RP2 RY12
81 80 30
7 82
10
15 12 5 82
7 6
10 20 23 13 13
DASH DISPLAY
10 FILTER 28
LIFT
10 28
10 TILT 28 30 30
12 28
AUX 1 HORN
10 28 P 13
10 AUX2 28
12 25 13
HORN SWITCH
Sequence #5. Selecting a Direction & Energizing The PS Contactor

Sequence #6: Turning on the Traction Controls
A. Depressing the accelerator pedal slightly closes the 1MS switch and supplies battery positive voltage
through the #15 wires to terminals LP3 and RP3
B. When the traction controls senses battery positive at terminals LP3, RP3, and LP4, RP4, and 0 volts at
terminals LP5, RP5 the control starts pulsing the forward field transistors and the armature transistors.
NOTE
The field transistors of this control do the job of directional contactors as well as supplying power to the
drive motor fields. A separate set of transistors supplies power to the armature.
C. By pressing the pedal further a signal from the accelerator is sent through the #29 wires to terminals LP7 &
RP7 of the traction controls and starts an internal time delay which controls the oscillator.
D. The traction controls pulse the field and armature transistors. Current now flows from the battery, through
the line contactor, 1FU fuse, Master & Slave POS terminals, through the armature and field transistors of
each control, out through the controls NEG terminals to battery negative.
- The interaction of magnetic energy between the motor fields and armature causes the armature to rotate.
- As the accelerator is pressed further down the signal voltage supplied to the controls changes from
approximately 3.5 volts at creep to 0.2 volts at full speed.
- The control pulses the transistors at a constant 2200 pulses per second but increases the ON time of each
pulse to increase motor speed.
- The CTS-450 Traction Controls regulates the armature current to field current separately to maintain the
desired speed at all times regardless of the load weight or floor grade.
Voltages Present:
A. Battery positive volts
B. See explanation above
C. Less than 3.5 volts at terminals LP7 & RP7
D. See explanation above

BATTERY
D
30 30
2
L PUMP LOCK SWITCH
32 32
2FU P PUMP MOTOR

3FU POS 500 A
1FU
500
15
D
CTS-450 CTS-450
Master Slave
12 A1 LA1 RA1 A1
A FIELD D D FIELD
A
2 32 30
S2 LS1 RS2 S2
NEG NEG PD
12 A2 LA2 RA2 A2
3
KEY 1
NEG
2 2 2
50
MASTER
2 2 LP1 LP10 50
12
13
10 10 LP2 C ACCELERATOR
2
L LP7 29 13
10 24 LP17
10
PS 60 LP18
STEER ANGLE
FWD
6 LP4 LP9 21 13 13
PARK
B
SWITCH
8 LP5 29 SLAVE 2
10
C RP7 RP1
30
7 31 31 LP14
LP12 19 19 RP12
A A LP21 49 RP10
38 15 LP3
LP15 23 RP16
1MS
27
BRAKE
6 8 15 LY5 LY12 LP6 7 7 RP6
12 7 SWITCH
31 13
15 15 RP3 A
7 7
8 8 RP5
6 6 RP4
B
31 31 31 RP14
10 10 10 RP2 RY12
81 80 30
7 82
10
15 12 5 82
7 6
10 20 23 13 13
DASH DISPLAY
10 FILTER 28
LIFT
10 28
10 TILT 28 30 30
12 28
AUX 1
10 28 P 13
10 AUX2 28 HORN
12 25 13
HORN SWITCH
Sequence #6. Turning on the Traction Controls

Sequence #7: Brake Pedal Regen
A. The operator depresses the foot brake pedal when slowing or stopping is required. This releases the foot brake switch
lever disconnecting wire #7 from wire #38 and connecting the wire #7 to wire #31. Wire #31 now supplies battery
positive voltage to terminals LP14 & RP14 of the traction controls. The truck is now in the brake regen mode.
B. In the brake regen mode, the armature transistor connecting A2 to battery negative is turned OFF. The motor field
transistors continue to pulse to increase current flow.
C. The truck continues to travel due to inertia. The armature becomes a generator because it is rotating against a
strengthened motor field. This generated current from the armature to battery provides retarding torque to slow the
truck.
D. As the armature slows the generated current reduces below the preset Brake Regen C/L value set in Function 21 of
the controls. The regen transistors are then pulse and motor field current is increased up to its preset value to
maintain the desired brake regen current limit. This provides the necessary retarding torque to slow the truck to a
smooth, controlled stop.
E. The controls are locked in the brake regen mode until the controls sense that there is no generated regen current,
indicating that the truck has stopped, or the brake pedal is released removing the positive voltage from wire #31.

BATTERY
D
30 30
2
L PUMP LOCK SWITCH
32 32
2FU P PUMP MOTOR

3FU POS 500 A
15
1FU
500 C
CTS-450 CTS-450
Master Slave
12 A1 LA1 RA1 A1
A FIELD
C
FIELD
A
2 32 30
S2 LS1 RS2 S2
NEG NEG PD
12 A2 LA2 RA2 A2
3
KEY
B 1
SWITCH LEFT DRIVE MOTOR B RIGHT DRIVE MOTOR 2
NEG
2 2 2
50
MASTER
2 2 LP1 LP10 50
12
13
2
L LP7 29 13
10 24 LP17
10
PS 60 LP18
STEER ANGLE
FWD
6 LP4 LP9 21 13 13
PARK
SWITCH
8 LP5 29 SLAVE 2
A RP7 RP1
30
10 31 31 LP14
7
LP12 19 19 RP12
LP21 49 RP10
38 15 LP3
LP15 23 RP16
1MS
27
BRAKE
6 8 15 LY5 LY12 LP6 7 7 RP6
12 7 SWITCH
31
A 13
15 15 RP3
7 7
8 8 RP5
6 6 RP4
31 31 31 RP14
A
10 10 10 RP2 RY12
81 80 30
7 82
10
15 12 5 82
7 6
10 20 23 13 13
DASH DISPLAY
10 FILTER 28
LIFT
10 28
10 TILT 28 30 30
12 28
AUX 1
10 28 P 13
10 AUX2 28 HORN
12 25 13
HORN SWITCH
Sequence #7. Brake Pedal Regen

Sequence #8a: Regenerative Braking (Plugging)
Regenerative braking (using the reverse power of the drive motors as a brake) is attained when changing direc-
tion from forward to reverse (or reverse to forward).
A. The directional lever is moved from forward, opening the forward switch.
B. While the lever is in the neutral position, both directional switches are open.
C. The controls stop functioning because the positive voltage has been removed from terminals LP4 &RP4 of
the traction controls.
NOTE
The truck is coasting forward

BATTERY
30 30
2
L PUMP LOCK SWITCH
32 32
2FU P PUMP MOTOR

3FU POS 500 A
1FU
500
15
CTS-450 CTS-450
Master Slave
12 A1 LA1 RA1 A1
A FIELD FIELD
A
2 32 30
S2 LS1 RS2 S2
NEG NEG PD
12 A2 LA2 RA2 A2
3
KEY 1
NEG
2 2 2
50
MASTER
2 2 LP1 LP10 50
12
13
2
L LP7 29 13
10 24 LP17
10
PS 60 LP18
C
STEER ANGLE
FWD A
6 LP4 LP9 21 13 13
PARK
SWITCH
8 LP5 29 SLAVE 2
RP7 30
10 RP1
7 31 31 LP14
LP12 19 19 RP12
B LP21 49 RP10
38 15 LP3
LP15 23 RP16
1MS
LP16 27
BRAKE
SWITCH 6 8 15 LY5 LY12 LP6 7 7 RP6
12 7
31
RP3
C 13
15 15
7 7
8 8 RP5
6 6 RP4
31 31 31 RP14
10 10 10 RP2 RY12
81 80 30
7 82
10
15 12 5 82
7 6
10 20 23 13 13
DASH DISPLAY
10 FILTER 28
LIFT
10 28
10 TILT 28 30 30
12 28
AUX 1
10 28 P 13
10 AUX2 28 HORN
12 25 13
HORN SWITCH
Sequence #8a. Regenerative Braking (Plugging)

Sequence #8b: Regenerative Braking (Plugging)
D. The operator moves the directional lever through neutral to reverse, closing the reverse directional
switch.
E. With the reverse switch close, positive voltage is applied through the #8 wires to terminals LP5 & RP5 of
the traction controls. The controls sense that the truck has been moving and that the lever has been
moved through neutral. This initiates the Regen signal. The truck is now in the regen mode.
F. In the regen mode, the armature transistor connecting A2 to battery negative is turned OFF. The motor
field transistors continue to pulse to increase current flow in the original forward direction.
G. The truck continues to travel in the forward direction due to inertia. The armature becomes a generator
because its rotating against a strengthened motor field. This generated current from the armature to battery
provides retarding torque to slow the truck.
H. As the armature slows the generated current reduces below the preset Regen C/L value set in Function 9 of
the controls. The regen transistors are then pulsed and motor field current is increased up to its preset value
to maintain the desired regen current limit. This provides the necessary retarding torque to slow the truck to
a smooth, controlled stop.
J. When regen current can no longer be maintained above the preset value, the regen mode is canceled. The
motor fields are now switched to the reverse direction. The truck now accelerates normally in the reverse
direction.

G G
BATTERY
30 30
2
Line PUMP LOCK SWITCH
32 32
2FU P PUMP MOTOR

FU2 POS 500 A A
1
5
1FU
500 A G G
A G
CTS-450 CTS-450
Master Slave
12 A1 LA1 RA1 A1
A FIELD
G
FIELD
A
2 32 30
S2 LS1 RS2 S2
NEG NEG PD
12 A2 LA2 RA2 A2
3
KEY
SWITCH
F F 1
LEFT DRIVE MOTOR RIGHT DRIVE MOTOR 2
NEG
2 2 2
50
MASTER
2 2 LP1 LP10 50
12
13
2
L LP7 29 13
10 24 LP17
10
PS 60 LP18
STEER ANGLE
FWD
6 LP4 LP9 21 13 13
PARK
SWITCH
8 LP5 E 29 SLAVE 2
RP7 30
10 RP1
7 31 31 LP14
LP12 19 19 RP12
D LP21 49 RP10
38 15 LP3
LP15 23 RP16
1MS
LP16 27
BRAKE
12 7
31 13
15 15 RP3
7 7
8 8 RP5 E
6 6 RP4
31 31 31 RP14
10 10 10 RP2 RY12
81 80 30
7 82
10
15 12 5 82
7 6
10 20 23 13 13
DASH DISPLAY
10 FILTER 28
LIFT
10 28
10 TILT 28 30 30
12 28
AUX 1
10 28 HORN SWITCH P 13
10 AUX2 28 HORN
12 25 13
Sequence #8b. Regenerative Braking (Plugging)

Sequence #9: Steer Potentiometer Operation
The TMG truck is equipped with a steer potentiometer mounted on the steer trunnion. As the truck turns the
potentiometer also turns signaling the traction controls to reduce the speed of the inside drive wheel. The inside
motor slows down proportional to how tight the turn is. In a full tight turn, the inside drive wheel reverses,
providing maximum control and traction of the drive wheels.
A. The master control provides a voltage signal from LP9, through wire #21 to the steer potentiometer.
B. As the steer potentiometer is turned it sends a varying voltage signal through the #19 wires to terminals
LP12 & RP12 of the traction controls.
Voltages Present:
A. Approx. 4.3 volts at wire #21
B. As measured on the#19 wires when the steer wheel is:

centered = 2.15 volts
full left turn = 0.72 volts or less
full right turn =3.53 volts or higher

BATTERY
30 30
2
Line PUMP LOCK SWITCH
32 32
2FU P PUMP MOTOR

FU2 POS 500 A A
1 1FU
500 A
5
A
CTS-450 CTS-450
Master Slave
12 A1 LA1 RA1 A1
FIELD
A FIELD
A
2 32 30
S2 LS1 RS2 S2
NEG NEG PD
12 A2 LA2 RA2 A2
3
KEY 1
NEG
2 2 2
50
MASTER
2 2 LP1 LP10 50
12
13
2
L LP7 29 13
10 24 LP17
10
PS 60 LP18
STEER ANGLE
FWD 21
6 LP4 A LP9 13 13
PARK
SWITCH
8 LP5 29 SLAVE 2
30
10 B RP7 RP1
7 31 31 LP14
LP12 19 19 RP12 B
LP21 49 RP10
38 15 LP3
LP15 23 RP16
1MS
LP15 27
BRAKE
12 7
31 13
15 15 RP3
7 7
8 8 RP5
6 6 RP4
31 31 31 RP14
10 10 10 RP2 RY12
81 80 30
7 82
10
15 12 5 82
7 6
10 20 23 13 13
DASH DISPLAY
10 FILTER 28
LIFT
10 28
10 TILT 28 30 30
12 28
AUX 1
10 28 HORN SWITCH P 13
10 AUX2 28 HORN
12 25 13
Sequence #9. Steer Potentiometer Operation


Section 3.
Handset Operation
Purpose of Handset ........................................................................................................................ 2
Connection and Start-Up .............................................................................................................. 2
Function Setting Procedures ......................................................................................................... 3
Status Code Scrolling Procedure .................................................................................................. 4
TMG248 Traction Controller Function Settings ........................................................................ 5
TMG248 Pump Controller Function Settings ............................................................................. 6
Function Descriptions .................................................................................................................... 7
FUNCTION 1 UNUSED FUNCTION ......................................................................................... 7
FUNCTION 2 CREEP SPEED ..................................................................................................... 7
FUNCTION 3 CONTROLLED ACCELERATION ..................................................................... 7
FUNCTION 4 CURRENT LIMIT (ARMATURE) ...................................................................... 7
FUNCTION 5 PLUGGING CURRENT LIMIT ........................................................................... 7
FUNCTION 6 UNUSED FUNCTION ......................................................................................... 7
FUNCTION 7 MINIMUM FIELD CURRENT ............................................................................ 7
FUNCTION 8 MAXIMUM FIELD CURRENT .......................................................................... 8
FUNCTION 9 REGEN CURRENT LIMIT .................................................................................. 8
FUNCTION 10 MINIMUM FIELD CURRENT FOR REGEN ..................................................... 8
FUNCTION 11 SPEED LIMIT 1 –FULL STEER ......................................................................... 8
FUNCTION 12 SPEED LIMIT 2 – MAXIMUM SPEED LIMIT .................................................. 8
FUNCTION 13 SPEED LIMIT 3 –SPEED LIMIT ........................................................................ 9
FUNCTION 14 INTERNAL RESISTANCE COMPENSATION ................................................. 9
FUNCTION 15 BATTERY VOLTS ............................................................................................. 10
FUNCTION 16 ACCELERATOR PEDAL POSITION REGEN ................................................ 10
FUNCTION 17 CONTROL TYPE SELECTION ........................................................................ 10
FUNCTION 18 STEER PUMP TIME DELAY ........................................................................... 11
FUNCTION 19 MAINTENANCE CODE HOURS (TENS / UNITS) ......................................... 11
FUNCTION 20 MAINTENANCE CODE HOURS (Thou/Hund) ............................................... 11
FUNCTION 21 BRAKE PEDAL REGEN CURRENT LIMIT ................................................... 11
FUNCTION 22 PERFORMANCE MODE ................................................................................... 11
FUNCTION 23 ERROR COMPENSATION ............................................................................... 11
FUNCTION 24 FIELD WEAKENING START .......................................................................... 12
FUNCTION 25 MONITOR .......................................................................................................... 12
FUNCTION 26 ARMATURE/FIELD RATIO ............................................................................. 12
FUNCTION 27 UNUSED FUNCTION ....................................................................................... 12
FUNCTION 28 STORED STATUS CODE LAST FAULT FLAG ............................................. 12
FUNCTION 29 HOUR METER (Tens / Units) ............................................................................ 12
FUNCTION 30 HOUR METER (Thou/Hund) ............................................................................. 12
FUNCTION 48 MODE 1 CONTROLLED ACCELERATION ................................................... 13
FUNCTION 49 MODE 1 REGEN CURRENT LIMIT ................................................................ 13
FUNCTION 50 MODE 1 BRAKE PEDAL REGEN CURRENT LIMIT .................................... 13
FUNCTION 51 MODE 1 MAXIMUM SPEED LIMIT ............................................................... 13
SM 616, April ’98 Copyrighted Material Handset Operation • 19-3-1

Purpose of Handset Connection and Start-Up

The Handset consists of a light emitting diode (LED)
display and a keyboard for data entry. WARNING
Before connecting or disconnecting the
The purpose of the Handset is to allow authorized Handset tool, turn off the key switch, un-
personnel to perform the following functions: plug the battery and jack up the drive
• Monitor existing system fault codes wheels of the vehicle.
• Monitor intermittent random fault codes Capacitors should be discharged by dis-
• Monitor battery state of charge on systems with connecting the battery, turning the key
BDI switch on, and sounding the horn until the
sound dies away.
• Monitor hourmeter reading
At the transistor control traction card, unplug the “Y
• Monitor or adjust the following control functions:
plug” if the dash display is in use, and plug in the
- Creep speed Handset to the plug location “Y” on the control card.
- Armature Controlled Acceleration After installing the Handset tool, plug the battery in
- Regenerative Braking Current Limit and turn the key switch on.
- Armature and Field Current Limit
- Plugging Distance (Current)
- Pedal Position Plug Range or Disable
- Speed Limit Points
- Truck Management Fault Speed Limit
- Internal Resistance Compensation for Battery
State of Charge Indication
- Selection of Control Type.
Handset
Y Plug
Motor Controller
19-3-2 • Handset Operation Copyrighted Material SM 616, April ’98

The following is the start-up display sequence that will

occur:
Function Setting Procedures
With the Handset connected, hold down the CONT
key and turn on the key switch. This will place you in
the set up mode, ready to monitor or adjust control
function settings.
NOTE
The term “push” means to depress key for
approximately one second.
Setup Mode
A
t
this point, another function can be monitored/changed

by pushing another function number, or the vehicle
can be placed in the run mode by holding the ESC key
down for one second or longer. The display will return
to either the diagnostics mode, the BDI display, or a
blank display (if BDI is not used and there are no fault
NOTE
codes). The vehicle can now be operated with the
The vehicle can be operated with the Hand- Handset connected or the Handset can be disconnected
set connected, however, the adjustment before operation.
knob must be set fully clockwise to insure
the control operates at top speed.
NOTE
WARNING You can return to the segment check mode
Before making any adjustments to the con- at any time: With parking brake set, hold
trol, you must consult the operating and down the ESC key until 8888 appears in
maintenance instructions supplied by the the display.
vehicle manufacturer. Failure to follow
proper set up instructions could result in
mis-operation or damage to the control
system.

Status Code Scrolling Procedure

A register contains the last 16 stored status codes that
shut down vehicle operation (that is, Pulse Monitor
Trip faults that can be reset by cycling the key switch)
and the battery state of charge and hour meter
reading at the time the fault occurred. The oldest of
the 16 status codes is overwritten each time a new
status code occurs.

TMG248 Traction Controller Function Settings

FUNCTION BUTTON MASTER SLAVE D ESCRIPTION
CODE FACTORY FACTORY
SETTING SETTING
W ITH K EY SWITCH O N AND PARKING BRAKE SWITCH O PEN (P ARKING B RAKE A PPLIED)
2 2 045-055 045-055 Creep
3 3 008-012 008-012 C/A
4 4 255 Current Limit
5 5 106-110 106-110 Plugging (Fine Plug Adjustment)
6 6 N/A N/A N/A
7 7 086 086 Minimum Field Current (TMG12/13 & 15s only)
080 080 Minimum Field Current (TMG15 & 18/20 only)
095 095 Minimum Field Current (TMG20x/25 only)
8 8 255 255 Maximum Field Current

9 9 170-174 170-174 Regen Armature C/L (Coarse Plug Adjustment)
10 10 159-161 159-161 Minimum Field Current-Regen
11 11 095-105 095-105 Speed Limit- Full Steer
12 12 000 000 Maximum Speed Limit
13 13 000 000 Speed Limit (Maintenance, Anti-Stall, Options)
14 14 024 024 IR Comp
15 15 037-039 037-039 Battery Voltage
16 CONT/1 039-043 039-043 Pedal Position Plug
17 CONT/2 057 121 Card Type
18 CONT/3 133-137 133-137 Steer Time Delay
19 CONT/4 255 255 Maintenance Hours 50 Hours (001=1 hour)
20 CONT/5 255 255 Maintenance Hours 200 Hours( 001=100 hours)
21 CONT/6 055-065 055-065 Brake Pedal Regen
22 CONT/7 000 000 Performance Mode
23 CONT/8 032 032 Regen Cancel
24 CONT/9 056 056 Field Weakening Start
25 CONT/10 000 000 Monitor
26 CONT/11 014 014 Field Amps / Armature Amps Ratio
27 CONT/12 000 000 Hourmeter Minutes
28 CONT/13 000 000 Last Fault Flag
29 CONT/14 000 000 Hour Meter - Tens/Units
30 CONT/15 000 000 Hour Meter - Thou/Hund
W ITH K EY SWITCH O N AND PARKING BRAKE SWITCH C LOSED (P ARKING BRAKE REEASED)
48 CONT/1 014-018 014-018 Mode 1 - CA
49 CONT/2 146-150 146-150 Mode 1 -Regen Current Limit
50 CONT/3 070-080 070-080 Mode 1 - Brake Pedal Regen
51 CONT/4 000 000 Mode 1 - Maximum Speed Limit
52 CONT/5 011-015 011-015 Mode 2 - CA
53 CONT/6 152-156 152-156 Mode 2 - Regen Current Limit
56 CONT/9 008-012 008-012 Mode 3 - CA
60 CONT/13 008-012 008-012 Mode 4 - CA
63 CONT/ESC 000 000 Mode 4 - Maximum Speed Limit
NOTE
Functions highlighted in bold can be adjusted outside these parameters to suit customersÕ needs.

TMG248 Pump Controller Function Settings

FUNCTION BUTTON PUMP D ESCRIPTION
CODE FACTORY
SETTING
W ITH K EY SWITCH O N
2 2 074-076 IR Compensation Start
3 3 024-026 C/A
4 4 250-255 Current Limit
5 5 N/A N/A
6 6 N/A N/A
7 7 150-200 IR Compensation Rate
8 8 N/A N/A
9 9 N/A N/A
10 1
10 N/A N/A
11 11 075-077 *Aux 2 Speed - Basic Setting (see below)
12 12 061-063 *Aux 1 Speed - Basic Setting (see below)
13 13 061-063 *Tilt Speed - Basic Setting (see below)
14 14 255 Lift Speed (set at maximum)
15 15 000 Battery Voltage
16 CONT/1 009-011 Speed Torque Compensation
17 CONT/2 058 Card Type
18 CONT/3 N/A N/A
19 CONT/4 N/A N/A
20 CONT/5 N/A N/A
21 CONT/6 N/A N/A
22 CONT/7 184 Performance Mode
23 CONT/8 N/A N/A
24 CONT/9 N/A N/A
25 CONT/10 N/A N/A
26 CONT/11 N/A N/A
27 CONT/12 N/A N/A
28 CONT/13 000 Last Fault Flag
29 CONT/14 000 Hour Meter - Tens/Units
30 CONT/15 000 Hour Meter - Thou/Hund
W ITH K EY SWITCH O FF
48 CONT/1 072-076 Mode 1 - CA
49 CONT/2 040-042 Mode 1 -Aux 1 Speed
50 CONT/3 105-115 Mode 1 - Lift Speed
51 CONT/4 N/A N/A
52 CONT/5 060-064 Mode 2 - CA
53 CONT/6 047-049 Mode 2 - Aux 1 Speed
55 CONT/7 N/A N/A
56 CONT/9 048-052 Mode 3 - CA
59 CONT/12 N/A N/A
60 CONT/13 024-026 Mode 4 - CA
NOTE
Functions highlighted in bold can be adjusted outside these parameters to suit customersÕ needs.
* Hydraulic speeds are set at the above basic settings unless specified differently at time of order.
Set the speed setting for the GPM desired as described;
1.5 GPM = 057-059, 2.5 GPM = 061-063, 4.0 GPM = 068-070,
5.5 GPM = 075-077, 7.0 GPM = 081-083, 10.0+ GPM = 250-255

Function Descriptions FUNCTION 5 PLUGGING CURRENT LIMIT

(Push 5)
FUNCTION 1 UNUSED FUNCTION Allows the adjustment of the plugging distance of the
truck. The larger the current setting the shorter the
(Push 1) stopping distance.
This function is not used on this control. NOTE
Because these controls are equipped with
FUNCTION 2 CREEP SPEED Regen braking that will slow the truck al-
most to a stop, this plugging current limit
(Push 2)
setting has a minimal effect on the overall
Allows the adjustment of the creep speed of the truck. stopping distance of the truck.
Creep speed can be adjusted when the accelerator- Range: 55 to 455 amps
input voltage is between 3.9 and 3.3 volts.
Setting: 0 to 255
Resolution: 1.56 amps per set unit
Range: 2% to 15% ON-Time
Example: A setting of 20 = 86.2 amps
Setting: 0 to 255
Resolution: 0.05% per set unit
FUNCTION 6 UNUSED FUNCTION
Example: A setting of 20 = 3% ON-Time
(Push 6)
This function is not used on this
FUNCTION 3 CONTROLLED ACCELERA- control.
TION
(Push 3)
FUNCTION 7 MINIMUM FIELD CURRENT
Allows for the adjustment of the rate of time it takes (Push 7)
for the controls to accelerate to 100% applied battery
voltage to the motors on hard acceleration. Allows for the adjustment of the field weakening level
in order to set the top speed of the motors.
Range: 0.1 to 22.0 seconds NOTE
Setting: 0 to 255 This function is used to optimize the motor
and control performance and this setting
Resolution: 0.084 seconds per set unit
has been determined by Clark Engineer-
Example: Setting of 20 = 1.78 seconds CA ing. This setting must not be changed from
the published factory settings.
FUNCTION 4 CURRENT LIMIT (ARMA-
TURE)
(Push 4)
Allows for the adjustment of the armature current
limit of the controls.
NOTE
This function is used to optimize the motor
ing. This setting must not be changed from

FUNCTION 8 MAXIMUM FIELD CURRENT FUNCTION 11 SPEED LIMIT 1 –FULL STEER

(Push 8) (Push 11)
Allows for the adjustment of the maximum field Allows for the adjustment of the speed limit (maxi-
current in order to obtain the maximum torque of the mum battery volts to motor) when the steer angle
motors. potentiometer signals the controls that the steer wheel
has been rotated to an angle of 66°. The steer angle
NOTE potentiometer will signal the controls to reduce the
This function is used to optimize the motor maximum speed of the outside motor in proportion to
and control performance and this setting the steer wheel angle between 16° and 66°.
ing. This setting must not be changed from NOTE
the published factory settings. This function is used to optimize the motor
FUNCTION 9 REGEN CURRENT LIMIT ing. This setting must not be changed from
(Push 9) the published factory settings.
Allows for the adjustment of the Regen braking

current limit. The higher the current the shorter the FUNCTION 12 SPEED LIMIT 2 – MAXIMUM
stopping distance. SPEED LIMIT
Range: 52 to 468 amps (Push 12)
Setting: 0 to 255 Allows for the adjustment of the maximum speed limit
Resolution: 1.63 amps per set unit (maximum battery volts to motor) during normal run
Example: A setting of 20 = 84.6 amps mode. Clark currently sets this function to 0 (no speed
limit) however, this function can be set to limit the top
speed of the truck to the customer’s desires.
FUNCTION 10 MINIMUM FIELD CURRENT Range: 100% to 0% applied batt volts
FOR REGEN
Setting: 51 to 180
(Push 10)
000 for no speed limit
Allows for the adjustment of the minimum field Resolution: 0.78% per set unit
current to be used during the Regen braking mode.
NOTE Example: A setting of 71 = 84.4% battery volts
(71 – 51 = 20, 20 x 0.78 = 15.6,
has been determined by Clark Engineer- 100 - 15.6 = 84.4%)

FUNCTION 13 SPEED LIMIT 3 –SPEED • The truck should be tested when the dash display
LIMIT has a reading between 80 and 20, a fully charged
or discharged battery will not allow an accurate
(Maintenance, Anti-Stall, and
test to be performed.
Options)
• Drive the truck in top speed for at least 2 minutes
(Push 13) across a flat floor, at the end of the drive note and
Allows for the adjustment of the maximum speed limit record the reading on the trucks dash display.
(maximum battery volts to motor) during one of the This reading is known as the “Dash Display
following conditions: Reading”.
• Maintenance - the hour meter has exceeded the • After allowing the truck to set for about 5
preset hours if function 19 and 20. This indicates minutes measure the voltage between the “POS”
that the truck is due for scheduled PM service. and “NEG” terminals on the SCR panel. Divide
The –99 Status Code is displayed. the voltage read by the number of cells in the
trucks battery (36 volt battery has 18 cells), this is
• Anti-Stall - speed limit is activated if the control known as the “Open Circuit Volts Per Cell”.
receives a signal indicating that the truck is in a
stalled condition. The –28 or –82 Status Code • For the following steps refer to the Chart on the
displays. following page.
• Options - speed limit is activated if the control • Mark the chart with the Dash Display Reading
receives a signal indicating that the brushes in taken from the truck on the bottom line of the
one or more motors are worn to the replacement graph. Draw a vertical line from the Dash
length or the motors have exceeded their maxi- Display Reading mark made straight up to the
mum operating temperature. The –90 through – top of the graph.
95 Status Codes displays. • Mark the chart with the truck’s Open Circuit
Volts Per Cell on the left hand side of graph,
Clark currently sets this function to 0 (no speed limit)
marked Open Circuit Volts Per Cell. Draw a
however, this function can be set to limit the top speed
horizontal line straight across the graph to the
of the truck to the customer’s desires.
right hand side.
Range: 100% to 0% applied batt volts
• Locate and mark the point where the two lines
Setting: 51 to 180 meet, this is the level of IR compensation the
000 for no speed limit truck is programmed for.
Resolution: 0.78% per set unit • If the mark is on or very close to the diagonal
black line called “Ideal Compensation”, no
Example: A setting of 71 = 84.4% battery volts adjustment to the program is necessary.
(71 – 51 = 20, 20 x 0.78 = 15.6, • If the mark is above the Ideal Compensation line,
100 - 15.6 = 84.4%) lower the Function 14 programmed setting by 1
or 2 points.
FUNCTION 14 INTERNAL RESISTANCE • If the mark is below the Ideal Compensation line,
COMPENSATION raise the Function 14 programmed setting by 1 or
2 points.
(Push 14)
• If a program adjustment was made, disconnect the
Calibrates the truck’s electrical system to the battery battery for 30 seconds, then repeat the test to
and/or application so that the BDI and the Lift verify if the proper level of compensation has
interrupt system functions accurately. If Function #14 been attained.
is not set correctly to match the battery or application,
the customer may complain that the truck’s battery is NOTE
either over or under-discharged when the lift interrupt The voltage readings must be taken with a
system locks out the hydraulic controls. quality digital volt meter and the reading
must be read to at least two digits past the
decimal point (example 37.42 volts). Fail-
Refer to the following for instructions on how to tell if ure to make an accurate voltage reading
the IR Compensation is properly set for the type will result in an inaccurate Function 14/IR
battery installed and application. Compensation setting.

Below is an example test where the Dash Display NOTE

Reading was ‘45’ and the voltage reading was 36.54 THE FOLLOWING FUNCTIONS HAVE FUNCTION
volts. The battery has 18 cells, so the Open Circuit NUMBERS LARGER THAN THE NUMBERS ON THE
Volts Per Cell is 2.03 volts. The example graph below HANDSET KEYBOARD. To access these func-
shows that this truck has the proper level of compen- tions, the parking brake must be applied
sation. Ideal Compensation
(parking brake switch open), and push the
(Ideal Setting)
CONT key and the number shown in the
2.14
2.13 following instructions at the same time.
2.12
2.11 Compensation Too Low
2.10 (IR Comp Funtion setting
2.09 too high, lower setting)

FUNCTION 16 ACCELERATOR PEDAL
2.08
2.07
POSITION REGEN
Open
Circuit
2.06
2.05
(Push CONT 1)
Volts 2.04
Per 2.03 Allows the adjustment of the accelerator pedal posi-
2.02
Cell
2.01
tion regen range. The pedal position will reduce the
(Measure 2.00
Compensation Too High
(IR Comp Funtion setting
regen current to the value set by this function as the
1.99 too low, increase setting)
open circuit
voltage at 1.98
accelerator is returned to the creep speed position.
SCR "POS" 1.97 Maximum regen current is obtained with the accelera-
and "NEG" 1.96
terminals 1.95
tor in the top speed position.
and divide
by the
1.94
95 85 75 65 55 45 35 25 15 5
Range: 55 to 455 amps
number of 100 90 80 70 60 50 40 30 20 10 0
battery cells) Setting: 0 to 255
Dash Display Reading
(After at least 2 min running) Resolution: 1.56 amps
Dash Display
at 009,
1.160 S.G.
+/- .005
FUNCTION 17 CONTROL TYPE SELECTION

(Push CONT 2)
FUNCTION 15 BATTERY VOLTS Allows for selecting the type of control being used.
(Push 15) Control Type Set Units
Allows the adjustment of voltage range. In order for Master 057
the BDI to function properly, the settings in the Slave 121
following table must be entered.
NOTE
Battery Volts Set Units This function is used to optimize the motor
36 Volts Between 32 and 44 and control performance and this setting
48 Volts Between 45 and 69 has been determined by Clark Engineer-
NOTE the published factory settings.
The TMG is not a dual voltage truck. The
controls need to be adjusted for the voltage
setting as the truck was built.

FUNCTION 18 STEER PUMP TIME DELAY FUNCTION 21 BRAKE PEDAL REGEN

(Push CONT 3) CURRENT LIMIT
(Push CONT 6)
Allows the adjustment of the time delay for the power
steer contactor to drop out when the directional switch Allows for the adjustment of the Brake Pedal Regen
is returned to neutral. Current Limit. The higher the setting the shorter the
Range: 0.5 to 63 seconds stopping distance when the brake pedal is depressed,
activating the brake switch which supplies the brake
Setting: 129 to 255 pedal regen signal to the controls.
Resolution: 0.5 seconds per unit Range: 0 to 100% of Regen C/L
Example: Setting of 149 = 10.5 seconds Setting: 0 to 255
NOTE Resolution: 0.392% per set unit
Drop out is 1.5 seconds after the park brake Example: A setting of 60 = 23.5% of the set
switch opens.
Regen C/L value as set in Function 9.
FUNCTION 19 MAINTENANCE CODE FUNCTION 22 PERFORMANCE MODE

HOURS (TENS / UNITS)
(Push CONT 7)
(Push CONT 4)
This is a read only function and does not require
Allows the adjustment of the tens and units hours of adjustment. This function displays the current perfor-
the maintenance code activation time. mance mode (turtle — rabbit) that the control is
Range: 0 to 99 currently selected.
Setting: 0 to 99 Range: Turtle to Rabbit Modes
Resolution: 1 hour per set unit Setting: 161 to 164
Example: A setting of 50 = 50 hours Resolution 161 = Turtle to
164 = Rabbit
FUNCTION 20 MAINTENANCE CODE NOTE
HOURS (Thou/Hund) For trucks without Clark Command dash
(Push CONT 5) display, a setting of 161 will automatically
be displayed.
Allows the adjustment of the thousands and hundreds For trucks with the Clark Command dash
of hours of the maintenance code activation time. display option, the setting displayed will
Range: 0 to 99 depend on the level of performance selected
Setting: 0 to 9900 by the operator using the dash display.
Resolution: 100 hours per set unit

Example: A setting of 20 = 2000 hours FUNCTION 23 ERROR COMPENSATION
(Push CONT 8)
NOTE
Hour meter activation setting is the sum of This function is used to reduce the ripple in the field
the settings of Functions 19 and 20. current due to interaction between motor field design
Example: Using the examples above, main- and the digital field current regulation circuit in the
tenance code activation is 2050 hours. control.
NOTE

FUNCTION 24 FIELD WEAKENING START FUNCTION 28 STORED STATUS CODE

(Push CONT 9) LAST FAULT FLAG
(Push CONT 13)
Allows the setting of the armature current at which
minimum field current is achieved. There is no need to use this function. For the last
Range: 0 to 414 amps recorded status code, compare the recorded hour
meter readings in the stored status code register.
Setting: 0 to 255
Resolution 1.65 amps per set unit
FUNCTION 29 HOUR METER (Tens / Units)
(Push CONT 14)
FUNCTION 25 MONITOR Allows the setting of the displayed hour meter reading
for the “ones” and “tens” digits. Use in conjunction
(Push CONT 10) with Function 30 to set the displayed hour meter.
Allows the monitoring of certain control functions by Range: 0 to 99 hours
looking directly at the RAM of the microprocessor. Setting: 0 to 99
Because the absolute memory locations need to be
known, this function should not be used without Resolution: 1 hour per set unit
detailed instructions from a Clark Service Engineer. Example: 23 = 0023 hours
To ensure optimum operation of the control, this
function must be left with 000 stored in this register. FUNCTION 30 HOUR METER (Thou/Hund)
(Push CONT 15)
FUNCTION 26 ARMATURE/FIELD RATIO
Allows the setting of the displayed hour meter reading
(Push CONT 11) for the “hundreds” and “thousands” digits. Use in
Sets the ratio between the armature and the field conjunction with Function 29 to set the displayed hour
current when transitioning from minimum field to meter.
maximum field current. Range: 100 to 9900 hours
NOTE Setting: 0 to 99
This function is used to optimize the motor Resolution: 100 hours per unit
and control performance and this setting Example: 49 = 4900 hours
ing. This setting must not be changed from NOTE
the published factory settings. Hour meter reading is the sum of the set-
tings of Function 29 and 30.
Example: Using the examples above, hour
FUNCTION 27 UNUSED FUNCTION meter reading is 4923 hours.
(Push CONT 12)
NOTE
This function is not used on this control. THE FOLLOWING FUNCTIONS HAVE FUNCTION
NUMBERS LARGER THAN THE NUMBERS ON THE
HANDSET KEYBOARD. To access these func-
tions, the parking brake must be released
(parking brake switch closed), and push
the CONT key and the number shown in
the following instructions at the same time.

NOTE FUNCTION 50 MODE 1 BRAKE PEDAL

CLARK COMMAND DASH DISPLAY INTERACTIVE REGEN CURRENT LIMIT
MODES.
(Push CONT 3)
The following functions (Functions 48
through 63) are mode settings that are acti- This Brake Pedal Regen Current Limit takes affect
vated from the optional Clark Command when the Mode 1 settings are called for by the Clark
dash display. Command dash display.
Allows for the adjustment of the Brake Pedal Regen
Current Limit. The higher the setting the shorter the
FUNCTION 48 MODE 1 CONTROLLED stopping distance when the brake pedal is depressed,
ACCELERATION activating the brake switch which supplies the brake
(Push CONT 1) pedal regen signal to the controls.
This Controlled Acceleration takes affect when the Range: 0 to 100% of Regen C/L
Mode 1 settings are called for by the Clark Command Setting: 0 to 255
dash display.
Resolution: 0.392% per set unit
Allows for the adjustment of the rate of time it takes Example: A setting of 60 = 23.5% of the set
for the controls to accelerate to 100% applied battery
Regen C/L value as set in Function 9.
voltage to the motors on hard acceleration.
Range: 0.1 to 22.0 seconds
FUNCTION 51 MODE 1 MAXIMUM SPEED
Setting: 0 to 255
LIMIT
Resolution: 0.084 seconds per set unit
(Push CONT 4)
Example: Setting of 20 = 1.78 seconds CA
This Maximum Speed Limit takes affect when the
Mode 1 settings are called for by the Clark Command
FUNCTION 49 MODE 1 REGEN CURRENT dash display.
LIMIT Allows for the adjustment of the maximum speed limit
(Push CONT 2) (maximum battery volts to motor) during normal run
mode. Clark currently sets this function to 0 (no speed
This Regen Current Limit takes affect when the Mode
limit) however, this function can be set to limit the top
1 settings are called for by the Clark Command dash
speed of the truck to the customer’s desires.
display.
Range: 100% to 0% applied batt volts
Allows for the adjustment of the Regen braking
current limit. The higher the current the shorter the Setting: 51 to 180
stopping distance. 000 for no speed limit
Range: 52 to 468 amps Resolution: 0.78% per set unit
Setting: 0 to 255 Example: A setting of 71 = 84.4% battery volts
Resolution: 1.63 amps per set unit (71 – 51 = 20, 20 x 0.78 = 15.6,
100 - 15.6 = 84.4%)
FUNCTION 52 MODE 2 CONTROLLED

ACCELERATION
(Push CONT 5)
Same as Function 48.
This Controlled Acceleration takes affect when the
Mode 2 settings are called for by the Clark Command
dash display.

FUNCTION 53 MODE 2 REGEN CURRENT This Brake Pedal Regen Current Limit takes affect
LIMIT when the Mode 3 settings are called for by the Clark
Command dash display.
(Push CONT 6)
Same as Function 49. FUNCTION 59 MODE 3 MAXIMUM SPEED
This Regen Current Limit takes affect when the Mode 2 LIMIT
settings are called for by the Clark Command dash (Push CONT 12)
display.
FUNCTION 54 MODE 2 BRAKE PEDAL This Maximum Speed Limit takes affect when the Mode
REGEN CURRENT LIMIT 3 settings are called for by the Clark Command dash
display.
(Push CONT 7)
Same as Function 50. FUNCTION 60 MODE 4 CONTROLLED
This Brake Pedal Regen Current Limit takes affect ACCELERATION
when the Mode 2 settings are called for by the Clark (Push CONT 13)
FUNCTION 55 MODE 2 MAXIMUM SPEED This Controlled Acceleration takes affect when the Mode
LIMIT 4 settigns are called for by the Clark Command dash
display.
(Push CONT 8)
Same as Function 51 FUNCTION 61 MODE 4 REGEN CURRENT
This Maximum Speed Limit takes affect when the Mode LIMIT
2 settings are called for by the Clark Command dash (Push CONT 14)
display.
FUNCTION 56 MODE 3 CONTROLLED This Regen Current Limit takes affect when the Mode 4
ACCELERATION settings are called for by the Clark Command dash
display.
(Push CONT 9)
Same as Function 48. FUNCTION 62 MODE 4 BRAKE PEDAL
This Controlled Acceleration takes affect when the Mode REGEN CURRENT LIMIT
3 settings are called for by the Clark Command dash (Push CONT 15)
display.
FUNCTION 57 MODE 3 REGEN CURRENT This Brake Pedal Regen Current Limit takes affect
LIMIT when the Mode 4 settings are called for by the Clark
(Push CONT 10)
Same as Function 49. FUNCTION 63 MODE 4 MAXIMUM SPEED
This Regen Current Limit takes affect when the Mode 3 LIMIT
settings are called for by the Clark Command dash (Push CONT & ESC)
display.
FUNCTION 58 MODE 3 BRAKE PEDAL This Maximum Speed Limit takes affect when the Mode
REGEN CURRENT LIMIT 4 settings are called for by the Clark Command dash
display.
(Push CONT 11)

SET TO 12 FOR 72" & 73’’ OHG OPTIONS
SET TO 10 FOR ALL SEAT SWITCH OPTIONS
BOLD TYPE INDICATES SETTINGS WHICH ARE DIFFERENT THAN GE FACTORY PRE-SET SETTINGS.
THESE SETTINGS MUST BE CHANGED AT CLARK.
SM 616, Dec ’02 Copyrighted Material Handset Operation • 19-3-15

19-3-16 • Handset Operation Copyrighted Material SM 616, Dec ’02

SET TO 12 FOR 72" & 73" OHG OPTIONS
SET TO 0 FOR ALL SEAT SWITCH OPTIONS



EPG 15/18, TMG EXCEPT USA

EPG 15/18, TMG EXCEPT USA

Section 4.
Diagnostic Status Codes
Introduction Initial Troubleshooting

Use the instructions outlined in the status code charts to Check resistance on R x 1000 scale from frame to
troubleshoot the CTS450 controller. power and controller terminals. A resistance of less than
20,000 ohms can cause misleading symptoms.
If mis-operation of the vehicle occurs, a status code will
Resistance less than 1000 ohms should be corrected
be displayed on the Dash Display for vehicles equipped
first.
with a Dash Display or by plugging a Handset into the
controller’s Y plug socket and then reading the status Before proceeding, visually check for loose wiring, mix-
code as explained in Section 3. aligned linkage to the accelerator switch, signs of
overheating of components, etc.
With the status code number, follow the procedures
outlined on the chart to determine the problem.
Tools and Test Equipment
NOTE The following are required.
Due to the interaction of the logic
• Clip leads
card (in each controller) with all
vehicle functions, almost any status • Volt-ohm meter (20,000 ohms per volt)
code or controller fault could be • Basic hand tools.
caused by the logic card. After all
other status code procedures have
been followed and no problem i s Status Code Charts
found, the controller should then be The charts begin on the next page and are arranged by
replaced as the last option to status code number.
correct the problem.
Status codes, as they actually display on the handset,
consist of two or three digits with a minus sign or the
CAUTION letter “A” in front of them. There are three general
Before trouble-shooting, jack up arrangements for the characters in the code:
the drive wheels, disconnect the “– ” (minus sign) followed by two digits means
battery and discharge the capacitors. that the code pertains to the master traction
Re-connect the battery as needed for controller.
the specific check.
Capacitors should be discharged b y “A” followed by two digits means that the code
disconnecting the battery, turning pertains to the slave traction controller
the key switch on, and sounding the “– ” (minus sign) followed by three digits means
horn until the sound dies away. that the code pertains to the hydraulic pump
controller.
SM 616, April ’98 Copyrighted Material Diagnostic Status Codes • 19-4-1

TRACTION
STATUS CODE
DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION
Segments do not illuminate on the Dash
NONE Display and/or the Handset.
No input voltage to the control card or the display unit.
MEMORY RECALL
NO CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Display screen on Dash Display and/or
Handset is blank.
Circuits valid POSSIBLE CAUSE

for Positive or negative control voltage is not
present.
Traction • Insure that the key switch is closed and
Controller voltage is present between LP1(wire #2)
of the Master Control & battery negative
(Power Terminal ‘NEG’). Also check for
voltage between LP2(wire #10) of the
Master Control and control negative.
Open circuit between control card Plug Y &
the Dash Display or Handset.
• Check for and open circuit or loose
connection going from the ‘Y’ plug and
the Dash Display or Handset.
Defective Dash Display or Handset.
• Replace Dash Display or Handset.
TRACTION
STATUS CODE
No Park Brake switch input (no voltage to This status code will be displayed when P6 of either controller
-01 LP6 or RP6) is less than 50% battery volts.
MEMORY RECALL
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Circuits valid Mis-adjusted or park brake switch.
for • Check to see that the park brake closes
properly when brake handle is pushed
Traction forward releasing the park brake.
Controller
Open circuit between battery positive and P6
of both controls.
• Check for loose connections or broken
wires :
- Between the park brake switch and P6
- Between the key switch and the battery
positive side of the park brake switch.
- Between the park brake switch and P2.
• On vehicles with the seat operated park
brake option, check seat switch, relay, and
the wiring to both.
19-4-2 • Diagnostic Status Codes Copyrighted Material SM 616, Jul ’01

TRACTION
STATUS CODE
Forwark directional switch is closed on initial This status code will be displayed when LP4 or RP4 is greater
-02 power up. than 60% of battery voltage at initial key switch on.
MEMORY RECALL
SYMPTOM
Control will not operate because of Static
Return to Off(SRO) lock out.
POSSIBLE CAUSE
Circuits valid Forward directional switch is closed on initial
for start up (i.e. closure of battery, key switch or
Traction park brake switch).
Controller • Return directional switch lever to neutral
and then return lever to forward position.
Forward directional switch is welded closed
or misadjusted to be held closed.
• Replace or adjust directional switch to
insure that it opens when the directional
switch is returned to neutral.
Short circuit between P4 (wire #6) and
positive.
Disconnect the wire (#6) from P4 and check
for a short circuit between positive and the
wire #6 that was connected to P4.
Defective control.
• Replace the controller unit.
TRACTION
STATUS CODE
Reverse directional switch is closed on initial This status code will be displayed when LP5/RP5 is greater
-03 power up. than 60% of battery voltage at initial key switch on.
MEMORY RECALL
SYMPTOM
Control will not operate because of Static
Return of Off (SRO) lock out.

for Reverse directional switch is closed on initial
start up (i.e. closure of battery, key switch or
Traction park brake switch).
Controller • Return directional switch lever to neutral
and then return lever to reverse position.
Reverse directional switch is welded closed
or mis-adjusted to be held closed.
• Replace or adjust directional switch to
insure that it opens when the directional
switch is returned to neutral.
Short circuit between P5 (wire #8) and
positive. Disconnect the wire (#8) from P4
and check for a short circuit between positive
and the wire #8 that was connected to P4.
Defective control. Replace the controller unit.
SM 616, Jul ’01 Copyrighted Material Diagnostic Status Codes • 19-4-3

TRACTION
STATUS CODE
This status code will be displayed when LP7/RP7 is less than
-05 1MS switch or brake switch fails to close. 2.5 volts and LP#/RP#P3 is less than 60% of battery volts.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid Defective brake switch circuit.
for • Check brake switch to insure closure with
brake pedal released.
Traction
Controller • Check for open circuit or loose connections
in wiring from park brake switch to brake
switch and from brake switch to 1MS
switch.
Defective 1MS switch circuit.
• Check 1MS switch to insure closure when
accelerator is depressed.
• Check for open circuit or loose connections
in wiring from brake switch to 1MS switch
and from P3 to 1MS switch.
Defective 1MS switch. Refer to the wire diagrams located under the seat
• Check 1MS switch replace accelerator deck for proper wire numbers and connection
assembly is defective. points.
TRACTION
STATUS CODE
This status code will be displayed when LP4/RP4 and P5 are
Accelerator depressed with no direction
-06 selected.
less than 60% of battery volts, and P7 is less than 2.5 volts
(accelerator volts at Wire #29).
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid Accelerator pedal is depressed before closing
for forward or reverse directional switch.
• Status code will disappear when directional
Traction switch is closed or when accelerator pedal
Controller is released.
Defective directional switch
• Check forward or reverse switch to insure
closure when direction is selected.
Open circuit between directional switch(es)
and battery positive or between directional
switch(es) and P4 or P5.
• Check all control wires and connections,
refer to wiring diagram under the seat deck.

TRACTION
STATUS CODE
This status code will be displayed when the accelerator input
Accelerator input voltage too high on power
-07 up after initial key switch closure.
voltage at LP7/RP7 is higher than 3.7 volts, and a directional
contactor is picked up.
MEMORY RECALL
SYMPTOM
Control will not operate when accelerator
pedal is depressed or status code -07 is
displayed then disappears when the vehicle
starts to accelerate.
Circuits valid
for POSSIBLE CAUSE
Traction Accelerator input mis-adjusted or defective.
Controller • Input voltage at P7 should be less than 3.7
volts. Adjust or replace accelerator unit to
insure that the voltage or replace accelerator
unit to insure that the voltage at P7 will
vary from 3.5 volts to less than .5 volts
when the pedal is depressed.
Open circuit between battery negative and pin
1 of accelerator plug SO/PL2.
Check for broken wires or loose connections
at SO/PL2 of the accelerator.
Short circuit from battery positive to wiring
in accelerator input circuit. Refer to the wire diagrams located under the seat
• Disconnect wire from P7 and measure deck for proper wire numbers and connection
voltage at wire to negative. Should be less points.
than 3.7 volts.
TRACTION
STATUS CODE
This status code will be displayed when the accelerator
Accelerator input voltage too high on power up
input voltage at LP7/RP7 is less than 3.0 volts, and any of
-08 after initial key switch closure.
the following connections are opened and closed : battery
plug or key switch.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid Accelerator input mis-adjusted or defective.
• Input voltage at P7 should be more than 3.0
for volts. Adjust or replace accelerator unit to insure
Traction that the voltage at P7 is more than 3.0 volts
Controller before depressing pedal.
Short circuit between battery negative and TB1 in
accelerator input circuit.
• Disconnect wire #29 from P7 of both controls.
Check for short circuit from wire to battery
negative.
• Defective Accelerator
Check for battery volts between Wire #38 & #13 at
the accelerator, if correct replace accelerator.
Defective Card Refer to the wire diagrams located under the seat
• Disconnect wire from P7. Measure voltage from deck for proper wire numbers and connection
TB1 to negative. Voltage should be greater than points.
4.5 volts, if not, replace control.

TRACTION
STATUS CODE
Both the forward and reverse directional This status code will be displayed when LP4/RP4 and LP5/RP5
-09 switches are closed at the same time. are greater than 60% of battery volts at the same time.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid Forward or reverse directional switch welede
for closed or mis-adjusted to be held closed.
• Replace or adjust directional switches to
Traction
insure that they open when directional
Controller switch is returned to neutral.
Short circuit between battery positive and P4
and/or P5.
• Disconnect wires #6 & #8 from P4 and P5
of both controls and check wire for short
circuit to positive side of directional switch.
Defective Control
• Disconnect wires and measure voltage at
P4 and P5. Voltage should be less than
60% of battery volts.
TRACTION
STATUS CODE
This status code will be displayed when LP12/RP12 is greater
-10 Steer angle potentiometer voltage is too high. than 3.9 volts.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid Steer angle potentiometer input mis-adjusted
for or defective. Loose or missing connections at
P9 or P12 of either controls.
Traction
• Input voltage at P12 should be less than
Controller 3.9 volts at all times. Insure the proper
adjustment of the steer potentiometer.
• As measure at LP12/RP12 (wire #19) when
the steer wheel is centered = 2.15v, full
LH tum = 0.73, full RH turn = 3.53v.
Defective control.
• Replace control unit.
Refer to the wire diagrams located under the seat

deck for proper wire numbers and connection
points.

TRACTION
STATUS CODE
1MS switch closed on power up after initial This status code will be displayed when LP3/RP3 is greater
-11 key switch closure. than 60% of battery voltage when the key switch is closed.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid 1MS switch input mis-adjusted or defective.
for • Input voltage at P3 should be less than
60% of battery volts at key switch closing.
Traction Adjust or replace accelerator unit to insure
Controller that the voltage at P3 is less than 60% of
battery volts before closing the start switch.
Short circuit between battery positive and P3
(wire #15) in 1MS switch input circuit.
• Disconnect wire #15 from LP3/RP3.
Check for short circuit from this wire to
battery posXitive.
Resistance should be greater than 4.7K
ohms.
Defective control.
• Disconnect wire from LP3/RP3. Measure •
voltage from LP3/RP3 to negative. Voltage
should be zero, if not, replace control.
TRACTION
STATUS CODE
This status code will be displayed when LP12/RP12 is less than
-12 Steer angle potentiometer voltage is too low. 0.39 volts.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid Steer angle potentiometer input mis-adjusted
for or defective. Loose or missing connections at
P19 and P12.
Traction • Input voltage at P12 (wire #19) should be
Controller greater than 0.39 volts at all times Insure
the proper adjustment of the steer
potentiometer.
• As measure at LP12/RP12 (wire #19) when
the steer wheel is centered = 2.15v, full
LH turn = 0.73, full RH turn = 3.53v.
Defective control.
• Replace control unit.

points.

