CLARK Service Update Teleconference Notes

August 18th, 2010

Attendees: Chuck Moratz, VP North American Truck Operations, CLARK Material Handling Company.
Glen Wood, Tech Pub Manager, CLARK Material Handling Company.
Clark Simpson, Sales Engineer, CLARK Material Handling Company.
Jim Clark, I. C. Truck Product Service Manager, CLARK Material Handling Company.
Mark Dyster, Truck Product Manager, CLARK Material Handling Company.
Russ Davies, Elect. Truck Product Service Manager, CLARK Material Handling Company.
Debbie Tackett, CLARK Parts, Product Support and Customer Service Manager.
Mike Guerrero, Mexico Region Sales Representative, International Customer Service.
Dave Nicolette, Technical Trainer, CLARK Material Handling Company.

76 Dealership Locations participated in the Teleconference.

Two separate Teleconferences were conducted, one at 10:00AM Eastern Daylight Time for
the Eastern and Central Time Zones, and the second Teleconference at 4:00PM Eastern Time
for the Mountain and Pacific Time Zones.

The next Service Update Teleconference is scheduled for Wednesday, October 13th, 2010, the Morning
Conference will be held at 10:00AM EDT, the Afternoon Conference will be held at 4:00PM EDT. If
you have any questions contact Dave Nicolette at davenicolette@clarkmhc.com.

TOPICS THAT WERE DISCUSSED

TRAINING & MISCELLANEOUS – DAVID T. NICOLETTE
Training:
The TIER IV Regional Training Courses are currently being conducted and the Training Schedule is
very busy, if yopu are planning on scheduling CLARK Technical Training at your Dealership we are
recommending you contact CLARK Training and confirm Training Dates for 2011. For more information
about the scheduling Training at your Dealership contact Becky Smith at beckysmith@clarkmhc.com or 1-
859-422-6584, or David T. Nicolette at davenicolette@clarkmhc.com or 1-859-422-6547. The current
confirmed Regional Training Courses are:

August 24th to 26th

Mid-West Region
Regional Training School
Subject and Location
JUNIPER L.P.Gas Multiport
Fuel Injection and CLARK
Internal Combustion Lift Trucks
Lift Truck Center, Inc.
Wichita, KS

AND

PAGE 1
SERVICE UPDATE TELECONFERENCE NOTES APRIL 2010
 CLARK Service Update Teleconference Notes
August 18th, 2010
September 14th to 16th
Western Region
Regional Training Course
Subject and Location
JUNIPER L.P.Gas Multiport
Fuel Injection and CLARK
Internal Combustion Lift Trucks
Holt of California,
West Sacramento, CA

2010 Schedule for the National Service Update Teleconference:

The tentative schedule for the National Service Update Teleconference for the remainder of 2010 is
as follows:
Wednesday, October 13th, 2010.
Wednesday, December 1st, 2009.
These dates are tentative and may be changed as schedules and activities change.

I.C. PRODUCT – JIM CLARK, AND CLARK SIMPSON

GEN2 C232 & P232 Inching Cable Linkage:
Several Dealers have reported problems keeping the Inching Pedal adjusted correctly. The Inching
Pedal should be adjusted so that it disengages the transmission prior to applying the brakes. If this
adjustment is incorrect it will enable the operator to apply the Service Brakes without disengaging the
transmission while operating the Lift Truck with there left foot riding on the Inching Pedal. The issue is the
Inching Linkage on both Cushion and Pneumatic Model Gen 2 trucks. If your Inching Linkage is out of
adjustment, the operator can drive with their foot riding on the Inching Brake Pedal causing the Brakes to
drag. If this is adjusted correctly the Inching Pedal should disengage the Transmission prior to applying the
Brakes. If you find that the Inching Linkage under the Cowl Cover is worn and needs to be replaced, we
have a New Part Number for that Linkage. The New Part Number is #8087060 and it replaces the Part
Number #8040122 Link. We will have a SI bulletin written and released in Parts Pro in the near future. If
you have any questions give me a call.

WOODWARD TIER III Software:

We now have Woodward TIER III Software Version V12 released and available for download for all
Models. The Software can be located in Parts Pro under the PDF files, Truck Service and Service Manuals,
EPA 2007 System Service. When you open this index you will find several PDF files. Scroll down until
you see the Program Update File. If you are setting up a new computer, you will want to perform an update
after you install the program.

WOODWARD TIER III Engine Surge:

We have had a few complaints from the Dealers about an Engine RPM Surge in the TIER III
Woodward Fuel Systems. We are in the research stage of this problem with Woodward, we currently do not

PAGE 2
SERVICE UPDATE TELECONFERENCE NOTES APRIL 2010
 CLARK Service Update Teleconference Notes
August 18th, 2010
know what the root cause of the Engine RPM Surge is. If you are experiencing this problem please contact
Jim Clark at 1-859-422-6423 or jimclark@clarkmhc.com .

