CLARK FORKLIFT OSQ 126 162 192 SM 1201 SERVICE MANUAL

OSQ 126/162/192

Service Manual SM-1201 FEB 2020

REV 1.0

All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of the publisher, except in the case of brief quotations embodied in critical reviews and certain other noncommercial uses permitted by copyright law.

CLARK Material Handling Co. 700 Enterprise Drive Lexington, KY 40510 www.clarkmhc.com

© CLARK Material Handling Company 2020

Table of Contents Contents Foreword Introduction..................................................................................................................................................FW-2 About the Manual........................................................................................................................................FW-3

Group SA Safe Maintenance Section 1 Safety........................................................................................................................................ SA-1-1 Section 2 Lifting, Jacking, and Blocking ����������������������������������������������������������������������������������������������� SA-2-1 Section 3 Towing...................................................................................................................................... SA-3-1

Group PM Planned Maintenance Section 1 Planned Maintenance Overview ��������������������������������������������������������������������������������������������PM-1-1 Section 2 Service and Lubrication Schedule ����������������������������������������������������������������������������������������PM-2-1 Section 3 Planned Maintenance Form ���������������������������������������������������������������������������������������������������PM-3-1

Group 12 Battery Section 1 Absorbed Glass Mat (AGM) Battery ��������������������������������������������������������������������������������������� 12-1-1 Section 2 Industrial Lead-Acid Battery ��������������������������������������������������������������������������������������������������� 12-2-1

Group 13 Electrical Section 1 Controls..................................................................................................................................... 13-1-1 Section 2 Switches.................................................................................................................................... 13-2-1 Section 3 Horns and Lights ��������������������������������������������������������������������������������������������������������������������� 13-3-1

Group 15 Wiring Section 1 Wiring Diagrams ���������������������������������������������������������������������������������������������������������������������� 15-1-1 Section 2 Wiring Schematic �������������������������������������������������������������������������������������������������������������������� 15-2-1 Section 3 Fuses......................................................................................................................................... 15-3-1

Group 16 Motors Section 1 Drive Motor................................................................................................................................ 16-1-1 Section 2 Steer Motor................................................................................................................................ 16-2-1

Table of Contents

Group 17 Contactors Section 1 Main Contactor ������������������������������������������������������������������������������������������������������������������������ 17-1-1 Section 2 Pump Contactor ����������������������������������������������������������������������������������������������������������������������� 17-2-1

Group 19 Controllers Section 1 Controllers................................................................................................................................ 19-1-1 Section 2 Controller Settings ������������������������������������������������������������������������������������������������������������������ 19-2-1 Section 3 Controller Alarms �������������������������������������������������������������������������������������������������������������������� 19-3-1 Section 4 Basic Controller Programming ���������������������������������������������������������������������������������������������� 19-4-1

Group 20 Drive Axle Section 1 Drive Unit................................................................................................................................... 20-1-1

Group 22 Wheels Section 1 Drive Wheel............................................................................................................................... 22-1-1 Section 2 Load Wheels............................................................................................................................. 22-2-1 Section 3 Caster Wheels........................................................................................................................... 22-3-1

Group 23 Brake System Section 1 Electromagnetic Brake ������������������������������������������������������������������������������������������������������������ 23-1-1

Group 29 Hydraulics Section 1 Hydraulic Pump and Motor Assembly ����������������������������������������������������������������������������������� 29-1-1 Section 2 Solenoid Valve.......................................................................................................................... 29-2-1 Section 3 Accumulator.............................................................................................................................. 29-3-1 Section 4 Hydraulic Schematic ��������������������������������������������������������������������������������������������������������������� 29-4-1

Group 34 Upright Section 1 Platform & Frame ��������������������������������������������������������������������������������������������������������������������� 34-1-1 Section 2 Lift Chains................................................................................................................................. 34-2-1 Section 3 Cylinders................................................................................................................................... 34-3-1

Group 40 Specifications Section 1 Height, Weight, and Speed Specifications ���������������������������������������������������������������������������� 40-1-1 Section 2 Decal Locations ����������������������������������������������������������������������������������������������������������������������� 40-2-1

Foreword The CLARK OSQ is a mobile multipurpose elevated platform vehicle that is designed to efficiently pick and transport goods in the warehouse or storeroom, assist in overhead maintenance, and other related tasks. It is to be used indoors on clean, level surfaces only. Do not use on mezzanines or balcony areas.

