Beruflich Dokumente
Kultur Dokumente
ESM 12-25
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SERVICE MANUAL
SM556
CONTENTS
GROUP PAGE
Foreword ii
...
How to Use this Manual III
Pictorial Index iv
Safety and Operational Checks iv
Recommended Planned Maintenance
and Lubricatiin Schedule V
Safety Signs and Messages vi
User Safe Maintenance Practices vi
GROUP PAGE
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
FOREWORD
Clark Equipment Company welcomes you to the growing group of professional people who own, operate
and maintain Clark lift trucks. This manual wiil familiarize you with service maintenance and overhaul
information about your new truck. It has been especially prepared to help you maintain your Clark lift truck
in an efficient and safe operating condition.
Regular, correct maintenance and care of your lift truck is not only important for full and efficient truck life, it
is essential for your safety. A faulty Iii truck is a potential source of danger to the operator, and to other
personnel working near it. The importance of maintaining your Iii truck in a safe operating condii by
servicing it regularly and, when necessary, repairing it promptly cannot be emphasized too strongly.
To assist you in keeping your fii truck in good operating condition, this manual includes an outline of
planned maintenance (PM) procedures that are considered essential to the life and safe performance of
your truck. Brief procedures for inspections, operational checks, deaning, tubncatiin, and adjustments are
included for your reference.
. ,.
Clark recommends that a planned maintenance and safety inspection program (PM) be performed by a
trained and authorized mechanic on a regular basis. The PM program provides the opportunity to make
thorough inspections and checks on the safe condition of your truck. Necessary adjustments and repairs
can be done during the PM, which will increase the life of components and reduce unscheduled downtime.
The need for major adjustments, repairs, or replacements is found and corrections made as required, not
after failure has occurred.
SM556 ii
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
HOW TO USE THIS MANUAL
This manual is intended to be used by persons who are trained and authorized to do lift truck maintenance.
The recommended procedures for routine servicing and adjustments as well as for removal and overhaul of
major components of the truck are outlined. It is written to show and describe the adjustment, removal,
disassembly, inspection, repair, and assembly steps that are normally required to service these compo-
nents.
The detailed procedures are arranged in sequence by numbered GROUP and Section. The GROUP
numbers are the same as the component group in the Master Parts Book. Each GROUP has its own Table
of Contents, so that you can find the various topics within more easily. If you cannot find a topic in the Table
of Contents, check the Index at the back of the manual.
Component specifications, information notes and safety messages are included at the proper step of each
procedure. To be better prepared to do the necessary service work, please take time to read the entire
procedure, including any speciaf instructions; before doing anywork.
Speciffcations of selected truck components are included at the back of the manual for easy reference.
Also refer to the Operator’s Manual, located on the truck, for additional information and instructions on the
operation and maintenance of your truck.
If you have need for more information on the care and repair of your truck, please contact your authorized
Clark dealer.
,_ . .
NOTICE - The descriptions and specifications included in this manual were in effectat the time ofprinting. Clark
Equipment Company reserves the right to make improvements and changes in specifications or design, with-
out notice and without incurring obligation. Please check w2h your authorized CLARK dealer for information
on possible updates or revisions.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
PICTORIAL INDEX
1. Control Handle
2. Traction Control Panel
3. Lift Pump & Motor
4. Steer Pump & Motor
5. Service Brake
6. Drive Motors (2)
7. SumpTank
8. Battery
5 9. Steer Axle & Housing
1O.Steer Torque Generator
6 11. Brake Reservoir
12. Steer Control and Valve
bn and bolts
tration and other warning
V
devices
Check steering operation 0
Check brake operation 0
.
Check directional and speed control
operation
Check lift, tilt, aind aux.
_._ operation
Check upright, lift ch(ains and fasteners
Check load backrest extension and forks
SM556 iv
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
RECOMMENDED PLANNED
MAINTENANCE and LUBRICATION
SCHEDULE
lmproperorcareless techniques cause accidents. Don’t The following instructions have been prepared from
take chances with incorrect or damaged equipment. current industry and government safety standards
READ and UNDERSTAND the procedures for safe applicable to industrial truck operations and
driving and maintenance outlined in this manual. maintenance. They are listed hereforthe reference and
safety of all workers during inspection / maintenance
STAY ALERT! Follow safety rules, regulations and operations. When in doubt of any inspection /
procedures. Accidents can be avoided by recognizing maintenance procedures, please contact your local
dangerous procedures or situations before they occur. CLARK dealer.
DRIVE AND WORK SAFELY and follow the safety 1.Powered industrial trucks can become hazardous if
signs and their messages displayed on the truck and in maintenance is neglected. Therefore, suitable
this manual. maintenance facilities, trained personnel and procedures
shall be provided.
SAFETY SIGNS and MESSAGES are placed in this
manual and also on the lift truck to provide instructions 2. Maintenance and inspection of all powered industrial
and to identify specific areas where potential hazards trucks shall be done in conformance with the
exist and special precautions should be taken. Be sure manufacturers recommendations.
you know and understand the meaning of these instruc-
tions, signs and messages. Damage to the truck or 3. A scheduled planned maintenance, lubrication and
death or serious injury to you or other persons may inspection system shall be followed.
result if these messages are not followed.
4. Only trained and authorized personnel shall be
NOTICE permitted to maintain, repair, adjust and inspect industrial
This message is used when special informa- trucks and in accordance with the manufacturer’s
tion is required to clarify procedures or identify specifications.
components pertaining to the truck.
5. Properly ventilate work area, vent exhaust fumes,
keep shop clean and floor dry.
IMPORTANT
This message is used when additional atten-
6. Avoid fire hazards and have fire protection equipment
tion is required for proper operation or mainte-
present in the work area. Do not use an open flame to
nance of the truck.
check electrolyte level. Do not use open pans of fuel or
flammable cleaning fluids for cleaning parts.
A ! CAUTION
This message is used as a reminder of safety
7.Before Starting To Work On Truck:
a) Raise drive wheel free of floor or disconnect power
practices which can result in personal injury if source and use blocksorother positive truck positioning
proper precautions are not taken. devices.
b) Put blocks under the load-engaging means,
A WARNING
This message is used when a hazard exists
innermast( or chassis before working on them.
c) Disconnect battery before working on the electrical
system.
which can result in injury or death, if proper
precautions are not taken. 8. Operation of the truck to check performance must be
conducted in an authorized, safe, clear area.
A DANGER
This message is used when an extreme hazard
exists which will result in death or serious injury
if proper precautions are not taken.
Copyrighted
SM556 vi Material Rev Jan ‘96
Intended for CLARK dealers only
Do not sell or distribute
9. Before Starting to Drive the Truck: connections must be inspected and maintained in
a) Be in operating position. conformance with good practices. Special
b) Turn on power. attention must be paid to the condition of electrical
c) Check functioning of lift and tilt systems. insulation.
d) Check directional and speed controls.
e) Check steering. 17. To avoid injury to personnel or damage to the
9 Check brakes. equipment, consult the manufacturers procedures
g) Check warning devices. in replacing contacts on any battery.
h) Check any load handling attachments.
18. Industrial trucks must be kept in a clean
10. Before Leaving the Truck: condition to minimize fire hazards and help in the
a) Stop truck. detection of loose or defective parts.
b) Fully lower forks or attachment device.
c) Allow directional control to return to neutral. 19. Modiiiations and additions that affect capacity
d) Turn off the control / ignition switch. and safe truck operation must not be done without
e) Chock wheels if truck must be left on an the manufacturer’s prior written approval.
incline. Capacity, operation and maintenance instruction
plates, tags or decals must be changed
11. Brakes, steering mechanisms, control accordingly.
mechanisms, warning devices, lights, lift overload
devices, guards and safety devices, lift, reach and 20. Care must be taken to assure that all
rotation mechanisms, and frame members must be replacement parts, including tires, are
carefully and regularly inspected and maintained in interchangeable with the original parts and of a
a safe operating condition. quality at least equal to that provided in the original
equipment. Parts, including tires, are to be
‘12. Special trucks or devices designed and installed per the manufacturers procedures.
approved for hazardous area operation must Always use genuine CLARK or CLARK - approved
receive special attention to ensure that parts. ;
maintenance preserves the original, approved safe
operating features. 21. When removing tires, follow industry safety
practiced. Most important, deflate pneumatic tires
13. All hydraulic systems must be regularly completely prior to removal. Following assembly
inspected and maintained in conformance with of tires on multi-piece rims, use a safety cage or
good practices. Tilt and lift cylinders, valves and restraining device while inflating.
other similar parts must be checked to assure that
“drift” or leakage has not developed to the extent 22. Use special care when removing heavy
that it would create a hazard. components from the truck, such as
counterweight, upright, etc. Be sure that lifting and
14. When working on hydraulic system, be sure handling equipment is of the correct capacity and
the battery is disconnected and upright is in its fully in good condition.
lowered position, and hydraulic pressure relieved
in hoses and tubing.
/\ ! WARNING
Always put blocks under the carriage and
upright rails when necessary to work with
upright in an elevated position.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Planned Maintenance
GROUP PM
PLANNED MAINTENANCE
AcheckmarkorentryismadeonthePMReportFormwhenthePM
is performed. Please note the special coding system for indicating
the importance of needed repairs and/or adjustments.
When you have finished the PM inspections,be sure to give a copy VISUAL INSPECTION
of the report to the designatedauthorityor thepersonresponsiblefor First, perform a visual inspection of the lift truck and its
lift truck maintenance. components. Walk around the truck and take note of any
obvious damage and maintenance problems. Check for loose
Do not make repairs or adjustments unless au- fasteners and fittings.
thorized to do so. For safety,it is good practice to:
Check to be sure all capacity, safety, and warning plates or
Remove all jewelry (watch, rings, bracelets, etc.) before decals are attached and legible.
working on the truck.
Disconnect battery from truck receptacle before work- IMPORTANT
ing on electrical components. NAMEPLATES & DECALS
Always weaf safety glasses. Wear a safety (hard) hat in Do not operate a lift truck with damaged or missing
industrial plants and in special work areas where protec- decals and nameplates. Replace them immediately.
tion is necessary or required. They contain important information.
A
Be sure that the driver’s overhead guard, load backrest
extension, finger guards, and any other safety devices are in DANGER
place, undamaged, and attached securely. Uprights can drop suddenly. Look at the up-
right, but keep hands out.
IMPORTANT
For trucks equipped with spark-enclosed (EE) con- Check the upright assembly. Inspect the upright rails, car-
struction, or with polyurethane tires, check the riage rollers, lift chains, lift and tilt cylinders. Look for
ground strap for wear and secure attachment. obvious wear, and damaged or missing parts. Check for any
loosepartsorfittings. Checkforleaks,anydamagedorloose
Check all of the critical components that handle or carry rollers, and rail wear (metal flaking). Carefully check the lift
the load. chains for wear, rust and corrosion, cracked or broken links,
stretching, etc. Check that the lift and carriage chains are
correctly adjusted to have equal tension. Check that the lift
chain anchor fasteners and lccking means are in place and
tight.
Be sure all safety guards and chain retainers are in place and
not damaged. Inspect the carriage stops and cylinder retainer
bolts. Check all welded connections.
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.
IMPORTANT
. Uprights and lift chains require special attention
and maintenance to maintain them in safe oper-
ating condition. Refer to Lift Chain Mainte-
nance section for additional information.
Check the overhead guard for damage. Be sure that it
is properly positioned and all mounting fasteners are in
Forks
place and tight.
Inspect the load forks for cracks, breaks, bending and wear.
The fork top surfaces should be level and even with each
Check the load backrestfordamage. Inspect the welds
other. The height difference between both fork tips should be
on the carriage and load backrest for cracks. Be sure
no more than 0.25 inch (6mm).
that the mounting fasteners are all in place
and tight.
IMPORTANT
Ifload backrest has been removed,
a bolt and washer must be in place
on each end of the top fork bar to
act as a fork stop.
max. wear
A WARNING
If the fork blade at the heel is worn down by more
than lo%, the load capacity is reduced and the fork
must be replaced. Do not attempt to fill with weld.
Inspect the forks for twists and bends. To check, put a IMPORTANT
2”x4”~24” long block on the blade of the fork with the 4” Personnel working on wheels and tires must be
surface against the blade. Put a 24” carpenters square on the trained and qualified to do wheel and tire maiu-
top of the block and against the shank. Check the fork 18” tenance.
above the blade to be sure it is not bent more than 1 inch
maximum. Pneumatic Tires
Carpenter Square Check for the correct air pressure on trucks with pneumatic
\
tires.
Blade -
A ! CAUTION
Check tire pressure from a position facing the
tread of the tire, not the side. Use a long-handled
gauge to keep your body away from the side. If
tires are low, don’t add air. The tire may require
removal and repair. Have the tire and wheel
inspected by a person trained and authorized to
do tire and wheel maintenance. Low tire pres-
sure can reduce the stability of your lift truck
and cause it to tip over.
Inspect the fork latches. Be sure they are not damaged or
broken and operate freely and lock correctly. Check the fork Inspect pneumatic tires and wheels carefully for:
stop pins (or bolt and washer) for secure condition. Damaged tire.
Damaged wheels or loosening of the locking rings on
multi-piece rims.
Wheels and Tires Loosening of the clamping bolts and nuts on two-piece,
Check the condition of the drive and split-rim wheels.
steer wheels and tires. Remove Low inflation pressure.
A DANGER
objects that are embedded in the
RIM SEPARATION
Remove the air from tires before doing any work
on tires or rims. Multi-piece rims cans separate
with enough force to cause injury or death.
Check all wheel mounting bolts to
be sure none are loose or missing.
Replace missing bolts and tighten
loose bolts to the correct torque
before operating the truck.
FUNCTIONAL TESTS
Travel
Reverse
Battery Load Test The main pump motor should start to run as the lever moves
from the neutral position and upright should rise. Return the
Battery Indicator
Tilt Control control handle to the neutral position. Pump motor should
stop. Push control handle forward into the LOWER position
until upright starts to lower.
Check the battery disconnect by pulling back the disconnect Return control handle to NEUTRAL. Steer pump motor
lever. The connector should separate smoothly. If it does not, should stop.
have it repaired.
IMPORTANT
Before Driving The Truck, Do These Tests: The steering system and steer axle should be
inspected periodically for wear, leaking seals,
etc. Check for any changes in steering action.
Hard steering, excessive freeplay (looseness) or
unusual sounds when turning or maneuvering
indicates a need for inspection and servicing.
Never operate a truck which has a steering sys-
tem fault.
TEST DRIVE THE TRUCK Check the accelerator control while conducting the speed
range tests. It must move easily and smoothly throughout the
IMPORTANT acceleration stroke, andreturn withoutbinding. There should
It is recommended that these tests be conducted be no restriction to movement on either acceleration or
with a rated capacity load, if possible. deceleration.
Operate ONLY in a pedestrian and traffic free aisle. An Test the service brake (drive motor cut-off) switch. Drive the
empty parking lot with a smooth, level surface is also a good truck FORWARD (or in REVERSE) at creep speed. While
operating location. holding the control handle steady in creep-speed position,
release brake pedal. The braking action should interrupt
Test the truck for proper operation and drive train function power to the drive motor and stop the truck. Depress the
by driving the truck in both the forward and reverse direc- brake pedal. The drive motors should again start moving the
tions. Drive first in a straight line and slowly through a series truck.
of full right and left turns.
method, the ESM is m intended for use on 15% grades, FORWARD, then back to NEUTRAL. Next, test shift from
except as encountered for short distances such as dock plates. NEUTRAL to REVERSE, then back to NEUTRAL. Check
If no grade is available, the brakes can be approximately for positive control action when changing directions.
tested by measuring the stopping distance as follows. Test
only with an unloaded truck in a pedestrian and traffic free Listen for clunking, squealing, grinding, scraping or other
aisle. An empty parking lot with a smooth, level surface is unusual noises. Check for vibration. Listen for wheel bearing
alsoagoodoperatinglocation.Markalineonthefloorornote or other specific running noise.
a floor joint as a measurement line. Starting at a point
approximately 150 to 200 feet in front of the line, drive the Lift Mechanism and Controls
truck in a straight line at full speed towards the line. As the NOTE: It is recommended that these tests be conducted with
front wheels roll over the line apply the brakes by raising the a rated capacity load, if possible.
brake pedal. When the truck has come to a complete stop,
safely park the truck at this same spot and measure the Test the operation of the hydraulic system and upright.
distance from the front wheels to the measurement line. This
is your stopping distance. Compare to the table below for the A ! CAUTION
model you are working with. If the measured distance is less Be sure there is adequate overhead clearance
thanthetablevaluethenthebmkesaresatisfactorilyset(The before raising the upright.
approximate rule of thumb is that the stopping distance for an
ESM without a load shall be between l-1/4 (one and one
quarter)and 1-1/2(one and one half) times the length of the
truck with no forks.)
Modei Distance inches
ESMl2 100
ESM15S 100
ESM15 97
ESM17 94
ESM20 92
ESM22 90
ESM25 90
Cycle (raise to full height and then lower) the upright at both
Do not operate lift truck if the brakes are not slow and fast speed, with the upright tilted slightly back-
operating properly. wards. Watch the upright assembly as it rises. All move-
ments of the upright, fork carriage, and lift chains must be
Check steering control operation. First, drive the truck in a even and smooth, without binding or jerking motions. Watch
straight line. The truck must drive in a straight line without for chain wobble or looseness; the chains should have equal
drifting toward either side. Then, drive slowly (creep speed) tension and move smoothly without noticeable wobble.
through a series of full right and left turns. Check steering
response and smoothness of operation. Turning effort must Check function of the control handle and main hydraulic
be the same in either direction. If there is a steering problem, valve. Listen for abnormal noises in the hydraulic valve, main
have it repaired. Also refer to Group 17, Drive Motor Cut-Out hydraulic pump, and system components.
check and adjustment.
If the maximum fork height is not reached, there is low oil
level in the hydraulic sump tank, or severe binding within the
upright.
Do not operate lift truck if steering system is not
operating properly.
A WARNING
FALLING FORKS
IMPORTANT
It is recommended that the following tests also be Do not walk or stand under raised forks. The
conducted with a rated capacity load, if available. forks can fall and cause injury or death.
Test for general drive train operation. Drive the truck at Check the upright rails, rollers, carriage, lift chains and
various speeds and operating conditions, in both FORWARD cylinders as they move. Watch for binding or excessive
and REVERSE directions. Test shifting from NEUTRAL to freeplay (looseness) between the carriage and the upright
PM-8
Copyrighted Material SM 556, Jan’96
Intended for CLARK dealers only
Do not sell or distribute
Planned Maintenance
solution of baking soda and water. etc.) in the air or on the floor, will require more frequent
cleaning. If air pressure does not remove heavy deposits of
Refer to Group 12, Battery Maintenance, for additional grease, oil, etc., it may be necessary to use steam or liquid
information. spray cleaner. Do not clean electrical components with steam.
AIR CLEANING
Always maintain a lift truck in a clean condition. Do not
A WARNING
Failure to perform these procedures will cause a
allow dirt, dust, lint, or other contaminants to accumulate on
loss of brakes and may cause property damage
the truck. Keep the truck free from leaking oil and grease.
au/or severe or fatal bodily injury.
Wipe up all oil spills.
Keeptbecontmlsandfloorboardcleananddry. Acleantruck
With the brakesreleasedrotate thebrake drum by hand so that
makes it easier to see leaks, loose, missing or damaged parts,
the shoe pivot pins are visible. Let the foot pedal return to its
and will help prevent fires. A clean truck will mn cooler.
full up position. Measure the angle of the brake arm to a
suaightlinethroughthepivotpins.Seesection23-4-02. If the
The environment in which a lift truck operates will determine
angle is more than 12’ the brakes need adjusting. Also inspect
how often and to what extent cleaning is necessary. For
the shoe lining condition. If the lining appears to be less than
example, trucks operating in manufacturing plants which
3/32” further checking by disassembly is needed. Record on
have a high level of dirt or lint (e.g., cotton fibers, paper dust,
the PM report form and, if you are not the maintenance
mechanic, notify the maintenance department. Do not use the Hydraulic Oil Filter
truck until these conditions are corrected. Repeat these checks Remove and replace the hydraulic system fluid filter per
on both left and right-hand side brakes. recommended PM schedule, or as required by truck operating
conditions and usage. Install a new oil filter. Be sure to
Critical Fastener Torque Checks follow the installation instructions printedon thefilter. Check
Fasteners in highly loaded (critical) components can quickly for leaks after installation of the filter. Also, check that the
fail if they loosen. Loose fasteners can cause damage or hydraulic line connections at the filter adapter are tightened
component failure. For safety, it is important that the correct correctly.
torque be maintained on all fasteners of components which Always use genuine CLARK parts.
directly support, handle or control the load, or protect the
operator. Sump Tank Breather Maintenance
Remove the sump tank fill cap/breather and inspect for
excessive contamination and damage. Clean or replace the
Check torque of critical items, including:
fill cap/breather, per recommended PM schedule or as re-
Overhead guard; drive axle mounting; drive and steer wheel
quired by operating conditions.
mounting; counterweight mounting; load backrest exten-
sion; tilt cylinder mounting and yokes; upright mounting &
components. Access to the Drive Axle
The best method to use for reaching the drive axle check
points (oil level/fdlerplug and drain plugs) is dependent upon
LUBRICATION, FLUIDS AND FILTERS
the style of upright, carriage and attachments on your truck.
Hydraulic Sump
One method is to raise the upright carriage to provide easy
Check the hydraulic sump tank fluid level. Correct fluid level
access to the drive axle from the front.
is important forproper hydraulic system operation. Low fluid
level can cause pump damage. Overfilling can cause loss of
RefertoMachineJackingandBlockingsectionforadditional
fluid or lift system malfunction.
information on supporting the upright.
Hydraulic fluid expands as its temperature rises. Therefore,
it is preferable to check the fluid level at operating tempera-
ture, after approximately 30 minutes of truck operation.
Tocheckthefluidlevel,firstparkthetruckonalevelsurface. Block the wheels. Be sure to put blocking under
Put the upright in a vertical position and lower the fork the carriage and upright rails.
carriage fully down. Pull the dipstick out, wipe it with a clean
wiper and reinsert it fully into the dipstick tube. Remove the
dipstick and check the oil level. Keep the oil level above the
A WARNING
AN UPR%HT OR CARRIAGE CAN
LOW mark on the dipstick by adding recommended hydrau- MOVE UNEXPECTEDLY.
lic fluid only, as required. DO NOT OVERFILL. Chain or block the carriage and rails. Failure to
follow this warning can result in serious injury.
Check the condition of the hydraulic fluid for color, clarity,
and contamination. Change (replace) the oil as necessary. Drive Axle Fluid
The drive axle inspection and service plug openings are
Hydraulic Fluid and Filter Change shown by the following illustration.
Drain and replace the hydraulic sump fluid every 2000
operating hours, or sooner, as required. Replace the hydrau-
lic oil filter at every oil change. Replace the sump tank
breather/fill cap every 1000 operating hours.
1. Fill/oil level dipstick plug. Also acts as the breather cap. Upright and Tilt Cylinder Lubrication
2. Drain plug. Clean the fittings and lubricate the tilt cylinder rod end
bushings, front end only.
Check the drive axle fluid level with the truck on a level
surface and oil at operating temperature. Clean the fittings and lubricate the upright trunnion bushings
(one fitting on top of trunnion, each side).
Remove the flmd level inspection plug located in the front
surface of the drive axle center housing. Wipe dipstick clean Lift Chains
and reinstall. Remove dipstick and examine. Oil level should Lubricate the entire length of the rail lift and carriage chains
be between the two marks on the dipstick. If oil level is low, with Clark Chain and Cable Lube.
add enough oil to bring oil level up to full mark on dipstick.
DO NOT OVERFILL. NOTE: Do not lubricate the carriage roller rails.
Add recommended fluid only, as required. Refer to Specifi-
cations for drive axle recommended oil specification.
IMPORTANT
Check the PM interval (operating hours), or the
condition of tbe oil to determine if the drive axle
fluid needs to be changed.
A DANGER
Do not raise truck by lifting under the counter-
weight. Be sure to put blocking under the frame
to keep the truck safe.
SM556 12 - 01 - 1
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Non-Conductive Cover, 12-01-02 BATTERY MAINTENANCE
A! WARNING
BATTERY SERVICE
BATTERY SERVICE MUST BE DONE
BY TRAINED PERSONNEL. BATTERY ’
ACID CAN CAUSE SEVERE BURNS
AND INJURY.
Persons maintaining storage batteries must wear Once the battery is out of the truck,
protective clothing such as face shield, long sleeves a lifting device equipped with an
and gauntlet gloves. insulated spreader bar and safety
hooks can be used to transport
this style of battery.
Battery Cleaning
A DANGER
Hydrogen emissions from charging batter-
ies are flammable. No smoking shall be
allowed in the charging area. Do not
check the electrolyte level with an‘ open
flame. Do not allow open flame, sparks
or electric arcs in the battery charging
area. The easiest and most satisfactory method of clean-
ing a battery is to wash it occasionally with a low
SM556 12 - 01 - 2
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
pressure cold water spray. The top can also be
washed off with a baking soda solution (add a box of
baking soda to a pail of water and stir untildissolved)
and rinsed with clear water. It is wise to have this
solution around a battery room at all times. Be sure
all vent caps are tightly in place during cleaning
operation.
BATTERY MAINTENANCE:
Refer to the battery vendor for their recommended
procedures.
SM55612-01 -3
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 13 SECTION 01 All contactors are controlled by drivers in the oscilla-
tor card to energize at proper time.
ACCELERATORAND
DIRECTIONAL CONTROL The plugging function of oscillatorcard senses change
SYSTEM in direction of motor rotation. Plugging uses reverse
motor torque to smoothly slow down and then re-
verse travel direction of the truck. Thevoltage at TBl
will determine rate of plugging.
CONTENTS NO.
SM556 13 - 01 - 1
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
5. SWITCH CONTACTS DO NOT MAKE OR BREAK 3. Identify and disconnect control handle wire
CURRENT PROPERLY. terminals.
a) Contacts may be worn or welded.
Replace contact module. 4. Loosen clamping screw (items 06.094 & 06.186)
b) Cam may be deformed. and remove lever and ball-joint assembly. Disas-
Replace cam(s). semble lever and ball-joint assembly only if it requires
service.
2. Remove two front covers and top compartment 6. Remove master switch mounting screws (item
cover. 13.448) and remove master switch (item 13.400).
06.1
06.05
30.086 -&
SM556 13-01-2
Copyrighted Material Rev. Jan’96
Intended for CLARK dealers only
Do not sell or distribute
7. Withdraw control handle lever (item 06.101) from 13-01-04 MASTER SWITCH
bellcrank (item 06.143). Do not disassemble control DISASSEMBLY
handle further unless washer and snap ring (items
06.182 & 65.576) or pushbutton switch replacement NOTE
is required. Disassemble only as far as necessary to
replace suspected component.
PushbuttonSwitch Replacement
1. Use a felt pen to scribe a line across the major
To replacea switch, remove allen screws and switch assembly which will serve to help assemble parts in
cover plate in end of control handle. Push switch up correct order. When viewed from square shaft end,
out of control handle with a screwdriver.Cut switch exposed resistors are on RH side of switch along with
wires and solder wires to new switch. Push new contact markings of ‘F’ and ‘2’. Markings ‘R’ and ‘3’
switch down into control handle. Install switch cover are on LH side. Also, RH side has two cam operated
plate and allen screws. switches, and LH side has one plus spacer.
10. Inspect nylon bushings (items 06.053 & 30.151) 3. Grasp assembly across ends to keep assembly
for wear or damage. Replace if required. fromseparating and pulloutward on square shaft and
spring assembly. Shaft will pull out of square bore in
PoTENTIC++ERASSEMBLY cam.
/RESISTOR SiOE
R SIDE)
LEFT
SM556 13 - 01 - 3
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4. Remove thin plastic cover. Note that square 7. Install fasteners and tighten to a torque of
screw hole bosses are on exterior of cover and [1,4-2,7 N-m] 6-12 Ibf in.
match slots in metal outside cover.
8. Install mounting bracket on face of master switch
5. Plastic cam is exposed and can be pulled off and tighten screws.
potentiometer shaft. Use pliers to pull cam off po-
tentiometer. 9. Adjust potentiometer shading disk to intersect
LED. Remove square shaft corner, insert screw
6. Remove three (3) switches from plastic shell driver down square shaft and into potentiometer
housing. Note that switches are Identical and two shaft slot. Viewing from potentiometer end, align
are on RH side. Remove spacer. to potentiometer shading disk (flat side marked top)
vertical to resistor side of housing-This will assure
7. Remove plastic housing from potentiometer that switch travel is equal in each direction. Insert
assembly. square are shaft cover.
1. Install plastic switch housing to potentiometer 2. Install bellcrank to valve link (items 30.085 &
assembly, aligning screw slots. Potentiometer shad- 30.732) with pins (items 30.087 8 30.091), wash-
ing ing disk must be positioned with flat facing to- ers (items 90.797 8 30.644), and clips (items 30.088
wards right side (resistor side). Line must be cen- 8 90.387).
tered inside of LED. Install cam on potentiometer
shaft with long arc pointing towards bottom of plastic 3. Carefully insert control lever (item 06.101) and
cover and square bore of cam square with plastic wires through bellcrank (item 06.143).
switch cover. Do not push cam fully on shaft; stop
about [l mm] or l/32 inch short to prevent shaft Master Switch Installation
from binding on housing.
4. Mount master switch (item 13.400) to bellcrank
2. Install switches in slots in housing. F side (RH with screws (item 13.448).
side) has two switches, R side has spacer and
switch. Switches have three (3) push-on spade 5. Connect master switch wires to proper termi-
connection posts, the middle post being off center. nals. Cover terminals with Clark 3799761 shrink
Position switches so that off center is toward top, tubing.
making center post closer to top terminal post.
6. Set center line to center line length of ball-joint
3. Install thin plastic cover, making sure square assembly to 2 l/4”. Make sure both locknuts, (item
bosses are to outside surface of this cover (these 05.524), are tightened against the ball-joints.
bosses mate into slots on adjoining cover).
7. Install lever and ball-joint assembly. Torque
4. Insert shaft and spring assembly into square bore clamping screw (item 06.186) to 23-31 Ibf-ft [2,5-
in cam. Note that legs of spring are on same side 3,5 Nm]. Hold control lever horizontal and torque
of assembly as external resistors. clamping screw (item 06.094) to 15-20 Ibf-ft [1,6-
2,3 Nm).
5. Install shaft assembly (with springs in place) and
thin plastic cover onto assembly. 8. Connect control handle wires to proper termi-
nals. Cover terminals with Clark 3799761 shrink
6. Put housing in place over spring assembly. Be tubing.
sure that boss on inner surface goes between
spring legs 9. Install top compartment cover and two front
covers.
CONTENTS NO.
13-02-02 MAIN PUMP MOTOR 5. Adjust lift switch (item 13.114)) so that switch
SWITCH ADJUSTMENT roller is.in corner of the detent of the valve spool
link (item 30.085) as shown. Tighten switch
1. Turn key switch OFF. mounting screws. Adjust lower switch (item
13.116) in same manner.
2. Remove two front and top compartment covers.
6. Turn key switch ON and test main pump
3. Make sure control handle is in the neutral switches for correct operation.
position.
7. If the switches are correctly adjusted, but the
pump motor does not start running when the
control handle is moved to the lift or lower position,
a switch or the wiring is defective. Replace the
switch or repair wiring as required.
SM556 13 - 02 - 1
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GROUP 14 SECTION 01
ELECTRICAL SYSTEM AND
COMPONENTS
CONTENTS NO.
..y;
.;..+
,. /
,
SM556 14 - 01 - 1
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13.023
PART OF 13.023
‘.
13.781 FILTER, PRESSURE SOLENOID VALVE COIL 65.918 FILTER, CONTROL SELECTOR RELAY - "Rl"
13.783 FILTER, CONTROL SELECTOR RELAY - "R4" 65.919 FILTER, CONTROL SELECTOR RELAY - "R3"
13.853 FILTER, LIFT/LOWER SOLENOID VALVE COIL 90.641 WASHER, CONTROL SELECTOR RELAY FASTENER
13.973 SPACER, HORN MOUNTING 90.757 WASHER, HORN MOUNTING FASTENER
30.902 COVER, DEVICE SELECTOR VALVE SWITCH 92.558 NUT, UPRIGHT CONTROL LIFT SWITCH FASTENER
33.442 LOCRWASHER, CONTROL SELECTOR RELAY FASTENER 95.082 FASTENER, CONTROL SELECTOR REIAY
33.443 NUT, CONTROL SELECTOR RELAY FASTENER 95.820 NUT, UPRIGHT CONTROL LOWER SWITCH FASTENER
60.095 SWITCH, HORN
60.180 CONTROL, BATTERY DISCBARGE INDICATOR
60.181 FASTENER, BATTERY DISCHARGE INDICATOR CONTROL
SM556 14-01-2
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CONTROL WIRING
14.005 HARNESS, INSTRUMENT PANEL WIRING
SM556 14-01-3
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Al
POWER WIRING
14.039 RECEPTACLE6 CABLE,BATTERY
14.040 RECEPTACLE,BATTERY
14.087 CONDUCTOR,DRIVE XOTOR (RA-2)
14.088 CONDUCTOR,DRIVEMOTOR (RS-2)
14.089 CONDUCTOR,DRIVEMOTOR (RS-1)
14.091 CONDUCTOR,RYD..PUMPMOTOR.(PM-A)
14.347 CONDUCTOR,STERRPUMP MTOR @S-A)
14.348 CONDUCTOR,STRRR PUNT MOTOR (PS-S)
14.509 CONDUCTOR.RYD. PUMP MOTOR (PM-S)
14.522 CONDUCTOR,DRIVEEZDMR @A-l)
14.606 CONDUCTOR,DRIVRMOTOR (U-l)
14.607 CONDUCTOR, DRIVEMOTOR (LA-2)
14.608 CONDUCTQR.DRIVRMOTOR (LS-2)
14.609 CONDUCTOR, DRIVEKtTOR (LS-1)
18.089 STRAP, CABLE
SM556 14-01-4
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GROUP 16 SECTION 01 The presence of any oil on or near motor could
indicate either bad bearings or leaking hydraulic
ELECTRIC MOTOR system. Determine cause and repair problem
GENERAL MAINTENANCE before extensive motor damage occurs.
MOTOR INSULATION
SM556 16 - 01 - 1
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6. Brushes must be replaced when worn to
TEST FOR MOTOR INSULATION approximately half of original length.
RESISTANCE TO GROUND
(USING A VOLT - OHM METER) IMPORTANT
NEW BRUSHES MUST BE OF SAME
Use a Simpson 260-6~ or equivalent VOM, SIZE AND GRADE (MATERIAL
calibrated on the Rx1 0,000 scale. SPECIFICATION) AS REPLACED
BRUSHES.
1. Disconnect battery from truck receptacle.
Observe how- brushes are assembled in brush
2. Disconnect power cables from all motor holders, and position of brush lead (brush shunt).
terminals. New brushes must be installed in same manner.
3. Connect the positive lead of the VOM to all 7. Check brush shunt for good contact with brush
terminal studs of test motor. Use jumper wires to holder. Be sure shunt is not damaged or burned
connect between motor terminals. Connect VOM since this may cause brush spring to carry current
negative lead to motor frame. and lose tension.
NOTE: Test all terminals individually, or 8. If brushes do not need to be replaced, and
joined together, as noted. commutator is in good condition, install brushes
and brush springs into brush holders.
VOM must show l,OOO,OOOohms (1 megohm)
resistance or higher for a good motor insulation. IMPORTANT
ALWAYS REPLACE BOTH BRUSHES
5. If less than 1 megohm is measured, air clean AND SPRINGS. DO NOT REUSE OLD
motor and repeat test of motor resistance. If air SPRINGS.
cleaning does not make an improvement, motor
will have to be removed from truck for closer Be sure brush spring is correctly placed on brush
inspection and repair if needed. holder and that brush is free to slide in brush box.
BRUSH AND COMMUTATOR INSPECTION 9. Clean and check brush box and connector
screws. Tighten if loose. Be sure brush box shunt
1. Remove brush cover(s) and remove brushes connection is tight. Install brush cover on motor
from brush holders. Clean brushes and holders. case.
Check brush holders for damage.
10. Check and tighten all motor bolts. Check
2. Inspect condition of brushes. Remove each lower nut on each terminal post. It should be
brush from brush holder and inspect brushes and installed finger-tight, then tightened another l/4
commutator for worn condition and uneven wear. turn with a wrench.
SM55616-01-2
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GEA-7053
LIGHT TAN FILM over entire commutator MOTTLED SURFACE with random film pot- SLOT BAR-MARKING, o slightly darker HEAVY FILM con appear over entire
surface is one of many normal conditions tern is probably most frequently observed film, appears on bars in a definite panem area of efficient and normal commuta-
often seen on a well-functioning machine. condition ol commutators in industry. related to number of conductors per slot. tor and, if uniform, is quite acceptable.
STREAKING on the commutator surface signals the THREADING of commutator with fine lines results GROOVING is a mechanical condition caused
beginning of serious metal transfer to the corbon when excessive metal transfer occurs. It usually leads by abrasive moteriol in the brush or atmos-
brush. Check the chart below for possible cwses. to resurfacing of comnw+a+or and rapid brush weor. phere. If grooves form, start corrective action.