TRACTION
STATUS CODE
This status code will be displayed when the battery volts are
Battery voltage is too low or control card is
-15 mis-adjusted.
less than 1.95 volts per cell at initial key switch on. See table
below.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid Discharged battery
for • Check battery for proper open circuit
voltage as shown in `Trouble Shooting
Traction Diagram', charge battery, if required.
Controller
Defective battery
• Check each battery cell for proper voltage
(greater than `.95 volts at cell). Replace or
repair battery.
Incorrect control card adjustment.
• Check Function 15 for proper adjustment
for battery being used. See SM-616 for
details.
Adjust to proper settings.
Check `minimum' battery volts at LP1/RP1
(wire #2) and NEG.
TRACTION
STATUS CODE
This status code will be displayed when the battery volts are
Battery voltage is too low or control card is
-16 mis-adjusted.
less than 2.4 volts per cell at initial key switch on. See table
below.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid Incorrect control card adjustment.
for Check Function 15 for proper adjustment for
battery being used. See SM-616 for details.
Traction Adjust to proper setting.
Controller
Battery over charged or incorrect battery used.
• Check battery for proper open circuit
voltage per table at right. If voltage is
excessive, check battery charger for proper
output voltage.
Check `maximum' battery volts at LP1/RP1
(wire #2) and NEG.

TRACTION
STATUS CODE
This status code will be displayed when the control type selection
-17 `Control Type' selection is invalid. value is set to an invalid number.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid Invalid card type selection.
for Check Function for proper setting, refer to the
setup parameters for correct setting.
Traction
Controller Adjust and set card type value as instructed NO GRAPHIC
by the service manual SM-616.
FOR THIS STATUS CODE
TRACTION
STATUS CODE
Motor field current is high on start up in the This status code will be displayed when the current draw in the
-23 reverse direction. motor field is too high at start up in the reverse direction.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid Defective control.
for • Replace controller unit.
Traction
Controller

TRACTION
STATUS CODE
Motor field current is high on start up in the This status code will be displayed when the current draw in the
-24 forward direction. motor field is too high at start up in the forward direction.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Traction
Controller
TRACTION
STATUS CODE
This status code will be displayed when the power supply is
-27 Power supply is less than 10 Volts DC. less than 10 volts.
MEMORY RECALL
YES CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor closes and opens, then can
only be closed by opening and closing the key
switch.
Circuits valid
for POSSIBLE CAUSE
Discharged Battery
Traction • Check battery to insure proper state of
Controller charge.
Voltage may be dropping below 10 volts
DC under load.
Loose connection at LP1/RP1.
• Insure that the wire connection at P1 is
tight.
Defective control.
• Replace controller unit.

TRACTION
STATUS CODE
This status code will be displayed when the current in the motor
Motor field current is too high during the run field is sustained above a preset limit for longer than 35 or 70
-28 mode. seconds, depending on control type.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid Continued operation of vehicle in high motor
for current condition.
• Operate vehicle at lower motor current
Traction condition for 35 or 70 seconds, depending
Controller on control type. NO GRAPHIC
Function 7 is mis-adjusted to allow higher
than normal motor field current. FOR THIS STATUS CODE
• Adjust the function 7 setting per the
published Clark control parameters.
TRACTION
STATUS CODE
Motor armature current is too high during the This status code will be displayed when the motor current of
-29 run mode. (Dual Motor Proportioning Controls one control is greater than 125A while the motor current in the
Only) other control is less than 26A for a 16 sectond interval.
MEMORY RECALL CORRECTIVE
YES ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Control operates at the
reduced speed set by speed
limit setting in Function
Circuits valid 13.
for POSSIBLE CAUSE
Traction Continued operation of
Controller vehicle in high motor
current condition.
• Verify operation of
other control during the
run mode.
• Examine opposite
control for stored fauls,
which may have shut
down the oppsite
control.
• Verify the connection
between P16 of the
master and P15 of the
auxiliary control.

TRACTION
STATUS CODE
PMT enable signal from Slave control to This status code will be displayed when the voltage at wire #49
-30 Master at PL21 (wire #49) is missing during at PL21 of the master control is less than 5 volts. This fault is
SRO check (startup). not stored.
NO ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Auxiliary control
shutdown.

for • Check auxiliary control
for status codes.
Traction
Controller • Verify connection
between LPL21 of
Master control and
RP10 of Slave control.
• Plug handset in Slave
faults during startup.
Make sure the control
knob of handset is
turned fully clockwise.

points.
TRACTION
STATUS CODE
Open thermal protector(TP) or transistor over This status code will be displayed when the voltage at the
-41 temperature. termal protector is too high.
MEMORY RECALL
SYMPTOM
Reduced or no power to either or both traction
motors in control range.

for Control(S) is in thermal cut-back.
• Allow control(S) to cool, status code should
Traction disappear.
Controller
• Operate truck with wheels raised to
NO GRAPHIC
determine which control is in cut-back. FOR THIS STATUS CODE
Check for any reason for thermal cut-back.
• Check for brake drag
• Verify the operator is not pushing loads or
operating in an abusive manner.
Defective control.

TRACTION
STATUS CODE
This status code will be displayed when the voltage at the
-42 Motor armature offset voltage is too high. current sensor input is greater than 2.6 volts with no current
flowing in the motor circuit.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Traction
Controller
NO GRAPHIC
TRACTION
STATUS CODE
-43 Motor armature offset voltage is too low. current sensor input is greater than 2.4 volts with no current
flowing in the motor circuit.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Traction
Controller
NO GRAPHIC

TRACTION
STATUS CODE
This status code will be displayed when, during control
-44 Armature transistor did not turn off properly. operation, the armature transistor fails to turn off.
This will result in a PMT condition.
MEMORY RECALL
SYMPTOM
switch.
Circuits valid
for POSSIBLE CAUSE
Defective control.
Traction • Replace controller unit.
Controller
TRACTION
STATUS CODE
This status code will be displayed when, during control
-45 Armature transistor did not turn off properly. operation, the armature transistor fails to turn on properly.
This will result in a PMT condition.
MEMORY RECALL
SYMPTOM
switch.
Circuits valid
for POSSIBLE CAUSE
Defective control.
Controller

TRACTION
STATUS CODE
`Look Ahead' test for A2 volts less than 12% This status code will be displayed when the voltage at A2 is less
-46 of battery volts. than 12% of battery volts.
MEMORY RECALL
SYMPTOM
Line contactor will not pick up.
POSSIBLE CAUSE
Circuits valid Check for short circuit from the motor
for armature to the frame of the vehicle.
Traction Defective control.
Controller • Replace controller unit.
TRACTION
STATUS CODE
Motor field current is too low during the run This status code will be displayed when the current draw in the
-49 mode. motor field is too low during the run mode.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Traction
Controller NO GRAPHIC

TRACTION
STATUS CODE
This status code will be displayed during `key on' when the
Capacitor volts are low before the line
-51 contactor closes.
capacitor volt is less than 85% of battery volts at initial key
switch on.
MEMORY RECALL
SYMPTOM
Line contactor does not close when capacitor
does not precharge.

for Status code -51 may display if the key switch
is open and closed too quickly after the Line
Traction contactor has opened due to a PMT fault. To
Controller correct, turn key off to 10 seconds before
turning back to the on position.
Low or volts at LP1/RP1 wire #2
• Check wire #2 for open circuit. Repair
wire, if necessary.
Improper wiring of an accessory to the
controller side of Line contactor. Check for
drain from B+ buss bars.
Defective control.
TRACTION
STATUS CODE
This status code will be displayed when the control detects a
-52 Line contactor driver shorted on start up. shorted line contactor dirver during start up.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Traction

TRACTION
STATUS CODE
Controller `motor current sensor' input too This status code will be displayed when the voltage input from
-57 low during running. the current sensor is too low during running.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Traction
TRACTION
STATUS CODE
This status code will be displayed when field transistor drops
-66 FET field protection has shut down. high. The control is reset by recycling the key switch.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid • Bad fuse, should be checked for excessive
for volt drop. Do not check fuse w/ohm meter.
Traction • Line contactor tips welded open.
Controller Repair line contactor.
• Verify that there are no motor field shorts.
Motor fields should measure 0.6 to 0.7
ohms.
• Verify that there are no cable shorts
between :
B+ and F1 B+ and F2 A2 and F2
A1 and F2 F1 and F2
All of the above to frame
• An `A66' will be generated in the Slave
control anytime the Master control opens
the Line contactor (PMT). Both controls
interpret the sudden loss of B+ as a `66'
code.

TRACTION
STATUS CODE
This status code will be displayed when the armature transistor
-67 FET armature protection has shut down. SAT drop is high or line tips are open.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid • Line contactor tips welded open.
for Replace line contactor.
Traction • Verify that there are no motor armatrue
Controller shorts.
• Verify that there are no cable shorts
between the following points :
A1 and A2
B+ and A2
B- and A2
All of the above to frame
• Defective control.
Replace controller unit.
TRACTION
STATUS CODE
PMT enable signal from Slave control to This status code will be displayed when the voltage at master
-68 Master at PL21 (wire #49) drops below 5V PL21 drops below 5V.

SYMPTOM
Master is indicating that the
Slave control has shut down
Circuits valid but does not indicate why.
for POSSIBLE CAUSE
Traction • Slave control has shut
Controller down.
Install handset in Slave
control and monitor
reading as the truck is
operated. Make sure
the control knob of
handset is turned fully
clockwise.
• Verify the connection
between the Master
control LP21 and the Refer to the wire diagrams located under the seat
Slave control RP10 deck for proper wire numbers and connection
(wire #49). points.
19-4-18 • Motor Controls Specifications andCopyrighted

Description Material SM 616, Jul ’01
TRACTION
STATUS CODE
This status code will be displayed when the voltage on the
-76 Capacitor (1C) voltage too high. capacitor goes above limit voltage* during the regenerative
braking cycle.
MEMORY RECALL
SYMPTOM
Line contactor opens and closes, then opens
and can only close by opening and closing the
key switch.
Circuits valid
for POSSIBLE CAUSE
• Unplugging the battery connector during
Traction regenerative braking.
Controller
• Line contactor bouncing open during regen
• Main power fuse opening during regen
• Intermittent battery plug connection.
• Limit Voltage :
Limit Battery Voltage
50V 36V
70V 48V
TRACTION
STATUS CODE
Motor current is detected during regenerative This status code will be displayed when motoring current is
-77 braking. deteted during the regenerative braking cycle.
MEMORY RECALL
SYMPTOM
Line contactor opens and closes, then opens
and can only close by opening and closing the
key switch.
Circuits valid
for POSSIBLE CAUSE
Defective control.
Controller
SM 616, Jul ’01 MotorMaterial

TRACTION
STATUS CODE
-80 Voltage at capacitor (1C) is less than 14 volts. capacitor is less than 14 volts. This typically occurs during the
run mode of operation.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid Line contactor opened during run.
for • Check connection from LP17 to Line
Contactor Coil (wire #24) for loose
Traction connection.
Controller
• Check connection from battery (+) to Line
Coil (wire #10) for loose connection.
• Check power connection from battery (+)
cable to contactor buss bar.
• Check for blown fuse (FU1)
• Check for contaminated Line contactor tips.
Refer to the wire diagrams located

under the seat deck for proper wire
numbers and connection points.
TRACTION
STATUS CODE
This status code will be displayed when the battery voltage
-81 Battery voltage is less than 14 volts. measured at P1 is less than 14 volts.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid Line contactor opened during run.
for • Check connection from P17 to Line Coil (-
) for loose connection.
Traction
Controller • Check connection from battery (+) to Line
Coil (+) for loose connection.
• Check power connection from battery (+)
to contactor L.
• Check for blown fuse element.

TRACTION
STATUS CODE
Battery voltage is less than 24 volts for more This status code will be displayed when there is low battery
-84 than 5 seconds. voltage seen at LP1/RP1.
MEMORY RECALL
SYMPTOM
POSSIBLE CAUSE
Circuits valid • Dead battery.
for • High voltage drop in LP1/RP1 connection,
Traction wire #2.
Controller
TRACTION
STATUS CODE
Optional Over Temp Sensor Fault On LH This status code will be displayed when the voltage at PP16 of
-90 Drive Motor the Pump Logic Card is at zero volts (Battery Negative).
MEMORY RECALL
SYMPTOM
Status code - 90 flashes ‘on and off’.
POSSIBLE CAUSE WHEN TMM7A CARD IS USED

Circuits valid LH dirve motor temperature sender has closed Refer to the appropriate Optional wiring diagram
for connecting PP16 to negative via wire #61.
• Check for reason for overheated motor (ie for the option the truck has been equipped with.
Traction pushing loads, abusive operation, stuck Contact Clark Customer Service for copies
Controller brakes, etc)
& • Check for any stored status codes in Master
Pump control that may indicate reason.
Controller • Plug PP16 (pump) is shorted to negative.
• Defective motor sensor (shorted).
• Defective pump control.
Handset Installed In Control W/Control Knob
Not Turned Fully Clockwise
• Turn handset control knob full clockwise
when installed in the controller with the
truck operating.

TRACTION
STATUS CODE
Optional Over Temp Sensor Fault On Main This status code will be displayed when the voltage at PP11 of
-91 Hydraulic Pump Motor the Pump Logic Card is at zero volts (Battery Negative).
MEMORY RECALL
SYMPTOM
Status code -91 flashes `on and off’.

Circuits valid Hydraulic Pump temperature sender has closed Refer to the appropriate Optional wiring diagram
for connecting PP11 to negative via wire #65.
Traction excessive hyd pressure, abusive operation, Contact Clark Customer Service for copies
Controller , etc)
Controller
• Plug PP11 (pump) is shorted to negative.
Defective pump control
Not Turned Fully Clockwise
• Turn handset control knob full clockwise
when installed in the controller with the
truck operating.
TRACTION
STATUS CODE
Optional Over Temp Sensor Fault On RH This status code will be displayed when the voltage at PP15 of
-92 Drive Motor the Pump Logic Card is at zero volts (Battery Negative).
MEMORY RECALL
SYMPTOM
Status code -92 flashes ‘on and off’

Circuits valid RH Dirve motor temperature sender has closed
connecting PP15 to negative via wire #69. Refer to the appropriate Optional wiring diagram
for
Traction
pushing loads, abusive operation, stuck Contact Clark Customer Service for copies
Controller brakes, etc)
Controller
• Plug PP15 (pump) is shorted to negative.
• Defective pump control.

Not Turned Fully Clockwise. Turn handset
control knob full clockwise when installed in
the controller with the truck operating.

TRACTION
STATUS CODE
Optional Brush Wear Sensor Fault On LH This status code will be displayed when the voltage at PP3 or
-93 Drive Motor. PP4 of the Pump Logic Card is at battery positive volts.
MEMORY RECALL
SYMPTOM
Status code -93 flashes ‘on and off’.
POSSIBLE CAUSE
WHEN TMM7A CARD IS USED
Circuits valid LH Drive Motor Brush Sensor is in contact Refer to the appropriate Optional wiring diagram
for with the motor armature supplying positive for the option the truck has been equipped with.
volts to PP3 (wire #64) or PP4 (wire #63) on
Traction the pump control. Contact Clark Customer Service for copies
Controller • One or more of the LH drive motor brushes
& are worn out, R&R all LH motor brushes.
Pump PP3 or PP4
PP3 or PP4 (pump) is shorted to positive.
Controller WHEN SR Series PUMP
Defective BWI brush sensor (shorted). CONTROL IS USED
Defective pump card.

Not Turned Fully Clockwise. Turn handset Brush Sensor
TRACTION
STATUS CODE
Optional Brush Wear Sensor Fault On This status code will be displayed when the voltage at PP5 or
-94 Hydraulic Pump Motor. PP6 of the Pump Logic Card is at battery positive volts.
MEMORY RECALL
SYMPTOM
Status code -94 flashes ‘on and off’.
POSSIBLE CAUSE Refer to the appropriate Optional wiring diagram
Circuits valid Hyd Pump Motor Brush Sensor is in contact
with the motor armature supplying positive for the option the truck has been equipped with.
for
Traction
volts to PP5 (wire #68) or PP6 (wire #67) on Contact Clark Customer Service for copies
the pump control.
Controller • One or more of the pump motor brushes PP5 or PP6
& are worn out, R&R all pump motor brushes.
WHEN SR Series PUMP
Pump PP5 or PP6 (pump) is shorted to positive. CONTROL IS USED
Controller Defective BWI brush sensor (shorted).
Brush Sensor

TRACTION
STATUS CODE
Optional Brush Wear Sensor Fault On RH This status code will be displayed when the voltage at PP8 or
-95 Drive Motor. PP9 of the Pump Logic Card is at battery positive volts.
MEMORY RECALL
SYMPTOM
Status code -95 flashes ‘on and off’
POSSIBLE CAUSE
Circuits valid RH Drive Motor Bruch Sensor is in contace Refer to the appropriate Optional wiring diagram
for with the motor armature supplying positive for the option the truck has been equipped with.
volts to PP8 (wire #66) or PP9 (wire #59) on
Traction the pump control.
Contact Clark Customer Service for copies
Controller • One or more of the RH drive motor brushes
& are worn out, R&R all RH motor brushes.
PP8 or PP9
WHEN SR Series PUMP
Pump CONTROL IS USED
Controller PP8 or PP9 (pump) is shorted to positive.
Defective BWI brush sensor (shorted).
Brush Sensor
TRACTION
STATUS CODE
This status code will be displayed when the ‘normal’ hour
-99 Maintenance alert and speed limit. meter exceeds the ‘maintenance alert hours’ setting for the
vehicle.
MEMORY RECALL
SYMPTOM
Status code is displayed for 4 seconds when
the key switch is first turned on, and/or the
truck may run at a reduced speed.
Circuits valid
for CUSTOMER SELECTED SETTING WITH NO DIAGRAM
THE HANDSET:
Traction The -99 status code is displayed when the
Controller normal hour meter reading exceeds the
programmed ‘maintenance alert hours’ setting
selected by the user on Functions 19 & 20.
• Maintenance Code Hour Meter, Functions PM Service Is Now Due!!
19 and 20, are programmed with the
Handset and commands the dash to display
the status code -99 when the hourmeter
exceeds the maintenance setting.
• If desired, Maintenance Code Speed Limit,
Function 21, can be programmed with the
Handset to slow the max speed of the truck
when in maintenance alert.
Refer to SI-19-730-99 for more information.

PUMP
STATUS CODE
Key switch is open for more than 8 seconds This status code will be displayed when Aux2 switch is closed
-101 while the Aux2 switch is closed. with the key switch off.

SYMPTOM
• Aux2 switch is closed
and pump motor will
not exceed the speed
Circuits valid indicated by function
for 11.
Pump
Controller POSSIBLE CAUSE
• Defective Aux2 switch.
Replace Aux2 switch.
Wire #51 shorted to

negative.
PUMP
STATUS CODE
Key switch is open for more than 8 seconds This status code will be displayed when Aux1 switch is closed
-102 while the Aux1 switch is closed. with key switch off.

SYMPTOM
• Aux1 Switch is closed
and pump motor will
not exceed the speed
Circuits valid indicated by function
for 12.
Pump
Controller POSSIBLE CAUSE
• Defective Aux1
switch.
Replace Aux1 switch.
Wire #52 shorted to

negative.

PUMP
STATUS CODE
Key switch is open for more than 8 seconds This status code will be displayed when Tilt switch is closed
-103 while the Tilt switch is closed. with the key swtich off.

SYMPTOM
• Tilt Switch is closed and
vehicle will not exceed
the speed indicated by
Circuits valid function 13.
for
Pump POSSIBLE CAUSE
Controller • Defective Tilt switch.
Replace Tilt switch.
Wire #53 shorted to negative.
PUMP
STATUS CODE
Key switch is open for more than 8 seconds This status code will be displayed when Lift switch is closed
-104 while the Lift switch is closed with key switch off.

SYMPTOM
• Lift switch is closed and
vehicle will not exceed
the speed indicated by
Circuits valid function 14.
for
Pump POSSIBLE CAUSE
Controller • Defective Lift switch.
Replace Lift switch.
Wire #62 shorted to

negative.

PUMP
STATUS CODE
This status code will be displayed when the card type selection
-117 ‘Card Type’ selection is invalid. value is set to an invalid number.
MEMORY RECALL
SYMPTOM
Pump contactors will not close.
POSSIBLE CAUSE
Circuits valid Invalid card type selection.
for • Review function 17 in the Handset
Instruction sheets. Adjust and set card type
Pump value as instructed by the Clark TMG
Controller service manual SM-616. NO GRAPHIC
PUMP
STATUS CODE
This code will be displayed when the pump contactor coil
-123 Pump contactor coil current is low.
circuit current draw is less than 100 milliamps.
MEMORY RECALL
SYMPTOM
Pump contactor will not pick up. Status code
may alternate between code 123 and code
124. Complete checks for code 123, if the
Circuits valid problem is not found, perform checks for code
for 124.
Pump POSSIBLE CAUSE The Clark TMG is not equipped with a pump
Controller Defective Pump contactor coil circuit. motor 1A contactor. This Status Code should
• Check for open circuit or loose connection
between Wire #10 and positive side of
not appear.
Pump contactor coil.
• Remove plug B. Check ohmic value from
P2 to positive side of P coil. Value should
be between 10 and 14 ohms.
Defective 1A contactor coil.
• Remove plug. Check ohmic value from
positive side of coil to its plug connection.
Value should be between 10 and 14 ohms.

PUMP
STATUS CODE
T2 voltage is low. (Less than 88% of battery This status code is displayed when T2 voltage is less than 88%
-124 voltage.) of battery volts and the Pump dirver is energized.
MEMORY RECALL
SYMPTOM
Control does not operate. Status code may
alternate between code 123 and code 124.
Complete checks for 124, if the problem is
Circuits valid not found, perform code 123 check.
for
POSSIBLE CAUSE
Pump Open motor circuit
Controller • Check for open circuit or loose connection
in pump motor circuit from the A1
connection to the A2 connection on the
control panel.
• Defective pump motor fuse (2 FU), check
by performing a volt drop test.
PUMP
STATUS CODE
This status code is displayed when the ligic card power supply
-127 Logic card power supply is less than 10 VDC. is less than 10 volts.

SYMPTOM
Pump control fails to operate
or shuts down, then can only
be restarted by opening and
Circuits valid closing the key switch.
for
POSSIBLE CAUSE
Pump • Discharged battery
Controller
Check battery to insure proper
state of charge.
• Loose connection at PP1
(wire #12).
Insure that the cable connection
at pos buss bar is tight.
• Defective controller.
Replace control.

PUMP
STATUS CODE
Armature current is greater than 300A for This status code is displayed when armature current is maintained
-128 longer than 70 seconds at a level above 300A for >70 seconds.

SYMPTOM
Pump control fails to operate or
shuts down.

• Discharged Battery Check
for battery to insure proper state
Pump of charge.
Controller • Check for sticking hydraulic
control switches
• Possible operator misuse
• Check for defective motor,
excessive motor amps at low
pump pressure
• Check for hyd system
blockage.
PUMP
STATUS CODE
Open thermal protector (TP1) or transistor is This status code is displayed when the internal heatsink
-141 over temperature. temperature of the control exceeds 90 degrees C (195F)
MEMORY RECALL
SYMPTOM
Reduced or no power to pump motor in control
range.

for Control is in thermal cut-back.
• Allow control to cool, status code should
Pump disappear.
Controller
• If control cools to ambient temperature
NO GRAPHIC
and the fault remains when the control is FOR THIS STATUS CODE
restarted, replace the control.

PUMP
STATUS CODE
Pump Controller ‘motor current sensor’ input This status code is displayed when the voltage at the current
-142 is missing. sensor is greater than 0.1 volts with no current flowing in the
motor circuit.
MEMORY RECALL
SYMPTOM
No power to pump motor in control range.
POSSIBLE CAUSE
Circuits valid Defective controller unit.
for • Replace control.
Pump
Controller
NO GRAPHIC
PUMP
STATUS CODE
This status code is displayed when the voltage at the current
Pump Controller ‘motor current sensor’ input
-143 is too low.
sensor is greater than 0.1 volts with no current flowing in the
motor circuit.
MEMORY RECALL
SYMPTOM
No power to pump motor in control range.
POSSIBLE CAUSE
Circuits valid Control is defective.
Pump
Controller
NO GRAPHIC

PUMP
STATUS CODE
This status code is displayed when, during pump control
Power Transistor (Armature) did not turn off
-144 properly.
operation, the Armature transistor fails to turn off. This will
result in a PMT condition.
MEMORY RECALL
SYMPTOM
With no pump contactor, control may run
continuously.

for Control is defective.
Pump
Controller
NO GRAPHIC
PUMP
STATUS CODE
Power Transistor (Armature) did not turn on This status code is displayed when during pump control
-145 properly. operation, the armature transistor fails to turn on.

SYMPTOM
Pump control fails to
operate or shuts down, then
can only be restarted by
Circuits valid opening and closing the key
for switch.
Pump POSSIBLE CAUSE
Controller Control is defective.

PUMP
STATUS CODE
‘Look Ahead’ test for T2 volts less than 12% This status code will be displayed when the voltage at A2 is less
-146 of battery volts. than 12% of battery volts.

SYMPTOM
Pump control will not
operate.

Check for short circuit
for
from the motor armature
Pump to the frame of the vehicle.
Controller
Defective controller unit.
• Replace control.
PUMP
STATUS CODE
Capacitor volts are low before the line This status code will be displayed during ‘key on’ when the
-151 contactor closes. (Internal card function during capacitor volts is less than 85% of battery volts at initial key
precharge) switch on.
NO ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
Line contactor does not
close when Capacitor does
not pre-charge.
Circuits valid
for POSSIBLE CAUSE
Defective control fuse.
Pump • Check control fuse for
Controller open circuit, replace
fuse, if necessary.
Defective control.
Note : Repeated charging/

discharging the capacitors
during troubleshooting
will cause status code 51.
Also do not connect any
loads to the load side of
the line contactor.

SEVCON PUMP CONTROL (EPG 15/18 ONLY)
Calibrator Full Feature Led Description and how to clear Check....

Message Display
1 Thermal Cutback PUMP 8F Pump heatsink above 75°C. Heatsinking, Mounting,
HOT Allow controller to cool. Surfaces clean, fan req.
2 Battery High BATTERY 7F Battery > High battery personality. Correct battery voltage.
HIGH Recycle FS1 or Direction switch Loose or missing B+ to
controller.
3 Battery Low BATTERY 7F Battery < Low battery personality. Correct battery voltage,
LOW Recycle FS1 or Direction switch Discharged battery.
4 Pers Error PERS 1F Personalities out of range at power Reset personalities out
ERROR up. of range (shown as.....).
5 CRC error CRC 1F One or more personalities have been Check all personalities
ERROR corrupted. then recycle keyswitch.
6 Mosfet s/c MOSFET 3F Bypass contactor s/c or MOSFET s/c A/P /B- power wiring,
FAIL Recycle FS1 or Direction MOSFETs s/c.
7 Various internal FAIL off If any of these message are displayed Contact Servon.
controller power then the controller has failed one of
up messages its internal power up checks.
(highest priority)
SM 616, Sep ’02①

Jul ’01 MotorMaterial
Section 5.
Controllers Removal and Replacement
Removal
1. Park truck safely as described in Group SA. 4. Disconnect cables, wires, and bus bars as illustrated in
Group 13.
2. Discharge capacitors (as described in Group 13) by
disconnecting battery, turning key switch on, and 5. Remove mounting fasteners per illustration below.
sounding horn until sound dies off.
3. Remove seat deck as described in Group 38. (Counter- Installation
weight does not have to be removed, although doing so
improves access.) Reverse the removal procedure given above.
Six fasteners per

control.
Torque: 8-10 N•m NOTE

(71-88 in-lb) WIRING/CABLE CONNECTION AND
ROUTING. Refer to Group 13 for illustra-
tions.
SM 616, April ’98 Control Panel Removal and Replacment • 19-5-1

19-5-2 • Control Panel Removal ReplacementCopyrighted Material SM 616, April ’98

GROUP 20
GROUP 20
DRIVE AXLE
Drive Axle Specifications and Description ................... Section 1
Drive Axle Troubleshooting ........................................... Section 2
Drive Axle Fluid Check and Change ............................. Section 3
Drive Axle Removal and Installation ............................ Section 4
Drive Axle Overhaul ....................................................... Section 5
SM 616, April ’98 Copyrighted Material Drive Axle

GROUP 20
NOTES:
Drive Axle Copyrighted Material SM 616, April ’98

Group 20, Drive Axle
Section 1.
Drive Axle Specifications and Description
Specifications Description
Type: Separate housing and drive train for each drive See next page.
wheel. Each axle housing contains pinion and ring gear,
intermediate shaft, and axle shaft.
Transmission Fluid Type: Clark part no. 2794022
Fluid Capacity (each housing): 3.8 L (1 gal)
Axle-to-Frame Mounting Bolt Torque: 408-469 N•m (300-
340 ft-lb). Use Loctitle 271.
Fill Plug Torque: 54-61 N•m (40-45 ft-lb)
SM 616, April ’98 Copyrighted Material Specifications and Description • 20-1-1

Description
Each drive wheel is driven by a separate motor and drive train.
The drive axle consists of two independent housings that contain identi-
cal components for conveying power from each (left and right) drive
motor to each drive wheel.
The two housings bolt together to form a single drive axle.
Each housing contains a pinion (A) driven by the motor output shaft, a
ring gear (B) and ring gear shaft (C) driven by the pinion, and an output
gear (D) and axle shaft (E) driven by the teeth on the ring gear shaft.
The brake disc runs within an hydraulic caliper assembly, shown in

Group 23.
Ring Gear Shaft:
Drive Brake
20-1-2 • Specifications and Description

Gear Disc Brake Disc
Inspection Spline
Teeth
Cover
Pinion Ring Gear Bearing
Housing
B
C
A

Drive Axle
D
Shaft Gear
Fluid Level
Check Plug
E Drain
Plug
Drive Axle Components (bearing, seals, and retainers not labeled).

Axle Shaft
Left-hand housing shown.
SM 616, April ’98

Section 2.
Drive Axle Troubleshooting
Proper operation of the drive axle depends on the condition The following lists typical drive axle troubles and possible
of the other related components in the power train.. causes.
Therefore, to properly diagnose a suspected problem in the
drive axle, consider the drive axle fluid, drive axle assem- Truck Won’t Move in Either Direction
bly, controls, and drive motor as a complete system.
• Battery disconnected.
To identify and correct a drive axle fault, refer to the • Park brake on.
description in Section 1, along with symptoms and causes
indicated in this Secttion. • Check electrical control system. See Group 19.
• Check directional control switches. See Group 13.
Inspection and overhaul of the suspect components is de-
scribed in various locations within this Group. • Check contactors. See Group 17.
• Check drive motor. See Group 16.
Truck Moves Only in Forward or

Only in Reverse
• Check electrical control system. See Group 19.
• Check directional control switch. See Group 13.
Overheating
• Low or contaminated fluid level.
• Truck travel function being loaded excessively.
• Worn bearings.
• Check drive motor for air flow or damage. See Group
16.
• Brakes Dragging. See Group 23.
Loss of Power
• Low battery charge.
• Drive axle bearings worn or seized.
• Overheating – See Overheating above.
SM 616, April ’98 Copyrighted Material Drive Axle Troubleshooting • 20-2-1

20-2-2 • Drive Axle Troubleshooting Copyrighted Material SM 616, April ’98

Section 3.
Fluid Check and Change
WARNING
Access drive axle using safe procedures
in Group 2, “Safe Maintenance.”
SM 616, April ’98 Copyrighted Material Fluid Check and Change • 20-3-1
Drive Axle Fluid Level Check NOTI CE

Frequently replacing lubricant is an inex-
Check the drive axle fluid level with: pensive way to protect and prolong the safe
• Truck on a level surface. operating life of an essential and relatively
• Oil at operating temperature. costly major component such as the drive
axle.
1. Remove the fluid level inspection/fill plug located in
Extending the recommended intervals at
the front surface of each drive unit housing (two
which drive axle fluid is changed should be
places).
considered only after careful evaluation of
2. The oil level is correct (FULL) when it is at the lower your operating conditions and/or analysis
edge of the inspection plug opening. of the condition of the. oil.
IMPORTANT 1. Place a low, flat drain pan beneath the drive units. The
Use only fluid Clark part no. 2794022. Do pan capacity should be more than 6.6 L (14 pints)
not overfill. (drive axle total capacity).
3. After adding oil to the drive axle, wait several min- 2. Remove drain plugs (two) from bottom of drive units,
utes until the oil has distributed evenly throughout and fill plugs (two) from front of drive units.
the unit, and check for correct oil level.
3. While the drive units are draining, check the breather
4. Inspect each fill plug for damage. Replace as neces- vents (two) to be sure they are open and not damaged.
sary. Vents are located in the top front corners of the drive
units.
5. Install and tighten the plugs.
4. After drive units have drained, install drain plugs.
NOTICE
Check the planned maintenance interval 5. Fill each drive unit to bottom edge of fill plug opening
(operating hours), or the condition of the with recommended fluid.
oil to determine if the drive axle fluid 6. Install fill plugs.
needs to be changed.
7. Remove drain pan. Remove blocking and lower car-
riage.
Drive Axle Fluid Change
Drain and replace the drive axle fluid every 1000 operat-
ing hours. Vent
To change oil in the drive axle:

• The oil should be drained when it is warmed to
operating temperature.
• Put the truck in a level position.
• Apply the parking brake and block the wheels to
prevent the truck from moving.
• Turn key switch "OFF" and disconnect battery from
truck receptacle.
NOTICE
When suitable equipment is available, the Fill Plug
truck may be raised or hoisted up and
Torque:
placed in a level position on wheel cradles 54-61 N•m
to allow access under the axle. Otherwise, (40-45 ft-lb)
raise and block the fork carriage only
Drain Plug
high enough to provide access clearance
to the axle. Please refer to the blocking
and jacking procedure in Group SA. Drive Axle (Left Housing Only)
20-3-2 • Fluid Check and Change Copyrighted Material SM 616, April ’98
Section 4.
Drive Axle Removal and Installation
CAUTION Preparation
To perform this service procedure, it is
recommended that you first: 1. Turn key switch "OFF".
• Park truck on a hard, level surface in correct position 2. Open hood.

for using an overhead hoist, if available. 3. Disconnect battery from truck receptacle.
• Fully lower the upright. 4. Remove battery from truck as described in Group 12.
• Return all controls to neutral and turn key switch to
5. Remove floorboard as described in Group 38.
the "OFF" position.
• Apply the parking brake. 6. Remove bolts holding front battery plate amd lay back
plate to improve access.
7. Remove the upright as described in Group 34.
SM 616, April ’98 Copyrighted MaterialDrive Axle Removal and Replacement • 20-4-1
Removal 11. Lower front of truck frame to the floor. Truck frame
may also be blocked up under axle mounting surfaces.
After battery and upright have been removed: Block the steer wheel and be sure blocking is put safely
1. Drain the oil from drive units when truck is in a level under the frame.
position as described Section 2 of Group 20. 12. Attach hoist and move drive axle assembly to the
2. Attach a hoist with chains of correct capacity and overhaul disassembly area.
remove the drive wheels as described in Group 22.
Leave chains and hoist attached. Installation
CAUTION Reverse the above procedure to replace the drive axle.
Watch truck for signs of lateral instability. • Be sure to follow safe lifting and jacking procedures
It may tip sideways. You may have to sup- given Group SA, “Safe Maintenance.”
port or guide the sides of the truck or over-
• Apply Loctite 271 to axle mounting bolts threads and
head guard to prevent tipping.
properly torque axle mounting bolts.
3. Support truck with blocks under the frame as shown in • Retighten hydraulic fittings per procedure in Group
Group SA. Place blocks of wood under drive motors to 40.
support them, if motors were not previously removed.
4. Disconnect power cables from drive motors. Attach
tags to the motor cables for easy and correct identifica-
tion at assembly. Replace the nuts on motor terminals
to avoid losing them.
NOTE
Alternative Procedure: It is optional to re-
move drive motors before removing drive
axle from truck. Refer to GROUP 16.
5. Release the parking brake hand lever to provide freeplay

in the brake cable for removal
of the parking brake cable
yoke. If necessary, adjust the
cable to release tension as de-
scribed in Group 23,
6. Remove the yoke of parking
brake cable from the levers on
brake caliper assembly.
(Group 23.)
7. Disconnect hydraulic brake line from master cylinder.
Put caps on fittings to keep clean. (Group 23.)
8. Inspect your truck for any other wiring leads or op-
tional equipment that may have to be disconnected
before axle is removed.
9. Loosen and remove axle mounting bolts (nuts under-
neath) from axle on both sides of frame.
10. Raise truck frame slightly off of drive axle and move
the truck backwards away from axle assembly.
CAUTION
Truck may tip sideways. You may have to Torque:
support or guide the side of the truck or 408-469 N•m
overhead guard to prevent tipping. (300-340 ft-lb)
Apply Loctite 271.
20-4-2 • Drive Axle Removal and Replacement

Section 5.
Drive Axle Overhaul
Introduction .................................................................................................................................... 2
Drive Unit Disassembly ................................................................................................................. 2

Ring Gear Shaft Disassembly ........................................................................................................ 4
Input Pinion Gear Carrier Disassembly ........................................................................................... 6
Drive Axle Shaft Disassembly ......................................................................................................... 8
Ring Gear Shaft Inboard Bearing Removal ..................................................................................... 8
Cleaning and Inspection ................................................................................................................ 9
Drive Unit Reassembly ................................................................................................................ 10

Drive Axle Shaft Reassembly ........................................................................................................ 10
Input Pinion Gear Carrier Reassembly .......................................................................................... 12
Ring Gear Shaft Reassembly ......................................................................................................... 14
Drive Axle Reassembly ................................................................................................................. 16
Spiral Bevel and Hypoid Tooth Bearing Contact Chart .......................................................... 17
Special Tools Fabrication ............................................................................................................ 18
SM 616, April ’98 Copyrighted Material Drive Axle Overhaul • 20-5-1

Introduction Drive Unit Disassembly

Refer to Figures 1A and 1B. 1. Remove the brake caliper as shown in Group 23.
Drive unit disassembly and overhaul procedures are grouped 2. Remove the drive motors as shown in Group 16.
according to the following major sub-assemblies:
3. Remove the flange bolts and separate the two drive
axle housings. as shown in the Section, “Drive Axle
1 Ring gear shaft assembly, including bearing housing, Removal and Replacement.”
shaft, ring gear, straight and tapered roller bearings,
bearing cap, and oil seal. 4. Be sure all fluid is drained from each drive unit before
2 Pinion assembly, including pinion gear, bearing car- starting disassembly.
rier, bearings, and bearing retainer. 5. Remove the inspection (A) cover and gasket (B)from
top of unit. (Figure 1A.)
3 Drive axle shaft assembly, including shaft, gear, gear
retainer, bearings, and oil seal. 6. Remove the brake disc (C) by sliding it off the ring gear
shaft spline. (Figure 1B.)
Figure 1A. Drive Unit Sub-Assemblies
20-5-2 • Drive Axle Overhaul Copyrighted Material SM 616, April ’98

Figure 1B. Drive Unit Sub-Assemblies

Ring Gear Shaft Disassembly

Refer to Figure 2.
1. Loosen and remove the ring gear bearing housing 9. Loosen and remove the mounting bolts (P) and
mounting combination of bolts, nuts and lockwashers lockwashers (O), then remove the bearing cap (AA)
(L-M, X-Y). Then, remove the housing assembly (W) and oil seal assembly (Q) from housing.
from the drive unit main housing. 10. Remove the bearing preload shims (Z).
Bolt Torque: 54-62 N•m (40-46 ft-lb) 11. Press, or pry and pull, the old oil seal (Q) from the
2. Remove the ring gear bearing housing (ring gear bearing cap.
position) shims.(K). 12. Remove the outer bearing cup (U) if it is loose.
It is good practice to arrange parts in the sequence of 13. Remove the external snap ring (I) from shaft spline at
removal as an aid to inspection and correct reassemble. end of outer bearing cone.
3. Put the housing and shaft assembly, with the ring gear 14. Remove housing assembly from the vise. Support the
(E) up, in a vise. bearing housing and press the shaft (F) out of the
NOTE bearing cones (H, T). This can also be done by holding
Use blocks of wood to protect the shaft the housing and lightly tapping the shaft end on a
spline. wooden block on the bench or floor.
4. Carefully inspect the ring gear (E) for wear and dam- 15. Remove outer bearing cup (U), if not done previously.
age. Also, see inspection of pinion gear. Remove bearing cones (H, T). Remove inner bearing
5. To remove ring gear, loosen and remove the ring gear cup (G) from housing by pressing or using a puller.
fastener bolts (D).
NOTE
Bolt Torque: 20-27 N•m (15-20 ft-lb) Also remove, clean and inspect breather
6. Remove the ring gear (E) from the shaft. vent (N) in top side of ring gear bearing
housing. Replace vent, as needed.
7. Remove the housing seal (J) from groove in bearing
housing pilot flange. 16. Arrange the parts in the sequence of removal as an aid
to inspection and correct reassembly.
8. Turn the housing assembly over and clamp the pinion
end in the vise. Use wood blocking to protect the pinion Refer to Page 20-5-8 for ring gear shaft inboard bearing
gear teeth. removal.

Q
P
O
N
M
L
K
J
I
H
AA
G
F Z
Y
X
E W
D
C V
B
A U
T
Figure 2. Ring Gear Shaft Assembly

Input Pinion Gear Carrier Disassembly

Refer to Figure 3.
1. Loosen and remove the five fastener bolts (M) and 9. Remove the pinion and bearings assembly (G-H) from
lockwashers (N) from pinion bearing carrier (I). the carrier housing.
Bolt Torque: 77-88 N•m (57-65 ft-lb) 10. Clean and inspect the pinion tapered roller bearings
(F, H) for wear and other damage. Replace, as neces-
2. Tap lightly on the outer flange to loosen the carrier
sary. Replace worn or damaged bearing cups and
pilot flange from main housing.
cones as a set.
3. Remove input pinion carrier assembly (C-K) and
12. Clean and inspect the pinion (G) gear teeth and internal
(pinion gear position) shims from the main housing.
spline for wear and other damage. Replace, as needed.
4. Remove the pinion carrier seal (J).
5. Clamp carrier (I) housing flange in a vise. Loosen and NOTICE
remove the recessed hexhead pinion bearing retainer Replace ring and pinion gears as a matched
bolts (A), and washers (B). set.
6. Remove the outer pinion bearing retainer plate (C). 12. Check both input pinion bearing cups (E, H) for wear,
nicks or scratches that would render them unsuitable
7. Remove the pinion bearing retainer (bearing preload)
for further service. Replace bearing cups and cones as
shims (D).
a set.
8. Remove the outer pinion bearing cup (E). Tap lightly
13. Arrange the parts of the input pinion gear and carrier
on the back side (small end) of the pinion (G) with a
assembly in sequence of removal as an aid to inspec-
hammer and punch to move the pinion and bearings (F)
tion and correct reassembly.
outward and drive the cup (E) from carrier.

A
B
C
D
E
F
G
H
I
J
K L
M
N
Figure 3. Input Gear Carrier Assembly

Drive Axle Shaft Disassembly

Refer to Figure 4.
1. The axle shaft output gear retainer (M) is held in place 8. Then, remove the axle shaft and outboard bearing cone
by three bolts (N) in the end of the axle shaft. The bolts (C-D) assembly from the housing.
are held from loosening by bending a tab of the fastener
lock plate (M) against a flat of each bolt head. Unbend 9. Inspect the shaft, spline, seal surface, wheel mounting
the tabs for removal of the bolts by working through flange and holes, and bearing for wear and other
the opening in the main housing and using a hammer damage that would require repair or replacement.
and a screwdriver or punch to flatten the tabs. 10. Inspect the outboard bearing cup (D) for wear and
2. Loosen and remove the three gear retainer bolts (N). other damage, nicks, cracks, scratches, and signs of
failure from excessive heat.
3. Remove the bolts (N), lock plate (M), gear retainer
plate (L), and shims (K). Then, reach inside the main 11. Remove the axle shaft oil seal (B).
housing and remove the drive axle shaft gear (J) by If axle shaft bearings need to be replaced, remove the
sliding it off the spline of axle shaft (A). Lift the gear bearing cups (outer races) (C, D) by pulling them from
out of the drive unit housing. drive unit housing bores.
4. Arrange these parts in the sequence of removal as an
aid to inspection and correct reassemble. Ring Gear Shaft Inboard Bearing Removal
Continue with disassembly and removal of drive axle Refer to Figure 2.
shaft from the drive unit housing. 1. With axle shaft gear and input pinion carrier assembly
5. Remove the formed plug (0), which seals the hole in removed, the ring gear shaft inboard bearing (S) is
wall of main housing, for access to the end of axle readily accessible. Remove the straight roller bearing
shaft. Drive the plug from the opening by lightly by pulling from the outer race.
tapping it with a hammer. A large punch or rod may b 2. Inspect the inner bearing-rolling surface of the outer
used.. race (B) of ring gear shaft inboard bearing for wear and
6. Working through the access hole where the seal plug damage. Look for nicks and scratches, pitting or any
(O) was removed, use a hammer and a brass drift pin unusual wear pattern. Replace, as needed.
or heavy punch to drive on the inner end of the axle 3. If bearing outer race requires removal for replacement,
shaft (A) and move the shaft out of the inboard roller remove the inner snap ring (C).
bearing cone (I). The shaft must be moved at least 25
mm (1 inch). 4. Remove the outer race (B) with an extracting tool
(puller).
7. After moving the drive axle shaft outwards sufficiently
to loosen the bearing fit on shaft, remove the inboard 5. Arrange the parts of the drive axle shaft assembly and
bearing cone (I). the ring gear inboard bearing for inspection.

O
N
M
L
K
J
I
H
G
F
Figure 4. Drive Axle Shaft Assembly
E
D
C
B
A
Cleaning and Inspection

Clean all parts with a good grade solvent and dry thor-
oughly. Do not let bearings spin dry if drying parts with air
pressure.
Inspect all parts for wear and other damage that could cause
malfunction or early failure:
• Gears and splines
• Bolts, nuts and washers
• Housings and covers
• Bearing cups and cones
• Spacers and snaprings
• Shafts and machined surfaces
Replace and seals and gaskets
Replace all parts that have failed, including those parts that
are worn or damaged in such a way that further serviceabil-
ity is questionable.
It is recommended that all bearings be replaced at each
overhaul.

Drive Unit Reassembly 8. Assemble the drive axle shaft inboard bearing cone (I)
on the end of axle shaft (A).
• Apply very light coating of Permatex No. 2 to OD of
all oil seals and hole plugs before assembly.
NOTE
• Apply light coating of Crane Sealer to all pipe plugs. Be sure to hold the axle shaft firmly in
• Use Crane Sealer on all capscrews and studs with thru place in the outboard bearing. Support
holes (housing end only). (back up) the outer end of axle shaft to
• After assembly of parts using Permatex or Crane prevent shaft from slipping out of outboard
Sealer, clean all surfaces. There must not be any free bearing while tapping the inboard bearing
or excess material that could enter the oil system. into place. Suggestion: Turn (rotate) hous-
ing up and support it temporarily on axle
• All lead-in chamfers for oil seals and O-rings must be shaft outer end.
smooth and free from burrs. Inspect at assembly.
• Lubricate all O-rings with oil before assembly. 9. Install axle shaft inboard bearing (I) into correct posi-
tion.
• Apply a thin coating of grease between seal lips on
lip-type seals prior to assembly. 10. A special tool for pressing or driving the axle shaft
inboard bearing cone into place may be fabricated as
• Brush specified transmission fluid on all tapered and
shown by Diagram A on the last page of this Section.
straight roller bearing cups and cones.
Install axle shaft gear on spline of axle shaft (A).
11. Install shims (K) against end of shaft, then gear retainer
Drive Axle Shaft Reassembly
plate (L), lock plate (M), and the three retainer bolts
Refer to Figure 5. (N). Do not bend tabs of lock plate until bearing
preload has been checked.
1. Press new axle shaft outboard bearing cup (D) (outer
race) into housing bore tight and square against snap 12. Torque gear retainer bolts (N) to:
ring.
44-49 N•m (32-36 ft-lb)
2. Install new oil seal (B). Press seal into bore until outer
13. Rotate the axle shaft to check for correct axle shaft
surface is flush with end of housing.
bearing preload setting. Add or remove shims (K) at
3. Install new axle shaft inboard bearing cup (H). Press end of shaft under the axle shaft gear retainer plate to
bearing cup into housing bore until tight and square obtain a bearing preload value of 0.68-1.13 N•m (6-10
against snap ring (G). NOTE - The use of a 73 mm OD in-lb). This is the torque required to rotate the shaft.
piece of tubing or spacer ring as a driver is suggested.
For rotating the axle shaft when checking axle shaft
4. Next, install outer race (B on Fig. 2) for ring gear shaft bearing preload, it is recommended that a special
inboard bearing, if removed. Press the outer race into adapter tool be constructed. This construction is shown
housing bore until tight and square against outer snap in Diagram B on the last page of this Section.
ring.
This tool is designed to fit into the wheel mounting
5. Install inner snap ring (A on Fig. 2) in housing groove flange bolt holes of the axle shaft. Attach a torque
against bearing outer race. wrench in the 3/8-inch square drive hole at the center.
Turn shaft slowly to measure torque required to rotate
6. Install the ring gear shaft inboard roller bearing (D on
the shaft.
Fig. 2).
14. When the correct axle shaft bearing preload has been
7. Then, put the axle shaft into the drive unit housing (F)
set, be sure the bolts are tightened to the correct torque.
end.
Then, bend the tabs of the lock plate against the bolt
IMPORTANT
heads.
Be very careful not to damage seal lips
when inserting shaft spline and bearing 15. To complete the drive axle shaft reassembly, install
through the seal. plug (0, Figure 5.) in access hole in wall of main
housing.

O
N
M
L
K
J
I
H
G
E
D
C
B Figure 5. Drive Axle Shaft Assembly
A

Input Pinion Gear Carrier Reassembly

Refer to Figure 6.
1. Arrange the parts of the pinion gear bearing carrier for 12. Install new O-ring seal (U) in groove of carrier (I) pilot
assembly. flange.
2. Install the tapered roller bearing cones (F, G) on the 13. Put pinion bearing carrier (pinion gear position) shims
pinion gear by pressing the inner races until firmly (K) on the carrier mounting surface. For initial assem-
seated square and tight against shoulders on gear. Be bly, use same number of shims and washers (N) as
sure to use a pressing tool or tubing of the correct were removed at disassembly. Install several bolts to
diameter and press on inner race only to prevent align and hold shims in place.
damage to the roller cages.
14. Put the pinion gear and carrier assembly on drive unit
3. Install the input pinion inner bearing cup (H) by main housing.
pressing the cup into carrier bore tight and square
against the shoulder. Be careful not to damage O-ring seal surface when
installing carrier pilot flange into housing.
4. Put the pinion gear and bearing assembly (F-H) into the
carrier. Be sure it is seated correctly into inner bearing 15. Install mounting bolts and washers and tighten.
cup. Bolt Tightening Torque: 77-88 N•m (57-65 ft-lb)
5. Then, using a pressing tool or a piece of tubing of
correct diameter for cup, install outer bearing cup (E) NOTE
by pressing or driving on cup until seated lightly After reassembly of the ring gear and shaft
against outer bearing rollers. assembly (see following section), check the
ring and pinion gears for tooth bearing
6. Install the input pinion bearing retainer (bearing preload pattern (correct position) and backlash.
adjustment) shims (D). For initial assembly, use same
Add or remove carrier mounting shims
number of shims as were removed at disassembly. Be
(noted above) as needed to adjust pinion
sure holes in shims are aligned with bolt holes in
gear position. Be sure carrier mounting
carrier.
bolts are tightened to correct torque after
7. Install the outer pinion bearing retainer plate (C). shim adjustment.
8. Install and tighten the eight bearing retainer plate bolts
(A).
Bolt Tightening Torque: 7-10 N•m (5-7 ft-lb)
9. After assembly, turn (rotate) the input pinion gear in
the bearings to check for correct bearing preload set-
ting.
As an aid for rotating the pinion gear, a temporary tool
may be made using a discarded drive motor shaft spline
end with a nut welded to it.
10. Put the tool into gear spline and turn the pinion gear
slowly with a torque wrench to measure torque re-
quired to rotate the pinion.
Add or remove shims at end of outer bearing cup under
retainer plate to obtain bearing preload value of:
0.11-0.56 N•m (1-5 in-lb) torque required to rotate
pinion gear.
Available shim thicknesses: 0.003, 0.004, 0.007,
0.010, and 0.020 inch.
12. When correct pinion bearing preload has been set, be
sure retainer bolts are tightened to the correct torque.