Its function and operation is not like a car or ordinary vehicle. It requires specific instructions and rules for safe operation and maintenance.

The safe operation and service of this vehicle is of primary importance to CLARK. Our experience with vehicle accidents has shown that when accidents occur and people are injured or killed, the most common causes are: • An improperly trained operator or technician • An inexperienced operator or technician, unfamiliar with vehicle operation • Basic vehicle safety rules NOT being followed • The vehicle NOT maintained to a safe operating condition For these reasons, CLARK wants you to know how to safely operate and properly maintain your OSQ. This service manual is designed to assist you in operating your vehicle safely. This manual shows and describes correct safety inspections and important general safety rules and hazards of vehicle operation. It shows and explains the special components and features of your specific vehicle and their functions. The correct repair and maintenance procedures are shown and explained. Illustrations and important safety messages are included to provide a clear understanding.

Specific sections detailing proper maintenance, repair and troubleshooting are included for the vehicle service technician.

This service manual is not a training manual. It is a guide to help trained and authorized technicians safely and correctly service the vehicle by emphasizing and illustrating the correct procedures. This service manual cannot cover every possible situation that could result in an accident. You must be aware of possible hazards in your specific work area and make sure to correct or avoid them.

It is important that you know and understand the information in this manual and that you understand and follow your company's safety rules. Make sure that the vehicle is maintained to a safe, working condition. Do not return a damaged or malfunctioning vehicle back into service. Practice safe operation every time you service or operate the vehicle.

Let's join together to set high standards in safety!

FW-1

Foreword Introduction CLARK welcomes you to the growing group of professionals who own and/or maintain CLARK vehicles. We take pride in the long tradition of quality products and superior value the CLARK name represents. This manual will familiarize you with the maintenance and service information concerning the CLARK OSQ. It has been specially prepared to help you use and maintain your CLARK vehicle in a safe and correct manner.

Your CLARK OSQ has been designed and built to be as safe and efficient as today’s technology can make it. As manufactured, it meets all the applicable mandatory design and construction requirements of the ANSI / SAIA A92.6 - 2006 (R2014) American National Standard for Self-Propelled Elevating Work Platforms.

Safe service and operation of your vehicle requires both skill and knowledge on the part of the technician. The technician must know, understand, and practice the safe driving and load handling. The technician must be familiar with the construction and features of the vehicle and how they function. The technician must understand its capabilities and limitations, and ensure that it is maintained to a safe working condition.

Routine Servicing and Maintenance Regular maintenance and care of the vehicle is not only important for economy and utilization reasons; it is essential for operator safety. A faulty vehicle is a potential source of danger to the operator, and other personnel working near it.

As with all quality equipment, keep the vehicle in optimal operating condition by following the recommended schedule of Planned Maintenance.

Planned Maintenance CLARK recommends that a Planned Maintenance (PM) and safety inspection program be performed by a trained and authorized technician on a regular basis. This PM will provide an opportunity to make a thorough inspection of the safety and operating condition of the vehicle. Necessary adjustments and repairs should be completed during the PM, which will increase the life of components and reduce unscheduled downtime and increase safety. The PM can be scheduled through the CLARK dealer to meet the particular application and vehicle usage.

The procedure for a periodic Planned Maintenance program covers inspections, operational checks, cleaning, lubrication, and minor adjustments. These are described in this service manual. The CLARK dealer should be prepared to help with a Planned Maintenance program by offering trained service technicians who know the vehicle and can keep it operating efficiently and safely.

FW-2

Foreword About the Manual The examples, illustrations, and explanations in this manual should help you improve your skill and knowledge as a service technician.