COPPER DRAG, an abnormal build-up of commutator PITCH BAR-MARKING produces low or burned spots HEAVY SLOT BAR-MARKING can involve
material, forms most ohen at trailing edge of bar. Con- on the commutator surface. The number of these mark- etching of trailing edge of commutator bar. Pat-
dition is rare but con cause flashover if not checked. ings equals half or oil the number of poles on the motor. tern is related to number of conductors per slot.
Carbon Products
General Electric Company
Copyrighted Material
East Stroudsburg,Intended
Pa. 18301
for CLARK dealers only
Do not sell or distribute
4. Identify and disconnect motor leads. Replace the
GROUP 16 SECTION 02
motor terminal nuts to avoid loss.
DRIVE MOTOR
5. Disconnect hydraulic brake line to brake slave
cylinder on drive motor.
CONTENTS NO.
6. Remove motor mounting capscrews and washers
Motor Description 16-02-01 (items 16.001 & 93.363).
Motor Maintenance 16-02-02
Motor Removal 16-02-03 7. Use chain hoist and strap to remove drive motor
Motor Disassembly 16-23-04 from drive axle. Lower motor to floor or dolly.
Motor Inspection 16-23-07
Motor Assembly 16-23-09 n ! WARNING
Motor Installation 16-02-04 USE ONLY APPROVED HOIST,
CHAINS, AND STRAPS TO LIFT DRIVE
MOTOR. Be sure hoist and accessories
have correct capacity to safely support
16-02-01 MOTOR DESCRIPTION th8 load.
The drive motor is a series wound type with Class H 8. Remove and discard O-ring (item 20.275) from
insulation and integral cooling fan. The exterior drive motor flange pilot.
connections are easily accessible from side of motor
wheretheyareprotectedfromextemaldamage. The 9. Remove service brake. Refer to service brake
brushes are accessible and can easily be changed. group for details.
The motor has no armature shaft bearing on the drive
end; armature shaft is supported in drive axle pinion For Driv8 Motor Overhaul information, refer to
pilot. Group 16, Section 23.
n ! WARNING
AN UPRIGHT OR CARRIAGE CAN
MOVE UNEXPECTEDLY.
Chain or block the carriage and rails.
Failure to follow this warning can result in
serious injury.
SM55616-02-I
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16-02-04 DRIVE MOTOR
INSTALLATION
SM556 16 - 02 - 2
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GROUP 16 SECTION 03 n
! WARNING
USE ONLY APPROVED HOIST, CHAINS,
MAIN PUMP MOTOR AND STRAPS TO LIFT PUMP MOTOR. BE
SURE HOIST AND ACCESSORIES HAVE
CORRECT CAPACITY TO SAFELY
CONTENTS NO. SUPPORT THE LOAD
2. Turn key switch OFF and disconnect battery. ,+:yPut-match mark oneach end frame of motor and
extend mark onto body. This will assure exact
3. Remove battery. alignment of frames for assembly of motor.
4. Remove two front and top compartment covers. 2. Remove plastic brush covers.
5. Identify and remove motor leads. Replace motor 3. Remove brushes if they are to be replaced. If
terminal nuts to avoid loss. brushes are not to be replaced, all brushes should
be raised and locked in manner described above.
6. Put lifting strap on pump motor and raise hoist
chain until slack is taken up.
SM556 16 - 03 - 1
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PUMP MOTOR MOUNTING
16.500 lmmRAssn4RLY,RYDRADLxcPDMP
16.704 DAXPRNRR.PDl@ lQT0R VIBRATION
16.706 FAST-, PUHP MOYORMODNTYNG
29.106 FAsTmRR,EYDuDLfCPDxeAssRuBLY
92.591 NUT,PUHPB3?0RIWJNTINGPASlZNRR
SM55616-03- 2
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4. Use an impact tool to loosen mounting screws If a press is not available, it can be removed by
in drive end frame. careful use of a puller.
NOTE
The, ventilation fan is not normally
removed. If it is to be removed, it can be
removed by using heat very carefully to
expand the fan hub and allow it to be
pulled off without damage.
SM556,16-03-3
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2. DRIVE END FRAME. Check for cracks or other The bearing is retained with a snap ring. Remove
damage. Check bearing recess and snap ring internal snap ring from groove in frame at end of
groove for any signs of wear. bearing, then press bearing out of groove.
MOTOR RECONDITIONING
’ SM55616-03- 4
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Be careful not to damage commutator bars. Align match marks on end frame and motor body.
4. Install new bearing on armature shaft by 3. Install drive end frame mounting screws and
pressing inner race of bearing firmly against tighten lightly to temporarily hold assembly.
shoulder on shaft. Tighten alternately to assure good mechanical
alignment.
5. BEARING LUBRICATION. Replacement
bearings are packed with lubricant and need no 4. Put commutator end frame on work bench with
further lubrication. brush ring assembly facing upward.
SM556 16 - 03 - 5
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10. Use same tool set and procedure to tighten 2. Mate main pump to motor and fasten with pump
mounting screws in commutator end frame. mounting capscrews (item 29.106). Torque
capscrews to [65 - 73 Nom] 48 - 54 Ibfeft.
,:Y
,...*.’
16.500 7+&cc:+fl’
a) Inserting brushes in holder with lead wire in * Apply LocktiteTM242 before assembly
same position as when removed and make
sure brush is free in holder.
3. Install pump motor fasteners (items 16.706,
92.598, & 92.591). Torque nuts to (20 - 25
W Connect brush leads to correct terminals. N*m]l77 - 221 Ibf*in. Remove lifting strap.
cl Install new brush spring clip on top of each 4. Connect motor power cables to correct
brush.
terminals.
SM55616-03- 6
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IMPORTANT
GROUP 16 SECTION 04 PERMANENT - MAGNET MOTORS
STEER PUMP MOTOR SHOULD BE DtSAS-SEMBLED
ONLY IN AREA FREE OF
FERROUS METAL CHIPS
CONTENTS NO.
SM55616-04-1
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29
16,200 kfOYoaAssEwBLY,SYEEx
Puw .
16,225 FAsFENEB,szEEBPuHPmu
16.226 DMPEXER, STEEX PUHP mR VIBUYION
16.227 CODPLING,SYEERPDKPDRIVE
16.535 SP~,PDMPkWI'ORHWNITNG
90.891 LocKuAsHER.~PtlmPIou)(TIIw;F~
93.280 ltmumt, STEER Pwm mmu MmmNG NLsrENq
95.784 IuSaER, STEER HMP WTOR VIBUAYIONDAWENER
SM55616-04-2
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If shaft turns freely, go to item 3. 3. If motor turned freely, connect an ammeter in
circuit as shown.
Step 1: You will need a power source equal to If motor meets above conditions, the problem is
name plate voltage (36 volt). Use truck not in the motor.
battery with cable adapter.
=5.
36~
1. Loosen and remove clamping screw in brush
cover band.
SM556 16-04-3
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2. Remove brush cover band segments by prying Remove each brush from brush holder and inspect
cover pins out of engagement in motor housing. brushes and commutator for worn condition and
uneven wear, arcing, etc.
SM55616-04-4
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11. Separate pump from motor by removing pump NOTE: Be sure parts have match marks
fasteners (items 29.269 & 90.891). before disassembly.
IMPORTANT
PERMANENT MAGNET MOTORS
SHOULD BE DISASSEMBLED ONLY IN A
CLEAN AREA FREE OF FERROUS NOTE: It may not be necessary to remove
METAL CHIPS (IRON ORSTEEL). armature, unless. other inspection and
tests show requirement for repair or
1. Remove brush cover band. servicing of stator assembly, armature or
bearings. If armature removal is required,
2. Remove brushes and brush springs. refer to procedure listed below.
IMPORTANT
ARMATURE REMOVAL - RECOMMENDED
If brushes are left installed, raise all
brushes to locked position. PROCEDURE
SM556 16 - 04 - 5
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1. Reassemble either commutator end cover or
drive end cover to armature shaft and stator (C) Stator. Check magnets to be sure they are
housing. securely mounted.
2. Support and hold stator housing firmly on end (D) Inspect wire harness and all connections
cover. A helper will be required. on brush ring assembly for signs of damage
due to overheating.
3. Pull armature out of assembly in one quick
motion. (E) Brushes. Remove any carbon dust or dirt
from brush ring assembly. Check brushes for
wear and to make sure they are free in brush
NOTE: holders.
IT IS IMPORTANT THAT PULLING
MOTION ON THE ARMATURE BE
CONTINUOUS. DO NOT PULL
PART WAY OUT AND RELEASE. ARMATURE AND BEARING REPAIR
If pulling motion is not continuous, the magnets will 1. Check commutator condition for carbon build-
pull armature back into stator and cause severe up in undercuts between bars and excessive wear
damage. and runout, prior to reassembly. If necessary,
commutator should be turned and re-undercut.
4. Remove end cover from stator housing.
. 2. Remove bearings with a standard ball bearing
puller. Use extreme care not to damage armature
with bearing puller.
NOTE: Do not reuse bearings which have
been removed from armature shaft.
SM55616-04-6
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3. Take a complete armature assembly, with
BEARING LUBRICATION bearings installed, and insert comutator end
bearing into bearing bore of cover.
Replacement bearings are packed with lubricant
during manufacture and require no further
lubrication during life of bearing.
CAUTION
Care must be exercised at this point.
There is a strong magnetic attraction
between stator assembly and armature.
This magnetic attraction tends to pull
stator assembly rapidly downward. It is
important to have a firm grasp on stator
assembly and be sure fingers are free from
space between stator assembly and
commutator cover.
SM556 16-04-7
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10. Install pump drive coupling segment.
c
If leads are touching, a generator action will give
effect of friction in motor.
2. Fautty armature.
SM55616-04-8
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@A!3270
SM556 16-04-g
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Cl!!mK GROUP
16
GROUP
16
SECTION
23
Copyrighted Material
Intended for CLARK dealers only
Code: OH-540, MAR 86 Do not sell or distribute GROUP 16, Section 23, Page 1
GROUP ECSRK
16
16.034
I
ASSEMBLY
COYRLYE
I-
16.000
NON YEvKEAME
IYEMS MABKED ‘k”
r16.017
Copyrighted Material
GROUP 16, Section 23, Page 2 Intended for CLARK dealers only Code: OH-540, MAR 86
Do not sell or distribute
GROUP
Cl!mK
16
/ -’ ..
‘\,
.’ BRUSH REMOVAL AND INSPECTION
85M717
85M718
6 Inspect the condition,of the brushes.
Remove each brush from the brush holder
and inspect brushes and commutator for
worn condition and uneven wear, arcing,
burning, overheating, etc. Refer to
GROUP 16, Section 27, for more infor-
mation on motor maintenance and brush
inspection.
Copyrighted Material
Intended for CLARK dealers only
Code: OH-540, MAR 86 GROUP 16, Section 23, Page 3
Do not sell or distribute
GROUP
16
MOTORDISASSEMBLY
26621
IMPORTANT- If brushes
__ _ are left in-
stalled, raise all of the brushes to
the locked pos ition (Figure 26568).
26568
:
Copyrighted Material
GROUP 16, Section 23, Page 4 Intended for CLARK dealers only Code: OH-540, MAR 86
Do not sell or distribute
GROUP
CMRK
16
86M013
86M014
Copyrighted Material
Intended for CLARK dealers only
Code: OH-540, MAR 86 Do not sell or distribute GROUP 16, Section 23, Page 5
GROUP
16
_,_ .“’ ‘.
86M016
26612
26614
11 When the fan is reassembled on the shaft, make sure it is a tight fit.
Use "Loctite Retaining Compound 40" or equivalent on the inside of the
fan hub when reassembling fan.
Copyrighted Material
Intended for CLARK dealers only
GROUP 16, Section 23, Page 6 Code: OH-540. MAR 86
Do not sell or distribute
CLflRls GROUP
i(
16
COMPONENT
CLEANINGAND INSPECTION
After the motor has been disassembled, the components should be cleaned and
inspected for wear and damage.
Thoroughly clean all components, except bearings and armature, with a good
grade petroleum-base cleaning solvent and dry with compressed air. The
armature should be blown off with compressed air to remove the brush dust
and dirt from around the commutator and windings. Bearings should be wiped
clean with a cloth. After cleaning and drying, inspect the components for
problem areas that will require reconditioning:
,_". Brush Spring Tension (force per brush) NEW: [935-1077 g] 33-38 oz
-_
i WORN: [453 g] 16 oz
_..
Copyrighted Material
Code: OH-540, MAR 86 Intended for CLARK dealers only
GROUP 16, Section 23, Page 7
Do not sell or distribute
GROUP
* 16
MOTORRECONDITIONING
26615
Bearing Replacement
2661‘6
Bearing Lubrication
Replacement bearings are packed with lubri-
cant and require no further lubrication.
26617
Seal Replacement
26614
Copyrighted Material
GROUP 16, Section 23, Page 8 Intended for CLARK dealers only Code: OH-540, MAR 86
Do not sell or distribute
CLSRK GROUP
16
MOTOR REASSEMBLY
26613
26620
;j
86M016
Copyrighted Material
Code: OH-540, MAR 86
Intended for CLARK dealers only
GROUP 16, Section 23, Page 9
Do not sell or distribute
GROUP CL~WKI
16
86M013
26643
85M717 ..
_.
Copyrighted Material
GROUP 16, Section 23, Page 10 Intended for CLARK dealers only Code: OH-540, MAR 86
Do not sell or distribute
GRiilJP 17 SECTION 01
DRIVE MOTOR CUT-OUT
SWITCH CHECK AND
ADJUSTMENT
CONTENTS NO.
Ll! CAUTION
A!!
;
J.
._.:r
.
;
I
.._.r
Park truck on a solid, level surface. Be sure that truck is parked and blocked up
correctly to raise the drive and steer wheels off the
Lower forks to floor. floor. See CAUTION under 17-01-01 procedure.
Turn steering tiller so that steer wheels are in a 1. Turn key switch ON.
straight ahead travel position..
2. Turn tiller arm so that steer wheels are in a
Turn key switch OFF. straight ahead travel position. Note position of cut-
out cam (item 25.443). .
Jack and block the truck up to raise the steer and
drive wheels off the floor. Refer to Machine 3. Identify RH & LH cut-out switches (item 13.682)
Jacking and Blocking Group for details. by wires.
1. Remove two front and top compartment covers. RH Switch: Wire #51 (brown w/ green stripe)
3. Rotate control handle slowly to forward travel 4. Slowly turn tiller arm for a RH turn until cam
position. Both drive wheels will begin turning. rotates 41.5” from center position. Loosen
fasteners (item 13.683) for right hand switch and
4. Slowly turn the tiller arm to make a right turn. adjust switch position on mounting plate (item
The right drive wheel should stop turning when 13.684) until switch just closes, Repeat
., ,,I
6. If the respective drive motor does not cut-out 7. If, after adjustment, drive motors do not cut-out
correctly or the drive wheel stops turning at an properly, check switch continuity with a Volt - Ohm
steering axle trunnion angle other than that Meter. Replace switches as required and re-adjust.
specified, the cut-out switches require adjustment
or replacement. 8. Lower truck to floor.
SM556 17 - 01 -1
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GROUP 19 SECTION 01 The control circuit is energized by closing key
switch and foot brake switches and moving control
CONTROL PANEL handle to desired forward or reverse position.
Rotating control handle closes thelMS switch;
further rotation gives desired speed. This applies
CONTENTS NO. power to control card, which will close selected
directional contactor and complete circuits to drive
CONTROL PANEL DESCRIPTION 19-01-01 motor.
CONTROL PANEL MAINTENANCE 19-01-02
CONTROL TROUBLE-SHOOTING 19-01-03 The control card then supplies a gate pulse to #2
CONTROL PANEL REMOVAL 19-01-04 REC, turning it on to a conducting state. This
CONTACTOR INSPECTION 19-01-05 allows current to flow from battery through lC, 1X,
CONTROL PANEL INSTALLATION 19-01-06 ##2REC, motor field, motor armature, sensor, and
back to battery.
The EVlOOM CONTROL is an electronic device The control card then supplies a gate pulse to #l
that controls electrical power supplied to the REC, turning it on to a conducting state. This
vehicle drive motor to provide smooth power to allows current to flow from battery through #1
move the truck and to minimize power drain from REC, motor field, motor armature, sensor, and
battery. back to battery.
The control consists of a SCR unit and a contactor #5 REC turns on and allows current to flow
assembly unit. The SCR unit monitors power through T4-T3,1C, #l REC, #5 REC and to T4-T3.
demand of the truck and then responds by
controlling the power applied .to drive This current charges bottom of 1C positive with
components. The contactor panel contains respect to battery positive bus.’ This charging
switching devices to direct heavy power loads to cycle occurs in less than one millisecond [O.OOl
the drive motor and its components. second] and #5 REC shuts off. This charge is now
stored on capacitor until it is’time to turn off #l
REC. ’
SM556 19 - 01 - 1
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Current continues to flow in #l REC until control
card fires #2 REC. When #2 REC conducts, FIG. 2. Motor current illustration. The dotted line
capacitor 1C discharges around circuit composed shows average motor current.
of lC, #2 REC, 1X, and #l REC.
FIG. 2 shows nature of motor current which is
This discharge current opposes battery current composed of both battery current and inductive (or
through #l REC so that resultant current is zero. flyback) current.
Due to lack of holding current, #l REC is turned
off. It should be noted that measured average motor
current will be greater than average battery current.
Current continues to flow in #I2 REC, lC, motor
and battery loop until capacitor (card terminal 14) is The SCR control converts battery current at battery
fully charged negative. volts into a higher motor current but at a lower
motor voltage.
This charge exceeds battery voltage by an amount
which is a function of peak motor current, and #2 The time for next ON / OFF cycle to start is
REC turns off. determined by time that control card takes to
oscillate. This frequency of oscillation is controlled
FIG. 1 illustrates pulsing current from battery. by position of variable inductor in accelerator and
oscillator control circuitry in card.
PEAK
CURRENT Siow speed is obtained by having maximum input
volts from accelerator. As input volts decrease,
speed of motor increases. The SCR circuit is
capable of delivering approximately 95% of
AVERAGE maximum speed. For full speed operation, 1A
CURRENT contactor is closed to apply full battery voltage
across motor.
CONTROL FEATURES
e
s
ON
oNOi=F~ OFF
TIME
SM556 19 - 01 - 2
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
If the truck is moving and the directional lever is
300 moved from that direction selection to opposite
direction selection, the motor field is reversed.
250
200 The plug signal is initiated by the fact that the
directional switch has been shifted from one
150 direction to the opposite direction.
100
The motor armature, driven by the inertia of
50 vehicle, acts as a generator. This generated
1
current passes through the #4 REC and the
Ics
5 50
SCR RANGE TS
sensor. The oscillator circuit regulates at a plug
current limit level as set by the PLUG trimpot on
control card.
% ON TIME
This controls pulse rate of the #l REC to regulate
generated motor current and bring the truck to a
FIG. 3. Oscillator frequency curve.
smooth controlled stop and then reversal.
At CREEP, ON-TIME will decrease to
The accelerator input witI modulate plugging
approximately 0.8 milliseconds while OFF-TIME will
current. With the accelerator at maximum
rise to about 20 milliseconds. At full SCR
depression, the plugging trimpot will enable
operation; this condition will be reversed -(short
adjustment of plugging current limit from maximum
OFF-TIME and long ON-TIME).
to minimum current limit level. With the accelerator
at minimum depression, plugging current limit will
This variation of ON/OFF TIME of oscillator
be reduced to minimum.
produces optimum frequencies through SCR
range. The frequency curve of oscillator is shown
RAMP START. This feature provides full SCR
in Fig. 3.
torque to restart a vehicle on an incline. The
The rate at which oscillator may increase its percent memory for this function is the directional control
switch. When stopping on an incline, the
ON-TIME is limited by. “CONTROLLED
directional. switch must be left in its ORIGINAL a
ACCELERATION”. The minimum time required to
position to allow the control to assure full power
go from creep speed to 80-85 % ON-TIME point
may be varfed by trimpot (C / A) on card. This is when restarted. The accelerator will modulate
adjustable from approximately 0.5 seconds to 3.5 ramp start current.
4.5 seconds.
FULL POWER TRANSITION. This built-in feature
CURRENT LIMIT. This circuit monitors motor provides smooth transition from SCR to 1A
current by utilizing a sensor in series with armature. bypass. This is accomplished by the SCR
The information detected across sensor is fed continuing to pulse until 1A contactor power tips
back to card so current may be limited to a preset close.
value.
1A CONTROL. The contactor has two modes
If heavy load currents are detected, this circuit of control:
over-rides oscillator and limits average current to ‘a
value set by C / L adjustment pot. The C/L setting 1). TIMED PICKUP. This feature works with
is based on maximum thermal rating of #l REC and the accelerator. When the accelerator is
peak voltage on capacitor. activated so that the accelerator voltage is
reduced to 0.4 volts or less, then 1A time
Because of flyback current through #I3 REC, motor is enabled. The time delay pickup of 1A
current usually runs 2 to 3 times that of battery is provided by a circuit in card. This allows
current. The current limit is set with C / L trimpot on the truck to accelerate through SCR
card. range until 1A picks up, even if the
accelerator is actuated immediately.
PLUGGING, or slowing down of the truck is
accomplished when reversing by providing a small This time delay is adjustable by means of a
amount of retarding torque for deceleration. !A TIME trimpot on card.
SM558 19 - 01 - 3
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
2). If motor current is reduced during thermal
cutback to a point where 1A pickup would For these reasons, normal maintenance should
cause a severe torque increase, 1A timed guard against any action which will expose
pickup function will be disabled. components to excessive heat, (such as steam
cleaning).
STATIC RETURN TO OFF. This built-in feature of
control requires the operator to return directional The following DO’S and DONT’S should be
selection lever to neutral position whenever he observed:
leaves truck and then returns.
Any controls that will be used in ambients of
If brake switch or key switch is opened, the control [SO” C] 120” F or over should be brought to
will shut off and cannot be restarted until the attention of Clark Material Systems
directional lever is. returned to neutral position. A Technology Co.
time delay of 1.0 sec. is built into the control for
allowing momentary opening of brake switch, if a All external components having inductive
bump is encountered. coils must be filtered
THERMAL PROTECTOR (TP). This temperature The control should not be steam cleaned. In
sensitive device is mounted on 1 REC. lf the 1REC dusty areas, use low-pressure air to blow off
temperature begins to exceed design limits, the control. In oily or greasy areas, a mild solution
thermal protector will lower maximum current limit of detergent or denatured alcohol can be
and not allow the 1REC to exceed its temperature used to wash off control. Then use low
limits;. . . - ,_ pressure air to blow unit completely dry. The
control can also be cleaned with a Freon TF
Even at reduced current limit, the truck will normally degreaser.
be able to reach sufficient speed for full ,1A
operation, thereby allowing panel to cool. Terminal boards and other exposed SCR
control parts should be kept free from dirt and
As the panel cools, the thermal protector will paint that might change effective resistance
automatically return the control to full power status. between points.
SM556 19-01-4
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
19-01-03 CONTROL PANEL
TROUBLESHOOTING l * DIRECTIONAL CIRCUITS which
control forward and reverse contactors.
When diagnosing and correcting cause of trouble
with a SCR control, do not begin by l * ACCESSORY CIRCUITS which
disassembling components. control components, including horn,
battery indicator and hourmeter.
Start by analyzing complaint of symptoms. Make a
preliminary investigation of trouble. Then
systematically determine probable cause. ALL TESTING SHOULD BE
DONE WITH DRIVE WHEELS
The following points are fundamental to trouble- RAISED OFF THE FLOOR.
shooting a SCR system.
SM556 19 - 01 - 5
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
NOTE: A digital VOM (such as Simpson
Digital Multi-meter Model 461, or
equivalent) is recommended for all electrical
and control testing.
WARNING
ELECTRICAL SHOCK
DISCONNECT THE BATTERY AND
DISCHARGE THE CAPACITOR(S)
BEFORE HANDLING THE CONTROL
PANEL
SM556 19 - 01 - 6
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
CON TACTOR PANEL 19608-l
17.000 PANELhSSPIBLY,CONTAeraR
17.007 lAcoNTACTQRASSEmLY
17.015 TomcARm6~'REvmSE CourAmoRASspIBLY
17.023 P(A(pCmTACToRAsSEplBLY
17.033 PQWERSTEERINGCO2?TACmRASSE!BLY
SM556 19-01-7
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
17.021 J T L 19.576
CONTACTOR PANEL
SM556 19-01-8
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
90.323
93.810
ASSEMILY COMPLETE
17.750 SCR PANEL ASSEMBLY 90.197 LOCKWASHER. TERMINAL BLOCK CONDUCTOR FASTENER
14.056 FASTENER, TERMINAL BLOCK CONDUCTOR 90.198 WASHER. TERMINAL BLOCK CONDUCTOR FASTENER
15.129 CONDUCTOR, 65 RECTIFIER 90.323 LOCKWASHER, SCR PANEL TRANSFORMER FASTENER
17.057 FASTENER, CONTROL PANEL CONDUCTOR TERMINAL . ..91.089 LOCKWASHER.,CONTRGL PANEL CONDUCTOR FASTENER
.- -_.
17.751 TRANSFORMER, SCR PANEL 91.091 WASHER, CONTROL PANEL CONDUCTOR FASTENER
17.753 FASTENER, SCR PANEL TRANSFORMER 91.132 WASHER, SCR PANEL TRANSFORMER TERMINAL FASTENER
17.756 FASTENER, SCR PANEL TRANSFORMER TERMINAL 91.604 LOCKWASHER, SCR PANEL TRANSFORMER TERMINAL FAST
17.757 #4 REC. SCR PANEL 92.768 WASHER, SCR CONTROL PANEL MOUNTING HEAT SINK FAS
17.759 13 REC. SCR PANEL 92.769 LOCKWASHER. SCR PANEL MOUNTING HEAT SINK FAST
17.775 #2 REC. SCR PANEL 93.195 FASTENER, SCR PANEL 14 REC HEAT SINK
17.780 t5 REC. SCR PANEL 93.196 WASHER, SCR PANEL #4 REC HEAT SINK FASTENER
17.850 SHUNT, CURRENT LIMITING 93.205 WASHER, CURRENT LIMITING SHUNT FASTENER
65.280 HEAT SINK, SCR PANEL #4 REC 93.346 FASTENER, HEAT SINK
65.283 CONDUCTOR, SCR CONTROL PANEL 93.352 LOCKWASHER, CURRENT LIMITING SHUNT FASTENER
65.284 CONDUCTOR, SCR PANEL 93.587 WASHER, CURRENT LIMITING SHUNT FASTENER
65.285 CONDUCTOR, SCR PANEL 93.810 WASHER, SCR CONTROL PANEL TRANSFORMER FASTENER
65.309 FASTENER. SCR PANEL REC 94.197 LOCKWASHER. CONTROL PANEL REC HEAT SINK FASTENER
65.310 LOCKWASHER, SCR PANEL MAIN POWER VALVE SW FAST 94.225 FASTENER, CURRENT LIMITING SHUNT
65.366 INSULATOR. SCR PANEL 14 REC HEAT SINK 94.759 LOCKWASHER, CURRENT LIMITING SHUNT FASTENER
65.537 INSULATOR, SCR PANEL #4 REC HEAT SINK FASTENER 94.760 FASTENER, CURRENT LIMITING SHUNT
65.544 HEAT SINK, SCR PANEL VOLTAGE SENSOR
SM556 19 - 01 - 9
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
COLOR CODE
@-BLUE
-WHITE
:-GREEN
@-BROWN
764
V -VIOLET
FNK
@-GRAY
o- SIRICED
u\ 17.763
\-f&347
; PANEL 19464-l
17.750 scR PANEL ASSEMBLY (CONTINUED) 65.542 INSULATOR, SCR PANEL REC
14.054 BLOCK, TERMINAL 65.623 FILTER, PUMP SCR PANEL 63 REC
17.763 CAPACITOR, SCR PANEL COMMUTATING 65.630 FILTER. PUMP SCR PANEL t5 REC
17.764 BRACKET, SCR PANEL COMMUTATING CAPACITOR MOUNTING 65.631 .FILTER,..PUMP..SCR
PANEL 62 REC
17.765 FASTENER, COMMUTATING CAPACITOR MOUNTING BRACKET 90.195 LOCKWASHER, TERMINAL BLOCK FASTENER
65.062 SCREW, MAIN POWER VALVE THERMAL CUT-OUT 93.156 LOCKWASHER, OSCILLATOR SPEED CONTROL UNIT FAST
65.063 LOCKWASHER, MAIN POWER VALVE THERMAL CUT-OUT FAST 93.661 FASTENER, TERMINAL BLOCK
65.197 FASTENER, SCR PANEL I1 REC 93.870 WASHER, SCR PANEL TERMINAL BLOCK FASTENER
65.198 LOCKWASHER, SCR PANEL 11 REC FASTENER 94.476 FASTENER, SCR PANEL FILTER
65.311 WASHER, SCR PANEL I:1REC FASTENER 94.514 LOCKWASHER, SCR PANEL FILTER FASTENER
SM556 19-01-10
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
17,007 CONTAmoR ASSPIBLY. IA
17.101 COIL. 1A coNTAcToR
l?.lOS SPRING, 1A CONTACTOR ARMATURE RETURN
17,106 SEAT. 1A CONTACTOR ARUAlURz RzTtm SPRING
17.112 COUUCTOR SET, 1A CONTACTOR
17.97s
65.237
17.977
17.979
65.23% 19.L9L
19,516
65.237
65.238
91.us
91.546
17.112
19.516
SM556 19 - 01 - 11
1A CONTACTOR 19606-1
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
17.023 CONTAcToR AsSImLY. PUKP
17.161 COIL. Puwp CONTACTOR
17.165 SPRING, PUMP CONTACTORCONTACT RETURN
17.169 CONTACT SET. PVW CONTACTOR
17.172 SPRING. Pum CONTACTOR MOVABLE CONTACT
19.637
9.&*
- 17.534
SM556 19-01-12
PUMP CSMACTOR 19607-l
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
17.033 CONTACTOR ASSEMBLY, POWER STEERING
17.240 I
-17.243
8 (
-& i_
17’240 lg.899
19168-l
SM556 19-01 - 13
POWER STEERING PUMP CONTACTOR
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
19.600 CONTACTORASSENSLY.
PLUGGING
19.602
r -19.615 lg.600
1
SM556 19-01-14
PLUGGING CONTACTOR w67-’
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
17.015 CONTACTOR ASSEMBLY, FORWARD 8 REVERSE
NON SERVICEARLE
ITEMS MARKED 'h"
lg.496
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
19-01-05 CONTACTOR 8. Check armature and movable contact set for
INSPECTION free movement.
Do not use sandpaper or file tips. Any damage Loosen and remove four cover mounting screws
must be corrected by tip replacement. from coil frame.
Tips must be replaced before they wear through Remove cover. Be sure to note small return spring
and damage copper base. mounted under cover.
To remove and replace contact tips, use following Remove lock nut and washer from each contact
procedure: stud. Remove the fixed contact studs from top
cover.
1. Loosen and remove retaining lock nut,
lockwasher flat washer, spring seat,and spring Put new contact studs into top cover. Install
from armature bolt of center movable contact fasteners and tighten lock nut firmly on each stud.
tip set.
To replace moving contacts, lift moving contact
2.’ Remove movable contact tip set. assembly off body. Be careful to observe return
spring and washer locations on both sides of the
3. Loosen four long bolts holding fixed contact moving contact assemblies.
and insulators to assembly. Observe position
of short and long contact tip bus bar terminals. Hold stem of moving contact stud and remove lock
nut, lockwasher, return spring, insulator retaining
4. Remove bolts, lockwashers, insulators and washer and moving contact assembly.
two contact tips.
NOTE: Use care not to lose any of small
5. Install new contact tips by reversing above parts from assembly.
procedure. Check for correct positioning of
long and short fixed contact bus bars. Put new moving contact set on armature shaft and
install insulator retaining washer, return spring
6. Tighten four long bolts of fixed contact set’ Q.-(insulator-washer, lockwasher and locknut. Tighten
gradually and by even torque increments until locknut firmly.
firmly seated. (Tighten each fastener in a
sequential manner and use torque Remove lower fixed contacts from insulator cover %
increments to avoid overstressing and on coil. Replace with new contact tip assembly.
damaging insulator bars. DO NOT OVER Observe position of long and short contact tip bus
TORQUE! bars and connecting terminals.
7. Tighten armature and movable contact Assemble contactor by putting moving contact
assembly retaining nut. Tighten firmly but assembly armature shaft into coil plunger with
DO NOT OVERTORQUE. return spring on top of armature shaft.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Put top cover over spring and install cover
mounting screws. OSCILLATOR CARD REMOVAL
NOTICE
When assembling top covers to bases,
make sure they are installed with positive
sign (+) markings facing inward, i.e., FARA
(+) towards FB/RB (+), and that contact tip
bus bars are placed correctly.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Connect fourteen-conductor plug to top RH side
of card.
SM556 19-01 - 18
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
ESM 12-25
GROUP 19
EV-1 OOM
SEQUENCE OF OPERATiON
AND
TROUBLESHOOTING
Sh4656 19-02-01
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 1
DRIVE CONTROL
Drive control.
Power
Directional
SM556 19-02-02
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
.4& Gi
I
sM556 19-02-03
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 2
DRIVE CONTROL
Connect the battery.
C. The horn is operated by pushing the horn button which will supply
battery voltage to the horn through wire #25, and to negative
through wire #13.
Voltages Present:
A. Battery positive
8. Battery negative
C. Battery positive (wire.#25)
SM556 19-02-04
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
i
ri
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONS SEQUENCE 3
DRIVE CONTROL
Key Switch
E. The key switch relay coil closes the relay contacts, suppling battery
positive to the hydraulic function switchs through the #3 FU fuse and
wire #32.
Voltages present:
34556 19-02-06
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
--_-.,,- ___---
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 4
DRIVE CONTROL
After the key switch has been turned on, and with the brake switch still released,
A. Moving the directional switch to forward will close the forward switch.
B. Closure of the forward switch signals the oscillator card to supply a voltage
through terminal PA1 to the power steering contactor coil Negitive.
C. The power steering contactor coil is now energized, closing the power
steering contact tips.
D. The power steering motor now operates because current flows from
5 battery posit@ethrough 1FU, to the steer motor and to battery
negative. (Note permanent magnet motor).
3. This is done by the card sending voltage from terminal TB-2 to the
directional switch and sensing when the voltage returns to terminal
TB-5 (forward) or to terminal TB-6 (reverse).
4. The card also monitors the accelerator output voltage at terminal TBl .
The card will not allow the directfonai contactors to close if the
accelerator output voltage is below 2.5 volts.
NOTE: The hour meter operates when either the power steering contactor
is closed (which only operates when in either forward or reverse)
or by the hydraulic control circuit.
St4556 19-02-08
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
i
E
:
:
:
:
I
:
:
I
7,
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 5
DRIVE CONTROL
A. The brake pedal (FBS) must be depressed to close the brake switch points.
The brake switch is provided to prevent operating the motor with the brakes
applied, since this wastes energy and may overheat components.
B. Rotating the directional lever forward slightly will close the forward directional
switch.
C. With all switches in the forward directional control circuits closed, battery posi-
.* tive will be applied to terminals .TB-2 and TB-5 of the card. This voltage,
coupled with the voltage from the key switch on terminals TB-3 and TB-4
causes the card to complete the circuit from terminals PB-1 and PB-2 to the
forward contactor coils’ negative.
E. If #l REC is shorted, or the 1A tips are stuck closed, the blue wire to the card
plug pin 9 will be greater than 85% battery volts and the card will hold the
contacts open. (See note).
F. If the #/3 Ret or the #23 Ret is shorted, the blue wire to the card plug pin 9 will
be less than 25% battery volts and the card will hold the contactots open.
G. If the accelerator output voltage at terminal TBl , wire #29, is below 2.5 volts be-
fore directional switch is closed, the card will hold the contactors open.
Voltages present:
A. Battery volts.
B. Battery volts.
C. Battery volts on terminals TB-2 and TB-5.
D. 1O-l 3 volts acrosseach of the F coils.
G. Approximately 3.5 volts
.%I556 19-02-10
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BA-llERY
~111-111111-11111--- ~~~~T~__________________~
I POWER STEER MOTOR
7, ............ ... ........ ......... .. .. ........ .. ... ....... ...... .. .. ... . ..... ...... ...
i
:
i
I
i2
I
---I
RI-1ODM
OSCCARO CONNECTOR
rn
I--I
ACCELERATOR
“e PS3
* P84 ‘$f
* PS5 %
.. .,
A 13
Y KEYRS&;CH l3
%I!556 19-02-11
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SAllERY
1 RBHTFIELD) i R
-- CAROZ
-..NECTOR
I\
El
OPERATION SEQUENCE 6
DRIVE CONTROL
A. The coils’ magnetic fields pull the N. 0. power contacts closed, and
open the N. C. power contacts.
B. The card turns on the #2 REC by applying voltage to the white/red gate
lead. The #2 REC red lead provides gate lead filtering and is gate
current return path.
C. Positive potential on the ##2REC anode side of the capacitor now conducts
to negative as shown by the arrows. This leaves the capacitor 1C charged
to battery volts.
D. The card monitors the capacitor precharge. If card plug 14 (orange wire)
does not drop to battery negative, the card will not turn on #I REC. This
would occur if the capacitor were open or shorted, or if #I2 REC will not
gate on or is open.