A
B
C
D
E
F
G
H
I
J
K L
M
N
Figure 6. Input Gear Carrier Assembly

Ring Gear Shaft Reassembly diameter for cup, install the outer bearing cup (U) into
bearing housing (W) bore by pressing or driving on cup
Refer to Figure 7. until it is lightly seated against outer bearing rollers.
1. Arrange the parts of the ring gear shaft and bearing 12. Install new oil seal (Q) in ring gear housing bearing cap
housing for assembly. (AA).
2. Install new inner tapered roller bearing cup (G) by Press oil seal (Q) flush with end surface of cap.
pressing into bearing housing (W) until firmly seated
square and tight against shoulder in housing. Apply a thin coating of grease between seal lips.
3. Next, install bearing cones on ring gear shaft (F) by 13. Put at least two bolts (P) with lockwashers (O) in
first placing bearing housing (W) with inner cup (G) bearing cap (M). Then, install the bearing cap (bearing
assembly over spline end of shaft. preload) shims (Z) on bearing cap. For initial assem-
bly, use same number of shims as were removed at
4. Put shaft spline end through bearing housing (i.e., fit disassembly.
housing over spline end of shaft). Press inner bearing
cone (T) tight and square against shoulder on shaft. 14. Install bearing cap and shims on ring gear bearing
Press outer cone (H) tight and square against inner housing.
cone. 15. Install and tighten all bearing cap fastener bolts (P) and
5. Install snap ring (I) into groove in shaft spline at end of washers.
outer bearing cone. Bolt Tightening Torque: 44-49 N•m (32-36 ft-lb)
NOTE
16. After assembly of ring gear shaft and bearings into
Alternate procedure for installing bearing cones on bearing housing, and installation of bearing cap, turn
ring gear shaft: (rotate) the ring gear shaft in the bearings to check for
a) Install inner bearing cup (G), both bearing correct bearing preload setting. Use a thin-wall socket,
cones (T, H), and outer cup into bearing hous- or make an adapter tool from a discarded brake disc
ing. hub, to turn the shaft by the spline with a torque
b) Temporarily install the bearing cap (AA) to wrench.
clamp the bearings in place in housing. Tighten 17. Turn the ring gear shaft slowly with a torque wrench to
bearing cap bolts to hold the bearing cones measure torque required to rotate the shaft. Add or
tight and square. remove shims under bearing cap to obtain bearing
c) Start the ring gear shaft (F) spline end into the preload value of
bearing cones (T, H) and, holding the bearing 0.11-0.56 N•m (1-5 in-lb)
housing with shaft vertical, lightly tap the pin-
ion end of shaft on a wooden block on the bench torque required to rotate shaft.
or floor until shaft is installed in bearings. 18. After correct bearing preload has been set, be sure
d) Remove bearing cap (AA). bearing cap bolts are tightened to correct torque.
e) Install snap ring (I). 19. Then, install the ring gear bearing housing (ring gear
6. Turn the shaft and housing assembly over and clamp position) shims (K) over studs (V) on drive unit hous-
the spline end of shaft in a vise. Use wood blocking in ing (R). For initial assembly, use same number of
vise to protect the spline. shims as were removed at disassembly.
7. Install new O-ring seal (J) in groove of bearing housing 20. Install ring gear shaft and bearing housing assembly
(H) pilot flange. into drive unit housing.
8. Install the ring gear (E) on mounting flange of shaft. 21. Install and tighten the combination of bearing housing
mounting bolts (X, Y, L, M), nuts and lockwashers.
9. Install and tighten the ring gear mounting bolts (D).
Tightening Torques:
Bolt Tightening Torque: 20-27 N•m (15-20 ft-lb
Bolts 44-49 N•m (32-36 ft-lb)
10. Remove assembly from vise and clamp in vise on
housing flange. Use wood blocking to protect flange Nuts 54-62 N•m (40-46 ft-lb)
surfaces. 22. After installation of ring gear and shaft assembly, and
11. Using a pressing tool or a piece of tubing of correct

input pinion (earlier), check the ring and pinion gears ing of gear checking compound, e.g., red lead, to the
for tooth bearing pattern (correct position) and back- ring gear teeth. Rotate the ring and pinion through a
lash. minimum of one revolution. Temporarily install the
brake disc (shown on Figure 1) to provide a means for
Add or remove ring gear bearing housing shims (K) as
loading the gear teeth.
needed to adjust ring gear position and backlash. Be
sure bearing housing mounting bolts are tightened to NOTE
correct torque after shim adjustment. Bearing Contact Chart is at the end of this
23. Final adjustments in shim thicknesses under input Section.
pinion carrier and ring gear bearing housing should be After above checks and adjustments are made, con-
made based on measurement of gear mesh backlash tinue with final assembly of drive unit.
with a dial indicator and on visual check of gear tooth
bearing patterns. (Refer to Tooth Bearing Contact
Chart at the end of this Section.) Gear mounting
information is etched on the ring gear.
24. Ring and pinion backlash of
0.050-0.127 mm (0.002-0.005 inch)
should be measured with a dial indicator.
Put (set up) a dial indicator on the top surface of the
drive unit housing. Use a long adapter to reach the gear Q
tooth surface inside the assembly. Backlash should be P
measured at three places around the ring gear (rotate O
the gear). N
25. Check gear tooth bearing patterns by applying a coat- M
L
K
J
I
H
AA
G
F Z
Y
X
E W
D
C V
B
A U
T
Figure 7. Ring Gear Shaft Assembly

Drive Axle Reassembly

1. Install new gasket on inspection cover with Permatex
(use Permatex to attach gasket to cover only). Inspection
Cover
2. Install inspection cover to top of unit and tighten bolts.
3. Install brake disc by sliding on spline of ring gear shaft. Vent
Apply a thin coating of grease to outside of brake disc
hub before pushing through the seal. Be careful not to
Unit
damage seal lips when installing disc.
Joining
4. Install and tighten drain plug. Bolt
5. Fill drive unit with recommended fluid.

6. Install and tighten fill plug.
Tighten fill and drain plugs to:
54-61 N•m (40-45 ft-lb) torque
7. Connect the two (right and left hand) drive units Fill Plug
together to form the drive axle assembly. Install the
fastener bolts in drive unit flanges. Be sure drive units
are aligned with the top surfaces even and parallel with
each other. Locate on the top surfaces while tightening
Drain Plug
the flange bolts. Hold top surfaces within 1.02 mm
(0.04 inch) before torquing bolts of two units together.
Bolt Tightening Torque: Drive Axle (Left Housing Only)
200-217 N•m (148-160 ft-lb)

Spiral Bevel and Hypoid Tooth Bearing Contact Chart
ALL CONTACT BEARINGS SHOWN BELOW ARE ON RIGHT HAND SPIRAL RING GEAR—
THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH.
TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH

WHILE UNDER A LIGHT LOAD
TOE BEARING ON BOTH SIDES OF TOOTH—GEAR SET NOISY.

TO MOVE BEARING TOWARD HEEL INCREASE BACKLASH
WITHIN LIMITS BY MOVING GEAR AWAY FROM PINION.
HEEL BEARING ON BOTH SIDES OF TOOTH—GEARSET NOISY

AND COULD RESULT IN EARLY GEAR FAILURE. TO MOVE
BEARING TOWARD TOE DECREASE BACKLASH WITHIN LIM-
ITS BY MOVING GEAR TOWARD PINION.
LOW BEARING ON GEAR AND HIGH BEARING ON PINION.

CORRECT BY PULLING PINION AWAY FROM GEAR (INCREASE
MOUNTING DISTANCE.
HIGH BEARING ON GEAR AND LOW BEARING ON PINION.

CORRECT BY MOVING PINION IN TOWARD GEAR (DECREASE
MOUNTING DISTANCE.
BACKLASH SHOULD BE MEASURED WITH A DIAL INDI CATOR RIGIDLY MOUNTED

WITH THE STEM PERPENDICULAR TO THE TOOTH SURFACE AT THE EXTREME HEEL.

Special Tools Fabrication
23 mm
(0.905 in)
50-60 mm
(2.205-2.362 in)
25 mm
(0.984 in)
45 mm 5 mm
(1.77 in) (0.197 in)
Digram A. Axle Shaft Inboard Bearing Cone Driver. Construct as indicated.
130 mm (5.118 in)

Dia 12 mm (0.50)
35 mm (1.378 in)
5 mm
(0.196 in) 9.6 mm (0.377 in)
9.6 mm
(0.377 in)
25 mm (1.00 in)
76 mm (3.00 in)
152 mm (6.00 in)
Digram B. Adapter Tool for for Checking Axle Shaft Bearing Preload. Construct as indicated.

GROUP 22
GROUP 22
WHEELS AND TIRES
Wheels and Tires Specifications and Description ........ Section 1
Wheels and Tires Mounting and Maintenance ............ Section 2
SM 616, April ’98 Copyrighted Material Wheels and Tires

NOTES:
Wheels and Tires Copyrighted Material SM 616, April ’98

Group 22, Wheels and Tires
Section 1.
Wheels and Tires

Cushion tires are mounted on one-piece rims. A general
Cushion description of cushion tire removal and replacement ap-
pears in the section for cushion tires. However only trained
Material: Rubber except as noted. and experienced personnel with the proper equipment should
Size: attempt to change out cushion tires on the rims.
Drive Steer Pneumatic tires are mounted on multi-piece rims with lock-
TMG 12/13/15/15S: 18x7x12.1 18x7x12.1 ing rings.
TMG 17/18/20 18x8x12.1 18x7x12.1
TMG 20x/25 18x9x12.1 18x6x12.1 WARNING
(Urethane)
For your safety and the safety of others,
Mounting Nut Torques: Refter to mounting procedure in before you do tire or rim maintenance or
Section 2. service, read the OSHA rules regarding
owner responsibility. Do not work on tires
or rims unless you have been trained in the
Pneumatic correct procedures. Read and understand
Material: Rubber all maintenance and repair procedures on
tires and rims. Serious injury or death can
Size:
result if safety messages are ignored.
For US Market Drive Steer
TMG12/15: 18x7x8-16PR 18x7x8-16PR The Occupational Safety and Health Act (OSHA) specifies
TMG 15S: 18x7x8-16PR 18x7(Solid only) required procedures for servicing multi-piece rim wheels in
TMG 17/18/20 18x9x8-16PR – 29 CFR Section 1910.177. It is the owner’s responsibility
For Other Markets Drive Steer to comply with OSHA.
TMG13/15S/15/18 18x9x8 18x9x8 In accordance with OSHA, the owner must provide a train-
TMG13/15S/15/18/20x – 15x4 1/2 x8 ing program to train and instruct all employees who service
Mounting Nut Torques: Refter to mounting procedure in multi-piece rim wheels in the hazards involved and the
Section 3. safety procedures to be followed. Do not let anyone mount,
demount, or service multi-piece rim wheels without correct
Drive Steer training.
EPG 15 18x7x8-16PR 5.00x8-10PR The owner should obtain and maintain in the service area
EPG 18 18x9x8-16PR 5.00x8-10PR current copies of the United States Department of Trans-
portation, National Highway Traffic Safety Administration
publications entitled “Safety Precautions for Mounting and
Service Intervals Demounting Tube-Type Truck/Bus Tires,” and Multi-Piece
Wheel Mounting Bolts Check and Tightening: Every 50- Rim/Wheel Matching Chart” or other similar publications
250 hours of operation and each PM. applicable to the types of multi-piece rim wheels being
serviced.
Tire Condition: Daily inspection.
Tire Pressure Check: Daily inspection.
SM 616,
SM 616, Dec ’02①➀
Jul ’01 Copyrighted
WheelsMaterial
and Tires Specifications and Description • 22-1-1
22-1-2 • Wheels and Tires Specifications andCopyrighted

DescriptionMaterial SM 616, April ’98
Section 2.
Wheels and Tires Mounting and Maintenance
Drive and Steer Wheels Removal and Installation ..................................................................... 2
Cushion Tire Replacement ............................................................................................................ 2
Pneumatic Tire Maintenance ........................................................................................................ 3

Precautions ....................................................................................................................................... 3
Maintenance, Inspection, and Repair ............................................................................................... 4
Inspection and Minor Repair ........................................................................................................... 4
Wheel Disassembly and Tire Removal ............................................................................................ 5
Mounting of Directional Tread Tire ............................................................................................... 7
Directional-Tread Single Drive Tires ....................................................................................... 7
Directional-Tread Dual Tires .................................................................................................... 7
Filling Tires with Air ....................................................................................................................... 8
Filling Tires with Nitrogen .............................................................................................................. 8
Checking and Adjusting Tire Pressure ............................................................................................ 9

Wheels and Tires Mounting and Maintenance • 22-2-1
Drive and Steer Wheels Removal and Cushion Tire Replacement

Installation CAUTION
Replacement of the original equipment tires
Removal with tires other than those recommended
by CLARK may result in decreased oper-
1. Loosen wheel bolts then use a portable jack of correct ating performance and stability.
capacity placed under the frame of truck to raise drive
wheel off floor. See “Lifting, Jacking, and Blocking” 1. The correct procedure for tire removal and replace-
in Group SA for correct, safe procedures for jacking ment requires a suitable press for pressing old tire off
the truck. wheel and pressing new tire onto wheel.
2. Remove wheel bolts and lift the tire and wheel assem- IMPORTANT
bly from drive axle hub. Cushion tires cannot be reused after once
being pressed on and removed from the
Installation wheel. The correct press fit is destroyed
after one installation and removal. Replace
1. Install wheel and tire assembly on drive axle hub. with new tire.
Begin tightening the wheel bolt.
2. Use a crisscrossing bolt-tightening sequence to 2. Position tire on press, making sure there is adequate
pre-torque the wheel bolts 54-81 N·m (40-60 ft- clearance for the tire to be pressed off of wheel.
lb).
3. Use suitable tooling with the hydraulic press to cor-
rectly contact the base band of tire to press it off the
1 wheel.
3 6 4. Install new tire. Mount all tires with identification and
type markings toward outside of wheel. Tire is to be
pressed on wheel with the outer edges flush.
4
5
2
3. Begin the crisscrossing sequence again and torque

the wheel bolts to 255-275 N·m (188-203 ft-lb).
IMPORTANT
Do not over-torque the wheel bolts. Damage to
the wheel bolts, wheel, or drive-axle hub may
result.
4. Lower truck to floor and remove jack.
Drive Axle
Hub
22-2-2 • Wheels and Tires Mounting and Maintenance SM
SM616,
616,Dec ➀
’02’98
April
8. Never attempt to weld on an inflated tire/rim assembly.

Pneumatic Tire Maintenance
9. Clean rims and repaint to stop detrimental effects of
corrosion. Be very careful to clean all dirt and rust
Precautions from the lock ring gutter. This is important to secure
The following instructions supplement the OSHA require- the lock ring in its proper position.
ments. In the event of any conflict or inconsistency be- A filter on the air filling equipment to remove the
tween these instructions and the OSHA requirements, the moisture from the air line prevents a lot of corrosion.
OSHA requirements shall be controlling. The filter should be checked periodically to make sure
it is working properly.
WARNING 10. Make sure correct parts are being assembled. Ask your
Before you do tire or rim maintenance, distributor or the manufacturer if you have any doubts.
read the OSHA rules regarding owner re-
sponsibility. Read and understand all main- 11. Do not be careless or take chances. If you are not sure
tenance and repair procedures on tires and about the proper mating of rim and wheel parts, consult
rims. Do not work on tires or rims unless a wheel and rim expert. This may be the tire man who
you have been trained in the correct proce- is servicing your fleet, the rim and wheel distributor in
dures. Serious injury or death can result if your area, or the CLARK dealer.
the safety messages are ignored. 12. Mixing parts of one manufacturer’s rims with those of
another is potentially dangerous. Always ask manu-
1. Do not let anyone mount or demount tires without facturer for approval.
proper training.
13. Do not use undersized rims. Use the right rims for the
2. Never sit on or stand in front of a tire and rim assembly job.
that is being filled with air. Use a clip-on chuck and
make sure the hose is long enough to permit the person 14. Do not overload rims. Ask your rim manufacturer if
filling the tire with air to stand to the side of the tire, not special operating conditions are required.
in front or in back of the tire assembly. 15. Do not seat rings by hitting with a hammer while the
3. Never operate a vehicle on only one tire of a dual tire is filled with air pressure. Do not hit a filled or
assembly. The carrying capacity of the single tire and partially-filled tire/rim assembly with a hammer.
rim is dangerously exceeded, and operating a vehicle 16. Double check to make sure all the components are
in this manner can result in damage to the rim and truck properly seated prior to filling tire with air.
tip-over and driver injury.
17. Have the tire in a safety cage when filling with air.
4. Do not fill a tire with air that has been run flat without
18. When removing wheels, regardless of how hard or
first inspecting the tire, rim, and wheel assembly.
firm the ground appears, put hardwood blocks under
Double check the lock ring for damage. Make sure that
the jack.
it is secure in the gutter before filling the tire with air.
19. Block the tire and wheel on the other side of the
5. Always remove all air from a single tire and from both
vehicle, before you place the jack in position. Place
tires of a dual assembly prior to removing any rim
blocks under the truck frame as near as possible to the
components, or any wheel components, such as nuts
jack to prevent the truck from falling if the jack should
and rim clamps. Always remove the valve core to
fail.
remove air from tire. Be sure all air is removed.
20. Remove the bead seat band slowly to prevent it from
6. Check rim components periodically for fatigue cracks.
dropping off and crushing your toes. Support the band
Replace all cracked, badly worn, damaged, and se-
on your thigh and roll it slowly to the ground. This will
verely rusted components.
protect your back and feet.
7. Do not, under any circumstances, attempt to rework,
21. Bead breakers and rams apply pressure to bead flanges.
weld, heat, or braze any rim components that are
Keep your fingers away from the bead flanges. Slant
cracked, broken, or damaged. Replace with new parts
bead breaker about 10° to keep it firmly in place. If it
or parts that are not damaged, which are of the same
slips off, it can fly with enough force to kill. Always
size, type, and make.
stand to one side when you apply hydraulic pressure.

Maintenance, Inspection, and Repair 3. Check all wheel lug nuts or bolts to be sure none are
loose or missing. Have missing bolts replaced and
1. Park the truck as described in “Safe Parking” and loose bolts tightened to the correct torque before oper-
check for correct tire inflation air pressure. ating the truck.
• Drive 861 kPa (125 psi) - TMG
1000 kPa (145 psi) EPG 15
Inspection and Minor Repair
1034 kPa (150 psi) EPG 18
• Steer 861 kPa (125 psi all models) - TMG. Inspect pneumatic tires and wheels carefully for:
883 kPa (128 psi) - EPG 15/18 1. Low inflation pressure.
2. Damaged tires. Check tires for cuts and breaks.
CAUTION
Check tire pressure from a position facing the 3. Damaged wheels or loosening of the lock ring on multi-piece
tread of the tire, not the side. Use a long- rims.
handled gauge to keep your body away from
the side.
Wheel
Wedge
Lock
Ring
4. Check for loose nuts or bolts not in position.

5. Check the nuts or bolts for damage.
• If tires are low, do not add air. Have the tire
6. Check the surface of the wheels for bent flanges.
and wheel inspected by a person trained and
authorized to do tire and wheel maintenance. 7. Check all parts for rust or corrosion.
The tire may require removal and repair.
8. Mark the damaged areas with chalk so that the parts can be
• Incorrect (low) tire pressure can reduce the
removed from operation.
stability of a lift truck and cause it to tip over.
9. Remove all parts that are damaged and install new parts in the
IMPORTANT
same position.
Check wheels and tires for damage every
time you check tire pressure. Make re- 10. Replace parts with the correct sizes and types. See your parts
pairs when needed. Dirt can get into cuts manual.
and cause damage to the tire cord and tread.
Remove debris from all cuts. 11 . Include your truck serial number when ordering replacement
parts.
2. Check the condition of the drive and steer wheels and
tires. Remove objects that are imbedded in the tread.
Inspect the tires for excessive wear, cuts and breaks.
22-2-4 • Wheels and Tires Mounting and Maintenance SM
SM616,
616,Dec ➀
’02’98
April
.
Wheel Disassembly and Tire Removal
1. Remove valve core from the valve stem to be sure all 6. Repair tire and/or tube, as needed.
air is removed. 7. Check for cracks in the wheel.
WARNING
Before starting disassembly, remove the air
from the tire. Failure to remove the air
from the tire can result in serious injury.
2. Remove lock ring.
Lock Ring
Wheel
Wedge
Cracks in the wheel are caused by:

• Deep rim tool marks.
• Overload on wheels.
• Too much air pressure in the tires.
• Using the wrong size tires.
3. Remove wheel wedge. 8. Check for cracks in the lock ring.
4. Remove tire from wheel. 9. Check for cracks between the stud holes in the wheel.
Cracks are caused by:
• Loose wheel nuts.
• Wheel not installed correctly.
• Wrong size or type of parts used.
• Too much torque on the wheel fasteners. If the
wheel mounting parts are too tight, the studs or
bolts can break, causing cracks in the wheel be-
tween the stud holes.
• Too little torque on the wheel fasteners. If the
wheel mounting parts are too loose, damage to
parts and tire wear will result.
5. Remove the rubber inner tube protector (flap). 10. Check wedge ring for wear or damage. Corrosion
buildup will cause wear and damage to the wheel
wedge ring.
11. Clean the wheels. Remove rust and dirt.
12. Clean the tire bead seat area. Remove all rust and
rubber with a wire brush or wheel.

13. Clean wedge and lock rings. Make sure the seating 3. Install the tire onto the wheel rim, against the bead seat
surface and bead seat areas are clean. area.
14. Apply paint to the tire rim with a brush. Or, use an 4. Put the wheel wedge over the rim.
aerosol can of metal primer.
The parts must be clean and dry before you apply the
paint. Make sure to apply paint to the outside or tire
side of the rim. This is important because air is on the
metal surface of the tire side of the rim.
15. Apply lubricant on the tire side of the rim base. Do not
use a lubricant that has water or solvent which will
cause damage to the rubber.
NOTE 5. Install the wheel wedge.
Clark dealers can supply the correct lubri-
cant, which contains a rust inhibitor.
Tire Replacement and Wheel
Reassembly
1. Put the tube into the tire.
6. Put the side ring over the rim and install the lock ring
as shown.
IMPORTANT
Install washer 22.123 on tube over valve
stem before flap is installed, when specified.
See sketch. Refer to Service Parts List.
7. Connect air chuck and turn the tire over with the valve
stem down. Put 21 kPa (3 psi) of air into the tire.
2. Put the rubber tube protector (flap) over the tube.
22-2-6 • Wheels and Tires Mounting and Maintenance SM 616, April ’98
Mounting of Directional Tread Tire

All directional-tread tires are to be mounted in the correct
position with respect to the arrow cast on the side of the tire
as explained below.
8. Turn wheel to the other side. Check to make sure lock

ring is in correct location.
Directional-Tread Single Drive Tires

• Tire arrow to point in the direction of forward rotation.
Rotate wheel to bring arrow on tire above the wheel
center. Arrow must point toward front of truck.
9. Disconnect the air chuck. Use a mallet and hit the ring
to make sure the ring is fully installed.
Directional-Tread Dual Tires

1. Inside dual tire arrow to point in the direction of forward
rotation. Rotate wheel to bring arrow on tire above the
wheel center. Arrow must point toward front of truck.
10. Put the tire in an OSHA-approved safety cage.
2. Outside dual tire arrow to point in the direction of

rearward rotation. Rotate wheel to bring arrow on tire
above the wheel center. Arrow should point toward
rear of truck.

Filling Tires with Air

Follow these procedures when putting air into tires. All
wheel and tire assemblies must be filled in a safety cage.
The hose must have an adapter that can be connected to the
valve stem.
1. Attach an air hose to valve stem.
2. Open the control valve which will let compressed air
into the tire.
3. At intervals, close the control valve and check the
pressure in the tire by reading the gauge. Do not put too
3. Slowly turn the cylinder valve counterclockwise (CCW)
much pressure into the tire.
to open position.
4. Continue to fill the tire to the correct air pressure. See
the Operator’s Manual for correct tire inflation pres-
sure.
IMPORTANT
Put equal pressure in both tires of a dual
assembly. Do not put air into a tire that is
flat without first inspecting it and the wheel
for damage.
Filling Tires with Nitrogen

4. The tank gauge will now show tank pressure.
If your air supply does not have enough pressure to fill the
tire, you can use a pressurized cylinder of commercial
nitrogen gas to get the correct tire pressure. With the tire in
a safety cage, connect the nitrogen cylinder to the valve
stem with the use of an air chuck.
WARNING
Use nitrogen only. Do not use oxygen or
any other gas to fill tires. Make sure all
items of equipment used (nitrogen cylin-
der, regulator, gauges, hoses) are UL ap-
proved and in good condition. Use the 5. Turn the regulator valve clockwise (CW) until the
correct regulator and hose for the pres- regulator gauge reads the correct tire pressure. Fill the
sures that are necessary. tire with nitrogen.
1. Be sure tank valve is closed to connect hose to valve

stem. Tank valve is closed by turning handle on top of
tank clockwise to a stop.
2. Turn the regulator valve counterclockwise (CCW)
until you can feel no resistance from the regulator.
This will adjust the regulator pressure to a low pressure
near zero.
6. Turn the tank valve clockwise (CW) and close the Checking and Adjusting Tire Pressure
valve.
WARNING
Before you add air pressure to the tire,
make sure the lock ring is correctly posi-
tioned in the rim and wheel wedge. The
lock ring can separate from the rim with
enough force to cause injury or death.
7. Disconnect the air chuck from the valve stem.
1. Attach a clip-on air chuck to valve stem. Stand by the

side of the wheel and put the correct air pressure in the
tire.
8. Turn the regulator valve counterclockwise (CCW) to

the off position.
2. If your air supply does not have enough pressure to fill

the tire, you can use a nitrogen cylinder to get the
correct pressure.
9. Use a tire pressure gauge to check the tire pressure. If

necessary, put more air into the tire. Do this as many
times as necessary to reach the correct tire pressure.
CAUTION
Use a long-handled gauge so that your hand 3. Put a clip-on type air chuck on the nitrogen cylinder
does not go inside the cage, or in front of hose and attach it to the valve stem. Follow the
any component of a multi-piece wheel. procedures described previously for adjustment of the
nitrogen cylinder valves.
WARNING
Use nitrogen only. Do not use oxygen or
any other gas to fill tires.

GROUP 23, BRAKES
GROUP 23
BRAKES
Brake Specifications ....................................................... Section 1
Brake System Fluid Check, Fill, and Bleed .................. Section 2
Brake Pedal and Master Cylinder Removal, Replacement, and

Adjustment .............................................................. Section 3
Brake Caliper Removal and Replacement ................... Section 4
Parking Brake Removal, Replacement, and

Adjustment .............................................................. Section 5
Brake Overhaul .............................................................. Section 6
SM 616, April ’98 Copyrighted Material Brakes

NOTES:
Brakes Copyrighted Material SM 616, April ’98

Group 23, Brakes
Section 1.
Brake
Specifications Service Requirements

Service Brake: Operational checks and inspection of linkages, brake pads,
Type: Caliper. and brake lines are specified in the Periodic Service Chart
in Group PS.
Minimum lining/pad thickness: 0.67 mm (0.06 in).
Service brake linkage adjustment and lube are not normally
Fluid Type: SAEJ1703 (DOT-3) brake fluid only. required.
Fluid Capacity: 0.256 L (0.06 gal). Brake pads are self-adjusting.
Pedal Freeplay: 1-3 mm (0.039-0.118 in; measured at stop A leaking caliper or master cylinder should be overhauled
screw). or replaced.
Parking Brake: Parking brake should be adjusted if indicated by opera-
Type: Lever-type mechanically linked to brake assembly. tional check.
Holding Test: Rated load on 15% grade. The following sections in this Group provide service proce-
dures for the service and parking brake assemblies.
Description
(See illustration on the next page.)
The service brake pedal operates a master cylinder mounted
on the front cowl.
The master cylinder operates a caliper assembly centrally
mounted on the two drive axle housings.
When the caliper assembly is activated, its pads grip the
brake discs mounted on the inboard end of each drive axle
pinion shaft. Friction betwen the pads and disks slows or
stops rotation of the drive axle.
There is no power assist for the service brake.
The parking brake handle operates a ratchet and cable that
closes or releases the caliper assembly.
See Group 20,“”Drive Axle,” for more detail.
SM 616, April ’98 Copyrighted Material Brake Specifications • 23-1-1

Group 23, Brakes
Parking Brake and Linkage to Brake Caliper Reservoir, Pedal, Master Cylinder and Linkage
Brake Caliper and Brake Lines

Installation to Drive Axle
23-1-2 • Brake Specifications Copyrighted Material SM 616, April ’98

Group 23. Brakes
Section 2.
Fluid Check, Fill, and Bleed
Check and Fill

Inspect brake fluid level in reservoir through window in Proceed as follows:
left cowl cover. A flashlight may be needed.
1. Park truck on level floor. Put direction control in
If fluid level is below full mark, remove cowl cover as neutral. Lower forks to floor, tilt forward, and apply
described in Group 38 and fill reservoir to full mark with parking brake.
DOT 3 fluid.
2. Attach a clear hose to a bleed screw on the brake
caliper. Place the other end of the hose in a vessel
containing fluid.
3. Fill the brake fluid reservoir.
4. Open the bleed screw.
5. Pump the brake pedal until the fluid flowing from the
hose is free of bubbles.
Reservoir
Window
Bleeding 6. Continue pumping the brakes and tighten the bleed

Bleed brakes when: screw.
• The brake pedal feels spongy or low. 7. Repeat for the other caliper bleed screw.
• The master cylinder, caliper, or brake lines have been 8. Operate the brake pedal at various rates. If the pedal
leaking, repaired, or replaced. feels spongy or low, bleed the lines again.
• Troubleshooting indicates that air has been introduced 9. Refill the master cylinder to the full mark.
into the system.
Bleed Screw
Clear Bleeder
Hose
NOTE
Make sure that brake pedal
freeplay is correctly set be-
fore bleeding the brakes.
Bleed Screw
SM 616, April ’98 Copyrighted Material Brake Bleeding • 23-2-1

Group 23, Brakes
23-2-2 • Brake Bleeding Copyrighted Material SM 616, April ’98

Group 23, Brakes
Section 3.
Pedal and Master Cylinder

Removal, Replacement, and Adjustment
SM 616, April ’98 Pedal Material

Copyrighted and Master Cylinder R&R and Adjustment • 23-3-1
Group 23, Brakes
Components Disassembly Pedal Adjustment

Use Figures 1, 2, and 3 as guide to disassembly and adjust- With all components replaced and fasteners tightened to
ment. correct torque, adjust the pedal as follows:
1. Adjust pedal stop screw (item F) to provide 1-3 mm
Components Reassembly (0.04-0.12 in) of free play.
Replace the brake pedal components as shown in Figures 1 2. When free play is adjusted, tighten the jam nut on the
and 2 using fastener torques where shown. Also use the stop screw to set the distance.
following notes: 3. Adjust micro-switch to activate just before end of
1. Clean the reservoir and master cylinder hoses and pedal free play. See Group 13 for brake switch check
fittings. Make sure no contaminants enter the braking and adjustments.
system.
2. Adjust pedal free play and micro-switch as described
in “Pedal Adjustment” on this page.
3. After re-assembly and adjustment, the brake system
must be bled; see Section 2 in this Group. After
bleeding, check all fluid connections for leaks and test
brakes completely before returning truck to service.
4. Note orientation of pedal spring. Upper (shorter) end
catches in cowl bracket. Lower (longer) end catches on
pin in link.
23-3-2 • Pedal and Master Cylinder R&R and Adjustment

Group 23, Brakes
Torque:
20-25 N•m
(177-221 in-lb)
See Figure 2 for Larger View
C
A Hose to Master Cylinder
B Reservoir
D C Brackets Welded to Cowl

D Pedal
A E Pedal Spring
F Stop Screw
G Pedal Link
Torque: H Master Cylinder Link

F 40-45 N•m I Master Cylinder
E (30-33 ft-lb)
J Fitting to Brake Caliper
G Line
Torque:
H 8-10 N•m
(71-88 in-lb)
See Figure 3 for Larger View
I
Torque:
20-25 N•m
(177-221 in-lb) J
(4 fasteners)
Figure 1. Reservoir, Pedal, Linkage, and Master Cylinder Assembly.

Group 23, Brakes
Figure 2. Upper Area of Figure 1 Enlarged

Group 23, Brakes
Figure 3. Lower Area of Figure 1 Enlarged

Group 23, Brakes

Group 23, Brake
Section 4.
Brake Caliper Removal and

Replacement
SM 616, April ’98 Brake Caliper Removal and Replacement • 23-4-1

Group 23, Brake
Introduction Brake Replacement.

Figures 1 and 2 show: 1. To replace rotors:
• The brake mounting on the drive axle. a. Coat splines of brake rotor with an anti-seize
compound before installing in truck.
• The connections from the master cylinder to the brake.
b. Grasp rotor around the outer edge and line up with
The illustrations and accompanying text serve as a guide to the spline.
removal and replacement.
c. Push rotor onto splined shaft until it is fully
Before beginning this service procedure: engaged.
• Park the truck on a level surface and lower the upright d. Repeat for opposite rotor. Both rotors should be
completely. free to float on the splines.
• Raise and block the upright for better access as de-
2. Replace brake as shown in Figure 1:
scribed in Group SA.
a. Mount brake over disk.
• Return all controls to neutral and turn key switch to
OFF position. b. Set mounting bolts in place and torque to 0.5-2
N•m (0.4-1.5 ft-lb).
• Block the wheels.
c. Replace tube assemblies at the compression fit-
See Section 3 for procedures to remove brake pedal and tings. Do not overtighten.
master cylinder. See Section 6 for brake overhaul proce-
d. Press brake pedal to align brake and disk.
dures.
e. Torque mounting bolts to 60-65 N•m (44-48 ft-
lb).
Brake Removal
3. Replace rear cover. Torque top bolts to 60-65 N•m
1. Disconnect tube assemblies from brake at the com- (44-48 ft-lb); torque bottom nut to 170-190 N•m (125-
pression fittings shown in Figure 2. Move tubing out of 140 ft-lb).
the way; disconnect from the tee if necessary.
2. Remove the cotter pin from the parking brake caliper IMPORTANT
clevis (see Section 5). Both sides of brake must be checked and
3. Remove bolts and washers from brake mounting fully refilled with proper lubricant. See
bracket. Lift the caliper assembly from the transaxle. brake bleeding Section in this Group.
4. To remove the brake rotors:

a. Slide the left-side rotor off of the splined shaft and
lift out.
b. Repeat for opposite rotor.
c. Inspect axle seals per procedures in Group
Transaxle. Replace if worn, leaking, or damaged.
23-4-2 • Brake Caliper Removal and Replacement

Group 23, Brake
Torque: Caliper Assembly

60-65 N•m
(44-48 ft-lb)
Front Cover
Rear
Cover
Figure 1. Brake Mounting
Torque:
170-190 N•m
(125-140 ft-lb)
Drive Axle
Assembly
Brake
Disks
Tube
Assembly
Compression
Fitting
Figure 2. Brake Tubing Connections
Brake Rotors
SM 616, April ’98 Brake Caliper Removal and Replacement • 23-4-3

Group 23, Brake
23-4-4 • Brake Caliper Removal and Replacement

Group 23, Brakes
Section 5. Parking Brake Removal, Replacement, and Adjustment
Removal and Replacement 2. Set brake handle to Off (down) position.

Remove and replace parking brake components as shown in 3. Tighten adjustment set nut until all clearance between
the illustration. pads and disks is removed.
4. Loosen set nut 1/2 turn. This allows approximately
Adjustment 1 mm (0.03 in) gap between brake and pad.
5. Tighten jam nut.
Parking brake must be adjusted after removal and
replacement and at every PM. 6. Adjust parking brake by tightening or loosening the
operator’s adjustor in the brake handle so that the truck
1. Install parking brake assembly and adjust cable so that
holds on 15% grade.
caliper lever is horizontal.
7. See Group 13 for parking brake switch check and
adjustment.
Hand Lever
Assembly Torque:
240-300 N•m
(177-221 ft-lb)
Parking Brake
Switch
Torque:
30-32 N•m
(22-26 ft-lb) Pad
Disk
Set Nut
Jam Nut
Caliper
Lever
SM 616, April ’98 Copyrighted Material Parking Brake R&R and Adjustment • 23-5-1
Group 23, Brakes
23-5-2 • Parking Brake R&R and AdjustmentCopyrighted Material SM 616, April ’98
Group 23. Brakes
Section 6.
Brake Overhaul
IMPORTANT
Brake carrier and lining assemblies must
be replaced when lining material
is less than 0 .67mm (0.060 in).
Use the Disassembly and Assembly procedures to

overhaul the brake. Replace components using the
correct rebuild kit. Brake valves are not serviceable.
See Group Sections for procedures to remove, re-
place, adjust, and bleed brake and components.
SM 616, April ’98 Copyrighted Material Brake Overhaul • 23-6-1

Group 23, Brakes
Disassembly Assembly
Carrier and Lining Removal Caliper Assembly

1. Remove parking brake jam and adjustment nuts from 1. Slide the brake valves in place on the brake shoe pivots.
the adjustment bolt and washer.
2. Set the mounting brackets in position and install pivot
2. Remove the parking brake lever arm with adjustment retainer nuts; torque 115-129 N•m (85-95 ft-lb).
bolt and washer.
3. Remove the pad retainer nut from the sleeve and repeat Carrier and Lining Assembly
for opposite side.
1. Insert the outer carrier and lining assembly between
4. Push brake sleeves into bushings and remove carrier the brake shoe pivots. Position the carrier against
and lining assemblies. brake valve.
NOTE
Caliper Disassembly Apply a thin coat of an anti-seize com-
pound to the brake sleeves before installing
1. Remove the nuts securing the brake valves and brake
to carrier and liner assemblies.
shoe pivots in the mounting brackets.
2. Pull the mounting brackets apart from the brake valves 2. Install the sleeves through valve bushings and insert
and brake shoe pivots. threaded end of sleeves through the outer carrier and
lining assembly.
3. Install pad retainer nuts to sleeves; torque 75-85 N•m
Parts Inspection (101-115 ft-lb).
Brake carrier and lining assemblies must be replaced when
4. Install spacer plate between two carrier and lining
lining material is less than 0 .67mm (0.060 in).
assemblies and in the center groove of the actuating
All parts must be clean and free of dust and chips before pins.
assembly. Thoroughly clean all drilled passages, seal
5. Install the inner carrier and liner assembly between the
grooves, and threads in the brake valves. If parts are
outer carrier and lining assembly and the center spacer
damaged or worn, replace the brake valve.
plate.
1. Clean brake valves with solvent: NOTE
a. Check all cylinder bores for nicks, scratches, or Apply a thin coat of an anti-seize com-
corrosion and blend with crocus cloth. pound to the actuator pins before installing
to brake valves.
b. Check all fluid passages and grooves and clean
remaining dirt and fluid completely out. 6. Install two actuator pins into brake valve on side of
2. Inspect piston assemblies for scratches and nicks and parking brake lever arm.
7. Install adjustment bolt and washer with parking brake
blend with a crocus cloth. Replace the valve if piston lever arm through brake sleeves, spacers, and carrier
is badly scratched. and lining assemblies.
3. Check actuating pins for grooves. Pins with light 8. Install parking brake adjustment and jam nuts, do not
grooves may be rotated so grooved portion is opposite torque. See Section 5 for parking brake adjustment.
the end of the carrier and lining assemblies. Replace
If removed, install bleeder screws to valves (torque 4.5-11
deeply grooved actuating pins.
N•m [3.3-8.3 ft-lb]). See Section 4 for procedures to
4. Bushings should be flush with inside machined surface replace and adjust the brake.
of the valve. Press bushings flush if necessary.
5. Lubricate piston seals lightly with automotive brake
fluid or silicon grease compatible with brake fluid. Do
not use petroleum-based oils or lubricants.
23-6-2 • Brake Overhaul Copyrighted Material SM 616, April ’98

Group 23. Brakes
Bushing
Pad Retainer Nut; torque 75-85 N•m
(101-115 ft-lb)
Bleeder Screw; torque
4.5-11 N•m (3.3-8.3 ft-lb)
Parking Brake Adjustment and Jam Nuts
Actuating Pin
(Jam nut torque; 31-37 N•m [25-28 ft-lb])
Pivot Retainer Nut; torque 115-

Sleeve
129 N•m (85-95 ft-lb)
Spacer Fastener
Brake Carrier and

Valve Lining Operating
Assembly Cam
LH Mounting Brake
Bracket Valve
Brake Shoe
Parking
Pivot
Piston RH Mounting Brake Lever
Assembly Bracket Arm
Adjustment Bolt and

Washer
SM 616, April ’98 Copyrighted Material Brake Overhaul • 23-6-3

Group 23, Brakes
23-6-4 • Brake Overhaul Copyrighted Material SM 616, April ’98

GROUP 25/26
GROUP 25/26
STEERING
Steering System Specifications

and Description........................................................ Section 1
Steering System Troubleshooting .................................. Section 2
Steering Column and Component

Removal and Replacement ..................................... Section 3
Steering System Relief Pressure Check

and Adjustment ...................................................... Section 4
Steering Gear Overhaul ................................................. Section 5
Steer Axle Service ........................................................... Section 6
Steer Cylinder Overhaul ................................................ Section 7
Steer Pump Overhaul ..................................................... Section 8
SM 616, April ’98 Copyrighted Material Steering

NOTES:
Steering Copyrighted Material SM 616, April ’98

Group 25/26, Steering
Section 1.
Steering System Specifications and

Description
Steering System Type: Load sensing hydrostatic power All truck models have a hydrostatic power steering sys-
steering with variable ratio. tem, which is supplied with oil pressure from the main
hydraulic system pump. The steering handwheel oper-
Steering System Relief Pressure Setting:
ates the power steering gear (steering control valve) shown
8274-8963 kPa (1200-1300 psi).
on page 2, which directs oil flow to the steering cylinder
on the steer axle. The steering cylinder operates the
Service Intervals steering linkage and steer wheel described on page 3.
Check the steering system relief pressure annually or A steering system pressure relief valve, contained in the
after every 2000 hours of operation. Make a visual in- hydraulic pump assembly shown on page 4, prevents
spection of steering control unit hydraulic fittings peri- over-pressurization of the steering system. The pressure
odically to ensure that the fittings are tight with no leakage. relief setting can be tested using the gauge port of the
hydraulic pump.
Fastener Torques The steering gear shaft is connected to the handwheel by
Steering Handwheel Nut: 35-40 N·m (25.5-29.5 ft-lb) means of a jointed shaft. When the steering handwheel
turns, it causes the steering gear’s spool valve to shift
Steering Column Cover Hex Bolts: 2-3 N·m (18-27 in-lb;
from its closed neutral position to a “turn” position. This
1.5-2.25 ft-lb)
shifting of the spool directs flow to one end or other of
Directional Control Base Lock Nut: 0.8-1 N·m (7-9 in-lb; the steering cylinder, depending on the direction of the
0.6-0.75 ft-lb) turn. The amount of flow, and the sharpness of the turn,
Directional Control Base Flange Capscrew: 3.5-4.0 N·m depend on how far the handwheel is rotated. The more
(2.5-2.9 ft-lb) rapidly the handwheel turns, the more quickly the flow,
and the turn, occur.
Ignition Switch Ring Nut: 10-14 N·m (7.3-10.3 ft-lb)
The low pressure oil from the opposite side of the steer-
Tilt Lock Assembly Base-to-Cowl Bolts: 20-25 N·m ing cylinder is returned through the opposite port in the
(14.8-18.5 ft-lb) steering gear.
Orbitrol Bracket Bolts: 34-38 N·m (25-28 ft-lb) As the steering handwheel stops turning, centering springs
Lower Column Assembly Base-to-Steering Gear Bolts: in the valve automatically center the spool, stopping the
34-38 N·m (25-28 ft-lb) flow of oil to the cylinder.
Universal Joint Pinch Bolt: 25-30 N·m (18.5-22 ft-lb) Stops in the steer cylinder limit the how far the steer
wheels can be turned. It 4.5 turns of the hand wheel to
Wiring Harness Bracket Bolts: 11-13 N·m (8-9.5 ft-lb) turn from stop to stop.
In the event of a pump failure, the steering gear acts as a
limited emergency steering pump powered by manual
rotation of the handwheel. An internal check valve auto-
matically closes to divert the manually-generated oil flow
to the proper port of the steer cylinder. The handwheel
turning effort is considerably higher, however, than with
power steering.
’98➀
April’02
SM 616, Dec Copyrighted
SteeringMaterial
System Specifications and Description • 25-1-1
The column tilt-lock mechanism allows the operator to The column cover can be removed for service to steering
adjust the steering column. The column tilt lever knob column components. The entire column can be removed
releases the adjustment setting and the column returns to for service or replacement. The steering gear, attached to
the up position by the use of springs. The tilt lock mecha- the base of the column, can be removed without disas-
nism, the directional control lever, and the ignition switch sembling the other parts of the steering column.
are protected by the steering column cover.
Key Switch
Lock Nut
Horn contact Ring
Column Lower Cover
Direction Control Assembly Turn Signal Assy(EPG ONLY)
Wire Harness
Key Switch &Turn Signal SW Wire Harness
Directional Control SW
Tilt Lock Assembly
Direction Control & Turn Signal Assy
25-1-2 • Steering System Specifications andCopyrighted

Description Material SM 616, Dec ’02 ➀
(TMG ONLY)
The steer cylinder rod operates a drag link which pivots Steer Angle Sensor
the steer trunnion and steer wheel mounted to it. Assembly
A sensor mounted above the steer trunnion shaft, signals

the position of the wheel to the electronic control, which
then creates a speed differential between the two drive
motors to facilitate cornering.
Steer Trunnion
Mounting Plate
Steer Trunnion
Bearings
Steer
Cylinder
(hydraulic
lines on
page 4)
Steer Drag Link
Steer Trunnion
Steer Wheel and Bearings
Steer Linkage
SM 616, Dec ’98➀

April’02 Copyrighted
SteeringMaterial
Hydraulic Connections in Steering System

(TMG For USA)
Steering
Gear
Lines to/from
Steer Cylinder
TMG/EPG15-18
(TMG Except USA)
Lines to/from
Steering Gear
(TMG ONLY)
25-1-4 • Steering System Specifications andCopyrighted

Description Material SM616,
SM 616,Dec
April ➀
’02’98
Section 2.
Steering System Troubleshooting
No steering Truck turns in wrong direction

• Hydraulic fluid level very low. • Hydraulic lines not installed correctly.
• Air in hydraulic oil.
• Steering column sections not connected properly. Handwheel kickback
• Hose broken. • Check valve faulty (or not in system).
• Hydraulic pump contaminated or defective.
• Priority valve spool stuck.(EPG) Slow steering response
• Oil viscosity too high.
Hard steering • Contaminated or defective steering gear.
• Hydraulic fluid level low.
• Air in hydraulic oil. Chatter conditions
• Steering gear contaminated or defective. • Loose mountings or linkage. Make certain all mount-
ing fasteners and other linkage is tight.
• Relief valve setting too low; adjust or replace.
• System leaking. • Pressure relief valve set too low and is out of adjust-
ment; adjust or replace the relief valve.
• Incorrect tire pressure.
• Insufficient pump flow. Check pump for leaks and
• Axle load too heavy. see Group 29, Section 2.
• U-joint misalignment.
• Lack of lubrication. Unsatisfactory steering in either direction
• Defective steering gear. • Air in system due to excessive wear in steering
• Spring in priority valve broken.(EPG) cylinder. Check for air in system. Excessive noise or
foamy condition of hydraulic fluid indicates aera-
tion. Check that air is not entering the system through
High number of handwheel turns poor threads, cracked, split, or worn hoses, bad
• Steering cylinder seal leakage. pump seals, bad O-rings, bad gaskets, or loose
• Worn steering gear. connections on intake side of pump.
Worn cylinders result in leakage past the piston.
Steering handwheel spins freely Overhaul (see Group 26, Section 7) or replace the
steer cylinder.
• Air in system (cavitation).
• Incorrect system pressure due to worn pump. Re-
• Low oil supply. place the relief valve or repair or replace the pump
• Steering column detached from steering gear. (see Group 29).
• Defective steering gear.
Noise during turns
Jerky steering • Worn bearing(s) in steering arm; replace bearings.
• Steering gear malfunction because of worn parts or • Worn pin in steering knuckle; replace pin.
contamination. Steering gear may require overhaul.
’98➀
Dec ’02
SM 616, April Copyrighted Material Steering System Troubleshooting • 25-2-1
• Worn bearings in steering knuckle; replace bear- Low pressure at the pump
ings.
• Refer to the pump troubleshooting and overhaul
• Steering knuckle is loose; tighten castle nut.
procedures in Group 29.
Constant noise from steering axle

Low pressure at the steering gear
• Loose or worn hub bearing cones. Adjust or replace
• Refer to Section 5, “Steering Gear Overhaul.”
hub bearing cones. Replace bearing cones and bear-
ing cups as a set.
Low pressure at the steer cylinder
Fluctuating pressure • Seals worn out at piston rod end of steer cylinder;
replace seals.
• Faulty operation of relief valve. Fluctuating pres-
sure or loss of pressure in the system is usually
caused by scales, chips, sludge, or filings that have Steer cylinder rod binding or sticking
lodged between the relief valve and seat. A damaged • Binding of linkage. With hydraulic flow shut off
spring or worn valve may also be the cause of the from the cylinder and the rod end uncoupled, the rod
trouble. Flush and refill the system and replace the should slide freely in or out by hand. If the piston is
hydraulic return line filter element. If condition still binding, overhaul or replace the cylinder.
exists, replace the relief valve.
25-2-2 • Steering System Troubleshooting Copyrighted Material SM 616, April ’98

Section 3.
Steering Column and Component Removal and Replacement
Steering Column and Component Removal ................................................................................ 2

Key Switch Removal ....................................................................................................................... 2
Hand Wheel, Horn Contact Ring, and Directional Control Assembly Removal............................. 2
Detent Spring Removal .................................................................................................................... 3
Column Tilt Lock Assembly Removal ............................................................................................ 4
Steering Gear and Lower Steering Column Removal...................................................................... 4
Steer Column and Component Replacement .............................................................................. 5

Steering Gear and Lower Steering Column Replacement ............................................................... 5
Column Tilt Lock Assembly Replacement ...................................................................................... 6
Directional Control Assembly Reassembly ..................................................................................... 6
Directional Control Assembly and Key ........................................................................................... 7
Switch Replacement ........................................................................................................................ 7
Steering Hand Wheel Replacement ................................................................................................. 8
Key Switch
Lock Nut
Horn contact Ring
Column Lower Cover
Direction Control Assembly Turn Signal Assy(EPG ONLY)
Wire Harness
Key Switch &Turn Signal SW Wire Harness
Directional Control SW
Tilt Lock Assembly
Direction Control & Turn Signal Assy
SM 616, Dec ’98➀

April’01 SteeringCopyrighted
Column and Component Removal and Replacement • 25-3-1
Material
3. Remove the lock ring nut securing the key switch to the
CAUTION
lower cover. Label all wires and terminals for correct
connection when reassembling.
Key Switch
surface, such as a concrete floor with no
gaps or breaks. Key Wire #11
2. Put upright in vertical position and fully
Ground
3. Put all controls in neutral. Turn key switch
OFF and remove key. Lock
4. Apply the parking brake and block the Ring
wheels.
Battery
Wire #8
Steering Column and Component Starter
Wire #6
Removal
Hand Wheel, Horn Contact Ring, and
Use the following steps to disassemble the steering column
Directional Control Assembly Removal
for service to the:
• Key Switch 1. Disconnect the battery.
• Horn 2. Gently pry the horn button from the steering hand
• Directional Control Lever Assembly wheel hub using a small, flat-bladed screw driver.
• Column Tilt Lock Assembly Horn
Horn
• Upper and Lower Steer Column Button
Contact
• Steering Gear. Ring
Wire
Horn Horn
Determine which component requires service and check Wire
the procedure for removing that component. Read the pro- Wire
cedure completely before beginning disassembly.
Key Switch Removal

Hand
1. Disconnect the battery. Wheel
2. Remove the four socket head bolts holding the two

halves of the column cover together. The directional
control assembly and the key switch are exposed.
3. Disconnect the horn wire from the steer column and
unplug the horn contact wire from the terminal on the
bottom of the horn button.
4. Remove the nut holding the hand wheel to the steering
column.
5. Use a wheel puller to remove the hand wheel from the
steering column. Hand wheel has two M8X1.25
threaded inserts in the hub for this purpose.
Copyrighted
25-3-2 • Steering Column and Component Removal andMaterial
Replacement SM 616, April ’98
6. Unplug the horn contact ring wire from the terminal on 9. Lift the directional control lever and boot off the die-
the bottom of the handwheel. cast base.
Directional
Control Lever
Boot
Horn
Wire
Horn Contact
Ring Wire
7. Using a 2.5 mm hex key, remove the four socket head

bolts holding the two halves of the column cover 10. Unplug wires from directional switches. Label all
together. Remove the top cover. Gently pull the bottom wires and terminals for correct connection when reas-
cover away. sembling. Remove the direction control switches by
removing the mounting screws on the base.
Mounting
Screw
R F
Wiring
Connectors
and Terminals
Detent Spring Removal

NOTE
Use care when removing the bottom cover 1. If not already disassembled, remove the four socket
as the key switch wiring is attached. bolts holding the two sides of the column cover to-
gether. Remove the top cover.
8. Remove the horn contact ring. Unplug the wire from
2. Pry the two retainer clips from the posts on the direc-
the terminal on the bottom of the ring.
tional control base securing the detent spring. Lift
spring off posts.
Horn
Contact Retainer Clips
Ring
Detent Spring
SM 616, April ’98 SteeringCopyrighted

Material
Column Tilt Lock Assembly Removal 5. Remove the four bolts holding the base of the tilt lock
assembly to the cowl.
NOTE
The tilt lock assembly is not serviceable;
only the return springs are serviceable. The
tilt lock assembly should be removed only Tilt Lock
for replacement as a complete assembly. Assembly
1. Raise the operator’s seat deck and lift out the floor
plate.
2. Remove the left, right, and center cowl covers from
under the dash. See removal and replacement proce-
dures in Group 38.
3. See “Hand Wheel, Horn Contact Ring, and Directional
Control Assembly Removal” to remove the steering
hand wheel, horn ring, and directional control assem- Remove bolts
bly. from under cowl.
4. Unplug the key switch and directional control switches.

Label all wires for correct reassembly. Disconnect the
key switch and directional control wiring harness from
the main harness at lower right of cowl.
5. Loosen the pinch bolt of the lower universal joint Steering Gear and Lower Steering Column
connection. Removal
NOTE
Lower steer column is not serviceable. It
should be removed only for replacement as
a new assembly.
Upper
Steering 1. Put a pan under the truck to catch hydraulic fluid which
Column will drip when fittings are loosened. Label the four
hose fittings of the steering gear to make sure they are
reassembled correctly. Loosen and remove the hy-
Pinch Bolt draulic fittings at the steering gear. Cap the ends to
prevent fluid leaks. Cap the steering gear ports to
prevent dust and debris from getting into the steering
Tilt Lock Lower gear. Keep hydraulic ports and hoses clean.
Assembly Steering
Column
Steering
Gear
Copyrighted
2. If upper portion of the steering column has not been

removed, loosen the pinch bolt of the lower universal
Steer Column and Component
joint connection. Replacement
3. Remove the two bolts and spacers securing the lower These steps cover the procedures for reinstallation of the
column shaft and steering gear to the bracket on the steering column including the steering gear, the tilt lock
lower cowl. assembly, directional control assembly, key switch, and
steering hand wheel and horn.
Lower Column U-Joint
IMPORTANT
and Pinch Bolt
Make sure all parts are clean and dry be-
fore reassembling.
It may be necessary to assemble the steer-
ing column in place and hand tighten fit-
tings so that the correct alignment of the
entire column and parts can be checked.
Once you have the correct alignment,
torque all fittings to their correct specifi-
cations.
Bracket
Steering Gear and Lower Steering Column
Replacement
Spacers NOTE
If the upper steering column has not been
removed, the lower steering column must
Lower Column Shaft and be left loose at the universal joint pinch
Steering Gear connection to allow some play in the col-
umn for positioning the steering gear.
1. Attach the steering gear to the lower column base.