Please check with your authorized CLARK dealer for information on possible updates or revisions.

Take time to carefully read the Know Your Vehicle section. By acquiring a good basic understanding of your vehicle's features, and how they function, you are better prepared to operate it both safely and efficiently.

In Planned Maintenance (PM), you will find essential information about the correct servicing procedures and periodic maintenance of the vehicle, including recommended maintenance intervals and component capacities. Always follow these instructions and procedures.

We recommend to carefully read the Operator's Manual before operating the vehicle. Be sure to read and understand the information on the General Safety Rules and Operating Hazards in the Operator's Manual. Familiarize yourself with the various procedures in the operator's manual. Understand how all the gauges, indicator lights, and controls function.

Please contact your authorized CLARK dealer about any questions you may have about your vehicle’s features, operation, or manuals.

Operate the vehicle safely; careful driving is your responsibility. Drive defensively and think about the safety of other personnel who are working nearby. Know your vehicle’s capabilities and limitations. Follow all instructions in this manual, including all IMPORTANT, CAUTION, WARNING, and DANGER messages to avoid damage to your vehicle and to avoid any harm to yourself or others.

It is an OHSA requirement that the Operator's Manual and the Manual of Responsibilities be permanently attached to the vehicle. Keep these on the vehicle as a reference for anyone who may operate or service it. If the vehicle is not equipped with either of these manuals, obtain a replacement to be reinstalled to the vehicle.

Remember, your CLARK dealer is happy to answer any questions about the operation and maintenance of the CLARK OSQ and to provide you with any additional information should you request it.

IMPORTANT! The descriptions and specifications included in this manual were current at the time of printing. CLARK Material Handling Company reserves the right to make improvements and changes in specifications and/or design, without notice and without incurring obligation.

FW-3

Group SA

Group SA Safe Maintenance

Safety............................................................................Section 1 Lifting, Jacking, and Blocking.................................... Section 2 Towing..........................................................................Section 3

Group SA Section 1 Safety Safety Symbols and Messages Improper operation can cause accidents. Do not operate improperly setup or damaged equipment. Read and understand all the procedures for safe driving and maintenance described in this manual. Do not hesitate to ask for assistance. Stay alert and follow all safety rules, regulations, and procedures. Avoid accidents by recognizing and avoiding dangerous procedures or situations before they occur. Drive and work safely and follow the safety symbols and their messages on the vehicle and in this manual.

Safety symbols and messages are described in this manual and located on the vehicle to identify specific areas where potential hazards exist and provide instructions or special precautions that should be taken. Know and understand the meaning of these instructions, symbols, and messages. Damage to the vehicle, serious injury, or death to you or other persons may result if these messages are not followed.

NOTE This message is used when special information or instruction is needed relating to procedures, equipment, tools, specifications or other special data.

IMPORTANT! This message is used when special precautions or action should be taken to avoid damage to the vehicle or one of it's components.

CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in injury. It may also be used to alert against unsafe practices.

WARNING Indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death.

DANGER Indicates an imminently hazardous situation which, if not avoided, will result in serious injury or death.

SA-1-1

Group SA Safety Standards IMPORTANT! Your CLARK vehicle has been built to meet all applicable mandatory design and construction requirements of ANSI / SAIA A92.6 - 2006 (R2014) American National Standard for Self-Propelled Elevating Work Platforms. No additions, omissions, or modifications should be made to the vehicle that affect compliance to the above requirements or in any way minimize the effectiveness of the safety devices.

IMPORTANT! You should be familiar with the additional operating and maintenance safety instructions contained in the following publications: ANSI / SAIA A92.6: American National Standard for Self-Propelled Elevating Work Platforms (MEWPs). Available from: ANSI Headquarters, 1899 L Street NW 11th Floor, Washington, DC 20036.

NFPA 505: Fire Safety Standard for Powered Industrial Vehicles: Type Designations, Areas of Use, Maintenance and Operation. Available from: National Fire Protection Association, Inc., 1 Batterymarch Park, Quincy, MA 02169.