Voltages present:
SM!556 19-02-12
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BAl-fERY
3
FU
OPERATION SEQUENCE 7
DRIVE CONTROL
A. A signal from the accelerator module starts the time delay which controls
the oscillator in the card.
_,: (. ,.
B. The card applies a gate voltage to the #l REC through the white/blue
wire and the REC turns ON.
C. The interaction of magnetic energy between the motor fields and arma-
ture causes the motor armature to rotate.
D. The card now applies a gate voltage to the #5 REC through the
white/voilet wire and the REC turns ON.
SM656 19-02-13
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BAllERY
l----l-
2 2
I
5
flFU
s
I __
23REC
. .
22 12 ~
i 13
I2 i 13
13
4%
KEY
RELAYi
r’ I
* .lO
a
c
OPERATION SEQUENCE 8
DRIVE CONTROL
A. In preparation for turning OFF the #l REC and #5 REC, the card removes
the gate voltages.
B. Current continues to flow from T2 (+) to the capacitor through #5 REC and
T4-T3 reactor until both sides of capacitor are equal to battery positive.
C. Battery potential on both sides of the capacitor stops current flow. This
causes the reactor field to collapse, which results in an increased voltage
at T3.
D. This higher than battery positive voltage is stored into the capacitor, making
the battery (+) side appear to be (-) as compared to the T3 voltage.
StvI6!56
19-02-14
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BAllERY
CONNECTOR
OPERATION SEQUENCE 9
DRIVE CONTROL
E. Current from the capacitor continues to flow through the choke and
the #2 REC to battery negative until the capacitor reaches a potential
of battery volts. The choke works to limit the surge of current through
the ##2REC to a safe value.
Voltage Sequence:
Sbt556 19-02-15
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 10
DRIVE CONTROL
Flyback:
A. Current stops flowing through the #2 REC circuit when the capacitor
has reached battery voltage.
B. Because the battery no longer has a circuit through the motor, battery
current stops and the magnetic energy of the drive motor field is allowed
to collapse.
C. This collapsing magnetic field induces a voltage across the fields that is
opposite battery voltage.
- D. This voltage forces current through the armature and sensor and the #3
REC. This current (called “flyback” current) continues to drive the armature
during the #l REC OFF time.
Voltage Sequence:
.%I556 19-02-16
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BATTERY
A
3
Fu
DRIVE MOTOR
22 12
i3
OSC CARD
CONNEdTOR II
T4
4,
6.
OSCCARD CONNECTOR
._
I --.-..-._.........__ ~._:
10 +-aTB4 i
.....
...” . . . . . . . . . . . . . . . “.. ,........ . . . . . “.” . . . . . . . . . . . . . . . . . . . ..-_. . . . . . ““... . . . . __ . . . . . I..* JB3
t
LET;,UJ$FF
L1o-----%~SWITCH l3
RELAY
SM556 19-02-17
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 11
DRIVE CONTROL
Turning the #l REC ON and OFF produces a switching technique that controls
the power and speed of the truck. More (or longer) pulses produce more power.
D. The blue wire to the card plug ##9allows the card to sense pulsing. If the
#l REC fails to turn off, the card takes voltage away from PBl , PB2 or
PB3, PB4 so the directional coils de-energize, dropping out the contact tips.
E. The card will quickly re-close the contacts in a “look again” mode and drop out
the contacts if the problems still exist. Turn OFF the key to reset the PMT.
(See note).
Voltage present:
A. 3.5 to 4.0 volts at creep speed. 0.2 volts or less at top speed.
B. Less than 0.5 volts across TP is no cutback; greater than 3.4 volts across TP
is severe cutback.
NOTE: If PMT (pulse monitor trip) is tripped, power steer motor willcontinue to
to run regardless of directional lever position.
SM!556 19-02-18
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BAll-ERY
3 2 In
Fu FU
Q
12
12
iK
!zY
BAY
T T4
i
12 10
1x
1
RI-1OOM 0% CARD’
OSCCARO CONNECTOR
12
10-----_96~--28 52 -....&.\13 -
10 p1 34 51 . ..LL13 -
>v 1A
RIGM&JJi$FF
. .._ (_. ., x._ ,_ .i .. .- .-_
LlO rt
kYgz:cH l3 13
St4556 19-02-19
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 12
DRIVE CONTROL
1A Contactor Operation
Rotating the multi-function handle will gradually reduce the voltage output from the
accelerator control module which allows more frequent pulsing of the control
resulting in smooth speed and power control up to 85 to 90 percent of available
motor voltage.
B. After a short time delay, the card completes the circuit from PB5 through wire
#34, to the 1A contactor coil negative. This energizes the 1A coil.
C. The IA contactor power points close completing the control bypass circuit.
D. The card also monitors motor voltage and current flow through the sensor and
will energize the 1A coil, closing the 1A contacts anytime motor voltage is at 85
to 90 percent battery voltage (this is called a demand pickup).
E. The card has a built in thermal 1A hold-off. 1A will not dose if the control is in
severe thermal cut-back
Voltages present:
A. When accelerator voltage drops to 0.4 volts or less, the 1A timer will be
activated.
NOTE: Closure of either turn cut-off switch, disables the 1A contactor operation.
SM656 19-02-20
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BATTERY
FL Sl
3
FU
EV-1OOM
OSC CARD CONNECTOR
10
i
10 *la4
6 ...........................“‘7 ....... ... ..‘ .. ..... .......... ...........-...... 7 ........- .. ...... .. ... ..* TS3
LElX&JzFF
PM
PS4 &. ._......... !52--$++.-13-
28
pm P&____J, _&“db.,3 _
75 RIGHTC~T$JFF
-- 62. _ ._... A : . j
A
13
Y KMRES;CH l3
SM666 19-02-21
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATING SEQUENCE 13
DRIVE CONTROL
Plugging
Controlled plugging (using the reverse power of the motor as a brake) is attained
when changing direction from forward to reverse (or reverse to forward).
A. The multi-function control handle is moved from forward, opening the forward
switch.
‘B.+While the switch is in the neutral position, all directional coil circuits will
be open.
C. The card will stop functioning because voltage is removed from terminal TB5.
D. The card supplies voltage from PA1 keeping the power steering energized
up to 24 seconds.
E. Forward and 1A contactots will return to their normal position, opening the
drive motor circuit, because the contactor coils are de-energized.
SM556 19-02-22
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BATTERY
__.-_.-
3
n
2 2
FUG?
ae
2? 12
13
12- 13
13
4AU I I
A-J
T T4
1c 1x j
13
osc CARD2
-I CONNECTOR
__
Ib
,_+~-Jl3
L “1
a
I--d
ACCELERATOR
LEFWU;zFF
-524ll3- dl
-51 -\13 7
SM556 19-02-23
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 13
DRIVE CONTROL
Plugging (continued)
A. The operator rotates the control handle through neutral to reverse, closing
the reverse directional switch.
C. The card now completes the circuit from PB3 and PB4 (through wires #26
and ##27)to the reverse contactor coils’ negative. This energizes the
reverse coils.
SM556 19 - 02 - 24
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BAllERY
22 12
--i
I
%
K
RLY :w
4REc
; i
32 10
:‘........_........_____:
t-------lo
# ..... . . ...... ..”....... “..7..“.“.“..“..
10
32
SM556 19-02-25
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 13
DRIVE CONTROL
Plugging (Continued)
As the #I REC is turned ON, the truck is continuing to travel in the forward direction.
Because the drive motor fields have been reversed, the motor armature now
becomes a generator because it is driven against the magnetic effect of the field by
the trucks inertia.
A. The voltage polarity reverses across the armature of each motor. This changes
the voltage of Al to negative and that of A2 to positive. This voltage also causes
the #4 RECs to conduct and thus provides a path for the generated currents.
B. These generated currents flow through the sensor, which over-rides the main
oscillator section of-the card allowing only predetermined slow pulsing of the
control, as adjusted by the plugging trim pot in the card and the control handle
position. The card is locked into the plugging oscillator mode.
C. This also causes the card to complete the circuit from terminal PB6 through
wire #75 to the DC contactor coil negative. This energizes the DC contactor
coil and closes the DC contactor power tips. The DC contactor ensures that
the generated currents flow equally in the two motor armatures.
D. The card also over-rides the 1A timer section of the card and will not allow the
1A coil to energize during the controlled plugging operation.
E. This slow pulsing will bring the truck to a smooth stop. The voltage polarity
at the armatures will return to normal and the truck will start to accelerate
normally in the opposite direction of travel and the DC contactor will be
de-energized.
Voltage present:
NOTE 1: The truck will always have torque to restart on a ramp (incline) unless
the operator moves the directional switch into the opposite direction,
which will result in plugging torque only. This is called “ramp start”.
SM556 19-02-26
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BATEFlY
3
FU
11
12
12
1 sle
Ev-1WM OSC CARD’
T3
-i OSCCARD CONNECTOR
12
. . .. . 10 .. . . . . . . .. .
LEFT CUT-OFF
SWITCH
...A%?“...-.&~13 -
13
l3 13
RELAY
SM556 19-02-27
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATlON SEQUENCE 14
HYDRAULIC CONTROL CIRCUIT
After the key switch has been turned on, which energizes the key switch relay,
B. Current now flows through the #I3 FU, wire #22, key switch relay contacts,
wire #32, UP switch, wire #5, Dl blocking diode, wire #28, through the pump
coil and wire #13 to battery negative.
C. The pump contactor coil is now energized, closing the pump contact tips.
G. Voltage is supplied to the R2 relay through wire #28, blocking diode D3,
wire #35, through dropping resistor 2 RES and wire #21. Battery negative
is connected through wire #13.
H. The R2 relay is now energized, opening the normally closed R2A contacts
removing voltage from the tilt and aux switchs.
J. The R2C contacts close when the R2 relay is energized but, because the R3C
contacts are open, there is no voltage to these contacts.
K. Current now flows to the hour meter from wire #35, blocking diode D8, wire
#72 to wire #13, negative.
NOTE: The movement of the hydraulic valve spool now controls the lifting of
the upright
NOTE: The hour meter operates when either the power steering contactor
is closed (which only operates when in either forward or reverse)
or by the hydrauliccontrol circuit.
NOTE: The Filters (&,.J ) do away with voltage spikes generated by the
relays when they are de-energized.
SM556 19-02-28
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 15
HYDRAULIC CONTROL CIRCUIT
After the key switch has been turned on, which energizes the key switch relay,
B. Current now flows through the #3 FU, wire #22, key switch relay contacts,
wire #32, through the DOWN switch, wire #35, through the ##2RES dropping
resistor, wire #21 to the R2 relay and wire #13 to battery negative.
C. The R2 relay is now energized, opening the normally closed R2A contacts
removing voltage to the tilt or aux switchs.
;, j .
D. The R2C contacts also close when the R2 relay is energized but, because the
R3C contacts are open, there is no voltage to these contacts.
E. Current now flows to the hour meter from wire #35, blocking diode D8, wire
#72 to wire #13, negative.
NOTE: The movement of the hydraulic valve spool now controlls the lowering of
the upright
NOTE: The hour meter operates when either the power steering contactor
is closed (which only operates when in either forward or reverse)
or by the hydraulic control circuit.
NOTE: The Filters (k,ws ) do away with voltage spikes generated by the
relays when they are de-energized.
SM556 19-02-30
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Batt. Poe. Ban. Neg.
1
I !
d 1FJL i3
i
!I 1RES
5 . . . . . . . . . . . . . . . . . . . . . . . . . <. . . . . . . . . . . . . . 1, .................
+
~~~~~“-i-‘~~~__-,: i
--_-_-_q
!t 25 !
3
!
3FIL
!
3 RES
32 ......... ... r”7 ........ ..31 ......... .. .. 13
-74
3%
1OFIL
i
I 1lFlL
I
84
l3 i
I
........ .. ... .... ....7, ..I ......#...,-------------------.72 .--I- HM ---FTLFEr---_,3
u
DQ HOUR METER
“!_
12 aa------= 13
HORN
B%&
St4656 19-02-31
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 16
HYDRAULIC CONTROL CIRCUIT
After the key switch has been turned on, which energizes the key switch relay,
A. Pushing the tilt button on the multi-function control handle closes the ‘TILT
switch.
B. Voltage is now supplied through the normally closed R2A contacts, through
the ‘TILT switch, #I3 Res dropping resistor, to the R3 relay and wire #13
connects the relay to battery negative.
.C. The R3 rel.ay,cot!,is now_energized closing the normally open R3A, R3B,
and R3C contacts.
F. Voltage is also supplied to the Rl relay through the 1RES dropping resistor,
the PUMP contactor coil through the Dl blocking diode, and the R2 relay
through the Dl and D3 blocking diodes.
G. The Rl and R2 relays are now energized, closing the Rl A and the R2C
contacts and opening the normally closed R2A contacts breaking the circuit
to the function switchs.
H. Current now has a path to the HS-1 A, HS-1B, HS-2 and the HS3A
solenoids energizing them and directing the oil path to the tilt cylinders.
J. Current now flows to the hour meter from wire #35, blocking diode 08, wire
#72 and wire #13, negative.
K. The pump contactor has also been energized, closing the power tips and
the pump motor will now run.
NOTE: The movement of the hydraulic valve spool now controls the tilting
back of the upright.
NOTE: The hour meter operates when either the power steering contactor
is closed (which only operates when in either forward or reverse)
or by the hydraulic control circuit.
SM556 19-02-32
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Batt. PO..
Ban. ueg.
A
l-3
-13 __I_ t
-13 ----4
I
-13 ----•
3RES -
-cz]__-31’__ _“,3 -1-1
4FlL
t=
t
i
a4
-74 13
1_,,.~ -0*q
I
LLI
...._..............7, ..........))...+-------------------.72 .---- HM ---F~L~Ey--13
u
DQ
HOURMETER
_i_
Sh4556 19-02-33
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 17
HYDRAULIC CONTROL CIRCUIT
After the key switch has been turned on, which energizes the key switch relay,
A. Pushing the tilt button on the multi-function control handle closes the ‘TILT’
switch. -
9. Voltage is now supplied through the normally closed R2A contacts, through
the ‘TILT switch, #3 Res dropping resistor, to the R3 relay and wire #I3
connects the relay to battery negative.
, C. The R3 relay coil is now energized closing the normally open R3A, R39, and
R3C contacts.
F. Voltage is also supplied to the PUMP contactor coil through the D2 blocking
diode, and to the R2 relay through the D2 and D3 blocking diodes.
G. The R2 relav is now energized, closing the R2C contacts and opening the
normally closed R2A confacts breaking the circuit to the function switchs.
H. Current now has a path to the HS-1A, HS-1 9, and the HS-3A solenoids,
energizing them and directing the oil path to the tilt cylinders.
J. Current now flows to the hour meter from wire #35, blocking diode D8, wire
#72 and wire #13, negative.
K. The pump contactor has also been energized, closing the power tips and the
pump motor will now run.
NOTE: The movement of the hydraulic valve spool now controls the tilting
forward of the upright.
NOTE: The hour meter operates when either the power steering contactor
is closed (which only operates when in either forward or reverse)
or by the hydraulic control circuit.
SM556 19-02-34
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
wt. Neg.
A
1 FIL
I-3
_. _r_..- - .-v
_!h. DOWN
.__-d &45---+ +L-C-s2--+----92~~4t-
AUXl i
-13
i
10FlL
I 11FIL
I
I
i
*4----c&3 -1
f
n---m35 -- El
;;
!
. . . . . . . . . . . . . . . . . . . . . 7, . . . . . . ..I #..+-------------------q.---- HM --‘I~~L~~~---,~ -I--
u
DO HOUR MEJER
J_
12 *ab-----25 13 -_“.._I
HORN
SM656 19-02-36
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 18
HYDRAULIC CONTROL CIRCUIT
After the key switch has been turned on, which energizes the key switch relay,
A. Pushing the AUX 1 button on the multi-function control handle closes the
‘AUX 1’ switch.
B. Voltage is now supplied through the normally closed R2A contacts, through
the ‘AUX 1’ switch and the #4 RES dropping resistor to the R4 relay and
through the D5 diode and #3 RES dropping resistor to the R3 relay. Wire
#13 connects the relays to battery negative.
,I C. The R3 and R4 relay coils are now energized dosing the normally open
R3A, R3B, R3C and R4A contacts and shifting the R4C contacts.
E. Voltage is now supplied to the R3 and R4 relays through the Dl and D4 diodes,
through the R3B contacts and the 3RES resistor to the R3 relay and the R4A
and 4RES to the R4 relay. The AUX 1 switch can now be released without
interrupting current to the R3 or R4 relays.
F. Voltage is also supplied to the Rl relay through the 1RES dropping resistor,
the PUMP contactor coil through the Dl blocking diode, and the R2 relay
through the Dl and D3 blocking diodes.
G. The Rl and R2 relays are now energized, closing the RlA and the R2C
contacts and opening the normally closed R2A contacts breaking the circuit
to the function switchs.
H. Current now has a path to the HS-1 A, HS-1B, HS-2 and the HS-3B
solenoids energizing them and directing the oil path to the attachment.
J. Current now flows to the hour meter from wire #35, blocking diode D8, wire
#72 and wire #13, negative.
K. The pump contactor has also been energized, closing the power tips and
the pump motor will now run.
NOTE: The movement of the hydraulic valve spool now controls the aux 1
back function of the attachment.
NOTE: The hour meter operates when either the power steering contactor
is closed (which only operates when in either forward or reverse)
or by the hydrauliccontrol circuit.
St4656 19-02-36
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
:...... *.................... 7, .... ...“. ...~~-~~~~~~~~~~~~~~~~~~.~~-- ---11----13
FILTER
D9 HOUR METER
J_
I-._..- 12 13
HORN
WITCH
SM556 19-02-37
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 19
HYDRAULIC CONTROL CIRCUIT
After the key switch has been turned on, which energizes the key switch relay,
A. Pushino the AUX 1 button on the multi-function control handle closes the
‘AUX 1’ &itch.
B. Voltage is now supplied through the normally closed R2A contacts, through
the ‘AUX 1’ switch and the #4 RES dropping resistor to the R4 relay and
through the D5 diode and #3 RES dropping resistor to the R3 relay. Wire
#13 connects the relays to battery negative.
,
C. The R3 relay coil is now energized closing the normally open R3A, R3B, and
R3C contacts and the R4 relay coil is energized closing the R4A contacts
and shifting the R4C contacts.
F. Voltage is also supplied to the PUMP contactor coil through the D2 blocking
diode, and to the R2 relay through the D2 and 03 blocking diodes.
G. The R2 relay is now energized, closing the R2C contacts and opening the
normally closed R2A contacts breaking the circuit to the function switchs.
H, Current now has a path to the HS-1 A, HS-1B, and the HS-38 solenoids,
energizing them and directing the oil path to the attachment.
J. Current now flows to the hour meter from wire #35, blocking diode D8, wire
#72 and wire #13, negative.
K. The pump contactor has also been energized, closing the power tips and the
pump motor will now run.
NOTE: The movement of the hydraulic valve spool now controls the AUX 1
forward function of the attachment.
NOTE: The hour meter operates when either the power steering contactor
is closed (which only operates when in either forward or reverse)
or by the hydraulic control circuit.
SM556 19-02-38
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Ban. PO..
Ban. tdeg.
; A
I l-3
12 d 1 FIL
I
i
! 1lFIL
i 84 f<), ,3
!
I
1-m--~ II
&; Ia
... ... ...... ... ... .. . ....*..... p- -1--_---_______1 ___.n.____~___~~A___,3
HOUR METER
j_
12 5-25 13
HORN
.si%z4
%I556 19-02-39
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 20
HYDRAULIC CONTROL CIRCUIT
After the key switch has been turned on, which energizes the key switch relay,
A. Pushing the AUX 2 button on the multi-function control handle closes the
‘AUX 2’ switch.
B. Voltage is now supplied through the normally closed R2A contacts, through
the ‘AUX 2’ switch and the #5 RES dropping resistor to the R5 relay,
through the D6 diode and #4 RES dropping resistor to the R4 relay and
through the D5 diode and #3 RES dropping resistor to the R3 relay. Wire
#13 connects the relays to battery negative.
C. The R3, R4 and R5 relay coils are now energized closing the normally open
R3A, R3B, R3C, R4A, R5A and R5C contacts, opening the R5B contacts and
shifting the R4C contacts.
E. Voltage is now supplied to the R3, R4 and R5 relays through the Dl and D4
diodes, through the R3B contacts and the 3RES resistor to the R3 relay, the
R4A and 4RES to the R4 relay, and the R5A, D7 diode and 5RES to the R5
relay. The AUX 2 switch can now be released without interrupting current to
the R3, R4 or R5 relays.
F. Voltage is also supplied to the Rl relay through the 1RES dropping resistor,
the PUMP contactor coil through the Dl blocking diode, and the R2 relay
through the Dl and D3 blocking diodes.
G. The Rl and R2 relays are now energized, closing the Rl A and the R2C
contacts and opening the normally closed R2A contacts breaking the circuit
to the function switchs.
H. Current now has a path to the HS-1 A, HS-1B, HS-2 and the HS-1
solenoids energizing them and directing the oil path to the attachment.
‘:‘.‘i’
J. Current now flows to the hour meter from wire #35, blocking diode D8,
wire #72 and wire #13, negative.
K. The pump contactor has also been energized, closing the power tips and
the pump motor will now run.
NOTE: The movement of the hydraulic valve spool now controls the AUX 2
back function of the attachment.
NOTE: The hour meter operates when either the power steering contactor
is closed (which only operates when in either forward or reverse)
or by the hydraulic control circuit.
St465619-02-40
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Batt. Pea.
S&t. Neg.
i
14
-774
10FIL
i3 -4
i
i
I”__~ II El
. .._................. 7, .. ... ... ..#...e ~11111~1_1~~111~_~_. n .-1-- 1-111--w-13 _I__
D9 FILTER
J_ HOUR MEER
12 13
HORN
SWITCH
St&!56 19-02-41
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATION SEQUENCE 21
HYDRAULIC CONTROL CIRCUIT
After the key switch has been turned on, which energizes the key switch relay,
A. Pushing the AUX 2 button on the multi-function control handle closes the
‘AUX 2’ switch.
B. Voltage is now supplied through the normally closed R2A contacts, through
the ‘AUX 2’ switch and the #5 RES dropping resistor to the R5 relay,
through the D6 diode and #@IRES dropping resistor to the R4 relay and
through the D5 diode and #3 RES dropping resistor to the R3 relay. Wire
#13 connects the relays to battery negative.
C. The R3, R4 and R5 relay coils are now energized closing the normally open
R3A, R3B, R3C, R4A, R5A and R5C contacts, opening the R5B contacts and
shifting the R4C contacts.
E. Voltage is now supplied to the R3, R4 and R5 relays through the D2 and D4
diodes, through the R3B, R4A and R5A contacts and the 3RES, 4RES and
5 RES dropping resistors. The AUX 2 switch can now be released without
interrupting current to the R3, R4 or R5 relays.
F. Voltage is also supplied to the PUMP contactor coil through the D2 blocking
diode, and to the R2 relay through the D2 and D3 blocking diodes.
G. The R2 relay is now energized, closing the R2C contacts and opening the
normally closed R2A contacts breaking the circuit to the function switchs.
H. Current now has a path to the HS-1A, HS-1B, and the HS-1 solenoids,
energizing them and directing the oil path to the attachment.
K. The pump contactor has also been energized, closing the power tips and the
pump motor will now run.
NOTE: The movement of the hydraulic valve spool now controls the AUX 2
forward function of the attachment.
NOTE: The hour meter operates when either the power steering contactor
is dosed (which only operates when in either forward or reverse)
or by the hydraulic control circuit.
SM556 19-02-42
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Batt. PO&
Batt. Neg.
1 FIL
i
!
13 ------f
i
04 I
-74 13 -.--i
i
.
i
I_,,,~ __&
.............................+p-
:
*a-----e 13------I
HORN
.G%
SM!556 19-02-43
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
CHECKING COMPONENTS
1.170-1.190 25 % CHARGED
1.110-1.130 ~ DISCHARGED
SM556-19-03-01
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
CHECKING #l ,2. 5 REC’S CSCR’S\
STEP 1: Set meter to R X 10,000 and calibrate. Connect positive meter lead to
anode of SCR. Connect negative meter lead to cathode of SCR. Results
should be above 100,000 ohms.
STEP 2: With meter set as in Step 1, connect the meter positive to the cathode of
SCR. Connect the meter negative to the anode of the SCR. Again, the
Iresultsshould be above 100,000 ohms.
STEP 3: Set the meter to R X 1 and calibrate. Connect positive meter lead to the
gate terminal. Connect the negative meter lead to the cathode. Results
should be from 10 to 200 ohms.
STEP 4: With the meter set as in Step 3, connect the meter positive to the cathode
of the SCR. Connect the negative lead to the gate terminal. Results
should be from 5 ohms to infinity.
NOTE
SM556-19-03-02
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
STEP 1 R X 10,000 SCALE 100,000 OHMS OR MORE
CHECKING SCR’S
RECTIFIERS
CHECKING SCR’S
RECTIFIERS
1
SM656 1g-03-03
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
STEP 3 R X 1 SCALE 10 TO 250 OHMS
CHECKING SCR’S
RECTIFIERS
CHECKING SCR’S
RECTIFIERS
SM556 19-03-04
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
#2 AND #5 PRESS PACK RECTIFIERS
GATE CATHODE
I
v
+
I
3
0
C0
ANODE
SM55619-03-05
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
TO CHECK CAPACITOR (IC)
GO TO STEP 2.
CHECKING CAPACITOR
STEP 2
CHECKING CAPACITOR
SM556 1Q-03-06
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
CHECKING COMPONENT WITH VOM (ONLY)
STEP 1
DISCONNECT BATTERY.
y$C;;F&GE CAPACITOR
,
DISCONNECT ALL WIRES
FROM THE FILTER BLOCK.
STEP 2
SM556 19-03-07
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
CHECKING COMPONENT WITH VOM
OPERATION - NUMBER
3 AND 4 RECTIFIERS
~O;;~fTRIl-Y IS IN-
OHMMETER TEST:
MEASURE RESISTANCE
FROM CATHODE TO THE
ANODE.
A READING OF 50,000
OHMS INDICATES THE
RECTIFIER IS GOOD.
GO TO STEP 2.
IF METER REGISTERS
BELOW 50,000 OHMS, A
NEW RECTIFIER SHOULD
BE INSTALLED.
TESTING #3 AND #4 RECTIFIERS
STEP 2
A READING OF 7 TO 12 OHMS
CA-FDE . .,.._ INDICATES THE RECTIFIER
IS GOOD.
SM556 1g-03-08
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
b
C
STEP 4
CHECKING COMPONENT
SM556 19-03-09
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
CHECKING COMPONENT WITH VOM (ONLY)
CHECKING SENSOR
St4556 19-03-l 0
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
[11ClOClO
TPLUG -
BLACK
CHECKING COMPONENT
THERMAL PROTECTOR
Do not remove the Thermal protector from the #l rectifier heatsink. Remove the
“2” plug from the card. Using a VOM (R X 100 scale) measure the resistance between
the black and gray wires With the #l Rectifier heatsink at room temperature (24°C or
75°F) the meter should read 50 to 200 ohms. Replace thermal protector if readings
are other than this range.
Sh4556 19-03-l 1
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
T-5 T-4
T-3
A-l
COMPONENT CHECKING
REACTOR/CHOKE MODULE
SM55619-OS-12
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
CARD ADJUSTMENTS
EVIOOM ONLY
CREEP C/A
I I
CREEP 4.5
C/A 6.5
,
C/L 9
PLUG 8
SM556 19-03-13
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
CARD VOLTAGE CHECKS
TB-6 Key off .... . ... . .... .. ... .. . .. ... .. ... .. .. . .. ... .. ... .. .. .. . .. . 0 v.
Key on, accelerator rotated to reverse,
brake pedal depressed .. ..... ..... .. .... .... ....... . ....B+ v.
ShA55619-03-14
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
CONNECTOR PLUG
EVI OOM ONLY
I 1
NOT
#62
NOT USED
#27
#24
#26
#34
“Z” PLUG
St4556 19-03-l 5
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
RECOMMENDED TEST, TEST sheet. Open circuit battery voltage is
EQUIPMENT AND measured as follows:
PROCEDURES STEP #l: Turn Digital Multi-meter ON
Select 200 volts, DC scale.
1. Tests #1 through #6 require drive wheels 8. Before connecting battery to truck, visually
be raised off floor. inspect to be sure contactor tips are not
welded.
2. Always inspect condition of battery cables
and connector of battery being used for 9. The preferred method of disabling any
test. If battery cables are worn out, cable function / component (e.g., preventing 1A
ends at terminations cracked, or cable contactor from closing) is to disconnect
insulation broken / cracked, battery should appropriate control wire, in order to break
not be used for test but should be sent for electrical circuit. Use of cardboard and / or
repair or maintenance. any other mechanical device is not
advised. These methods should only be
3. No extension cables should be used to used if breaking electrical connections is
connect battery to truck for test. It is not practical. SUCH METHODS SHOULD
recommended to install battery in truck for BE USED WITH CAUTION!
test whenever possible. When such
installation is not practical, battery should B. PROCEDURES:
be set on floor close to truck battery
receptacle, to eliminate need for 1. GROUND FAULT CONDITION:
extension cable.
STEP #l: Disconnect battery from truck
4. Always inspect condition of battery cells receptacle and turn key switch OFF.
for proper water level.
STEP ti: Turn ON Digital Multi-meter;
5. Before conducttng any test, measure select resistance measurement
open circuit voltage of battery. Record function, 200,000 Ohm scale.
measured value, nominal rating of battery
volts, and battery type number on test
SM556 19 - 04 - 01
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
STEP #3: Connect Red lead of Multi-meter 3. SCR CURRENT LIMIT:
to POSITIVE (+) terminal of truck
receptacle and connect BLACK lead of STEP #l : Raise drive wheels off floor. Make
Multi-meter to an unpainted surface sure truck is in cold condition.
(e.g., bolt, etc.) of truck frame. Record
resistance. STEP #2: Connect shunt to measure
battery current (i.e. connect in series
STEP #4: Connect RED lead of Multi-meter with positive or negative cable).
to negative (-) lead of truck receptacle
and leave BLACK lead of Multi-meter STEP #/3: Install jumper wire on foot brake
connected as in Step #3. Record switch to defeat its operation.
resistance.
STEP #4: Disconnect control wire #34 from
STEP #5: Compare values obtained in 1A contactor coil negative terminal and
Steps #3 and #4 against specification to tape up.
determine PRESENCE / ABSENCE of
GROUND FAULT. STEP #5: Connect battery to truck
receptacle, turn key switch ON.
NOTE: It is recommended that if ground
fault is detected on truck, tests for other STEP #6: To obtain a HARD STALL
parameters should be conducted ONLY condition of the motor, do not depress
, AFTER.ELIMINATING CAUSE OF AND foot brake pedal, gradually rotate the
THEREBY GROUND FAULT. multi-function control handle to the
FULLY FORWARD position. Measure
2. POWER STEER IDLE CURRENT: and record highest current reading
(voltage across shunt) obtained.
STEP #l : Raise drive wheels off floor.
STEP #7: Subtract power steer idle current
STEP #2: Connect current monitoring from reading obtained in Step #6 to
shunt to measure battery current. Shunt obtain SCR CURRENT LIMIT FOR
sensor wires are connected to Digital DRIVE SYSTEM.
Multi-meter. The voltage reading across
these two sensor wires gives Direct STEP #8: Repeat Steps #6 and #7. Take
Current reading. Turn ON the Digital average of two (2) readings and compare
Multi-meter: select DC VOLTS. average value to specifications.
STEP #4: Measure and record voltage 2. There should be wait (idle) period
across shunt sensor wires (or terminals). minimum of two (2) minutes between
! Steps #6 and #8.
STEP #5: The voltage reading obtained in
Step #4 is a direct reading of POWER 3. Drive wheels should be allowed to turn
STEER IDLE CURRENT using between Step #6 and #8.
conversion of 1 mV equal 10 Amps for
500 Amp, 50 mV shunt. (i.e. 1.0 mV 4. 1A FREE WHEELING CURRENT:
equals 10 Amps)
STEP #l : Raise drive wheels off floor.
NOTE: Precaution should be taken not to
touch steering handwheel while taking STEP #/2: Install jumper wire on foot brake
measurements / readings in Step #4. switch to defeat its operation.
SM556 19-04-02
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
STEP #7: Stop Watch reading is 1A TIME
STEP #4: Connect shunt to measure DELAY. Repeat Steps #5 through #7 at
battery current. least four (4) times. Take average of all
readings as 1A TIME DELAY to compare
STEP #5: Connect battery to truck against specifications.
receptacle, turn key switch ON.
6. CREEP SPEED MOTOR VOLTS:
STEP #6: Depress the foot brake pedal,
rotate the multi-function control handle STEP #l : Raise drive wheels off floor.
to the FULLY FORWARD position.
STEP ##2: Connect RED lead of Multi-meter
STEP #7: Gradually release the brake pedal to pig-tail of commutating diode (#3
until the battery current reading is REC) and BLACK lead of Multi-meter to
between 100-200 Amps. Hold brake negative (-) terminal on control panel.
and control handle in these positions for
a minimum of ten (10) minutes. STEP #3: Turn Digital Multi-meter ON;
select DC Volt measurement function,
STEP #6: After ten (10) minutes, depress 20 Volt scale.
the brake pedal completely while still
holding the control handle fully rotated. STEP #4: Install jumper wire on foot brake
After current reading has stabilized, switch to defeat its operation.
measure and record it.
STEP #5: Connect battery to truck
STEP #9: Release the control handle receptacle, turn key switch ON.
completely. After current reading has
stabilized, measure and record it as STEP #6: With the foot brake pedal in the
POWER STEER IDLE CURRENT. UP position, gradually rotate the control
handle until1 the FORWARD switch
STEP #lo: The difference of current closes. Record voltage reading of meter.
readings obtained in Steps #6 and #9 is
1A FREE-WHEELING CURRENT and STEP #7:Repeat step #6. Average of two
must be used to compare against reading is CREEP SPEED MOTOR
specifications. VOLTS and should be compared
against specifications.
5. 1A TIME DELAY:
7. PLUGGING:
STEP #l : Raise drive wheels off floor.
STEP #l :Lower drive wheels to floor,
STEP #2: Install jumper wire on foot brake remove jumper wire from foot brake
switch to defeat its operation. switch.
STEP #3: Connect battery to truck STEP #2: Connect battery to truck
receptacle, turn key switch ON. receptacle, turn key switch ON, drive
truck to open space or aisle where at
STEP #4: To obtain a HARD STALL ‘least [76.m] 250 feet of running space is
condition of the motor, do not depress available.
foot brake pedal.
STEP #3: Drive in the FORWARD direction
STEP #5: Rotate the multi-function control at top speed. After the 1A contactor has
handle to the FULLY FORWARD picked up (closed) and truck has
position as fast as possible and start traveled in top speed mode at least 123
Digital Stop Watch the moment control m] 75 feet, change direction of travel to
handle stops. FULL REVERSE.
SM556 19-04-03
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
STEP #4: If truck continues to travel forward
with continuously decreasing speed
until truck stops and smoothly
accelerates in reverse direction,
PLUGGING function is correct.
NOTE:
SM556 19-04-04
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SYMPTOM 1
MFlEcTloNALccNTAclc%ls
wlLLNoTcLosE.
4
aixxccM7wLFusE2Fu.
1
c+lEcKAnJLsTMENT
YES
OF MRECTiCML
CU4lXlLASSENLLY
MASIJFE’AXTAGEON
TERM. TS5 (FWD) & TS6
(REbJOFOSC.C.MO.
cHECxFOR.9iCRTFRm
NO WIRE X15 TO WIRES X6 6
x8 &OPERATION OF FWD /
REVSWITCHES. REPAIR/
CHECK IF MRECTIONAL
CONTACTORTIPS ARE
C.+ECKFoRSHoRT
FROM WIRE Xl 5 TO
No WIRES x6 8 X8 &
UNPLUG MTIERY. CHECK IF CC CONDCTOR IS OPERATION OF FWD I
CHECKFcmSwRT REV SWTTCHES.
FRoMBATrERY REPAIR /REPLACE.
msm~ TO 72. I
J
TERMS. lWlRES#lOl OF
NO
+YES
CeGcAm ~‘C+i5xCcuTACTCRSFORBNLnNG
OR OPEN CC4L REPAIR I REPLACE
c+lEcKrxLwmNum
OFSFlAKESWlTCH NO
AND WIRE 115.
REPAIR I REPLACE.
SM556 19 - 05 - 01
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SYMPTOM 2
DlRECllONALCONlACTORS
u_a~.mpMRm
AUOISLESCRHUYTRUCK
irnwww wrnwxx~
INSCRRANOE
OIECKTHERW
pRoTEcroRFoRlilGN
RESlSTANCE OR LOOSEI
&u)CONNECllONSTO
cARDTPL!JG
WITHSRAKEPEDAL
-AmcoNFRoL
l-!ANDCEHFWDORREV 4 YES
MEASUREVOLTAGEUJ72
OiSCONNEcTwlRE
x28 FROM TERM. TBl 1 FORLOWRESISTANCE. 1
OFOSCCARD.