4. Remove the bolts to detach the steering gear from the Torque the two bolts to 34-38 N•m (25-28 ft-lb).
lower steering column. 2. Set the column into position with the lower column
assembly aligned through the bracket mounted on the
lower frame cowl.
Lower
Steering
Column
Bracket
Steering
Control Spacers
Valve
Lower Column Shaft and

5. Remove the lower shaft and steering gear assembly Steering Control Valve
from the truck.

Material
3. Coat the splines of the lower assembly with a light coat Directional Control Assembly Reassembly
of anti-seize lubricant and insert into the universal
joint pinch connector of the upper assembly. Match the 1. Slip the lever boot onto the lever if it has been removed.
skip tooth on the spline with spline on universal joint.
2. Make sure the flange capscrew and clamp are on the
Torque the pinch bolt to 25-30 N•m (18.5-22.25 ft-lb).
directional control base.
4. Reconnect the clean hydraulic fluid lines to the clean
steering gear. Make sure the hoses are reconnected to
the correct ports. Torque the fittings per Group 40,
“Hydraulic Fitting Tightening Procedure.”
Capscrew
Bracket
Clamp
3. Install the detent spring on the posts of the base and

secure with the retainer clips.
Retainer
Steering Clips
Gear
Detent
Spring
Column Tilt Lock Assembly Replacement

1. Set the tilt lock assembly onto the cowl. Replace the
four bolts and torque to 20-25 N•m (14.8-18.5 ft-lb).
Tilt Lock
Assembly
Connect u-joint 4. Reset the forward or reverse switch onto the base and
pinch connector secure with screws.
with lower
column spline. Mounting
Screw
R F
Replace bolts
under cowl.
2. Coat the splines of the lower assembly with a light coat Wiring
of anti-seize lubricant and insert into the universal joint Connectors
pinch connector of the upper assembly. Match the skip and Terminals
tooth of the lower column spline shaft to that on the
universal joint. Torque the pinch bolt to 25-30 N•m
(18.5-22.25 ft-lb.)
Copyrighted
5. Apply a thin coat of grease in the bore of the directional c. Rotate the directional control lever in the forward
control lever. Slip the lever onto the directional control direction (push lever up) until a #8 (or 4 mm)
base. screw can be inserted into the middle detent on the
lever.
d. Loosen the mounting screw on the forward switch
Directional
and adjust the switch box to achieve continuity
Control Lever
and Boot
through the switch.
e. Remove #8 (4 mm) screw and return lever to
neutral detent. Switch must break continuity, If
switch does not break continuity, it must be read-
justed using the above steps.
f. When adjustment is correct, torque switch box
mounting screws to 0.8-1.0 N•m (7-9 in-lb; 0.6-
0.73 ft-lb).
g. Repeat procedure for Reverse switch.
6. Tighten the capscrew/clamp of the directional control
lever assembly to 3.5-4 N•m (2.5-2.9 ft-lb).
• Clean the capscrew and apply Loctite 262 before
applying torque. Directional Control Assembly and Key
Switch Replacement
7. Adjust the directional control using the following
illustration: 1. Disconnect the negative lead at the battery.
#8 or 4 mm 2. Slip the directional control assembly onto the steering
Detent screw Forward
column shaft.
Spring Switch
Reverse
Switch
Directional
Direc- Control
tional Assembly
Lever R F
Wire #82
Common
Wire #78 Wire #73 Wire #82

Normally Normally Open Common
Open 3. Clean the capscrew, apply Loctite 262, and tighten the
clamp bolt of the assembly to 3.5-4 N•m (2.5-2.9 ft-
a. Loosen mounting screws and set the directional
lb).
switch boxes to approximately the middle of the
mounting slot on the assembly base. 4. Check the assembly for smooth operation and make
b. Connect a continuity meter on the forward switch necessary adjustments before proceeding.
from the Common terminal to the Normally Open 5. Connect the wiring to the directional control switches
terminal. If the adjustment procedure is being according to the labels you made during disassembly.
performed with the directional control assembly
mounted on the steering column, connect the 6. Connect the key switch wiring harness ends to the key
continuity meter from the Normally Open termi- switch terminals according to the labels you made
nal to vehicle ground. during disassembly.

Material
7. Set the key switch into the mounting hole on the lower Steering Hand Wheel Replacement
half of the column cover. Tighten the lock ring nut to
10-14 N•m (7.5-10.3 ft-lb). 1. Reconnect the horn contact ring wire from the base of
the handwheel to the bottom of the horn button.
Key Switch
Key Switch Wire
Lock #11
Ground
Ring
Horn
Contact Horn
Ring Wire
Battery Wire
Starter Wire #8
Wire #6
8. Reconnect the horn contact ring wire to the horn 2. Apply a coat of insulating paste (Clark part no. 2802205)
contact ring. to horn contact ring, then set the handwheel into
position and tap with a rubber or plastic mallet to seat
it on the column.
Horn
Contact 3. Tighten the nut onto the column to a torque of 35-40
Ring N•m (25.5-29.5 ft-lb).
4. Screw the horn wire into the column and plug it into its
connection on the bottom of the horn button.
Horn
Contact
Ring
Wire Horn
Wire
9. Slip the horn contact ring onto the steering column.

The groove in the ring should be on the lower portion
of the ring when it is replaced on the column. The
terminal should be on the right-hand side of the truck.
10. Join both halves of the cover over the upper column.
The parting line of the boot must be aligned with the
parting line of the two cover halves. Set the directional
control lever boot into the correct position. The horn 5. Set the horn button into place and pop it into position
ring contact should be positioned so that the two cover carefully. The horn symbol should be parallel to the
halves fit the groove in the ring. Tighten the four socket CLARK lettering on the hand wheel.
bolts to 2-3 N•m (1.5-2.25 ft-lb).
6. Reconnect the leads at the battery.
7. Replace the center cowl cover over the steering col-
umn. See Group 38 for instructions to replace the cowl
covers. Torque the screws to 8-10 N•m (5.5-7.5 ft-lb).
Copyrighted
IMPORTANT 9. Set the floorplate back into the driver’s compartment

If you set the column loosely into place to and lower the operator’s seat deck.
assure correct alignment, recheck that all Start the truck to check the function of the key switch.
mounting brackets, the universal pinch Make sure no fluid leaks are evident in the steering control
joint, and all fasteners are torqued to their valve hydraulic fittings. Remove the wheel chocks to check
correct limits. See the individual steps in all functions of the steering column, including key, direc-
the reassembly procedures to find torque tional controls, tilt lock mechanism, and steering gear for
limits. correct operation before returning the truck to service.
8. Replace the right and left cowl covers. The top lip of
the two covers must be inserted under the edge of the
dash before securing the covers in place. Torque the
cover set screws to 8-10 N•m (5.5-7.5 ft-lb).

Material
25-3-10 • Steering Column and ComponentCopyrighted

Removal and Material
Section 4.
Steering System Relief Pressure

Check and Adjustment
Steering system relief pressure settings above the speci- The check and adjustment procedure requires installation
fied values can cause failure of the hydraulic lines, dam- of a a tee fitting and pressure gauge into the steering gear
age to seals in the steering gear, and damage to the steer pressure line.Steering system relief pressure setting may
axle. be checked using a Mico Quadrigage (Clark Part No.
The steering system’s pressure relief valve is located in 1800106) or with a conventional pressure gauge, 0-20,700
the head of the steer pump and is adjustable. Pressure kPa (0-3000 psi).
checks should be made every 2000 hours or at least yearly. To check and adjust the pressure:
1. Tilt the steering column fully forward, raise the seat
deck, and remove the floorboard.
CAUTION 2. Clean the fitting and connect the tee and pressure
SAFE PARKING. Before working on truck: gauge as shown.
1. Park truck on a hard, level, and solid sur-
or breaks.
OFF and remove key.
4. Apply the parking brake and block the
wheels.
WARNING
Do not use your hands to check for hydrau-
lic leakage. Use a piece of cardboard or P
paper to search for leaks. Escaping fluid
under pressure can penetrate the skin caus-
ing serious injury. Relieve pressure before 3. Turn the key on and operate the steering and/or
disconnecting hydraulic or other lines. hydraulic system to warm the hydraulic fluid.
Tighten all connections before applying
pressure. Keep hands and body away from IMPORTANT
pinholes and nozzles which eject fluids un- Do not operate system over relief any
der high pressure. longer than required to read the pressure
gauge. Prolonged time at relief pressure
If any fluid is injected into the skin, it must
can result in a damaged pump and valve.
be surgically removed within a few hours
by a doctor familiar with this type of injury
or gangrene may result.
SM 616, April ’98 Copyrighted

Steering System Material
Relief Pressure Check and Adjustment • 25-4-1
4. Turn the steering handwheel in one direction until the b. Adjust the pressure.
steering cylinder reaches its stop (relief bypass). Hold - Specification : 8340-8830kPa(1210~1280psi)
handwheel in relief position until pressure reading is
taken, and then release. Pressure should read 8274- - To increase : turn clockwise
8963 kPa (1200-1300 psi). - To decrease : turn counter-clockwise
5. To adjust the steering relief pressure: - L-Wrench Size : 6mm
TMG(For USA)
a. Remove plug that covers relief valve adjusting
port.
Plug
Adjustor
6. Repeat check and adjustment prccedure until correct

relief pressure is set.
• If the correct relief pressure cannot be maintained,
consider overhauling or replacing the pressure
relief valve as shown in the steer pump removal
and overhaul Section of this Group..
7. Disconnect the tee and pressure gauge, reconnect
Nose of lines, and reinstall the adjustment port plug.
Pump
Housing
b. Adjust pressure with slotted screw inside of port.

Clockwise adjustment raises the relief pressure
setting; counterclockwise adjustment lowers the
relief pressure setting.
EPG15-18/TMG(Except USA)
a. Remove Plug.
L-Wrench Size : 8mm
25-4-2 • Steering System Relief Pressure Check and Adjustment

Copyrighted Material SM 616, Dec ’02 ➀
Section 5.
Steering Gear Overhaul
Disassembly(TMG For USA) ........................................................................................................ 2

Meter (Gerotor) End ........................................................................................................................ 2
Control End ...................................................................................................................................... 2
Parts Inspection(TMG For USA) ................................................................................................. 4
Reassembly(TMG For USA) ......................................................................................................... 4

Control End ...................................................................................................................................... 4
Meter (Gerotor) End ........................................................................................................................ 6
Steering unit(EPG15-18, TMG Except USA) .............................................................................. 8

Disassembly ..................................................................................................................................... 8
Assembly ....................................................................................................................................... 11
Assembly Pattern for Standard Bearings ....................................................................................... 12
Priority Valve(EPG15-18, TMG Except USA) .......................................................................... 16
IMPORTANT
Before removing any component for overhaul, make sure the correct repair
parts, seals, and gasket sets are available.
NOTE
The following material does not show the load sensing port on the steering gear
(steering control unit). The port is located in the center of the other four ports.
The load sensing port requires no special overhaul procedures.
SM 616, Dec ’98➀

April’02 Copyrighted Material Steering Gear Overhaul • 25-5-1
Disassembly(TMG For USA) 5. Remove meter (gerotor). Be careful not to drop star
(rotor).
Cleanliness is extremely important when repairing a steer-
ing gear. Work in a clean area. Before disconnecting lines, Rotor
clean port area of unit thoroughly. Use a wire brush to
remove foreign material and debris from around exterior
joints of the unit.
NOTE
Although not all illustrations show the unit
in a vise, it is recommended to keep the
unit in the vise during disassembly. Follow
the clamping procedures explained
throughout the text.
Meter (Gerotor) End 6. Remove seal from meter.
1. Clamp unit in vise, meter end up. Clamp lightly on 7. Remove drive spacer(s).
edges of mounting area, as shown. Use protective 8. Remove drive.
material on vise jaws. Do not overtighten jaws.
Capscrew
9. Remove spacer plate.

10. Remove seal from housing.
2. Remove capscrews. Control End

11. Remove housing from vise and place on a clean soft
cloth to protect surface finish. Use a thin-bladed screw-
driver to pry retaining ring from housing.
3. Remove end cap.

4. Remove seal from end cap.
25-5-2 • Steering Gear Overhaul Copyrighted Material SM

SM616, ➀
Dec ’02’98
616Decril
12. Place assembly so shaft is horizontal. Rotate spool and IMPORTANT

sleeve until pin is horizontal. Push spool and sleeve Do not bind spool and sleeve in housing.
assembly forward with your thumbs just far enough to Rotate spool and sleeve assembly slowly
free seal gland bushing from housing. Remove bush- when removing from housing.
ing.
17. Push pin from spool and sleeve assembly.
18. Push spool partially from control end of sleeve, then
remove six centering springs from spool carefully by
hand. Note their position in the unit before they are
removed.
Pin
13. Remove quad ring seal from seal gland bushing.
14. Use a thin-bladed screwdriver to pry dust seal from

seal gland bushing. Do not damage bushing.
15. Remove two bearing races and the needle thrust bear-
ing from spool and sleeve assembly.
19. Push spool back through and out of sleeve. Rotate
spool slowly when removing from sleeve.
20. Remove seal from housing.
16. Remove spool and sleeve assembly from cap (14-hole)

end of housing.
21. Remove set screw from housing.

22. Screw a 1/8-inch-24 NC machine screw into end of
check ball seat. Then pull on screw with pliers to lift
seat out of housing.
23. Remove two seals from check valve seat.
24. Tip housing to remove check ball and check ball
retainer.
SM 616, April ’98 Copyrighted Material Steering Gear Overhaul • 25-5-3

Parts Inspection(TMG For USA) 4. Lubricate check ball seat and seals thoroughly before
installing seat in housing. When installing seat do not
Inspect all parts for damage, cracks, broken parts, damaged twist or damage seals. Install check ball seat in hous-
threads, corrosion or erosion of surfaces, worn spots, nicks ing; insert open end of seat first. Push check ball seat
or scratches. to bottom of hole.
Check all mating surfaces. Replace any parts that have 5. Install set screw. Use a 5/16-inch Allen wrench to
scratches or burrs that could cause leakage. Discard all old torque set screw to 11 N•m (100 in-lb; 8.3 ft-lb). To
seals and replace with new ones. prevent interference of parts, make sure top of set
Clean all metal parts in clean solvent. Blow dry with air. Do screw is slightly below housing mounting surface.
not wipe dry with cloth or paper towel because lint or other
6. Assemble spool and sleeve carefully so that the spring
matter can get into the hydraulic system and cause damage.
slots line up at the same end. Rotate spool while sliding
Do not use a coarse grit or try to file or grind these parts.
parts together. Some spool and sleeve sets have iden-
If parts are left exposed, cover them with a clean cover to tification marks; align these marks. Test for free rota-
prevent airborne dust from collecting on them. tion. Spool should rotate smoothly in sleeve with
finger tip force applied at splined end.
Reassembly(TMG For USA)

Refer to Service Parts Book when ordering replacement
parts. A good service policy is to replace all old seals with
new seals at overhaul.
NOTE
Lubricate all seals (with exception of new
quad ring seal) with clean petroleum jelly
such as Vaseline.
Do not use excessive lubricant on seals for
meter (gerotor) section. 7. Bring spring slots of both parts in line and stand parts
Make sure all parts are clean and free of on end of bench. Insert spring installation tool (avail-
dust. Before assembly, lightly coat all in- able as Part No. 6000057) through spring slots of both
ternal metal parts with oil. parts. Position three pairs of centering springs (or two
sets of 3 each) on bench so that extended edge is down
and arched center section is together. In this position,
Control End insert one end of entire spring set into spring installa-
1. Use a needle-nosed pliers to lower check ball retainer tion tool, as shown.
into check valve hole of housing. Make sure retainer is
straight (not tilted on edge) in housing.
On those units which use the low torque centering

springs, there are two pairs of centering springs (or two
sets of each) and one pair (two) spring spacers. The
spring spacers are installed together between the two
sets of centering springs. The installation procedure is
the same as that used on the standard (three pairs of
centering springs) units.
2. Install check ball in housing.
3. Lubricate 5/8-inch diameter seal and 7/16-inch diam-
eter seal. Install seals on check ball seat, as above.

SM616,
616,Dec ➀
’02’98
April
8. Compress extended end of centering spring set and 13. Install two bearing races and the needle thrust bearing
push into spool sleeve assembly withdrawing installa- in the order shown.
tion tool at the same time.
9. Center the spring set in the parts so that they push down
evenly and flush with the upper surface of the spool
and sleeve.
10. Install pin through spool and sleeve assembly until pin
becomes flush at both sides of sleeve.
14. Install 1-1/4-inch diameter dust seal in seal gland

11. Position the spool and sleeve assembly so that the bushing; flat or smooth side of dust seal must face
splined end of the spool enters the 14-hole end of down towards bushing.
housing first.
15. Install dry quad ring seal in seal gland bushing. Smooth
seal in place with your finger. Do not use any seal that
falls freely into pocket of bushing. Seal should not
“fall” into place but should require light force to seat.
IMPORTANT
Be extremely careful that the parts do not
tilt out of position while being installed.
Push parts gently into place with slight ro-
tating action; keep pin nearly horizontal.
Push the spool assembly entirely within the
housing bore until the parts are flush at the
meter end or 14-hole end of housing. Do
not push the spool assembly beyond this
point to prevent the cross pin from drop-
ping into the discharge groove of the hous-
ing. With the spool assembly in this flush
position, check for free rotation within the
housing by turning with light finger tip
force at the splined end.
12. Place housing on clean, lint free cloth. Install 2-1/8-

inch diameter seal in housing.

16. Install seal gland bushing over the spool end with a Meter (Gerotor) End
twisting motion. Tap the bushing in place with a rubber
hammer. Make sure the bushing is flush against the 18. Clamp housing in vise, as shown. Clamp lightly on
bearing race. edges of mounting area. Do not overtighten jaws.
On those units which use the Teflon seal, install the

Teflon back-up ring into the recess cut into the seal
gland bushing. Install the Teflon seal over the spool
end, then carefully install the seal gland bushing over
the spool end using a rotary motion.
NOTE
The seal gland bushing which is used with
the Teflon seal is not the same as the seal
gland bushing used with the standard quad-
ring seal. The seal gland bushing with the
Teflon seal has an identification groove cut
into the outer diameter of the bushing. The
grooved bushings can only be used with the
Teflon seals and the non-grooved bushings NOTICE
used only with the quad-ring seals. Check to ensure that the spool and sleeve
are flush or slightly below the surface of
the housing.
IMPORTANT
Clean the upper surface of the housing by
wiping with the palm of clean hand. Clean
each of the flat surfaces of the meter sec-
tion parts in a similar way when ready for
reassembly. Do not use cloth or paper to
clean surfaces.
19. Install 3-inch diameter seal in housing.
Spacer Plate
17. Install retaining ring in housing. After installing ring, Seal

tap on ring or pry with screwdriver around entire
circumference of ring to properly seat ring in groove.
20. Install spacer plate. Align bolt holes in spacer plate

with tapped holes in housing.
21. Rotate spool and sleeve assembly until pin is parallel
with port face. Install drive, making sure you engage
drive with pin.
25-5-6 • Steering Gear Overhaul Copyrighted Material SM 616, April ’98

24. Install drive spacer(s) when used, in meter.
IMPORTANT
Failure to properly install drive and pin
may cause unit to self steer.
NOTE
To assure proper alignment, mark spline
end of drive shaft with a line parallel to slot
on other end, before installing.
22. Install 3-inch diameter seal in meter (gerotor).
25. Install 3-inch diameter seal in end cap.

26. Install end cap on gerotor, and align holes.
27. Install 7 dry cap screws in end cap. Pretighten screws
to initial torque of 17 N•m (150 in-lb), then torque
screws to final torque of 31 N•m (275 in-lb) in the
sequence shown.
23. With seal side of meter toward spacer plate, align star
valleys on drive. Note the parallel relationship of
reference lines A, B, C, and D in figure. Align bolt
holes without disengaging meter from drive. Be sure
star has engaged drive spline in position shown.
A
28. Inspect the assembly to be sure all parts have been

installed and fasteners correctly installed and tight-
ened.
(Reprint courtesy of EATON Corporation)

Steering Unit(EPG15-18, TMG Except USA) Torque wrench 0~7 kgf·m(0~50 lbf ft)
13mm socket(12 point)
Tools 6, 8 and 12mm hexagon sockets
Holding tool 12mm screwdriver
2mm screwdriver
13mm ring spanner
6, 8 and 12mm hexagon L wrench
Plastic hammer
Tweezers
Assembly tool for O-ring and kin-ring.
The tools listed above are not available from SAMSUNG.
Disassembly
In repair keep all parts clean. Be sure the steering unit is
thoroughly cleaned and free of dirt and debris prior to
disassembly.
Place the steering unit in the holding tool and remove the
screws in the end cover (6-plus one special screw).
Assembly tool for cardan shaft
Assembly tool for dust seal
Remove the end cover, sideways.
25-5-8 • Steering Gear Overhaul Copyrighted Material SM616,

SM 616,April
Dec ’02
’98
Lift the gerotor set(with spacer if fitted) off the unit. Take Remove O-ring.
out the two O-rings.
Remove cardan shaft.

Shake out the check valve ball(φ8 mm)
Shake out the two anticavitation check valve balls.(if
equipped)
Remove distributor plate.
Take care to keep the cross pin in the sleeve and spool
horizontal.
The pin can be seen through the open end of the spool.
Press the spool inwards and the sleeve, ring, bearing
races and needle bearing will be pushed out of the
housing together.
Screw out the threaded bushing over the check valve.
SM 616, Dec
April’02
’98 Copyrighted Material Steering Gear Overhaul • 25-5-9
Take the ring, bearing races and needle bearing from sleeve Press the neutral position springs out of their slots in the
and spool. The outer(thin) bearing race can sometimes spool
“stick” in the housing, therefore check that it has come out.
Press out the cross pin. Use the special screw from the end Remove dust seal and O-ring / kin-ring.
cover.
Screw out the plug using and 6 mm hexagon L wrench.

A small mark has been made with a pumice stone on both Remove seal washers.
the spool and sleeve close to one of the slots for the neutral
position springs (see drawing)
If the mark is not visible, remember to leave a mark of your
own on the sleeve and spool before the neutral position
springs are disassembled.
Unscrew the relief set screw using and 6 mm hexagon L

wrench.
Carefully press the spool out of the sleeve.

SM616,
616,April ’98
Dec ’02
Shake out the spring and piston. The valve seat is boned Line up the spring set.
into the housing and cannot be removed.
Guide the spool into the sleeve.

Make sure that spool and sleeve are placed correctly in
The pressure relief valve is now disassembled. relation to each other.
Assembly
Before assembly clean all parts very carefully, replace all Press the spring together and push the neutral position
seals and O-rings, and lubricate all parts with hydraulic oil. springs into place in the sleeve.
Assemble Spool And Sleeve

When assembling spool and sleeve only one of two pos-
sible ways of positioning the spring slots is correct. There
are three slots in the spool and three holes in the sleeve in
the end of the spool/sleeve opposite to the end with spring
slots. Place the slots and holes opposite each other so that
parts of the holes in the sleeve are visible through the slots
in the spool.
Place the two flat neutral position springs in the slot.
Line up the springs and center them.
Place the curved springs between the flat ones and press
them into place.
SM 616, Dec
April’02
Guide the ring down over the sleeve. Turn the steering unit until the bore is horizontal. Guide the
outer part of the assembly tool into the bore for the spool/
WARNING sleeve.
The ring should be able to rotate free of the
springs.
Fit the cross pin into the spool/sleeve.

Grease O-ring and kin-ring with hydraulic oil and place
them on the tool.
Fit bearing races and needle bearing as illustrated.
Hold the outer part of the assembly tool in the bottom of the
steering unit housing and guide the inner part of the tool
completely to the bottom.
Assemble Pattern For Standard Bearings
1 ;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;; ;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
;;;;;;;;
Press and turn the O-ring / kin-ring into position in the
2 housing.
;;;;;;;; ;;;;;;;;
;;;;;;;; ;;;;;;;;
;;;;;;;;
;;;;;;;; ;;;;;;;;
;;;;;;;;
1. Outer bearing race
4 2. Needle bearing
3. Inner bearing race *(thicker)
5 4. Spool
5. Sleeve

SM 616,April
Dec ’02
’98
Draw the inner and outer parts of the assembly tool out of Screw the threaded bushing lightly into the check valve
the steering unit bore, leaving the guide from the inner part bore. The top of the bush must lie just below the surface
in the bore. of the housing.
With a light turning movement, guide the spool and sleeve

into the bore. Grease the O-ring with mineral oil approx. viscosity
WARNING 500 cSt at 20°C.
Fit the spool set holding the cross pin hori-
zontal.
Place the distributor plate so that the channel holes

match the holes in the housing.
The spool set will push out the assembly tool guide. The O-
ring and kin-ring are now in position.
Guide the cardan shaft down into the bore so that the
Turn the steering unit until the bore is vertical again. Put
slot is parallel with the connection flange.
the check valve ball into the hole indicated by the arrow.
Dec ’02
Place the cardan shaft as shown so that it is held in position Fit the spacer, if any.
by the mounting fork.
Place the end cover in position.
Grease the two O-ring with mineral oil approx. viscosity

500 cSt 20°C and place them in the two grooves in the
gerotor assy.
Fit the gerotor assembly on the cardan shaft.
Fit the special screw with washer and place it in the hole
shown.
WARNING
Fit the rotor and cardan shaft so that a
tooth base in the rotor is positioned in rela-
tion to the shaft slot as shown. Turn the
stator so that the seven through holes match
the housing. Fit the six screws with washers and insert them. Cross-
tighten all the screws in several stages.
3.0±0.3 kgf·m(22±2 lbf·ft)

SM 616,April
Dec ’98
’02
Place the dust seal ring in the housing. Ther dust seal ring Fit the spring.
must be placed only after the pressure relief valve has been
fitted.
Screw in the relief screw with an 8 mm hexagon L wrench.

Fit the dust seal ring in the housing using special tool and a Adjust the pressure setting on a test bench or in the vehicle.
plastic hammer.
Press the plastic plugs into the connection ports. Do NOT

use a hammer.
Install the plug with dust seal into the housing using an 8
mm hexagon L wrench.
5.1±1 kgf·m(37±7 lbf·ft)
Fit the piston.
Dec ’02
Pull out the plug with seal ring (alu.) and spring.
Priority Valve(EPG15-18, TMG Except USA)
Tools
Torque wrench
Hexagon (Allen) socket 8 mm
Hexagon socket(12 point) 22 mm
Open-end spanner 22 mm
Nylon pin
Allen wrench 8 mm
These tools are not available from SAMSUNG.
Press out the spool using the nylon pin.
Disassembly
Screw out the PP plug using the 8 mm hexagon Allen
Wrench. Remove the seal ring (alu.) Cleaning
Clean all parts carefully in cleaning solvent.
Inspection and Replacement
Check all parts carefully and make any replacements nec-
essary. All seal rings must be replaced.
Lubrication
Before assembly, lubricate all parts with hydraulic oil.
Assembly
Guide the spool into the bore. Use the nylon pin to center
the spool in the bore.
Loosen the LS plug using the 22 mm open-end spanner.

SM 616,April
Dec ’02
’98
Put in the PP plug. Remember seal ring. Tighten the LS plug with a torque wrench using a 22 mm
hexagon socket.
5±1 kgf·m (36±7 lbf·ft)
Guide the spring and LS plug into the bore. Remember seal
ring.
Tighten the PP plug with a torque wrench using a 8 mm
hexagon Allen socket.
5±1 kgf·m(36±7 lbf·ft)
SM 616, Dec
April’02
25-5-18 • Steering Gear Overhaul Copyrighted Material SM 616, April ’98

Group 25/26 Steering
Section 6.
Steer Axle Service (TMG Only)

Steer Axle Trunnion Bearings Check .......................................................................................... 2
Steer Trunnion Bearing Adjustment ........................................................................................... 2
Steer Wheel Bearing Maintenance ............................................................................................... 3
Steer Wheel Bearing Adjustment ................................................................................................. 3
Steer Wheel Bearing Lubrication and Replacement .................................................................. 4
Steer Angle Sensor Removal and Replacement ......................................................................... 5
Steer Cylinder Removal and Replacement .................................................................................. 6
Trunnion Removal and Replacement .......................................................................................... 6
Steer Axle Linkage Removal and Replacement .......................................................................... 7
Trunnion Bearings Removal and Replacement ......................................................................... 7
NOTE
DUAL-WHEEL and SINGLE-WHEEL STEER AXLES.
This Section shows overhaul procedures for a single-wheel
steer axle. However, the procedures and torque specifica-
tions can be applied to the dual-wheel steer axle as well.
Single-Wheel Steer Axle Dual-Wheel Steer Axle
SM 616, Dec ’98➀

April’01 Copyrighted Material Steer Axle Service • 25-6-1
CAUTION
face, such as a concrete floor with no gaps or
breaks.
2. Put upright in vertical position and fully lower
the forks or attachment.
OFF and remove key.
wheels.
Steer Axle Trunnion Bearings Check

1. Be sure that truck is parked and blocked up correctly to 3. Disconnect the rod end of the steer cylinder as shown
raise the steer wheel off the floor. below. This will allow the steer axle to be moved
(rotated) freely while adjusting the trunnion bearings.
2. Inspect the steer axle and trunnion for damage and
wear. 4. Bend lock washer tab clear of slot in locknut. Loosen
locknut several turns, but do not remove.
3. Check the steer axle trunnion bearings for excessive
free-play or looseness. Hold the steer wheel with both 5. Loosen the bearings by rotating the trunnion shaft
hands and try to move the entire steer axle in the and/or shaking the steer wheel from right to left.
trunnion bearings. Be sure that any movement that you
6. Tighten the retaining nut to 271 N•m (220 ft-lb) to seat
feel is not due to wheel bearing clearance free-play. If
the bearings. Then loosen the retaining nut and re-
the trunnion bearings have excessive looseness, the
tighten to 20-27 N•m (14.8-20.0 ft-lb).
bearings require adjustment.
Locknut
Steer Trunnion Bearing Adjustment
Lockwasher
1. Remove battery from truck, for best access to top of
steer axle trunnion. Refer to Group 12 for battery
removal procedure.
It is not necessary to remove the hood and counter-
weight. However, access to the steer trunnion bearings
is much easier when the counterweight is removed.
7. Bend a lock washer tab back into a slot in the locknut.
2. Remove the drive motor steer angle sensor assembly
that is mounted atop the steer trunnion. The procedure 8. Check for free movement of the trunnion shaft and
is shown later in this Section. bearings by turning the steer axle to the right and left.
Trunnion Shaft 9. Check trunnion bearing preload.
Nut and Put a torque wrench on the locknut. It should require
Cotter Pin 2.0-2.7 N•m (1.5-2.0 ft-lb) rolling torque to rotate the
steer axle in the trunnion bearings. Tighten or loosen
Torque the retaining nut to obtain correct preload torque.
65-75 ft-lb
(89-103 N•m). 10. Install steer cylinder rod end, steer angle sensor assem-
bly, and battery.
Installation of steer angle assembly is described later in
this Section. Adjustment is described in Group 13.
Rod End
Ball Stud
25-6-2 • Steer Axle Service Copyrighted Material SM 616, April ’98

Steer Wheel Bearing Maintenance Steer Wheel Bearing Adjustment

The steer wheel bearings are retained and adjusted by a
1. Be sure that truck is parked and blocked up correctly to
self-locking bearing nut. With truck properly blocked:
raise the steer wheel off the floor.
NOTE 1. Remove hubcap by tapping lightly on the outer edge of
It is optional to raise and block up entire hubcap.
truck. 2. Loosen spindle (bearing adjusting) nut and bearings:
After spindle nut is loosened, hit the top of wheel to
2. To check the steer wheel bearings for excessive free loosen the bearings.
play or looseness, hold the wheel with both hands and
try to rock it from side to side. Also, try to pull it in and IMPORTANT
out along the wheel spindle. There should be a small SPINDLE NUT SHOULD BE REPLACED
amount of free movement. (The maximum allowable WITH A NEW ONE each time it is re-
bearing end play is 0.08 mm [0.003 in]). If the wheel moved because holding torque capability is
has excessive end play, the bearings require additional partially destroyed with each removal.
service and/or adjustment.
3. Tighten spindle nut to the correct tightening torque
while rotating the wheel by hand: 230-244 N•m (170-
180 ft-lb).
NOTE
Set the steer wheel bearing adjustment by
torquing the self-locking spindle nut to the
specified value. Overtightening causes drag
and results in lower travel speed and higher
power use. Some additional adjustment may
be required however. See next step.
4. Check for correct bearing adjustment by rotating the

wheel by hand. Wheel should rotate freely or with only
slight “drag.” Readjust bearings as necessary.
5. Install the hub cap by tapping it into place with a rubber
or plastic-faced hammer.
Spindle Nut
Hub Cap
SM 616, April ’98 Copyrighted Material Steer Axle Service • 25-6-3

Steer Wheel Bearing Lubrication and 9. Clean and inspect the bearing cups and cones for wear
and other damage. Replace if necessary.
Replacement
NOTE
To clean, repack and adjust bearings: Always replace damaged bearing cups and
cones as a set.
1. Be sure that truck is parked and blocked up correctly to
raise the steer wheel off the floor. 10. If bearings require replacement, remove the grease
2. Remove the wheel and tire assembly. (Place a block of seal and the inner bearing cone using a brass drift pin
wood under the tire to prevent rotation of the wheel or rod to drive the bearing and seal out of the hub.
when loosening the lug bolts. Use a pry bar under the Grease seal may be first removed by using a puller or
tire to help move the wheel on and off the wheel hub.) prying out of the bore in hub (damage is unimportant;
install new seal at assembly). Use a standard puller to
IMPORTANT remove the bearing cups.
It is recommended that you first remove
the wheel when servicing the bearings. The 11. Install new bearing cups by pressing into wheel hub.
heavy weight of the wheel and tire can cause Be sure cups are fully seated in bearing bore.
damage to the grease seal when the wheel
12. Pack the bearings with grease and install the inner
hub is moved on the spindle. It also makes
bearing in the hub.
the work simpler and easier.
13. Recommended greasing procedure:
3. Remove hub cap from wheel hub. a. Use MP grease NLG # 2.
4. Clean the excess grease from around the spindle nut. b. Pack bearings with grease before assembly.
c. Pack cavity in hub between bearings one-half full
5. Loosen and remove the spindle nut. with grease at assembly.
6. Remove the outer bearing cone. 14. Put the hub on the spindle. Be careful not to damage
seal lip when moving the hub over the end of spindle
7. Pull the wheel hub off the spindle. Hold the hub firmly and threads.
to avoid dragging the grease seal at the back side across
the threads on spindle end. 15. Install the outer wheel bearing after it has been packed
with grease.
8. Clean the old grease out of center of wheel hub.
16. Install NEW spindle nut. Adjust spindle nut and bear-
ing as explained on page 3.
Cup, Outer
17. Replace hub cap and remove truck from blocks.
Hub Cap
Spindle Nut
Cone, Outer
Torque
230-244 N•m
(170-180 ft-lb)
but follow full
adjustment proce-
dure on page 3.
Hub
Cup, Inner
Cone, Inner
Seal

Steer Angle Sensor Removal and

Replacement
Removal of entire assembly. Replacement is reverse Removal and replacement (reverse order) of potenti-
order: ometer only. Replacement is reverse order:
A. Potentiometer wires. A. Potentiometer wires.
B. Fastener and washer D. Cable clamp
C. Bracket/Assembly F. Locknut
E. Potentiometer
NOTE
Potentiometer shaft holder (G) and fas-
tener may remain on steer axle. NOTE
Potentiometer (E) wire leads should point
toward front of truck,.
SM 616, Dec ’98➀

April’01 Copyrighted Material Steer Axle Service • 25-6-5
Steer Cylinder Removal and Trunnion Removal and Replacement

Replacement
Support trunnion with a sling and hoist of adequate capac-
1. Disconnect battery and remove it from the truck. ity.
2. For best access, remove counterweight as described in Removal and Replacement. Replacement is reverse order:
Group 38. C. Remove and replace steer cylinder as described
previously.
3. Raise and block rear of truck.
D. Trunnion mounting bolts.
4. Remove wheel as described in Group 22.
E. Trunnion assembly.
5. Removal and Replacement. Replacement is reverse
order: Replacement Note: If necessary, replace trunnion bear-
ings and linkage as described in on following pages
A. Hydraulic fittings. before replacing trunnion assembly.
Replacement note: Clean fittings. See Group 40,
Hydraulic Fitting Tightening Procedure.”
B. Cotter pin and nut.
C. Steer cylinder.
Torque
89-103 N•m
(65-75 ft-lb)
B
Torque
339-381 N•m
(251-280 ft-lb) D
B
C
Torque
89-103 N•m
A (65-75 ft-lb)

Steer Axle Linkage Removal and Trunnion Bearings Removal and

Replacement Replacement
Removal: Remove trunnion assembly as described on Removal: Separate upper trunnion casting from axle
previous page. and linkage as shown in previous sections.
Removal and Replacement.Replacement is reverse Removal and Replacement. Replacement is reverse
order: order:
A. Locknut and lockwasher. A. Seal
Replacement Note: Adjust locknut as explained B. Seal
under “Steer Trunnion Bearing Adjustment” pre-
viously in this Section. C. Cone
B. Fastener and bushing Replacement Note: Pack cones with grease meet-
ing spec MS9C. Clark part no. 3762514
C. Steering arm
D. Fastener D. Cone
E. Fastener E. Cup
F. Drag link. F. Cup. A
Replacement Note: Replace trunnion bearings as
shown in next column before reassembling linkage. C
B
A Torque E
240-270 N•m
(177-199 ft-lb)
D
Torque F
20-25 N•m
(14-18 ft-lb)
E
Torque
20-25 N•m
(14-18 ft-lb)
SM 616, April ’98 Copyrighted Material Steer Axle Service • 25-6-7


Section 7.
Steer Cylinder Overhaul (TMG Only)
IMPORTANT
Before removing any component for overhaul, make sure the
correct repair parts, seals, and gasket sets are available.
SM 616, Dec ’98➀

April’01 Copyrighted Material Steer Cylinder Overhaul • 25-7-1
Preparation For Disassembly Cylinder Inspection

IMPORTANT 1. Carefully clean all parts in an approved solvent and
Overhaul tilt cylinders only in a clean, dust- place on a clean surface.
free location, using clean tools and equip- 2. Check the piston and rod for damage. Look for gouges,
ment. Dirt or grit will damage the highly- scratches, corrosion, or evidence of unusual wear.
machined surfaces and will result in leak- Minor surface damage may be repaired by use of fine
age or premature failure of components. abrasion cloth or stoning. Deeper damage will require
Cleanliness of the hydraulic circuit is ex- replacement of piston rod assembly. Be sure the threads
tremely important to the proper operation on the rod are undamaged.
and maintenance of the system. Be sure the
3. Inspect the cylinder tube internal bore for wear,
work area is clean.
scratches or other damage. Deep gouges or pitted
1. Before disassembly, the exterior of the tilt cylinder surfaces require replacement of parts. Check the out-
should be carefully cleaned to remove all dirt and side of the entire cylinder for damage. Inspect all welds
grease accumulation. for cracks. Inspect the ports to be sure they are free of
contamination and that the threads are clean and not
2. Be sure all hydraulic oil has been removed from the damaged.
cylinder. Stroking the piston rod will help force the oil
out. 4. Put a light coating of hydraulic fluid on all parts. If
parts are to be left disassembled for awhile, they should
3. Before starting disassembly, the tilt cylinder should be
be covered with a clean cloth.
carefully examined to determine if there is any evi-
dence of external damage.
Cylinder Reassembly
Cylinder Disassembly 1. Install piston rod wiper and rod U-cup, and tube seal
in the gland. Make sure U-cup and wiper are installed
The tilt cylinder can be held by clamping the base end or in proper orientation as shown in the illustration.
the tube in a vise while disassembling.
2. Install tube seal, shear ring, tube end back up seal, and
IMPORTANT tube end seal on gland.
Do not use excessive force when clamping
3. Replace the piston packing and expand ring..
on the tube.
4. Install gland on piston rod. Use gentle pressure and
1. Remove the external retaining ring from the gland. careful movements to avoid damage to the U-cup seal
2. Push the gland assembly into the cylinder tube until the and rod wiper when these parts are moved over the
tube end seal ring and backup ring come off the gland piston rod end.
and the shear ring becomes accessible. NOTE
3. Pry under the ring’s outer edge with a soft metal pick Reassemble cylinder carefully to prevent
and pull the ring from its groove and out of the tube. damage to seals.
2. Carefully pull the rod and piston assembly and gland 5. Install piston and rod assembly. Be careful not to
from the cylinder tube. Remove gland from rod. damage the piston seals when installing the piston into
end of cylinder tube.
WARNING 6. Insert gland assembly over rod and into cylinder tube,
The use of compressed air to blow the pis- compressing the shear ring to fit into the tube. Push
ton out of the barrel is not recommended. gland inward until shear ring snaps into its groove in
High-pressure air can result in piston and the tube.
rod being ejected at high velocity (explo-
7. Install external retainer ring.
sively), causing severe injury to personnel
and property damage. 8. Check the assembly by making sure the piston slides
freely within the cylinder.
3. Remove and discard the piston packing and expand
ring from the piston.
4. Remove and discard the tube seal, rod U-cup seal, and
rod wiper from the gland.
25-7-2 • Steer Cylinder Overhaul Copyrighted Material SM 616, April ’98

Grease Fitting
Dust Cover
Ball Stud
Ball Stud
Retainer
Cap
Piston
Piston Packing
Expand Ring
Gland
Tube Seal
Shear Ring
Tube End Seal Back-Up Seal
Tube End Seal
Retaining Ring Dust Cover

Ball Stud
U-Cup
Roll Pin
Wiper
Rod
Grease Fitting
Mounting Ends Overhaul

Ball Stud Housing
The cylinder base and rod ends mount to the frame and axle
via bull stud joints. The dust covers, housings, and ball
studs can be replaced if damaged.
To remove the rod end mounting, first remove the roll pin
with a drift punch. Then unscrew housing from rod.
To remove ball studs from either joint, remove caps and
retainers first.
Inspect the ball stud and housing races for damage. Replace
damaged parts and reassemble joint reversing above proce-
dure. Grease joints with multi-purpose grease NLG#2.
SM 616, April ’98 Copyrighted Material Steer Cylinder Overhaul • 25-7-3

25-7-4 • Steer Cylinder Overhaul Copyrighted Material SM 616, April ’98

Section 8. Steer Pump Overhaul (TMG For USA)
Removal and Replacement
The pump can be removed by itself, or the motor/pump

assembly can be removed as a unit as show below. Set up a
shallow pan to catch oil from hoses and pump.
Removal and Replacement (reverse order):

A. Battery plate mounting screws. Loosen fasteners and
tilt back plate for access. To install fasteners, tap in
with hammer.
B
B. Suction line from sump. C
Note: Keep disconnected lines elevated to prevent

leakage.
C. Supply line to steering circuit.
D. Motor/pump assembly mounting screws.
E. Pump mounting screws.
NOTE
Tighten fittings per “Hydraulic Fitting Tight-
ening Procedure” in Group 40.
Battery Plate
Steer Pump
A E
Torque Fasteners D
and E
20-25 N•m
(177-221 in-lb) Steer Pump Motor
SM 616,
616, Dec ’98➀
April’02 Copyrighted Material Steer Pump Overhaul • 25-8-1
Routine Maintenance Pressure Relief Valve Overhaul

• No maintenance is necessary other than periodic checks Disassemble and assemble pump nose assembly as illus-
for tightness of the mounting bolts and port fittings trated. Clean, inspect, and, if necessary, replace the com-
plus visual examination for oil leaks. The unit should ponents. Lubricate with clean hydraulic fluid before
be kept externally clean, especially in the area of the reassembly.
shaft seal as dirt can accelerate seal wear and cause
leakage.
Plug
• The unit must be operated on clean hydraulic fluid.
Directions for filter service in this Group must be Adjustor
adhered to. A fluid cleanliness level of ISO4406 17/14
Spring
or better is recommended to give maximum life.
Seal
Steer Pump Overhaul
Spring
The construction of the steer pump is nearly the same as the Valve
main hydraulic pump covered in Group 29/30. Differences
include mounting flanges and the addition of a pressure
relief valve to the steer pump.
Refer to Group 29/30 for overhaul of the pump itself. For
overhaul of the relief valve, refer to the next heading.
Nose of
Pump
Housing
25-8-2 • Steer Pump Overhaul Copyrighted Material SM 616, April ’98

Section 9.
Steer Axle Specifications and Description
Specifications Service Intervals
Steer Linkage Inspection and Lubrication : Even 50-250

Steering System Relief Pressure Setting 8620-9300 kPa hours and each PM.
(1250-1350 psi)
Steering Wheel Bearing Inspection and Lubrication : Every
Steer Cylinder Type : Double-acting, Piston-type. 50-250 hours of operation.
Turning Radius : Max. Internal turning Angle : 81° Steer Cylinder Seals Leakage Check : Every 50-250 hours
Max external Turning Angle : 56° and each PM.
Bearing Grease : Grade No. 2 Ep multi-purpose grease, Power steering Relief Pressure Check : Every year or 2000
Clark Part MS-107C hours of operation.
Fastener Torques Description
Steer Axle Mounting Bolts : 104.9-126.5 N·m (77.5-93.5 ft

The steer axle has the steer cylinder, steer knuckles, and
lb)
steering links mounted on it. All these components can be
Cylinder to Axle Mounting Bolts : 100-110 N·m (74-81 ft removed, serviced, and replaced.
lb)
The steering gear (steering control unit) at the base of the
steering column directs hydraulic fluid to one end or the
other of the steer cylinder to p;ivot the steer wheels.
The steer axle is bolted to the truck frame. The steer cylin-
der is connected to the steering knuckles by steer links,
Mounting trunnions allow the axle to tilt independently of
the truck and “silent” mounts cushion the axle on the
turnnions.
All bearings used in the steer axle linkage have lubrication
fittings and are serviceable. Axle removal, replacement,
and service for all components, including overhaul of the
steer cylinder, is explained in the Sections for this Group.
SM 616, Dec
D ’02’02 Copyrighted Material Steer Pump Overhaul • 25-9-1
Steer Axle and Mounting(EPG15-18)
25-9-2 • Steer Pump Overhaul Copyrighted Material SM 616, Dec ’02

Section 10.
Steering Axle Wheel Bearing Maintenance and Adjustment
Wheel Bearing Check .................................................................................................................... 1
Wheel Bearing Lubrication ........................................................................................................... 1

Bearing Disassembly ....................................................................................................................... 2
Bearing Reassembly ........................................................................................................................ 3
Wheel Bearing Adjustment ........................................................................................................... 4
IMPORTANT
WARNING
Wheel Bearing Lubrication
SAFE PARKING. Before working on truck: These procedures cover bearing lubrication for the steering
1. Park truck on a hard, level, and solid surface, such axle. Use the procedures to clean, repack and adjust bearing.
as a concrete floor with no gaps or breaks.
2. Put upright in vertical position and fully lower the
Wheel mountion Hub
3. Put all controls in neutral. Turn key switch OFF and
remove key.
4. Apply the parking brake and block the wheels.
5. Remove Battery Connector.
Wheel Bearing Check

Wheel bearings check should be performed every PM. Wheel Steer Axle Knuckle
bearings need adjustment only after 2000 hours or as needed.
It is recommended that you clean and repack the bearings
before adjustment. Check hourmeter total hours and refer to
the truckís PM schedule. See steer wheel bearing lubrication
procedure below.
To check the steer wheel bearings for excessive free play or
looseness:
1. Grasp the wheel with both hands and try to move it by a
rocking motion top-to-bottom.
2. Try to pull it in and out along the wheel spindle.
Watch for excessive free movement in wheel bearings or
steering knuckle bearings. There should be a small amount of
free movement. If the wheel has excessive free movement,
the bearings require additional service and/or adjustment.
SM 616, Dec ’02 Copyrighted Material

Steering Cylinder Removal and Replacement • 25-10-1
Bearing Disassembly 2. Refer to the exploded view illustration of the wheel

bearing assembly. Loosen and remove the hubcap from
1. Be sure truck is parked and blocked up correctly and hub.
safely to raise steer wheels off the floor. Refer to “Lift-
ing, Jacking, and Blocking,” in the Group “SA.” 3. Clean the excess grease from around the wheel nut.
NOTE 4. Remove cotter pin, loosen and remove wheel nut.
Because of the heavy weight of the wheel 5. Remove outer bearing by pulling out on the hub slightly
and tire, it is suggested to first remove the to loosen bearings.
wheel and tire assembly from spindle when
servicing the bearings to avoid damage to
the grease seal when the wheel hub is moved
off or on the spindle. It also makes the
work simpler and easier.
25-10-2 • Steering Cylinder Removal and Replacement

Copyrighted Material Sep ’02
SM 616, Dec
6. Pull the hub off the knuckle. Support the hub to avoid Wheel Bearing Adjustment
dragging the grease seal at the back side across the thread
on knuckle end. The steer wheel bearings are retained and adjusted by the
wheel nut.
7. Clean the old grease out of center of the hub.
NOTE
8. Remove the inner bearing cone and grease seal. You should clean and repack the wheel
9. Clean and inspect the bearing cups and cones for wear or bearings before performing a wheel bear-
other damage. Replace, as necessary. ing adjustment. See ìWheel Bearing
Lubricationî in this Section for the com-
IMPORTANT plete procedure.
Keep serviceable bearing cups and cones
matched together. Always replace bearing
cups and cones as a set. WARNING
SAFE PARKING. REFER TO PAGE 1.
10. Inspect grease seal for wear and damage. Replace as
necessary. It is recommended to install a new grease 1. Make sure the truck is parked on a level, hard surface,
seal whenever old ones are removed. the upright is fully lowered, the drive wheels are
chocked, and the steer wheels are jacked and blocked
securely. Refer to “Lifting, Jacking, and Blocking” for
Bearing Reassembly safe procedures.
NOTE 2. Remove hubcap.
Use Grade No. 2 EP multi-purpose grease,
3. Remove and discard cotter pin.
Clark MS-107C.
4. Loosen wheel nut.
1. Install grease seal a the knuckle.
5. After wheel nut is loosened, hit the top of wheel to
2. Pack the bearings with grease and install the inner bear- loosen the bearings. This moves the bearings free of
ing on the kunckle. their seated, running position.
3. Install the hub on the knuckle. 6. Rotate hub or wheel counter clockwise and torque wheel
4. Pack the bearing with grease and install on the knuckle nut to 27.5-29.4 N·m (20.3-21.7 ft-lb).
5. Assemble washer and castle and nut. 7. Back wheel nut up until it is loose.
6. Loosen castle nut in 1/4~1/2 round after tightening 8. While turning the hub or wheel counter clockwise,
knuckle nut in 27.5~29.4 N·m (20.3~21.7 ft·lb) rotating torque the wheel nut to 6.9-9.8 N·m (5.1-7.2 ft-lb).
hub. 9. Back up wheel nut to nearest castellation slot and install
7. Install a split pin in the first groove of a castle nut in the new cotter pin.
loosing directing after tightening in 6.9~9.8 N·m (5.1~7.2 10. Recheck for correct bearing adjustment by rotating the
ft·lb) wheel by hand. Wheel should rotate freely or with only
8. Install hub cap. slight “drag”. Readjust bearings by adjusting wheel nut
as necessary to avoid binding in bearings.
11. Bend cotter pin tabs over.
12. Pack the area around wheel nut with grease.

Section 11.
Steering Axle Removal and Replacement (EPG 15-18)
Steer Axle Removal ........................................................................................................................ 2
Steer Axle Replacement ................................................................................................................. 3
SM 616, Dec ’02 Copyrighted

Steering AxleMaterial
Removal and Replacement (EPG15-18) • 25-11-1
CAUTION
gaps or breaks.
wheels.
Steer Axle Removal

CAUTION
1. Remove the counterweight before removing the steer Axle must be supported before any attach-
axle. Refer to Group 38, Section 2, “Counterweight Re- ing fasteners are removed.
moval and Replacement.” (It is possible to remove the
steer axle without removing the counterweight but much 4. If another lift truck is used to temporarily support axle
easier if it is removed). while removing, put forks in center of carriage about 305
mm (12 in) apart. Move forks under axle and raise itjust
WARNING toremoveits weight from mountingbolts. Or use a por-
Do not remove the counterweight unless table floor jack to carefully support the axle at its center
you have training and are familiar with the section.
correct procedures. Counterweights can fall 5. Loosen and remove mounting bolts.
if not handled correctly and cause severe
injury or death. 6. Carefully withdraw the axle from beneath the truck and
move to safe storage.
WARNING
Do not raise truck by hoisting on overhead
guard or by jacking or lifting on counter-
weight.
2. Block the drive wheels of the truck and raise and block
the rear end. Remove steer wheels. See “Lifting, Jack-
ing, and Blocking” in Group “SA” for safe procedures to
jack the truck.
CAUTION
Make sure truck is correctly raised and
safely blocked using hardwood blocks un-
der the frame. Be sure the blocking will
permit installation of the axle without dis-
turbing the blocking.
3. Loosenandremove hydraulic steering lines from steering

cylinder. Plug fittings and cap open ends of lines. Keep
all hydraulic fittings and openings clean.
25-11-2 • Steering Axle Removal and Replacement (EPG15-18)

Copyrighted Material Dec
SM 616, D ’02’02
6. Install bolts and tighten to 104.9-126.5 Nfim (77.5-93.5

ft-lb).
Silent Mount
7. Remove temporary axle support from under truck.
8. Connect the hydraulic lines to steering cylinder.
Steer Axle
IMPORTANT
Make sure all fittings and openings on the
hydraulic lines are clean.
9. Carefully raise the truck off the blocking as described in

“Lifting, Jacking and Blocking”. Remove the blocking
and lower the truck to the floor.
10. If removed, reinstall countenveight; refer to Group 38,
Section 2, “Counterweight Removal and Replacement”.
11. Check the axle and steering system for proper opera-
tion. Operate the steering gear to move the steer wheels
Steer Axle Replacement to maximum travel in both directions. Note any un-
usual motion or noise. If the system appears to be
Replacement is the reverse of removal. operating correctly, drive the truck slowly. Fully steer
the vehicle in each direction and check response.
CAUTION
Make sure truck is correctly raised and 12. Check steering cylinder hose line connections and cyl-
safely blocked using hardwood blocks un- inder rod seals for any evidence of oil leakage before
der the frame. Be sure the blocking will returning the truck to service.
permit installation of the axle without dis-
turbing the blocking.
1. If silent blocks have been removed from axle, install new

silent block assemblies. Use a rubber or plastic mallet to
seat the silent mounts onto theaxle trunnions.
2. Make sure that the silent blocks are positioned correctly
on the rear frame.
3. Use a fork lift truck or mobile floor jack to temporarily
support and raise the axle into place under the truck. If
another lift truck is used to handle axle, center the forks
with about 305 mm (12 in) spreadbetween them. Place
steer axle assembly in secure position on fork tips. If
hydraulic jack is used, be sure axle is securely supported
on jack pad.
WARNING
Heavy components can fall and cause se-
vere injury. Keep your body clear at all
times.
4. Install axle assembly into frame by slowly raising it up.