SA-1-2

Group SA Safe Maintenance Practices The following instructions have been prepared from current industry and government safety standards applicable to self-propelled elevating work platform vehicle operation and maintenance. These recommended procedures specify conditions, methods, and accepted practices that aid in the safe maintenance of industrial vehicles. They are listed here for the reference and safety of all personnel during maintenance operations. Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work.

When in doubt of any maintenance procedure, always contact your local CLARK dealer.

Never operate or park the CLARK OSQ on an incline or sloped surface.

Only operate the CLARK OSQ indoors on a smooth, flat surface.

1.

2.

Powered industrial vehicles can become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities, trained personnel, and procedures must be provided.

Maintenance and inspection of all powered industrial vehicles shall be done in conformance with the manufacturer’s recommendations.

3.

A scheduled planned maintenance, lubrication, and inspection program shall be followed.

4.

Only trained and authorized technicians shall be permitted to maintain, repair, adjust, and inspect industrial vehicles. Work should be performed in accordance with the manufacturer’s specifications.

5.

Properly ventilate the work area and keep shop clean and floor dry.

6.

Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check for level or leakage of electrolyte, hydraulic fluid, or gear oil. Do not use flammable cleaning fluids for cleaning parts.

7.

Before starting work on the vehicle: a.

Raise wheels off of floor and use blocks or other positive vehicle positioning devices.

b.

Disconnect battery before working on the electrical system.

SA-1-3

8.

Operation of the vehicle to check performance must be conducted in an authorized, safe, clear area.

9.

Before starting to drive vehicle: a.

Be in operating position with harness and tether connected.

b.

Make sure the parking brake is engaged.

c.

Turn the key switch to the ON position.

d.

Check the function of the speed control, steering, braking, and all warning devices.

10. Before leaving the vehicle: a.

Stop the vehicle.

b.

Fully lower the operator's platform.

c.

Press the emergency stop switch.

d.

Turn the key switch to OFF position.

11. Brakes, steering, controls, warning devices, lights, governors, guards, safety devices, and frame components must be thoroughly and regularly inspected and maintained in a safe operating condition.

12. Special vehicles or devices designed and approved for hazardous area operation must receive special attention to ensure that maintenance preserves the original, approved, safe-operating features.

13. The vehicle manufacturer’s capacity, operation, and maintenance instruction plates, tags, or decals must be maintained in legible condition.

14. Batteries, motors, controllers, limit switches, protective devices, electrical conductors, and connections must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of electrical insulation.

15. To avoid injury to personnel or damage to the equipment, consult the manufacturer’s procedures in replacing contacts on any battery connection.

16. Industrial vehicles must be kept in a clean condition to minimize fire hazards and help in the detection of loose or defective parts.

17. Always park or store the vehicle in a clean area to minimize risk of fire.

18. Modifications and additions that affect capacity and safe vehicle operation must not be done without CLARK's prior written approval. Capacity, operation and maintenance instruction plates, tags, or decals must be changed accordingly. This is an OSHA requirement.

Group SA 19. Care must be taken to assure that all replacement parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment. Parts, including tires, are to be installed per the manufacturer’s procedures. Always use genuine CLARK or CLARK-approved parts.

20. Use special care when removing heavy components from the vehicle, such as the counterweight, operator platform, upright, etc. Make sure that all lifting and supporting equipment is of the correct capacity and in good, working condition. Removal of heavy vehicle components may affect the stability of the vehicle.

Always safely block or support the frame during major or heavy component removal.

21. Batteries, motors, controllers, limit switches, protective devices, electrical conductors, and connections must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of electrical insulation.

22. To avoid injury to personnel or damage to the equipment, consult the manufacturer’s procedures in replacing contacts on any battery connection.

23. Industrial vehicles must be kept in a clean condition to minimize fire hazards and help in the detection of loose or defective parts.

24. Always park or store the vehicle in a clean area to minimize risk of fire.

25. Modifications and additions that affect capacity and safe vehicle operation must not be done without CLARK's prior written approval. Capacity, operation and maintenance instruction plates, tags, or decals must be changed accordingly. This is an OSHA requirement.