-voLTAoE
ON WIRE x29 AS
CONTRawNu_EIs
IROTKlEDTOUCSE
FWDsWrrC+i. I
cHEcKcumNurrYoF
co~Acr0Rnpsm
LrxJirEopENONBoTH
NOTE:
ML TESTING SHOULD SE DONE WITH
DRIVE WHEELS RAISED OFF FLOOR.
SATTEFiYSHOULDSEUNPLUGGED
FOR CONNECTING OR DISCONNECTING
ANY WIRES AND/OR COMPONENTS.
RECCNNECTWl##220N
ORANGEWIRON-
AS ACCELEMTOR IS
ROTATED IN SCR RANGE
ri -1
CHKXGITENANDYELLOW
NO WlFlESCW cuwENTsENscR
FCR CONllNUilY, BROKEN
INSULATION AND LOOSE I
DEFECTIVE (Iz REC. SADCONNECllONTOCARD
REpvIcE TPLUG.
SM556 19-05-02
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SYMPTOM 3
C4C6ENOPOWEP_AUMSJ_E
SCRHUMTRUCK
INOPERATlM Wml ACCEL
INSCRRANGE.
I ,
lJNPLlmsmrERY.
ol-GEM. 1c. m
cnscawEcTaREc. .
c+!EcuQREcFcR
CeEN
I
~PROTK;TORFCMFENORIF
lHELEADSAFlE SHomEDTon REC
UlliCcE I
Dlscct.lNEcTY2REc.
CHECK ri, REC SHORT.
DEFECTNE x2 REC.
NOTE:
ALL TESTING SHOULD SE DONE WITH
DRIVE WHEELS RAISED OFF FLOOR.
BATTERY SHOULD BE UNPLUGGED ) NO
FOR CONNECTING OR DISCONNECTING ID~CONNECT~.S~~~ I
ANY WIRES AND/OR COMPONENTS.
SM556 19-05-03
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
+
C+iECK IF 1A CONTACTCR
TIPS ARE WELCEO.
NOTE:
AU TESTING SHOULD BE DONE WITH
DRNE WHEELS RAISED OFF FLOOR.
BATTERY SHOULD BE UNPLUGGED
FOR CONNECTING OR DISCONNECTING
ANY WIRES AND/OR COMPONENTS.
SM556 19-05-04
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SYMPTOM 5 SYMPTOM 6
HIIFfSFmM-sENsoFl
ARE CONNECTEDTO PIN #4AND
PIN x3 RESPECnVELY OF T
PLUGONCSC.CX3O.NoTETlMT
YELLcwWlRESHDULDBEC
WA!TDNESECUUD,THENCUSE TO SKITERY NEGATIVE AND NOT
MRECTlONAL SwlTCJi OF
COhTACTORSTMTWlLLNOT
C4.OSE-WXTh3EON
OTHERDlFlmONALIwurTERM REPAIR I REPLACE.
(TS5ORTSS)OFOSC.CAFlD.
M3SUREVUTAGEoNNoN-
CLOSlNGMRECTK)(JALINPUT
TSRM.(TS6ORTSS)ANDCOlLS
POSITIVE WIRES 1110.
IDISCONNECT BOTH 14 REC’S.
CHECK#4RJKZS FCRCPEN. I
J
CHECXCXXullNUlTYANDK#l 1
PRWER-ON
WIRES X10 AND x23.24 OR
x26.27 S OPERATION OF
DIRECTIONAL SWITCH ( FWD I
REV). REPAIR/REPLACE.
-voLTAGE-EACt
COILOF CONMCTORS lHATWlLl
N0Ta.0s5Sum~n~
omEcTiuNMRQTATECONTROL NOTE: ALL TESTING SHOULD SE DONE WITH
l-wxxEmcREEP-.READ
DRIVE WHEELS RAISED OFF FLOOR.
M3ERFORRRSTO.SSEC.AND
AmER 1 SEC.
BATTERY SHOULD SE UNPLUGGED
FOR CONNECTING OR DISCONNECTING
ANY WIRES AND/OR COMPONENTS.
cztiEcKmAcToRsm
MEu-lANlcfu SINOI~ OPEN
COILS AND REVERSERS FOR NO
INTERMmENTNoRMALLY
CLOSED POWER TIPS. REPAIR
REPuaz.
1NO
SM55619-05-05
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SYMPTOM 7
1ACONTACTCflWlLLNOTCLOSE 1
4
UNPLUG MllERY. CHECK 1A
INSTAUAJUMF%RFROMWlRE
X7 TO WlRE X15 ON FOOTSRAKE
SWITCH. PLUG BATTERY. WrrH
MAKE PEWREUZASED, ROTATE
C4BlROLHANCLETOTOPSPEED.
MEASUREVUTSONGFUYLEM
FROMTHERMLPROiECTORAT
0% CAFiD‘Z PLUQ PIN 15.
CONTRU_ IN THERMAL-
ALLcwTRUcKTOcooLFEamx
1ACUNTACTOROPEK4TlON.
MEASURE VOLTAGE ACROSS 1A
&
NO CO!LCLOSEKEYANDFS
ShlTCHES ROTA-l.5 COML
HAWXE FaRToP SPEED.
MEASURE VOLTS FOR FIRST 0.5
SEC. AND AFIER 1 SEC.
,*,
0Sc.CARD2PLUG.cHEcKTHERMK
PRO~ANowRESFcflOPEN. I
NO DEFECnVE 1A
CCNTACTORCOlL
MPOTFUUY
I
REPAIR REPLACE.
#h-rAcrOR
1 DEFEcmEOSc.cARD.REPlAcE
SM556 19 - 05 - 06
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SYMPTOM 8
NO
PMTTRIPS awrfnb4iz HYCRAUJC
.swlTaesAR-OAOPENEO.
CMCKFORTHEVOLTAGESPIKES
ON FOSmM AND NEGATlVE
WIRES TO HYDRAULIC ClRCUT
MS. F!+JOSCURCEAND
ELIMINATETHE SPIKES.
WLTAGE ON P. s.
CONTACTORTERMlNALTO
WHlc+lBAllERYmm?vE
CAmEcONNBza
CLOSEKEYANDFCXXBRAKE
SWITCHES. h!EMURE VCLTAGE
ON TERMINALS TS4, T&3 AND
TEaOFOSc.mRO.
ME4SuREvOL-rAGEA##5s
PScQlL SELECTA
c%REclloN. READ wlER
FOR FIRST 0.5 SEC AN0
SM556 19-05-07
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP19 SUPPLEMENT
- Monitorexistingsystemfauftcodes forbothtraction
and pump SCR systems Verify Display Segments for
* Monitor intermittent random status code one second
* Monitor battery state of charge on IX systems
- I
- Monitor hourmeter reading on traction and pump
SCR systems I
Value changes
while blii
Thisfunctionallowsfortheadjustmentofthefieldweak-
ening contactordropoutcurrent.Thii setting allowsthe
FW contactor to drop out when the vehicle requires FUNCTION 12 SPEED UMIT 2 (SL2)
greater than 300% of the full load level runhing current (Pueh12)
for greater torque.
Same as Function 11 except using SL2 limit switch for
Range 85 to 895 amps (EVl 00) input.
98 to 1343 amps (EVZOO) -
Set Oto285 FUNCTION 13 SPEED UMfT 3 (SL3)
Resolution 3.28 amps per set unit (EVlOO) (Push13)
4.88 amps per set unit (EV200)
Example . Setting of 20 = 130 amps Same as Function 11 except using SE3 limit switch for
input.
FUNCTION 9 REGEN BRAlkiNG k/L’
u-w TheSL3setspeediimitisalsoadivatedbytheTnrdc
Management Module fault codes 90 and 93. See in-
This function allows for the adjjstment of the Regen structions for IC3848TMMlA Truck Management
brakingcurrent limit.The higherthe current the shorter Module for detaii.
the stopping distance.
FUNClYON 14 INTERNAL RESISTANCE .
Range 75to83oamps COMPENBATION
Set oto255 (P-h14)
Resolution 22ampspersetunit
This functfon ls used when the Battery Discharge
Example: Settingof20=119amps lndiir is present Adjustment of this function will
improvethe accuracy of the BDI. In order to made this
FUNCTION 10 REGEN START setting the voltage drop of the battery under bad must
(PushlO) first be determined by folbwing the steps listed bekw.
Thishrnctionallowsfortheadjuamentofthepercenton 1.Loadthetractionmotorto1OOanpsin1Aand
time at which the control will start to regen. Adjustment record the voltage (Vo) at the SCR positiie and
of this function allows the OEM to set the regen start negativepowerterminal.
speed of the vehicle to eliminate regen attemptswhen 2Loadthetrac&ionmotorto2OOampsinlAand
motor regen current is low. recordthevoftage(V~) at the SCR positive and
negative powertenninal.
Range Oto95%ontime 3. Calculate voltage drop o/p) as follows:
Set 0 to 258 v0-vo-vL
Resolution .3796per set unit 4. Use the tabie befowto determine the setting using
the cafcufatedVDas a reference.
Example: Settfngof29= 7.4%ontfme
Thiifunctionalbwsfortheadjjofthespeedlimit
( maximumbattery volts to the motor ) when the SLl
limit switch input signal is received by the controf card.
SLl limit switch is a normaltyclosed switch connected
to battery negative,the switch opening enables speed
limit.
Copyrighted Material
SM548
Intended for CLARK dealers only
Do not sell or distribute
FUNCTlON15 BATIERY VOLTS
(Pushl5) RI100 standard
Function wfth FW Limit RegenFW
Thi: functionallowsfor the adjustmentof vottagerange
for controlsequippedwith the BatteryDischargeIndica- STD C/L 0 to 4 2Oto24 40 to44
tion function. In order for the BDI to operate properfy, High C/L 5to9 25 to 29 45to49
the setting as shown in the table must be entered . STD C/L
(Auto plug) 1oto14 3oto34 50 to54
Battery volts Set unlts High C/L
(Auto plug) 15to19 55to59
24 volts Between 0 and31
36 votts Between32and44 Ev200 Standard
48 volts Between45 and 69 Functbn wlth FW RegerWV
72 volts Between 70 and 80
84votts Between81 and 153 SlyI c/L 64 to 68 84to88 104to108
36M8 votts Between184and250 STD C/L
No BDI Between251 and 255 (Auto plug) 74 to 78 94to98 114to118
To d&able the pedal positbn p&g functfon, adjj the Range 1.5to65seconds
current value to the same cunent value as the ptug Setting BetweenOand128
distance cutrent. Resobtii .5secondspersetunit
This function allows for the adjustment of the current 1) To activate a speed limit if a normally cbsed switch
limit of the control. The rating of the control will deter- is opened between PA4 and negitiie.
mine the range of adjustment for this function. Please
referto the operating instructionaforthe C0fltfOi Used in 2) To reverse the dire&on of the in-board motor and
yourvehicle. activateaweedlimitifanofmaUvopenswitchis
cbwd behkn PA4 and negitik.
Range seecontmi
CR cunms
Set OtO255 Set 128orgreatertoselectopitbnl above.
Copyrighted Material
Set dealers
Intended for CLARK O-127toseiectoptbn2above.
only
Do
SM546not sell or distribute
19-l 4-6
EVl69 EV296 EVlW EV2m
FUNCTION11 SPEED LlMD=1 (PA6 OR PA6) 7 11.44
VD 07.63
VD Se$tg 01.34
VD 00.89
VD
(Pushll)
3 07.60 06.07 18 01.27 00.85
4 06.72 03.81 19 01.20 al.80
This functionallows forthe adjustmentof the speed limit
( maximumbattery volts to the motor ) when the Ll or f 04.67
03.81 03.06
0264 20 01.14
01.09 00.78
00.73
Rl limit switch input signal is received by the control 7 @.27 02.18 ii 01.04 00.69
card. Ll or Rl limit switch is a normallyclosed switch 8 02% 01.91 23 00.99 00.66
connected to battery negative, the switch opening 9 02.64 01.69 24 00.95 00.63
10 02.28 01.62 26 00.91 00.61
enables speed limit.
11 0208 01.39 26 00.66 00.69
12 01.90 01.27 27 00.86 00.67
Range 96% to 0% battery vofts
13 01.76 01.17 28 00.82 00.66
Set Oto180 14 01.63 01.08 29 00.79 00.63
15 01.62 01.01 30 00.76 00.51
Settingof 0 set unitswilldisablespeedlimitfunctionand __ '16 .01.43 00.85 31 00.74 00.49
allow top speed with no limit switch connected.
FUNCTION 15 BATTERY VOLTS
(Push15)
FUNCTION 17 CARD TYPE SELECTlON Pick up on directional switch closure and drop out
( Push CONT and 2 ) time delay on directional switch opening.
This function allows for the selection of the card type Range .5 to 63 seconds
used for your vehicle’s application. The table below Setting 129to255
shows the setting_to.select .card appkation type de_ . ResoWon-.. .5secondsper3et .unit
pending on which control card is used.
Example: Setting of 149 - 10.5 seconds
Evloo Standard
Function with PW ~Dropoutwiilbe 1.5 secondsafterthe seat switch opens.
STD CR 0 to 4
Hiih CR 5to9
STD C/L
(Auto plug) 1oto14
High C/t
Wo plug) 15to19
Ev200 Standard
Function with FW
STD C/L 20 to 24
STD C/L
Muto plug) 30 to 34
Copyrighted Material
SM548
Intended 19-14-8
for CLARK dealers only
Do not sell or distribute
DESCRIPTIONOF FUNCTION NUMBERS FOR:
Control Card IC3645EVLXCDlPX FUNCTION11 SPEED UMIT 1 (SLl)
(Pushll)
FUNCTION 1 STORED FAULT CODE
( Push 1) This functionallowsforthe adjustmentof the speed limit
( maximumbattery votts to the motor ) when the SLl
Thisfunction registercontains the last status code that limit switch input signal is receivedby the control card.
shut down vehicle operation ( PMT type fault that is SLl limit switch is a normallyopen switchconnectedto
reset by cycling the key switch ) . This statuscode will batterynegative,the switchclosingenablesspeedlimit.
be over writteneach time a new fault occurs and can be
cleared from memoryby adjusting the value to zero. Range 0% to 100% battery volts
Set 0 to 255
FUNCTtON2 INTERNAL RESISTANCE ResoWon .375 volts per set unit
COMPENSATIONSTART Example Setting of 50-l 6.75 vofts
(Push2)
This function allows for the adjustment of the current FUNCTION 12 SPEED UMIT 2 (SL2)
level at which the internal resistance compensation (Push12)
feature (Function 16) will take effect.
Same as Function 11 except using St.2 limit switch for
Range 0 to 1325 amps input.
Set 52 to 255
Resolution 6.5 ampsper set unit FUNCTION13 SPEED LIMIT3 (SL3) .
(Push13)
Example: Setting of 72 - 130 ampa
Same as Function 11 except using SL3 limit switch for
FUNCTtON3 CONTROLLED ACCELERATlON input.
AND 1A TIME
(Push3) FUNCTtON14 SPEED LIMIT 4 (SL4)
(Push14)
This function allows for the adjustment of the rate of
time it takes forthe controlto accelerateto 96% applied Same as Function11 except using SL4 limit switch for
battery voltage to the motor on hard acceleration.The input.
1A contactor will automaticallyclose .2 seconds after
the controlled acceleration stops and the accelerator
input is less than .5 volts or less than 56 ohms.
BDILockoutmeansthattheBDIsignalfromthetraction
control must be present inorderforthe pumpcontrolto
operate. This control will stop operation when the
battery state of charge reaches 10%.
wmnlng:TheseBettlng~bedmgalby~
personnelonly, following ln8tructionsauppkd by
the manufacturer. Card type 8ebcUon mu8t be
made within the capabllltlw of tha SCR control
panel used and the auppottlngmkal
de&es. Failure to comply with proper appllcatlon
standards could rwult &I mlsopemtkn or damage
to the control and/or matan.
Copyrighted
SM548 Material
19-14-l 0
Intended for CLARK dealers only
Do not sell or distribute
EVIOO LXT CONTROL PANEL
GROUP 19
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
STATUS CODE ’ DESCRPTION MEMORY No
RECALL
BLANK NodisplaymDashDisp~ycirHmdsa
DISPLAY
--lFrG--
SYMITOM
Disp$y screen on dash display OTbat&et is blank
POSSIBLE CAUSE
,i.
78
Positive ot negative conml volt5 missing.
lw
- rnsutcthatwith key switch0%voltage is pmetlt be
twmn Pi7 and PZ3 (NEG). and voltage is p==t
bsvozn TB4 and PZ3 (NEG).
3pcn ckuit bctwcul logic cad plug “y” and Dash Display or
krandscr
- alcckfumpcncimlitorlcQsccoancctionsbaween
each wire going be- logic card plug “Y” ami Da&
, Disphy/~Hanctsct FigurcL
3&ctivcDailDisplay/Handsct
- RcplaceDashDisplay/Handsu STATUS INDICATION CRITERIA
SYMPTOM
FOlWXdOfrevast amtactcuwinnazpickup.
POSSIBLE CAUSE
Mis-adjusedadcfaxivc fQt rwirriL
* c&dLsatswitchmilnmplcipudo8ut8.
Copyrighted Material
Still548
Intended 19-15-2
for CLARK dealers only
Do not sell or distribute
STATUS CODE DESCRIPnON MEMORY No
Forwarddimiodswirchisclosedoninitialpowaup. REXXLL
SYMPTOM
Fomard contactor will not pick up static return to off (SRO) lock
SWITCH
mu. ACCEi
IF
START
USED
h 4 SWlTCif
POSSIBLE CAUSE TB4
b 2
TB3
Forward directional switch closed on initial power up (closure of i
battery plug, key switch or scat switch).
. Return dircaional switch lever to neutral and then select
a direction.
FvfD
Fmvard directional switch is welded closed or m&adjusted to he
held clod
TBS
* Rcpiacemadjustdin!Yxionals~tchtoins~~ic. .-
opens when dkdonal switch is mumal to ncutml.
Figure L
Short circuit hecwecn TB2 and TBS.
. DlsumWxwiIcfmmTB5andc~forshm~
*
hctwcenTB2aridwhc. !3TATUS INDICATION CRITERIA
ThiSSQKUSCOdCWillkdiSphpdWhUlTB5isgreaerthan
kfective cd 6o%hataryvoltsatinitialpowaup.
* DisamncctwircatTBs;~voltagcatTB5,
shouldtJclcssthan60960fhatruyvolts.
I
03 CmCm Traction
SYMPTOM
Revnrccoriaccwillnotpickupspric-moff(SRO)lock SWITCH
3x.
l
TB4
TB2
lB6
Copyrighted Material
Intended for CLARK dealers only
Do not sell or19-15-3
SM548 distribute
DESCRIPTION MEMORY ym
STATUS CODE RECALL
Swswitchiqmbwafmini6dswq
-04 Traction
SmfPTOM
Folwardorlwer!Ruxlw willnot pick-up. --J-zE-G\ ACCEiFRATCfl
START
Folwardorrcvcrscktionalswitchcl&ontiti s*lrtq.
* Depress accclcralDrtoclose start switch. SmlS de
~chqp~~if~vcrscdinxtionalswitchorto(nif
forward directional switch is closed. If eitherof these
~sappear,~&&nalswitchtonedand
rhenscleathcctcsid~tion.
- Iflcsstim6o%bmuyvoltagc.Removewireand
m~rnt~vd~~wiretoSCRXlCgative.VdUC STATUSINDICATION CRITERIA
ShOUldbelUSthll22kohms. ThismulsccdcisdisplayaiwhulTB2volragcislessthrn
f5o%oftmtexyvoltsatini~sciTt-q(seatstiticlosurt).
Copyrighted Material
Intended for CLARK dealers only
SM548 19-15-4
Do not sell or distribute
STATUS CODE
Afai&mrdepressaiwit!lmdirtcrian~&clu
DE!3CRKPTION MEMORY
RECALL
No
SYMPTOM
6 MRECTKWL
FonvatdorrWcIsccontactorwill not pickup. FCII REV SWlTaiES
b ?
l
POSSIBLE CAUSE m
Accehator pedal is depressed before closing forwardor IVJ~ 0
Tm
dimxional switch.
. Statuscc& will disappearwhendkcciionalswitchis
closedof whenacceleratorpedalis dead.
Defectivedimxionalswitch
* checkfmWudormene switchto insureclo~ure
whendirectionis sclccted.
STATUS CODE
-inplltvolmgctoohigh.
DESCRIPTION MEMORY
RECALL
No
SYMPTOM TBI
bwardor rcvcr3ccontactcxpicksupbutamtrolwillnatopenoe
whenatxeiuatapablisdqawsdasmttucodeMisdisplayai
hendisappmwhcnrhcvchidesrpato-
POSIBLE CAUSE
4cceluataiqmt&djnseda&fadvs
* r4nxtvolmgcuTB1simldbolcuthm3.7vola.
Adjusta@ rcalamrlmittoiasmcthsthb
voltaspuTBlwiuv8rykfll35vobtohrthM5
voltswlwltbpaWicckprud
$ICllcirccritbCtWCUl~~VCdTBlinrcelentrrinpm NEG
5rcuiL
- ~fabmkaiwimaalooaeammdonsaapcn FiopeL
potmimem/voltagcsppplyinthc~shownin
Figm 1.
STATUS INDICATION -
%artcimitfKmlbamrypoaitivetowiIingin-inppt
- niasmtMal&winbedisp&dwbmtboaadlamriItpat
volmgcuTB1ishighathm3.7voluaxirdimiod
. *
Dlsamzm wimfmmTBldm-volrageuwirc axmcmispichdup.
tomgahvcSlmuldbczfovdufapaantianwtypc
andlusthau3.7voltafll!rsdidstalctypc~
inI=
Copyrighted Material
Intended for CLARK dealers only
Do not sell or19-15-5
SW48 distribute
STATUS CODE
Accehaxinpmvoitagemolowollpowcrupa
DESCRIPTION MEMORY
RECALL No
-08 switchdome. ,
CIRCUIT Traceou
SYMPTOM
Forwad mrcvcrsc contwor doa not pick up.
POSSIBLE CAUSE
Aaxiaator input mis-adjusted (T defective. ACCELERATOR
- Input voltage at TBl should be mote than 3.0 volts.
Adjust or replace acx&ramunitttliIlsurcthatthc
voltage at TB 1 is mQe than 3.0 volts before dqessing 1
K-l
Shcrtcimitbctwcenbatmync~vcandTBlinaccd~input 4
cimlit. NEG
. -
DUcomwtwirefromTsT;checkfarshon~6iom
witeoobattctyncgativcRc&anccshouldkgrerm nrprcI.
than 4.7K ohms.
. DucoMectWkhXflTB1.MeasllrtVOl~fromTBl
* nisstamscodcwinbcdispl8yaiwhen thealxehax~
toIlcgativc.v01tagcshouldbcgxeamrthan43volft voltageatTB1islustllaa3.0volt%adany0fthcfolloeg
ifnosn@acccaxd anlnwhsrreapeaodaadclocdbumyplllgorsertswitdl
aakCySWitCh.
STATUS CODE
BothfMmdandrcversc-~hedrrrsclossdutb
DESCRIPTION MEMORY
RECALL
No
-09 sunctime.
Copyrighted Material
Intended for CLARK dealers only
SM546
Do not sell19-16-6
or distribute
STATUS CODE DESCRIPTION MEMORY No
RECALL
-15
Baany volts too low.
CIRCulT TraEtian
BATT
7 SYMPTOM CONN
+rward orrwcr3c mntactur will not pick up.
+
POSSIBLE CAUSE _t pq
Dischargedbattery BATTERY +
. Check battery fur proper open circuit voltage a~ outlined NOMINAL MINIMUM
infigml andchargebamyifrequircd BATTERY LlMiT VOLTS
VOLTS Q 1.95
Defective battery T-
BATT 24 23.4
. Checkeach baamy all for proper voltage (gnam than
CONN 36 35.1
1.95 volt? at cdl). Replace or repair barmy.
48 46.8
72 70.2
bcomct wmrol card adjustment
t 84 81.9
. Checkfunction 15 fur pmpcr adjustment for battcty
being used. See handset inmmion sheet for derails. Figurel.
Adjust u) proper settings.
STATUS CODE
Balmyvolatootigll. DESCRIPTION MEMORY
RECALL
No
-16 TraEeioo
SYMPTOM .
Forwardandrevcrscc~ willnacpickq.
gjjy
PO!#IBLE CAUSE
W
IIlc0XIWtcOllUOlC3ldadjpstmmt +
* chcckfurrriar1sfcrpropcrldjllsmpemforbatiuy
Copyrighted Material
Intended for CLARK dealers only
Do not sell or
SM548 5-7
distribute
19-l
STAWS CODE DESCRIPTION MEMORY No
IavaAidcxrdtypeselectioa, RECALL
SYMPTOM
Forwaid
orrevuscontactma
willnotchc.
POSSIBLE CAUSE
InvaMcardtypereleclioIL
* Rwiew flmction 17 in the Handset Insuuction sheets.
Adjustandsctcardtypcvai~~insaucoedbyOEM
service mamud
STATUSINDICATIONCRITERU
TlliSspmsCOdCiSdiSph)dWllCZlthCCXdtypeSCldUl
valneissertoaninvdidnumbcr.
Fcmvardarcvase-
coilcmcntlow.
STATUS CODE DESCRIPTION MEMORY
‘No
RECALL
I
23 CIRm Trmioll
!WMPTOM
FarwaniOrnvaSe caneEonWilIIlOtpiCkRpSpmrCOdC~
lltlslatcbctwecnaxle23and&24.~cbeckfaaYcb +
23,ifthcproblemisnotfolI&pcrfamc&ckfaaldo24.
- Remowp~B.Cbsekabmicvdmha1PB4oopod
tivesi&ofFcoiI.VduodmaHbal(F14dims.MJs
samcchkfaRalil.
FilarrL
IDcfcfkvc IA, RB, SP,aFWamtxxrad.
- RcmuveplngB.t3eckobmicvdnehnnpo&ivoside
OfdlCOiltOiIS~phlgcomrscdoaV~ STATUSINDICATION CRlTERu
shoddbc1614ohu. l%iSspmrCOdBiSdiSp&?dWhUlthBClSZUttQlWinthO
famda-amamx coir&l+tirkS8dU100~
Copyrighted Material
-. for CLARK dealers only
Intended
SM548 19-158
Do not sell or distribute
DESCRIPTION
STATUS CODE
‘I-2
voltage
too
high.
(circacr
than 12% of batmryvolts).
MEMORY
RECALL
No
SYMPTOM n
SCR cona-oidoes not operate.Statuscode may alterrue between
code 23 andcode 24. Completechecksfor 24, if theproblemis not F R
found,pcrfotmcode 23 check. 51 fZ t t
mul i
0 l
POSSIBLE CAUSE 6 Ic i
*1 I R
DefectiveF or R contactor. W4
l
I* .
. ForRpowcrtipsfailtoclosebecause: _W l
1) w&lai normallyclosedpowertips. *t .
wz
2) Bindingconmctortip assembly. F~ R fgiii!d~
3)DefcctivcForRctorcoiL 42 : ’
(s&staaucode23)
*
Dcmve Rwzoa~ --
* chcckRBcontactorpowertipsforclosureandprupcr F%glUtL
pick up.
* chcckforopcncircuitcrloosecomlcctionsbctwcul
positiveside of RB con- coil andPB2. STATUS INDICATION CRITERIA
ThisstatuscodcisdisplayedwhcnT2voltsisgnucrtban
Openmotorcircuit 12%ofbateryvoltsandthcFandRd1iverisencqizd.
- Checkforopencircuitorloosccomzctiuninmoar
cinxit&omthcAl comWdontotbeA2coMec&non
theSCR connol panel.
DefectivelW,SP or Fw ConW
f Pufomcimksas-illsmpr23.
DESCRIPTION MEMORY y#
STATUS CODE
1AamtacmrQesnotdropoutardropaocUskly. RECALL
P
SYMPTOM
ih~tiplifeonFandRorlAcontlrtn.Stamscode46displayed
mdno faultfound
POSSIBLE CAUSE
Yoe:Thisstatluc&canallybcfoundbyusingtheh8ndW=d -I--
1A
ookingatfuncdonl.T&issmuucodcisfoatWcdaaatnm-
kshoolingaidfarsmmscodc46
Muxive lA- T2
* CbccklArrrmym forbindingaslowaperrrdoawhcn
droppias-
T
nsm,L
Copyrighted Material
Intended for CLARK dealers only
SM548
Do not sell or19-15-9
distribute
STATUS CODE DESCRIPTION MEMORY yes
shmalcoildIivuforRB,sPmlWamacm. RECALL
-26 mm Trwtim
SYMPTOM
RB,
SP ,,r nv contactm picas up immay when J=Ywi=h is I ’ ’
:loscd.
POSSIBLE CAUSE
Defective coil driver imcmal to logic card.
* Replace logic cad.
PB6 l
PB2 l
opcnthcmld~arcutuoiovera
DESCRIPTION MEMORY No
STATUS CODE
RECALL
-41
Deflxtivethum8lpmmalx.
. DlSCQUWWifUfbllFZ1rrdpzs.A!IUXlempar
*
tmc(29Ca7YF)mmm8rui8mmbawaabtck
andgnywirt.RcpkeTPifotlmkvdIJaisgleatcxthim
3ooohu.
Copyrighted Material
Intended for CLARK dealers only
SM548
Do not sell 19-15-10
or distribute
STATUS CODE DESCRIPTION MEMORY
No
SCRmooxcum5ntscnsoritqmtmissing. RECALL
SYMPTOM
Nopowcrtoaa&nmotorinSCFtrangc.
POSSIBLE CAUSE
opsensorwin:circlittoFz4. I
. check for lcesc collncction or broken wire (green wilt) l ?Z4
from culTem sensor to PZA on the logic cad.
1
NEG
SYMPTOM
StdlcurrcnuiaScRrangehighL7thannanulawlwlcontrollabla
withCn adjustment A2
POSSIBLE CAUSE 0 -
DpcnsensorwitecitaittopP. SCR
CURRENT 0 - PZ3
- chcckfalooec- abmkenw%eQellow
Will2)hllCUUUltsaWtOpPaOiOgiCd
NEG
STATUSINDICATION -
l%ssatllscod8isdisphycdwknvolmgcbawaxlPY7
aldncg8tiveisleuthut.84voltswi$lnoclmtatflowing
inmaaacircttk
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
DESCRIPIlON MEMORY y_
STATUS CODE
IREC did not mm off propdy. RECALL
r
=44 mm Tractioa
SYMPTOM
Fonvxdarrcnnecon-opcaandd-v~-o~Y~
closedby openingaad closingthe key switch.
POSSIBLE CAUSE
Dcfaxive 5 REC circuit.
* Chcckforshorled5REc.
DcfaMJe2REcckcuiL
- Checkforshoncd2REc.
* chcckf4xshgaed2REG~~~’
fiw=L
Openchoke(lx).
. ChcckftxopcncitcuitbctwccaT5 andT3.Ohmmetcr
shouldredzaoolmw. STATUSINDICATION tDWI’ERIA
1 REC d&ctivc.
. Turnofftimcfa1RECoutofspa%nthNofidd nissmtuSco&isdiSplaycdwhctLdmingsCRopcmt+
tcstispossiblc.Rcphcc1RECafm-checks,rhow 1REcfdstomtnofE
noprobiemfouod
P
SYMPTOM
Forwardarlwene contacttxwill~aadcloa,thcaapmd
thencaaodybeclosalbycqeahgdcloeiIlgtbulay~
POS!SlBLE CAUSE
D&cfivc2REccircuiL
- chskfarshaed2RBC
* checkfa&lxmd2RECinmbba(22REC).
DCfUSiWlRECciIUtiL
- CllefAfccfJpmc.itcdar~colmscrionrbctwcuI1
REc8adpza(vvbiwbh~)
2ZREC
- CkkfaopcnL5Imlitarlotl6e-bewen1*
piopI1.
REc(3REcsmlbber)mdPz9.(bltlewire)
DZfWliVClREC!. STATUSINJXCATIONCIWERIA
Iw *. taapm1RECgmeAeJdtutm8yamay ThirSmmscadeiSd&&ycdlhen1RECfd8togaleoo.
aotshuwdcfaxRqhce1REcrfmabovecbeck&
showaoproblemfaund.
Copyrighted Material
Intended for CLARK dealers only
Stvl548
Do 19-1112
not sell or distribute
STATUS CODE DESCRIPTION MEMORY No
Loolr~oestfar’Izvoltt.(Gream~85%ofbarmyvolo) RECALL
-46 a- Traction
!3YMPTOM .
ForwardCnICVCXSCconlactcu will not pick up.
4)
POSSIBLE CAUSE
DcfBxive1 REC.
. Check for shorted 1 REX.
1A -=
0 c
. check for dcfaxivc 1 REC insulator (co-therm) that
may short 1 REC heat sink to base plate. 0 c
Ql-1.
aIs4
SYMPTOM
Fulwardor
ICWSCCUiltXXIXWiUOpCIlddo&,tkSlOpClld @au@*- @
(0866 0 ‘mc
fhencanonlykckxcdbyopelitlgaadcloringthckeyswitch
U-
7 ZIG
9!!i!q- 6 ]
P0SSIBI.S CAUSE Pm
Dcfa3ivc2REcciImit
- Chccktimt2REcwillgamaL
* Checkforupca~aloorsrmnrr?rinnbctwcea2 1
REcgam8edPzlo.(whiw&dwire)
* Chcckfuopalcimlitalawecaarr;ctiao1REc8nd m
ICthmlghthe2REcc
F@=L
ForRcontactccqowutipsbomcingapca.
- C&cktfutpo~~tipa~PaadRcooac~~ ’
QrlotbOwseopndmingapartom(&mZ STATUS INDICATION CRITERU
speedbmnpr-daw-). nlissamsccdcisdisplapdwhm~2REcfailamtmn
on.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SM548 19-15-13
DESCRIPTION MEMORY
STATUS CODE No
RECALL
Lookakadtcstfolrzvoiu(lesstban12%t0nuyvolts).
m
48 CIRCUIT T&On
SYMPTOM
Forward
orrcvcrsc
contactor
willnot pick Up.
POSSIBLE CAUSE
Dcfcctive folward or rcvcrsc c0Iltactor.
. Check for welded forward or ~crse COUtaCtOrpOWa
tips.
PO!WBLE CAUSE
Dcfectivc 5 REC ckcuit
* Checkfarshcmd5REC.
* clla&forqKatzhcuizcrloosscaurocrion-5
REC gale ami Fz12 (whiwkiolct wire).
m=t
Shurtcd2RECcircd
* Ch&2REcand2FtECsmb&r(22RE~forshcxt
cimd SIATUS INDICATION CYWERIA
Thisst8mcaleisdia@ycdwbeatbe5mC6Icrlit~.m
Dcfet.ivclzsqmci~cbcuiT. mnm.
* chcckforopulcaprcioca.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SM548 19-15-14
capcim
volt3
low. DESCRIPTION MEMORY
I
STATUS CODE NO
I50
RECALL
CIRCUIT TXtiOtl
UsA
SYMPTOM
Fonvarcimnversc coIltacmpicksup. Gxltrol does not operate. @@w9*- 69
@Q6Q 0 lREc
WSB- RD*rt
POSSIBLE CAUSE
Defective 2 REC circuit URE
,. q Q 2-c
,
open circuit or loose colltlcclion between spider
PZIC
assembly and 5 REC (BUS A).
opcllcircuitar1ooscconnectionbcnvccn5RECand
2 REC. I
open&zircuitor1oosecoMeclionbaween2REcaad ,C
I-
PZ11(raiwire)andbetween2REC~andPZlO 1 .2&c
(whit4red wile).
ml-1.
Chak2RECtoinsurethatitwillgatcon.
51
EXCCSSiVCCi3pCitIXVOlt8gCWbCllmotracmrenti.lhi~
.
I
CIRCulT Tlaceal
SYMPTOM
Fowatdorrcvcrsccontacwapenandclosc,tbcncauonlybc
closcdbyopulingandclosingthekeyswioch.
PO!B’XBLE CAUSE
Excusivcsourceinrlwrrr
+ Taglimwihmt~~beingwd.
* Bauuycabiarrslmlal~
Higbpc&cmcntinlwtlr.
- checkflxskclcdfiold~
* chcckfilrsholtcd8Tmuln8~
m-r.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
sM54a 19-l 5-i 5
STATUS CODE DESCRIPTION MEMORY yes
EXCC3SiVC~VOl~WhUIUlOtaClXUCUtiSiOW.
RECALL
-52 I
SYMPTOM
5nwaxdormmsccon~openaadclose,ti~~~ybe
:losai by opening and dosing the key switch.
POSSIBLE CAUSE
tiassive sour inductana.
. TaglineswithoutfiltPsarcbcingusai
- checkforopencimtitcrloc6eco, zlnmionill4REc
circuit.
Copyrighted Material
Intended for CLARK
SM546 dealers only
19-15-16
Do not sell or distribute
STATUS CODE DESCRIPTION MEMORY yes
ShadF.~a1Actnmcaxcoildrivcr. RECALL
SYMPTOM
zmurcd
willnotoperate.
POSSIBLE CAUSE
Defectivelogic card.
F&placelogic cad
DESCRIPTION MEMORY y#
STATUS CODE
clarcntsulsoroutpmvolagc~~c L
RJXALL
Copyrighted Material
Intended for CLARK dealers only
SM548
Do not sell19-15-17
or distribute
DESCRIPTION MEMORY No
STATUS CODE
RCgUlCUUClXSUlSXiIlpUtm RECALL
I
70 CIRCUIT Trdat
SYMlpM
culuolQesnot.operaa~ POS SENSOR 2
POSSIBLE CAUSE
Ddectivcregal sensorinput citcuit.