Engine Coolant Anti-Freeze:

Engine Coolant Anti-Freeze has been one of the most overlooked Maintenance Items in the past
several years, and it may have been costing your Customers money. There are basically three types of Anti-
Freeze, the first is Inorganic Acid Technology (IAT) Green in color, the second is Organic Acid Technology
(OAT) Orange in color and Hybrid Organic Technology (HOAT) Yellow in color, and the third type is
Heavy Duty Coolant and is Red in color, they are all made from 95% or more Ethylene Glycol. The Big
Deal with the different types of Anti-Freeze is the Corrosion Protection Additives otherwise known as
Supplemental Coolant Additive (SCA). Because the three types of Anti-Freeze are 95% or more Ethylene
Glycol they can be mixed without curdling and turning into sludge, but it will reduce the SCA Levels and
may cause problems with corrosion in the Engine and Radiators.
CLARK IC Lift Trucks come from the factory with the Standard IAT Green Anti-Freeze Coolant and
our recommendation is that the Engine Coolant be drained and the System flushed and filled with new
Engine Coolant Anti-Freeze once a year or every 2,000 hours of operation. We are currently researching the
possibility of changing over to the Heavy Duty Red Coolant at the Factory, but that decision will be made
sometime in the future.
Engine Coolant must be an Anti-Freeze and Water Mixture, CLARK recommends a 50/50 Mixture.
Generally when Anti-Freeze is mixed at 70% strength or greater it will lose its Corrosion Protection and Heat
Transfer Capabilities, that’s why it is best to mix the Anti-Freeze to a 50/50 solution with water.
The water used in the Engine Cooling System is also critical, once again straight tap water is
not recommended. You do not need Distilled Water, but the water must be Mineral Free, without Salts,
Mud, Rusts, or other contaminants. CLARK recommends using the Premixed 50/50 Solution from the Anti-
Freeze Manufacturer, it does not need any diluting and it comes with De-Ionized Water.
It is also extremely important that the Cooling Systems be maintained in the “FULL” Condition, do
not depend on the visual level of the Recovery Bottle, remove the Radiator Cap (after the Engine has had
time to cool down) and check the Coolant Level to insure it is FULL. If air enters into the Cooling System
it may cause the Coolant Additives or other contaminants in the water to precipitate out of the solution and
clog the Cooling System.
If you want to change the Engine Coolant Anti-Freeze to the Heavy Duty Red Color, CLARK Part
Number is #ZXEDRU1, this is a one (1) Gallon Container and it is already PreMixed. It is
EXTREMELY IMPORTANT that before filling the Cooling System with the Heavy Duty Red Anti-Freeze
(ZXEDRU1), you MUST FIRST flush the System using CLARK Part Number #ZXC01 Super Flush.
Look for SI-01-807-09 “Coolant Maintenance” to be rewritten to address these issues in the near future. If
you have any questions contact Clark Simpson at clarksimpson@clarkmhc.com .

PAGE 3
SERVICE UPDATE TELECONFERENCE NOTES APRIL 2010
 CLARK Service Update Teleconference Notes
August 18th, 2010
ELECTRIC PRODUCT – RUSS DAVIES AND MARK DYSTER
Damaged TMX Wire Harness

We have recently seen a couple of TMX Wiring Harnesses damaged behind the Counterweight. We
have seen it show up as an Intermittent Encoder Bearing and other Intermittent Failures. If you have an
intermittent failure you may want to remove Counterweight to make sure the Wiring Harness has not been
damaged by the Cable & Harness Retaining Pin next to the Steer Cylinder. If you do end up pulling the
Counterweight I recommend that you put a piece of ¼” Rubber Tubing over the Pin to eliminate future
damage to the harness.

HWX/PWX Alarm Codes

We have had several questions about the alarm codes on the HWX/PWX. First when you turn the
Key Switch to the “ON” Position, the Dash Display shows a Code #16 then a Code #26 or a Code #28, these
Codes are Start-Up Codes that come up every time you turn the Key Switch to the “ON” Position. The
Code #16 is the Display Starting-Up, and the Code #26 or Code #28 are the Software Versions in the ZAPI
Controller.
Most the other Alarms show up as 3 Digit Numbers (Example: #783 or #791) but the Service
Manual only has 2 Digit Codes (#78 or #79). So all you need to do is “DISCARD” the Third Digit to get
the correct 2 Digit Code (#78 or #79) and match it up with the Alarm Codes in the Service Manual.

PARTS ISSUES AND UPDATES DEBBIE TACKETT:

Aftermarket Programs:
Debbie explained the Parts Aftermarket Programs available to the Dealers through the CLARK
Intranet.

MISCELLANEOUS ADMINISTRATIVE ISSUES AND UPDATES

GLEN WOOD AND CHUCK MORATZ:

National Service Managers and Trainers Meeting:

Glen explained the New PartsPRO Enhancements.

PAGE 4
SERVICE UPDATE TELECONFERENCE NOTES APRIL 2010