26. Care must be taken to assure that all replacement parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment. Parts, including tires, are to be installed per the manufacturer’s procedures. Always use genuine CLARK or CLARK-approved parts.

27. Use special care when removing heavy components from the vehicle, such as the counterweight, operator platform, upright, etc. Make sure that all lifting and supporting equipment is of the correct capacity and in good, working condition. Removal of heavy vehicle components may affect the stability of the vehicle.

Always block or support the frame during major or heavy component removal.

SA-1-4

Group SA Section 2 Lifting, Jacking, and Blocking Lifting Points (using crane or hoist) WARNING Avoid possible injury or death when lifting heavy components. Using defective or undersized lifting equipment could result in damage to equipment or serious injury and/or death. Make sure all lifting equipment is: free of defects, meets the load capacity requirements and is OSHA certified (if applicable).

D

C CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

A

B

CAUTION Never perform maintenance or service work on a vehicle that seems unstable or has been improperly raised and supported.

• Use lifting points A and B to lift or raise the entire vehicle.

• Use lifting points C and D to lift and/or secure the operator's platform while performing maintenance.

CAUTION Prior to performing any maintenance, check the vehicle for a stable condition on the blocks or jack stands.

SA-2-1

• Use tie down points A, B, C, and D to secure the vehicle during shipping or transport.

Group SA Raising Front of Vehicle

1.

Park the vehicle safely.

2.

Install an appropriate hoist or lifting device to the front lifting points (A) on the vehicle as shown.

3.

Install hardwood blocking under the frame as shown.

4.

Slowly lower the vehicle onto the blocking.

Raising Rear of Vehicle

Raising Entire Vehicle

1.

Park the vehicle safely.

2.

Install an appropriate hoist or lifting device to the front and rear lifting points (A and B) on the vehicle (as shown).

3.

Install hardwood blocking under the frame as shown.

4.

Slowly lower the vehicle onto the blocking.

Raising the Vehicle Using a Floor Jack CAUTION When jacking the vehicle, use appropriate tools such as wedge blocks, hardwood blocking, or wheel chocks to secure the vehicle and prevent tipping or rollover.

1.

Park the vehicle safely.

2.

Install an appropriate hoist or lifting device to the rear lifting points (B) on the vehicle (as shown).

3.

Install hardwood blocking under the frame as shown.

4.

Slowly lower the vehicle onto the blocking.

1.

Position a jack under the vehicle frame on one side.

2.

Carefully raise the vehicle approximately 1" (25 mm) and install hardwood blocking under the frame.

Position the blocks for maximum stability.

3.

Repeat this procedure for the other side.

SA-2-2

Group SA

WARNING Side-to-Side Tipping. When jacking the vehicle up, be sure the upright is fully lowered. Do not raise one side of the vehicle more than 2" (52 mm) at a time to avoid tipping the vehicle over laterally.

4.

Continue raising the vehicle not more than 1" (25 mm) at a time, and only as high as needed to complete the maintenance work.

5.

Position blocks of the same size under each side of the vehicle to ensure it will be level when raised.

6.

When work is complete, lowering is the reverse procedure of raising the vehicle. Make sure all tools and spare parts have been removed from under the vehicle.

Blocking the Upright 1.

2.

Park the vehicle safely.

Install an appropriate hoist or lifting device to the front and rear lifting points (C and D) on the operator's platform as shown.

SA-2-3

3.

Install hardwood blocking to support the upright.

4.

Slowly lower the operator's platform onto the blocking.

Group SA Section 3 Towing Towing the OSQ

Towing with the OSQ

IMPORTANT!

Fastener

Attempting to move the vehicle with the EM-brake engaged will cause damage to the vehicle.

If the vehicle becomes disabled and needs to be manually moved or towed, the electromagnetic (EM) brake MUST be disabled before attempting to move vehicle.

Lock Plate

Attempting to move the vehicle will cause damage to the vehicle's brake system.

1.

Remove the fastener and plate from the tow hitch.