* chc&yellowscnsrawirefcRopcncircuitorloose
connncction between scmur (welded coMcction~ ad 7 REC
PA4
POS SENSOR 2
It ?I
YEL GRN
PA& bP*5
v
STATUS INDICATION C
TItiSspnuCOdCiSdiSphyl!4-lWhCttillpUtSigUdUPASi3
txlisshg
Copyrighted Material
Intended for CLARK dealers only
..__-.-
SM548
Do not sell or19-15-18
distribute
DESCRIPTION MEMORY No
STATUS CODE
Regulcontacalrdasnotpickup. REXALL
SYMPTOM +
Regen
conaddoesnotopemc.
POSSIBLE CAUSE
h
@Cn COMCCtiOn PA6 C&lit.
in thC
DRIVE
MOTOR F82 PA6
. c&?ck for open circuit or loose COnneCtiOn between PA6
9
and the A2 connection of the RB contactor. A2
17
. chcCkfOrOpen&Cllit~hJSCCOMCCtiOnbCtween~ 0 A
REcandthcA2conncctionofthcRBcotltacaa. - 13%
C0&4CTOR
A2
FisrvcL
_. - - -
DESCRIPTION MEMORY
STATUS CODE
RegCtlWHJICtordOMnotdlUpO RECALL
Yes
SYMPTOM
Forward~rCnnecOntWtXopmsandcloses,thUlapauandCm
onlycloscbyopcningandclosittgrbckeyswish.
DRIVE
POSSIBLE CAUSE MOTOR PA6
Defecti~ RB camcta.
A2
. check- amactccfa-dopartiolland l7
exasaivewematmovillgpatu. *
4c
W-1.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
DESCRIPTION ’ MlBfORY yes
STATUS CODE
Rcgcncon~pi~upmslow. RECALL
II
74 -CUI’I Tracrion
SYMF’TOM +
ForWdCatWCtSC contm%x opens anti closa thal opens and call &.
oaly close by o@llg and closing the key switch.
DRIVE &
POSSIBLECAUSE MOT6R PB2 PA6
Defective RB comactor.
* chcckRBclmacmforsm00rhn~0foperationand A2
17
excessive war on moving part%
4c A
WS SENSOR 2
!SYMPTOM
blwaxdor meneam~opauaadclorer,tbenopcluaudCan
mlycloscbyopeningaadclaingtbckyswiacb
POSSIBLE CAUSE
lREcmtnofffailuIenotrttosdto~
* sallvchicleillbath-Ildmculystrmrcodw
displ8yaltbatm8ymoR8clcmlydeenstbshilmemode.
TtDUb&S&OtprnSrSt8tMCOdR
LRECtUUlOffrckosdtOrsgse 0
* ckkfabors- akdlrgmpmlm~ -RB cgml
halbawypodivomRB-Azcooasrioa.
* c!kkfaloo88~gntbe~~inpn M
cixcuiu. +
~Ydlowwirefmnseasa2toPA4
.ckenwilekanscnsa2tQPA5. PiolrrrL
~wii17eunRBcaomcuxtDPA6.
mAm INDICATION tXW%RlA
DefectivcmuKrdrcoit Tbi#Smxuc&iSdi@yedwllalalyf8ihm3af1REcto
. Checkmoaxciadtftrapmalawamsuias
=~dpriruwcyck
- chccklnotfx~far~serring.
ForRammcaxpowexbounciqopa~
- InsurctbatFatdR conmcbxcbesnotbormcs~
dnrhlgld?iclc~(ii~ovsrspsod
Copyrighted Material
bmnprrrddOCk~~-
Intended for CLARK dealers only
DoSW548
not sell or distribute
19-15-20
capaEirorovavoltagcdlningrcgcn.
DESCRIPTION MEMORY’ yes
STATUS CODE
RECALL
I
76 CIRCUIT TlXCtiOLI
SYMITOM
Forward or ICVCISC contactor opens and closes, then opens and can
only close by opening and closing the key switch /I *
FUSE LINE
BAT-r fl CTFI
CONN CAPACITOR
POSSIBLE CAUSE
l
Intmminenr connection in battery power circuit 1 F T
DESCRIPTION MEMORY No
STATUS CODE
uscrddinaistaalscode-seeoEM RECALL
!WMPTOM
staalsccdeflashcsonandoff.vchiclcspeedmayarmaynotbe
pz%iFJ
1
BATTERY _I
NEGATIVE
- DcfcctivuMn4lcard
FtprcL
NoTE:WbenSCRpump~isusaiwithinmnrlT~~l
fllDClkiDpUtt+Z&WdiSPA3OnprnnplOgiCcard STATUS INDICATION CRITERIA
ThiS~CCJ&kdiSp@3dWhL%t&~8ttUkMl1
dTMMliS8t?XOvalrr.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SM!548 19-15-21
USQd&ixdscamscocle-sccO
STATUS CODE DESCRIPTION MEMORY No
RECALL
91
L
I TMMl
SYMPTOM
StfltUSCO&flashesOllandOff.
POS!DLE CAUSE ‘- ;;
f&r defined
satuscodeisdisplayed
byswitch closure to negative. 3
. See OEM insuuction manual for c0mctiVe action
requind
SW3
orhcrcauses:
. Tenninal3shatedtonc@vc.
BATTERY T
. Dcfkctivc iuput swiazh(she). NEGATIVE
. Defoctire:~&s~
Figurel.
NoTE:WhcnSCRpumpcoadisdwithintcd~~
fuucti0ns~inputccImiMlisPA6onthcpumplogiccald
STATUSINDICATION CRITERIA
Thissmalscodcisdisplayalwhentllevollageatlrdd3
OfTMMlisat~VOlU.
UscrddildstamsCOdt-WOEM
STATUS CODE DESCRIPTION MEMORY No
RECALL
-92 TMlUl
SYMPTOM
St%llSCOdCfhShSOlldC&
&v
POSSIBLE CAUSE
USad&IlCdSCWCUkisdiSpiryed~SWitChcbrratOI&@iVC 4
* scc0EMiasulmhdbrr cmuxivertiao
lsqpirsd
SW4
otbrcausuz
- Tcnnid4shamdtnmgmiva
BATTERY _I
NEGATIVE
-inpotrwioch(rborsd).
N~WhcnSCRpampcaaadisrwdwithintanalTMMl RonrL
functi~,inppt-isPB6oathc~ca1d.
SIATUS INDICATIONCRITERIA
nissaal8aYdlDisdiqkycdwbmtbvollageummiml4
ofTMMlisatosn,vola
Copyrighted Material
Intended for CLARK dealers only
Do!3&48
not sell or distribute
19-15-22
DESCRIPTION MEMORY No
STATUS CODE
uscrdalalstaalscak-scfoEMills RECALL
-93
SYMPTOM
Stamscode flashes on and off. Vehicle speed may or may not be
POSSIBLE CAUSE
Userdefinedstatuscodeis displayedby switch closure or motor
brush sensor closurt to negadve.
. SeeOEM’ueanmion manual for concctive action
required
3thcrcausex
* Tuminal5ur6shortcdtonc8ativc.
wYIE:when SCR pump control is used with interal TMMl func- STATUS INDICATION CRITERIA
ions,inputtumiaalisPA1andPA2onthepumplogiccard. ThisstatuscodeisdisplaycdwhetIthevokagcat-5
a6ofTMI4llisatzcrovoIa.
DESCRIPTION MEMORY No
STATUS CODE
uscrd&IlaismnlsaYde-seeoEM RECALL
SYMPTOM
statusccldeflashesoaand&
POSSIRLE CAUSE
Usad&ncdstatuscodcisdisplaycdbyswkhclosutcamoax
bmshscnstxclosuretotlcgative.
- sccoEM-maml8lfor camdvedal
reqpirrd
otk(Taulcs
- TenlliMl8ar1oskrEdtotBgntiv8.
* DcfadvcTMMlcatd.
FioaL
NUIE:Wha~SCRpumpaxwlku&withimunaITMMl
funcdw,inputte&ulisPA4aadPASontbcpumplogicatd STATUS INDICATION m
Tl1iss~mr~icdispl@wbattbevoimgcatmminll8
trlOdTM4llLaoaovolQ
Copyrighted Material
Intended for CLARK dealers only
Do not sell or
SM548 distribute
19-15-23
uJerdcfinaisQuu¶codt-scc
STATUS CODE DESCRIPTION MEMORY No
RECALL
SYMPTOM
StupsCOCkfhk3OlliUldOfE
POSSIBLE CAUSE
u~a defined SEUUScode is displayed by switchclosureor motur
brushsensorciosuIeto negalive.
* sccoEh4 -on manualfor clxraxive a&m
SW12
nq-
otbcrcauses:
. Tumid11or12shortcdtoncgatin.
* Dcfcctivcillputstitch(shorted~.
. .._ .-.
- DdkctivcTMh41cad
W-L
NOTEzWhcnSCRpumpcontrolisuscdwitbintcd~l
lillbau,inputtcHniMlisPB1andPB2ondlcpumplogiccard. STATUS INDICATION CRITERW
TbissmmsaYdeisdisplayaiwhe.nthcvol.lagcat-
11cc12dTMMlisatzaovolu.
STATUS CODE
halidcardtypescibiaa
DESCRIPTION MEMORY
RECALL
No
m
117 CIRCUrr Pump
SYMPTOM
3nttol will not opera@.
POSSIBLE CAUSE
iwalidcaldtypesekcIiaA
* Revicwtilucwl17inthe~Inmpctionskcu
AdjustudxtcktdypevalmuinsaaadbyOEM
xkalumunl
-1.
STATUSINDICATION m
Tbisstanscaleisdirplrysdwhen~cadLypo#Lcrioll
vabai8aetmmilmlidMmlbm.
Copyrighted Material
Intended for CLARK
SM548 dealers
19-l 5-24 only
Do not sell or distribute
STATUS CODE DESCRIPTION MEIVORY No
Pump contactor coil cmrult low. RECALL
SYMFTOM
?ump amtactor will not pick up. Status code may alternate between r
t
:odc 23 and code 24. Complete check for code 23, if the problem is
lot foul& perform check for ccdc 24.
+
Figurct
STATUSINDICATIONCRITERIA
Thisstatusco&isdisplayedwhenthecurrcntdrawinthc
pumpcQntactor~circuitislcssfhan1ooma . .
STATUS CODE
12 DESC~ON MEMORY
RECALL
No
-124
voltage too high. (Greater than 12% d battery volts).
CIRCUIT Pump
T2
SYMPTOM
iCRcontroldounotaperate.S~WdC~yalta7WEktween
~123andcode124.compleoecbccbta1~,iftheproblemis P P
lot folK&pufcamcode 123chaTk.
POSSIBLE CAUSE F +
Dcfaxivcpumpalamazx. R +
* PlmlppOWtip6failtocloeblWLW * m4*
m l
nolrc1.
Opcnmoax&xiit
* aKckforapaltzimitarloose-in-
citcuit&xnt&Al amaecoimm~A2rmnrrirrral STATUSINDICATIONCRITEXIA
thCSCRCUtUCdpUlI& lItiSsatluCOhiSdiSp&dWhT2VdC3iSgresmlhtl
1246ofhaacryvQIuandtIlopumpdIivcrk~
Dcfazdvc 1A contxtu
- PufatnchazksasomlinsdinsmtiL9123.
Copyrighted Material
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Do not sell19-15-25
SM548 or distribute
STATUS CODE DESCRIPTION MEMORY yes
1Aconmcux&ullotriropoutordFopsoatdowly. RECALL
I
125
POSSIBLE CAUSE
Nooe:Thisstanwcodecanonlybefouadbyufiagthehandsetand 1A
lootigatfumion1.Thisstatusaxieis~asam-
bkshooting aid far statuscode 46.
Defective 1A amtsxce T2
a CkcklAcootacou forbindingarslowopcmionperationwhen
,drapping-
T--f-
Figurel.
STATUS CODE
open~~ar’amcrdoverpempr
DESCRIPTION -OR’
RECALL
No
I
141 I CIRCUIT Fkup
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SM648
Do not sell 19 5-26
or distribute
STATUS CODE
scxulotcralucn~scnsorinp
DESCRIPTION MEMORY
RECALL
No
.
I)
142 CIRCUIT Pump
VOM
NopowcrmpumpmotorinSCRrange
POSSIBLE CAUSE
Dpalsensorwirt~tsoPZ4.
. Checkfor loose cmnection or b~~kcnwtt @en wire) SCR * PZ4
fromcurrcntscxwxt0pz4onthclogiccard. CURRENT l
*
NEG.
I
143 CIRCUIT Pump
CAUSE +-
POSSIBLE 0 *
opulsaufxwirccircpitmm. SCR
.PZ3
- amck6ahFmnerrirra 4cbm&awixuo_tlbw CURRENT 0
Wh)hlIlcmrsntsQ#lOpL3OnlOgiCd
NEG
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stma
Do not sell19-i
or distribute
5-27
STATUS CODE DESCRIPTION MEMORY yes
RECALL4
1144
lRECdidnotumloffpropdy.
CIRCUIT Pump
*
SYMPTOM
Pumpconnrctonapenardclose,thtncanonlybedosedbyapen-
illgaxldclasingdlckcytitch.
POSSlBLE CAUSE
Defective 5 REC circuk
- alcckforshort#15REc.
. check-2 ~.&@&~_---- “.
FigurrL
3pcn ChokB(lx).
- CbaAforopcacitcuitbetweenT5andT3.Olmmctcr
shouldrwdoeroohtm. STATUS INDICATION CRITERIA
I RECdefective.
+ TumofftimcfcrlRECoutofspaSMmNoiicld ThisstamscodctidisplayaiwhcsdmiagsCRopention,
tcstispossibkRcplacc1REcaffrraboveckckshow l~Cfails~~o&
llOpblUllfOUd
=145
1REcdidaotalnlonpropdy.
CIRCurr Pllmp
SYMPTOM
Rmlpamortorwillopalaudclmc,~opalrmd~caadybc
ascdbyopmitlgadfuiagthekcyswitdL
POSSIBLE CAUSE
D&ctivc2REccitcd
* amckfmdnxd2REc
MCCtiV81RECchcpit
* Ckcktrropea~arbas--1
Rxalldzz3.(wbiwblmwim)
2aEc
* c2Eck~opcacimitarlooso-bawren1‘
RahL
REc(3REcsnubller)andm9.(bhlewite)
Copyrighted Material
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Do not sell19-15-28
SM548 or distribute
STATUS CODE DESCRJPTION MEMORY No
RECALL
-146
IJJakabmdwtfarnvoia.(Grwiuth8n85%afbannyvala)
ICIRCUIT I
Pump
POSSIBLE CAUSE
3efccTivc 1 REC.
- chcckforshoncd 1 REC.
- checkfordcfcclivc1REcinsula.tcR(c&thum)ti
mayshcnt1REchcatsinktobasephte.
-147 1
2REcdocsnottlmlonpzupcrly.
CIRCUIT Pump
4
SYMPTOM
Ehlmpccmzmorwillopulanddoae,rbenopalaudthulcanonlybc
clc4aibyopulhgandclosingthclRyswitch.
POSSIBLE CAUSE
De~vc2REccircpa
* c!lecktha2REc!willgmaa.
- (=heckfaopencilcuitalam-between2
RJx@mmdPzlO.(~wirt)
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
St&j48 19-15-29
STATUS CODE DESCRIPTION MEMORY No
RECALL
-148
~Pbedtutfor~vdu(lurdwt12%ktpayvolts).
i
CIRCUIT Pump
POSSIBLE CAUSE
kfuxiw fcmvatdar IcverscCuIl-.
* ckckforwcl&dfawdarlEvctsc contxuxpowu
tips.
* cIleckforsluggishopmtionoffaw8tda-
QIIMQ.
hfdve3REcl5xcniL
. c&&far-j&& .’ %‘.
* Cbcckfcfsbatcd3RECsaIlbkr(23REC).
bcs8tcaxeuly.sccflmction17far-~ tm 12’Adbacryvaltr
STATUS CODE
ICIRculT I
Pump
I I A
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Do not sell or19-l
distribute
5-30
SM548
STATUS CODE DESCRIPTION MEMORY
No
RECALL
150
CapnciDxVolLs
low.
I
CIRCUIT Pump
as.
SYMPTOM
bmp contacmrpicksup.Control does not OPcIatc. 6aOQ*- Q
aaaa 0 IRc
WS8- mm
POSSIBLE CAUSE Y-
kfective 2 REC cinxit. d 2=
q i
Open circuit or loose connectiOn bctwaa spider
PZIO
assembly and 5 REC (BUS A).
t
chadc2REca,insurefhatitwiugflreon. Figurel.
Exccssivccapacitor~whenm DESCRIPTION
STATUS CODE MEMORY yes
RECALL
-151 MP
SYMPTOM
mmpconlactorupcnaudclose,thulcanonlybcclwedbyopening
andclosiagthckcyswirch.
Highpeaklzuncntinmour.
- ckkftxshatcdfiddwindirlg.
Copyrighted Material
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Do not sell19-l
SM548 or distribute
5-31
STATUS CODE
Excessive
capaciufrvoltage
when DESCRIPTION MEMORY yes
-152
momrcmxemis low. RECALL
CIRCUIT pump
SYMPTOM
Fumpconracm open and close, then can only be ~bscd by opening
and closing the key switch.
POSSIBLE CAUSE
Excessive source inductance.
* un-filteredtaglines arcbeingusal.
Dcfaxivc4REccircuik
* chcckforsholTcd4REc.
- checkfoLclpeaL~-C~~ rg;
cYircuit.
QiP=1.
kfcctivc 3 REC circuil.
* chcckforqmlcircuitorloosc coMcclioniJl3REc STATUS INDICATION CRITERIA
CirclliL TllissmmsaxkisdispIa~whcnc8pacit4xvoltscxca?d
22!5voltYandmotxxclxmzntisle3sthanu)oalnp&
-154
Sharadpumpa1Aammcnxcoildriver.
. CIRCUIT Pmnp
SYMPTOM
Conaol will not F.
POSSIBLE CAUSE
DefectivclogiccaIli
. Replacelogicard.
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Intended for CLARK dealers only
SM548
Do not sell or19-l 5-32
distribute
STATUS CODE DESCRPI’XON MEMORY j yes
cumnt)Qw oqmt voltqppoinityc&CL RECALL
SYMPTOM
Pump conmcwr open and clwe. rhen can only be closed by opening
and closing the key switch.
POSSIBLE CAUSE
Rverxd yellow and green current scnors wires
. Inslmrllafthe:-grceawimconnect,mPz4withnO
open circuiu.
-yellow wire comam to PZ3 with no
open circuiu or loose cotuleaions.
Rcvenedpowacablc~
. rnsumtbatthebalmyncgilivccablecaMecatoscR
NEGandthemotaA2cablecotmaxsmSCRti
L
STATUS INDICATION CRITERU
Thissranucodcisdisplaycdwhal~volagciaputtopz4
aadPz3istkwnlagpolmi~.
Copyrighted
SMs48 19-15-33
Material
Intended for CLARK dealers only
Do not sell or distribute
CHECKINGCOMPONENTS
Ail trouble-shooting is written to check all outside devices and eliminate them as the source of the
symptoms. The conclusion being then that the card is faulty.
Unplug A, B, and 2 plugs by pressing down on tab with wide blade screwdriver
and rotating 90 degrees.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Capacitor 1C
Disconnect the battery and discharge the capacitor. Measure ohms through the capacitor using the R
x 10,000 scale. Meter should read zero and then swing slowly to above 100,000 ohms. Replace the
capacitor if above reading is not obtained.
NOTE: . ..
Control is arranged so that the F and R contactors do not break currenL Check to see that
the 1A contactor drops out before the F or R contactor.
Most contactor coils are polarity sensitive. The left-hand termir& must be connected to
positive.
Potentiometer in Accelerator
To check operation of the potentiometer, discoxmectthe battery and disconnect the wire
at control card TBl. Connect a VOM to the wire that was removed from TBl and to
negative. Place the VOM on the R x 100 scale. With the accelerator in the creep speed
position, the ohms reading should be 4800 to 6000 ohms. With the accelerator in the top
speed position, the ohm nading should be 50 ohms or less. With the wire disconnected as
above, check for resistance of 1 megohm or higher fi-ompot wire to the truck frame.
These arc silicon controBcd r&.&rs. Before checking, disconuect the battery and
discharge Ci3&&~ lc Disconnect gate leads Of Sa’S at the sa tCKflid
Coxwct the positive lead to the anode, co~cct the negative lead to the cathode as shown
m 0 0
SM548 19-16-2
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
NOTE
Copyrighted Material
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control card. Read the resistance between these two wires with the VOM set on the R x
900 scale. VOM should read 100 to 200 ohms if the 1REC heatsink is at room tempera-
ture (25C or 7%). Set the VOM to the highest ohm scale and read Tom each wire end to
the 1REC heatsink Reading should be infinity.
Filter Block(23FLetc.)
To check, disconnect all wires f?om the filter block on removal f?om panel. With VOM on
the R x 10,000, touch the leads to the filter terminals to charge the filter. After a few
seconds, reverse the meter leads and touch the filter terminah The VOM needle will
deflect and return to infinity. If this capacitor action is not observ& replace the filter
block.
Filter block test 4K is only to detect an open or shorted filter. If the control has sympo-
tams as in lE, inter-change22REC and 25REC and tq again. If the problem is corrected,
the old 25REC is marginal and should be replaced If the problem is not corrected replace
both filters.
Refm to panel wiring diagram to locate windings. With VOM on R x 1 scale, measure
choke or reactor winding. Reading should be less than 1 ohm.
Copyrighted Material
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Do not sell or distribute
REPLACEMENTOF EV-100 COMPONENTS
When replacing stud semiconductors such as 3REC and 4REC, it is not necessary to torque these
devices to a specific value.
Remove module by backing out the two screws at the &vice sides.
Clean the insulator surface with a clean rag and isopropyl alcohoL
Inspect the insulator surface for tears or cracks. If defective, replace. Wipe a light layer.
of machine oil on the base and smooth the insulator into position.
NOTE: Insulator not required for 2REC and SREC.
Set new module on insulator and start screws back into base. Be sure to use the original
screws and washers. Run screws in to base “finger tight”.
Check that the bottom of the module is flat against the insulator or base.
Capacitor
Reverseproc&mtoreplacecapacit(=
NOTE: When replacing these devices, use the original hardware in the same holes, as the
inserts are used for electrical connections.
Copyrighted Material
Intended for CLARK
SM548 dealers only
19-18-8
Do not sell or distribute
EVl 00-LXT
CARD
FUNCllON
SET-UP
OCT91
19-l 6-6
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
EVl 00-LXT
CARD
FUNCTION
SET-UP
FAULT CODE
I 8 I 001 NA .
9 001 NA
10 001 NA
I 11 I 001 NA
I 001 NA
13 001 NA
.
14 15 IR COMP
I .
16 38 - 42 PEDAL PLUG
17 000 - 004 CARD lYPE .
OCT91 SM548
19-16-8
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
EVl 00-LXT
CARD
FUNCTION
SET-UP
4 . .
250 - 255 C/L
5 148 - 152 PLUGGING
I.
0
I.
250 - 255 106 - 110 1ADO
7 001 - 003 TURN SWITCH SPEED LIMIT
.
.
8 001 I I NA
I.
I
9 001 NA
I.
10 001 NA
I.
11
I.
052 - 055 TURN SWITCH SPEED LIMIT
12 001 I I NA
I.
1
13 001 NA j
I.
14 14 IR COMP
I.
15 I.
032 - 044 BATT VOLTS
16 038 - 042 PEDAL PLUG
I.
17 I.
000 - 004 CARD TYPE
18 175 - 177 S/P TIMER
I.
I.
I.
I.
OCT 91
19-16-9
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
EVl 00-LXT
CARD
FUNCTION
SET-UP
TM TRUCKS ONLY
FUNCTIONSElllNGS
CODE I TM22l25 W/EE I
EXCEIT SElllNGS FOR
TM22/25 WIEE I DESCRIPTION
I FAULT CODE
2 018 - 022 CREEP
3 004 - 006 C/A & 1A TIME
4 250 - 255 C/L
5 148 - 152 PLUGGING
6 250 - 255 106 - 110 1ADO
7 001 - 003 TURN SWITCH SPEED LIMIT
I 8
9
! 001 1 I NA
r 001 NA
10 001 NA
11 052 - 055 TURN SWITCH SPEED LIMIT
12 001 NA
I NA
I 14 I 14 I I IR COMP
15 032 - 044 BATT VOLTS
16 038 - 042 PEDAL PLUG
17 000 - 004 CARD TYPE
18 175 - 177 S/P TIMER
OCT 91 SM548
19-16-10
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
T
OP15B ONLY,
FUNCTION
SETTING DESCRIPTION
CODE
*These functions control the speed of the vehicle when mast is raised.t never
be bvoassed or set above the soecifications described above.
The function should be adjusted to the prescribed setting and then the speed of the vehicle
should be checked and the function readjusted, if necessary.
Function 11 controls the speed of the truck at lift heights between 24” & 150”.
Top speed of the truck must be 2.5 MPH.
Function 12 controls the speed at lift heights above 150: when traveling
in a straiaht line.
Top speed of the truck must be 1.O MPH.
Function 13 controls the speed of the vehicle af lift heights above 150” when
the truck is steered beyond 10 degrees off center and when above 226”.
The truck must not travel though the contactors will close.
The travel speed is determined by timing the vehicle through a 50-foot run.
At 2.5 PMH, the vehicle will take 14 seconds to travel 50 feet.
At 1.0 MPH, the vehicle will take 34 seconds to travel 50 feet.
OCT 91 19-16-11 SM548
Copyrighted Material
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Do not sell or distribute
1I
EVl 00-LXT
CARD
FUNCTION
SET-UP
OCT 91 19-16-12
Copyrighted Material
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Do not sell or distribute
GROUP 20 SECTION 01 Check fluid level by removing dipstick on the right
hand axle end. Wipe dipstick clean and reinstall.
DRIVE AXLE Remove dipstick and examine. Fluid level should
be between the two marks on dipstick. If fluid level
is low, add enough fluid to bring level up to full
mark on dipstick. DO NOT OVERFILL.
SM556 20 - 01 - 1
Copyrighted Material
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Do not sell or distribute
DRIVE MOTORS Y&i!
_
20-01-04 DRIVE AXLE REMOVAL 9. Remove drive wheels.
MAKE
n!
SURE
WARNING
BLOCKS ARE n ! WARNING
SECURE AND PLACED SO THAT USE ONLY APPROVED HOIST, CHAINS,
CLEARANCE TO AND STRAPS TO LIFT THE DRIVE AXLE
THERE IS
AXLE WITHOUT AND MOTORS. BE SURE HOIST AND
REMOVE
INTERFERING WITH BLOCKING ACCESSORIES HAVE CORRECT
CAPACITY TO SAFELY SUPPORT THE
OR TRUCK.
LOAD
SM556 20 -01-2
Copyrighted Material
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Do not sell or distribute
IMPORTANT
TO AVOID INJURY, REMOVE AXLE
MOUNTING FASTENERS IN THE
FOLLOWING ORDER
20,239 - g
17. Remove axle rear mounting fasteners (items
90.358, 94.085, & 20.377) from each side of
frame.
SM556 20 - 01 - 3
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
PINION SET
20.337 RH /
ASSEMBLY
CoMPLErE
20.376 1
DRIVE AXLE - RH
20.376 AXLE ASSEHSLY, DRIVE RH 20.542 BEARING, DRIVE AXLE SHAFT OUTER
20.201 SRM, DIFFERENTIAL PINION BEARING CARRIER 20.544 SEAL, DRIVE AXLE SHAFT
20.212 SEAL, DIFFERENTIAL PINION BEARING CARRIER 20.546 FASTWER, DRIVE AXLE END HOUSING
20.227 FASTENER, THICK FLANGE TO AELE HOUSING 20.553 CONE, DRIVE AXLE SHAFT INBOARD BEARING
20.228 FASTENER, THIN FLANGE TO AXLE HOUSING 20.565 RETAINER, DRIVE.AXLE SHAFT BEARING
20.230 CONE, DIFFERENTIAL PINION BEARING 20.579 CUP, DRIVE AXLE.SRAFT INBOARD BEARING
..- SHAFT; DRIVEAXLE
20.236 CARRIER, DIFFERENTIAL PINION BEARING 20.586’
20.238 SHIM KIT, DIFFRRENTIAL PINION BEARING CAGE 20.636 SRAFT, DRIVE AXLE RING GEAR
20.239 FASTENER, DIFFERENTIAL PINION BEARING CARRIER 20.638 CONE, RING GEAR SHAFT OUTBOARD BEARING
20.240 SPACER, DIFFERENTIAL PINION BEARING 20.646 CUP,RINGGEAR SHAFT INBOARD BEARING
20.248 RING 6 PINION SET, DIFFERENTIAL 20.647 LOCATOR, DRIVE AXLE SRAFT INBOARD BEARING
20.252 CONE, DIFFERENTIAL PINION INNFR BEARING 20.649 CUP, DIFFERENTIAL PINION INBOARD BEARING
20.288 SPACER, PINION BEARING CONE 20.666 SPACER, DRIVE AXLE RING GEAR SHAFT INBOARD BRG
20.316 CUP, DIFFERRNTIAL PINION OUTBOARD BEARING 20.667 SPACER. DRIVE AXLE RING GEAR SHAFT
20.387 HOUSING, DRIVE AXLE RH 20.668 SPACER, DRIVE AXLE SHAFT INBOARD BEARING
20.427 PLUG, DRIVE AXLE DRAIN 20.819 NUT, DRIVE AELEPINION SRAFT LOCK
20.520 RETAINER. DRIVE AXLE SHAFT GEAR 20 e 835 RETAINER, DRIVEAELERINGGEAR
20.522 GEAR, DRIVE AELE SHAFT 20.837 CUP. RINGGEAR SHAFT OUTBOARD BEARING
20.524 BEARING, DRIVE AXLE RING GEAR SHAFT 90.663 DCWEL RING, AXLE HOUSING FASTENER
20.539 HOUSING, DRIVE AXLE END RH 95.782 FASTENER. DRIVE AXLE SHAFT BEARING RETAINER
SM556 20 - 01 * 4
Copyrighted Material
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Do not sell or distribute
26. From inside the axle end housing, use a soft
hammer to drive the output gear pinion (item
20.636) out of the housing (item 20.388).
Remove loose inner bearing cone (item 20.524)
from housing. Clean and inspect bearing for wear
or damage. Replace as required. Bearing cone and
cup should be replaced as a set. Remove spring
bushing (item 20.667) from output gear pinion.
20. Remove the output shaft (item 20.588) from 3. Inspect all components for wear or damage.
housing cover. Replace as required.
21. Press outer bearing cone (item 20.542) off 4. Replace all oil seals and O-rings.
output shaft (item 20.586). Clean and inspect
bearing for wear or damage. Replace as required. 5. Use Permatex”and Loctitem only where
Bearing cone and cup should be replaced as a set. specified.
22. Remove oil seal (item 20.544) and outer 6. All lead-in chamfers for oil seals and O-rings
bearing cup (item 20.542) from housing cover must be smooth and free from burrs. Inspect at
(item 20.539). assembly. Correct as necessary.
23. Remove snap ring and back-up ring (items 7. Coat all bearings with transmission fluid before
20.647 & 20.668) from housing cover (item installing.
20.539).
SM556 20 - 01 - 5
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3. Slide spring bushing (item 20.667) onto output install flange & pinion assemby. Torque capscrews
gear pinion (item 20.636). install pinion into axle to [67 Nmm]49.5 Ibfeft.
end housing (item 20.388).
15. Lock the bevel gear nut (item 20.835) by
4. Install inner bearing cone (item 20.524) onto crimping the nut into the groove in the end of
pinion (item 20.636). Install spacer (item 20.666), pinion shaft (item 20.636).
bevel gear (item 20.248), Apply Locktitem No.92
to a new bevel gear nut (item 20.835) and install. Install inner bearing cup (item 20.579),
Tighten bevel gear nut to give a running torque of &&ig ring (20.668) and snap ring (item 20.647)
[0.7 Nom] 6.2 Ibfain on the pinion bearing. into axle end housing (item 20.388).
5. Install pinion bearing cups (items 20.316 & 17. Install outer bearing cup & cone (item 20.542)
20.649) into motor mounting flange (item 20.236). into output shaft housing (item 20.539). Apply a
thin coating of grease between the lips of oil seal
6. Press inner bearing cone (item 20.252) onto (item 20.544). Apply a thin layer of Permetexm #2
pinion (item 20.248) and insert pinion into motor to the outside diameter of oil seal and install.
mounting flange (item 20.236).
18. Insert output shaft (item 20.586) through
7. Slide backing washer (item 20.240), spring housing (item 20.359). Do not damage oil
bushing (item 20.288), backing washer (item seal (item 20.544) with spllnes of output
20.238), and outer bearing cone (item 20.230) shaft. Slide output gear (item 20.522) onto shaft.
onto pinion (item 20.248). Apply Locktite TMNo.92 to nut (item 20.520) and
install. Torque nut with special tool to j200 Ngm]
8. Apply Locktitem No.92 to slotted nut (item 147.5 Ibfeft . Use fabricated tool to keep output
20.819) and install on pinion. Tighten nut to give a shaft from turning.
running torque of [0.5 Nom] 4.4 Ibfain on the
pinion bearing. Use special tool to torque nut. 19. Apply a thin layer of Permetexm #2 to
machined surface of housing cover (item 20.359).
9. Check motor pinion and bevel gear mesh Apply Lo&item No.92 to capscrews (item 20.546)
adjustment. Note: Mesh adjustment is made with and install housing cover to axle end housing
motor mounting flange shims (item 20.201) and (item 20.388). Torque capscrews to 167 Nom] 49.5
bevel gear spacer (item 20.666). Mark teeth of Ibfaft .
motor pinion and bevel gear with gear checking
compound. 20. Slide bearing cone (item 20.553) onto output
gear shaft. Apply Locktitem No.92 to nut (item
10. Install flange & pinion assembly into axle end 20.565). Install nut and torque to [68 N*m] 50.2
housing (item 20.388), using shim (item 20.201) to Ibfeft with special tool. Apply Locktite” No. 92 to
align assembly with housing. Install and tighten locking screw (item 95.782). Lock nut (item
only 2 flange capscrews (item 20.239). Note: Do 20.565) with screw. Torque screw to [13 Nom] 9.6
not install O-ring (item 20.212 at this time). Ibf*ft.
11. Rotate the pinion several times in a clockwise 21. Apply a thin layer of Permetex” #2 to
or counterclockwise direction and check against machined surface of axle end housing flanges.
the tooth bearing contact chart on pages 8 & 9. Mate the two axle end housings together and drive
Pinion gear backlash should be 0.0078 - 0.0040 in roll pins (item 90.663). Apply Locktitem No. 92
inch. ..I .; to capscrews(item 20;227. & .20.228) and fasten
axle end housings together. Torque capscrews to
12. Adjust pinion by changing the number of [67 N*m] 49.5 Ibfmft.
flange shims (item 20.201). The bevel gear is
adjusted by grinding the gear spacer (item
20.666) to the thickness required. Use a surface 20-01-07 DRIVE AXLE
grinder to remove material from the gear spacer. INSTALLATION
13. When gear mesh adjustment is correct, 1. Make sure truck is blocked in a secure manner
remove (2) capscrews and flange & pinion and that there is clearance to move axle in place
assembly. Coat O-ring (item 20.212) with from underside of truck without disturbing
transmission fluid and install. Apply Locktitem blocking.
No.92 to all flange capscrews (item 20.239 and re-
SM556 20 - 01 - 6
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2. install drive motors to d&e axle assembly. Refer 16. Connect battery and test drive axle operation.
to drive motor installation group for details.
fi ! WARNING
USE ONLY APPROVED HOIST, CHAINS,
AND STRAPS TO LIFT THE DRIVE AXLE
AND MOTORS. BE SURE HOIST AND
ACCESSORIES HAVE CORRECT
CAPACITY TO SAFELY SUPPORT THE
LOAD
IMPORTANT
TO AVOID INJURY, INSTALL AXLE
MOUNTING FASTENERS IN THE
FOLLOWING ORDER
SM556 20 - 01 - 7
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SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
FIG. 1
w
FIG. 2 \%+ .
TOE BEARING ON BOTH SIDES OF TOOTH - GEAR SET NOISY. TO MOVE -: _ ‘I,
BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOV- ‘1 \
.h
ING GEAR AWAY FROM PINION.
FIG. 3
FIG. 4
FIG. 5
BACKLASH
BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICU-
LAR TO THE TOOTH SURFACE AT THE EXTREME HEEL.
SM556 20 - 01 - 6
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SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
LARGE END ALL CONTACT BEARINGS SHOWN BELOW ARE ON RIGHT HAND SPIRAL
RING GEAR - THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH.
FIG. 1
TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH
WHILE UNDER A LIGHT LOAD
FIG. 2
TOE BEARING ON BOTH SIDES OF TOOTH - GEAR SET NOISY. TO MOVE
BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOV-
ING GEAR AWAY FROM PINION.
FIG. 3
HEEL BEARING ON BOTH SIDES OF TOOTH - GEARSET NOISY AND
COULD RESULT IN EARLY GEAR FAILURE. TO MOVE BEARING TOWARD
TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD
PINION.