5. Reset the two mounting plates under the silent blocks of
the axle.
SM 616, Dec ’02 Copyrighted

Steering AxleMaterial
Removal and Replacement (EPG15-18) • 25-11-3
Section 12.
Steering Cylinder Removal and Replacement
WARNING 2. Remove the cotter pin from the bottom of the steering link
pin. Steering link pin attaches steer cylinder rod end to
SAFE PARKING. Before working on truck: steering link.
1. Park truck on a hard, level, and solid.
2. surface, such as a concrete floor with no gaps or
breaks.
remove key.
Steer Cylinder Removal

The steer cylinder can be removed from the steer axle for
overhaul or replacement without removing the steer axle NOTE
from the truck. The cylinder should be overhauled or replaced Mark left-side and right-side parts for cor-
if steering problems or troubleshooting information indicate rect reassembly.
the cylinder is malfunctioning. See Group 2.5, Section 2,
3. Tap steer link pin upward until it clears the steering link
“Steering System Troubleshooting,” for steering problem
bearing and remove the pin.
diagnoses. See Section 5 in this Group for steer cylinder
overhaul procedures. 4. Rotate the steering link away from the cylinder rod end.
1. Place a drain pan under the steer cylinder and remove the 5. Remove steer link bearing from steering link.
hydraulic lines from the cylinder fittings. Cap fittings and 6. Repeat steps 1 through 5 for the opposite side of the steer
lines to prevent fluid from leaking and to protect the cylinder.
components and hydraulic system from dust and dirt.
Label hoses and fittings for correct reassembly. 7. Remove the four steer cylinder mounting bolts and wash-
ers from the steer axle.
Cylinder is now ready to be removed from the steer axle
body. Cylinder must be lifted off dowel pins positioning
cylinder to axle body.
WARNING
Cylinder is somewhat heavy and bulky.
When removing cylinder from mounting
be prepared to lift and move the full weight
of the cylinder.

Parts Inspection 2. Position the steering link with the cylinder rod end.
Reuse steer link bearing if still serviceable. Install new
Completely inspect all parts: bearings if scoring or wear marks are evident or if the
1. Clean all bearings, cups, seals, pins, and other parts in an bearings do not operate smoothly.
approved cleaning fluid.
2. Inspect all parts for scratches, chips, scoring, and uneven
or heavy wear. Check steering links to be sure they are
not bent or twisted. Check all threaded parts for damage.
3. Replace all parts showing excessive wear or signs of
damage.
4. If parts are to be left exposed, coat all mating surfaces of
parts with a light layer of engine oil. Keep all parts clean
and covered.
5. Remove and clean all grease fittings before reassembling
cylinder components. 3. Rotate steering link into cylinder rod end and align
Refer to Section 5, “Steer Cylinder Overhaul”, if pressure bearing hole with rod end.
check or troubleshooting tips indicate a problem with steer 4. Tap pin through steer link bearing hole with cotter pin
cylinder performance. hole on lower end.
IMPORTANT
Steer Cylinder Replacement Make sure bearing is properly aligned with
1. Remount the steer cylinder onto the steer axle dowel pin in the hole.
pins; set bolts and washers in place and torque mounting
bolts to 100-110 N·m (74-81 ft-lb). 5. Install the cotter pin to the steering link hole.
6. Repeat steps 1 to 5 for opposite side.
7. Clean and replace hydraulic hoses on correct, clean,
cylinder fittings. See “Group 40, Hydraulic Fitting Tight-
ening Procedure” for replacement procedures.
WARNING
Cylinder is somewhat heavy and bulky.
When remounting cylinder to steer axle 8. Check to be sure all lube fittings are installed. Fill all
body, be prepared to lift and maneuver the lubrication points with correct lubricant. See recom-
full weight of the cylinder as you set it into mended greasing procedure above.
position.
9. Test function of steer cylinder before returning the truck
to service.

SM 616, D ’02’02
Section 13.
Steering Cylinder Removal and Replacement
Preparation for Steer Cylinder Disassembly and Overhaul ...................................................... 2
Steer Cylinder Disassembly .......................................................................................................... 2
Steer Cylinder Disassembly .......................................................................................................... 2
Parts Inspection .............................................................................................................................. 2
Steer Cylinder Reassembly ........................................................................................................... 3
Operational Pressure Test ............................................................................................................ 4\
IMPORTANT

Preparation for Steer Cylinder Parts Inspection

Disassembly and Over haul 1. Carefully clean all parts in an approved solvent and place
Refer to Section 5 for removal of steer cylinder from the on a clean surface.
steer axle body. 2. Check the piston for chips, cracks, and looseness on the
rod. If loose, replace rod and piston assembly.
IMPORTANT 3. Be sure the piston-seal groove in the piston is smooth,
true, and undamaged.
Cleanliness is of extreme importance in the
repair and overhaul of this assembly. 4. Check the piston rod for damage. Look for scratches,
grooves, gouges, pitting, corrosion or other evidence of
unusual wear. Minor surface damage may be repaired by
1. Overhaul steer cylinder only in a clean, dust-free loca- use of fine abrasion cloth or stoning. Deeper damage will
tion, using clean tools and equipment. Dirt or grit will require replacement of piston rod assembly.
damage the highly-machined surfaces and will result in
5. Carefully inspect the cylinder internal bore for wear,
leakage or premature failure of components. Cleanliness
scratches, corrosion or other damage. Check the outside
of the hydraulic circuit is extremely important to the
for damage. Inspect all welds for cracks.
proper operation and maintenance of the system. Be sure
the work area is clean. 6. Inspect the cylinder ports and threads to be sure they are
free of contamination and that the threads are clean and
2. Before disassembly, the exterior of the steer cylinder
not damaged.
should be carefully cleaned to remove all dirt and grease
accumulation. 7. Check the gland for cracks or damage that could cause
failure.
3. Be sure all hydraulic fluid has been removed from the
cylinder. Stroking the piston rod will help force the fluid 8. Deep gouges or pitted surfaces require replacement of
out. parts.
4. Before starting disassembly, the steer cylinder should be 9. Put a light coating of hydraulic fluid on all parts. If parts
carefully examined to determine if there is any external are to be left disassembled for a period of time, such as
damage. overnight, they should be covered with a clean cloth.
Steer Cylinder Disassembly Steer Cylinder Reassembly

1. Clamp the steer cylinder assembly in a vise. Wrap the Check to make sure the overhaul kit you have is correct
cylinder in a course cloth to prevent slipping and scratch- and that all parts are included.
ing. Use extreme caution when tightening vise and do
not overtighten; cylinder can be bent, distorted, and po- IMPORTANT
tentially destroyed.
2. Loosen nuts and remove the rod from cylinder assembly. Be sure inside of cylinder and all parts are clean
before starting reassembly. Assemble cylinder
3. Remove one gland by pulling it from cylinder barrel and carefully to prevent damage to seal lips and O-
pulling it off the piston rod. rings. Seals should be lubricated with hydraulic
4. Remove the piston and rod assembly from the Cylinder. oil to assist assembly into cylinder barrel and
gland. Heating seal rings in boiling water be-
5. Remove gland from opposite end of steer cylinder. fore starting assembly will aid in assembly.
6. Remove the seal and O-ring set from the piston. Discard
seals. Replace with new seal set at assembly.
1. Install new piston seal on the piston.
7. Remove (inner) gland packing (O-ring) seal. Replace
with new seals at assembly. 2. Install new gland packing (O-ring) seal and dry bearing
on inner end of gland.
8. Remove the rod (U-cup) seal and dust wiper from gland
and discard. Note direction of seal and wiper seating for 3. Install new dust wiper and rod (U-cup) seal in outer end
correct reassembly. Replace with new seals and wipers of gland and install retainer ring.
at assembly.

SM 616, D ’02’02
IMPORTANT
Be sure the rod wiper and dust (U-cup) seal are
installed in the correct directions.
4. Lightly lubricate the cylinder and gland mating surfaces

with hydraulic oil before assembly.
5. Install the gland onto the cylinder bore rim, making sure
gland is fully seated on cylinder.
6. Install piston and rod assembly into the cylinder.
NOTE
A special part is included in the parts kit to
allow you to slip the gland over the rod end
without damaging the gland seals.
7. Repeat above procedure for installation of opposite gland.

8. Install the tie rods and nuts.
Operational Pressure Test

Once cylinder is remounted on axle (see Section 4), con-
nect pressure source in turn at each port. Extend piston rod
at each side and test with internal pressure of 13790 kPa
(2000 psi). At this pressure no leakage must occur. Typical
operating pressure is 8620kPa (1250psi).

GROUP 29/30
GROUP 29/30
MAIN HYDRAULIC SYSTEM
Main Hydraulic System

Specifications and Description ............................... Section 1
Fluids and Filters ............................................................ Section 2
Hydraulic System Troubleshooting ............................... Section 3
Hydraulic System Pressure Check and Adjustments .. Section 4
Main Hydraulic Pump Removal and Overhaul ........... Section 5
Main Hydraulic Control Valve

Removal and Overhaul ........................................... Section 6
NOTE
This group covers the main hydraulic pump, sump, filters, and main
control valve.
Other hydraulic-related components and circuits are described and

illustrated in Group 25 “Steering Column and Gear,” Group 26
“Steering System,”Group 32 “Tilt Cylinders,” and Group 34
“Uprights.” Refer to these groups for hydraulic components not
covered in this group.
SM 616, April ’98 Copyrighted Material Main Hydraulic System

GROUP 29/30
NOTES:
Main Hyrdraulic System Copyrighted Material SM 616, April ’98

Group 29/30, Main Hydraulic System
Section 1.
Main Hydraulic System

Specifications .................................................................................................................................. 2
Serviceable Items ........................................................................................................................... 2
Service Intervals ............................................................................................................................. 2
Fastener Torques ........................................................................................................................... 2
Description ...................................................................................................................................... 3
Steering and Filtration Illustration ................................................................................................... 4
Sump, Main Pump and Control Valve Lines Illustration ................................................................ 5
Sump, Tilt, Lift and Aux Lines Illustration ..................................................................................... 6
Hydraulic Schematic ...................................................................................................................... 7
SM 616, April ’98 Hydraulic

Copyrighted System Specifications and Description • 29-1-1
Material
Group 29/30 Main Hydraulic System
Specifications
Hydraulic Fluid Type: Clark specification MS-68 (Clark Flow Control Adjustments: Adjustable from 4 to 38 L/min
part #1802155 and #1800236) (1 to 10 gpm). Before adjusting, turn fully counter-clock-
Hydraulic Pump Type: Integral gear-type pump and motor wise to stop. Each 1/4 clockwise turn of the adjustment
assembly. increases flow by 3 L/min (.75 gpm).
Sump Capacity: Usable oil = 19 Litres (5.0 Gal)

FLOW CONTROL ADJUSTMENTS
Filter Type: Disposable, 25 micron, full flow return line oil
filter and a 10 micron filter cap/breather filter. FLOW CLOCKWISE
L/min (gpm) TURNS OF
Main Relief Valve Setting: 20,000 to 21,000 kPa (2900 to ADJUSTMENT
SCREW
3000 psi) at rated flow.
6 (1.5) 0.50
Auxiliary Relief Valve Setting: 13,300 to 14,300 kPa (1925 9 (2.5) 0.75
to 2075 psi) at rated flow. 15 (4) 1.50
Rated Flow: 21 (5.5) 2.125

26 (7) 3.00
Lift spool (spool #1): 76 L/min (20 gpm).
38 (10) 4.50
Tilt spool (spool #2): 38 L/min (10 gpm).
Auxiliary spool (spool #3): 38 L/min (10 gpm).
Integral Pressure Compensated Flow Control Settings:
Tilt spool (spool #2): 15 L/min (4.0 gpm). Serviceable Items
Auxiliary spool (spool #3): 9 L/min (2.5 gpm).
Serviceable items are the pump, motor, return line filter,
Tilt Flow Settings: main control valve, and cylinders. Other components, such
Tilt Speed Flow as hoses, fittings, and clamps, and the load-lowering flow
Upright Usage (o/sec) Lpm (gpm) valve are nonserviceable and should be replaced if worn or
3937 mm (155 in) MFH & above 2.5 6 (1.5)
damaged.
Below 3937 mm (155 in) MFH 3 9 (2.5)
Maximum Pressure Drop at Rated Flow:
Inlet to outlet: 689 kPa (100 psi).
Service Intervals
Lift spool (spool #1): Hydraulic Fluid Level Checks: Every 8–10 hours or daily.
- Inlet to cylinder port: 689 kPa (100 psi)
Hydraulic Fluid Change (Drain and Refill): Every 2000
- Cylinder port to outlet: 550 kPa (80 psi).
hours of operation or every year.
Tilt spool (spool #2):
- Inlet to cylinder port: 689 kPa (100 psi) Hydraulic Fluid Filter Replacement: After the first 50 hours
- Cylinder port to outlet: 550 kPa (80 psi). of operation, then every year or 2000 hours of operation.
Auxiliary spools (spools #3 and #4): Hydraulic System Relief Pressure Check: Every year or
- Inlet to cylinder port: 345 kPa (50 psi) every 2000 hours of operation.
- Cylinder port to outlet: 207 kPa (30 psi).
29-1-2 • Hydraulic System Specifications and Description

Description
The following description focuses on hydraulic circuitry When all the control valve spools are in neutral, the micro
controlled by the main hydraulic control valve, that is, the switch turns the pump motor OFF and no fluid flows. When
lift/tilt/aux circuit. Various other hydraulic systems come a spool is partially shifted and the associated cylinder or
into play, however, and are mentioned. The entire hydrau- other actuator has not reached its end-of-travel, some of the
lic system is depicted in the schematics at the end of this fluid flows to the cylinder (or other actuator) and the rest
Section. flows to the sump line. In both cases, the pressure in the
Descriptions of the braking and steering circuits are given system should be less than the amount required to open the
in Groups 23 and 25. relief valves.
The hydraulic sump is equipped with a full-flow return line The main relief valve vents flow to the sump when one of
filter, and filter cap/breather. the following conditions is present:
• The operator continues to hold the lift control in the
The main hydraulic pump is driven by its own electric
lift position after the lift mechanism reaches its end-
motor and draws fluid from the sump. The steering pump
of-travel.
is driven by the steer pump motor and draws fluid from the
same sump.(TMG) • Too heavy a load is being lifted.
From the main control valve, the oil is directed to the lift • The operator continues to hold the tilt control in the
cylinders, tilt cylinders, auxiliary function and back to the tilt position after the tilt mechanism has reached its
sump. From the steering valve, oil is directed to the steering end-of-travel (This is called “tilt bypass.”)
cylinder as described in Group 25/26 and to the sump via • Auxiliary relief fails to operate.
the return line filter. The auxiliary relief valve vents flow to the sump when the
The main hydraulic control valve features an open-center, operator continues to hold the attachment control in the
parallel-circuit type modular design. It has the main (lift/ operated position after the attachment reaches its end-of-
tilt) pressure relief valve, a secondary pressure relief valve travel.
for optional auxiliary components, a lift spool, a tilt spool Main and auxiliary relief pressure settings can be checked
with an integral counterbalance valve, optional auxiliary through a gauge port on the pump.
spools, and adjustable pressure-compensated flow controls.
All spools are low-leakage design. A tilt-lock valve built into the main control valve assembly
locks the upright into its current tilt position when the truck
The main valve has from two to four valve sections. Each is turned off. A load lowering flow valve mounted on the
section performs a separate function; standard two spool upright limits the speed at which the operator can lower a
assemblies have a inlet/lift section (with fluid inlet port), a load, decreasing the speed for heavier loads. A velocity
tilt section, and an outlet section. A third and fourth section fuse built into one of the lift cylinder ports prevents the
may be added to control auxiliary components. upright from falling rapidly should a hydraulic line rupture
When lift attachments are used, an auxiliary section may be or be disconnected.
added to the outer (RH) side of the standard (lift/tilt only)
main valve. The optional auxiliary sections also have an
adjustable relief valve and can be assembled with optional
flow control levels.
The valve spools are arranged in standard sequence (from
the operator’s position) to first provide lift control, then tilt,
and finally auxiliary control. The control levers are spring-
loaded (by the valve spool centering springs) to return them
to neutral when released. Oil flow is controlled by how fast
and how far the control handles are moved. Excess oil flow
is returned to the sump. A check valve prevents reverse
flow.
SM 616, Dec ’98➀

Decil’02 Hydraulic
Material
Pressure Line
Steer Cylinder
Steering
Gear
Return Line

Copyrighted Material SM616,
SM 616,Dec
April ➀
’02’98
**
*
**
Return Line
’98➀
April’02
SM 616, Dec Hydraulic
Material
Load
Lowering
Flow Valve
Main
Control
Valve
Lift/Lower
Line
Aux
Lines
Tilt Cylinder Lines
Sump, Tilt, Lift and Aux Lines Illustration

1. Hydraulic Sump Tank
Tilt Lift 2. Filter, Breather & Strainer
SM 616, Dec
Optional Cylinders Cylinders
Optional
Dil ’98
Rotator Sideshifter 3. Lift Pump & Motor
’02 ➀
4. Steer Pump & Motor
5. Power Steering Valve
6. Return Line Filter & Bypass Valve
7. Brake Master Cylinder
Load Lowering
2000 Flow Valve 8. Main Hydraulic Valve
PSI AUX 2 AUX 1 Tilt Lift
Copyrighted
Steer
3000 Cylinder
PSI
HydraulicMaterial

L R

5
Brake Slave
Cylinder 3
6
P1 M
T P
7
4
P2 M
2
1000
PSI
1
2818074

Hydraulic Schematic(TMG For USA)

SM616,
616,April ’98
Dec ’02
SM 616, Dec ’02

Dil ’98 HydraulicMaterial
Section 2.
Fluids and Filters
Hydraulic Sump Tank Fluid Level Check ................................................................................... 2
Hydraulic Fluid and Filters Change ............................................................................................ 2

Filter Change .................................................................................................................................... 2
Breather Maintenance ...................................................................................................................... 3
Fluid Change .................................................................................................................................... 3
SM 616, April ’98 Copyrighted Material Fluids and Filters • 29-2-1

Hydraulic Sump Tank Fluid Level Hydraulic Fluid and Filters Change
Check • Drain and replace the hydraulic system fluid every
1. Check the hydraulic sump tank oil level with: 2000 operating hours, or once a year.
• Truck on a level surface. • Replace the hydraulic oil filter at every oil change.
• Upright in the vertical position. • Replace the sump tank breather every 1000 oper-
• Fork carriage fully down. ating hours.
• Oil at operating temperature.
Filter Change
2 Pull the dipstick out, wipe it with a clean wiper, and
push it back into the dipstick tube. Remove the dipstick 1. Remove and replace the hydraulic system filter per
again and check the oil level indication. recommended planned maintenance schedule, or as
may be required by truck operating conditions and
3. Check the condition of the hydraulic fluid (age, color
usage.
or clarity, contamination), to determine if it should be
replaced. 2. Install a new oil filter. Be sure to follow the installation
instructions printed on the filter.
Refer to PM records for operating time since last oil change.
3. Check for leaks after installation of the filter. Also,
Refer to next page if fluid needs to be changed.
check that the hydraulic line connections at the filter
4. The hydraulic system oil level should be between the adapter are tightened correctly.
oil level markings on dipstick. NOTE
In the event of failure of a major hydraulic
system component, such as the main pump,
or the possibility of severe contamination
of the fluid, samples of hydraulic oil should
be submitted to an independent commer-
cial laboratory for analysis of the contami-
nant level.
NOTE
Approximately 2.8 L (0.75 gal) of hydrau-
lic oil is required to fill the hydraulic tank
from the "L" (LOW) mark to the "F"
(FULL) mark. DO NOT OVERFILL.
Use MS-68 fluid.
5. Add recommended fluid only, as required.
NOTE
Remove or pull dipstick part way out to
Filter Head
vent air from tank while filling.
When adding fluid, check the fluid level
again with the dipstick after operation of
the truck including operation of the up-
right through several lift cycles.
Filter
29-2-2 • Fluids and Filters Copyrighted Material SM 616, April ’98

Breather Maintenance Fluid Change

1. Remove the hydraulic sump tank fill cap/ breather and
inspect for contamination and damage. CAUTION
2. Clean or replace the fill cap/breather, per recom- SAFE PARKING. Before working on truck:
mended planned maintenance schedule, or as required 1. Park truck on a hard, level, and solid
by operating conditions. surface, such as a concrete floor with no
gaps or breaks.
OFF and remove key.
wheels.
There is no drain plug in the hydraulic sump tank. Unless
the sump tank is to be removed for other repair or mainte-
nance, the hydraulic fluid can be changed by one of the
following methods:
• Remove of the sump breather/filler cap and strainer and
draw the fluid out with a separate pump and hose.
• Pump the fluid out by using the truck’s hydraulic sys-
tem. This method, described below, may be used most
easily and satisfactorily for routine changing of the
fluid.
’98➀
April’02
SM 616, Dec Copyrighted Material Fluids and Filters • 29-2-3
1. Remove the snap-on cap and connect a suitable drain 4. Move tilt control lever to the back tilt position to start
hose to the diagnostic check port fitting. the lift pump. A steady stream of used oil should flow
from the drain line. Hold tilt lever in this position until
NOTE: Use quick-disconnect adapter fitting.
sump tank is empty. Release the tilt lever immediately
when flow becomes unsteady .
5. Turn the key switch OFF.
Adaptor Fitting
6. Disconnect drain line from truck and replace cap.
Cap 7. Remove and discard old oil filter and install new filter
as described previously.
8. Remove and replace the sump breather cap as de-
scribed previously.
9. Refill the sump tank with Clark MS-68 Hydraulic
Fluid.
2. You will need a drain pan of 19 L (5 gal) minimum
capacity. Be sure the outlet end of the drain line is 10. Check truck operation. Turn key switch ON. Operate
directed into the drain pan and held from moving when the hydraulic system. Cycle the lift system several
pressurized. times: Raise the lift carriage to full height and lower
fully down. Check for leaks. Recheck sump tank fluid
3. Turn key switch ON. level.
CAUTION
IMPORTANT
Be sure there is adequate overhead clearance
EMPTYING SUMP. Continue the next step before raising upright.
until the sump is empty. At that point, the
pump speed increases noticeably and a
whining sound is heard. Release the tilt le- 11. Turn the key switch OFF.
ver immediately when this occurs.
29-2-4 • Fluids and Filters Copyrighted Material SM 616, April ’98

Section 3.
Hydraulic System Troubleshooting
Noisy Pump ..................................................................................................................................... 2

Pump Not Delivering Hydraulic Fluid ......................................................................................... 2
Failure to Build Pressure ............................................................................................................... 2
Pump Not Developing Sufficient Pressure ................................................................................... 2
Pump Output Low ......................................................................................................................... 2
Foaming Fluid ................................................................................................................................ 2
Overheated Pump and/or Fluid .................................................................................................... 2
External Leakage ........................................................................................................................... 2
Shaft Seal Leakage ......................................................................................................................... 3
No lift, tilt, or auxiliary function ................................................................................................... 3
No motion, slow or jerky action of hydraulic system ................................................................. 3
Foaming hydraulic fluid ................................................................................................................ 3
Overheated hydraulic fluid ........................................................................................................... 3
Load cannot be lifted to maximum height ................................................................................... 3
Oil leaks at top of lift (secondary) cylinder(s) ............................................................................. 3
Oil leak at tilt or auxiliary function cylinder ............................................................................... 3
Load will not hold .......................................................................................................................... 3
Oil leaks at either end of main hydraulic valve spool ................................................................. 4
Spring-centered spools do not return to neutral ......................................................................... 4
No relief valve action (high pressure) ........................................................................................... 4
Load drops when spool is moved from neutral to lift position ................................................. 4
SM 616, April ’98 Copyrighted MaterialHydraulic System Troubleshooting • 29-3-1

Noisy Pump Pump Output Low

• Hydraulic fluid level low; measure and correct fluid • Cavitating pump; see “Noisy Pump.”
level. • Air in fluid or wrong fluid; drain and fill with correct
• Fluid viscosity too high; change to specified fluid. fluid.
• Air leak at pump inlet line; check plumbing tightness. • System relief valve set too low or too high, stuck or
• Inlet line restriction; check for foreign material or line leaking; correct relief valve, pump may be OK.
kinks, check and clean sump suction screen. • Overheated fluid; see “Overheated Pump and/or Fluid.”
• Air leak at pump shaft packing; replace packing. • Contaminated fluid; eliminate contamination source
• Defective hydraulic pump; continue other trouble- and replace fluid.
shooting items, then consider servicing or replacing • Gear face, body or cover nicked; repair or replace
pump. pump.
• Excessive side loading, wear plate tight in body bore,
Pump Not Delivering Hydraulic Fluid pinched thrust plate; inspect and service pump.
• Hydraulic fluid level low; check and correct fluid

level. Overheated Pump and/or Fluid
• Inlet line restriction; check for foreign material or line • Low viscosity fluid; drain and fill with correct fluid.
kinks, check and clean sump suction screen. • Contaminated fluid; drain fluid, replace filter, and fill
• Air leak in suction line; check plumbing tightness. sump.
• Fluid viscosity too high; check fluid viscosity and • Cavitating pump; see “Noisy Pump.”
change to specified fluid. • Pump drive shaft misaligned; check mounting and
• Defective hydraulic pump; continue other trouble- alignment.
shooting items, then consider servicing or replacing • Axial loading on drive shaft; check shaft end clear-
pump. ance and shaft alignment; check for worn key/spline.
• Relief valve usually in bypass; check relief setting.
Failure to Build Pressure
• Hydraulic fluid level low; measure and correct fluid External Leakage
level.
• Excessive system pressure; replace pressure control
• Defective relief valve or pump; perform pressure check valve on main hydraulic valve.
to test valve and pump.
• Faulty or distorted pump seal gasket; replace seal
gasket.
Pump Not Developing Sufficient Pressure • Damaged surfaces on pump body or cover; correct
• Leak in hydraulic control system; check system for and replace as required.
and correct leaks.
• Inlet line restriction; check for foreign material or line Shaft Seal Leakage
kinks. • Damaged or worn seal; replace.
• Defective hydraulic pump; continue other trouble- • Shaft scratched or worn or seal nicked; repair (polish)
shooting items, then consider servicing or replacing or replace and add new seal.
pump.
29-3-2 • Hydraulic System TroubleshootingCopyrighted Material SM 616, April ’98

• Front cover bearing out of position; replace front Overheated hydraulic fluid
cover assembly.
• Thin fluid; drain and fill with correct fluid.
• Shaft seal housing bore scratched; replace front cover
• Fluid contaminated; drain sump, replace filter, and
assembly.
refill.
• Improper fit of shaft; replace front cover assembly.
• Cavitating pump; check hydraulic plumbing for air-
• Contamination; inspect and service pump. tight hoses and connections.
• Pump operated in wrong rotation; replace shaft and • Pump driveshaft misaligned; check mounting and
pressure loading seals. alignment.
• Seal installed backwards; inspect and service seal. • Axial loading on drive shaft; check shaft end clear-
ance and shaft alignment; check for worn key/spline.
No lift, tilt, or auxiliary function • Relief valve in bypass; check relief setting.
• Hydraulic fluid very low; check and fill to correct
level. Load cannot be lifted to maximum height
• Hose or fittings broken; replace component. • Hydraulic fluid low; check and fill to correct level.
• Defective main lift valve; check other Troubleshoot- • Hydraulic pump defective; check other Troubleshoot-
ing items for possible cause, then consider rebuilding ing items for possible cause, then consider rebuilding
or replacing main lift valve. or replacing pump.
• Hydraulic pump defective; check other Troubleshoot-
ing items for possible cause, then consider rebuilding Oil leaks at top of lift (secondary) cylinder(s)
or replacing pump.
• Plugged vent line; check and clear line.
• Worn or damaged piston seal; rebuild cylinder.
No motion, slow or jerky action of hydraulic
• Scored cylinder wall; replace cylinder.
system
• Spool not moved to full stroke; check travel and link-
age adjustment. Oil leak at tilt or auxiliary function cylinder
• Relief valve not properly set, stuck in place, and/or • Worn or damaged seal; rebuild cylinder.
worn; check and clean valve, replace if necessary. • Scored piston rod; repair or replace rod.
• Dirt or foreign particles lodged between relief valve See Group 34, “Cylinder Removal, Overhaul, and Replace-
control poppet and seat; check valve and clean. ment.”
• Valve body cracked inside; check and replace entire
valve.
Load will not hold
• Oil bypassing between lift spool and valve body;
Foaming hydraulic fluid overhaul valve and spool.
• Low oil level; check and fill to correct level. • Spool not centered; see spool remedies for correcting
• Wrong fluid; drain and refill with correct oil. problems when spools do not return to neutral.
• Oil too heavy; change to correct viscosity. • Oil bypassing piston in cylinder; repair or replace
• Pump inlet line restriction or line kinked; clean line or cylinder.
repair kinked hose.
• Hydraulic pump cavitating (pumping air with fluid); Oil leaks at either end of main hydraulic valve
check hydraulic plumbing for airtight hoses and con- spool
nections on inlet side of pump.
• Defective O-ring seals; rebuild valve.
Spring-centered spools do not return to

neutral
• Broken springs; rebuild valve.
SM 616, April ’98 Copyrighted MaterialHydraulic System Troubleshooting • 29-3-3

• Entrapped foreign particles; check and clean system

and valve.
• Bent spool; replace with new valve section.
• Misalignment or binding of linkage; check and align/
adjust linkage.
No relief valve action (high pressure)

• Small particles of dirt in relief valve subassembly;
check, clean, and/or replace relief valve, clean hole.
• Relief valve subassembly installed backwards; rein-
stall correctly.
Load drops when spool is moved from

neutral to lift position
• Dirt or foreign particles lodged between check valve
ball and seat; check and clean.
• Sticking or scored check valve; clean if sticking, re-
place if scored, replace poppet.
29-3-4 • Hydraulic System TroubleshootingCopyrighted Material SM 616, April ’98

Section 4.
Hydraulic System Pressure Checks and Adjustments
Relief Pressure Checks .................................................................................................................. 2
Main Pressure Relief Adjustment ................................................................................................ 3
Auxiliary Pressure Relief Adjustment ......................................................................................... 3
Flow Control Adjustments ............................................................................................................ 4
CAUTION
1. Park truck on a hard, level, and solid surface, such as a
concrete floor with no gaps or breaks.
2. Put upright in vertical position and fully lower the forks or
attachment.
remove key.
SM 616, April ’98 Hydraulic System Pressure Check and Adjustments • 29-4-1
Relief Pressure Checks

Following is the procedure for checking main hydraulic NOTE
valve lift pressure and auxiliary relief pressure (if the
Use quick-disconnect adapter fitting,
truck is equipped with an auxiliary component).
Clark Part #913125.
Hydraulic system relief pressure setting may be checked
3. Check main relief pressure: Turn key switch on,
using a Mico Quadrigage (Clark Part No. 923770) or
move the tilt control lever to full back (or forward)
with a conventional pressure gauge with suitable pres-
tilt relief position. Hold tilt control in relief position
sure range calibration. To cover all models of the truck, a
until pressure reading is obtained, and then release.
gauge with capacity range of 0 to 34,475 kPa minimum
Gauge should read 20,000 to 21,000 kPa (2900 to
(0 to 5000 psi) is recommended.
3000 psi).
WARNING IMPORTANT
HYDRAULIC FLUID SAFETY. Keep all Do not operate system in relief any longer
hydraulic ports and components clean. than required to read the pressure gauge.
Wipe the area on the pump around the 4. Check auxiliary relief pressure: (Truck must have
diagnostic check port completely clean auxiliary component and auxiliary section added to
to prevent any contamination from en- main hydraulic valve.) Move the auxiliary control
tering the hydraulic system. lever to full back or forward relief position. Hold
When checking the hydraulic system, do auxiliary control in relief position until pressure
not use your hands to check for leakage. reading is obtained, and then release. Gauge should
Use a piece of cardboard or paper to read 13,300 to 14,300 kPa (1925 to 2075 psi).
search for leaks. Escaping fluid under
pressure can penetrate the skin causing
serious injury. Relieve pressure before
disconnecting hydraulic or other lines.
pressure. Keep hands and body away
from pinholes and nozzles which eject
fluids under high pressure.
1. Remove the covers enclosing the main hydraulic
valve to access the hydraulic system pressure diag-
nostic check port.
2. Remove the cap from the gauge port on the valve and
connect pressure gauge to the fitting.
29-4-2 • Hydraulic System Pressure Check and Adjustments SM 616, April ’98
Main Pressure Relief Adjustment Auxiliary Pressure Relief Adjustment

IMPORTANT IMPORTANT
Main pressure relief setting is set at the The auxiliary relief setting only applies
factory and should not be adjusted. If the to a hydraulic valve that has auxiliary
relief pressure does not measure within sections added.
the setting range, a hydrostat in the pres-
To adjust the hydraulic system auxiliary pressure relief
sure relief valve must be replaced. If you
valve:
attempt to adjust the hydrostat in the
relief valve, your warranty on the equip- 1. Loosen the jam nut on the auxiliary relief valve
ment may be voided. adjustment screw.
To replace the hydraulic system main pressure relief Jam Nut and
valve: Adjustment Screw
1. Remove the plug, O-ring, and spring from hydraulic
valve port shown in the following illustration.
Plug
Main Pressure
O-Ring Relief Valve
Spring
Auxiliary
Pressure
Relief Auxiliary Pressure Relief Valve
Valve
2. Turn the adjustment screw to set the auxiliary pres-

sure relief setting to the normal range.
3. Reset the jam nut on the auxiliary relief valve adjust-
ment screw.
2. Remove the main pressure relief valve.

3. Screw open the main pressure relief valve and re-
move the hydrostat in the valve.
4. Replace the hydrostat in the same position with the
new unit.
5. Recap the pressure relief valve and replace in the
valve body.
6. Replace the spring, O-ring, and plug.
SM 616, April ’98 Hydraulic System Pressure Check and Adjustments • 29-4-3
Flow Control Adjustments

Flow control can be adjusted to meet the specifications
given in Section 1.
To make the following adjustments, position the tilt cyl-
inders mid-way in their stroke (upright vertical).
1. Remove the nut from the main hydraulic valve tie-
bolt stud.
Remove nut
and tie-bolt.
Adjust flow here.
Bottom View of Typical Valve (no auxiliary attachments).

2. Remove the stud from the valve.
3. Turn the flow control adjuster fully counterclock-
wise to the stop. Do not tighten against stop, or you
can damage valve seat.
4. Turn adjuster clockwise per flow control specifica-
tions in Section 1.
5. Repeat steps 3 and 4 for each flow control change
required.
6. Reinstall the tie bolt stud in the valve. Torque the
stud to 38-43 N•m (28-32 ft-lb).
7. Reinstall the nut on the tie bolt and torque to 38-43
N•m (28-32 ft-lb).
29-4-4 • Hydraulic System Pressure Check and Adjustments SM 616, April ’98
Section 5.
Main Hydraulic Pump Overhaul
Removal and Installation .............................................................................................................. 2
Routine Maintenance ..................................................................................................................... 3
Overhaul ......................................................................................................................................... 3
Preparation for Pump Disassembly .................................................................................................. 3
Disassembly ..................................................................................................................................... 4
Inspection and Repair ...................................................................................................................... 4
Body .......................................................................................................................................... 4
Mounting Flange and End Cover .............................................................................................. 4
Bushes ....................................................................................................................................... 4
Gears ......................................................................................................................................... 4
Reassembly ...................................................................................................................................... 5
Running-In ..................................................................................................................................... 6
SM 616, April ’98 Copyrighted Material Main Hydraulic Pump Overhaul • 29-5-1
Removal and Installation
CAUTION
SAFE PARKING. Before working on truck: Te remove or replace pump and leave motor installed,
proceed as follows (replacement is reverse order):
surface, such as a concrete floor with no A. Loosen/tighten bracket clamp screw (A) and shift
gaps or breaks. motor/pump assembly as ncessary for punp ac-
cess or mounting.
lower the forks or attachment. B. Hydraulic fittings.
Keep lines elevated to prevent dripping of fluid.
Tighten per hydraulic fitting tightening procedure
in Group 40.
C. Mounting bolts.
D. Ground lead.
wheels.
E. Main pump.
NOTE After installation:

To remove motor and pump as an Check operation of hydraulic system and fluid level of
assembly, refer to motor removal sump. Add MS-68 hydraulic fluid as necessary.
procedure in Group 16.
29-5-2 • Main Hydraulic Pump Overhaul Copyrighted Material SM

SM616,
616,Dec ➀
’02’98
April
Routine Maintenance Overhaul

• No maintenance is necessary other than periodic checks
for tightness of the mounting bolts and port fittings Preparation for Pump Disassembly
plus visual examination for oil leaks. The unit should
be kept externally clean, especially in the area of the
shaft seal as dirt can accelerate seal wear and cause IMPORTANT
leakage. Before removing any component for over-
• The unit must be operated on clean hydraulic fluid. haul, make sure the correct repair parts,
Directions for filter service in this Group must be seals, and gasket sets are available.
adhered to. A fluid cleanliness level of ISO4406 17/14 • Overhaul pump only in a clean, dust free location,
or better is recommended to give maximum life. 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. Be sure
the work area is clean.
• Plug openings before cleaning and brushing to avoid
contaminating internal parts. Clean exterior of pump
with a good grade solvent and dry thoroughly. Use a
wire brush if necessary to remove dirt accumulations.
• Before beginning disassembly, scribe match marks on
the body and cover to ensure that pump will be as-
sembled in the same manner as it was shipped from
factory. If the body or rear cover is replaced during
overhaul, scribe a match mark on the new part as on
the part it replaced. This ensures that inlet and outlet,
with respect to rotation, is kept the same.
Disassembly The body can only be reused if the cut-in is bright and
polished in appearance and the depth does not exceed .08
mm (.003 inch).
IMPORTANT
Keep parts in order as removed to assure The body should be replaced if the surface is scored, has a
correct assembly later. matt appearance or shows signs that the tip of the gears
have dug in and torn away the surface material.
1. Lightly mark the end cover, body and mounting flange The body should be inspected to ensure that there is no
(3, 9 and 12) to ensure reassembly in the correct superficial damage which may adversely effect performance
position. or sealing. Pay particular attention to the port threads and
body O-ring seal recesses.
2. Remove bolts and spring washers (1 and 2).
3. Remove end cover (3), body O-ring (4), bushing seal Mounting Flange and End Cover
and back-up seal (6 and 5).
The inner surfaces should be inspected to ensure that there
4. Turn the unit over and lightly tap the mounting flange is no unusual wear or scoring in the regions where the body
(12) to disengage if from the locating dowels and slide O-rings and bushing seals contact, which could result in
the flange squarely off the shaft. external leakage.
Check the shaft seal recess for scoring or damage that could
Important
result in oil leakage around the outer diameter of the shaft
Be careful not to damage the machined seal. Replacement shaft seals can be refitted with Loctite
bore in mounting section (15) when remov- hydraulic sealant to overcome slight damage in this area.
ing the seal because this will result in leak-
age past seal.
Bushings
5. Remove circlip (14) and shaft seal (13).
The side faces which abut the gears should be perfectly flat
6. Remove body O-ring (4), bushing seal and back-up showing no sign of scoring. Characteristically, there are
seal (6 and 5). bright polished areas on this surface caused by loading
7. Before removing the internal components mark the against the gear side faces, which is often more pronounced
bushes to denote the location in the body. On a plain on the low pressure side. These should be replaced if there
area away from seal location mark: is any general scoring or fine scoring with a matt appear-
ance or tearing of the surface material. Often there is a
FD = Bushing on driveshaft flange end witness where the tips of the opposing gears have wiped an
F = Bushing on driven gear flange end overlap resembling a half moon shape. There must be no
noticeable wear step as it is critical that the bushing side
CD = Bushing on driveshaft cover end face is completely flat to the gear side face.
C = Bushing on driven gear cover end
The bushing bearing liners are acceptable providing that
they are not scored or show other damage. The general
8. With the unit lying on its side, hold the driveshaft (10) outside area of the bushing should not show any prominent
and pull it squarely out of the body bringing with it the signs of wear.
bushes (7 and 8).
9. Remove driven gear (11) and the two remaining bushes Gears
. The gear side faces should be examined for bruising or
Inspection and Repair scoring. Often, with operation on contaminated fluid scor-
ing shows between the root of the gear and the journal
Each component should be thoroughly cleaned, carefully
undercut, which leaves a wear step. If a wear step can be
examined and assessed for suitability of reuse. Below is a
felt, coincidental with the root diameter, by drawing a
guide for inspection the various components.
sharp pointed tool across the surface from the undercut
outwards towards the tip of the gear, then the gear is
Body unserviceable.
Inspect the body bore cut-in where gears wipe into the The gear teeth should then be carefully examined to ensure
body. that there are no signs of bruising or pitting.
29-5-4 • Main Hydraulic Pump Overhaul Copyrighted Material SM 616, April ’98
4
5 6
8 9
10
7
6 5 12
1 2 3 4
14
7
11
8
13
Main Hydraulic Pump
1. Bolt 8. Bushing
2. Spring Washer 9. Body Dowel Sub-Assembly
3. End Cover 10. Drive Shaft
4. Body O-ring 11. Driven Gear
5. Back Up Seal 12. Mounting Flange
6. Bushing Seal 13. Shaft Seal
7. Bushing 14. Circlip
The journal bearing surfaces should be completely free

2. Place the end cover (3) against the undowelled end of
from scoring or bruising. The surface should appear highly
the body (9) and stand the assembly on the cover so the
polished and smooth to the touch.
dowels are uppermost and to the lefthand side.
Examine the area where the shaft seal lips run on the
3. Fit driveshaft (10) and driven gear (11) into their
driveshaft, which shows up as a polished ring or rings. If a
original positions in the body.
noticeable groove can be felt or there is scoring, the shaft
should be replaced. 4. Refit flange end bushes (FD and FI) into their original
bores remembering the “C” cut-out must be to the side
Provided the driveshaft spline is not damaged or worn and
of the body with the cusp removal flat and match the
the gears have not been harmed as described above, then
cover end bushes.
the gears can be reused. If, however, the gears are damaged
they must be replaced as a matched set. 5. Fit new body O-ring (4), bushing seal and back-up seal
(5 and 6), ensuring that the seals locate correctly in the
As a matter of good practice, when pumps have been
seal grooves.
dismantled, all seals should be replaced. It is most im-
portant that only genuine Clark seals be used. 6. Fit new shaft seal into the recess in the mounting flange
with the “garter” spring facing into the pump. Refit
circlip (14). If the seal recess was scored then Loctite
Reassembly hydraulic sealant must be applied to the outer diameter
Ensure all parts are perfectly clean and lubricate bushes and of the seal.
gears with clean hydraulic fluid (ensure O-ring recess and
7. Fit shaft seal assembly sleeve over driveshaft and
end faces of body remain dry). This will assist assembly of
carefully refit mounting flange (12), ensuring that it
components into the body bores.
locates squarely onto the dowels in the body. Remove
1. Refit cover end bushes (CD and CI) into the undowelled assembly sleeve.
end of the body from where they were removed. The
8. Holding the whole unit together, carefully turn it over,
‘’C’ shape cut-out in the bushes must be to the side of
ensuring that it is supported on the mounting flange
the body with the cusp removal flat as shown.
and not the driveshaft.
9. Remove end cover (3) and fit new body O-ring (4),
bushing seals and back-up seals (6 and 5). FLANGE END
Location
10. Replace the end cover and refit bolts and spring wash- Dowels
ers. Torque tighten bolts to 46-51 N•m (34-38 lb ft).
11. Pour a small amount of clean hydraulic fluid into a port
Cusp
and check that the shaft can be rotated without undue Removal
force using a smooth jawed vice.
Position of
Driveshaft
ARRANGEMENT OF BUSHES & GEAR SET IN BODY
Running-In
A unit which has been reassembled with either new gear, It is recommended that the unit is run-in at 1500 rpm,
bushes or body, must be carefully run-in before it is sub- initially, at zero pressure for one minute, then in stages with
jected to full working conditions. the pressure increased by 500 psi every minute, until maxi-
Ideally this should be done on a test rig as shown below, mum rated pressure has been attained. Frequently check the
where pressure can be gradually applied and any wiping system temperature, enduring that it does not exceed the
from the body cut-in arrested by filters. maximum permissible figure of 80* C. If the temperature
exceeds the system or unit specification, the test must be
delayed and operated off-load until acceptable tempera-
tures are obtained.
Test Pressure Variable

Tank Unit Gauge Restrictor Flow Meter
Micronic Relief
Strainer
Filter Valve
Typical Pump Test Circuit
29-5-6 • Main Hydraulic Pump Overhaul Copyrighted Material SM 616, April ’98
Section 6.
Hydraulic Control Valve Removal

and Overhaul
Hydraulic Control Valve Removal ............................................................................................... 2
Preparation for Valve Removal ....................................................................................................... 2
Control Valve Linkage Disassembly ............................................................................................... 2
Valve Removal ................................................................................................................................ 2
Hydraulic Control Valve Replacement ........................................................................................ 3

Valve Replacement .......................................................................................................................... 3
Control Valve Linkage Reassembly ................................................................................................ 3
Reinstall Valve ................................................................................................................................. 4
Lift and Tilt Pump Switches Adjustment......................................................................................... 4
Operational Checks .......................................................................................................................... 4
Preparation for Disassembly ............................................................................................................ 5
Hydraulic Control Valve Overhaul .............................................................................................. 5

Disassembly ..................................................................................................................................... 6
Cleaning, Inspection, and Repair ..................................................................................................... 7
Reassembly ...................................................................................................................................... 8
Relief Valve Settings ....................................................................................................................... 8
CAUTION
1. Park truck on a hard, level, and solid surface, such as
a concrete floor with no gaps or breaks.
remove key.

Copyrighted Control Valve Removal and Overhaul • 29-6-1
Material
Hydraulic Control Valve Removal Control Valve Linkage Disassembly

IMPORTANT Remove the cotter rings and clevis pins connecting the lift
Keep all hydraulic ports, components, and and tilt (and auxiliary, as applicable) lever rods from the
fittings completely clean during valve re- hydraulic valve spools. Back off the lower jam nut at the
moval and replacement to prevent any con- turn buckle to allow the valve spool to be rotated before
tamination from entering the hydraulic sys- removing the clevis pins.
tem.
Preparation for Valve Removal

1. Park truck in a safe position and fully lower the upright.
2. Return all controls to neutral, apply the parking brake,
turn the key switch OFF, and disconnect the battery. Clevis
3. Move all hydraulic control levers to all working posi- Pin
tions and return them to neutral. Be sure there is no Cotter
hydraulic pressure applied to the system by attach- Ring
ments.
4. Remove floor plate.
5. Remove the right cowl cover from under the dash in the Turnbuckle
operator’s compartment. See removal and replace-
ment procedures in Group 38. Lower Jam
6. Air clean the hydraulic valve and fittings. Nut
7. Place a drain pan under the truck and loosen and

remove all hydraulic lines from the valve. Plug the Valve Spool
valve ports. Mark or tag each line as removed to assure
correct position of line at assembly.
Valve Removal
1. Remove the three hex capscrews mounting the hydrau-
lic valve to the hydraulic assembly bracket. Two of the
To
capscrews thread into the valve itself; the third is
Upright
secured with a flange nut.
Hydraulic Assembly
Bracket ( Cowl)
Return Line
to Sump
Feed Line
from Pump Tilt Cylinder
Lines
2. Remove valve assembly from truck. See Section 6 for
8. Cap ends of lines to keep them clean. Tie ends of lines valve overhaul instructions.
to truck to prevent loose ends dropping and leaking oil NOTE
onto floor. Be sure to clean up any oil spills and dry
the floor to prevent accidents.
29-6-2 • Hydraulic Control Valve Removal and Overhaul

Hydraulic Control Valve Replacement Control Valve Linkage Reassembly

1. Insert the clevis pins through the rod-end clevises and
Valve Replacement valve spools of the lift and tilt spools (and auxiliary-
lever rods and spools where applicable) and secure
1. Position the main valve on the hydraulic assembly with the cotter rings. Rotation of the valve spools is
bracket (lower cowl). Install valve mounting fasteners required to allow insertion of the clevis pins. Rotate
and tighten hand tight so that valve mounting can be spools back so all pins are in line.
adjusted for alignment with the lever connecting rods.
Hydraulic Assembly
Bracket (Lower Cowl)
Clevis
Pin
Cotter
Ring
Turnbuckle
2. Install the hydraulic lines on the proper ports. Make
sure all lines are clean, are routed correctly in the truck, Lower Jam
and are not kinked. Torque fittings according to “Hy- Nut
draulic Fitting Tightening Procedure” in Group 40.
Valve Spool
To Upright NOTE
The illustration above and system specifi-
cation torques also apply for auxiliary hy-
draulic functions, such as a side-shifter or
rotator.
2. When alignment between the lever rods and the valve
is set and levers are inline and level with one another,
tighten the valve mounting capscrews and flange nuts
to 40-50 N•m (30-33 ft-lb).
Return Line
to Sump
Feed Line Tilt Cylinder

from Pump Lines
3. Adjust the valve to align with the lever connecting

rods.

Material
Lift and Tilt Pump Switches Adjustment Operational Checks

1. Operate the truck and hydraulic system. Check the
1. Turn key switch to the OFF position. system for leaks.
2. Loosen switch mounting screws. WARNING
3. Adjust switch to activate after 2 mm (0.08 in) of spool Do not use your hands to check for hydrau-
travel from neutral. lic leakage. Use a piece of cardboard or
paper to search for leaks. Escaping fluid
4. Tighten mounting screws. under pressure can penetrate the skin caus-
ing serious injury. Relieve pressure before
disconnecting hydraulic or other lines.
pressure. Keep hands and body away from
Micro Switch pinholes and nozzles which eject fluids un-
der high pressure.
Switch
Mounting If any fluid is injected into the skin, it must
Bracket be surgically removed within a few hours
by a doctor familiar with this type injury
or gangrene may result.
2. Check the operation of the valve and hydraulic system
by moving the valve control levers to the various
Switch positions. The levers must operate smoothly with no
shown
binding. When released from any working position,
mounted
the levers must return sharply to their neutral positions.
If valve spools do not move or return to correct position
for full function of lift, tilt, or auxiliary cylinders:
a. Loosen jam nuts on adjustment turnbuckles of
lever rods.
Turnbuckle
Jam Nut
b. Adjust turnbuckle to increase or decrease spool

movement to correct measure.
c. Retighten turnbuckle jam nuts to 39-44 N•m (28.5-
32.5 ft-lb).
3. If valve was disassembled or overhauled. Check relief
pressur as described in the hydraulic system pressure
check Section of this Group.
4. Replace the cowl cover under the operator’s compart-
ment dash. See removal and replacement procedures in
Group 38.

Hydraulic Control Valve Overhaul

The following overhaul instructions describe a two spool IMPORTANT
assembly with the inlet/lift section, a tilt (or auxiliary) CLEANLINESS. Overhaul valve only in a
section, and outlet section (outlet section contains no spool). clean, dust-free location, using clean tools
and equipment. Dirt or grit will damage the
Preparation for Disassembly highly-machined surfaces and will result in
leakage or premature failure of components.
Cleanliness of the hydraulic circuit is ex-
IMPORTANT
tremely important to the proper operation
PARTS. Before removing any component
for overhaul, make sure the correct repair
work area is clean.
• Clean outside of valve with a good grade of solvent

and dry thoroughly.
• Before starting disassembly, the valve should be care-
fully examined to determine if there is any evidence of
external damage.
Inlet/Lift Section.
See Figure 1 for
close-up view.
Outlet/Aux Section.
See Figure 3 for
close-up view.
Tilt/Aux Section.
See Figure 2 for
close-up view.
Main Hydraulic Valve Exploded View.

Material
Disassembly 2. Remove and label all parts between the sections for
correct reassembly. These include:
During disassembly, pay particular attention to identifica-
a. Retainers and seals which are included in the
tion of parts for reassembly. Spools are selectively fitted to
replacement seal kit.
valve bodies and you must return each spool to the same
body from which it was removed. You must also be sure to b. O-rings, springs, and ball which are replaced
reassemble the valve sections in the original order. separately.
NOTE NOTE
Valve sections may or may not require sepa- Keep parts in order as removed and avoid
ration for overhaul. mixing the sections and parts.
If only valve spools are being overhauled, you do not have 3. Disassemble each valve spool, one at a time, from
to separate the sections. For a complete overhaul, including bottom of valve as shown in the illustration.
replacement of the seals, retainers, O-rings, springs, and 4. Remove the valve spools by tapping lightly on the top
balls used between the sections, follow steps 1 and 2. To end with a soft-faced hammer to drive them out of the
overhaul only the valve spools, begin with step 3. valve body.
1. Remove the nuts and studs connecting the valve sec- 5. Arrange the parts in the sequence of removal.
tions.
Plug O-ring
AUXILIARY PRESSURE Spring

MAIN PRESSURE
RELIEF VALVE (adjustable)
RELIEF VALVE
Set Screw Relief Plug
Nut
Plug
Relief Plug
O-ring
O-ring O-ring (4 required)
Ball
Inlet/Lift Body
Seal
Retainer
Lift Spool Assembly
(Construction shown in
Figure 2.) O-ring
Seal O-ring
Figure 1. Inlet/Lift Body, Main Pressure Relief Valve, and Auxiliary Pressure Relief Valve.
See Figures 2 and 3 for remainder of valve.