2.

Install the cart or trailer to the tow hitch.

IMPORTANT!

The maximum towing capacity for all OSQ models is 2500 lbs (1133 kg). Do not exceed this weight to prevent damage to the vehicle.

3.

Reinstall the fastener and lock plate to secure the item being towed.

To release the EM brake: • Lift up on the lever located on top of the drive motor.

SA-3-1

Group PM

Group PM Planned Maintenance

Planned Maintenance Overview................................. Section 1 Service and Lubrication Schedule............................. Section 2 Planned Maintenance Form........................................Section 3

Group PM Section 1 Planned Maintenance Overview Planned Maintenance

Required Inspections

The Planned Maintenance (PM) consists of periodic visual and operational checks, vehicle inspection, lubrication, and scheduled maintenance intended to find issues early, discover malfunctioning components, and allow for optimal operational performance of the vehicle. Performing routine PM can save overall time and money for the customer and help prevent major repairs, reduce downtime, and drastically increase the vehicle's life and reliability.

Frequent Inspections

IMPORTANT! All PM inspections, service, and maintenance work must be performed by a qualified and authorized technician.

The operator should perform the Daily Inspection (DI) procedure described in the Operator’s Manual and refer any required service to a qualified CLARK service technician to perform the Planned Maintenance and any additional needed maintenance.

IMPORTANT! All vehicle service records, including the Frequent and Annual Inspections, must be maintained for a minimum of four (4) years.

All service and service intervals in this manual are based on normal vehicle usage of eight (8) hours per day, five (5) days per week. If the vehicle is used in excess of this, then the frequency of inspection and maintenance should be adjusted accordingly. If you have questions or concerns about determining your vehicle's PM plan, please contact your nearest CLARK dealer for any assistance.

Always use genuine CLARK replacement parts when servicing or maintaining your OSQ support vehicle.

IMPORTANT! All replacement parts must be identical or equivalent to the original component being replaced.

PM-1-1

The owner and user are required by ANSI A92.6 to ensure Frequent Inspections of the CLARK OSQ vehicle are performed whenever one of the following occurs: • The vehicle was purchased used, unless it's determined that the frequent and annual inspections are current.

• The vehicle has been in service for three (3) months or 150 hours, whichever comes first.

• The vehicle has been out of service for a period longer than three (3) months.

Annual Inspections The owner and user are required by ANSI A92.6 to ensure Annual Inspections of the CLARK OSQ vehicle are performed every 13 months or 700 hours from the date of the previous annual inspection, whichever occurs first.

NOTE Refer to Group PM, Section 3 of this manual for an example of the CLARK OSQ Frequent / Annual Inspection form.

Copies of this form are available from your local CLARK dealer.

Group PM OSQ Component Location

Drive Motor Electric Steer Motor

Hydraulic Unit

Controllers

Control Arms Upright Drive Unit

Load Wheels

Caster Wheels Operator's Platform Battery

Warning Lamp

Drive Wheel

PM-1-2

Group PM Section 2 Service and Lubrication Schedule Interval

Daily

Monthly

Operating Hours

8-10

50-250

Every 3 Months

Every 6 Months

450-500 900-1000

Yearly 2000

Controls and Switches Check control arm switch and button function

■

Check alarm function

■

Check emergency stop switch function

■

Check limit switch function

■

Check cables and terminals for damage

■

Check controller and contactor mounting Check fault information and operating hours

■ ■

Battery and Drive System Check battery cables for damage or corrosion

■

Check the battery charger and its connector

■

Check motor mounting bolts, tighten as needed

■

Check motor cable connections

■

Check steering for bearing noise

■

Check drive unit fluid level

■

Check drive unit for leaks

■

Check the wheels for damage and wear

■

Check the load wheel bearings and mounting

■

Check travel speed

■

Lubricate the steering bearing

■

Lubricate the large ring gear

■

Lubricate the drive motor bearings

■

Replace drive unit fluid

PM-2-1

■

Group PM

Interval

Daily

Monthly

Operating Hours

8-10

50-250

Every 3 Months

Every 6 Months

450-500 900-1000

Yearly 2000

Hydraulic System Check for proper hydraulic system function

■

Check hoses, pipes, and fittings for leaks and damage

■

Check cylinders for leaks

■

Check for cylinder damage

■

Check the reservoir tank for leaks

■

Check the hydraulic fluid level Check the emergency lowering valve

■ ■

Check the relief pressure

■

Replace the hydraulic fluid and filter

■

Braking System Check for proper brake function

■

Check EM-brake air gap (0.2 mm to 0.4 mm)