FIG. 4
LOW BEARING ON GEAR AND HIGH BEARING ON PINION. CORRECT
BY PULLING PINION AWAY FROM GEAR (INCREASE MOUNTING DIS-
TANCE.
FIG. 5
HIGH BEARING ON GEAR AND LOW BEARING ON PINION. CORRECT
BY MOVING PINION IN TOWARD GEAR (DECREASE MOUNTING DIS-
TANCE.
BACKLASH
BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICU-
LAR TO THE TOOTH SURFACE AT THE EXTREME HEEL.
SM556 20 - 01 - 9
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GROUP 22 SECTION 01 22-01-02 CUSHION DRIVE TIRE
REMOVAL
CUSHION WHEELS AND
TIRES
SAFETY NOTE
To perform this service procedure,
CONTENTS NO. it is recommended that you first:
DRIVE & STEER TIRE SPECS 22-01-01 Park truck on a level surface.Put
DRIVE WHEEL REMOVAL 22-01-02 the upright in a vertical position and
DRIVE TIRE INSPECTION 22-o l-03 lower the carriage fully down.
DRIVE TIRE REPLACEMENT 22-o l-04 Turn key switch OFF.
DRIVE WHEEL INSTALLATION 22-01-05
STEER WHEEL REMOVAL 22-01-06
STEER TIRE INSPECTION 22-01-07 Use a portable jack of correct capacity placed
STEER TIRE REPLACEMENT 22-O l-06 under the frame of the truck to raise the drive
STEER WHEEL INSTALLATION 22-03-09 wheel off the ground. Refer to Machine Jacking
and Blocking Group for details.
NOTICE
The cushion drive and steer tires specified
for the ESM 12 - 25 Series fork lift trucks
were chosen after extensive testing as the
best combination of tread and shape
design and material compounding,
including hardness, to provide the
required wear and handling characteristics.
ESM 12,158,15 18x7x12.1 2 Remove the tire and wheel assembly from the
ESM 17,20 18X8X1 2.12 drive axle hub.
ESM 22,25 18x9x1 2.12
Steer Tire Size: All models 9x5 22-01-03 CUSHION DRIVE TIRE
.INSPECTION
IMPORTANT Remove objects (nails, metal fragments, etc.)
The user Is advised that embedded in the tread of the tire. Be careful not
replacement of the original to further damage the tire when removing these
equipment tires with tires other objects.
than those recommended by
CLARK may result in decreased
operating performance and
stability.
SM556 22 - 01 - 1
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Position tire on a hydraulic press. Be sure there is
Check the tire for separation from the base band. If adequate clearance for the tire to be pressed off
a thin steelrule or similar tool can be inserted more wheel assembly.
than [I2 mm] 0.5 inch into the separation area from
the side of the tire, the tire should be replaced. Be sure to take note of the mounting distance that
the original tire is offset on the wheel (distance
from edge of tire base band to edge of wheel).
Check the tire tread. If the tread is worn down to [6
mm] 0.25 in. or less in height, the tire should be Use suitable tooling with the hydraulic press to
replaced. correctly contact the base band of tire to press it off
the wheel.
Check the tire for damage from chunking or heat
damage. This is a judgment requirement for
replacement. In general, if the damage is greater
than [12 mm] 0.5 in. deep and involves more than
[650 mm21 4 in2 , it will usually affect the tire
performance and the tire should be replaced.
SM556 22 01-2
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Use a portable jack of correct capacity placed
under truck frame to raise truck off the floor and
permit drive tire and wheel assembly to be
positioned on truck drive axle hub.
SAFETY NOTE
To perform this service procedure,
it is recommended that you first:
Check the tire for separation from the base band. If
Park truck on a level surface.Put
a thin steel rule or similar tool can be inserted more
the upright in a vertical position and
than [12 mm] 0.5 inch into the separation area from
lower the carriage fully down.
the side of the tire, the tire should be replaced.
SM556 22 - 01 - 3
Copyrighted Material
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I
</\;F&.,
0-c-__
/ ---_ -’
\ --__
r
26.352
26.353 -/ ‘,U _/ -\ .
‘\-’ --+a,
26.139 \
.134 ‘, ‘h%
26.134 BEAlUNG,STEBVIEL~I-
26.139 BEUING,ST'EER~~~
26.140 T~~Tw~~sTEEX~EELHW-B~~#G
26.222 AxLESEAFT,STEERwHm
26.223 FASTENER.sfeERwlIEEL~s~
SM55622-01 -4
Copyrighted Material
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Position tire on a hydraulic press. Be sure there is
adequate clearance for the tire to be pressed off
wheel assembly.
SM556 22 - 01 - 5
Copyrighted Material
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GROUP 22 SECTION 02
A! WARNING!
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
In accordance with OSHA, the owner must provide a training program to train
and instruct all employees who service multi-piece rim wheels in the hazards
involved and the safety procedures to be followed. Do not let anyone mount,
demount or service multi-piece rim wheels without correct training.
The owner should obtain and maintain in the service area current copies of
the United States Department of Transportation, National Highway Traffic
Safety Administration publications entitled “Safety Precautions for Mounting
and Demounting Tube-Type Truck/Bus Tires” and “Multi-Piece Rim/Wheel
Matching Chart” or other similar publications applicable to the types of multi-
piece rim wheels being serviced.
SM556 22 - 02 - 1
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GROUP 22 SECTION 02
PNEUMATIC WHEELS AND
TIRES
CONTENTS NO.
/\ ! WARNING
Remove the air from the tires
before you remove wheels from
the truck.
SM556 22-02-2
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Check the condition of pneumatic drive wheels
and tires. Remove objects that are imbedded in TIRES INSTALLED ON LOCK-RING TYPE
the tread. Inspect the tires for excessive wear, WHEELS
cuts and breaks.
A! CAUTION
To perform these service procedures, it is
recommended that you first:
SM556 22 - 02 - 3
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Do not sell or distribute
Check for cracks in the wheel.
/
4. Using the wrong size tires.
0/
,Check ,.fordracks -W.,the lock ring.
SM556 22 - 02 - 4
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Do not sell or distribute
Clean the wheels. Remove rust and dirt.
SM556 22 - 02 - 5
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22-02-04 PNEUMATIC DRIVE TIRE
REPLACEMENT
I
or tire side of the rim. This is important because air
is on the metal surface of the tire side of the rim.
_L_-A J- * Ml7
x3, - &II
InEEL
4v.s IbJSTILL WASnER
VALVE
22 09s wlwEEt4
STEM OPEwPui *No nJ9E.
SM556 22 - 02 - 6
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Connect air chuck and put [21 kPa] 3 psi of air into
the tire.
Put the wheel wedge over the rim.
Use a mallet and hit the ring to make sure the ring is
Put the side ring over the rim and install the lock fully installed. Disconnect the air chuck.
ring as shown.
SM556 22 - 02 - 7
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FILLING TIRES WITH AIR
IMPORTANT
Put equal air 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.
Put the tire in an OSHA-approved safety cage.
FILLING TIRES WITH NITROGEN
Follow the procedures on the next two pages
when you put air into your tires.
HOW TO ADJUST THE REGULATOR ON
THE NITROGEN CYLINDER
A! WARNING
Make sure all items of equipment used
(nitrogen cylinder, regulator, gauges, hoses) Be sure cylinder valve is closed.
are UL approved and in good condition. Use
the correct regulator and hose for the
pressures that are necessary.
/\ ! WARNING
Use nitrogen only. DO NOT use oxygen or Turn the regulator valve counterclockwise (CCW)
any other gas to fill your tires. until you can feel no resistance from the regulator.
This will adjust the regulator pressure to a low
pressure near zero.
SM556 22 - 02 - 8
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SAFETY
CAGE
AIR
GAUGE /
SHUTOFF \\ I I
VALVE \ a
SOUR CE
OF A,IR
SUPP LY
Slowly turn the cylinder valve counterclockwise The tank gauge will now show tank pressure.
(CCW) to open position.
SM556 22 - 02 - 9
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Turn the regulator valve clockwise (CW) until the
regulator gauge reads the correct tire pressure. Fill
the tire with nitrogen.
Turn the regulator valve counterclockwise (CCW)
to the off position.
n ! CAUTION
Use a long-handled gauge so that
your hand does not go Inside the
cage, or in front of any component
of a multi-piece wheel.
Turn the tank valve clockwise (CW) and close
the valve.
SM556 22-02-10
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Put a clip-on type air chuck on the nitrogen
cylinder hose and attach it to the valve stem. Refer
to “How to adjust the regulator on the nitrogen
cylinder” for details.
/\ ! WARNING
Use nitrogen only to fill your tires.
DO NOT use oxygen or any other
gas.
/\ ! WARNING
Before you add air pressure to the DIRECTIONAL-TREAD TIRES
tire, make sure the lock ring is
correctly positioned In the rlm and All directional- tread tires are to be mounted in the
side ring. The lock ring can
correct position with respect to the arrow cast on
separate from the rim with enough
the side of the tire as explained below.
force to cause injury or death.
INSIDE
FRONT OF TRUCK
SM556 22-02-11
Copyrighted Material
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corrosion. The filter should be checked
Use a portable jack of correct capacity placed periodically to make sure it is working properly.
under truck frame to raise truck off the floor and
permit drive tire and wheel assembly to be 9. Make sure correct parts are being assembled.
positioned on truck drive axle hub. Ask your distributor or the manufacturer if you have
any doubts.
Install drive wheel mounting bolts and tighten to a
torque of [225 - 275 Nom] 188 - 203 Ibf*ft. 10. Do not be careless or take chances. If you are
not sure about the proper mating of rim and wheel
Lower truck to floor and remove jack. parts, consult a wheel and rim expert. This may be
the tire man who is servicing your fleet, the rim and
wheel distributor in your area, or the CLARK
22-02-06 SAFETY PROCEDURES dealer.
1. Do not fill a tire with air that has been run flat 11. Mixing parts of one manufacturer’s rims with
without first inspecting the tire, rim and wheel those of another is potentially dangerous. Always
assembly. Double check the lock ring for damage. ask manufacturer for approval.
Make sure that it is secure in the gutter before
filling the tire with air. 12. Do not use undersized rims. Use the right rims
for the job.
2. Never sit on or stand in front of a tire and rim
assembly that is being filled with air. Use a clip-on 13. Do not overload rims. Ask your rim
chudk and make sure hose is long enough to manufacturer if special operating conditions are
permit the person filling the tire with air to stand to required.
the side of the tire, not in front or in back of the tire
assembly. 14. Do not seat rings by hiiing with a hammer while
the tire is filled with air pressure. Do not hit a filled
3. Do not let anyone mount or demount tires or partially-filled tire/rim assembly with a hammer.
without proper training.
15. Double check to make sure all the components
4. Always remove all air from a tire and prior to are properly seated prior to filling tire with air.
removing any rim components.
16. Fill the tire with air in a safety cage.
Always remove the valve core to remove air from
tire. Be sure all air is removed from the tire. Check 17. When removing wheels, regardless of how
the valve stem by inserting a piece of wire through hard or firm the ground appears, put hardwood
the stem to make sure it is not plugged. blocks under the jack.
5. Check rim components periodically for fatigue 18. Block the tire and wheel on the other side of
cracks. Replace all cracked, badly worn, damaged the vehicle, before you place the jack in position.
and severely rusted components. Place blocks under the truck frame as near as
possible to the jack to prevent the truck from falling
6. Do not, under any circumstances, attempt to if the jack should fail.
rework, weld heat, or braze any rim components
that are cracked, broken or damaged. Replace 19. Remove the bead seat ‘band slowly to prevent
with new parts or parts that are not damaged, which it from dropping off and crushing your toes.
are of the same size, type and make. Support the band on your thigh and roll it slowly to
the ground. This will protect your back and feet.
7. Never attempt to weld on an inflated tire/rim
assembly. 20. Bead breakers and rams apply pressure to
bead flanges. Keep your fingers away from the
8. Clean rims and repaint to stop detrimental bead flanges. Slant bead breaker about 10” to
effects of corrosion. Be very careful to clean all dirt keep it firmly in place. If it slips off, it can fly with
and rust from the lock ring gutter. This is important enough force to kill. Always stand to one side
to secure the lock ring in its proper position. when you apply hydraulic pressure.
A filter on the air filling equipment to remove the 21. When using a cable or chain sling, stand away
moisture from the air line prevents a lot of (clear). It might break.
SM556 22-02-12
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Group 23, Brakes
Group 23
Section 1
Reservoir
Bleeder Screw
Foot
Brake Bleeding Procedure 7. Cheek level in brake fluid reservoir and refill as required.
1. Turn key switch OFF and disconnect battery. 8. While an assistant pumps the brake pedal, crack each
bleeder screw separately to expel air into fluid containers.
2. Remove two front and top compartment covers. Repeat this pumping procedure 5 or 6 times, or until all air
is removed from brake system. Frequently check the
brake fluid level in the reservoir and refill as required.
0
Reservoir
+E!s IMPORTANT
Be sure ends of bleed lines remain fully im-
mersed in fluid or air will be drawn back into
brake system.
NOTE
A brake system pressure bleeder may also be
3. Clean all dirt and contamination from brake fluid reser- used. Follow direction furnished with unit.
voir and cap. Fill brake fluid reservoir to full mark.
NOTE
Use only SAE J1703b DOT 3 brake fluid.
Bleeder Hose
Il
Air Bubbles
Brake Fluid
Group 23
Section 2
When pressure is applied to the foot pedal, the push rod 1. Turn key switch OFF and disconnect battery.
contacts the plunger and pushes it down the bore of the 2. Identify and disconnect wire leads to drive motor cut-off
cylinder. During the first [0.08 mm] l/32 inch of movement, switch.
the spring washer fitted under the valve head resumes its 3. Disconnect line to brake slave cylinders.
natural “bowed” shape and closes the port to the fluid 4. Pinchoffanddisconnectfluidreservoirline(item23.794).
reservoir. As the plunger continues to move down the bore, 5. Remove master cylinder bracket fasteners (items 90.493
fluid is forced through the brake lines to the brake slave & 94.784). Remove master cylinder and bracket as an
cylinders. assembly.
6. Remove cotterpin and clevis pin (items 92.026 & 23.118)
When pressure on the foot pedal is released, the plunger from master cylinder push rod clevis. Remove master
moves back with the return of the brake fluid. The final cylinder mounting boltsand nuts (items 23.156 & 90.092)
movement of the plunger compresses the spring washer, and withdraw mastercylinder from bracket (item 23.434).
lifting the valve seal off its seat and opening the fluid
reservoir port Brake fluid then moves freely between the
master cylinder and the fluid reservoir.
90.493
94.784
L 23.434
Plunger
Push Rod Assembly
Retaining
Washer
Circli
Dust-
Cover
Retainer
4. Coat the piston seal and cylinder bore with clean brake
fluid. Insert the piston assembly, valve end first, com-
pletely into the cylinder bore, easing the entrance of the
piston seal.
5. Position the push rod and retaining washer and install the
c&lip.
Group 23
Section 3
When pressure is applied to the foot pedal, the master 1. Turn key switch OFF and disconnect battery.
cylinder forces fluid to the slave cylinders. The slave cylin- 2. Remove two front covers and top compartment cover.
ders in turn disengage the brakes by rotating the brake arms 3. Disconnect line to brake slave cylinder.
against spring pressure. When pressure on the foot pedal is 4. Release pushrod spring pressure by backing off locknut
released, fluid is forced from the slave cylinders as the brake and adjusting nut (item 23.859).
arms return under spring pressure. The release of brake fluid 5. Remove slave cylinder mounting fasteners (items 23.259
pressure allows the brakes to engage. & 95.794).
6. Remove slave cylinder assembly.
. .
o.~~.”:
:” .
-? ______..
... ,....,‘:
‘..
;\,
“,x.
$$ . . ..:,,- ..
_..’
“’ .h L /=FTHAND
.!!
ye....:*_ c..;.* +’ :
!
i MOTOR
RIGHTHAND
MOTOR
- FRONT
Cleanthecylinderbodyandothermetalpartsinacommercial
parts cleaning fluid and thoroughly rinse with a Stoddard-
type solvent or clean brake fluid. Clean rubber parts in
Stoddard-type solvent and rinse in clean brake fluid. Use only
low-pressure compressed air or a lint-free cloth to dry parts.
Lay the cleaned paas on a clean sheet of paper and protect
from contamination until reassembly.
Inspect the piston and cylinder bore for visible score marks,
ridges, and corrosion. Check that the cylinder bore is smooth
to the touch. Replace the slave cylinder if there is any doubt
about its serviceability.
Group 23
Section 4
Brake Operation
The brakes are spring applied and hydraulically released. Removing allfoot force from the foot pedal will fully apply the brakes.
Raising the foot pedal releases the hydraulic pressure in the slave cylinder, allowing the spring forces t&rotate the brake arms
thus applying the brakes. Brake arm rotation rotates a cam inside the brake assembly that forces the brake shoes onto the brake
drum.
90.766 ~ _ 90.997
23.252
,,/ :.,
3. . .._. .._,b. .‘; LEFTHAND
:‘&.z.v.g.3,
.....n&:..@ ; MOTOR
<?............... y&
..&
.,+.::............... ..-;y<:.: ..,
‘, .... ::_...;:.::a.
-. ..........
. .
FRONT
2”
Figure 2.
l$z!j- 90.997
I
90.996 @
22.408
22.404
e 22.407
23.319
I
Figure 3. Knott Brake
Note: Some ESM trucks have been fitted with adjustable 8. With the brakes applied that is, the foot pedal in the fully
length push rods. For all of the following procedures raised position, release andremove the nut (item90.997) and
this push rod should be set to 7.559” (192mm) long, washer (item 90.996) on the top of the brake drum.
over all length. 9. Depress the pedal to release the brakes and block the pedal
in the down position. Remove the drum (item 22.408) from
IMPORTANT the motor shaft, using a soft facedmallet as needed. Remove
Read the complete instructions before starting work. the key (item 16.041) from the keyway in the shaft.
10. Remove the shoes (item 22.404) from the brake assembly,
being careful to not lose the springs (item 22.407) on the
1. Safely park the truck on level surface.
shoes. Place shoes in a place that will not contaminate them
2. Lower forks to the ground.
with oil.
3. Tum off key switch 11. Inspect theconditionoftheshoeliningmaterial. Itshouldnot
4. Disconnect the battery. be glazed. There should be more than 3/X?’ of thickness of
5. Remove the front covers to gain access to the brake assem- material left on the shoe. If the lining material shows signs of
blies. heavy glazing, or heat distress such as cracking or discolora-
6. Depress the foot pedal to release the brake. Rotate the brake tion, then the shoes and linings MUST be replaced. Do not
drum by hand so that the brake shoe pivot pins can be seen proceed with this adjustment. See Brake Shoe Replacement
through the vent holes in the brake drum. instructions. Always replace shoes in sets, both left and right
7. Measure, from a straight line through the brake shoe pivot sides. DO NOT replace only one shoe, or only one side.
pins, the angle of the brake arm. If the angle is within the 0 12. Ifthebrakeshoesareinguudusableconditionandthearmneeds
to 12’ as shown in Fig. 2, then the brake arm is correctly adjustment,then continue with the following procedures.
adjusted. Inspect the amount of lining on the shoe through 13 Inspect the drum for scoring or any other abnormal wear.
the drum vent hole. If the lining appears to be less than 3/32 Service drum surface or replace drum as needed.
of an inch, the drum must be removed for a closer examina- 14. Remove the cotter andthe pin (item 90.765,95.745,90.766)
tion of the shoes and drum. Brakes with more than 3/32” of connecting the brake arm to the push rod.
lining material and the arm between 0” and 12” are fit for 15. Loosen and remove the four fasteners holding the brake
continued service. If the angle is greater than 12”the brakes backing plate to the drive motor.
must be adjusted. These checks must be performed for both 16. Remove the snap ring holding the brake arm (item 23.3 19)
the left and right hand side brake assemblies. and cam together.
17. Lift the backing plate just enough to allow removal of the The ANSI standard requirement for these brakes is that they
arm and cam from the backing plate. Be careful to not hold the truck and a rated load on a 15% grade. If such a grade
have the arm/cam assembly come apart. They are splined is available, after adjustment, the brakes can be tested by
together. slowly and carefully driving the truck with a rated capacity
lS.Carefully separate the cam from the arm, noting their load straight up a known 15% grade, with the load upgrade
relative positions, and, then reposition the cam in the arm and bringing the truck to a stop with the brakes applied. If the
by indexing one spline m from the slave cylinder. brakes hold the loaded truck stationary on the grade the
19. Replace the arm/cam assembly into the backing plate and brakes are satisfactorily set. After observing the performance
seat the snap ring back into its groove. Ensure the snap of the brakes slowly drive the truck straight back down the
ring is fully seated in the groove. grade. Do not try to perform any maneuvers on the grade.
20. Set the backing plate on the motor, insert and torque the While this is a test method, the ESM is m intended for use
fasteners, [20-22 N.m] 177-1941bf.in., holding the plate on 15% grades, except as encountered for short distances
to the motor. such as dock plates. If no grade is available, the brakes can be
21. Install the brake shoes and springs. approximately tested by measuring the stopping distance as
22. Pump the foot pedal to extend the push rod from the slave follows. Test only with an unloaded truck in a pedestrian and
cylinder. Connect the arm to the push rod with thepin and traffic free aisle. An empty parking lot with a smooth, level
cotter. Slip the drum on the motor shaft and release the surface is also a good operating location. Mark a line on the
footpedal.Measmetheangleofthearmagain.Iftheangle floor or note a floor joint as a measurement line. Starting at
is within the 0” to 12” as shown in Figure 2, the adjustment a point approximately 150 to 200 feet in front of the line, drive
is correct. If the angle is still not within this range then the buck in a straight line at full speed towards the line. As the
index the arm one more spline. front wheels roll over the line apply the brakes by raising the
23.When the setting is correct, depress the foot pedal and brake pedal. When the truck has come to a complete stop,
block in the down position. Remove the drum, insert the safely park the truck at this same spot and measure the
key in the keyway and replace the drum. Release the foot distance from the front wheels to the measurement line. This
pedal to its up position. is your stopping distance. Compare to the table below for the
model you are working with. If the measured distance is less
24.Replaceand torque, [95-108 N.m] 70-80lbf.ft. thewasher
than the table value then the brakes are satisfactorily set. (The
and nut on the motor shaft. Note thepedal should be in the
approximate rule of thumb is that the stopping distance for an
raised position to facilitate torquing the nut.
ESM without a load shall be between l-114 (one and one
25. Repeat for the other brake
quarter) and l-1/2 (one and one half) times the length of the
26.Check and, set as needed, the brake actuating spring on
truck with no forks.)
both brakes. With the brakes applied the spring length
should be 2”. Be sure when tightening the two nuts to use
Model Distance inches
TWO wrenches. If two wrenches are not used damage to
ESM12 100
the brake lever will result.
ESMlSS 100
27. Replace the front covers.
ESM15 97
28. Connect the battery. ESM17 94
29. Check the operation of the brakes. They should not pull ESM20 92
to either side. ESM22 90
IMPORTANT
ESM25 90
TheESM brakes are not self adjusting, but need to be
periodically inspected and adjusted accordingly. If
adjustments are not made as required, the slave Brake Disassembly
cylinder can run out of stroke, and the springs will IMPORTANT
not apply the brakes. This condition will not be a Read the complete instructions before starting work.
sudden event, but will result in a gradual loss of 1. Safely park the truck on level surface.
braking capability. If the brakes begin to get “soft”, 2. Lower forks to the ground.
this is an indication that the slave cylinder may be 3. Turn off key switch.
“bottoming out” and the brakes have not been ad- 4. Disconnect the battery.
justed as needed. Checking the brake adjustment 5. Remove the front covers to give access to the brake
setting in addition to the driving test must be part of assemblies.
the Planned Maintenance program. When the covers 6. With the brakes applied, that is, the foot pedal in the fully
are removed for air cleaning the travel controls, the raised position, release and remove the nut and washer on
brake arm positioning and lining wear must be in- the top of the brake drum.
spected, recorded and corrected as necessary.
7. Depress the pedal to release the brakes and block the pedal 12. If the setting is now correct, depress the foot pedal and
in the down position. Remove the drum (item 22.408) from block in the down position. Remove the drum (item
themotor shaft, using a soft facedmallet as need. Remove the 22.408), insert the key (item 16.041) in the keyway and
key (item 16.041) from the keyway in the shaft. replace the drum. Release the foot pedal to its up posi-
8. Remove the shoes (item 22.404) from the brake assembly, tion.
being careful to not lose the springs (item 22.407) on the 13. Replace and torque, [95-108 N.m] 70-80 lbfft. the
shoes. Place shoes in a place that will not contaminate washer (item 90.996) and nut (item 90.997) on the motor
them with oil. shaft. Note: The pedal should be in the raised position to
9. Remove the cotter and the pin (items 90.766 and 90.765) facilitate torquing the nut.
connecting the arm to the push rod. 14. Repeat for the other brake.
lOLoosen and remove the four fasteners holdingthe brake 15. Check and, set as needed, the brake actuating spring to
backing plate (item 22.406) to the motor. Lift the backing the correct length of 2”. Be sure when tightening the two
plate from the end of the motor. nuts to use TWO wrenches. If two wrenches are not used
11.Remove the snap ring holding the brake arm and cam damage to the brake lever will result.
.ogether and remove cam (item 23.319) and lever from 16. Replace the front covers.
>acking plate. 17. Connect the battery.
18. Check the operation of the brakes. They should not pull
Brake Shoe Replacement to either side.
IMPORTANT 19. Burnish the brakes. Load the truck with a rated load and
Always replace shoes in sets, that is, all four shoes fasten the load to the carriage with a chain. Operate
for both left and right hand-side brakes. Do not ONLY in a pedestrian and traffic free aisle. An empty
replace single shoes, or two shoes on only one side. parking lot with a smooth level surface is also a good
operating location. Run the truck close to maximum
speed and apply the brakes bringing the truck to a
1. Safely park the truck on level surface.
complete stop. Immediately operate in the opposite
2. Lower forks to the ground.
direction and repeat the procedure. Continue for ap-
3. Turn off key switch. proximately 20 times. You should try to get the brakes
4. Disconnect the battery. hot but do not overheat them. When 20 repetitions have
5. Remove the front covers to gain access to the brake been completed, re-check the brake settings and readjust
assemblies. as needed.
6. With the brakes applied, that is, the foot pedal in the fully
raised position, release and remove the nut and washer
Brake Assembly
on the top of the brake drum.
1. Replace the arm/cam assembly into the backing plate
7. Depress the pedal to release the brakes and block the
(item 22.406) and seat the snap ring back into its groove.
pedal in the down position. Remove the drum (item
Ensure the snap ring is fully seated in the groove.
22.408) from the motor shaft, using a soft faced mallet as
2. Set the backing plate back on the motor, insert and
needed. Remove the key (item 16.04 1) from the keyway
torque, [20-22 N.m] 177-1941bf.m the fasteners (item
in the shaft.
90.998) holding the plate to the motor.
8. Remove the shoes (item 22.404) from the brake assem-
3. Install the brake shoes and springs (items 22.404 and
bly. Discard old shoes.
22.407).
9. Position replacement shoes on the anchor pins. The ends
4. Pump the foot pedal to extend the push rod. Reconnect
of the shoes must be firmly seated in the pin groove and
the arm to the push rod with the pin and cotter (items
on the cam.
90.765 and 90.766). Slip the drum on the motor shaft and
10. Install the two tension springs (item 22.407) on the
release the foot pedal. Measure the angle of the arm. If
shoes.
the angle is within the 0’ to 12”as shown in Figure 2, the
11. Pump thefootpedaltoextendthepushrodfrom theslave
adjustment is correct. If the angle is still not within this
cylinder. Reconnect the arm to the push rod with the pin
range then index the spline .as needed. See Section 23-04-
and cotter (items 90.765 and 90.766). Slip the drum on
02.
the motor shaft and release the foot pedal. Measure the
5. If the setting is now correct, depress the foot pedal and
angle of the arm again. If the angle is within the 0” to 12
block in the down position. Remove the drum, insert the
as shown in Figure 2 the adjustment is correct. If the
key (items 16.041) in the keyway and replace the drum.
angle is still not within this range then index the spline as
Release the foot pedal to its up position.
needed.
6. Replace and torque [95- 108 N.m] 70-80 lbf.ft. the washer
(items 90.996 and 90.997) and nut on the motor shaft.
Group 23
Section 4A
90.766 _ _ 90.997
90.765 \
7.. 71
23.252
23.859
0
0
0
0
0
Figure 2.
22.408
-
91.233
22.411
22.404 - I
SHOES
Q- 22.407
$
91.231 -9 ; /
ACTUATOR ARMS
22.405
CAM ASSEMBLY -E
23.319 -I$?+
y 22.406
da
91.258 -
&a
23.349 - MOUNTING PLATE
Figure 3.
1. Safely park the truck on level surface. 8. With the brakes applied, that is, thefoot pedal in the fully
2. Lower forks to the ground. raised position, release and remove the nut and washer
3. Turn off key switch. on the top of the brake drum.
4. Disconnect the battery. 9. Depress the pedal to release the brakes and block the
5. Remove the front covers to give access to the brake pedal in the down position. Remove the drum from the
assemblies. motor shaft, using a soft faced mallet as needed Remove
6. Depress the foot pedal to release the brake. Rotate the the key from the keyway in the shaft.
brake drum by hand so that the brake shoe pivot pins can 10. Inspect the condition of the shoe lining material. It
be seem through the vent holes in the brake drum. should not be glazed. There should be more than 3/32”
7. Measure, from a straight line through the pivot pins, the of thickness of material left on the shoe. If the lining
angleof thebrakearm. Ifthebrakearm isnotstraight,but material shows signs of heavy glazing, or heat distress
is “bent” at the splined joint in its middle, then measure such as cracking or discoloration, then the shoes and
the angle as if the arm were a straight line between its two linings MUST be replaced. Do not proceed with this
end points. If the angle is within the 0” to 12’ as shown adjustment. See Brake Shoe Replacement instructions,
in Figure 2, then the brake arm is correctly adjusted. section 23-4A-04. Always replace shoes in sets, both left
Inspect the amount of lining on the shoe through the and right sides. DO NOT replace only one shoe, or only
drum vent hole. If the lining appears to be less than 3/32 one side.
of an inch, the drum must be removed for a closer 11. If thebrakes are in good usable condition and the arm needs
examination of the shoes and drum. Brakes with more
adjustment, then continue with the following procedures.
than 3/32” of lining material and the lever between 0”
12. Inspect the drum for scoring or any other abnormal wear.
and 12” are fit for continued service. If the angle is
greater than 12” the brakes must be adjusted. These Service drum surface or replace drum as needed.
checks must be performed for both the left and right 13. Remove the cotter and the pin connecting the brake arm
handside brake assemblies. to the push rod.
14. Remove nut and washer (item 91.258,23.349). Index follows. Test only with an unloaded truck in a pedestrian and
the outer half of the brake arm one notch on the spline traffic free aisle. An empty parking lot with a smooth, level
in the brake arm away from the slave cylinder. surface is also a good operating location. Mark a line on the
15. Slip the drum onto the motor shaft and release the foot floor or note a floor joint as a measurement line. Starting at
pedal. a point approximately 150 to 200 feet in front of the line, drive
16. Measure the angle of the arm as before. If the angle is the truck in a straight line at full speed towards the line. As the
not between 0’ and 12’ as shown in Figure 2 then front wheels roll over the line apply the brakes by raising the
remove the drum and index one more notch on the brake pedal. When the truck has come to a complete stop,
spline. When the correct setting is obtained then insert safely park the truck at this same spot and measure the
the key in the keyway. With the pedal depressed, in- distance from the front wheels to the measurement line. This
stall the drum. With the foot pedal released, that is, is your stopping distance. Compare to the table below for the
with brake applied, torque the drum retaining nut to model you are working with. If the measured distance is less
[95-108 N.m] 70-80 lbf.ft. than the table value then the brakes are satisfactorily set. (The
17. Repeat for the other brake. approximate ruleof thumb is that the stopping distance for an
18. Check and, set as needed, the brake actuating spring on ESM without a load shall be between l-114 (one and one
both brakes. With the brakes applied the spring length quarter) and l-112 (one and one half) times the length of the
shouldbe 2”. Be sure when tightening the two nuts to use truck with no forks.)
TWO wrenches. If two wrenches are not used damage to Model . Distance inches
the brake lever will result. ESM12 100
19. Replace the covers. ESMlSS 100
20. Connect the battery. ESM15 97
21. Check the operation of the brakes. They should not pull ESM17 94
to either side. ESM20 92
IMPORTANT ESM22 90
The ESM brakes are not self adjusting, but need to be ESM25 90
periodically inspected and adjusted accordingly. If
adjustments are not made as required, the slave
cylinder can run out of stroke, and the springs will Brake Disassembly
not apply the brakes. This condition will not be a IMPORTANT
sudden event, but will result in a gradual loss of Read the complete instructions before starting work.
braking capability. If the brakes begin to get “soft”, 1. Safely park the truck on level surface.
this is an indication that the slave cylinder may be
2. Lower forks to the ground.
“bottoming out” and the brakes have not been ad-
3. Turn off key switch.
justed as needed. Checking the brake adjustment
4. Disconnect the battery.
setting in addition to the driving test must be part of
the Planned Maintenance program. When the covers 5. Remove the front covers to give access to the brake
assemblies.
are removed for air cleaning the travel controls, the
brake arm positioning and lining wear must be in- 6. With the brakes applied, that is, the foot pedal in the fully
spected, recorded and corrected as necessary. raised position, release and remove the nut and washer
on the top of the brake drum.
The ANSI standard requirement for these brakes is that they 7. Depress the pedal to release the brakes and block the
hold the truck and a rated load on a 15% grade. If such a grade pedal in the down position. Remove the drum from the
is available, after adjustment, the brakes can be tested by motor shaft, using a soft faced mallet as need. Remove
slowly and carefully driving the truck with a rated capacity the key from the keyway in the shaft.
load straight up a known 15% grade, with the load upgrade 8. Remove clip and washer (items 90.766 & 95.795).
and bringing the truck to a stop with the brakes applied. If the Remove brake arm pin (item 90.765). Release the foot
brakes hold the loaded truck stationary on the grade the pedal.
brakes are satisfactorily set. After observing the performance 9. Remove brake shoe retainers (items 91.233 & 22.411).
of the brakes slowly drive the truck straight back down the 10. Remove brake cam nut and washer (items 23.330 &
grade. Do not try to perform any maneuvers on the grade. 91.231)
While this is a test method, the ESM is m intended for use 11. Lift off brake shoe set. If brake shoes are to be replaced,
on 15% grades, except as encountered for short distances unhook return springs (item 12.407). Place shoes in a
such as dock plates. If no grade is available, the brakes can be place that will not contaminate them with oil.
approximately tested by measuring the stopping distance as 12. Remove actuator arm nut and washer (items 23.336 &
92.463). Remove actuator arm (item 23.75 1).
13. Remove brake drive blocks (item 22.405). shouldbe 2”. Be sure when tightening the two nuts to use
14. Remove brake cam (item 23.319). TWO wrenches. If two wrenches are not used damage to
15. Remove the brake mounting plate capscrews (item the brake lever will result.
90.998) and remove brake mounting plate (item 22.406). 19. Replace the covers.
16. If drive motor is to be serviced, remove the brake bracket 20. COMCYZt the battery.
fasteners (items 95.788, 95.791, 95.790 & 95.789). 21. Check the operation of the brakes. They should not pull
Remove brake bracket (item 22.546, R.H. or 22.547, to either side.
L.H.) from drive motor). 22. Burnish the brakes. Load the truck with a rated load and
fasten the load to the carriage with a chain. Operate
ONLY in a pedestrian and traffic free aisle. An empty
Brake Shoe Replacement
parking lot with a smooth level surface is also a good
IMPORTANT
operating location. Run the truck close to maximum
Always replace shoes in sets, that is, all four speed and apply the brakes bringing the truck to a
shoes for both left and right hand-side brakes. complete stop. Immediately operate in the opposite
Do not replace single shoes, or two shoes on only direction and repeat the procedure.
one side. Continue for approximately 20 times. You should try to
1. Safely park the truck on level surface. get the brakes hot but do not overheat them. When 20
2. Lower forks to the ground repetitions have been completed recheck the brake
3. Turn off key switch. settings and readjust as needed. Check brake stopping
4. Disconnect the battery. ability per 23-4A-3 Brake Inspection and Adjustment.
5. Remove the front covers to give access to the brake
assemblies. Brake Assembly
6. With the brakes applied, that is, the foot pedal in thefully 1. If removed to service the drive motors, instaIl brake
raised position, release and remove the nut and washer bracket (item 22.546, R.H. or22.547, L.H.) with bracket
on the top of the brake drum. fasteners (items 95.788, 95.791, 95.790 dz 95.789).
7. Depress the pedal to release the brakes and block the Torque fasteners to [9.4-10.6 N.m] 83-94 lbf.in.
pedal in the down position. Remove the drum from the 2. Install brake mounting plate ( item 22.406) with mount-
motor shaft, using a soft faced mallet as need. Remove ing plate fasteners (items 90.998). Torque fasteners to
the key from the keyway in the shaft. [20-22 N.m] 177-194 Ibf.in.