Cleaning, Inspection, and Repair 4. Inspect the main pressure relief valve for damage.
Relief valve must be free from contamination, burrs,
1. Discard all old seals. Wash all parts in a clean mineral
and scoring. Plug, spring, and O-ring should be cleaned
oil solvent and place them on a clean surface for
and inspected for damage.
inspection.
2. Carefully remove any burrs by light stoning or lapping. NOTE
Be sure there is no paint or burrs on mating surfaces of Entire relief valve assembly must be re-
valve bodies. placed if damaged. Relief valve pressure is
3. Inspect valve spools and bores for burrs and scoring. If controlled by a hydrostat in the valve re-
scoring is not deep enough to cause leakage, the lief valve assembly and is set at the fac-
tory. No adjustments are recommended; if
surfaces can be stoned or polished with crocus cloth. If
pressure relief setting is not in recom-
scoring is excessive, valve body and spool must be
mended range, hydrostat must be replaced.
replaced. Check each valve spool for free movement in
its bore.
Tilt or Auxiliary
Spring Body
Quad Ring
O-ring
Quad Ring
Sleeve
Retainer
Dust
Springs
Cover
Spool
“C” Washers
(2 required)
Screw
Ball (Used only in lift section.)

O-Ring
Spool
Flow Control Poppet (Used only
Plug in tilt & auxiliary sections.)
Spring
O-Ring Spring
Ball Adjustable Flow

Control Nut
COUNTER- O-Ring
BALANCE VALVE
(Tilt & auxiliary Retainer Back-up
Ring Flow Ring
sections only.)
Adjuster
FLOW CONTROL
Figure 2. Valve Spool and Tilt (or Auxiliary) Body . Differences in lift (or tilt) and auxiliary components noted.
See Figures 1 and 3 for remainder of valve.

Material
5. Inspect the lift and tilt relief valves for damage. Check
4. Install seal rings and the seal ring retainer in the
the relief valve for smooth free movement in its bore.
grooves in body of each inlet and center section. Use
The valve poppet should move easily from only the
petroleum jelly to hold the seals in place. Carefully
force of its own weight.
place the sections together in the same order in which
6. Inspect the valve body to make sure it has not been they were removed.
physically damaged. Examine all threads to be sure
5. Torque dust-cover screws to 10.8-13.5 N•m (8-10 ft-
they are clean and not damaged or burred. Inspect all
lb).
bores and poppet seats. Poppet seat must be even all
around its circumference with no nicks, burrs, or 6. Reinsert studs between valve sections and torque nuts
indentations in any of the seat face. to 27-34 N•m (20-25 ft-lb).
7. All springs should be free of corrosion and not broken
or bent. Relief Valve Settings
8. If parts must be left unassembled for a period of time After overhaul and reinstallation of the main hydraulic
or overnight, cover with a lint-free clean material. valve, the hydraulic system relief pressure and auxiliary
valve relief pressure settings (if truck and valve are equipped
with an auxiliary component and section) must be checked.
Reassembly See the hydraulic system checks and adjustments Section
Use the exploded view illustratiosn of the valve section, of this Group (30) for procedures.
spools, and relief valves for reassembly. If the truck is not equipped with any auxiliary equipment,
1. Assemble valve in reverse order of disassembly. no adjustments are necessary. If an auxiliary section has
2. Coat all parts with clean hydraulic oil to facilitate been added to the hydraulic valve and auxiliary compo-
assembly and provide initial lubrication. Petroleum nents have been installed on the truck, check the relief
jelly can be used to hold seal rings in place during pressure. See the hydraulic system checks and adjustments
assembly. Section of this Group (30) for procedures.
3. Use new O-rings and seals for all parts.
Tie-Bolt
Torque:
37.8-43.2 N•m
(28-32 ft-lb)
Figure 3. Outlet Body/Aux Section. See Figures 1 and 2 for remainder of valve.

GROUP 32
GROUP 32
TILT CYLINDERS
Tilt Cylinder Specifications and Description ............... Section 1
Checks and Adjustments ................................................ Section 2
Tilt Cylinder Removal and Installation ........................ Section 3
Tilt Cylinder Overhaul ................................................... Section 4
IMPORTANT
Other hydraulic-related components and curcuits are described and Illustrated in Group 25/26,
"Steering," Group 29/30, "Hydraulic System", and Group 34, "Uprights." Refer to these other
groups for hydraulic components not covered in this group.
SM 616, April ’98 Copyrighted Material Tilt Cylinders

GROUP 32
NOTES:
Tilt Cylinders Copyrighted Material SM 616, April ’98

Group 32, Tilt Cylinders
Section 1.
Tilt Cylinder Specifications and Description
See Group 29 for hydraulic system specifications. The tilt cylinders provide backward and forward tilt of the
upright. The forward and back tilt angles are governed by
Tilt Cylinder Type: Double-acting
the cylinder stroke and by use of spacersand differentlength
Maximum Operating Pressure: 21,000 kPa (3,000 psi) rod ends. The tilt cylinders are pin-mounted to the truck
Tilt Ranges: (188 Triple Stage Upright): 3o back tilt and 5o frame and upright using yokes, clevises, and pins. Pins are
forward tilt held in place by a lock plate and fastener to prevent the pins
from working their way out.
The tilt cylinders are serviced by removing them from the
Fastener Torques truck and disassembling them for complete overhaul, in-
Rod-End Yoke Bolts: 170-190 N•m (125-140 ft-lb) cluding installation of new seals and or other cylinder
components.
Service Intervals The tilt lock valve is integrated into the tilt section of the
main hydraulic control valve. The tilt lock valve prevents
Tilt Cylinder Drift Test: Every 50-250 hours or each PM. the upright from tilting forward when the truck is not
Tilt Cylinder Check and Adjustment: Every 50-250 hours running. The tilt lock valve is not serviceable and must be
or each PM. replaced as a valve section if defective.
Tilt Cylinder Rod Seal Condition Check: Every 50-250

hours or each PM.
Tilt Cylinder Mounting Check and Tightening: Every 50-
250 hours or each PM.
Tilt Cylinder Rod-End Check and Tightening: Every 50-
250 hours or each PM.
Tilt Cylinder Rod-End Lubrication: Every 50-250 hours or
each PM.
Tilt Cylinders
SM 616, April ’98 Copyrighted Tilt

Material
Cylinder Specifications and Description • 32-1-1
32-1-2 • Tilt Cylinder Specifications and Description

Section 2
Tilt Cylinder Checks and Adjustments
Tilt Cylinder Drift Test ................................................................................................................. 1
Drift Causes and Remedies .............................................................................................................. 2
Tilt Cylinder Racking Check ........................................................................................................ 2

Forward Adjustment ........................................................................................................................ 2
Backward Adjustment ...................................................................................................................... 3
Tilt Flow Control Adjustments ..................................................................................................... 3
CAUTION
or breaks.
OFF and remove key.
2500mm(98.5in)
wheels.
Tilt Cylinder Drift Check

To check tilt cylinder drift, a rated capacity load is placed
on the forks, lifted up and held to determine if the tilt
cylinder rods moves (drifts) in a specified length of time. 4. Measure and write down the distance between the
It is recommended that a test load, made up of a full- cylinder-spacer face and the rod-end yoke.
capacity load equally distributed on a 1220 x 1220 mm (48
x 48 in) pallet, be used. The material used to make up the Measure rod
test load must be stacked to provide load stability and must distance here
not extend beyond the pallet. It must be secured on the
pallet. Refer to the truck data plate for capacity rating.
1. Adjust fork width as wide as possible to distribute the
load. Refer to truck nameplate for capacity rating.
CAUTION
Test load must be stacked stably, not ex-
tend beyond the pallet, and be secured on
the pallet.
2. Drive the forks into the load pallet until the test load and
pallet rest against the load backrest. Apply the parking 5. Wait five minutes and measure and write down dis-
brake and chock the wheels. tance between rod end and spacer.
3. Raise the capacity load 2500 mm (98.5 in) off the 6. The measurement must not exceed the following
ground and tilt the upright vertical. Shut off the truck. measures:
Temperature Drift
50o C (122o F) 0.5o, 3.1mm @ 1 min
5o, 31.1mm @ 10 min
April
SM 616, Jul ①
’98
’01 Copyrighted Material Tilt Cylinder Checks and Adjustments • 32-2-1
Drift Causes and Remedies

Tilt cylinder drift indicates the following possible prob-
lems:
• Tilt cylinder hydraulic circuit hoses or fittings are
leaking. Check the circuit components and repair as
necessary.
• Cylinder piston seals are worn, damaged, or defective
allowing fluid past the piston and causing the rod to
drift. Consider rebuilding the cylinders if the other
remedies in this list are not successful. See Section 3
for cylinder removal and replacement and Section 4 for
cylinder repair, if necessary.
• The main hydraulic tilt valve is misadjusted, worn, or Forward Adjustment
defective. Fluid is leaking past the valve and causing 1. Slowly tilt upright fully forward to the end of the tilt
the tilt cylinders to drift. See Group 30 for hydraulic cylinder stroke.
valve troubleshooting. 2. As the cylinders approach the end of the stroke, watch
both piston rods for equal movement and upright for
Tilt Cylinder Racking Check twisting. Note if upright “racks” (is twisted at the end
of its movement by unequal stroke of tilt cylinders).
Upright racking occurs when tilt cylinder strokes are un-
NOTE
equal. Cylinders should be checked regularly during opera-
Correct the twisting effect by shortening
tion to determine if cylinder strokes are the same. To check
the cylinder that is the longest length. For-
for racking:
ward twisting must be adjusted before back-
• Make sure truck is parked on level surface with park- ward twisting. If forward adjustment is not
ing brake applied and wheels chocked. needed, continue with backward adjust-
• Check condition of the tilt cylinder, rod-end yoke, ment.
mounting pins, piston rod, rod wiper, cylinder gland,
3. To adjust, loosen rod-end yoke capscrew on the tilt
etc., for excessive wear or damage. Make repairs be-
cylinder that extends the farthest, and turn piston rod
fore making twisting adjustment.
into rod-end yoke to shorten.
• Use a capacity load (see truck nameplate) centered on
the forks.
CAUTION
Be sure to secure the load to the fork car- Loosen
capscrew.
riage to keep it from falling off when tilted
forward.
Turn to adjust.
Raise the upright only to the height that
will allow the fork tips to clear the floor
when tilted fully forward.
Forward Adjustment: Pneumatic-tire truck rod-end yoke

orientation shown.
32-2-2 • Tilt Cylinder Checks and Adjustments

NOTE 4. Use rod shims to fill in the space between the rod-end
Use wrench flat on rod under spacer (if yoke and spacer. Screw rod back into yoke the same
installed). Move spacer for access. number of turns needed to remove.
4. Continue to turn rod into rod end until tilt cylinder
strokes are equal.
Rod Shim
IMPORTANT
The rod must be threaded onto the rod-end Rod-End
Cylinder Rod Yoke
yoke a distance at least as great as the
diameter of the rod plus 6.5 mm (0.25 in).
Wrench Flat
Add 6.5
mm (.25
in) to
diameter
of rod. Spacer
Thread rod into rod-
end yoke the rod
diameter plus 6.5 mm
(0.25in). 5. Tighten capscrew of the rod-end yoke to 166-193 N•m
(122-142 ft-lb), and repeat the racking test.
5. Tighten capscrew of the rod-end yoke to 166-193 N•m
(122-142 ft-lb), and repeat the racking test. 6. Repeat steps 1-5 for fine corrections if any racking
remains evident.
6. Repeat steps 1-5 for fine corrections if any racking
remains evident. 7. When no racking occurs, retighten yoke capscrew to
166-193 N•m (122-142 ft-lb).
7. When no racking occurs, retighten capscrew of the
rod-end yoke to 166-193 N•m (122-142 ft-lb). 8. Check all tilt functions before returning the truck to
service.
8. Check all tilt functions before returning the truck to
service.
Backward Adjustment
Perform forward check and adjustment first. Then:
Tilt Flow Control Adjustments
1. Slowly tilt upright fully backwards while watching See checks and adjustments Section of Group 29/30 for
piston rods. They should both bottom out at the same adjustment procedure.
time. If they don’t, adjust backward tilt using the
following steps.
2. Stop the upright when the first tilt cylinder bottoms out
against its rod spacer.
3. Go to the opposite cylinder and remove the capscrew
on the rod-end yoke and screw rod out of yoke. Count
the number of turns required to remove the rod from
the yoke.
SM 616, April ’98 Copyrighted Material Tilt Cylinder Checks and Adjustments • 32-2-3
NOTES
32-2-4 • Tilt Cylinder Checks and Adjustments

Section 3.
Tilt Cylinder Removal and Replacement

Tilt Cylinder Removal and Replacement • 32-3-1
CAUTION
1. Park truck on a hard, level, and solid Tilt Cylinder Removal and Replacement
gaps or breaks. 1. Move tilt lever back and forth several times to relieve
2. Put upright in vertical position and fully any pressure.
lower the forks or attachment. 2. Use an adequate chain and hoist to support the upright
3. Put all controls in neutral. Turn key switch so that it cannot fall when tilt cylinder pins are re-
OFF and remove key. moved.
wheels. WARNING
The upright assembly is heavy. Use only
hoists with enough capacity to lift the en-
tire assembly. Keep hands and feet away
from the assembly. Use prybars to move
the assembly into position for tilt cylinder
replacement.
Also support cylinder with a sling to pre-
vent the cylinder from dropping when pins
are removed.
3. Removal Sequence. (Replacement is reverse order).

See page 3.
A. Hydraulic lines.
Removal note: Put a drain pan under the truck at
each tilt cylinder position before removing the
hydraulic lines. Cap lines.
B. Mounting bolt.
C. Washer.
D. Locking pin.
E. Mounting pin.
Installation note: Make sure the spherical bearing
is aligned so that pin fits smoothly in yoke.
F. Cylinder assembly.
G. Spherical bearing.
H. Spherical bearing.
Parts Inspection
NOTE
1. Clean all bearings, pins, and other components in an If the rod-end yoke has been removed from
approved cleaning fluid. the rod or loosened for adjustment, rein-
2. Inspect all parts for scratches, nicks, dents, and wear. stall the clamp bolts to a torque of 166-193
Check the cylinder rods to be sure they are smooth with N•m (122-142 ft-lb). Nuts must be on inside
no scratches. Check all threaded parts for damage. of upright rails
3. Replace all parts which show damage. 4. See Section 2 for tilt cylinder adjustment procedures.
4. If parts are to be left exposed, coat all mating surfaces When adjustments are made, check all upright compo-
of parts with a light layer of engine oil. nents under load before returning the truck to service.
32-3-2 • Tilt Cylinder Removal and Replacement

A
See Group 40
for hydraulic
fitting tighten-
ing procedure.
H
Upright must be supported with
adequate capacity hoist. D
G
E
Cylinder must be
supported with sling.
B Torque: 20-22 N•m

(177-221 in-lb)
Tilt Cylinder Removal Replacement Steps (ref. page 2)

Tilt Cylinder Removal and Replacement • 32-3-3
32-3-4 • Tilt Cylinder Removal and Replacement

Section 4.
Tilt Cylinder Overhaul
IMPORTANT
Before removing any component for overhaul, make sure the correct
repair parts, seals, and gasket sets are available.
SM 616, April ’98 Copyrighted Material Tilt Cylinder Overhaul • 32-4-1

Preparation For Disassembly 3. Remove and discard the piston seal and O- ring from
the piston.
IMPORTANT
Overhaul tilt cylinders only in a clean, dust-
free location, using clean tools and equip-
ment. Dirt or grit will damage the highly-
machined surfaces and will result in leak-
age or premature failure of components.
Cleanliness of the hydraulic circuit is ex-
tremely important to the proper operation
work area is clean.
1. Before disassembly, the exterior of the tilt cylinder
should be carefully cleaned to remove all dirt and
4. Remove and discard the rod U-cup seal, static seal, and
grease accumulation.
piston rod wiper from the gland.
2. Be sure all hydraulic oil has been removed from the
cylinder. Stroking the piston rod will help force the oil
out. Inspection
3. Before starting disassembly, the tilt cylinder should be 1. Carefully clean all parts in an approved solvent and
carefully examined to determine if there is any evi- place on a clean surface.
dence of external damage. 2. Check the piston and rod for damage. Look for gouges,
scratches, corrosion, or evidence of unusual wear.
Disassembly Minor surface damage may be repaired by use of fine
abrasion cloth or stoning. Deeper damage will require
The tilt cylinder can be held by clamping the base end or replacement of piston rod assembly. Be sure the threads
the barrel in a vise while disassembling. on the rod are undamaged.
IMPORTANT 3. Inspect the tilt cylinder barrel internal bore for wear,
Do not use excessive force when clamping scratches or other damage. Deep gouges or pitted
on the barrel. surfaces require replacement of parts. Check the out-
side of the entire cylinder for damage. Inspect all welds
1. Remove the retaining ring on the gland with snap ring for cracks. Inspect the ports to be sure they are free of
pliers. contamination and that the threads are clean and not
2. Push the gland assembly into the cylinder barrel to damaged.
provide access to the shear ring. 4. Put a light coating of hydraulic fluid on all parts. If
3. With a brass punch, drive the shear ring inward to parts are to be left disassembled for awhile, they should
compress it and provide access to its outer edge. Then be covered with a clean cloth.
pry under the ring’s outer edge with a soft metal pick
to compress the ring some more. This allows you to
pull the ring over the shoulder in the barrel and extract
Reassembly
the ring. 1. Install piston rod wiper, rod U-cup, and static seal on
2. Carefully pull the rod and piston assembly, and gland the gland. Make sure U-cup and wiper are installed in
from the cylinder barrel. Remove gland from rod. proper orientation as shown in the illustration.
2. Replace the piston O-ring and piston seal.
3. Install gland on piston rod. Use gentle pressure and
WARNING careful movements to avoid damage to the U-cup seal
The use of compressed air to blow the pis- and rod wiper when these parts are moved over the
ton out of the barrel is not recommended. piston rod end.
High-pressure air can result in piston and
rod being ejected at high velocity (explo- NOTE
sively), causing severe injury to personnel Reassemble cylinder carefully to prevent
and property damage. damage to seal lips and O-rings.
32-4-2 • Tilt Cylinder Overhaul Copyrighted Material SM 616, April ’98

4. Install piston and rod assembly into cylinder barrel. Be 6. Install the shear ring: Slip it over the rod and, with a
careful not to damage the piston seals when installing brass punch, drive it in until it travels past the shoulder
the piston into end of cylinder. and snaps against the barrel wall. The pull the gland
5. Insert gland over rod and into cylinder until the entire and piston assembly forward to make the snap ring
gland is below the shoulder the shear ring seats against. seat against the shoulder in the barrel wall.
Be careful not to damage gland static seal. 7. Check the assembly by making sure the piston slides
freely in and out of the cylinder.
See Section 3 for replacement procedures; see Section 2
for checks and adjustments before returning the truck to
service.
Shear Ring
Spacer
Gland Static Seal Cylinder Barrel
Retaining Ring
Gland
Rod
Wrench Flat
Rod Wiper
Rod U-Cup
Seal
Piston Piston Seal and
O-Ring
Cut-Away View of Tilt Cylinder
SM 616, April ’98 Copyrighted Material Tilt Cylinder Overhaul • 32-4-3

NOTES:
32-4-4 • Tilt Cylinder Overhaul Copyrighted Material SM 616, April ’98

GROUP 34
GROUP 34
UPRIGHTS
Upright Specifications and Description ............ Section 1
Troubleshooting ................................................... Section 2
Upringht Inspection............................................. Section 3
Carriage and Upright Roller Clearance

Checks and Shim Adjustments ........................... Section 4
Cylinder Removal, Shimming,

Overhaul, and Replacement ............................... Section 5
Upright Chain Inspection, Adjustment,

and Replacement ................................................. Section 6
Fork and Carriage Removal and

Replacement ......................................................... Section 7
Upright Removal and Replacement ................... Section 8
SM 616, Jul ’01 Copyrighted Material Uprights

NOTES:
Uprights Copyrighted Material SM 616, Jul ’01

Group 34, Uprights
Section 1.
Upright Specifications and Description
General Specifications Upright

Upright Type Number Cylinder Type
Upright Weight: Approximately 330 kg (730 lb) to ap-
proximately 700 kg (1550 lb) without carriage. Standard V1204 Piston-Type Lift Cylinder
Carriage Weight: Approximately 80 kg (180 lb) to 100 kg

(220 lb) with a 37 inch carriage. TSU M1203 Piston-Type Secondary Cylinder
Fork Weight: Approximately 40-65 kg each (90-145 lb) M1204 Piston-Type Secondary Cylinder
HiLO H1205 Ram-Type Secondary Cylinder
IMPORTANT
H1206 Ram-Type Secondary Cylinder
Before hoisting, the weights of upright,
carriage, forks and attachments being lifted
must be combined to determine what lifting Drift:
capacity is required of the hoisting
equipment. Upright should not drift (fall) 100 mm (4 in) in ten minutes
under a capacity load. If drift over 100 mm (4 in) in ten
Capacities and Lift Heights: Upright, carriage, and fork minutes is evident, cylinder should be checked for internal
capacity and upright lift heights are listed on the truckís leakage. See Section 3 for drift test procedures.
data plate.
Lubricants: Fastener and Fitting Torque Specifications
• All Purpose Grease (MS-9)
Load Back Rest: 170-190 N•m (125-140 ft-lb)
• Innerslide Lubricant (Clark P/N 886396)
• Chain and Cable Lube (Clark P/N 886399) Chain Anchor Bolt Jam Nut: 80-150 N•m (59-110 lbf-in)
Carriage Side-Thrust Roller Bolts: 34-40 N•m (26-30 lbf-in)
Cylinder Types Hose Fittings: See Group 40, “Hydraulic Fitting Tightening
Standard uprights use two lift cylinders. Triple stage and Procedure.”
Hi-Lo uprights use three cylinders, a primary (center- Rod End Bolts: 164-190 N•m (122-142 ft-lb)
mounted) cylinder, and two secondary cylinders. All pri-
mary cylinders used on triple-stage uprights (TSUs) & Tilt Cylinder Rod-End Mounting bolt: 25-30N•m (221-266
Hi-Lo are piston cylinders. lbf-in).
The Secondary cylinders used on Hi-Lo uprights are ram
cylinders.
IMPORTANT
Before removing any component for
overhaul, make sure the correct repair
The types of cylinders used on the truck are listed below.

Check the first five characters of the upright number stamped
on the upright of the truck to determine the type of cylinder,
piston or ram, used on the upright.
SM 616,
616,Jul
Dec ①➁
’01’02 Copyrighted Material
Upright Specifications and Description • 34-1-1
Group 34, Uprights
Service Intervals Forks use a hanger design for mounting on the carriage.
Auxiliary attachments may be added to the upright for
• All upright components should be visually checked
specialized handling operations. The hydraulic circuit is
every day during the Operatorís Daily Inspection.
modified with a hose adapter kit and an auxiliary section is
• A thorough visual inspection should be performed added to the main hydraulic valve to operate the attachment.
by a trained service professional every 50-250 hours.
The lift and secondary cylinders on standard uprights, Hi-
• Lift chains should be inspected and lubricated every Lo uprights and triple-stage uprights (TSUs) may be either
50-250 hours or monthly. piston-or ram-type cylinders. The primary cylinder on TSUs
• Lift chain tension should be checked every 50-250 and Hi-Lo uprights are piston-type cylinder. See the chart
hours or monthly. under “Specifications” to determine the type of cylinder
• Upright and carriage roller checks should be used on the upright you are servicing.
performed every 50-250 hours or monthly. Piston-type cylinders contain a by-pass check valve in the
• Roller patterns should be checked every 6 months or piston that allows air and fluid that have accumulated in the
after 1000 hours of service. rod end of the cylinder to return to the system. The check
• Racking and drift tests should be performed every 6 valve can be removed and cleaned if indicated by
months or after 1000 hours of service. troubleshooting. A non-serviceable check-ball-type
cushioning function is built into ram and piston cylinders
• The complete extended inspection should be for smooth staging during the lowering cycle. The primary
performed at least every year or 2000 hours of cylinder on TSUs incorporates cushioning on the lift cycle.
operation. A flow control valve in the hydraulic port of the lift cylin-
ders (secondary cylinders on TSUs) prevents the mast from
Description falling rapidly in case of sudden fluid pressure loss due to
line breaks or other malfunction of the hydraulic circuit.
The upright assembly includes the lift chains, lift cylinders,
As explained in more detail in Group 30, the main pump
carriage, forks, and mast or rail sets. Each of the components
sends fluid to the main hydraulic control valve, which
can be serviced using the tests, checks, adjustments, and
contains spools that route fluid to the lift cylinders and tilt
removal and replacement procedures in the following
cylinders. The valve assembly also contains a counter-
Sections.
balance valve that prevents upright tilt when the truck is not
The upright uses the hydraulic cylinders and chain sets to operating.
lift the carriage and rail sets. On standard, two-stage uprights,
Fluid flow rates for lift functions are factory set and not
the lift cylinders lift the carriage with chains and directly
adjustable. Flow rates for tilt and auxiliary functions are
lift the inner rail set. On triple-stage uprights, the primary
controlled by adjustments on the main hydraulic valve. A
(free-lift) cylinder lifts the carriage by chains. When the
non-adjustable “load-lowering” flow valve mounted on the
primary cylinder reaches its maximum extension, fluid is
upright limits upright lowering speed.
diverted to the secondary lift cylinders, which lift the inner
rails using a second set of chains and lift the intermediate Groups 29 and 30 contain general hydraulic information
rails by direct lift. including upright hydraulic functions. Other hydraulic
checks for the upright appear in “Troubleshooting,” Sec-
On Hi-Lo uprights, the primary (free-lift) cylinder lifts the
tion 2.
carriage by chains. The secondary cylinders directly lift the
inner rail set by rod.
Hi-Lo uprights not used second set of chain for secondary
cylinder.
Friction and play between the nesting rails is controlled by
roller sets mounted on the rails and carriage. When rails or
rollers become worn, the gap between the rollers and rails
becomes larger, creating more play in lifting and lowering
operations. The rail web to roller side clearances can be
reduced by shimming the rollers to close the gap between
the roller and rails. The gap between the rail flange and
roller bearing surface can be reduced by the use of oversize
rollers on a one-time basis.
34-1-2 • Upright Specifications and Description

SM616,
616,Dec ’01 ➁
Jul ’02 ①
Group 34, Uprights
Upper Roller
Lift Cylinder
Chain Sheave
Chain Anchor
Outer Rail Set
Lift Chain
Load Lowering
Flow Valve
Typical Standard Upright Assembly
Lower Roller
Inner Rail Set
Carriage
Upper Roller
Secondary
Load Lowering Cylinder
Flow Valve Hose Inner Rail Set
Chain Sheave
Primary Cylinder/
Carriage Chain
Chain
Anchor
Outer Rail Set
Primary
Cylinder
Lower Roller
Carriage
Typical Hi-lo Upright Assembly
SM
SM 616,
616,Jul
Dec ①➁
’01’02 Copyrighted Material
Upright Specifications and Description • 34-1-3
Group 34, Uprights
Hose Sheave
Outer Rail Set
Upper Roller
Secondary Cylinder
Upper Roller
Chain Anchor
Load Lowering
Flow Valve
Primary Cylinder
Chain Sheave
Primary
Cylinder/
Carriage
Chain
Lower Roller
Intermediate
Rail Set
Inner Rail Set

Lower Roller
Typical Triple-Stage Upright Assembly

SM616,
616,Dec ’01 ➁
Jul ’02 ①
Group 34, Uprights
Typical Triple Stage Upringht-Overhead View
Adjustment shims Carriage

Roller
External thrust roller
Carriages and Roller Sets
SM 616, Jul ’01 Copyrighted MaterialUpright Specifications and Description • 34-1-5

Group 34, Uprights
Two-Hose Adaptation for the Triple Uprigt
Two-Hose Adaptation for the Standard Uprigt Two-Hose Adaptation for the Hi-Lo Uprigt

SM616,
616,Dec ’01 ➁
Jul ’02 ①
Group 34, Uprights
Section 2.
Troubleshooting
The visual inspection and the operational checks presented • Fit between roller edge and rail flange excessively
in Section 3 should be used to determine problems with the loose in rails; replace with oversized, “Select-Fit”
upright. Possible problems, causes, and remedies are listed rollers. See “Upright Roller Clearance Check and
below. Shim Adjustment.”
Other troubleshooting information about the hydraulic • Dry lift chain; lubricate chain.
circuit and components appears in the troubleshooting • Dry hose sheave or rollers; check condition of all
Sections of Groups 29 and 30. Use these other sheaves and rollers and lubricate as necessary.
troubleshooting Sections for more detailed problem isolation
• Damaged chain sheaves; check condition of chain
with Upright hydraulic functions.
sheaves and repair or replace.
• Excessive fork hanger or carriage fork bar wear;
WARNING
inspect and replace as necessary.
The procedures for troubleshooting
uprights, carriages, and forks involve • Seals dry; lubricate rod.
movement of the components. Failure to • Seals dry - all primary cylinders; remove gland and
follow these warnings can result in serious add 100 ml (3.4 oz) of hydraulic oil to rod side of
injury. piston, see “Cylinder Removal, Shimming, Overhaul,
Make sure overhead clearances are and Replacement.”
adequate before raising the upright to full
lift height. No lift, tilt, or auxiliary function
Do not walk or stand under raised forks.
• Hydraulic fluid level low; check level and fill.
Block carriage and upright whenever
• Broken hoses or fittings; check and repair.
making checks with the upright elevated.
• Damaged or blocked sump strainer; check and clean.
Keep clear of load and carriage when
making any check or adjustment. • Hydraulic pump defective; see Group 29 for pump
troubleshooting.
Keep your arms and fingers away from
moving parts of the upright. • Defective main hydraulic control valve; see Group
30 for valve troubleshooting.
Do not reach through open areas of the
upright. • Defective upright load-lowering flow valve;
disassemble valve, check and clean or replace.
Upright noise
No lift function but tilt operates
• Bent or broken components; inspect upright
thoroughly and repair or replace components as • Broken hoses or fittings; check and repair.
required. • Cylinder is damaged; inspect and repair.
• Damaged upright roller; check condition of rollers • Main hydraulic control valve, lift section defective;
and replace defective rollers. see Group 30 for valve troubleshooting and service
• Roller scuffing rails; clean and lubricate rails. information.
• Roller (carriage or upright) shimming needs • Upright load-lowering flow valve damaged;
adjustment; check and adjust as required. disassemble valve, check and clean or replace.
SM 616, Jul ’01 Copyrighted Material Troubleshooting • 34-2-1

Group 34, Uprights
Load cannot be lifted to maximum height • Defective priority valve; see Group 30 for valve
troubleshooting information.
• Hydraulic fluid level low, check level and fill.
• Defective upright load-lowering flow valve; remove
• Debris in upright; check and clean.
valve clean, inspect, and replace if necessary.
• Hydraulic hose fittings loose or damaged; check and
torque correctly (see Group 40 for specifications) or
replace. Lowering speed sluggish
• Check cylinder for external leakage; replace cylinder • Damaged or binding upright roller; check condition
if cracked. of roller and replace if necessary.
• Cylinder shimming is incorrect; check and adjust • Damaged or kinked hydraulic hose or tube; check
shimming. condition of hose and tube, repair or replace as
necessary.
• Internal leakage on lift or secondary piston cylinders;
remove rod and piston and clean check valves; also • Defective upright load-lowering flow valve; check,
clean and inspect/replace piston seals. See Section 5. clean and replace valve if necessary.
• Defective velocity fuse; remove fuse from cylinder
• Cylinder check valve on lift or secondary piston
hydraulic port, clean and recheck for proper opera-
cylinders not functioning properly; remove rod and
tion.
piston and clean check valves; also clean and inspect/
replace piston seals. See Section 5.
• Hydraulic pump defective; see Group 29 for pump Load bounces excessively when lowering
troubleshooting information. • Air in hydraulic system, TSU and Hi-Lo ram-type
• Upright rails binding: cylinders; set capacity load on upright and lift from
fully collapsed to full lift height for 10-15 cycles.
a. Perform a visual inspection and check for worn,
or distorted parts, broken or cracked rails or tie- • Defective upright load-lowering flow valve; check,
bars, correct chain and hosing placement and clean and replace valve if necessary.
operation • Defective main lift valve; see Group 30 for valve
b. Check rollers for contamination and proper troubleshooting and service information.
operation, perform roller clearance check and • Defective velocity fuse; remove fuse from cylinder
adjustment. hydraulic port, clean and recheck for proper opera-
tion.
Lift speed sluggish

Upright mis-staging (TSU & Hi-Lo lifting)
• Hydraulic fluid level low; check level and fill.
• Debris in upright roller area of carriage; check and
• Broken hoses or fittings; check and repair.
clean.
• Pump inlet line restricted; remove from pump and
• Interference between carriage and inner rail or
clean.
cylinder; check staging alignment and adjust or repair
• Damaged or binding upright roller; check condition as necessary.
of roller and replace if necessary.
• Bent or broken carriage or inner rail; replace part -
• Internal leakage on piston-type lift and secondary do not try to repair by welding.
cylinders (with load); perform cylinder checks listed
• Damaged or binding carriage roller; check condition
under ìLoad cannot be lifted to maximum height.î
of roller and replace if necessary.
• Hydraulic pump defective; see Group 29 for pump
• Carriage roller shimming or thrust roller out of
troubleshooting information.
adjustment; perform roller checks on carriage and
• Defective main lift valve; see Group 30 for valve make adjustments as necessary.
troubleshooting and service information.
• Damaged or kinked primary cylinder hose; check
• Defective velocity fuse; remove fuse from cylinder condition of hose, repair or replace as necessary.
hydraulic port, clean and recheck for proper
• Primary cylinder chain or chain sheave binding or
operation.
damaged; inspect and repair.
• Internal leakage in primary lift cylinder; perform
cylinder checks listed under “Load cannot be lifted
to maximum height.”
34-2-2 • Troubleshooting Copyrighted Material SM

SM 616, Jul ’01
616, Dec ①
’02 ➁
Group 34, Uprights
• Damaged primary lift cylinder causing binding in • Defective velocity fuse; remove fuse from cylinder
the cylinder; inspect and repair or replace cylinder. hydraulic port, clean and recheck for proper
• Defective velocity fuse; remove fuse from cylinder operation.
operation. External leakage on primary cylinder
• Gland loose; check and tighten primary cylinder
Upright mis-staging (TSU lowering) gland to 135 N·m (100 ft-lb) and glands on lift
• Debris in upright roller area or tie bar area; check (secondary) cylinders to 100 N·m (73 ft-lb).
and clean. • Cracked cylinder tube; replace tube.
• Bent or broken carriage or inner rail; replace part - • Rod seal damage; replace seals and check for:
do not try to repair by welding. - Damaged rod seal groove in gland; check for
• Damaged or binding roller on upright; check damage to groove and replace seal or gland if
condition of roller and replace if necessary. necessary
• Carriage and upright roller shimming or thrust roller - Scored cylinder wall; repair or replace cylinder
out of adjustment; perform roller checks on upright tube if necessary
and/or carriage and make adjustments as necessary. - Leaking check valve; clean and replace if
• Damaged or kinked lift cylinder hose; check necessary
condition of hose, repair or replace as necessary. - Leaking O-ring seal on check valve; replace check
• Lift cylinder chain or chain sheave binding or valve.
damaged; inspect and repair. • Gland static seals (O-rings and back-up ring)
• Bent cylinder rod; inspect and replace rod and/or damaged; replace back-up ring.
cylinder as necessary. • Gland static seals sealing surface damaged; check
• Internal leakage in piston-type cylinders; perform groove and bore and repair or replace as necessary.
cylinder checks listed under “Load cannot be lifted
to maximum height.”
External leakage on lift (Standard) and
• Damaged lift cylinder causing binding in the cylinder;
secondary cylinder (TSU & Hi-Lo)
inspect and repair or replace cylinder.
• Gland loose; check and tighten gland on cylinders to
• Defective velocity fuse; remove fuse from cylinder
100 N·m (73 ft-lb).
operation. • Cracked cylinder tube; inspect and replace tube.
• Seal damage in piston-type cylinders; replace piston
seals and rod seals.
Upright mis-staging (Standard and Hi-Lo
upright lowering) • Damaged seal groove, piston-type cylinders; check
for scratches, nicks, or burrs and repair or replace
• Damaged or binding roller on upright; check rod and piston.
condition of roller and replace if necessary.
• Scored cylinder wall, TSU piston-type cylinders;
• Top carriage roller retaining cap screw loose; check replace tube and all seals.
and replace cap screw.
• Scored or damaged rod; replace rod and all seals.
• Lift cylinder chain or chain sheave binding or
• Damaged gland back-up seal; inspect and replace
damaged; inspect and repair.
seal.
• Debris in upright roller area or tie bar area; check
• Gland static seals sealing surface damaged; check
and clean.
grooves and bore.
• Bent or broken carriage or inner rail; replace part -
do not try to repair by welding.
Oil leak at top of lift cylinder
• Carriage and upright roller shimming or thrust roller
• Scored cylinder wall; see Section 5.
out of adjustment; perform roller checks on upright
and/or carriage and make adjustments as necessary. • Worn or damaged gland rod-seal; see procedures for
piston-type cylinders under “Cylinder leaking
internally.”
SM 616, Dec ① ➁
D’01’02 Copyrighted Material Troubleshooting • 34-2-3
Group 34, Uprights
Unsatisfactory lift or tilt cylinder drift test results • Cylinder hydraulic fittings loose or worn; check
• Cylinder leaking internally; remove cylinder gland fitting O-rings, tighten fittings according to Group
and check: 40,“Hydraulic Fitting Tightening Procedure.”
a. Primary cylinder should have only 3.4 ounces • Check valve worn or damaged; remove rod and
(100 ml) on rod side of the piston piston, clean check valve and replace if necessary.
b. Piston-type lift and secondary cylinders should • Control valve spool linkage malfunctioning,
be dry on rod side of piston. damaged, or worn; see Group 30, Section 5 for
linkage adjustment and/or replacement.
If fluid is leaking past piston:
• Counterbalance function in main hydraulic control
a. On piston-type cylinders, remove rod and piston, valve malfunctioning, damaged, or worn; inspect
clean check valves and clean and inspect/replace and clean or replace if necessary.
piston seals
b. On ram-type cylinders, inspect/replace rod and
piston.
See Section 5.
34-2-4 • Troubleshooting Copyrighted Material SM 616, Jul ’01

Group 34, Uprights
Section 3.
Upright Inspection
Basic Visual Inspection .................................................................................................................. 2
Extended Inspection ...................................................................................................................... 3

Forks ................................................................................................................................................ 3
Lift Chains ....................................................................................................................................... 4
Carriage and Upright Weldments .................................................................................................... 5
Carriage and Upright Rollers ........................................................................................................... 6
Cylinders .......................................................................................................................................... 7
Hydraulic Plumbing ......................................................................................................................... 9
Upright Drift .................................................................................................................................... 9
CAUTION
1. Park truck on a hard, level, and solid surface, such as a
concrete floor with no gaps or breaks.
2. Put upright in vertical position and fully lower the forks
or attachment.
3. Put all controls in neutral. turn key switch OFF and
remove key.
Upright
Load
Backrest
Carriage
Forks
SM 616, Jul ’01 Copyrighted Material Upright Inspection • 34-3-1

Group 34, Uprights
Basic Visual Inspection Lift Chains

Use the following steps to conduct an initial visual inspection Inspect the chains for:
of the upright. This is the same type of inspection operators • Proper lubrication. The links should have a coat of oil
should be conducting on a daily basis. on all surfaces. Lubrication oil should penetrate
If you note problems with any component during the basic completely into chain joints.
visual inspection, continue with ìExtended Inspectionî for • Good condition of the chain links and pins. No rust,
checks and service. corrosion, stiffness, or cracking should be evident.
Pins should not be turned or protruding.
WARNING • Excessive side wear or edge wear on the chain plates.
The procedures for checking, maintaining, • Correct, equal tension on chain sets.
and adjusting uprights, carriages, and forks
involve movement of the components. • Secure anchor bolt, adjustment nut, and jam nut
Failure to follow these warnings can result mounting.
in serious injury. Always use extreme • Correct alignment of the chain anchors to the chain
caution. and chain sheaves. Adjust turned chain anchors.
Do not walk or stand under raised forks. • Loose, broken, or damaged anchor bolt pins and cotter
Keep clear of load and carriage when pins. Replace defective pins and cotter pins.
making any check or adjustment.
Keep your arms and fingers away from Rollers
moving parts of the upright. Inspect the upright and carriage rollers for:
Do not reach through open areas of the • Broken or loose rollers.
upright.
• Loose, broken, or misadjusted thrust roller on the
carriage.
General • Obvious signs of failed bearing seals.
• Check to make sure all fasteners are secure. NOTE
• Check to make sure the upright lifts and lowers Some grease will purge from the bearings
smoothly with and without a capacity load. in the first 100-200 hours of operation.
• Check for visible damage to components. • Excessive looseness in carriage or upright roller
shimming.
Forks
• Check function and security of the fork latch. Upright and Carriage Weldments
• Inspect the forks for cracks, especially the hanger and Inspect the upright and carriage for:
heel areas.
• Debris or foreign objects on the components.
• Check for wear in the fork heel. If heel wear is evident,
• Bent, cracked, or broken components.
perform the extended inspection.
• Undesirable wear on or contact between components.
• Inspect the fork hanger and carriage fork bar for
excessive wear. • Irregular roller patterns and signs of excessive wear
or scraping on the rails.
• Inspect for bent forks.
Load Backrest Hydraulic System

• Inspect load backrest for damage such as cracks or Inspect the upright hydraulic system components for:
bending. • Damage or wear on all hoses and hydraulic tubes.
• Check for tight mounting fasteners. • Leaks on hoses, fittings, or valves.
• Leakage on the cylinders.
• Excessive drift in lift or tilt operations.
34-3-2 • Upright Inspection Copyrighted Material SM 616, Jul ’01

Group 34, Uprights
Extended Inspection
The extended inspection should be performed whenever
the basic visual inspection indicates upright problems, as
specified for PMs, or at least every 2000 hours.
Forks
Forks have a limited service life because of wear and
fatigue. Forks should be tested every 50-250 hours using a
visual inspection, a fork thickness check, a fork bending
check, and a fork gap check. If replacement is necessary,
always replace the pair to ensure fork integrity.
Fork AlignÂment Fork Bending Check

1. Park the truck on a flat, even surface, tilt upright to 2. Set a carpenter’s square on the block against the fork
vertical position, and set forks 25-50 mm (1-2 in) shank
above the ground.
3. Check the fork 508 mm (20 in) above the blade to make
2. Compare fork arms to be sure they are straight, on the sure it is not bent more than 14.5 mm (0.6 in) at the
same plane (level), and the same length. maximum.
3. Measure the distance from the fork tips to the ground. 4. If blades are bent over the 14.5 mm (0.6 in) allowance
The height difference between the forks tips should be they should be replaced as a set.
no more than 6mm(0.25in).
See Section 7, “Fork and Carriage Removal and
Replacement,” for procedures to remove and replace the
forks.
Fork Fatigue
Fatigue cracks normally start in the heel area or on the
underside of the top hanger. If cracks are found, the fork
should be replaced. Dye penetrants or magnaflux can be
used for a more accurate inspection.
Fork Wear and Heel Wear

Industrial Truck Association (ITA) standards require that a
Fork Arm Height fork be removed from service when the blade or heel
thickness is reduced by 10% over its original thickness. If
4. If the fork tips are not aligned within the specified
the heel is 10% smaller than the arm, the load capacity
6mm(0.25in) difference, the cause of the problem
could be reduced by 20%. A 5,000-pound (2272 kg) capacity
must be determined and corrected before returning the
fork with 10% wear can only safely handle 4,000 pounds
truck to service. If replacement is necessary, always
(1818 kg).
replace the forks in a set.
Use of fork wear calipers are recommended (Clark part
Fork Bending number 1803641) to gauge fork wear as follows:
Overloading, glancing blows against solid objects, or picking 1. Use the outside jaws of the caliper to measure fork
up loads unevenly can bend or twist a fork. Use the following thickness in the shank area of the fork.
procedure to check for fork bending.
1. Place a 50 x 100 x 610 mm (2 x 4 x 24 in) wood block
flat on the fork. Make sure the block is not resting on
the heel radius.
SM 616, Dec ’02①➁

Jul ’01 Copyrighted Material Upright Inspection • 34-3-3
Group 34, Uprights
NOTE
NOTE A small amount of lubricant can be applied
Hold the caliper square and use light to the fork latch. Do not over lubricate and
pressure to squeeze the outer jaw tips allow lubricant to run down on carriage
against the fork shank. Take care not to fork bar.
accidentally alter the reading of the calipers.
2. Check fork stops for widening of notches or rounding
2. Check the fork blade area to the inside jaws of the of top edge. Replace the carriage if fork stops are
caliper. excessively worn.
3. If the inside jaws fit over the fork in the blade area,
wear exceeds allowable 10% wear and a new set of Lift Chains
forks should be installed.
The following checks should be performed every 50-250
Fork Hanger Wear and Carriage Fork Bar Wear hours to ensure correct chain performance See Section 6 for
more complete chain inspection and maintenance
Inspect the fork hangers and carriage fork bar. Excessive procedures.
wear can cause the fork to disengage the fork bars or reduce
fork hanger life. Chain Wear (Stretch) - All Lift Chains
Lift chain stretch due to wear in the joints can be measured
using a measuring tape or Clarkís chain check ruler.
• If fork hangers are excessively worn, replace the forks

as a set. Chain Check Ruler - Clark Part Number 59-960-9908
• If carriage fork bar is excessively worn, replace the
carriage. When any section of the chain has worn and increased its
original length by 3% or more, the chain must be replaced.
IMPORTANT
When checking chain wear, always measure a segment of
Welding is not recommended for repairing
the chain that rolls over a sheave.
forks or carriage. Replace the worn parts
with new parts.
Fork Latch and Carriage Fork Stops

1. Check fork latches for proper operation. Latches should
operate smoothly. The spring should be in good
condition and securely lock the fork into position.
Replace the fork latch if it does not operate properly.
34-3-4 • Upright Inspection Copyrighted Material SM 616, Jul ’01

Group 34, Uprights
IMPORTANT 3. If one chains moves more than the other;

Never replace a single chain in a set. Always a. Lower the forks to ease tension on the chains.
replace the two chains in a set for consistent
lift operation. Always replace anchor pins b. Adjust chain adjustment nuts for equal tension on
when replacing chains. both chains. See Section 6 for chain adjustment
procedures
1. For example, measure a 305 mm (12 in) segment of the
4. Repeat the tension test and make adjustments until the
chain that does not roll over a sheave and count the
tension is equal on both chains when the carriage and
number of links in the segment.
upright are raised.
2. Find an area of the chain that normally runs over the
sheave. This can usually be identified by wear on the
plate edges that roll over the sheave.
Carriage and Upright Weldments
The carriage and upright should be checked for fatigue
3. If the same number of links measures over 315 mm
cracks and bent components every 2000 hours or every
(12.36 in) the chain must be replaced.
year..Fatigue cracks start in areas of stress after a high
If using a chain check ruler, see instructions on the ruler. number of load cycles. Stress concentrations typically exist
in welded joints, in the area around a welded joint, or in the
Chain replacement procedures appear in Section 6.
corners of parts. Dye penetrant, magnaflux, or other crack
Chain Length detection methods can be used to find or trace cracks. If
cracks are found in any structural weldment, the component
IMPORTANT should be replaced before returning the truck to service.
Perform a chain length check and
adjustment every 50-250 hours. Checks and • Bent components indicate excessive loading or high
adjustments should also be performed to impacts to the weldments. Bent components are usually
adjust for chain stretch and tire wear. structurally damaged and should be replaced.
• Inspect roller contact patterns on the rail sections.
Chain length must be adjusted if: Roller contact patterns should be smooth and regular.
• The fork-to-ground clearance is less than 5 mm (.20 - In some applications, it may take up to 500 hours
in) or more than 25 mm (1.0 in) when the upright is of operation to develop a roller contact pattern on
vertical. the flange of the rail.
• The center of the bottom carriage roller comes within - In applications where heavy loads are common, a
20 mm (0.80 in) of the bottom edge of the inner rail. rail lubricant may be required to allow proper
• The carriage safety stop hits the inner rail stop at full wear-in on the roller.
lift height. • Check rails and carriage for wear due to undesirable
• On TSU and Hi-Lo, the difference between the bot- contact between components. Such contact can be an
tom of the inner rail and the outer rail is greater than indication of broken rollers, loose components, foreign
10 mm (0.40 in). objects or debris on the upright, or a broken weldment.
- If contact or rubbing exists, the condition must be
See Section 6 for chain length adjustment procedures.
corrected immediately.
Chain Tension - Rail and carriage weldments with damage should
be replaced.
IMPORTANT
Center any auxiliary attachments before • Tie bar areas should be free of foreign objects and
beginning tension check debris. The roller area of the rail should be cleaned
every 500-1000 hours in a normal application.
1. Raise the upright enough to put tension on the chains - In applications where excessive amounts of
to be checked. contaminants settle in the rail channels, cleaning
may be required on 50-250 hour intervals.
2. Push the chains forward and pull them backward; the
- If excessive contamination exists, the rollers should
amount of tension should be equal on both sides.
be exposed and the bearing seal areas cleaned
thoroughly.
WARNING
See Section 4 for carriage roller and upright roller
Do not reach through the upright to push
removal and installation.
chains for tension check.
’02①➁
Jul ’01
SM 616, Dec Copyrighted Material Upright Inspection • 34-3-5
Group 34, Uprights
Carriage and Upright Rollers Shoulder

Roller shaft
Carriage Thrust Rollers
shims
• The external thrust roller runs along the outside flange
of the inner rail to control lateral load on the carriage. Bearing outer race
External thrust rollers are found on all uprights.
External thrust roller
Indications of broken or damaged rollers include:

• Part of all of roller bearing missing
• Bearing outer race loose
• Scraping noise from the upright
The extenal thrust roller should be checked for smooth • Scraping of carriage fork bar on inner rail (carriage
rotation, seal integrity, radial bearing tightness, and a tight rollers)
cap screw. A roller should turn smoothly without sticking • Upright rail sections scraping together (upright rollers)
and be grit free. Replace the roller if any defect is found. • Upright mis-staging
External thrust roller cap screws have a locking patch to • Excessive looseness of the rail section or carriage
prevent the cap screw from backing out. Repeated removal demonstrated by the following load test.
will deteriorate the ability of the patch to hold the cap
screw. If the cap screw is backing out without holding, a NOTE
new cap screw is recommended. The cap screw can also be Some grease will purge from the bearings
cleaned and set using thread locking compound Loctite 271 in the first 100-200 hours of operation. This
(Clark Part 1802302). is not necessarily a sign of a failed roller
bearing seal.
NOTE
Some grease will purge from the bearings Load Test
in the first 100-200 hours of operation. This
A load test helps you to determine the amount of clearance
is not necessarily a sign of a failed roller
between the moving upright parts. The upright requires
bearing seal.
some lateral movement between the interlocking rails and
The external thrust rollers are not adjustable. the carriage. But, too much or too little clearance can be the
cause of binding and uneven operation.
Carriage and Upright Main Load Rollers
Inspect the carriage and upright main load rollers for broken, WARNING
loose, or rough bearings. Defective rollers should be An upright or carriage can move
replaced. unexpectedly during service procedures
causing severe injury:
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.
34-3-6 • Upright Inspection Copyrighted Material SM

SM616,
616,Dec ①➁
Jul 1’02
Group 34, Uprights
1. Place a capacity load on the forks and secure it to the 2. Excessive lateral shift in the upright at, or near, full
carriage. maximum fork height (MFH)
3. Irregular roller patterns on the rail.
CAUTION
Signs of over shimming include:
Test load must be stacked stably, not extend
beyond the pallet, and be secured on the 1. Mis-staging or hanging up of the upright
pallet. Operate the truck only from within 2. Excessive wear in the rail web
the operatorís compartment.
3. Premature bearing failure.
2. Tilt the upright back slightly and raise the upright to its
Perform the following roll pattern check and the load test if
maximum extension several times. Note the smoothness
the need for roller shimming is suspected. See Section 4
of operation, the carriage play, and play between the
for detailed clearance measurement procedures.
rails.
3. Move the load 100 mm (4 in) off center on the forks and Roll Patterns
resecure it to the carriage. Impressions made by rollers on upright rails are called roll
4. Raise the upright to its maximum extension and lower patterns. Roll patterns can provide indication of the need
the load to the floor several times. for upright or carriage adjustment.
5. Repeat the step, moving the load 100 mm (4 in) off
center to the other side. WARNING
6. Raise the upright to its maximum extension and lower making any checks or adjustments.
the load to the floor several times.
Carefully observe the smoothness of operation, particularly 1. Elevate the carriage about 1.3 m (4 feet).
in carriage play, and play between the rails. If any unusual 2. Apply a light, thin layer of grease to the roller contact
movement, staging, or noise occurs during the test, correct area.
the problem before returning the truck to service. Continue 3. Lower the forks and pick up a capacity load. Raise and
with the following roller shimming checks if too much play lower the upright several times.
is evident in the carriage and rails in the load test. The
troubleshooting guide may also help to identify specific 4. Back out from the load and raise the carriage.
problems with upright operation. Compare the impressions of the rollers on each side of the
upright rails. The impressions should look the same on both
Roller Side-Clearance
sides. Look for signs of metal scoring or gouging which can
The carriage and upright rollers are shimmed between the indicate excessive pressure caused by damaged or
inner race and the roller shaft shoulder to maintain minimal misadjusted rollers.
clearance between the side of the roller and the web of the
Carriage rollers, including side-thrust rollers, and all upright
adjacent rail. Shim adjustments help accommodate
rollers can be checked by examining roll patterns. If irregular
manufacturing tolerances and wear in the upright rail
impressions result from the checks, perform the “Lift
sections.
Cylinder Shimming Check” and the “Load Test” to further
Side Clearance diagnose problems.
Roller See Section 4 for procedures to measure clearances and
adjust carriage or upright rollers.
Roller Shaft
and shoulder Cylinders
Rail Web
Use the Drift Test, presented under “Hydraulic Checks”
below, for additional diagnosis of cylinder condition. See
Section 5 for cylinder repair.
External Leakage (All Cylinders)
Signs of loose shimming include: To check for external leakage on the primary cylinder:
1. Clean the top of the gland and rod to remove any
1. Excessive lateral (side-to-side) movement in the upright
buildup of debris.
rail sections
SM 616, Jul ’02①➁