■

Check EM-brake fasteners

■

Check braking distance (36" or 92 cm)

■

Lift System Check upright for damage

■

Check lifting chains for stretch and wear

■

Check safety guard and cover

■

Check rollers for correct adjustment

■

Check lifting and lowering speed

■

Lubricate the lifting chains

■

▲

Lubricate the rollers

■

▲

Lubricate the upright rails

■

Miscellaneous Check decals, manuals, and data plate are correct and installed with the vehicle

■

Check casters for wear

■

Check front stabilizer gap ( <1/2" or 13 mm)

■

PM-2-2

Group PM Lubrication Points (1/2)

5

1

3

4

2

Item

Component

Service Interval

1 2

Steering Motor Gear Drive Unit Steering Bearing

150 hours or monthly 150 hours or monthly

3 4 5

Stabilizer Caster Wheels Load Wheels Rear Pick Tray

150 hours or monthly 150 hours or monthly 250 hours or monthly

PM-2-3

Group PM Lubrication Points (2/2)

10

6, 7 ,8

9

Item

Component

Service Interval

6 7

Upright Rails Upright Rollers

150 hours or monthly 250 hours or monthly

8 9 10

Lifting Chain Drive Unit Hydraulic Unit

250 hours or monthly 2000 hours or yearly 2000 hours or yearly PM-2-4

Group PM Recommended Lubricants Component

Type

CLARK TOTALIFT Part Number

Capacity

Interval

Hydraulic Unit

ISO AW 32 Hydraulic Fluid (MS-68)

1800236 (qt) 1802155 (gal)

126" = 6.87 qt (6.5 L)* 162" = 8.99 qt (8.5 L)* 192" = 9.94 qt (9.4 L)*

Every 2000 hrs or yearly

Drive Unit

SAE 80W-90 GL-5 Gear Oil

1808014 (qt) 1808015 (gal)

1.46 qt (1.38 L)

Every 2000 hrs or yearly

Chassis

NLGI #2 Grease (MS-107C)

VV70133

N/A

Every 150 hours or monthly

Upright Rails

CLARK Innerslide Lube

886396

N/A

Every 250 hours or monthly

Lift Chains

CLARK Chain Lube

886399

N/A

Every 250 hours or monthly

* Dependent Upon Model / Maximum Lift Height

PM-2-5

Group PM

Group PM Section 3 Planned Maintenance Form

PM-3-1

Group PM

OSQ Annual / Frequent Inspection Report DEALER INFORMATION COMPANY: ADDRESS: CITY/STATE/ZIP: MODEL: BATTERY SPEC.:

SERIAL:

OWNER / END USER INFORMATION COMPANY: ADDRESS: CITY/STATE/ZIP: VEHICLE INFORMATION: HOUR METER: UPRIGHT SIZE: OPTIONS: PREVIOUS INSPECTION:

INSPECTION REQUIREMENTS per ANSI A92.6 (ANNUAL AND FREQUENT) ANNUAL INSPECTION: The owner and user are required by ANSI A92.6 to ensure annual inspections of the CLARK OSQ vehicle occur and are performed no later than 13 months from the date of prior annual inspection or every 700 hundred hours of use, whichever occurs first. This annual inspection is to be performed by a mechanic that is qualified and authorized to perform service on CLARK OSQ vehicles. All service records must be maintained.