8. Inspect drum for scoring or other abnormal wear. Ser- 3. Apply Lubriplate #63OAA, or equivalent to the sides of
vice brake drum surface, or replace as required. four anchor posts on the brake mounting plate.
9. Remove clip and washer (items 90.766 & 95.795). 4. Install brake cam (item 23.3 19) on post nearest notches
Remove brake arm pin (item 90.765). Release the foot on the brake mounting plate.
pedal. 5. Install brake drive blocks (item 22.405) on mounting
10. Remove brake shoe retainers (items 9 1.233 & 22.411). plate. Note: Large end of brake drive blocks must face
11. Remove brake cam nut and washer (items 23.330 & center of brake.
91.231) 6. Install actuator arms (item 23.751) on brake mounting
12. Unhook return springs (item 13.407), and reuse on the plate. Align sides of actuator arms with shoulders of
new shoes. Lift off brake shoe set and discard brake cam. Install brake actuator arm fasteners (items
13. Apply Lubriplate #63OAA, or equivalent to the sides of 23.336 & 92.463). Torque fasteners to [3-5 N.m] 2644
four anchor posts on the brake mounting plate. lbf.in.
14. Position replacement shoes on anchor pins. Brake shoes 7. Assemble brake shoes (item 22.404) with return springs
must be level with actuator arms (item 23.751). Install (item 22.407). Install brake shoe set over drive blocks on
brake shoe retainers (items 91.233 & 22.411). Torque brake mounting plate. Be sure the brake shoes are level
retainers [3-5 N.m] 2644 lbf. in. with the actuator arms.
15. Align brake drum keyway with motor shaft key, (item 8. Install brake shoe retainers (items 91.233 & 22.411).
16.041) depress foot pedal and install brake drum. Tap Torque to [3-5 N-m] 2644 lbf.in.
on top surface of brake drum with a soft faced mallet to 9. Install brake cam fastener (item 22.330 & 91.231).
seat drum on motor shaft. Torque to [2-3N.m] 18-26 lbf.in.
16. Install drum washer and fastener (items90.996 &90.997). 10. Depress the foot pedal and block in the down position.
Release foot pedal. Torque fastener to [95-108 N.m] 70- Install brake arm pin, clip, and washer (items 90.765,
80 lbf.ft. 90.766,95.795). Note: Brake adjusting nut and lock nut
17. Adjust brake arm within 0” and 12” per Figure 2. (item 23.859 may be adjusted to ahow instaIIation of
18. Check and, set as needed, the brake actuating spring on brake arm pin. Two wrenches mbe usedon these nuts.
both brakes. With the brakes applied the spring length
11. Align brake drum keyway with the motor shaft key (item
16.04 1 and install brake drum. Tap on the top of the drum
surface with a soft faced mallet to seat the drum on the
shaft.
12. Install brake drum fastener and washer (items 90.996 &
90.997). Torque nut to [95-108 N.m] 70-80 lbf.ft. Re-
lease the foot pedal.
13. Adjust brake arm within 0” and 12” per Figure 2.
14. Check and, set as needed, the brake actuating spring on
both brakes. With the brakes applied the spring length
should be 2”. Be sure when tightening: the two nuts to use
TWO wrenches. If two wrenches are not used damage to
the brake lever will result.
15. Replace the covers.
16. Connect battery.
17. Check the operation of the brakes. They should not pull
to either side.
NOTE
If new shoes were installed they must be bur-
nished. See brake shoe replacement (23-4A-4)
NOTE
Check brake stopping ability per (23-4A-3) Brake
Inspection and Adjustment.
STEERING GEAR TROUBLESHOOTING 25-Ol-02 When steering tiller arm is turned, it causes the
valve spool to shift from its closed neutral position
STEERING GEAR REMOVAL 25-01-03 to a “turn” position and allows oil under pressure to
flow to steering actuator. When steering tiller arm
STEERING GEAR DISASSEMBLY 25-o l-04 stops turning, centering springs in valve
automatically center spool, stopping flow of oil
STEERING GEAR PARTS INSPECTION 25-01-05 pressure to steering actuator.
STEERING GEAR ASSEMBLY 25-01-06
The low-pressure oil from steering actuator is
STEERING GEAR INSTALLATION 25-01-07 returned through the opposite port in valve. It is
controlled by the same spool as the high pressure
port.
SM556 25 - 01 - 1
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
In event of power or pump failure, steering gear identified and can be installed in same location at
can develop sufficient hydraulic power for limited, assembly.
emergency steering only by manual movement of
steering tiller arm. An internal check valve closes 4. Disconnect hydraulic lines from steering gear
automatically to divert this generated oil flow to and cap open ends. Plug ports in steering gear.
selected port of steering actuator. However,
steering tiller arm turning effort is considerably 5. Remove steering gear capscrews and
higher than with power steering. This method of lo&washers (items 25.034 & 90.102).
steering should be limited to emergency use only
6. Remove steering gear assembly from truck.
SM5.56 25-01-2
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
9. Remove spacer plate.
Seal
5. Remove meter (gerotor) assembly from housing 12. Rotate seal and sleeve until pin is horizontal.
(be careful not to drop star). Then, use fingers to push spool and sleeve
assembly forward until gland bushing clears
6. Remove seal from meter. housing. Remove bushing.
Dust Seal A
6. Remove drive. 13. Remove quad ring seal from seal gland
bushing.
SM556 25 - 01 - 3
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
14. Use a thin-bladed screwdriver tip to pry dust 16. Push spool part of the way off control end of
seal from seal gland bushing. Be careful not to sleeve sufficient to expose six (6) centering
damage bushing. springs. Remove these springs carefully. Note
their position in unit before they are removed.
Needle Bearing
Thrust Race 19. Push spool opposite way after springs have
Bearing \ been removed. Separate spool from sleeve by
rotating slowly as sleeve is pushed off.
Pin
22. Thread al/6 - 24 NC machine screw into end
of check ball seat. Then pull on screw using pliers
(or equivalent method) to pull seat out of housing.
16. Remove spoof and sleeve assembly from cap 24. Remove check ball by tilting housing and
end of housing. NOTE: Be careful not to bind lightly tapping on side of housing if ball sticks.
spool and sleeve in housing. Rotating spool and
sleeve slowly while removing will help prevent 25. Remove steer gear check valve retainer.
binding.
17. Push pin from sleeve and spool assembly. 25-01-06 STEERING GEAR PARTS
INSPECTION
..I
--. : 1:~lnspecthoosing~fordamage;including cracks or
broken parts, damaged threads, corrosion or
erosion of surfaces, worn spots, burrs or scratches
on machined surfaces.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
4. Make sure sleeve assembly does not bind Install seat in housing using care not to damage
when it is rotated on spool. Inspect assembly for seals when installing seat. Insert open end of seat
any corrosion, nicks or scratches, or evidence of first.
damage.
4. Install set screw and tighten to a torque of [ll
5. Check bearings and races making sure they are N-ml 100 Ibf*in. Top of set screw should be slightly
not damaged and that they rotate without being below surface of . housing mounting surface to
noisy or have evidence of binding. prevent interference of parts.
o- Set Screw +
See Figure 12A 1
5/a**
Check 6all Seat
7116
- \
Retainer
3. Put new seals on check ball seat. Lubrfcate seal Compress free ends of centering springs together
with petroleum jelly before installing seat. as springs are inserted into spool and sleeve
assembly.
SM556 25 - 01 - 5
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Center springs in assembly to ensure they push
evenly and are flush with outer surface of spool
and sleeve assembly. Needle
Pin
7. Install pin into sleeve and spool assembly until it 11. Install needle thrust bearing.
is flush with outer surfaces.
12. Install a new dust seal in dust seal bushing with
flat or smooth side of dust seal face down toward
bushing.
Reraining
Ring
Seal
Gland -
8. Insert sleeve and spool assembly into housing Bushing
(from end opposite check valve assembly). (wirh seals)
SM556 25-01-6
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Make sure spool and sleeve are flush or slightly
below face of housing. Be sure surfaces are Meter (Gerotor) Star Valley ,A
clean.
19. Install new seal in meter. 23. Install seven (7) fasteners holding cap and
meter to housing and tighten to an initial torque of
117 Nmm]150 Ibf4n .
SM556 25 - 01 - 7
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Retighten these fasteners to a torque of [31 Nem]
275 Ibfain in the sequence shown above.
SM556 25 - 01 - 8
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 26 SECTION 01
STEERING AXLE A! WARNING
All lifting used in this
components
procedure must be in good
CONTENTS NO. condition, meet the lifting
requirements, and have OSHA
STEERING AXLE REMOVAL 26-01-01 approval labels when requlred.
STEERING AXLE INSTALLATION 26-01-02
26-01-01 STEERING AXLE 8. Remove the upper fork bearing retainer (item
26.238) and carefully lower and remove the steer
REMOVAL axle fork.from the truck.
Park truck on a solid, level surface. 10. Inspect steer axle fork lower housing (item
Lower forks to floor. 26.232) for wear or damage. Replace, if required.
Turn key switch OFF.
SM556 26 -Ol- 1
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;.:
/- 26.238
95.785
26.341
e26.237
@ - 26.235
1 \/ 26.232
STEERING AXLE
26.233, _~/.,FASTENER,.STEERAXLE.FO=HOUSING
26.235 BEARING, STEER AXLE FORK UPPER
26.237 RETAINER. STEER AKLE FORX BEARING
26.238 FASTENER, STEER AXLE FORK BEARING
26.341 THRUST WASHER, STEER AXLE FORK UPPER BEARING
SM556 26 - Ol- 2
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GROUP 26 SECTlON 02 b) Contaminated oil.
Drain oil, clean filter and fill.
POWER STEERING PUMP c) Cavitating pump.
See 1a, b, c, d
d) Drive shaft not aligned.
CONTENTS NO. Check mounting and alignment.
e) Axial loading on drive shaft.
GENERAL DESCRIPTION 26-02-01 Check shaft end clearance.
PUMP TROUBLESHOOTING 26-02-02 Check shaft alignment.
PUMP REMOVAL 26-02-03 Check for worn key or spline.
PUMP DISASSEMBLY 26-02-04 f) Relief valve usually in bypass.
PUMP PARTS INSPECTION 26-02-05 Check relief setting.
PUMP ASSEMBLY 26-02-06
PUMP INSTALLATION 26-02-07 4. Low Pump Output.
PUMP RELIEF VALVE ADJUSTMENT 26-02-08
a) Cavitating pump.
See la, b, c, d
b) Air in fluid.
26-02-01 STEERING PUMP See 2b.
DESCRIPTION c) Relief valve leakage or valve set too low.
Check relief valve.
The power steering pump is a fixed-displacement d) Overheated oil.
type gear pump. The steering system relief Check oil temperature.
pressure is controlled by a pressure relief valve in
the power steering pump. This valve is set at a 5. Shaft Seal Leakage.
fixed relief pressure value of [6895 kPa]lOOO psi .
a) Damaged or worn seal.
Replace seal.
b) Front cover bearing out of position.
26-02-02 STEERING PUMP
Replace front cover assembly.
TROUBLESHOOTING c) Scratches on shaft seal housing bore.
See 5b.
Before steer pump is removed and/or d) Improper fit of shaft.
disassembled, check following list of problems and See 5b.
solutions. It could save cost, time, and effort.
6. External Leakage.
1. Noisy Pump.
a) O-ring damaged.
a) Low supply of oil. Replace C-ring.
Fill reservoir. b) Damaged surfaces in O-ring groove.
b) Oil too heavy. Replace damaged part.
Change to correct viscosity.
c) Inlet line has restriction. 7. Failure to Build Pressure.
Check for foreign material.
Clean filter or strainer. a) .Defective relief valve.
d) Air leak in inlet line. Repair and reset valve.
Check plumbing tightness. b) Low oil supply.
FiN reservoir.
2. Foaming Oil.
26-02-03 STEERING PUMP
a) Cavitating pump.
See la,b,c, and d
REMOVAL
b) Wrong fluid.
Drain and fill with correct oil. 1. Remove pump and motor assembly from truck.
See steer pump motor group for details.
3. Heated Pump and/or Oil.
a) Thin oil
Drain and fill with correct oil.
SM556 26-02-l
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POWER STEERING PUMP 26164-l
29.200 PlRfP4SLssMSLY.
STEER 29.284
16.227 COUPLING,STEERPDMPDBIVE 29.283
29.102 8EAL,STEERPm4PDRIVESmAm 29.286
29.190 PLIlIWER,8TEEEPlMPRELIEFVALVE 29.287
29.206 B~UI.RIMG,SIEPSPDHPS~ I. :!:,29:288
..
SM556 26-02-2
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26-02-04 STEERING PUMP
DISASSEMBLY
3. Remove capscrews and lockwashers (items 11. Disassemble idler shaft and gear assembly
29.269 & 90.891). only if necessary for replacement of these parts.
4. Carefully separate pump and motor. Put motor As these parts are removed from end cover,
in a safe place. carefully note position of each to be sure of correct
reassembly.
5. Use a sharp scribe or marker to scribe a line or
punch marks into body halves to assure correct
/
positioning of parts at assembly. i0
SM556 26-02-3
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26-02-05 STEERING PUMP
PARTS INSPECTION
SM556 26-02-4
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26-02-06 STEERING PUMP
ASSEMBLY
---it-E
I
SM556 26-02-5
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5. Install new gasket and assemble the pump body
onto end cover. Be sure the dowel pin is in place.
Install and tighten the assembly fastener bolts to
draw pump together. At this point, rotate the drive
shaft to be sure the pump turns freely. The pump
body and cover can be shifted slightly to allow the
gears to turn freely. Then torque assembly bolts to
[12,88 - 14,24 Nom] 9.5 - 10.5 Ibfeft. Check again
to verify that pump shaft still turns freely.
SM556 26-02-6
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GROUP 26 SECTION 03 26-03-01 STEER TORQUE
STEER TORQUE GENERATOR GENERATOR DESCRIPTION
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LOCKSCREW HOLE
26.36 1
26.356 UPPER
pi--b 26.250
I I
SM556 26 - 03 - 2
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GROUP 26 SECTlON 03 26-03-01 STEER TORQUE
STEER TORQUE GENERATOR GENERATOR DESCRIPTION
92.237
SM556 26 - 03 - 1
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26.361 \ /
.E -
26.359
26
26.258
26.356 UPPER
26.357 UPPER
26.358 BACK,STEERTORQUEGRNEBATox
26.359 PISTON,STRRR TORQUR GRNRRATORCYLINDER
26.360 SELU,STRRRTORQUEGENERATOBOUTPUTPISTON
26.361 CYLINDER,STFZR TORQUEGWERATOR RYDBAULIC
26.362 PELLRT,STERRTORQUE GEN. CYL. RRTAINING
SM556 26 - 03 - 2
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7. Hook lift straps to chain hoist and apply tension 26-03-04 STEER TORQUE
to torque generator with hoist. Carefully pry GENERATOR PARTS INSPECTION
torque generator loose from steer axle cone with a
screwdriver. 1. Clean all torque generator components and lay
on a clean sheet of paper. Protect pans from dirt
Note and comtamination before reassembly.
Be sure to retrieve and set aside locating key
(item 26.355) 2. Inspect all parts for wear or damage. Replace
parts as required.
26-03-03 STEER TORQUE
GENERATOR DISASSEMBLY 26-03-05 STEER TORQUE
GENERATOR ASSEMBLY
Note
When working on steer torque generator, it is
1. Install upper retaining ring (item 26.356) and
important to keep internal parts free from dirt and
upper pinion bushing (item 26.357) in generator
other contaminants.Throroughly clean exterior of
housing.
torque generator before disassembly.
Disassemble torque generator in a clean work area.
2. Insert rack into generator housing. Position rack
to extend an equal distance from each side of
generator housing.
1.. Remove lock screws (item 95.819) and plastic
pellets (item 26.362). from generator housing
3. Insert pinion into generator housing, meshing
(item 26.258).
pinion teeth with teeth on rack. Be sure pinion
2. Remove cylinder tubes (item 26.361) from shaft keyway is In same location as at
generator housing by unscrewing with a spanner
disassembly.
wrench.
4. Pack pinion and rack teeth with general
3. Remove pistons (item 26.359) from cylinder puur&ose (No. 2) grease. Pill gear cavity with grease
.
tubes by pushing them out with a brass drift pin
inserted through the cylinder port. Note: Drift pin
5. Install lower bushing (item 26.357) and lower
maximum diameter is 0.5 inch.
retaining ring (item 26.356) over pinion and into
4. Remove piston seals (item 26.360) from generator housing.
pistons and discard.
6. Install new seals (item 26.360) on pistons (item
5. Position rack (item 26.358) at midpoint of travel. 26.359).
Rack should extend an equal distance from each
side of generator housing. Note and record 7. Lubricate pistons with hydraulic oil and install
into cylinder tubes (item 26.361). Be carefull not to
location of pinion shaft keyway. Keyway
locatlon will be needed to properly nick or damage the piston seals during installation.
assemble torque generator.
8. Screw cylinder tubes into generator housing
6. Remove lower retaining ring (item 26.356). Pull I .._
with spanner wrench. Torque cylinder tubes to
pinion (item 26.263) and lower bushing (item [40.7 N*‘m] 30 tbfaft .
26.357) from generator housing.
9. Install nylon pellets (item 26.362) and
7. Remove rack (item 26.358) from generator lockscrews (item 95.819). Tighten lockscrews
housing. firmly to retain cylinder tubes in generator housing.
SM556 26 - 03 - 3
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26-03-06 STEER TORQUE
GENERATOR INSTALLATION
,. .. .
GENERATOR .- ‘. ‘.
SM556 26 - 03 - 4
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GROUP 29 SECTION 01 c). Cavitating pump.
%e 1 [a, 1 .b, 1 .c, 1 .d
MAIN HYDRAULIC PUMP d). Drive shaft not aligned.
Check mounting and alignment.
e). Axial loading on drive shaft.
Check shaft end clearance.
CONTENTS NO. Check shaft alignment.
Check for worn key or spline.
PUMP DESCRIPTION 29-01-01 f). Relief valve usually in bypass.
PUMP TROUBLESHOOTING 29-01-02 Check relief setting.
PUMP REMOVAL 29-01-03
PUMP DISASSEMBLY 29-01-04 4. Low Pump Output.
PUMP PARTS INSPECTION 29-01-05
PUMP ASSEMBLY 29-01-06 a). Cavitating pump.
PUMP TEST PROCEDURE 29-01-06 See l.a, l.b, l.c, 1.d
PUMP INSTALLATtQN 29-o l-07 b). Air in fluid.
See 2.b.
c). Relief valve leakage or set too low.
Check relief valve.
29-01-01 PUMP DESCRIPTION d). Overheated oil.
Check oil temperature.
The main hydraulic pump is a fixed-displacement,
high-performance, pressure-compensated gear 5. Shaft Seal Leakage.
pump.
4. Damaged or worn seal.
Replace seal.
29-01-02 PUMP b Front cover bearing out of position.
Replace front cover assembly.
TROUBLESHOOTING
cl* Scratches on shaft seal housing bore.
See 5.b.
Before the main hydraulic pump is removed and/or
d). Improper fit of shaft.
disassembled, check the following list of problems
See 5.b.
and solutions. It could save cost, time and effort.
6. External Leakage.
1. Noisy Pump.
a). O-ring damaged.
a). Low supply of oil.
Replace O-ring.
Fill the reservoir.
b). Damaged surfaces in O-ring groove.
b). Oil too heavy.
Replace damaged part.
Change to correct viscosity.
c). Inlet line has restriction.
7. Failure to Build Pressure.
Check for foreign material.
Clean filter or strainer.
a). Defective relief valve.
d). Air leak in inlet line.
Repair and reset valve.
Check plumbing tightness.
_b).. Low oil supply.
“Fill reseivoir.
2. Foaming Oil.
SM556 29-01 -1
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2. Use a sharp scribe or marker to scribe a line or
put punch marks into body halves to assure correct
positioning of parts at assembly.
r
2
1. Before disassembling the pump, be sure the 5. Remove the rear cover. The dowel pins may
work area is clean. Overhaul pump only in a clean, remain with either section. Keep parts in order as
dust-free location, using clean tools and removed to assure correct positioning at assembly.
equipment. Dirt or grit will damage the highly-
machined surfaces and will result in leakage or
premature failure of the pump.
SM556 29 - 01 - 2
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ASSEMBLY - 29.100
COMPLETE
WEAR ?lAlE
29.117- AND SEAL KIT
29550-l
HYDRAULIC PUMP
SM556 29 - 01 - 3
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screwdriver to pry it out. Be careful not to damage
the seal bore in the cover when prying seal out.
SM558 29 - 01 - 4
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7. Inspect the body and cover for wear and
scoring. If the gear contact surface on the low
pressure (inlet) side exceeds [0.012 mm] 0.005 in.
wear depth, replace the body assembly. If the
body is usable, remove any burrs with a suitable
burring tool.
SM556 29-01 -5
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Matchmarks on the ends of the drive and driven
shafts must face the rear of the pump.
Insert the sleeve into the shaft seal from the front If press is not available, insert the fasteners and
of the pump until the sleeve contacts the drive tighten evenly to a torque of [38 - 43 Nom] 28 - 32
gear bushing. Ibf*ft.
Install the drive gear with the long journal toward 9. After tightening, make sure the drive shaft turns
the front of the pump. freely without binding or grabbing.
SM556 29-01-6
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4. Repeat this cycle (Step 3) for 3 minutes but
using one-half the input speed as above.
SM556 26-01 -7
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GROUP 30 SECTION 01
MAIN HYDRAULIC VALVE
CONTENTS NO.
Refer to Specifications Group for main hydraulic Move control handle to full back-tilt relief position.
system relief pressure settings. Hold control handle in relief position until pressure
_. ,..Lzr.eadingis obtained,andthen release.
Hydraulic system relief pressure setting may be
checked with a pressure gauge of 0 to 124132 IMPORTANT - Do not operate system
kPa] 3500 psi capacity. over relief any longer than necessary to
read pressure gauge.
SM556 30 - 01 - 1
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30-01-03 MAIN VALVE TROUBLESHOOTING
Oil leaks at either end of spool Defective O-rings in valve body Replace O-rings
No motion; slow or jerky action Relief valve worn or stuck in base Repair or clean relief valve
No relief valve action (high pressure) Small particle of dirt plugging orifice in Remove relief valve and
relief valve sub-assembly check orifice for blockage.
Clear orifice if blocked.
Upright or carriage will not hold Oil by-passing between spool and Replace valve
body
Upright or carriage mOves when Dirt or foreign particles lodged between Disassemble, clean, and
spool is moved from neutral to a check valve poppet and seat reassemble check valve
power position
SM556 30-01-2
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30-01-04 MAIN VALVE REMOVAL 30-01-05 VALVE DISASSEMBLY
1. Turn keyswitch OFF and disconnect battery. IMPORTANT - Overhaul valve only in a
clean, dust-free location, using clean tools
2. Remove battery. and equipment. Dirt or grit will damage
highly-machined surfaces and will result in
3. Remove two front covers and top compartment leakage or premature failure of
cover. components. Cleanliness of hydraulic
circuit is extremely important to proper
4. Air clean main valve and fiiings. operation and maintenance of system.
5. Loosen and remove all hydraulic lines from Clean outside of valve with a good grade solvent
valve. Mark or tag each line as removed to ensure and dry thoroughly.
correct position of line at assembly. Cap ends of
lines to prevent contamination 1. Before starting disassembly, valve should be
carefully examined to determine if there is any
evidence of external damage.
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NOTE:
NON SERVICEABLE
ITEMS MARKED “N”
30.000
-*I .
SM556 30-01-4
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replaced. Check the valve spool for freedom of necessary. Refer to main pump motor switch group
movement in the bore. for details.
SM556 30 - 01 - 5
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GROUP 31 SECTION 01 provided through a spin-on, full-flow return-line
filter in the power steering circuit.
HYDRAULIC SYSTEM
CONTENTS NO. 31-01-02 HYDRAULIC FLUID AND
FILTER CHANGE
GENERAL DESCRlPTlON 31-01-01
HYDRAULIC FLUID & FILTER CHANGE 31-01-02 There is no drain plug in the hydraulic sump tank.
HYDRAULIC SUMP TANK 31-01-03 When the sump tank must be drained of all fluid;
MAIN HYDRAUUC AND LIFT LINES 31-01-04 the procedure is to remove the pump suction line
HYDRAULIC STEERING LINES 31-01-05 from the sump outlet fitting and allow the fluid to
HYDRAULIC TlLT LINES 31-01-06 drain into a suitable drain pan. Unless the sump
tank is to be removed for other repair or
maintenance, the hydraulic fluid can be changed
by one of the following methods:
31-01-01 GENERAL
DESCRI,PTION 1) Removal of the hydraulic sump fill cover
assembly (sump filler cap adapter) and pumping
The parts of the main hydraulic system are the Fn\fl&:;ut by suction using a separate pump
hydraulic sump tank, main hydraulic pump and .
motor, main hydraulic valve, selector solenoid
vafve; and associated hydraulic lines and hoses. 2) Pumping the fluid out by using the truck
hydraulic system. This method, described
The parts of the hydraulic steering system are the below, may be used most easily and
steer pump and motor, steer gear, and steer satisfactorily for routine changing of the fluid.
torque generator.
SAf ETY NOTE
BREATHER CAP To perform this service procedure, it is
recommended that you first:
-SUMP CAP ADAPTOR
Park truck on a level surface.
8 Put the upright in a vertical position and
g
lower the carriage fully down.
Return control handle to neutral and turn
key switch OFF.
4
Remove the two front compartment covers for
SCREEN access to the hydraulic oil filter.
SM556 31 - 01 - 1
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Remove the snap-on cap and connect a suitable
drain hose line to the diagnostic check port fitting.
NOTE: Use quick-disconnect adapter fitting, Clark
Part No. 3797029.
Turn key switch OFF. Check truck operation. Turn key switch ON.
Operate the hydraulic system. Cycle the lift system
Disconnect drain line from the truck. Replace several times: raise the lift carnage to full height
cap on main valve check port fitting. and lower fully down. Check for leaks.
1.1.- ,‘SAFETY .I%
NOTE
NOTICE - If old oil is excessively dirty or
hydraulic system contaminated, it is Be sure there is adequate overhead
recommended that the sump tank be clearance before raising upright.
completely drained by removing the pump
suction line from the sump outlet, and Turn key switch OFF.
flushed with clean oil.
Check sump tank fluid level again. Add
recommended fluid as required. DO NOT
OVERFILL.
SM556 31 - 01 - 2
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SUMP BREATHER CAP
PRE-FILTER SCREEN
SM556 31 - 01 - 3
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l-31.019 /- 31.388
30.952 STANu~D~V~ILO
31.480 ,y-31.393
28.752
p; TO UPRIGHT
L30.060
- :i
.; 31.387
-ai.wi
MAIN HYDRAUUC & LIFT LINES
23.832 FITTING, SELEtXORVb3+VR OUTLET 31.037 FITTING, VALVE DISCRARGE FORT
27.024 PLUG, DRV. SRL. SOL. VALVE OUTLET PORT 31.038 SEAL. VALVE DISCHARGE PORT FITTING
27.025 SEAL. DW. SEL. SOL.VALVE C5 PORT 31.109 LINE, MAIN VALVE DISCRARG&
27.028 FITPING, DEV. SEL. SOL. VUVE Cf PORT 31.191 LINE, VALVETO sum RETURN
28.158 SEAL, HIGR PRESSDRE CARRY OVERLINE 31.195 LINE, VALVEPO SUKP RE
28.291 FITTING, PUMP OUTLET 31.198 PITTING, LIFT CYL. RF.TURNSUKP INLET
28.649 FIlTINC,VALVR LIRPRRSSURRLXNE " ~rCLAHP~VALVR~~TO~SUXP~RETURN LINE
.‘-35.387-
28.752 SRAL. PRESS.GAlJGEPORTFIlTMC 31.388 LINE, VALVE SUMP RETDRN
28.802 SEAL,HYD. PuplpODTLEr LINE 31.393 CAP. VALVE TO SUMP RETURNLINE
30.059 SEAL, CARRYOVER FIT1?NGINNER 31.421 SRAL. PUKP OUTLET PORT FITTTNG
30.060 SEAL.CARRYOVERFIlTfNGOUTER 31.480 FIlTING. PRESSURE GAUGE PORT
30.061 FITTING,HIGR PRESSURE CARRY OVRR 31.537 FITTING, VALVE SECONDARY INLET PORT
30.431 FImINC, HIGH PRESSURE CARRY OVea 31.538 SEAL, VALVE SECONDARYINLET PORT FITTING
30.952 DUST CAP. PRESSURE GAUGE PORT FITTING 31.586 FITTING,LIFT CYL. VENT LINE
31.001 LINE, sum OUTLET 31.628 SEAL. V&Vi? INLfi PORT LINE
31.002 CLAk@.sDMPOUTLETLINE 31.919 SEAL, VALVE.SUMF RErURN LINE
31.003 LINE,PuKP INLET 31.950 LINE.RIGRPRRSSURECAF.RY0VER
31.004 CLAm.PmPINLETLINE 32.110 SEAL, MAIN VALVE OD'ILETLINE
31.006 LINE, PUMP INLET 32.112 SEAL.VALvE Sm RETURN LINE
31.007 CLAMP. PUMP INLET LINE 33.503 FITTING, SOLENOID VALVE INLET
31.008 FITTING, PUMP INLET 33.504 SEAL, SOLENOID VALVE INLET FIlTING
31.010 SEAL, ~IIfLETFITTING 33.513 SEAL. SRLECTORVALVEOUTLET FITTING
31.013 SEAL, Puw OUTLET FITTING 33.761 FITTING,DEV. SEL. SOL. VALVE C4 PORT
31.016 FI'ITING,PUMP ODTLeP 33.762 SEAL, DEV. SEL. SOL. VALVE CL PORT FITTISc.
31.018 LINE, PW OUTLET 34.ss7 STRAP, LIFT CYL. PRESSURE LINE
31.019 LINE. VALVE INLET 34.559 SEAL, VALVE TO LI= CYL. LINE
31.023 siaL,vAtvEmmFfm~~ 51.339 FITTING. SELECTOR VALVE Cl PORT
31.030 LINE, VALVE TO LIFT CYL. 51.340 SEAL, SRLECTOR VALVE Cl PORT FITTING
31.036 FIlTING, MAIN VALVE INLET PORT 66.149 SEAL, LIW CYL. LINE FITTING
Copyrighted Material
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SM556 31 -Do
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- 4 sell or distribute
26.265 SEAL, TORQUE GENERATOR PRESSURE PORT 31.098 CLAMP, STEER PUMP INLET HOSE
26.363 SEAL, TORQUE GENERATOR INLET FITTING 31.100 TUBE, STEER PUMP INLET
27.044 BRACKET, RELIEF VALVE MOUNTlNG 31.102 FIITING, STEER PUMP INLET
28.059 SEAL, STEER VALVE CONTROL PORT FllTlNG ‘R 31.104 Fll-l-ING, STEER PUMP PRESSURE PORT
28.060 FITTING STEER VALVE CONTROL PORT ‘R 31.115 LINE, STEER PUMP OUTLET
28.061 LINE, STEER VALVE CONTROL ‘R 31.120 LINE, STEERING SUMP RETURN
28.062 LINE, STEER VALVE CONTROL lL 31.122, FITTING, STEERING SUMP RETURN LINE
28.065 SEAL; STEERVALVE CONTROL PORT FITTING ‘L’ ’ .. ;;.;‘t$ - “’ ClAMP,STEER LINES
28.066 FIlTlNG, STEER VALVE CONTROL PORT ‘L- LINE, STEER PUMP INLET
28.133 FITTING, RELIEF VALVE INLET PORT 31:149 FIlTlNG, STEER LVALVE INLET PORT
28.134 SEAL, RELIEF VALVE INLET PORT 31.150 FllTlNG STEER VALVE DISCHARGE PORT
28.136 FIllING, RELIEF VlAVE OUTLET PORT 31.164 LINE, STEER VALVE DISCHARGE
28.246 SEAL, RELIEF VALVE INLET LINE FllTlNG 31.373 SEAL, STEER PUMP PRESS. PORT FIT-I-ING
28.247 SEAL, RELIEF VALVE OUTLET LINE FITTING 31.399 SEAL, STEER VALVE DISCHARGE PORT
28.262 LINE, TORQUE GENERATOR “Cl” 31.449 SEAL, STEER PUMP INLET PORT
28.352 CAP, POWER STEERING GAUGE PORT FITTING 31.462 SEAL, STEER VALVE OUTLET PORT ‘L
28.383 FI-ITING, POWER STEERING GAUGE PORT 31.465 SEAL, STEER VALVE OUTLET PORT ‘R”
28.674 SEAL, RELIEF VALVE INLET PORT FllTlNG 31.466 SEAL, STEER VALVE INLET PORT
28.675 SEAL, RELIEF VALVE OUTLET PORT FllTlNG 31.606 LINE, STEER PUMP INLET
28.751 SEAL, POWER STEERING GAUGE PORT Fill-ING 31.683 FITTING, TORQUE GENERATOR INLET ‘Cl”
28.760 SEAL, RELIEF VALVE OUTLET PORT 31.684 FIlTlNG, TORQUE GENERATOR INLET “C2”
28.799 SEAL, STEER VALVE OUTLET PORT FllTlNG 31.690 LINE, TORQUE GENERATOR ‘C2
28.801 SEAL, STEER PUMP OUTLET PORT FITTING 31.830 SEAL, FILTER INLET PORT FllTlNG
28.804 SEAL, STEER VALVE INLET PORT FllTlNG 31.974 FITTING, RELIEF VALVE OUTLET LINE
30.662 VALVE ASSEMBLY, RELIEF 33.056 FASTENER, RELIEF VALVE
31.043 FITTING, FILTER INLET PORT 95.874 FASTENER, RELIEF VALVE MTG. BRKT.
31.044 SEAL, FILTER INLET PORT 95.875 NUT, RELIEF VALVE FASTENER
31.047 SEAL, FITLER OUTLET PORT
31.050 FITTING, FILTER OUTLET PORT ,
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SM556Do31
not- 01
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REV JAN 90
CLqRH N&erzrn:Handling
.31.077
31.364
31.072 ’ l- 26.833
28.830 Seal, RH Tilt Cyl. Anchor Port Line Fitting 31.162 Fitting, RH Tilt Cyl. Anchor Port
28.831 Seal, LH Tilt Cyl. Rod Port Line Fitting 31.364 Seal, LH Tilt Cyl. Rod Port
28.832 Seal, RH Tilt Cyl Anchor Port Line Fitting 31.365 Seal, RH Tilt Cyl. Rod Pot-l
28.833 Seal, RH Tilt Cyl. Rod Port Line Fitting 31.366 Seal, LH Tilt Cyl. Anchor Port
28.834 Seal, LH Tilt Cyl. Anchor Port Line Fitting 31.367 Seal, RH Tilt Cyl. Anchor Port
28.835 Seal, LH Tilt Cyl. Rod Port Line Fitting 31.370 Fitting, Tilt Cyl. Rod Port Line
28.836 Seal, Tilt Cyl. Rod Port Line Fitting 31.372 Fitting, Tilt Cyl. Anchor Port Line
28.837 Seal, Tilt Cyl. Rod Port Line Fitting 31.600 Fitting, RH Tilt Cyl. Rod Port
30.563 Seal, Valve Port (C3) Ftiing
30.565 Seal, Valve Port (C2) Fitting
Copyrighted Material
Intended for CLARK dealers only
SM55631 -01 -6Do not
REVdAN
sell or distribute
GROUP 32 SECTION 01 2. Disconnect the hydraulic lines from the tilt
cylinders and cap the ends of the lines to prevent
TILT CYLINDER contamination of the lines. Note: Put a drain pan
under the truck at the tilt cylinder position when
CONTENTS NO. removing hydraulic lines.
TtLT CYLINDER REMOVAL 32-01-01 3. Remove the tilt cylinder rod end retainer
TILT CYLINDER DISASSEMBLY 32-01-02 capscrew and washer (items 34.091 & 34.090).
TlLT CYLlNDER INSPECTION 32-01-03
TlLT CYLINDER ASSEMBLY 32-01-04 4. Remove each tilt cylinder rod end (item 32.027)
TILT CYLINDER INSTALLATION 32-01-05 by pulling it off the upright attachment pin.
TILT CYLINDER ADJUSTMENT 32-01-06
5. At the anchor end of the tilt cylinder, remove
both spring clip retainers (item 32.034) from ends
of mounting pin (item 32.033).
32-01-01 TILT CYLINDER
REMOVAL 6. Drive the mounting pin (item 32.033) from tilt
cylinder anchor end and frame brackets.
1. Be sure all hydraulic attachments are in a 7. Remove the tilt cylinder from the truck.
position of rest and the upright and carriage are in a
fully lowered position. TILT CYLINDER ROD END REMOVAL
, _, ,... ~ .1 Ij , . _I., ,
32.027
90.438
--l
34.091 J 32.053 1
34.090 --I
SM556 32 - 01 - 1
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I ASSSMUY
COYfim
- 32.000 32.105-
__._____
32.002K -
\-32.002
L 32.024
MUKID “K”
TILT CYLINDER
SM556 32 -01 - 2
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10. Remove shim(s) (item 32.102) and spacer Make sure the threads on the rod are free of
(item 32.014) (if used) from tilt cylinder rod. Note damage.
location and number of shims removed. This will
aid initial setting at installation. 3. Check the bore of the cylinder for any damage.