Dec’01 Copyrighted Material Upright Inspection • 34-3-7
Group 34, Uprights
2. Check rod surface for defects or unusual wear. 2. Cycle the upright 5-10 times through the first 2/3
• Nicks, burrs, or other sharp defects can cause length of the primary stroke and lower forks completely.
damage to the seal and will lead to leaks. The rod 3. Slowly lift the carriage 305-610 mm (1-2 ft) into the
should be repaired or replaced. secondary lift stage then lift to full extension.
• For piston-type cylinders, small blunt defects in 4. If the carriage does not lift to full height, the problem
the top and midsection of the rod can be tolerated is likely an internal leak and the cylinder should be
in this cylinder design. The high pressure sealing overhauled.
is over the last several inches of stroke. This type
of defect is acceptable if leakage is not evident. 5. If the carriage does lift to full height, but you still
suspect an internal leak, repeat the procedure with a
3. Check for external leakage from the cylinder barrel, 40-70% capacity load.
gland O-rings and backup ring, and the rod seal. NOTE
The primary cylinder normally has
approximately 100 ml (3.4 oz) of hydraulic
fluid on the rod side of the piston as a pre-
charge.
Use the Drift Test, presented under “Hydraulic Checks”

below, for additional diagnosis of cylinder condition. See
Section 5 for cylinder repair.
Internal Leakage on Piston-Type Lift and Secondary

Cylinders
To check for internal leakage in Standard lift and TSU
secondary cylinders:
1. Lift the upright to MFH then lower forks completely.
2. Cycle the upright 5-10 times through the first 2/3
length of the lift cylinder stroke and lower forks
• The gland O-rings and backup ring are near-zero completely.
leakage seals. If, after cleaning the gland and tube, 3. Lift the upright to full MFH.
oil accumulates to form a run, the O-rings and
Watch for the lift cylinder to increase lift speed. If you see
backup ring should be replaced (see Section 5).
an increase in lift speed, one or both of the lift cylinders
• External leakage from the barrel requires have an internal leak and requires overhaul.
replacement of the barrel.
If the upright does not increase lifting speed, but you still
NOTE suspect an internal leak, repeat the procedure with a capacity
The seals are installed with lubricant and a load. If the upright does not extend to full MFH, the problem
trace amount will be in the gland/tube is likely an internal leak and the cylinder should be
interface area. overhauled.
4. After cleaning the top of the gland and the barrel, cycle Lift Cylinder Shimming
the upright 5-10 times. If a ring of oil forms to run 3 mm The lift cylinders on standard, TSU and Hi-Lo uprights
(0.125 in) down the rod, the cylinder must be overhauled bottom out at the end of the stroke to limit upright exten-
or replaced. sion. The upright has dual lift cylinders and the cylinders
Internal Leakage on Primary Cylinder extension length must be equal. If not, “racking” or side-to-
side shifting, results. Rod extension length is made equal
To check for internal leakage on the primary cylinder: by using shims under the rod end of the cylinder. To
1. Lift the upright to maximum height then lower forks determine if shimming of the cylinders is required to pre-
completely. vent racking, perform the following operational check:
34-3-8 • Upright Inspection Copyrighted Material SM616,

SM 616,Dec
Jul ’02 ①
’01 ➁
Group 34, Uprights
Upright Drift
CAUTION
Make sure truck is parked on level surface Drift tests check cylinder, main valve, and hydraulic circuit
with parking brake applied and wheels integrity under load pressures. A load is held elevated for
chocked; make sure overhead clearance is an extended period to determine how much the upright
adequate to extend upright to its full height. “drifts” (moves) over a specified time period. A tilt cylinder
drift test appears in Group 32, Section 2, “Tilt Cylinder
1. Center the forks or attachments on the upright. Checks and Adjustments.”
2. Check for equal chain tension.
WARNING
3. Raise the upright from the retracted position to full lift
An upright or carriage can move
height. Note the point when the lift cylinders reach the
unexpectedly during service procedures
end of their stroke.
causing severe injury:
• If the upright shifts right or left noticeably,
shimming is required. Do not walk or stand under raised forks.
• Repeat the check three times before adding shims. Keep clear of load and carriage when
NOTE Keep your arms and fingers away from
Offset or unbalanced loads and off-center moving parts of the upright.
attachments can cause the upright to shift
even with proper lift cylinder shimming. Do not reach through open areas of the
upright.
See Section 5 for lift cylinder shimming procedure. Racking Failure to follow these warnings can result
adjustments for tilt cylinders appear in Group 32, Section in serious injury.
2, “Tilt Cylinder Checks and Adjustments.”
1. Raise the empty upright and carriage to its full extension
and lower to a point halfway down from full extension.
Hydraulic Plumbing
2. Shut off the truck. Apply the parking brake and chock
Use the Lift Cylinder Shimming Check, the Load Test, and the wheels.
the following Drift Test to check the performance of the
hydraulic system. 3. With a pencil or chalk, make a mark across the rails on
one side of the upright.
1. Check all fittings for leakage. Disassemble fittings and
inspect the seals. Replace seals as required. See Group WARNING
40 for hydraulic fitting tightening procedures. Keep clear of load and carriage when
2. Check all hoses and tubes for wear and damage. making any checks or adjustments. Do not
a. Hoses or tubes with scrapes or kinks should be use the upright to climb; use an approved
replaced. platform.
b. Hoses with outer cover wear exposing the
reinforcement braiding should be replaced.
Mark upright
rails here
SM 616, Jul ’01 ① Copyrighted Material Upright Inspection • 34-3-9

Group 34, Uprights
4. Wait five minutes and recheck the mark. Measure and Drift Causes and Remedies
write down the distance the marks on the inner and
If drift of 50 mm (2 in) or more is evident under a half-load,
intermediate rails have drifted from the mark on the
consider the following causes and remedies:
outer rail.
• The main hydraulic valve is misadjusted, worn, or
5. If upright rails drift 50 mm (2 in) or more in the ten
defective. Fluid is leaking past the valve and causing
minutes, read and follow the procedures presented in
the upright cylinders to drift. See Group 30 for
“Drift Causes and Remedies.”
hydraulic valve troubleshooting and service.
6. If no drift does not exceed 50mm (2 in) in the ten • Upright hydraulic circuit hoses or fittings are leaking.
minutes, retest the upright with a 50% load. Adjust fork Check the circuit components and repair as necessary.
width as wide as possible to lift the half-load equally
distributed on a 1220 x 1220 mm (48 x 48 in). Refer to • Cylinder piston seals are worn, damaged, or defective
truck nameplate for capacity rating. allowing fluid past the piston causing drift.
• Primary cylinder or piston-type lift or secondary
CAUTION cylinders have a check valve that allows oil to flow
Test load must be stacked stably, not extend back to the rod side of the cylinder. This check valve
beyond the pallet, and be secured on the may be clogged or defective. Inspect the check valve
pallet. for proper sealing and operation.
Consider rebuilding the cylinders if the first two remedies
in this list are not successful. See Section 5 for removal,
overhaul, and replacement procedures for primary and
secondary cylinders.
34-3-10 • Upright Inspection Copyrighted Material SM

SM616,
616,Dec ’01 ➁
Jul ’02 ①
Group 34, Uprights
Section 4.
Carriage and Upright Roller Clearance Checks

and Shim Adjustment
Introduction .................................................................................................................................... 1
Roller Side Clearance Checks ....................................................................................................... 3

General Roller Side Clearance Checking Procedure ....................................................................... 3
Directions for Checking Specific Rollers ........................................................................................ 4
Carriage Rollers ........................................................................................................................ 4
Upright Rollers ......................................................................................................................... 5
Oversize Rollers ............................................................................................................................. 6
Lift Roller Shimming ..................................................................................................................... 6

Carriage Roller Shimming ............................................................................................................... 6
Upright Roller Shimming ................................................................................................................ 7
Upright Disassembly ................................................................................................................ 7
Roller Removal, Shimming, and Replacement ......................................................................... 8
Upright Reassembly .................................................................................................................. 9
Overshimming ............................................................................................................................... 10
IMPORTANT
Before removing any component for WARNING
overhaul, make sure the correct repair parts Use an approved safety platform to reach
and/or kits are available. the upper areas of the upright. Never use
the upright as a ladder.
WARNING
An upright or carriage can move Introduction
unexpectedly:
Standard and Hi-Lo upright assemblies have two lift roller
• Do not walk or stand under raised forks sets mounted on the rails, three lift roller sets mounted on
• Kee clear of load and carriage when the carriage, and on external thrust roller set mounted on
making any check or adjustment the carriage.
• Keep your arms and fingers away from
moving parts of the upright. The triple-stage upright assemblies have four lift roller sets
• Block the carriage or upright when mounted on the rails, three lift roller sets mounted on the
working with the components in a raised carriage, and one thrust roller sets (“external”) mounted on
position. the carriage. (see the “Roller Side Clearance Chart” on next
• Do not reach through open areas of the page.)
upright. Each carriage and upright lift roller is nested within its
• Never attempt to move or align the rails adjacent rail set. The front “face” of the lift roller handles
by hand. Use a prybar. front-to-back friction and play between the nesting segments
Failure to follow these warnings can result of the upright assembly, the side “face” of the roller radius
in serious injury. handles side-to-side friction and play. The rollers are canted
(tilted) to allow the side face to bear properly on the web.
SM 616, Dec ’02①➁

Jul ’01 Carriage and Upright RollerMaterial
Copyrighted Clearance Checks and Shim Adjustment • 34-4-1
Group 34, Uprights
Rail flange wear can cause excess play between the lift Gap
rollers and the rail flange. The only way to correct this is to
Lift Roller
install oversize rollers-only one size of which is available.
If oversize rollers were fitted previously, the only remedy Side Face
for excessive front-to-back play is to replace the rail set. Shoulder Of Clearance
(carriage middle rollers are always standard-size rollers;
see “Oversize Rollers” later in this Section for details on Rail Web
roller replacement.)
The gap between the roller “side” and the web of adjacent Rail Flange
rail set affects the side-to-side motion of the upright-which
should be as small as possible without causing the sliding
segments to bind.
Roller Side Clearance Chart
Web Area Gap at Mimimumm Span of Rail Set Gap at Maximum Span of Rail Set
Roller Set# Forming Gap Targeta Allowedb Targeta Allowedb
(mm) (in) (mm) (in) (mm) (in) (mm) (in)
#1 Front, Inner rail 0.5-1.5 0.02-0.06 0.05-1.25 0.02-0.05 d d 2.25 0-0.09
#2 Front, Inner rail 0-0.75 0-0.03 0-1.5e 0-0.06 d d 2.25 0-0.09
#3 Back, Inner rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#4 Back, Inner rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#5 Back, Intermd rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#6 Back, Intermd rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#7 Back, Outer rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
a. Target is the desired gap after reshimming the roller set.

b. Allowed is the acceptable gap when checking roller set.
d. Ideal is same as final measured gap at minimum width point of rail set.
e. Measured at top of inner rail.
34-4-2 • Carriage and Upright Roller Clearance Checks

Copyrighted and Shim Adjustment
Material SM
SM616,
616,Dec ’01 ➁
Jul ’02 ①
Group 34, Uprights
You check the performance effect of the lift roller side 2. Position the carriage or rails so that the roller set you
clearance by means of the load test described in Section 3. want to check is at the mark for the narrowest span on
To evaluate with certainty that the clearance is excessive, the adjacent nesting rail set.
you perform the checks given below.
To correct excessive lift roller side clearance, you add
shims as described later in this Section.
Narrowest
span
Roller Side Clearance Checks
The same basic procedure is used for checking all the lift
rollers. That general procedure is given in the subsection
Widest
directly below. Special instructions for specific rollers follow span
that subsection. Follow those directions (in the subsection
called “Directions for Checking Specific Rollers”) and you
will be directed to general and specific information you
need.
Example of Aligning Roller Set with Widest and
General Roller Side Clearance Checking Narrowest Spans Marked on Adjacent Rail Set.
Rail sets are shown separated for clarity.
Procedure
For each roller set, you need to measure the gap between 3. Clamp the rails together opposite the roller you intend
the outside face of a roller and its adjacent nesting rail. In to check. Use wooden shim blocks to protect the rails.
general, the lift roller side clearance check procedure is as Place clamp as close to roller as possible. Torque
follows: clamp to 25 N·m (20 ft-lb).
1. With the spanner tool, find and mark the narrowest and
widest spans in each rail set at the roller-contact areas
in the rail webs:
• Inner Rail Set-Mark narrowest and widest spans
for both the front and back web areas.
• Outer and Intermediate Rail Sets-Mark narrowest
and widest spans for the back web area only.
4. Measure the gap with a feeler gauge. Make sure roller

is tight against its shoulder. Write down the result.
5. Repeats steps 2 through 4 for the widest span marked

on the rail set.
Web Areas on Typical Rail Set
Spanner Tool.
Clark Part #180109
SM 616, Dec ’02①➁

Group 34, Uprights
6. If the clearance at the widest rail set span is more than Top Carriage
2.25 mm (0.09 in), the roller set needs shimming.
If the clearance at the narrowest rail set span is more
than 1.0 mm (0.04 in), the roller set should be shimmed;
however, it is OK for the middle carriage roller gap to
be up to 1.5 mm (0.06 in).
7. Repeat entire procedure for each roller set, following
the instructions in “Directions for Checking Specific Rollers
Rollers” below.
Directions for Checking Specific Rollers

Use these directions to supplement the general procedures
1. Move the top carriage lift roller to the narrowest span
given above.
on the inner rails set.
Carriage Rollers 2. Clamp rail to one side as in general procedures. Check
Bottom Carriage Rollers clearance of lift roller on clamped side.
Follow the general procedure above.
Middle Carriage Rollers

The middle rollers are difficult to access and require the
following special procedures.
1. Raise the carriage until the middle rollers are at the top
of the inner rails.
2. Measure roller side clearance at the top of the inner
rails. Note measurement here:
_____________________.
If gap is less than 1.5 mm (0.06 in), shimming is not
required.
If gap is more than 1.5 mm (0.06 in), check clearance
at narrowest span by comparison with the top of the rail The lift roller to stand off from the web by .01 to 1 mm
set as follows: (0.001-0.03 in).
a. With spanner tool, measure span of inner rail set 3. Check clearance on lift roller opposite clamped side as
at top of the front web area. Note measurement in the general procedures. If clearance is greater than
here: _____________________. 1.25 mm (0.05 in), the roller set should be shimmed.
b. With spanner tool, measure span of inner rail set 4. Move clamp to opposite side and check clearance on
at narrowest span of front web area. Note clamped side as in step 2 directly above. Gap should be
measurement here: _____________________. 0.01-1.0 mm (0.001-0.03 in).
c. Subtract measurement in step b from measurement
5. Move the top carriage lift roller to the widest span on
in step a, Write result here:
the inner rail set and check clearance as in general
b-a= _____________________. procedures.
If the calculated gap is less than or equal to the gap
measured in step 2, the roller set does not require
shimming. Otherwise, the roller set should be
shimmed.

Material SM
SM616,
616,Sep ’01 ➁
Jul ’02 ①
Group 34, Uprights
Upright Rollers Oversize Rollers

1. Remove the carriage as described in Section 7 of this At the time of roller shimming, you may want to
Group. replace the lift rollers with oversize rollers to
2. Fully extend the upright making sure carriage hoses counter rail flange wear as detected by inspection
and chains are secured out of the way to prevent and the load test. Because there is only one size
damage. of oversize rollers, you can install them only if
they were not installed previously.
WARNING Identify oversize rollers as
An upright or carriage can move follows: If a roller is
unexpectedly: oversize, it has an indented
ïDo not walk or stand under raised forks radius in the outer edge of
• Keep clear of load and carriage when its mounting side, as shown
making any check or adjustment below.
moving parts of the upright. Lift Roller Shimming
• Do not reach through open areas of the
upright. You need to shim lift rollers if the roller side clearance
• Never attempt to move or align the rails checks indicated that clearance was excessive at either the
by hand. Use a prybar. narrowest or widest span of the roller set’s adjacent rail set.
• Use an approved safety platform to reach Your objective in shimming is to add only enough shims to
the upper areas of the upright. Never use bring the clearances at both the widest and narrowest spans
the upright as a ladder. into tolerances. In practice, you achieve this by shimming
Failure to follow these warnings can result to obtain the smallest possible clearance at the narrowest
in serious injury. span of the rail set.
3. Follow the “General Roller Side Clearance Checking
Procedure” given earlier in this Section. Carriage Roller Shimming
The clamping procedure is as illustrated below. Using the measurement you recorded in previously in the
“Roller Side Clearance Checks,” determine the number of
shims required to reduce the carriage roller clearance at the
narrowest span on the inner rail to 0-0.75 mm (0-0.03 in):
1. Remove the carriage as described in Section 8, “Fork

and Carriage Removal and Replacement.”
2. Remove the rollers (note the number of shims already
on the roller shafts, if any).
• Clean and inspect roller bearings, shims, and
shafts.
• Replace any defective parts.
①
SM 616, Dec ’02 ➁ Carriage and Upright RollerMaterial
Group 34, Uprights
3. Add shims to the top and bottom rollers as determined Upright Roller Removal
in the previous steps.
1. After the carriage has been removed, lower the upright
• Install shims with the same number on each side. rails until both of the secondary (final) lift cylinders are
• When an odd number of shims is required, always completely collapsed.
place the odd shim on the same side on all roller
2. Jack the truck and block under the frame so that the
sets.
bottom of the upright is approximately 254 mm (10 in)
4. Use a straight bar to determine the number of shims to off the floor. See ìLifting, Jacking, and Blockingî in
add to the middle roller shaft as shown in the following Group SA for safe procedures.
illustration. This shimming may be asymmetric,
3. Set the parking brake and block the steer wheels.
meaning the numbers of shims do not have to match
those of the top and bottom rollers. 4. Tilt the upright to as near vertical as possible.
5. Using a hoist and lifting strap of adequate capacities,
connect the lifting strap to the inner rail on standard &
Hi-Lo uprights or intermediate rails on triple-stage
uprights. Lift hoist to remove slack from the strap.
5. Reinstall all bearings; torque top roller fasteners to 40-

45 N•m (30-33 in-lb).
6. Disconnect the flow control valve manifold from

Upright Roller Shimming the upright bracket.
Use the following procedures to remove, shim, and replace
rollers. Use the preceding checks to determine the number
of shims required to reduce the roller clearances to 0.75
mm (0.03 in) or less.
WARNING
Use an approved safety platform. Never
use the upright as a ladder.
CAUTION
The carriage should be removed for
shimming or when any service is performed 7. Disconnect the cylinder guide bolts. In Hi-Lo upright,
on the upright. See Section 8, for removal disconnect the secondary cylinder hose.
and replacement procedures.

Material SM616,
SM 616,Dec
Jul ’02 ①
’01 ➁
Group 34, Uprights
8. Secure the cylinder to prevent its falling and disconnect Roller Removal, Shimming, and Replacement
the cylinder rod retaining bolts.
To add shims to, or replace the rollers:
1. Use a puller to remove the rollers from the posts. Or,
gently pry the rollers off the posts. Pry at different
points around the bearing to work it off. Do not damage
the bearing seals on the backside of the roller.
2. Inspect all roller components when removed:
NOTE
For 4-hose adapters, you must disconnect
a. Clean and inspect the rollers, shims, and roller
the hose sheave and bracket. This is not
shafts.
necessary for 2-hose adapters.
b. Bearings should be in good condition and allow
9. Move the sheave with the hoses and any other connected the roller to spin smoothly with a true rotation.
components out of the way. c. Clean rail sections and add lubricant if necessary.
10. Disconnect the rail cylinders by raising the rails to free d. Replace any worn or damaged component.
the cylinder rod ends from the tie bar. Tilt the cylinders
inward and secure out of the way of the tie bars. 3. If the clearance check indicated an even number of
shims needed, split the number evenly between the
11. Lower the assembly completely to expose the rollers. rollers on either side of the upright.
The lower roller set of the inner rail and upper roller set of 4. If the clearance check indicated an odd number of
the outer rail on standard and triple-stage uprights are now shims needed, keep the odd number to the same side on
exposed for shim adjustment. all rails of the upright. If three shims are needed, for
example, add one to the rollers on the left side. Add the
other two on the rollers on the right side.
5. Reposition the rollers onto the roller shaft and use a
plastic or hard-rubber mallet to gently tap the roller.
Seat the roller evenly by continuing to tap gently until
it is fully seated and snug against the added shims.
SM 616, Dec ’02①➁

Group 34, Uprights
Upright Reassembly 3. Reconnect the cylinder guide bolts. Do not tighten

until inner and/or intermediate rails are in the fully
The following steps detail the procedures for reassembling
lowered position. Torque guide bolts nuts to 20-25
the upright.
N·m (14.8-18.5 ft-lb).
WARNING
The upright can move unexpectedly:
upright.
• Never attempt to move or align the rails
by hand. Use a prybar.
in serious injury.
1. Connect the lifting strap to the inner rail on standard & 4. Reconnect the cylinder rod bolts. Torque rod bolts to
Hi-Lo uprights or intermediate rails on triple-stage 20-25 N·m (14.8-18.5 ft-lb). In Hi-Lo upright, Recon-
uprights and raise the rails just high enough to clear the nect the secondary cylinder hose.
lift cylinders. Use a prybar to guide the rails and allow
the rollers to reenter the rail channel.
5. Replace the 4-hose sheave and bracket assembly onto

the upright. Torque nuts to 20-25 N·m (14.8-18.5 ft-
lb).
6. Reconnect the load lowering flow valve to the upright
bracket. Torque nuts to 20-25 N·m (14.8-18.5 ft-lb).
2. Reposition the rail cylinders and slowly and carefully
lower the rails to seat the rod end into the mounting.

Material SM
SM616,
616,Dec ’01 ➁
Jul ’02 ①
Group 34, Uprights
7. Jack up the truck only enough to remove the blocking Overshimming

and slowly lower the truck so that its full weight is on
the floor. Use these steps to check for overshimming:
8. Replace the carriage and forks. 1. With the forks removed, lift the upright to maximum
fork height.
9. Test the upright lift and tilt functions; make sure all
upright components work correctly and smoothly. 2. Slowly lower the upright.
Check for overshimming as described in the next • The carriage should not bind or hang up at any
subsection. Repeat the load test to make sure the point along the rails.
upright works correctly under load. When you are sure • If the carriage binds or hangs up, and the rails are
all components are operating correctly, perform the not clogged with grease or debris, the carriage
chain adjustment checks in Section 3 before returning requires reshimming. See “Troubleshooting” for
the truck to service. other mis-staging problems.
SM 616, Dec ’02①➁

Group 34, Uprights
Section 5
Cylinder Removal, Shimming, Overhaul,

and Replacement
Cylinder Types ............................................................................................................................... 1
Lift Cylinder Shimming Procedure .............................................................................................. 1
Primary Cylinder Removal and Replacement (TSU Only) ....................................................... 2
Lift and Secondary Cylinder Removal and Replacement .......................................................... 3
Cylinder Overhaul ......................................................................................................................... 4

Cylinder Disassembly ...................................................................................................................... 4
Parts Inspection and Service ............................................................................................................ 5
Cylinder Reassembly ....................................................................................................................... 5
Cylinder Types CAUTION

Standard uprights use two lift cylinders. Hi-Lo and Triple To remove, or partially remove, the
stage uprights use three cylinders, a primary (center- cylinders from the upright for shimming
mounted) cylinder, and two secondary cylinders. All pri- or overhaul, start with the truck in a safe
mary cylinders used on Hi-Lo and triple-stage uprights position:
(TSUs) are piston cylinders. The secondary cylinder used • Turn key switch to OFF and remove key
on Hi-Lo uprights are ram cylinders. • Parking brake applied
IMPORTANT • Directional lever in neutral
Before removing any component for • Forks lowered completely
overhaul, make sure the correct repair • Wheels blocked.
Upright Upright
Lift Cylinder Shimming Procedure
Type Number Cylinder Type To shim the lift cylinders to correct unequal cylinder stroke:
Standard V1204 Piston-Type Lift Cylinder 1. Fully lower upright until both lift cylinders are
TSU M1203 Piston-Type Secondary Cylinder collapsed.
M1204 Piston-Type Secondary Cylinder 2. Attach a hoisting strap to the tie bar of the inner rail or
intermediate rail tie bar of TSUs.
Hi-Lo H1205 Ram-Type Secondary Cylinder
H1206 Ram-Type Secondary Cylinder
SM 616, Jul ’02①➁

Dec’01 Cylinder Removal,
Copyrighted Shimming, Overhaul and Replacement • 34-5-1
Material
Group 34, Uprights
2. Disconnect and cap the hydraulic line at the base of the

CAUTION cylinder.
Make sure hoisting equipment is of ad-
equate capacity and in good working or- 3. Remove and discard cotter pins from chain anchor bolt
der. pins on the cylinder.
3. Remove the cylinder rod retaining bolt. In Hi-Lo

upright, Remove the cylinder hoses.
Load Lowering
Flow Valve
4. Remove the pins, draw the chain through the sheave,

and drape the chain over the carriage.
4. Slowly lift the inner (or intermediate) rails off the top
of the cylinder to expose the cylinder rod top.
CAUTION
Block rail in up position.
5. Insert shim(s) over rod end of cylinder with the shorter

stroke to compensate for unequal stroke length.
6. Slowly lower the inner or intermediate rail back onto
the rod ends. 5. Remove the snap ring holding the chain sheave (and
hose bracket, if equipped) on the rod end and move
CAUTION assembly off top of rod.
Do not try to maneuver the cylinder or
rails with your hands. Use a prybar.
7. Replace cylinder rod retaining bolt to secure rod end

into inner or intermediate rail mounting hole. Torque
the cylinder rod retaining bolts to 20-25 Nfim (14.8-
18.5 ft-lb).
8. Repeat the racking test and adjustment until no racking
is evident during upright lift extension.
9. Check all upright functions before returning the truck
to service.
Primary Cylinder Removal and

Replacement (TSU & Hi-Lo)
Remove the primary cylinder for replacement only. Cylin-
der can be overhauled without removing it from the up-
right. See“Cylinder Overhaul” for procedures.
1. Make sure the cylinder is completely collapsed and
pressure is released.
34-5-2 • Cylinder Removal, Shimming, Overhaul and Material

Copyrighted Replacement SM
SM616,
616,Dec ’01 ➁
Jul ’02 ①
Group 34, Uprights
6. Disconnect cylinder mounting bolts and cylinder base 4. Disconnect and cap the hydraulic line from the base of
mounting bolts. each cylinder. Remove the mounting bolts from the
manifold block.
Use these steps in reverse to replace the cylinder. Check

Group 40 for hydraulic fitting tightening procedures. If
complete cylinder was torque hydraulic line bracket to 40-
45 N•m (30-33 ft-lb);torque cylinder mounting coller bolt
nuts to 70-80 N•m (52-59 ft-lb)
Lift and Secondary Cylinder Removal 5. Lower the carriage

and Replacement
Only piston-type lift and secondary cylinders must be connect the lifting strap to the inner rail on standard
removed from the upright for overhaul. The cylinder gland uprights and inner and intermediate rails on triple-
and rod can be removed for overhaul while leaving the stage uprights.
cylinder tube mounted on the truck.
1. Make sure the cylinders are completely collapsed and
pressure is released.
2. Tilt the upright to as near vertical as possible.
lift the carriage to access the hydraulic lines at the base
of the cylinders.
CAUTION
Make sure hoisting equipment is of
adequate capacity and in good working
order.
7. Disconnect the cylinder guide bolts.
SM 616, Jul ’02①➁

Dec’01 Cylinder Removal,
Material
Group 34, Uprights
8. Disconnect the cylinder rod retaining bolts. 1. Clean the rod-end and gland thoroughly to prevent
contamination from falling into the cylinder during
disassembly.
2. With a blunt punch or chisel, bend the lock ring out of
the locking grooves of the gland.
3. Use a spanner wrench to remove the gland. Reuse the
lock ring if undamaged.
4. Carefully lift the rod out of the cylinder and place in a
clean area.
5. Inspect the tube and tube end for damage and cover the
cylinder tube end to prevent contamination.
6. Remove all rings and seals from the piston and the
9. Remove the cylinders by raising the inner rail (and gland.
intermediate rail on the triple stage upright) to free the
Rod Wiper
cylinder rod ends from the tie bar.
Rod Seal
10. Remove any shims and note number and location. O-Ring
11. Lift the cylinders off the base mount. Back-Up Ring
Gland
Use these steps in reverse to replace the cylinders. Torque O-Ring
the cylinder rod retaining bolts to 20-25 N•m (14.8-18.5 ft- Tube
lb). Torque the cylinder guide bolt nuts to 30-35 N•m Rod
(22.2-25.6 ft-lb). Check Group 40 for hydraulic fitting
tightening procedures.
Spacer
Retaining Ring
Cylinder Overhaul
Check Valve
Use these steps to overhaul the primary and lift and Piston
secondary cylinders. Cylinder Seal
NOTE Snap Ring
Wear Ring Pin
During overhaul, set rod or cylinder on a
work bench with adequate support for safe
and convenient disassembly. Two sets of
4x4 in (100x100 mm) ìVî-notched blocks
are helpful; one set for the cylinder barrel
and one set for the piston rod. The blocks
prevent nicks and scratches from harming 7. For piston-type cylinders:
the piston or rod. a. Remove the check valve from the piston for
inspection and cleaning by removing the snap ring
Cylinder Disassembly from the piston bore.
• To overhaul the primary cylinder, it is not necessary to
remove the cylinder from the upright. Instead, free the
rod end of the cylinder as explained in “Cylinder
Removal.”
• To overhaul piston-type cylinders, you should remove
the cylinders from the upright as explained in “Cylinder
Removal.” The cylinders have seals on the piston, and Check Valve. Arrow shows direction of flow
the rods must be removed for seal replacement. b. Use a blunt hook to pop the check valve out.
• The ram-type lift cylinders are sealed on the rod only.
IMPORTANT
The only serviceable seals are inside the gland. It is not
Use extreme care that you do not make
necessary to remove these cylinders from the upright
nicks and burrs on the interior surface area
for overhaul. Instead, free the rod end of the cylinder
of the cap or cylinder or the piston.
as explained in “Cylinder Removal.”

SM616,
616,Dec ’01 ➁
Jul ’02 ①
Group 34, Uprights
Parts Inspection and Service 3. Replace the piston seals:

a. Primary cylinder pistons require a piston seal and
1. Clean all parts completely in a suitable solvent. Dry all
wear ring. Install the piston seal from the top of the
parts with a soft clean cloth.
rod. Use a ring compressor to compress the piston
2. Inspect cylinder barrel and bore for cracks, pining, seal. This prevents damage to the seal during
scoring, or other irregularities that may require reassembly.
replacement of the barrel.
3. Inspect the piston and rod for nicks, scratches, scoring,
or other defects that may demand new parts.
4. Check all gland and piston seal grooves for nicks,
burrs, and scratches that can damage seals during
reinstallation.
5. Inspect and clean the check valves. b. Piston-type lift and secondary cylinder require a
6. Inspect all seals, including the check valve O-ring. cylinder seal, a back-up ring, and a wear ring on
the piston. Install the cylinder seal from the top of
NOTE the rod.
Minute imperfections inside the cylinder
barrel or on the piston or rod may be
improved for acceptable use by careful
honing. However, removal of material that
produces a notch, groove, or out-of-
roundness may cause excessive leakage
during operation and a shortened life.
7. Use new parts as necessary. Always use the Packing c. Ram-type lift (secondary) cylinder piston require
Kit listed in the parts manual. New kits include all the seals.
seals, wiper rings, wear rings and O-rings necessary 4. For protection against corrosion, lubricate spacers
for the particular cylinder. (where used) with petroleum-based hydraulic fluid.
Slide the spacer onto the rod.
Cylinder Reassembly 5. Insert the piston and rod into the cylinder. Be careful
not to scratch or damage the cylinder gland nut threads.
Take care when installing these parts to make sure that no
parts are damaged. 6. For primary cylinders, add 3.4 oz (100 ml) of hydraulic
oil into the cylinder on the rod side of the piston.
1. Coat all packing, seals and rings in clean, hydraulic
oil (Clark part number 1800236 qt., 1802155 gal.) 7. Install the lock ring onto the gland. Lubricate cylinder
prior to reassembly. Coat the inside of the gland threads and screw gland onto cylinder. Be careful not
nut bore with hydraulic oil. to damage gland seal. Make sure the gland is fully
seated on the cylinder barrel. Deform the lock ring into
2. Replace the U-cup seal (groove toward bottom of slots in the tube and the gland.
cylinder), rod wiper, and O-ring and back-up seals
on the gland. 8. Check the assembly by making sure the piston slides
freely in and out of the cylinder.
9. Tighten the gland nut:
• On primary cylinders, tighten the gland nut to 100
N•m (75 ft-lb).
• On lift and secondary cylinders, tighten the gland
nut to 100 N•m (75 ft-lb).
This competes the cylinder repair procedure. Replace the
NOTE cylinders as described in ìCylinder Removal and
O-rings should be carefully installed to Replacement.î Complete the chain length adjustment in
eliminate cuts or twisting. Section 3 for correct carriage and rail position. When all
adjustments are completed, return the truck to service.
SM 616, Jul ’01 Cylinder Removal,

Material
Group 34, Uprights

SM616,
616,Dec ’01 ➁
Jul ’02 ①
Group 34, Uprights
Section 6
Upright Chain Inspection, Adjustment,

and Replacement
Periodic Inspections ....................................................................................................................... 3
Chain Length Adjustments ........................................................................................................... 4

Standard Upright Chain Length Adjustment ................................................................................... 5
Triple-Stage Upright (TSU) Chain Length Adjustments ................................................................. 5
Chain Lubrication .......................................................................................................................... 7
Chain Removal and Replacement ................................................................................................ 7

General Guidelines ........................................................................................................................... 7
Lift Chains (Standard and TSUs ...................................................................................................... 7
Primary Cylinder/Carriage Chains (TSUs) ...................................................................................... 8
Other Chain Service Notes ............................................................................................................ 8
Chain Configuration - Standard Upright Chain Configuration - Hi-Lo Upright
SM 616, Jul ’02①➁

Dec’01 Upright Chain Inspection,
Copyrighted Material Adjustment, and Replacement • 34-6-1
Group 34, Uprights
Chain Configurations - Triple Stage Uprights
34-6-2 • Upright Chain Inspection, Adjustment, and Replacement

Copyrighted Material SM 616, Jul ’01
Group 34, Uprights
Periodic Inspections Chain with rotated/displaced heads or abnormal pin

protrusion should be replaced immediately. Do not attempt
Each 50-250 hours of operation (more frequently in severe to repair the chain by welding or driving the pin(s) back
or extreme environments), chains should be inspected and into the chain. Once the press fit integrity between outside
lubricated. Inspection should focus on the following: 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. This condition
Elongation
damages the chain and increases frictional loading, and
When a length of 12.00 inches (305 mm) of new chain has should be corrected.
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 because it
receives the most 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.
Cracked Plates
The chains should periodically be inspected very carefully,
Chains should be replaced when wear exceeds 3% or front and back as well as side to side, for any evidence of
when 12 inches (305 mm) of chain is stretched 3/8 inch (10 cracked plates. If any one crack is discovered, the chain(s)
mm). should be replaced. It is important, however, to determine
the causes of the crack before installing new chain so the
condition does not repeat itself.
Edge Wear
Check the chain for wear on the link plate edges caused by • Fatigue Cracking - Fatigue cracks are a result of
running back and forth over the sheave. The maximum repeated cyclic loading beyond the chain’s endurance
reduction of material should not exceed 5%. This can be limit. The magnitude of the load and frequency of its
compared to a normal link plate height by measuring a occurrence are factors which determine when fatigue
portion of chain that does not run over the sheave. Distorted failure will occur. The loading can be continuous or
or battered plates on leaf chain can cause tight joints and intermittent (impulse load).
prevent flexing.
Fatigue cracks generally run from the pin hole toward the
Worn contours and worn surfaces on the outside links or edge of the link plate approximately 90o from the line of
pin heads should not exceed 5% of new link height. pull.
Fatigue cracks almost always start at the link plate pin
Turning or Protruding Pins hole (point of highest stress) and are perpendicular to
the chain pitch line. They are often microscopic in their
Highly loaded chain operating with inadequate lubrication early stage. Unlike a pure tensile failure, there is no
can generate abnormal frictional forces between pin and noticeable yielding (stretch) of the material.
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 allowed to operate
in this condition, a pin, or series of pins, can begin to twist
out of a chain resulting in failure. The pin head rivets
should be examined to determine if the “VEE” flats are still
in correct alignment.
SM 616, Jul ’01 Upright Chain Inspection,

Group 34, Uprights
• Stress - Corrosion Cracking - The outside link plates, Tight Joints

which are heavily press fitted to the pins, are particularly
susceptible to stress corrosion cracking. Like fatigue All joints in leaf chain should flex freely. Tight joints resist
cracks, these initiate at the point of highest stress (pin flexure and increase internal friction, thus increasing chain
hole) but tend to extend in an arc-like path between the tension required to lift a given load. Increased tension
holes in the pin plate. accelerates wear and fatigue problems.
Arc-like cracks in plates are a sign of stress corrosion. If lubrication does not loosen a tight joint, the chain may
have corrosion and rust problems or bent pins and must
More than one crack can often appear on a link plate. be replaced.
In addition to rusting, this condition can be caused by
exposure to an acidic or caustic medium or atmosphere. See Section 3 for detailed chain stretch, length, and tensions
checks.
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 Chain Length Adjustments
pin hole due to the press fit pin. No cyclic motion is
required, and the plates can crack during idle periods.
WARNING
The reactions of many chemical agents (such as battery
An upright or carriage can move
acid fumes) with hardened steel can liberate hydrogen
unexpectedly:
which attacks and weakens the steel grain structure.
• Do not walk or stand under raised forks
For this same reason, never attempt to electroplate a • Keep clear of load and carriage when
leaf chain or its components. The plating process making any check or adjustment
liberates hydrogen, and hydrogen embrittlement cracks • Keep your arms and fingers away from
will appear. These are similar in appearance to stress moving parts of the upright.
corrosion cracks. • Block the carriage or upright when
If a plated chain is required, consult Clark. Plated working with the components in a raised
chains are assembled from modified, individually plated position.
components which may reduce the chain rating. • Do not reach through open areas of the
upright.
• Corrosion Fatigue - Corrosion fatigue cracks are very
• Never attempt to move or align the rails
similar (in many cases identical) to normal fatigue
by hand. Use a prybar.
cracks in appearance. They generally begin at the pin
hole and move perpendicular (90◊) to the chain pitch
in serious injury.
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).
Ultimate Strength Failure

This type of failure is caused by overloads far in excess of
the design load.
Broken plate caused by overload.

Group 34, Uprights
Standard Upright Chain Length Adjustment b. Tilt upright fully back and completely lower.
To adjust chain length on the standard upright use the c. Raise carriage about 1 m (3.2 ft) and measure the
following illustration and procedures: 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.
Adjust chain
length here IMPORTANT
The carriage stop must not be allowed to
To carriage contact the upright stop under any
circumstance during normal operations.
1. Fork-to-ground clearance: If all three chain length requirements listed above cannot be
met, the tire diameter may be out of the design range
a. Set the upright to vertical position. allowance. Also, excessive tire wear will decrease carriage
stop clearance.
Oversized tires will reduce the bottom carriage roller
engagement on the inner rail when the carriage is in the
lowered position. The fork-to-ground clearance can deviate
from the 10-20 mm (0.40-0.80 in) allowance by a small
amount if necessary to maintain the safe 20 mm (0.80 in)
clearance of the bottom carriage roller to the lower edge of
the inner rail.
Triple-Stage Upright (TSU) and Hi-Lo Chain

Length Adjustments
b. Break the jam nuts loose on the chain anchors. Triple-stage uprights use two chain sets; one set for carriage
lift and one set for rail lift. Adjustment anchors for the lift
c. Turn the chain adjustment nuts until clearance cylinder stage are located at the back of the outer rail.
between forks and ground is 10-20 mm (0.40-0.80 Adjustment anchors for the primary lift stage are behind the
in). primary cylinder. Carriage chain anchors are not intended
IMPORTANT for adjustment.
For all chain anchor adjustments: For TSU inner rail lift chains, chain length must be adjusted
• Threaded chain anchors must be left free if the difference between the bottom of the inner rail and
to pivot in mounting hole. the outer rail is greater than 10 mm (0.40 in).
• Anchor cotter pin heads must be to the
For the TSU and Hi-Lo primary cylinder lift chain, the
inside of the upright.
chain length must be adjusted if:
• Torque jam nuts to adjustment nuts to
80-150 N•m (59-110 ft-lb) • The fork-to-ground clearance is less than 5 mm (0.20
• Make sure chain anchors are secured so in) or more than 25 mm (1.0 in) when the upright is
that no twist is evident in the chains. vertical.
2. Carriage roller position: • The center of the bottom carriage roller comes within
20 mm (.80 in) of the bottom edge of the inner rail.
a. Raise carriage about 1 m (3.2 ft) and smear a bead
of grease on the bottom 75 mm (3 in) inner rail in • The carriage safety stop hits the inner rail stop at full
the area of the roller pattern. lift height.
SM 616, Dec ’02①➁

Jul ’01 Upright Chain Inspection,
Group 34, Uprights
To adjust the cylinder lift chains on a TSU use the follow- IMPORTANT
ing illustration and procedures: For all chain anchor adjustments:
• 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
80-150 N•m (59-110 ft-lb).
• Make sure chain anchors are secured so
that no twist is evident in the chains.
2. Carriage roller position:
Adjust chain
length here 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
To inner rail rail in the area of the roller pattern.
1. Set the upright in the vertical position. b. Tilt upright fully back and completely lower.
2. Break the jam nuts loose on the chain anchors. c. Raise carriage again about 1 m (3.2 ft) and measure
the distance from where the center of the bottom
3. Adjust the chain anchor adjustment nuts until the carriage roller stopped to the bottom edge of the
bottom of the inner rail is within 2.5 mm (0.10 in) of inner rail. Distance should not be less than 20 mm
the bottom of the outer rail. (0.80 in) or chain length adjustment is required.
To adjust the primary cylinder lift chain on TSU and Hi-Lo 3. Carriage stop-to-upright:
use the following illustration and procedures:
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.
Adjust chain If all three chain length requirements listed above cannot be
length here
To carriage met, the tire diameter may be out of the design range
allowance. Also, excessive tire wear will decrease carriage
1. Fork-to-ground clearance: stop clearance.
a. Set the upright to vertical position. Oversized tires will reduce the bottom carriage roller
engagement on the inner rail when the carriage is in the
b. Break the jam nuts loose on the chain anchors. lowered position. The fork-to-ground clearance can deviate
c. Turn the chain adjustment nuts until clearance from the 10-20 mm (0.40-0.80 in) allowance by a small
between forks and ground is 10-20 mm (0.40-0.80 amount if necessary to maintain the safe 20 mm (0.80 in)
in). clearance of the bottom carriage roller to the lower edge of
the inner rail.

SM616,
616,Dec ’01 ➁
Jul ’02 ①
Group 34, Uprights
Chain Lubrication General Guidelines

Like all bearing surfaces, the precision-manufactured, • Chain Movement - Make sure that the chain operating
hardened-steel, joint-wearing surfaces of leaf chain require path is clear and that the chain articulates freely through
a film of oil between all mating parts to prevent accelerated its full range of operation.
wear.
• Lubrication - Assure that the chain is well lubricated
Maintaining a lubricant film on all chain surfaces will: with the heaviest oil that will penetrate the void between
• Minimize joint wear. the link plate apertures and the pins.
• Improve corrosion resistance. • Paint - Make sure the chain does not get painted over
• Reduce the possibility of pin turning. at any time.
• Minimize tight joints. • Protection - Where necessary, as a protection from

atmosphere or sliding wear, the chain may be covered
• Promote smooth, quiet chain action.
with a layer of grease. It should be noted, however, that
• Lower chain tension by reducing internal friction in the the grease will have to be removed at a later date for
chain system. chain inspection and relubrication.
Laboratory wear tests show #40 oil to have greater ability • Chain Mountings - Double check to be sure all chain
to prevent wear than #10 oil. Generally, the heaviest (highest fastening devices are secured and all adjustments have
viscosity) oil that will penetrate the joint is best. been made to assure uniform loading of multiple chain
Whatever method is used, the oil must penetrate the chain applications. Check chain anchors and pins for wear,
joint to prevent wear. Applying oil to external surfaces will breakage, and misalignment. Damaged anchors and
prevent rust, but oil must flow into the live bearing surfaces pins should be replaced.
for maximum wear life.
• Sheaves - Sheaves with badly worn flanges and outside
To prepare the chain for oiling, the leaf chain plates should diameter should be replaced. This wear may be due to
be brushed with a stiff brush or wire brush to clear the chain misalignment or frozen bearings.
space between the plates so that oil may penetrate the live
bearing area.
Lift Chains (Standard and TSUs)
Oil may be applied with a narrow paint brush or directly
poured on. Chain should be well flooded to be sure the oil To remove and replace the lift cylinder and/or carriage chain
penetrates the joint. set on standard and triple-stage uprights (TSU):
In locations difficult to reach, it may be necessary to use a 1. Attach a hoist strap on the carriage of the standard
good quality oil under pressure such as an aerosol can or upright or inner rail of the TSU.
pump pressure spray.
2. Lift the carriage or inner rail slightly to create slack in
the chains. Block the carriage or inner rail up for safety.
Chain Removal and Replacement 3. Remove the chain anchor pins on the outer rail and
pull the chains off of the sheaves on the inner or
WARNING intermediate rails.
The procedures for removing and replacing
chain sets involve hoisting and blocking
components.
• Do not walk or stand under raised forks.
upright.
in serious injury. See ìLifting, Jacking, and
Blockingî for safe blocking procedures.
SM 616, Jul ’01 Upright Chain Inspection,

Group 34, Uprights
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.
3. Remove the chain anchor pins from the back of the

carriage.
Lift Chain Removal from Carriage (standard upright)
4. Use these steps in reverse to replace the primary

Triple-Stage Upright Lift Chain Removal from Inner Rail cylinder/carriage chain.
Perform the chain length adjustment and chain tension
NOTE
check before returning the truck to service.
If a hose adapter assembly is used, the chain
sheaves must be loosened and removed to
prevent the hoses from stretching when the Other Chain Service Notes
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.
5. Use the steps in reverse order to replace the lift chain • Do not attempt to rework damaged chains by replacing
set. only the components obviously faulty. The entire
chain may be compromised and should be discarded.
Primary Cylinder/Carriage Chains (TSU & Hi- • Never electroplate assembled leaf chain or its
LO) components. Plating will result in failure from hydrogen
embrittlement. Plated chains are assembled from
1. Tilt the upright forward, lower it, and completely modified, individually plated components.
collapse the primary cylinder to create slack in the • Welding should not be performed on any chain or
chains. The carriage may also be lifted and blocked in component. Welding spatter should never be allowed
position and the primary cylinder completely collapsed to come in contact with chain or components.
to create slack in the chains.
• Leaf chains are manufactured exclusively from heat
2. Remove the chain anchor pins from the back of the treated steels and therefore must not be annealed. If
primary cylinder. Pull the chains through the chain heating a chain with a cutting torch is absolutely
sheave and lay over the carriage load backrest. necessary for removal, the chain should not be reused.

SM616,
616,Dec ’01 ➁
Jul ’02 ①
Group 34, Uprights
Section 7
Fork and Carriage Removal and Replacement
3. Lift tip of each fork and put a 100 x 100 mm (4 x 4 in)

CAUTION block under the fork arm near the heel.
1. Park truck on a hard, level, and solid CAUTION
surface, such as a concrete floor with no Forks weigh 40-65 kg (90-145 lbs) each.
gaps or breaks. Take care when lifting.
OFF and remove key.
wheels.
Fork Removal
Forks do not need to be removed to remove
the carriage.
1. Release the fork latches.
Blocking the Fork

4. Push down on tips of the forks to disengage the fork
hooks from the carriage fork bar.
5. Lift fork heel and remove block.
CAUTION
Latch Operation Forks are not stable sitting free in upright
2. Move each fork to the notch on the bottom of the lower position. Use care when working around
carriage cross bar. the forks.
6. Back the truck away from the forks.
Fork Replacement
1. Carefully drive truck up close to forks.
CAUTION
Forks are not stable sitting free in upright
position. Use care when working around
the forks.
2. Drag forks into position close to carriage and to line up

with the notche on the lower carriage cross bar.
3. Lift fork heel and place block under arm near the heel.
SM 616, Jul ’01 ForkMaterial

Copyrighted and Carriage Removal and Replacement • 34-7-1
Group 34, Uprights
4. Lift tips of forks to engage the fork hooks on the upper 4. Once the carriage is fully lowered, clamp the front of
carriage fork bar. one fork to the pallet to prevent the carriage from
falling over backwards when removed.
5. Remove blocks from under fork.
6. Check fork latches when repositioning forks to upper
carriage fork notches.
Carriage Removal
The carriage should be removed for shimming or when any
service procedure is performed on the upright.
WARNING
The procedures for checking, maintaining,
and adjusting uprights, carriages, and forks
involve movement of the components.
• Do not walk or stand under raised forks.
• Keep clear of load and carriage when
moving parts of the upright. 5. For carriage auxiliary components, the hose sheave
• Do not reach through open areas of the bracket must be unbolted from the primary cylinder
upright. chain sheave bracket. Move the hose bracket off the
• Always use a prybar to move the upright chain bracket.
or carriage.
in serious injury.
1. Set upright tilt to 0 degrees (vertical). Raise the carriage

about 12 in (305 mm).
2. Place a heavy pallet under the forks. Turn the key off.
3. Lower the carriage onto the pallet and keep lowering
(until the primary cylinder is all the way down on
TSUs). Before proceeding with the next step read the
following warning.
WARNING
You may need to pull on the hoses/cables
and chains while lowering the primary
cylinder to get it all the way down. This is
done to create slack in hoses/cables and
chains and to displace as much oil as
possible, which will reduce oil loss when
disconnecting hydraulic lines for auxiliary
components.
You may need a helper to hold the control
handle in the lowering position while you
pull on the carriage chains to fully collapse
the primary cylinder (on TSU & Hi-Lo).
When pulling on the chains to lower the
primary cylinder (on TSU & Hi-Lo), the
ignition must be off.
34-7-2 • Fork and Carriage Removal and Replacement

SM 616, Jul ’01
616, Dec ①
’02 ➁
Group 34, Uprights
6. Disconnect the carriage chains at the base of the

carriage. Pull chains back off primary cylinder sheave.
11. Lower the upright rails until both of the secondary

7. For carriage auxiliary components, disconnect hoses
cylinders are completely collapsed.
(2- or 4-hose assemblies) from carriage. Remove the
bolts and strap fixture also.
Carriage Replacement
To replace the carriage:
1. First check to be sure the carriage is securely clamped
to the pallet.
2. Move the truck up to the carriage assembly with the
inner rail centered on the carriage.
3. Raise the upright until the inner rail is high enough to
clear the upper carriage rollers.
4. Tilt the upright until it is at the same angle as the
carriage assembly.
5. Now slowly move the truck forward until the inner rail
is centered over the carriage rollers.
• Cap all lines to prevent leaks.

• Label all lines and fittings for correct reassembly.
8. Elevate the primary cylinder to its maximum height.
Be sure all hoses and loose parts are secured out of the
way to prevent damage.
9. Continue elevating the upright until the inner rail
clears the carriage.
10. Remove steer wheel blocks. Release the parking brake
and slowly back the truck away from the carriage.
SM 616, Jul ’01 ForkMaterial

Copyrighted and Carriage Removal and Replacement • 34-7-3
Group 34, Uprights
10. If the carriage is equipped with a carriage auxiliary

WARNING component, reconnect the hose sheave bracket to the
Never attempt to move or align the carriage top of the primary cylinder chain sheave barcket.
or bearings by hand. Use a pry bar.
6. Lower the upright until the inner rail clears all of the
carriage rollers.
NOTE
If the rail or bearings bind, raise the
upright, back away from the carriage and
check to be sure the carriage rollers are
installed properly.
7. When the inner rail has cleared the carriage rollers,

continue to lower the upright until the lift cylinders are
lowered completely.
8. Reset the truck in a safe position:
• Ignition off 11. Reconnect the hoses and mounting strap to the carriage
auxiliary component if the carriage is so equipped.
• Parking brake applied
• Directional lever in neutral
• Forks completely lowered
• Block steer wheels.
9. Reinstall the carriage lift chains to the base of the
carriage.
• Lubricate all O-rings with a light coating of system

hydraulic fluid or a compatible oil.
• Use two wrenches to tighten hose fittings to prevent
• Set anchor bolts so that no twist develops in the hoses from twisting.
chains. • See Group 40 for hydraulic fitting tightening
• Anchor pin heads must be pointing to the inside of procedures.
the upright.
12. Adjust carriage height according to Section 6 and
• Use new cotter pins. chain tension according to Section 3.
IMPORTANT 13. Remove the “C” clamp from the pallet and check the
Always use new anchor pins when replacing operation of the carriage and the upright. Carefully
chain sets. check for oil leaks. Make sure the carriage and upright
work smoothly and correctly before returning the truck
to service.
34-7-4 • Fork and Carriage Removal and Replacement

Group 34, Uprights
Section 8
Upright Removal and Replacement
This Section describes how to remove the entire upright

assembly from the truck. The carriage and forks must be CAUTION
removed from the upright assembly before the upright is SAFE PARKING. Before working on truck:
removed. (For uprights with an auxiliary component, a 1. Park truck on a hard, level, and solid
side-shifter for example, the two hydraulic hoses powering surface, such as a concrete floor with no
the auxiliary component must be removed before the carriage gaps or breaks.
is removed.) See Section 7, “Fork and Carriage Removal 2. Put upright in vertical position and fully
and Replacement,” for procedures to remove the carriage lower the forks or attachment.
and fork assembly from the upright. 3. Put all controls in neutral. Turn key switch
OFF and remove key.
wheels.
Tilt Cylinder
Mounting Stoper
Tilt Cylinder
Mounting Bolt
Cylinder Rod End
Grease Nipple
Spacer
Upright Mounting Pin
Outer Rail Set
Washer
Upright Mounting Bolt
Typical Upright Installation
SM 616, Jul ’01 Copyrighted MaterialUpright Removal and Replacement • 34-8-1

Group 34, Uprights
Upright Removal 2. Disconnect and cap hydraulic line at the load-lowering

flow valve. Secure the hose out of the way of the
The following procedures are for uprights with carriage upright.
and forks, or auxiliary components removed. See Section 7,
“Fork and Carriage Removal and Replacement,” for
instructions on removing the forks and carriage.
WARNING
The upright assembly is heavy. Use only
hoists with enough capacity to lift the entire
assembly. Keep clear of the assembly as it Disconnect
and cap line from
is being hoisted and set down. Keep hands main hydraulic
and feet away from the assembly. Use control valve.
prybars to move the assembly into position
for reattachment.
1. Attach a hoist and strap of adequate capacity to the

upright as shown below. Tension the hoist so that the
upright cannot fall when upright mounting pins and tilt
cylinder pins are removed.
NOTE
For two-hose adapter assemblies, the
hydraulic lines to the upright must also be
disconnected and capped.
Disconnect
lines here.
34-8-2 • Upright Removal and ReplacementCopyrighted Material SM 616, Jul ’01

Group 34, Uprights
3. Remove tilt cylinder rod-end, rod-end mounting bolt Upright Replacement

and stopper from upright.
1. Use an overhead chain hoist of adequate capacity and
an approved lift chain to lift upright into position.
Tilt Cylinder
Rod End
Tilt Cylinder
Mounting Stoper
Tilt Cylinder
Mounting Bolt
WARNING
Use prybars to move the assembly into
4. Remove upright mounting pin bolt and lift upright off
position for reattachment.
frame. See illustration on page 1.
5. Slowly set upright down on the floor, 100 x 100 mm 2. Install upright mounting pin and bolt. Torque to 25-
(4 x 4 in) blocking, or sturdy pallets set end-to-end. 30N•m (221~266 lbf-in)
Spacer
Washer
Upright Mounting Pin

Upright Mounting Bolt
SM 616, Jul ’01 Copyrighted MaterialUpright Removal and Replacement • 34-8-3

Group 34, Uprights
3. Install rod end pins, lock plates, and fasteners. Tighten NOTE
lock plate fasteners to a torque of 121-136 in-lb (19.3- Reconnect two-hose adapter assembly hy-
21.5 N·m). draulic lines to the upright-mounted
bracket.
Tilt Cylinder
Rod End
Tilt Cylinder
Mounting Stoper
Tilt Cylinder
Mounting Bolt
4. Attach hydraulic lines to the upright flow control 5. Remove the lift chain between the upright and hoist.
valve:
6. Completely check all upright and hydraulic compo-
nents under load before returning the truck to service.
7. See Section 8, “Fork and Carriage Removal and Re-
placement,” for steps to replace the carriage and fork
assembly.
• Lubricate all O-rings with a light coating of sys-

tem hydraulic fluid or a compatible oil.
• Use two wrenches to tighten hose fittings to pre-
vent twisting lines.
• See Group 40 for hydraulic fitting tightening
procedures.
34-8-4 • Upright Removal and ReplacementCopyrighted Material SM616,

SM 616,Sep
Jul ’02 ①
’01 ➁
GROUP 38
GROUP 38
COUNTERWEIGHT AND CHASSIS
Counterweight Specifications and Description ............ Section 1
Counterweight Removal and Installation ..................... Section 2
Overhead Guard Removal and Installation ................. Section 3
Floor Plate, Seat, and Seat Deck Removal

and Installation ............................................................... Section 4
SM 616, April ’98 Copyrighted Material Counterweight and Chassis

GROUP 38
NOTES:
Counterweight and Chassis Copyrighted Material SM 616, April ’98

Group 38, Counterweight and Chassis
Section 1.
Counterweight Specifications and Description
Specifications Maintenance Requirements
Counterweight Mounting Bolts Torque: 339-381 N•m WARNING

(251–280 ft-lb)
THE COUNTERWEIGHT IS EXTREMELY
Counterweight Weight: Different counterweights are used HEAVY. Do not remove the counterweight
based on truck capacity and battery compartment length, as unless you have training and are familiar with
follows: the correct procedures. Counterweights can
fall if not handled correctly and can cause
Battery Compartment
severe injury or death. Keep your hands, feet,
Truck Capacity Length Counterweight and body clear of the counterweight at all
2500 lb (1250 kg) 13.75” 1262 lb (573 kg) times.
3000 lb (1500 kg) 13.75” 1836 lb (834 kg)
HOISTING EQUIPMENT must be capable
3000 lb (1500 kg) 20.5” 914 lb (415 kg)
of handling the weight of the counterweight
3500 lb (1750 kg) 20.5” 1262 lb (573 kg) when removing or replacing. Make sure
4000 lb (1815 kg) 20.5” 1836 lb (834 kg) your lifting equipment is of adequate
4000 lb (2000 kg) 20.5” 2094 lb (950 kg) capacity to handle the weight.
5000 lb (2500 kg) 20.5” 2894 lb (1314 kg)
3000 lb (1500 kg) 29.5” 837 lb (380 kg) The counterweight must be maintained in good condition
and securely attached to the lift truck. Because of its heavy
3500 lb (1800 kg) 29.5” 1300 lb (590 kg)
weight and bulky mass, the counterweight must be care-
fully supported and handled. When removed from the truck,
store at floor level as shown below to be sure it will not fall
or tip, causing damage or injury.
Description
The counterweight is a solid, cast-iron piece mounted to the
back of the lift truck. It is used to counterbalance the loads
placed on the upright at the front of the truck. The weight
must be great enough to counteract forward tipping when
lifting or stopping with a capacity load. The battery pro-
vides much of the counterweight on an electric truck.
WARNING
BATTERY WEIGHT. The minimum
battery weight for your truck is stamped on Generic Illustration
the nameplate. Never operate the truck with

a battery that weighs less.
Large, hardened steel bolts hold the counterweight to the

frame.
SM 616, Jul ’02①➁

Dec’01 Copyrighted Material
Counterweight Specifications and Description • 38-1-1
38-1-2 • Counterweight Specifications and Copyrighted

DescriptionMaterial SM 616, April ’98
Section 2.
Counterweight Removal and Installation
CAUTION WARNING
SAFE PARKING. Before working on truck: Observe proper, safe lifting practices when
lifting counterweight on or off truck.
surface, such as a concrete floor with no Counterweight should only be lifted by ap-
gaps or breaks. propriately-sized eye bolt installed through
2. Put upright in vertical position and fully the top lifting hole.
Use only overhead lifting equipment having
3. Put all controls in neutral. Turn key a safe lifting capacity in excess of that of the
switch OFF and remove key. counterweight.
wheels.
1. Remove the battery as described in Group 12.

2. Install eye bolt into the counterweight. Eyebolt must be
able to lift up to 2894 lb (1314 kg), depending on the
truck model. (See weight specifications in Section 1.)
3. Using an overhead hoist with sufficient lifting capac-
ity, attach hoist chain to eyebolt. Slowly lift hoist until
slack is removed from chain.
4. Remove the counterweight mounting bolts from inside
the battery compartment.
Stand clear of the counterweight as it is being hoisted,
moved, or mounted.
5. Slowly lift the counterweight from the truck frame
until it is free from the counterweight hooks on the
frame and can be moved back to clear the electronic
controls. Take care not to damage the controls.
6. Slowly lower the counterweight onto a sturdy pallet.

Set the counterweight on its flat side if possible.
Generic Illustration
SM 616, Dec ’02 ➀ Copyrighted Material

Counterweight Removal and Installation • 38-2-1
Counterweight Installation
WARNING
Stand clear of the counterweight as it is

being hoisted, moved, or mounted.
During mounting, always use prybars for

location adjustments. Do not place any
part of your body between the counter-
weight and truck.
1. Inspect the counterweight mounting bolts and nuts to

make sure they are in good condition before installing.
Make sure the mounting nuts are in place in the
counterweight.
2. Slowly raise the counterweight high enough to clear
the counterweight hooks on the frame. Take care not
to damage the electronic controls. Slowly lower the
counterweight onto the frame hooks.
3. Make sure that the bolt holes in the counterweight
align properly with the mating holes in the frame.
4. Torque the mounting bolts 340-380 N•m
(251–280 ft-lb)
5. Remove the hoist and eyebolts.
IMPORTANT
Never allow a truck to be put into service

without the counterweight mounting bolts
in place. Check the bolts and torque regu-
larly.
38-2-2 • Counterweight Removal and Installation

Copyrighted Material SM 616, Dec ’02 ➀
Section 3.
Overhead Guard Removal and Installation
CAUTION WARNING
SAFE PARKING. Before working on Overhead guard must be in place to protect
truck: operator from falling objects.
gaps or breaks.
wheels.
It is not necessary to remove the overhead guard for normal
service or repair of the truck. If the overhead guard must be
rplaced or repaired, remove it as follows:
1. Remove the electric part all
2. Remove the seat deck from the truck
3. Support the cowl assembly with an overhead lifting
device and remove fasteners holding the front cowl
assembly to the overhead guard.
Cowl
Assembly
Torque:
41-47 N•m
(30-35 ft-lb)
Torque overhead guard mounting bolts:

4. Remove the overhead guard mounting bolts. 88-95 N•m (65-70 lb-ft)
5. Lift the overhead guard from the truck.

6. Reverse procedure for installation.
SM 616, Dec ’02 ➀ Copyrighted Material

Overhead Guard Removal and Installation • 38-3-1
38-3-2 • Overhead Guard Removal and Installation

Section 4.
Floor Plate, Seat, and Seat Deck

Removal and Installation
CAUTION

gaps or breaks.
wheels.
Floor Plate Removal and Installation

1. Tilt the steering column fully forward. 3. To replace the floor plate, position the front of floor
plate first, then unfold it into position.
2. Fold the floor plate on its hinge and lift out the
operator’s compartment. Rubber mat lifts out with
floor plate. Floor plate is not fastened to the truck. IMPORTANT
Make sure the accelerator pedal has a full
stroke and does not bind.
Refer to Group 13 for accelerator pedal and
control information.
SM 616, April ’98 Floor Copyrighted

Plate, Seat,Material
and Seat Deck Removal and Installation • 38-4-1
Seat Removal and Installation

Use the following illustrations as a guide to removing
installing the seat and seat deck components.
Torque:
6-13 N•m
(60-120 in-lb)
Seat Deck
Gas Spring
Torque:
Torque: 20-25 N•m
20-25 N•m (176-221 in-lb)
(176-221 in-lb)
Overhead Guard
Torque:
70-80 N•m
(52-59 ft-lb)
Torque:
41-47 N•m
(30-35 ft-lb)
Torque:
20-25 N•m
(176-221 in-lb)
Seat Deck
Leveler
38-4-2 • Floor Plate, Seat, and Seat Deck Removal and Material
Copyrighted Installation SM 616, Dec ’02 ➁
GROUP 40
GROUP 40
SPECIFICATIONS
Nameplates and Decals ................................................... Section 1
General Specifications .................................................... Section 2
Hydraulic Fitting Tightening Procedures ..................... Section 3
SM 616, April ’98 Copyrighted Material Specifications

NOTES:
Specifications Copyrighted Material SM 616, April ’98

Group 40, Specifications
Section 1.
Nameplate and Decals
Nameplate and Decal Locations ................................................................................. 2
Nameplate and Decals ................................................................................................. 4

Truck Data and Capacity Plate ............................................................................ 4
Warning Decal ..................................................................................................... 5
Operator Safety Decal.......................................................................................... 5
Polarity Warning Decal ....................................................................................... 6
Battery Connector Warning Decal ...................................................................... 6
Hand Safety Warning Decal ................................................................................ 6
Keep Away from Forks Decal ............................................................................. 7
SM 616, April ’98 Copyrighted Material Nameplate and Decals • 40-1-1

Nameplate and Decal Locations

<TMG>
TMG Service Chart
WARNING
Every 900 - 1000 hours or every 6 months BEFORE OPERATING lift truck, operator must:

• Be trained and authorized.
Extension, Forks
Transaxle
• Read and understand operator's
C
Lift Chains Fluid
Brake Operation
manual.
E
Tilt Cylinder Pins
Lube B
Brake Linings
• Not operate a faulty lift truck.
Overhead Guard
Mounting Bolts All Wheel Lugs • Not repair lift truck unless trained and authorized.
Axle Mounting Instruments, • Have the overhead guard and load backrest
& Fasteners
Hydraulic Oil
Filter
* Meters, Lights
Directional,
Speed Control
extension in place.
Drive Motor
*
Lift, Tilt, Aux.
Brushes
Steer Motor
Operation
Steering
DURING OPERATION, lift truck operator must:
Brushes
Battery Cables
Operation
Hydaulic Sump
• Wear a seat belt.
& Receptacles
Battery Load
A
Hydraulic Sump
Oil • Keep entire body inside truck cab.
Test Breather
Warning
• Never carry passengers or lift people.
Lift Motor
Brushes
Ground and
Static Chain
* D
Devices, Horn
Control Card
Conn. Y (12 Pin)
• Keep truck away from people and obstructions.
• Travel with lift mechanism as low as possible.
Tire / Wheel
and tilted back.
c
Battery Terminals,
Electrolyte Level Condition
Steer Axle Steer Axle Wheel

Counterweight
Fasteners
Overall Visual
Check
TO PARK lift truck, operator must:
Check / Lubricate Change or Replace Clean / Air Clean • Completely lower forks or attachments.
Monitor Indicator Lights • Shift into neutral.
A - Hydraulic Oil
Check / Air Clean
B - MP Grease
Check
C - Transaxle Fluid
*
D - Electrical Connector
and Service as Required
E - Brake Fluid • Turn off key.
Clark # 1800236 NLGI # 2 Clark #2776236 Grease Clark #2819910
• Intervals refer to elapsed hour meter time and are based on Clark's experience found to be suitable and convenient
Dot 3
• Set parking brake.
under normal operating conditions.
Clark Material Handling Co. Sit Down Rider 2798233
• Service and Maintain as per Service and Operator Manuals. Special or harsh conditions may need additional intervals.
Clark Material Handling Co. 2820267
TMG 12 / 15S / 15 / 17 / 20 / 25
2372604
IMPORTANT
--------------------
-------------------
-----------.
--------------------
------------.
WARNING
Disconnect battery before handling
electrical components.
Connect positine to positive, negative

to negative to prevent damage. 2811139
A
D
CAUTION
DOT3 only
to prevent failure
of braking system
2825871 ! WARNING
TRUCK CAN MOVE UNEXPECTEDLY!
BEFORE WORKING ON THIS TRUCK.

Raise drive wheels clear of operating surface.
Disconnect battery.
Discharge capacitor(s).
Refer to maintenance procedures.
BREAKING THESE RULES MAY CAUSE

SERIOUS OR FATAL INJURY TO
YOURSELF AND OTHERS.
2770314
Hydraulics Diagram 1. Hydraulic Sump Tank

Tilt Lift
Optional Optional 2. Filler, Breather & Strainer
Cylinders Cylinders
Rotator Sideshifter 3. Lift Pump & Motor
5. Power Steering Valve
Load Lowering 6. Return Line Filter &

Bypass Valve
2000 Flow Valve
PSI AUX 2 AUX 1 Tilt Lift 7. Brake Master Cylinder
8. Main Hydraulic Valve
8
Steer
3000
PSI
Cylinder
L R
5
Brake Slave
Cylinder 6 3
P1 M
T P
7
4
P2 M
2
1000
PSI
1 2818074
WARNING
BEFORE OPERATING lift truck, operator must:
manual.
• Not repair lift truck unless trained and authorized. Wiring Schematic Battery 36/48 Volts
Pump
2
+ -
TMG Service Chart
• Have the overhead guard and load backrest Lock
Switch
2
PS Motor
+ -
extension in place. 2
30
32
PS
30
32
30
32
30
32
30
32
2 FU P Pump Motor 32 30
POS 500 Every 900 - 1000 hours or every 6 months
S A
DURING OPERATION, lift truck operator must: 3 1 FU

15
2
FU
500 Every 2000 hours or every year
• Wear a seat belt. 12 POS LA1
LS2 S1
A1 A1
S1
RA1
RS1
POS
32 30
Extension, Forks
• Keep entire body inside truck cab. Left Right

Field
Transaxle
Field
13D Master Slave

13D 13D 13D 13D
Drive Drive C
WARNING
28 28 28 28
PL-4 SO-4
28 28 28 28 12 2
Traction A A
Traction Lift Chains Fluid
PL-5 SO-6
2B 2B 1
Key LS1 Motor Motor
S2 S2 RS2
1 10A 10A 2 Drive Motor Brake Operation
13D
A2
2
3 Dash 15A
6A
15A
6A
3
4 NEG Right Switch LA2
A2
RA2 NEG Tilt Cylinder Pins E
4 Display 8A 8A 5 S1 NEG 32 30
Lube B
• Keep truck away from people and obstructions. 82
7G
80
81
5
6
12
15
7A
29A
7A
29A
49
19A
6
7
10
12
A2
A1
Slave
Control
S1 A2
S2 A1
12 10 2
2 2
NEG
Overhead Guard
Brake Linings
31A 14 2 2 2 2
Mounting Bolts All Wheel Lugs
16 31A S2
POS
17 27 15 Master
28
18 23 16 3
15A
13D
10A
29A
7A
Axle Mounting
2B
6A
8A
28
19 13D 2 2 LP1 LP10 50 50 50 50

2 Instruments,
*
20 PL-5 SO-5 1 2
Disconnect battery before handling and tilted back.

10J 13A
13D 23 3 13 10 10 10 LP2 2
PD
30 13
& Fasteners Meters, Lights
4
5
13B Drive Motor 12
13D 13D 13D Gray 11 Left 10
L
LP17 LP7 29 29 13 13 13
Hydraulic Oil Directional,
NEG S1 10 24
28C 28B 28A 82 12
Steer Filter Speed Control
13A
13B
PS
10A
19A
28C
15A
29A
31A
28C
10J
28B
28B
28A
28A
7G
Master
13
Angle Accelerator
7A
28
80
81
82
2B
6A
8A
82
49
27
23
S1 A2
28
PL-3 SO-3 A2 10 10 50 LP18
29 2
3 Control FWD Directional Switch Drive Motor
*
NO
Lift, Tilt, Aux.

NO
NO
NO

COM
S2 A1
COM
COM
4 A1
COM
7 6 6 LP4 LP9 21 13 13 13 13
Filter
81 5
Park Slave Brushes Operation
AUX1
S2
AUX2
11 POS REV
Tilt
Lift
80 12 Brake 7 8 8 LP5
19 RP7 RP1 2 Steer Motor Steering
• Completely lower forks or attachments. Switch
10E
10G
10F
PL-1 SO-1
10G
10H
10F
10H
10J
Brushes Operation
7G
500
80
81
82
31 31 LP14 LP12 19 19 RP12 RP2 10

13A
13B
2A 10
28
1
13
2B
10 2
10H 10G 10F
Black 3
50 Accelerator
15 LP21 49 Battery Cables Hydaulic Sump
• Shift into neutral.
13B PD 12 10 49 RP10 RP14 31 31 30 13
10J 10J 6B 6 4
7G
7
10J
7G
7A
7G
7A 7E 7B
8B
7C
8
7
5
6 Foot
38
1MS
15 LP3
LP15 23 23
& Receptacles A Oil
10D 500 RP16
7A 29 7
Connect positine to positive, negative

Brake Battery Load Hydraulic Sump
• Turn off key.
7B
6B
7C
8B
21 9 L P
PL-7 SO-7
28 LP16 27 27 RP15
Park 50 10 Switch Test Breather
10D
N0
NC
7C
19 12
Traction
C
7B
80
81
82
7A
Brake
7E
1
2
3
4
7 6
7
31 14 LP6 7 RP6 RP4

PS
Enable Warning
• Set parking brake. Switch Lift Motor
23 15 12 10 7 31 6 8 15 LY5 LY12
*
7C
7B
6B
8B
13A
27 16 7
24
13
50
Brushes Devices, Horn

2
10D 10D 10D 24 17
to negative to prevent damage. 2811139

7D 60 18
Foot 49 21
31A
15B
29B
15
10A
15 15 RP5 8
RP3 Ground and
7A
Control Card
82
81
2B
2A
31
19A
10
80
7C
7C
19
21
50
24
60
Brake
7
7D
FWD REV RY12 D

NC
Static Chain
N0
60 60 Conn. Y (12 Pin)

C
60
Switch Switch Switch 24 24 24
7 7 7 7 7 8 6 31 10 30 13
7D 50
10B
50 6 81 80 82
10D
7C Tire / Wheel
2
Accelerator Battery Terminals,

31A
80
81
82
7A
8 8 8 8 8 8
38
31
7
21
Condition
13A
SO-2 PL-2 31A 31A 19 12 10 7 31 Electrolyte Level

13
4 38 38 31 31 19A Traction 6 6 6 6 6 6
15B 15B
3 15B 15B
13A Enable Steer Axle Wheel
2 29B 29B 29B 29B Steer Axle
1 13 13 13 13 13 13 13
31 31 31 31 31 31 31 31 31
10A
10B
Steer Angle
2A
82
81
2B
10
80
10D 10D
7A
2
7
10C 10C 10 10 10 10 10 10 10 10 10
10C 81 80 82 30 13 Counterweight Overall Visual
10D 12 10
12 12 2C 2C
10B
2
10B
2
10B
2
10B
2
7 Fasteners Check
12A 2D
Key
15 AMP Battery PS 7 7 6 15 12 Dash 5
Control
10C
Display
10C
Connector Check / Lubricate Change or Replace Clean / Air Clean

2D
Motor
7A
82
81
80
7A
Fuse
80
81
82
Switch
7
7
B- B+ 10 10 10 20 23 13
1 2D
Options 13H 13H 13H 13H 13H Monitor Indicator Lights
*
2
+ Pump 12 10 Filter 30 13
Check / Air Clean Check
and Service as Required
12A
SO-11 10 28
Horn Switch Horn -
Motor Lift P
10C
+ 36/48
Negative B - MP Grease C - Transaxle Fluid D - Electrical Connector
7A
10 28 28 30
30 A - Hydraulic Oil E - Brake Fluid
82
81
- NEG
80
7
12A VDC
Stand Off Tilt
S 10 28
10C
25 25 25 13C 13C 13C 13C

Clark # 1800236 NLGI # 2 Clark #2776236 Grease Clark #2819910 Dot 3
7A
80
81
82
7
AUX 1
A
12 10 28 13
10C
7A
10C
7A
10C
7A
10C
7A
10C
7A AUX 2
• Intervals refer to elapsed hour meter time and are based on Clark's experience found to be suitable and convenient
7
82
81
7
82
81
7
82
81
7
82
81
7
82
81
Wiring Diagram 10 28 Horn Switch
Horn under normal operating conditions.
80 80 80 80 80 2825645 12 12 25 13
2825646
• Service and Maintain as per Service and Operator Manuals. Special or harsh conditions may need additional intervals.
Clark Material Handling Co. 2820267
TMG 12 / 15S / 15 / 17 / 20 / 25
40-1-2 • Nameplate and Decals Copyrighted Material SM

SM616,
SM 616,
616,Dec
Jul
April
’01 ①
➁
’02’98
Nameplate and Decal Locations

<EPG15-18>

Load Backrest
Upright Rollers Extension, Forks
Transaxle
Lift Chains Fluid
Brake Operation
Tilt Cylinder Pins
Lube
Brake Linings
Overhead Guard
Mounting bolts All Wheel Lugs
WARNING Axle Mounting Instruments,

Hydraulics Diagram
& Fasteners
Drive Motor
* Meters, Lights
Directional, Tilt Lift
1. Hydraulic Sump Tank
Read the
Brushes
Hydraulic Oil
* Speed Control
Lift, Tilt, Aux.

Optional
Rotator
Optional
Sideshifter
Cylinders Cylinders
2. Filler, Breather & Strainer
3. Lift Pump & Motor
manual Filter
Steer Motor
Operation
Steering
Brushes Operation 5. Power Steering Valve
Battery Cables Hydraulic Sump 6. Return Line Filter &
& Receptacles Oil
Load Lowering Bypass Valve
Battery Load Hydraulic Sump 2000 Flow Valve
Test Breather
PSI AUX 2 AUX 1 Tilt Lift 7. Brake Master Cylinder
Lift Motor Warning 8. Main Hydraulic Valve
8
Brushes
Ground and
* Devices, Horn
Tire / Wheel
Buckle up! Static Chain
Battery Terminals,
Condition
Steer
Steer Axle Wheel
Electrolyte Level Bearings 3000
PSI
Cylinder
CAUTION
Steer Axle Control Card
L R
Linkage
5
Fasteners Check Brake Slave
Check/Lubricate Change or Replace Clean/Air Clean Cylinder 6 3
P1 M
T P
7
DOT3 only
Check/Air Clean Check Monitor Indicator Lights
*
and Servive as Required
P2 M
4
A - Hydraulic Oil B - MP Grease C - Transaxle Fluid D - Electrical Connector E - Brake Fluid 2
Apply brake Clark # 1800236 NLGI # 2 Clark # 2776236 Grease Clark # 2824625 Dot 3 1000
PSI
when leaving
truck
Intervals refer to elapsed hour meter time and are based on Clark's experience found to be suitable and convenient
under normal operating conditions.
Serive and Maintain as per Service and Operator Manuals. Special or harsh conditions may need additional intervals.
Clark Material Handling Asia. EPG 15/18 8028240
1 2818074
to prevent failure
Watch Out
of braking system
2825871
For Other
People
2372604
Most lift truck

INJURIES
are to other
people near
the lift truck.
Prevent
Overturns!
AVOID :
• slippery,
sloping,
or uneven
surfaces
• loads over
capacity on
nameplate
• unstable or
high loads
• low tire
pressure
• poorly
maintained
lift truck
• fast or
sharp turns
In Case of
Tip-Over:
Don't
jump
Hold on
tight
Brace feet
Lean
away
2798235
INSIDE OF COVER
CTWT
WARNING
BEFORE OPERATING lift truck, operator must:
manual.
! WARNING • Not repair lift truck unless trained and authorized.
• Have the overhead guard and load backrest
extension in place.
--------------------------------------------------------------------. Raise drive wheels clear of operating surface. DURING OPERATION, lift truck operator must:
---------------------------------------------.
WARNING
Disconnect battery. • Wear a seat belt.
• Keep entire body inside truck cab.
--------------------------------------------------------------------.
--------------------------------------------------------------.
Refer to maintenance procedures. • Never carry passengers or lift people.

BREAKING THESE RULES MAY CAUSE • Keep truck away from people and obstructions.
IMPORTANT
Disconnect battery before handling ------------------------------------------------------------------. SERIOUS OR FATAL INJURY TO
-------------------- ------------------------------------------------. YOURSELF AND OTHERS.
and tilted back.
------------------- electrical components.
c
2770314
-----------. -------------------------------------------------------------------.
-------------------------------------------------------------. TO PARK lift truck, operator must:
--------------------
------------. Connect positine to positive, negative
----------------------------------------------------------.
--------------------------------------------------------------------.
• Completely lower forks or attachments.
--------------------------------------------------------------. • Turn off key.
2791861 to negative to prevent damage. 2811139 ---------. • Set parking brake.
Jul
April
SM 616, Dec ’01 ①➁
’98
’02 Copyrighted Material Nameplate and Decals • 40-1-3
Nameplate and Decals 5. Truck weight – The approximate weight of the truck
without a load on the forks. The truck weight plus the
This section shows the nameplate (data and capacity plate) weight of the load must be considered when operating
and decals required to be on all operating Clark industrial on elevators, elevated floors, etc., to be sure it is safe.
trucks. The nameplate lists the data on the truck – type and
serial number – and the capacities of the truck. Decals
depict or explain the hazards the operator must avoid when
operating the truck. The nameplate and decals are placed in CAUTION
specific locations on the truck and are intended to warn
Before attachments are added, or if the truck
others working around the truck of its hazards as well. The
is modified after leaving the factory, you
nameplate and decals MUST BE IN PLACE on all trucks.
must contact your authorized Clark dealer
If any decals or the nameplate are missing from the truck, for authorization and a new nameplate as
check with your local Clark dealer for replacements. This is capacity will new affected. This is required
required by OSHA. by OSHA.
IMPORTANT From the factory this truck

meets Part II ANSI B56.1
Do not allow a lift truck with damaged or Model Type
missing decals or data plate to be placed in Serial No.
service. Replace them immediately. They Attachments
contain important information as described
in
on the following pages. This is required by A
B mm
OSHA. The location of all decals is also in lb
shown on the following pages. mm kg
in lb
Truck Data and Capacity Plate mm kg
in lb
The truck data and capacity plate provides essential infor- mm kg
mation about the truck. This information is important for in
both operators and service personnel. Operators can see Load C
mm
C. G. C
what the truck’s capacities and load ratings are. Service
Capacities are for
personnel must identify the truck model, type, and serial centered loads only.
number when ordering parts. Refer to numbers on example A B Capacities are with
data plate illustration. attachment or forks with
upright in vertical position.
1. Truck model number or registered name. Truck Weight lb or kg
w / Max Battery lb or kg
2. Truck serial number--An identification number as-
Max Battery lb or kg
signed to this particular truck and should be used when
Min Battery lb or kg
requesting information or ordering service parts for Max Amp Hrs. Volts No.
this truck from your authorized CLARK dealer. The 2811000
For other capacities consult Clark Material Handling Co., Lexington, KY
serial number is also stamped on the frame.
3. Attachment description (if any installed)--The user
must see that the truck is marked to identify the
attachment(s), including weight of the truck/attach- 1
ment combination and truck capacity with the attach- 2
ment. 3
4. Capacity rating, load center, and lifting height data--

Shows the maximum load capacity of this truck with 4
relation to load centers and fork heights (see diagram
on plate). Personal injury and damage to the truck can 5
occur if these capacities are exceeded. Do not exceed
the maximum capacity specified.
40-1-4 • Nameplate and Decals Copyrighted Material SM 616, Jul ’01

Warning Decal Operator Safety Decal

The Operator Safety Warning Decal describes basic safe The Operator Safety Decal depicts impor-
operating procedures that should be used when operating tant points about truck operation and warns WARNING
the truck. This decal depicts important points about truck operators about truck safety hazards. The Read the
operation and warns operators about truck safety hazards. Operator Safety Decal is meant as a re- manual
This decal is meant as a reminder for operators. It is placed minder for operators and is placed where
where operators can review the points daily as they conduct operators can review the points daily as
a visual inspection and prepare the truck for work. they conduct a visual inspection and pre- Buckle up!
pare the truck for work.
WARNING
Apply brake
when leaving
truck
BEFORE OPERATING lift truck, operator must: Watch Out

• Be trained and authorized. For Other
• Read and understand operator's People
manual.
• Not repair lift truck unless trained and authorized.
• Have the overhead guard and load backrest
extension in place. Most lift truck
INJURIES
DURING OPERATION, lift truck operator must: are to other
people near
• Wear a seat belt. the lift truck.
• Keep entire body inside truck cab.
• Keep truck away from people and obstructions. Prevent
Overturns!
and tilted back.
PP
• Completely lower forks or attachments.
AVOID :
• slippery,
• Turn off key. sloping,
• Set parking brake. or uneven
Clark Material Handling Co. Sit Down Rider 2798233 surfaces
• loads over
capacity on
nameplate
IMPORTANT • unstable or
high loads
Safety and warning decals are placed in • low tire
pressure
conspicuous locations on the truck to remind
• poorly
operators of essential procedures or to maintained
lift truck
prevent them from making an error that
• fast or
could damage the truck or cause personal sharp turns
injury. Safety and warning decals should be
replaced immediately if missing, damaged In Case of
or illegible. This is required by OSHA. Tip-Over:
Don't
jump
Lift trucks can be tipped over if operated improperly. Expe-

rience with lift truck accidents has shown that the driver
cannot react quickly enough to jump clear of the truck and Hold on
overhead guard as the truck tips. To protect operators from tight
severe injury or death in the event of a tip-over, make sure

this decal is in place to remind them to always use their seat Brace feet
belts.
Lean
away
2798235

Hand Safety Warning Decal

Battery Disconnect Warning Decal
This safety decal is placed on the upright to warn of the
danger of injury from movement between rails, chains, This warning decal is located on the front of the seat deck.
sheaves, fork carriage, and other parts of the upright assem- It warns of the danger of truck movement when removing
bly. Operators and others should never climb on or reach or inserting the battery connector by calling for turning the
into the upright. Personal injury will result if any body part key switch to OFF and setting the parking brake.
is put between moving parts of the upright.
! WARNING
Turn key switch off
and set parking
brake before
2791862
removing
or inserting battery
connector.
Keep Away from Forks Decal
This safety decal is placed on the upright to warn of the Truck may start in
danger of injury from forks when they are in the raised
position. Operators and others should never ride on or stand motion if you do not.
under forks or attachments. The forks can fall and cause
2743642
injury or death.
Polarity Warning Decal

This warning decal is located on the front of the seat deck,
adjacent to the Battery Disconnect Warning Decal. It notes
the need to disconnect the battery before handling electrical
components and to always make electrical connections posi-
tive to positive and negative to negative to prevent damage.
WARNING
! WARNING
• Disconnect battery before handling
• Connect positive to positive, negative

to negative to prevent damage.
40-1-6 • Nameplate and Decals Copyrighted Material SM 616, April ’98

Electric Truck Warning Decal

This warning decal is located on the inside of the electrical
contactor compartment door. It warns that to prevent unex-
pected movement of the truck when working on it, to raise
the drive wheels, disconnect the battery, discharge the ca-
pacitors and refer to maintenance procedures.
! WARNING

Raise drive wheels clear of operating surface.
Disconnect battery.
Refer to maintenance procedures.
BREAKING THESE RULES MAY CAUSE

SERIOUS OR FATAL INJURY TO
YOURSELF AND OTHERS.
2770314

40-1-8 • Nameplate and Decals Copyrighted Material SM 616, April ’98

Section 2.
General Specifications
Weights and Performance Specifications ........................................................................................................................... 2

Capacities ............................................................................................................................................................................... 2
Truck Weights and Axle Weights .......................................................................................................................................... 2
Parking Brake Test ................................................................................................................................................................. 2
Travel Speeds ......................................................................................................................................................................... 2
Turning Radius (outside) ........................................................................................................................................................ 3
Drift, Lift and Tilt Cylinders .................................................................................................................................................. 3
Lift Speeds, Upright ............................................................................................................................................................... 3
Critical Fastener Torque Specifications ............................................................................................................................. 3
Group Specifications ............................................................................................................................................................ 4

Group 16, Motors Specifications ............................................................................................................................................ 4
Group 17, Contactors Specifications ...................................................................................................................................... 4
Group 19, Motor Controls Specifications .............................................................................................................................. 5
Group 20, Drive Axle Specifications ..................................................................................................................................... 5
Group 22, Wheels and Tires Specifications ........................................................................................................................... 5
Group 23, Brake System Specifications ................................................................................................................................. 5
Group 25/26, Steer System Specifications ............................................................................................................................. 5
Group 29/30, Hydraulic Sytem Specifications ....................................................................................................................... 5
Group 32, Tilt Cylinder Specifications .................................................................................................................................. 6
Group 34, Uprights Specifications ......................................................................................................................................... 6
Group 38, Counterweight Specifications ............................................................................................................................... 6
SM 616, April ’98 Copyrighted Material General Specifications • 40-2-1

Weights and Performance Specifications

Capacities
For standard transaxle trucks and hydrostatic transmission trucks.
At 500 mm(24in)
Models Load Center
TMG 12 1250 kg (2500 lbs)
TMG 13 1250 kg (2500 lbs)
TMG 15S 1500 kg (3000 lbs)
TMG 15 1500 kg (3000 lbs)
TMG 17 1700 kg (3500 lbs)
TMG 18 1800 kg (4000 lbs)
TMG 20 1815 kg (4000 lbs)
TMG 20x 2000 kg (4000 lbs)
TMG 25 2270 kg (5000 lbs)
EPG15 1500 kg (3000 lbs)
EPG18 1800 kg (3500 lbs)
Note: Rated capacity applies when using uprights with maximum fork height up to and including TMG 12-15 3861 mm (152 in), EPG15-18 4072mm
(160 in).
Truck Weights and Axle Weights

Approximate weights for trucks with triple stage upright and minimum battery weight..
Empty Vehicle Empty Drive Loaded Drive Empty Steer Loaded Steer
Weight) Axle Weight Axle Weight Axle Weight Axle Weight
(kg/lbs)* (kg/lbs) (kg/lbs) (kg/lbs) (kg/lbs)
(For U.S market)
TMG 12 3381/7448 2003/4411 4088/9005 1379/3037 428/943
TMG 15S 3642/8022 1993/4390 4496/9903 1649/3632 508/1119
TMG 15 3528/7771 1971/4341 4328/9543 1557/3430 562/1237
TMG 17 3676/8097 1974/4348 4725/10407 1702/3749 540/1190
TMG 20 3937/8671 1966/4330 5110/11255 1966/4341 643/1416
TMG 25 44397/9684 1938/4268 5879/12949 2459/5416 788/1735
(For Other markets)
TMG 13 3223/7105 1844/4065 4034/8893 1379/3040 439/967
TMG 15S 3483/7678 1834/4043 4337/9561 1649/3635 646/1424
TMG 15 3369/7427 1812/3994 4169/9191 1557/3432 700/1543
TMG 18 3773/8318 1807/3983 4951/10915 1966/4334 622/1371
TMG 20x 3888/8571 1807/3983 4951/10915 2081/4587 937/2065
EPG 15 2970/6548 1293/2851 3821/8424 1677/3697 649/1431
EPG 18 3235/1132 1252/2760 4286/9449 1983/4372 749/1651
Note: Refer to the truck data plate for exact service and axle weights.
Parking Brake Test

For standard transaxle trucks.
The brake must be capable of holding the truck with a full rated-capacity load on a 15 % grade.
Travel Speeds
Maximum speeds with triple stage upright.
(For U.S market)
without load with load
TMG 12 12.9 kph (8.0 mph) 12.7 kph (7.9 mph)
TMG 15S 12.9 kph (8.0 mph) 12.7 kph (7.9 mph)
EPG 15 14.0 kph (8.6 mph) 13.0 kph (8.0 mph)
40-2-2 • General Specifications Copyrighted Material SM

SM616,
SM 616,
616,Dec
Jul
April ➁①
’01’98
’02
(For Other markets)

without load with load
TMG 15S 13.7 kph (8.5 mph) 13.5 kph (8.4 mph)
TMG 20x 14.4 kph (8.9 mph) 13.6 kph (8.5 mph)
Turning Radius (outside)

For standard transaxle trucks and hydrostatic transmission trucks.
mm in
TMG 12 1356 53.4
TMG 13 1356 53.4
TMG 15S 1356 53.4
TMG 15 1519 59.8
TMG 17 1519 59.8
TMG 18 1519 59.8
TMG 20 1519 59.8
TMG 20x 1530 60.2
TMG 25 1565 61.6
EPG 15 1810 71.3
EPG 18 1845 72.6
Drift, Lift and Tilt Cylinders

Upright Fork Downdrift: Should not exceed 100 mm (4 in) in a 10-minute period.
Tilt Cylinder Drift: Should not exceed 5o in a 10-minute period.
Determined by marking and measuring carriage descent and upright forward tilt from raised, non-tilted position with hydraulic fluid at operating
temperature; and a capacity load held evenly distributed on lift forks. (If a pallet is used, load should not extend beyond pallet; load should be stacked to
provide maximum stability.) Fork completely engaging load and adjusted as wide as possible to provide even distribution of weight.
Lift Speeds, Upright
Lift Speed (m/s) Lowering Speed (m/s)
TMG12(13) TMG15S TMG15 TMG18 TMG20X(25) EPG15 EPG18 TMG (12-25) EPG (15-18)
Loaded 0.34 0.34 0.32 0.28 0.26 0.41 0.39 0.48 0.48
STD
Empty 0.51 0.51 0.51 0.51 0.51 0.60 0.60 0.42 0.42
Loaded 0.40 0.40 0.40 0.37 0.27 0.40 0.38 0.43 0.43
TSU
Empty 0.58 0.58 0.58 0.58 0.47 0.58 0.58 0.39 0.39
Critical Fastener Torque Specifications

Tightening Torque, Dry
N·m TMG/EPG 15/18 ft-lb TMG/EPG 15/18
Drive Axle-to-Frame Mounting Bolts: 408-469 300-340
Drive Wheel Lug Nuts 255-275/157-193 188-203/116-142
Steer Wheel Lug Nuts 255-275/157-193 188-203/116-142
Steer Trunnion Mounting Bolts 339-381/104.9-126.5 251-280/77.5-93.5
Steering Handwheel Retaining Nut 35-40 25.5-29.5
Tilt Cylinder Yoke Clamp Bolts 166-193 122-142
Tilt Cylinder Pin Retainer Bolts 20-22 177-221
Counterweight Mounting Bolts (Bottom) 339-381 251–280
Dec’01
SM 616, Jul ’02
April ①➁
’98 Copyrighted Material General Specifications • 40-2-3
Group Specifications
Group 16, Motors Specifications
Drive Motors Brushes

Grade: CM880
General
Type: Shunt wound
Frame Size: 168.2 mm (6.625 in) diameter
Thickness of New Brush: 16 mm (0.63 in)
Internal Bearings: On commutator end only. Bearings are sealed and
lubricated with high-temperature grease for the life of the bearing.
Maximum Force per New Brush: 1021 gm (36 oz)
Rotation: Reversible; CW for forward travel; CCW for reverse travel
when viewed from drive end. Minimum Force per Worn Brush: 454 gm (16 oz)
Terminal Nut Torque: 8-10 N·m (71-88 in-lb) Brush Drop: 0.2 Volts @ 100 Amps
Armature Steer Pump Motor (TMG For USA)

Insulation: Class H General
Type: Permanent magnet field.
Fields
Frame Size: 168 mm (6.61 in) diameter
Insulation: Class H
Internal Bearings on Pump End Commutator End: Double-sealed and
Brushes lubricated with high-temperature grease for the life of the bearing.
Grade: CM8100 Insulation

Quantity: 1 Brush per holder; 4 brushes per motor Armature Components: Class H
Length of New Brush: 41.91 mm (1.65 in) Field Components: Permanent magnet
Thickness of New Brush: 12.70 mm (0.50 in.)
Brushes
Maximum Length of Worn Brush: 22.40 mm (0.88 in) Quantity: 1 Brush per holder; 4 brushes per motor
Maximum Force per New Brush: 1724 gm (61 oz) Length of New Brush: 26.9 mm (1.06 in)
Maximum Force per Worn Brush: 907 gm (32 oz) Width of New Brush: 25.4 mm (1.0 in)
Brush Drop: 0.4 V+ .00444I Volts Thickness of New Brush: 8.9 mm (0.35 in)
Maximum Force per New Brush: 506 gm (18 oz)
Lift Pump Motor
Minimum Force per Worn Brush: 180 gm (13 oz)
General Brush Drop: 1.0 Volts @ 30 Amps
Type: Series wound
Frame Size: 182 mm (7.15 in) diameter Group 17, Contactors Specifications
Weight (Approx.): 44 kg (97 lb) Standard Truck: One line contactor, one main pump contactor, one power
Internal Bearings on Pump End Commutator End: Bearings are double steering pump contactor
sealed and lubricated with high-temperature grease for the life of the bearing (EPG 15/18 truck apply just one line contactor)
Rotation: Unreversible; CCW, viewed from drive end Pump Control Option: One line contactor and one power steering pump
Terminal Nut Torque: 8-10 N·m (71-88 in-lb) contactor (EPG 15/18 adopt this system as stanford)
On-Demand Steering Option: One line contactor and one main pump
Insulation contactor
Armature Components: Class H
Mounting Fastener Torque: 8-10 N·m (71-88 in-lb)
Field Components: Class H

SM616,
616,Dec ➀
’02’98
April
Group 19, Motor Controls Specifications Group 23, Brake System Specifications
Drive Motor Control Service Brake

Type: GE CTS450 transistorized control providing separate excitation Type: Caliper
of motor fields and armature. One for each drive motor.
Minimum lining/pad thickness: 0.67 mm (0.06 in).
Voltage: 36 or 48 volts
Fluid Type: SAEJ1703 (DOT-3) brake fluid only
Lift Pump Motor Control Fluid Capacity: 0.256 L (0.06 gal).
Standard type: Contactor only (TMG) Pedal Freeplay: 1-3 mm (0.039-0.118 in; measured at stop screw).
Optional type: Transistorized. (TMG)
Voltage: 36/48 volts (TMG)
Parking Brake
EPG 15-18: SEVCON Powerpak 450A Type: Lever-type mechanically linked to brake assembly.
Holding Test: Rated load on 15% grade
Power Steering Pump Motor Control
Standard Type: Contactor only (See Group 17.) Group 25/26, Steer System Specifications
Optional Type: On-demand transistorized control, 36/48 volt.
Steering System Type: Load sensing hydrostatic power steering with vari-
able ratio.
Group 20, Drive Axle Specifications
Steering System Relief Pressure Setting: 8274-8963 kPa (1200-1300 psi).
Type: Separate housing and drive train for each drive wheel. Each axle
housing contains pinion and ring gear, intermediate shaft, and axle Steer Cylinder Type: Double acting, piston-type.
shaft. Steer Axle: Single wheel (optional dual-wheel) mounted on trunnion at
Transmission Fluid Type: Clark part no. 2794022 center rear of truck.
Fluid Capacity (each housing): 3.8 L (1 gal)

Group 29/30, Hydraulic Sytem Specifications
Axle-to-Frame Mounting Bolt Torque: 408-469 N·m (300-340 ft-lb).
Use Loctitle 271. Hydraulic Fluid Type: Clark specification MS-68 (Clark part #1802155 and
#1800236)
Fill Plug Torque: 54-61 N·m (40-45 ft-lb)
Hydraulic Pump Type: Integral gear-type pump and motor assembly.
Group 22, Wheels and Tires Specifications Sump Capacity: Usable oil = 19 Litres (5.0 Gal)
Cushion Filter Type: Disposable, 25 micron, full flow return line oil filter and a 10
micron filter cap/breather filter.
Material: Rubber except as noted.
Main Relief Valve Setting: 20,000 to 21,000 kPa (2800 to 3000 psi) at rated
Size: flow.
Drive Steer
Auxiliary Relief Valve Setting: 13,300 to 14,300 kPa (1925 to 2075 psi) at
TMG 12/13/15/15S: 18x7x12.1 18x7x12.1
rated flow.
TMG 17/18/20 18x8x12.1 18x7x12.1
TMG 20x/25 18x9x12.1 18x6x12.1 (urethane) Rated Flow:
Mounting Nut Torques: Refter to mounting procedure in Section 2. Lift spool (spool #1): 76 L/min (20 gpm).
Tilt spool (spool #2): 38 L/min (10 gpm).
Pneumatic Auxiliary spool (spool #3): 38 L/min (10 gpm).
Material: Rubber Integral Pressure Compensated Flow Control Settings:
Size: Tilt spool (spool #2): 15 L/min (4.0 gpm).
(For U.S market) Auxiliary spool (spool #3): 9 L/min (2.5 gpm).
Drive Steer Tilt Flow Settings:
TMG 12/15: 18x7x8-16PR 18x7x8-16PR Tilt Speed Flow
TMG 15S: 18x7x8-16PR 18x7(Solid only)
Upright Usage (o/sec) Lpm (gpm)
TMG 17 18x9x8-16PR –
TMG 3937 mm (155 in) MFH & above 2.5 6 (1.5)
(For Other markets) TMG Below 3937 mm (155 in) MFH 3 9 (2.5)
Drive Steer
TMG 13/15S/15/18: 18x9x8 18x9x8 EPG 15/18
TMG 13/15S/15/18/20x: – 15x4 1/2 x8 Below 4165 (164”)MFH 8 21 (5.5)
EPG 15 18x7x8-16PR 5.00-8-10PR 4165(164”)~5715 (225”)MFH 5 11 (3)
EPG 18 18x9x8-16PR 5.00-8-10PR 5715 (225”) MFH & above 3 6 (1.5)
SM 616, Dec
April
Jul ’02①➁
’98
’01 Copyrighted Material General Specifications • 40-2-5
Group 38, Counterweight Specifications

Maximum Pressure Drop at Rated Flow:
Inlet to outlet: 689 kPa (100 psi) Counterweight Mounting Bolts Torque: 339-381 N•m
(251–280 ft-lb)
Lift spool (spool #1):
- Inlet to cylinder port: 689 kPa (100 psi) Counterweight Weight: Different counterweights are used based on truck
- Cylinder port to outlet: 550 kPa (80 psi) capacity and battery compartment length, as follows:
Tilt spool (spool #2):
Battery Compartment
- Cylinder port to outlet: 550 kPa (80 psi) (For U.S market)
Auxiliary spools (spools #3 and #4): Model Truck Capacity Length Counterweight
- Cylinder port to outlet: 207 kPa (30 psi) TMG12 2500 lb (1250 kg) 13.75” 1262 lb (573 kg)
Flow Control Adjustments: Adjustable from 4 to 38 L/min (1 to 10 gpm). TMG15s 3000 lb (1500 kg) 13.75” 1836 lb (834 kg)
Before adjusting, turn fully counter-clockwise to stop. Each 1/4 clock- TMG15 3000 lb (1500 kg) 20.5” 914 lb (415 kg)
wise turn of the adjustment increases flow by 3 L/min (0.75 gpm).
TMG17 3500 lb (1750 kg) 20.5” 1262 lb (573 kg)
TMG20 4000 lb (1815 kg) 20.5” 1836 lb (834 kg)
TMG25 5000 lb (2270 kg) 20.5” 2894 lb (1314 kg)
(For Other markets)
Model Truck Capacity Length Counterweight
TMG13 2500 lb (1250 kg) 13.75” 1262 lb (573 kg)
TMG15s 3000 lb (1500 kg) 13.75” 1836 lb (834 kg)
TMG15 3000 lb (1500 kg) 20.5” 914 lb (415 kg)
TMG18 4000 lb (1800 kg) 20.5” 1836 lb (834 kg)
TMG20x 4000 lb (2000 kg) 20.5” 2098 lb (952 kg)
Group 32, Tilt Cylinder Specifications
EPG 15 3000 lb (1500 kg) 29.5” 838 lb (380 kg)
See Group 29 for hydraulic system specifications.
EPG 18 3500 lb (1800 kg) 29.5” 1300 lb (590 kg)
Tilt Cylinder Type: Double-acting.
Maximum Operating Pressure: 21,000 kPa (3,000 psi).
o o
Tilt Ranges: (188 Cascade Triple Stage Upright): 3 back tilt and 5
forward tilt.
Group 34, Uprights Specifications

See mamufacturer’s service manual.

SM616,
SM 616,Dec
616, Jul ’02
April ➁
①
’01’98
Section 3.
Hydraulic Fitting Tightening Procedure
1. Tighten fitting finger tight until it stops turning, while 2. Using finger tips only, lightly snug fitting with a
moving the fitting lightly side to side to prevent wrench until it bottoms out on the seat or port. Do not
cocking or thread damage. overtighten.

Hydraulic Fitting Tightening Procedure • 40-3-1
40-3-2 • Hydraulic Fitting Tightening Procedure

#40–1, Ungnam-Dong,
Changwon-City, Kyungnam,
Korea
Manufactured by
Printed in Korea
Intended for CLARK dealers only Dec, 2002

Montacargas SERVIS MANUAL SM-616

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Montacargas SERVIS MANUAL SM-616

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TMG 12-25

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Revision Revision Revision Revision

SM 616, Dec ’02 ➁ Copyrighted Material REVISION HISTORY - 1

2 - REVISION HISTORY Copyrighted Material SM 616, Dec ’02 ➁

Revision Revision Revision Revision

SM 616, Dec ’02 ➁ Copyrighted Material REVISION HISTORY - 3

4 - REVISION HISTORY Copyrighted Material SM 616, Dec ’02 ➁

Contents by Group and Section

SA SAFE MAINTENANCE 4. Brake Removal and Replacement

SM 616, April ’98 Copyrighted Material Contents-iii

Contents-iv Copyrighted Material SM 616, April ’98

Safety ............................................................................... Section 1

Lifting, Jacking, and Blocking the Truck ..................... Section 2

SM 616, April ’98 Copyrighted Material Safe Maintenance

Safe Maintenance Copyrighted Material SM 616, April ’98

Safety Signs and Messages Safe Maintenance Practices

SM 616, April ’98 Copyrighted Material Safety • SA-1-1

conducted in an authorized, safe, clear area. or defective parts.

SA-1-2 • Safety Copyrighted Material SM 616, Jul ’01

Lifting, Jacking, and Blocking

Raising Drive Wheels ..................................................................................................................... 2

Chaining the Upright in Raised Position ..................................................................................... 2

Raising Rear of Truck ................................................................................................................... 3

Raising Entire Truck ..................................................................................................................... 4

Shipping Tie-Down Instructions ................................................................................................... 4

7. Check for safe clearance between drive wheels, block

Triple Stage Uprights: Chain the center intermediate

Blocking a Typical Upright

Raising Rear of Truck

1. Park truck safely.

3. Put a floor jack under the frame just beyond the

5. When maintenance work is completed, lower the rear

Raising Entire Truck CAUTION

WARNING 6. Release the parking brake on the towed vehicle. Place

Direction of towing for distances of

Disabled truck with Tow truck moving at 8 kilome-

SM 616, April ’98 Copyrighted Material Towing • SA-3-1

SA-3-2 • Towing Copyrighted Material SM 616, April ’98

Maintenance Schedule .................................................... Section 1

Planned Maintenance Program .................................... Section 2

The PM Inspection Form ............................................... Section 3

SM 616, April ’98 Copyrighted Material Periodic Service

Periodic Service Copyrighted Material SM 616, April ’98

“Periodic Service” and “Planned Maintenance” ........................................................................ 2

Determining Maintenance Intervals ............................................................................................ 2

Service Chart/Lubrication Points ................................................................................................. 3

Recommended Periodic Service Schedule ................................................................................... 4

SM 616, April ’98 Copyrighted Material Maintenance Schedules • PS-1-1

“Periodic Service” and “Planned Determining Maintenance Intervals

PS-1-2 • Maintenance Schedules Copyrighted Material SM 616, April ’98

Service Chart/Lubrication Points

TMG Service Chart

Upright Rollers Load Backrest

Axle Mounting Instruments,

Steer Axle Steer Axle Wheel

Check / Lubricate Change or Replace Clean / Air Clean

SM 616, Dec ’02 ➀ Copyrighted Material Maintenance Schedules • PS-1-3

Service Chart/Lubrication Points

EPG15-18 Service Chart

Axle Mounting Instruments,

Check / Lubricate Change or Replace Clean / Air Clean

A - Hydraulic Oil B - MP Grease