11. Inspect tilt cylinder anchor end beating (item Parts with deep gouges or pitted surfaces will
32.043). Replace if worn or damaged. require replacement.
Be sure all hydraulic oil has been removed from the 4. Put a light coat of hydraulic fluid on all parts. If
cylinder. Stroking the piston rod will help force the parts are to be left out for a period of time or
oil out. overnight, they should be covered with a clean
cover.
When overhauling hydraulic components, it is
necessary to avoid any dirt particles from
contaminating the system.. ,cThesmallest particles 32-01-04 TILT CYLINDER
are capable of severely damaging the system. ASSEMBLY
2. Put the base end of the cylinder in a vise or use 1. Install a new packing (item 32.019) in the gland
an alternate method of preventing the cylinder assembly (item 32.017).
tube (item 32.002) from rotating.
2. install a new rod wiper (item 32.023) in the gland
3. Use a spanner wrench to loosen and remove assembly.
the end cap (item 32.024).
3. Install a new gland seal (item 32.015) on the
4. Carefully pull the piston rod assembly (item gland assembly.
32.036) and the gland assembly (item 32.017) out
of the cylinder bore. 4. Install a new piston seals and back-up rings
(item 32.005) on the piston.
5. Pull the gland assembly (item 32.017) off the
piston rod (item 32.036). 5. Coat the bore of the gland assembly and the
piston rod assembly with a light coat of hydraulic
6. Remove and discard the tilt cylinder gland seal oil.
(item 32.015) the gland packing (item 32.019) and
the wiper (item 32.023) from the gland assembly. 6. Slide the gland assembly onto the piston rod
assembly, being careful not to damage the gland
7. Remove and discard the piston seals and back- packing and rod wiper with the end of the piston
up rings (item 32.005) from the piston assembly. end.
1. Carefully clean all parts in an approved solvent 6. Install the gland assembly into cylinder tube.
and position them on a clean surface.
9. Install the gland nut and torque to [67 - 81 Nom]
2. Check the piston rod for any damage. Look for 50 - 60 Ibfaft .
gouges, scratches, corrosion or evidence of
unusual wear. Minor surface damage can be 10. Check the assembly by making sure the piston
repaired by use of fine abrasion cloth or stoning. rod will slide in the cylinder tube.
Deeper damage will require replacement of piston
rod assembly.
SM556 32-Ol- 3
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32-01-05 TILT CYLINDER To shorten, loosen the clamping fastener on the
INSTALL mATION rod end (item 32.027) and rotate the piston rod
CLOCKWISE into the rod end threads.
1. Install shim(s) (item 32.102) and spacer (item
32.014)(if used) on cylinder rod. When the racking effect has been corrected,
tighten the rod end fastener.
2. install rod end on cylinder rod. The number of 4. Slowly tilt upright fully backwards.
turns to install should be same as noted when rod
end was removed. If necessary, keep the tilt 5. Note if tilt cylinders “bottom out” (stop) at the
cylinder rod from turning with a wrench on the flat same time. If they don’t, tilt cylinder backward tilt
portion of the rod at the end of the threads. must be adjusted.
3. Install the rod end clamp bolt and nut (items 6. Slowly tilt the upright backward until one tilt
32.029 & 90.438). Torque the clamp bolt nut to cylinder “bottoms out” against its rod spacer (item
[20 - 25 N*m) 177 - 221 lbfmin. 32.014)or gland end cap (item 32.024).
4. Position the tilt cylinder in its location on the 7. Install rod shims (item 32.102) on rod to fill in
frame and install the hydraulic lines. space between rod end and spacer or gland end
cap.
5. Install the mounting pin (item 32.033) through
the tilt cylinder anchor end and frame brackets. 8. Test for proper forward and backward tilt
Install both mounting pin spring clip retainers, (item cylinder adjustment.
32.034).
SM556 32 - 01 - 4
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GROUP 33 SECTION 01
SELECTOR SOLENOID
VALVE 33-01-02 SELECTOR SOLENOID
VALVE TROUBLESHOOTING
SELECTORVALVE
Copyrighted Material
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Do not sell or distribute
27.031
30.572
27.033
33.523
30.572 COIL, LOWERING VALVE SOLENOID 25N MANIFOLD, SELECTOR SOL. VALVE USE 33.300
33.000 FLOW CONTROL, DEVICE
33.009 SF.ALKIT, DEVICE FLOW CONTROL
33.052 VALVE, SRLECTOR SOLENOID VALVE RELIEF
33.233 COIL, LIFI SOLENOID VALVE
SM556 33-01-2
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7. Remove selector solenoid valve fasteners (item 33-01-06 DEVICE SELECTOR
30.307). Remove selector solenoid valve. SOLENOID VALVE
IMPORTANT
Removevalve components only in a clean,
dust-free location, using clean tools and
equipment. Dirt or grit will result in leakage
“- or. premature failure of components.
Cleanliness of hydraulic circuit is extremely
important to proper operation and
maintenance of system.
SM56 33 - 01 * 3
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
ASSEMBLY COMPLETE
DOES NOT INCLUDE I- 33.360
’ t d ’ 27.027
@> 27.026
27.024
Copyrighted Material
Intended for CLARK dealers only
SM556 33 - 01 - 4 REV JAN 90
Do not sell or distribute
-.
‘. .
-.
.-\. ‘.
.’ ;,t::: ‘,._,_’ . ,
A’ :.
: x X\ -..
13.574 /,’ : ‘... ‘. ..
.‘-- ._
,.. -/;
\,/
I’
65.914
27.027
27.030
27.026 - CL
n 33.380
27.029 -
Copyrighted Material
Intended for CLARK dealers only
SM55633-01-5 .‘JAN90
Do not sell or distribute
CI!!IIRH
65.914 J 14.722 -I
Copyrighted Material
Intended for CLARK dealers only
SM55S 33 - 01 - 6Do not
-.. sell
: JAN 90
or distribute
GROUP 34 UPRIGHT 34-01 UPRIGHT
MAINTENANCE
CONTENTS NO.
Shim inspection at least every 500 hrs of
Upright, Maintenance 34-o 1 operation.
Upright, Shim I,nspection, Triple Stage 34-02
Carriage, Shim Inspection, Triple Stage 34-03 Check mounting fasteners.
Carriage, Shim Installation, Triple Stage 34-04
Upright, Triple Stage, Shim Disassembly 34-05 Check for leaks at hydraulic connections.
Upright, Triple Stage, Reassembly 34-06
Upright, Cylinder, Troubleshooting 34-07 Check for interference of hosing, chains, etc.
Upright, Cylinder Repair, Triple Stage 34-08 during lift operations.
Upright, Lit Chain, Maintenance 34-09 Keep piston rods and tops of cylinders clean.
Upright, Shim Inspection, Standard 34-l 0
Carriage, Shim Inspection, Standard 34-11 Always keep piston rods in retracted position when
Carriage, Shim Installation, Standard 34-l 2 not in use.
Upright, Standard, Shim Disassembly 34-l 3
Upright, Standard, Reassembly 34-l 4 Lubricate lift chain. Refer to 34-09 for instruction.
Standard Type Cylinder Troubleshooting 34-15
Upright, Cylinder Repair, Standard 34-16 Check chain adjustment and chain anchor adjustor
jam nuts.
SM556 34 - 01 - 1
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Check shimming of center roller on six (6) roller
carriage by raising upright until carriage top rollers
Rail/Roller Acceptance/Rejection List come out of top of inner rails.
SM547 34 - 01 - 2
Copyrighted Material
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UPRIGHT AND CARRIAGE SHIM
INSPECTION TRIPLE STAGE
Fiq.ure A -I Figure B I
6auge
center roller
J of six roller
carriage
‘C”
Clamp-_) w
! ,:
6auge
gauge
gauge
6auge
/
/
/
6auge 6auge
SM547 34 - 01 - 3
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34-05 TRIPLE STAGE SHIM Lower carriage and forks onto the pallet and
DISASSEMBLY continue to lower until the primary (center
mounted) cylinder piston rod is completely
Shimming of the upright should be performed by collapsed into the cylinder. It may be necessary to
maintenance personnel in a properly equipped have a helper hold the control handle in the
shop with overhead hoist chainfall. Think out each lowering position while you pull on the carriage
procedure. chains to fully collapse the primary (center
mounted) cylinder.
SM556 34 - 01 - 4
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Do not sell or distribute
As applicable on some models remove upper NOTE: Check to assure that upright tilt is still “0”
primary hose retainment bracket located on left degree vertical.
underside of top tie bar.
SM556 34 - 01 - 5
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The final lift cylinder is located on the right side of From the rear of the upright remove both lower
the upright, loosen but do not remove the lower chain anchor fasteners located on both inner rails.
support fastener(s). Note: on some models the left and right chain
anchor bolts are different lengths.
I.. ,,
Hydraulically raise the upright rails and remove From the left rear of the upright pull the Left chain
both blocks and the oil pan. anchor out and tie it to the top left outer tie bar
area.
Lower the upright rails completely.
Remove the final lift cylinder rod fastener, located
NOTE: Top of the rails should be flush on top of the intermediate rail top tie bar. Note:
Some models may have two fasteners in the top of
Wrap 3/6” chain/safety strap around the top tie bar final lift cylinder rod. In either case the lift chain
of the inner rails. With a hoist/chainfall raise the partially covers the cylinder rod fastener(s) and
inner rail high enough to insert a fourteen (14”) must be moved over to remove fastener(s).
inch block vertically under the primary lift cylinder
base. Lower the hoist/chainfall until the primary lift Remove the final lift cylinder lower support
cylinder base rests securely on the fourteen (14”) fastener(s) available from rear of upright.
inch block.
SM556 34 - 01 - 6
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From the front of upright pry the lower part of final 6. or it may be removed from the upper end of
lift cylinder over towards the center of the upright cylinder and lay the hose over the cowl. Also in
and pull right lift chain anchor out from right rear of this case, new tie straps will be required upon
the upright. Tie the right chain anchor to upper replacement.
right side of chain anchor bar adjustment area.
Disconnect the final lift cylinder hose on the
bottom of the divertor block located on the left side
of upright. Plug the hose and cap the fittings
with#12 male and female fittings. Tighten both
fittings.
SM556 34 - 01 - 7
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Raising the hoistichainfall detach the final lift 4) Also the outer rail upper rollers are now
cylinder upper mounting bracket from the tie bar exposed. Shim as needed.
hook and out the front of the upright. Lower the
cylinder onto a pallet or other adequate support.
, . - _ , ,. .. . , I
B. To expose inner rail and intermediate rail upper
rollers:
You Are Now Ready To Expose the Rail 1) With both rails resting on the floor wrap
Rollers For Shimming the 318” chain/safety strap around only the
intermediate rail top tie bar.
A. To expose the outer rail upper and intermediate
rail lower rollers: NOTE: Check to assure chain anchor mounts are
1) Wrap 3/8” chain/safety strap clear. Also assure the chain and anchors do not
around both the inner and intermediate rail top tie catch or jam when raising or lowering the rails.
bars and hook onto hoistlchainfall,
2) Raise the ,intermediate rail with
NOTE: Check to assure that lift chains and hoistlchainfall until a two (2’) foot 4x4 block can be
anchors will not catch or jam when raising and inserted horizontally, front to back across the tie
lowering the rails. bars and under the top of the intermediate rail tie
bar.
2) Raise both rails with hoist/ 3) Lower the intermediate rail until the tie
chainfall and remove the blocks from under the bar rests on the block.
primary cylinder and the intermediate rail. NOTE: Inner rail must remain on the floor during
3) Lower the rails to the floor which will this procedure.
expose the lower intermediate rail rollers. Shim as 4) Intermediate rail upper rollers are now
needed. exposed. Shim as needed.
NOTE: Both rails must be on the floor at this time.
SM556 34 - 01 - 8
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5) inner rail lower rollers are now exposed. WOOD BLOCKS
Shim as needed. CHART “F”
1 -6”-4X4
1-12”-4x4
1-14”-4x4
1 -2ft.-4x4
1-4ft.-4x4
4-12”-2x6
TOOLS AND SUPPLIES NEEDED Wrap 3/8” chain/safety strap around both the inner
CHART “D” and intermediate rail top tie bars. Then hook on
hoist/chainfall. Raise rails high enough to insert
1 1Omm allen wrench the 14” length 4x4” block under the primary lift
1Omm open end wrench or socket cylinder and the 12” length 4x4” block under the
: 13mm open end wrench and socket intermediate rail.
1 18mm open end wrench
1 19mm open end wrench and socket Lower rails onto blocks.
2 22mm open end wrench (or 7/8ths)
1 24mm socket Install final lift cylinder. Wrap the 3/8” chain/safety
1 30mm socket strap around cylinder just below its top retaining
1 9/l 6” open end wrench bracket. Hoist the cylinder and maneuver into the
l-1/4” angle wrench front of the upright making sure the hydraulic hose
: pair side cutters connection is toward the left side of the upright.
hammer Position the cylinder upper mounting bracket on
: small pry bars (12”) the tie bar hook. Reconnect the final lift cylinder
1 screwdriver (standard) hydraulic hose to the bottom of the divertor block
bng pry bar (about 3 ft. or longer) located on left side of upright. Install the return
: 6” “c” clamps + l-1/4” spacers vent line.
8 feeler gauges .OlO ea. 3/4” wide 12” long
Use the truck hydraulic system lever to slowly
extend the final lift cylinder piston rod end without
SUPPLIES ._raising_rails off blockto align with the intermediate
CHART “E” rail top tie bar mounting holes. Then install
fastener(s) in top tie bar into the end of final
Safety platform or stepladder cylinder piston rod.
3 #12 JIC female caps
3 #12 JIC male plugs Hydraulically raise intermediate rails and remove
Drain pan the 12 inch 4x4 * block.
Quantity of roller shims PN2359551
Sand paper NOTE: Do not remove 14 inch block under
Approximately 6 ft. of 3/8” chain/equivalent primary lift cylinder.
strap with hooks
6 - plastic wire ties Fully lower the intermediate rail.
Cleaning rags
Install both lower lift chain anchors with fasteners
loose (finger tight). Install final lift cylinder lower
SM547 34 - 01 - 9
Copyrighted Material
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mounting fasteners from rear of upright. free lift range. Close the high pressure valve. Mark
Remember, do not reach through upright rails. the position of the forks. After five minutes
measure the drift of the forks if any.
Raise intermediate rails hydraulically to put tension
on chains and tighten lower chain anchors. If the drift exceeded 718 of an inch, the primary
Recommended torque is 50-55 Ibf.-ft. cylinder is in need of repair.
Raise rails high enough to remove 14 inch block To check the secondary cylinder open the high
from under primary cylinder and install 4 foot length pressurs valve and continue to raise the maximum
4x4” block vertically under inner rail with a 2 foot load above the free lift range until the secondary
length 4x4” placed vertically under the cylinder piston rod is extended approximately one
intermediate rail. foot or more. Close the high pressure valve. Mark
th8 position of the forks. After five minutes
Lower the rails down onto the blocks. measure the drift of the forks, if any.
Install th8 bracket, hose and tube assembly at the If the drift of the forks exceeded 7/8 of an inch,the
base of the primary lift cylinder. Raise rails secondary cylinder is in need of repair. Open the
hydraulically and remove both blocks. high pressure valve and lower the load to the floor.
Completely lower upright to adjust lift chains at the NOTE: The drift dimensions specified are based
right hand outer rail upper tie bar. Turn the on conducting the inspection with the hydraulic oil
adjusting nuts .on. both chain .anchors until both temperature at 80-l 00 degrees fahrenheit.
chains are slack. Tighten the forward chain anchor
nut until the inner rail just begins to raise. Tighten
the rear chain anchor nut until both chains have 34-08 HYDRAULIC CYLINDER
equal tension. Lock the jam nuts on both chain REPAIR TRIPLE STAGE
anchors. Recommended torque is 110-130 Ibf.-ft.
using two wrenches and a third hand to hold the
Remove cylinder from upright (se8 34-05
chain anchor from turning.
Disassembly). Position cylinder on a work bench
with adequate support for safe and convenient
Drive truck up to the carrfage making sure the inner
disassembly. Two sets of 4x4” “V” notched blocks
rails are aligned with the carriage rollers. Check to
are helpful. One set for cylinder barrel and a
assure that the upright is still “0” degrees tilt. Raise
second set for the piston rod to prevent nicks and
inner rail high 8nOUgh to clear carriage rollers,
scratches from being inflicted on the piston or rod.
slowly mov8 forward where the upright inner rails
will lower over the carnage rollers. Assure that the
Clean entire cylinder to prevent dirt and other
final cylinder is fully COllapS8d. Reinstall the
contamination from entry into the cylinder during
carriage chains. Install the primary cylinder
reassembly. Parts may be cleaned with solvent or
hydraulic hose at the top of divertor valve block
mineral spirits and dried completely. If petroleum
located on the left side of the upright. If applicable
solvent is not available use hydraulic fluid
install upper primary hose retainment bracket
compatible with that used in vehicle system.
located on left underside of top tie bar. Remove
“c” clamp from fork to pallet. Raise carriage and
RemOV8 cylinder gland cap with proper size
back away.
spanner wrench or equivalent tool. Pull the piston
rod out of the cylinder barrel and-place it on a set of
Check for leaks. Check hydraulic oil in sump tank
“V” notched blocks. Remove all packings and
for proper level. Load test.
seals from the piston and the cylinder cap.
34-07 TRIPLE STAGE CYLINDER NOTE: Use extreme care that your tools do not
TROUBLESHOOTING make nicks and burrs on the interior surface area of
the cap or the exterior surface area of the piston.
To determine cylinder drift it is necessary to install a
high pressure shut off valve between the cylinder The U-cup seals are the most difficult to remove,
and the control valve. particularly from the cylinder cap. An electric
soldering gun tip (Weller 250 or equal) will melt
Open the high pressure valve and raise the forks through the U-cup seals in one or two minutes.
to maximum lift height. Lower forks to the floor and The soldering tip may need to be bent
raise a maximum load above the floor within the
SM547 34 - 01 - 10
Copyrighted Material
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approximately 90 degrees to effectively penetrate Use new parts as necessary. Always use new
the U-cup seal inside the cylinder cap. “Packing Kit” listed in the parts manual which
includes all the seals, wiper rings, wear rings and
After disassembly and cleaning inspect cylinder “0” rings necessary for the particular cylinder.
barrel and bore for cracks, pitting, scoring or other
irregularities that may require replacement of
barrel. Likewise inspect the piston and rod for
nicks, scratches, scoring or other defects that may
demand new parts.
66.400- FImL LIIT cn SEDER
66.409- WIPER
66.410- U-CUP
66.413- SPACER
66.414- BEARING
SM547 34-01 - 11
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Installation of U-cup seal onto the piston is
Installation of U-cup seal into the cylinder cap accomplished with the proper size piston cone and
requires the use of tool #2195AT. Collapse the seal driver tools equivalent to #2525AT drawings
rool handles to insert the U-cup seal with the U- on following pages.
side down. The tool has three pins. Place the tool
so two pins are on the inside of seal and one pin Place the seal on the cone end of the piston cone
on the outside of seal. tool with the U-side toward the point of the cone.
Now place the driver on the cone and tap the driver
until the seal is positioned on the wide end of the
cone tool. Position the wide end of the tool over
the bottom of the piston so the piston is all the way
into the countersink part of the tool. Continue to
drive the seal off the tool into the piston groove.
(16296 1.
DR&RM
b40
.375(9,525)0lA.
REF
HO ES
---_
\ 219%AT_
i
ASSEMBLED VIEW - I
03,te
3REV0
Oh X 2 b2 LG CWEC PIN
WELD IN RACE AFTER DE% I&Z ASH.
Procure or manufacture
all tools locally.
Copyrighted Material
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2526AT INSTALLATION TOOL
U-CUPTO PISTON LIFT CYLINDER
$%l.C&pE FOR
. co.00
‘,I WON’&
4.50
1 /
SM547 34 - 01 - 15
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34-09 UPRIGHT LIFT CHAIN During the inspection, check for the following
MAINTENANCE chain conditions:
Lift Chain Inspection and Measurement (3) SPAN - The number of pins in the length
(segment) of chain to be measured.
Inspect and lubricate the lift chains every truck PM
(50-250 hours). When operating in corrosive
environments, inspect the chains every 50 hours .
SM547 34 -01 - 16
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(4) PITCH - The distance from the center of one 5. Replace anchor pins and worn or broken
pin to the center of the next pin. anchors when installing new chains.
7
1. New Chain Length
2. Worn Chain Length 7. Lubricate chains when they are installed on the
3. Spm
4. Pitch upright.
‘SM556 34 - 01 - 17
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Rail/Roller Acceptance/Rejection List
Measure the rail to roller clearance using feeler
CHART “c” gauges at points shown in figure “B2 . Refer to
Chart “C” for shim tolerance.
Feeler Gauge will Shimmed
Seq Gauge Pass/not pass Correctly Qty Reinstallation of side thrust roller with lock patch
requires torque of 55 - 59 Ibf.-ft.
.020” Yes 0
.020" Try.040” -
.040- Yes 0
Try.060” - 34-12 CARRIAGE SHIM
;gI No 2 INSTALLATION STANDARD
Try 680”
1% 3
Remove carriage as described undere “Shimming
.080” Try%lO” -
of Upright for Single Stage”. Shim as needed.
Evaluation of shim requirements generally dictates
that a specific roller is acceptable until (.040) two
(2) shims are required. It is recommended that the
shims are split evenly within one shim from side to
side and that all the uneven quantity of shims are
on one side.
SM547 34 - 01 - 18
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UPRIGHT AND CARRIAGE SHIM
INSPECTION STANDARD
Figure A2 F&e 82
gauge
/ center roller
of six roller
. C.
carriage
ClanQL- .e
: b
6auge ._
OP?OSITE SIDE.
gauge
SM547 34 - 01 - 19
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34-13 UPRIGHT STANDARD SHIM
DISASSEMBLY
_ o”,
SM556 34 - 01 - 20
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NOTE: Check to assure that upright tilt is still “0” sling thru the lift eye of lower sling and around the
degree vertical. upper part of the cylinder and hook into
hoist/chainfall. Now take up the slack.
.
Hydraulically raise inner rail and place 12” - 18”
length 4x4 block vertically into the outer rail onto
the block. Turn key off.
SM556 34 - 01 - 21
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Carefully raise the lift cylinder out and up from the 1 18mm open end wrench
rear of upright. Lower the cylinder onto a pallet or 1 19mm open end wrench and socket
other adequate support. 2 22mm open end wrench (or 7/8ths)
1 24mm socket
1 30mm socket
1 9/l 6” open end wrench
1 1-l/4” angle wrench
1 pair side cutters
hammer
: small pry bars (12”)
1 screwdriver (standard)
long pry bar (about 3 ft. or longer)
: 6” “C” clamps + 1-l/4” spacers
8 feeler gauges .OlO ea. 3/4” wide 12” long
SUPPLIES
CHART “E”
SM556 34 - 01 - 22
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34-l 4 UPRIGHT STANDARD Repeat preceding paragraphs for the opposite
REASSEMBLY cylinder.
With chain or safety strap around top tie bar of Replace lift chain anchor clamp straps on both
inner rails, raise the inner rails to insert 12” - 18” cylinders.
length 4x4 block vertically into the outer rail
channel and under the inner rail. Lower inner rail Connect hydraulic hose and tube connectors at
onto the block. base of both lift cylinders.
SM547 34 01 - 23
Copyrighted Material
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Do not sell or distribute
other damage that will cause accelerated wear of includes all the seals, wiper rings, wear rings and
the seals. “0” rings necessary for the particular cylinder.
SM547 34 - 01 - 24
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Intended for CLARK dealers only
Do not sell or distribute
NOTE: Check to be sure the seal is
inserted with the U-side toward the Install cylinder in upright as described in upright
cylinder barrel. reassembly.
i/.-’
LIFT CYLINDER
%.Lw
I..ML
34.Lot
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X.U6
- X.60
3‘..1,
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I‘.‘79
SM547 34 - 01 - 25
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SEAL INSTALLATION TOOL LIFT
CYLINDER
T
1
(8599)
3.33 (73,i)
L88I
D 2-B
(162.6:
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01; X 2 b2 LG. WUEC PIN
Procure or manufacture
all tools locally.
4
SM547 34-01 -26
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
2525AT 1NSTALLATlON TOOL
U-CUP TO PISTON LIFT
CYLINDER
SM547 34 - 01 - 27
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
2526AT INSTALLATION TOOL
U-CUPTO PISTON LIFT CYLINDER
- .-
---
cp.00
I
4.50
_ J-'-m
GROlJP
34
SECTION
9R
UPRIGHT REMOVAL
.- .,
C’
..‘-“.
To perform this service procedure, it is
recommended that you first:
Truck Preparation
Copyrighted Material
Intended for CLARK dealers only
Code: OH-540, MAR 86 Do not sell or distribute GROUP 34, Section 9R, Page 1
UPRIGHT MOUNTING
UPRIGHT REMOVAL
Typical TM TSU upright assembly weight, USE APPROVED HOOKS, CHAINS AND
l;;; r;oks, is approximately [680 kg] CONNECTING LINKS WHEN REMOVING
. THE UPRIGHT. BE SURE THE HOIST
AND CHAIN HAVE CORRECT CAPACITY
TO SAFELY HANDLE THE LOAD.
1 Attach lifting chains and hoist to upright.
85M893
,,’ _
.
._
‘. ;:
‘.., ’
85M624
26573
Copyrighted Material
Intended for CLARK dealers only
Code: OH-540, MAR 86 Do not sell or distribute GROUP 34, Section 9R, Page 3
GROUP CMRU
34
17066
26574
/\ ! WARNING
REMOVING COUNTERWEIGHTSCAN
CAUSE LIFT TRUCK TO BE IMPORTANT
UNSTABLE. Use lifting hooks with safety latches to
Do not operate a lift truck or prevent hook from slipping from the lifting
handle loads with any eye
counterweights removed. Failure
to follow this warning can result In
severe injury or death. MAIN COUNTERWEIGHT
REMOVAL
/\ ! CAUTION
To perform this service procedure, it is
recommended that you first:
SM556 38 - 01 - 1
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
COUNTERWEIGHT
SM556 38 - 01 - 2
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
AUXILIARY COUNTERWEIGHT 5. Attach hook of chain hoist to the eye of the
REMOVAL bolt.
Note: Main counterweight and steer axle housing 6. Raise the hoist to take all slack out of the chain.
must be removed before auxiliary counterweight
can be removed. Refer to steering axle group to 7. Remove counterweight fasteners (items
remove steer axle housing. 38.875 & 91.202).
1. install lifting straps through core holes of 8. Use an overhead chain hoist of correct capacity
auxiliary counterweight. to lift the counterweight out of the truck.
2. Attach hook of chain hoist to tiiing straps. 9. Lower the counterweight to floor level. Move
counterweight carefully and store in a safe
3. Raise the hoist to take all slack out of the chain. location.
SM556 38 - 01 - 3
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
3. Use an overhead chain hoist of correct capacity
to lift the counterweight and lower into the truck.
Do not remove chain hoist hook yet.
AUXILIARY COUNTERWEIGHT
INSTALLATION 4. Install counterweight fasteners (items 38.875 &
91.202). Torque nuts to [19 - 21,5 N*m] 170 - 191
1. Install lifting straps through core holes of Ibf*in.
auxiliary counterweight.
51 Remove chain hoist hook.
2. Attach hook of chain hoist to lifting straps.
6. Remove eyebolt.
3. Use an overhead chain hoist of correct capacity
to lift the countennreight and lower into the truck.
Do not remove chain hoist hook yet. FRONT OPERATOR COMPARTMENT
COUNTERWEIGHT INSTALLATION
4. Install auxiliary countenveight fasteners and
retainer (items 95.901, 38.905, 95.900, &
38.882). Torque bolts to [70 - 80 Nom] 52 - 59 1. 1. Install eyebott in cored hole in top surface of
Ibf+t. Torque nut to [40 - 45 Nom} 30 - 33 Ibfeft. countenveight (item 38.886).
7. Remove chain hoist hook from lifting straps. 2. Attach hook of chain hoist to the eye of the
“j ,., .,.
bolt.
8. Remove lifting straps.
3. Use an overhead chain hoist of correct capacity
all steer axle housing. Refer to steer axle group for to lift the counterweight and lower into the truck.
Do not remove chain hoist hook yet.
Note: Auxiliary countemeight (item 38.881) and 5. Remove chain hoist hook.
steer fork must be installed first in truck.
6. Remove eyebolt.
1. Install eyebolt in cored hole in top surface of
main counterweight (item 38.869). 7. Install overhead guard assembly. Refer to
overhead guard group for details.
2. Attach hook of chain hoist to the eye of the
bolt. 8. Remove drive wheel chocks.
3. Use an overhead chain hoist of correct capacity 9. Install and connect battery.
to lift the counterweight and lower into the truck.
5. Remove eyebolt.
SM556 38 - 01 - 4
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 38 SECTION 02
MACHINE JACKING AND
BLOCKING
CONTENTS NO.
SM556 38-02-l
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
38-02-02 BLOCKING THE 38-02-03 RAISING REAR OF
UPRIGHT IN RAISED POSITION TRUCK WITH A JACK
This procedure is used to safely provide clearance Refer to Specifications Group for truck weights.
for access from the front of truck to components
on or near the drive axle. The truck may be raised by jacking at the rear and
blocking under the sides near the rear section of
WARNING the frame.
DO NOT STAND UNDER THE FORKS
WHEN BLOCKS ARE PUT UNDER THE 1. Park the truck safely. Put chocks at front and
CARRIAGE AND RAILS. THE FORKS rear of drive wheels.
CAN FALL AND CAUSE INJURY OR
DEATH TO PERSONNEL. NOTE - When convenient, it is
recommended to remove the battery from
truck, to reduce weight for both safer and
1. Park the truck safely. easier jacking.
::
2 . Put chocks in front of and behind drive wheels.
SM556 38 - 02 - 2
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
5. Lower the truck onto the blocks and remove the
jack. Check truck stability before performing any
. maintenance work.
Remove jack
1. Remove battery.
SM556 36-02-3
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 39 SECTION 01 Park truck on a solid, level surface in
correct position to use an overhead hoist.
OVERHEAD GUARD
Lower forks to floor.
n ! CAUTION
To perform this service procedure, it is
recommended that you first:
SM556 39 - 01 - 1
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
95.899
OVERHEAD GUARD
39.933 FASTEN’& 0VEREiEA.D GUARD @Mxn L&IX)
39.934 FASPENER, OveruIuD GUti (REAR LEGS)
39.936 FAS’PENER, OVERHEAD GUARD REAR
SUPPORT
39.948 LRG.OYERHEADGUUZDFRONT
39.953 Fh=EN=.owcBEM GUARD TOP SECTION
39.956 LRG;OVRRUWGUllRDREARRII
39.957 LEG,OW%lluDGUARDREARLR
39.962 TOP SRGTION,OVERBEADGUARD
90.129 NvT,-GUARDRRARLEG FASTENER
90.963 NVT. OVRRElW CllARD TOP SEcnON FASTENRR
SM556 39 - 01 - 2
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 39 SECTION 02
SHEET METAL AND TRIM
/- 39.532
-39.501 -93.671
SM556 39 - 02 - 1
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 40 SECTION 01
TRUCK DATA PLATE AND DECALS
R
r 4o.m
1- 40.001
r
40.089
40.121
r!5
40.108
7
. 40.162 t
81
0
i
L 93.575
DATA PLATES AND DECALS
37.205 TRAY, LITERATURE 40.054 DECAL. CONTROLS INSTRUCTION
40.000 PLATE, CAPACITY 6 SERIAL NUMBER 40.089 DECAL, WARNING
40.001 FASTENER, CAPACITY h SER. NUMBER PLATE 40.108 DECAL, ELEC. CLEAN INSTR.
40.006 DECAL, UNIVERSAL PATENTS 40.121 DECAL, BATTERY SPEC d RESTRAINT
40.010 DECAL, CLARK LOGO - 1.5" WHITE 40.130 DECAL, FORK SAFEn
SM556 40 - Ol- 1
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 40 SECTION 02
TRUCK DATA AND SPECIFICATIONS
Group
ESM12f15S 36V, 18 cell, 11 plate, 27.0 kWh, 775 amp-hr @ 6 Hour rating
ESM 15 36V, 18 ceil, 13 plate, 32.2 kWh, 930 amp-hr @ 6 Hour rating
ESM 17 36V, 18 cell, 15 plate, 37.6 kWh, 1085 amp-hr @ 6 Hour rating
ESM 20,22,25 36V, 18 cell, 17 plate, 43.0 kWh, 1240 amp-hr @ 6 Hour rating
16 MOTORS
SM556 40-02-l
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
19 ELECTRICAL COMPONENT/ TEST SPECIFICATIONS
Resistance values may range from 20,000 to 30,000 ohms, without problems.
When below 20,000 ohms, further testing must be conducted to repair problem.
FUSES:
CONTACTORS:
SM556 40-02-2
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
23 WHEELS AND TIRES
23 BRAKES
26 STEERING SYSTEM:
Power Steering System Relief Pressure Setting: 1000 psi (6894.8 kPa)
Recommended Power Steering Fluid: Uses main hydraulic sump oil supply
SM556 40-02-3
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
32 TILT CYLINDERS
Tilt Speed, Nominal: Thru 151 in MFH - 3.2 to 3.9 degrees / second
Above 151 in MFH - 2.4 to 2.8 degrees / second
34 UPRIGHTS
ESM 17 Loaded: 59 95 56 65
Empty: 101 80 93 85
ESM 20 Loaded: 55 95 52 65
Empty: 101 80 93 85
NOTE: Rated capacity applies when using uprights with maximum MFH up to
and including: HV STD 151 in (3835 mm) / HV TSU 152 in (3875 mm).
SM556 40-02-4
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
40 TRUCK WEIGHTS - Approximate, with typical upright:
ESM 12 15s 15 17 20 22 25
Service Weight
w/o load. Ibs 8425 8735 9055 9417 9752 10071 10686
Axle Loading:
w/o load, front, Ibs 4266 4404 4527 4659 4779 4814 5106
w/load, front, Ibs 4159 4331 4528 4758 4973 5257 5580
w/o bad, rear, Ibs 8911 9975 9987 10878 11731 12507 13673
w/ toad, rear, Ibs 2014 1757 2068 2040 2021 2064 2013
40 WIRE COpES
Color Code
Black 0 Example:
Brown 1 wire no. 13 is a brown
Red 2 stripe on an orange wire.
Orange 3
Yellow 4 Wire no. 33 is a solid
Green 5 orange wire.
Blue
Violet ;
White
Gray :
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
40 TORQUE CHART
W-inI lbf-ft
29 Main Hydraulic Valve Mounting Bolts 177 - 221 Ibf*in. (20 - 25)
32 Tilt Cylinder Yoke Clamp Bolts 125 - 140 Ibfaft. (170 - 190)
Tilt Cylinder Pin Retainer Bolts 177 - 221 Ibfmin. (20 - 25)
34 Upright Mounting Pivot Pin Bolts 177 - 221 Ibf=in. (20 - 25)
Upright Cylinder Retaining Bolts 50 - 55 Ibf*ft (68 - 75)
Load Backrest Extension Mounting Bolts 177 - 199 Ibfaft (240 - 270)
NOTE: When checking tightness of major fasteners on new trucks, the values may be less
than the recommended specification due to metal deformation and fastener stretch.
This is a normal occurrence and does not indicate that the fasteners were not correctly
tightened during assembly. Tighten to recommended specifications.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
40 LUBRICATION SPECIFICATIONS
Transmission Fluid
Drive Axle DEXTRON II ATF
Automatic Transmission Fluid
Hydraulic Fluid
Hydraulic Sump -
Normal Temp. Application Clark Specification
MS-68 Hydraulic Oil
Multi-purpose Grease
Wheel Bearings NLGI Grade No. 1
Steer Axle Fork Bearing Lithium soap base grease,
Clark Spec MS-9B and
_ .. .
MS-1 078, or equivalent
Chain Lube
Upright Lift Chains Clark #886399 Chain and
Cable Lube or equivalent
Dry-film Lubricant
Side Shifter, Attachments, Dow Coming Molykote 321 Bonded
Clamp Slides Lubricant, Graph-0-Kote ##220,
Molub-Alloy ##369Dry Lube,
or equivalent
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 40 SECTION 03
HYDRAULIC AND
ELECTRICAL DIAGRAMS
CONTENTS
HYDRAULIC DIAGRAM
ELECTRICAL SCHEMATIC
ELECTRICAL DIAGRAM
SM556 40 - 03 - 1
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SEE NOTE I g
EE/ES--ESM 12/158/15
TRUCKS ONLY.
A
8FZAKE
Sk(ITCH
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PD IN-22170.02
OP IN-22170.02A
I. WIRE X54A IS PLUGGED TO WIRE IIdA FOR
STANDARD TRUCK WITH NO AUX2 FUNCTION.
PL-4
SOLENOID BLOCKS
13E
HS IA
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L________
1. DISCONNECT EXISTING HIRE #I3
SHOWN IN OOYYEO LINES At PUMP
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AUXILIflRY FUNCTION ii/ RUXILIARY FUNCTION
HIvIS STF~N~~IR~ TILT CYLINDERS
LIFT CYLINDERS L-.8 ,477
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LOAD LOWERING II
FOR 4 HOSE FIDFiP-
VALVE II
II TFITION
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PO IN-22268.02
OP IN-22248.02A