FREQUENT INSPECTIONS: The owner and user are required by ANSI A92.6 to ensure frequent inspections of the CLARK OSQ vehicle occur and are performed in accordance with the following points: 1. If purchased used unless it's determined that the frequent and annual inspections are current. 2. The CLARK OSQ vehicle has been in service for three (3) months or 150 hours, whichever comes first. 3. The CLARK OSQ vehicle has been out of service for a period longer than three (3) months. inspection is to be performed by a mechanic that is qualified and authorized to perform service on the CLARK OSQ vehicles. All service records must be maintained.

INSTRUCTIONS: Refer to service/maintenance manuals for specific information regarding inspection procedures and criteria.

Indicate in the appropriate space as each item has been performed. If the item is found to be not acceptable, describe each discrepancy on an additional page and attach to the form. Immediate action must be taken to correct all discrepancies. The truck shall not be placed in service until all discrepancies have been corrected.

Put a 9 in the column that applies: P = Passed Inspection , F = Failed Inspection, C = Corrected FUNCTIONS and CONTROLS P Drive and operate the vehicle to test all functions. Ensure controls operate properly and return to OFF or NEUTRAL when released.

Ensure emergency power disconnect switch deactivates all movement and power and that the dead man's foot switch operate properly.

Instrument panel is clean and free of debris and dash display is functional.

Operator right side control arm functions properly. Horn / travel / lift / lower / travel switches are functional.

Operator left side control arm steering wheel functions properly.

Emergency lower button operates properly.

Ensure gate switches disable travel/lift and lower functions and flashing lights on the front and rear of the vehicle.

The drive wheel returns to NEUTRAL (straight forward) when powering up the vehicle and is accurately depicted on the display.

OPERATOR PLATFORM ASSEMBLIES P Upright sections are free of visual evidence of damage. Upright lift chains and hoses are inspected per the Service Manual.

Mast wiring harnesses are properly installed, seated in their pulleys and that there are no frayed or broken strands.

Chains are adequately lubricated and are not dry or rusty.

Upright cover plates are in place and securely attached for each section.

Upright operates smoothly to full height and descends smoothly. Ensure speed cutbacks occur at appropriate heights per the maintenance manual.

Platform guard rails are undamaged and gates open / close freely.

All nuts, bolts, pins, shafts, covers, bearings and wear pads are checked for proper installation, and do not have excessive wear, cracks or distortion.

F

C

F

C

PM-3-2

Group PM MODEL: DEALER:

SERIAL:

VEHICLE INFORMATION: UPRIGHT SIZE: OWNER / END USER:

HOUR METER:

HYDRAULIC SYSTEM Lift cylinder is free of damage, no evidence of leaks and that all hardware is secure and undamaged.

All hydraulic hoses, fittings and components are properly secured and that there is no evidence of leaks.

Ensure fluid level is correct in hydraulic tank.

Ensure hydraulic pump is secure and undamaged, operates properly and is free of leaks.

Ensure hydraulic control valve is secure and undamaged, operates properly and is free of leaks.

Ensure hydraulic oil breather/vented cap is clean, hydraulic tank cap is tight and vent is open.

POWER and DRIVE SYSTEM Ensure battery fluid level is correct (if applicable).

Visually inspect motors to ensure there is no damage.

Ensure battery charger scrolls through diagnostics when plugged in.

Ensure all electrical connections are tight, free of frays and corrosion.

Ensure battery meets weight and voltage requirements.

Ensure drive, load and caster wheels are properly installed, secure and do not have excessive wear.

Ensure all five wheels have contact with the floor.

Ensure the electronic brake operates properly.

GENERAL Ensure paint is in good condition and that there are not any issues with the overall appearance of the vehicle.

Inspect overall structural condition including welds.

Verify that no unauthorized modifications or additions have been made.

Grease and lubricate the upright channels per the service manual.

Ensure stability pads at base of unit (adjacent to caster wheels) are intact, properly secured and have not sustained any damage Ensure optional equipment such as anchor point, tether, full body harness and tow hitch are in good condition and fully functional (if applicable).

Inspect front and rear load trays for functionality and damage.

MANUALS - DECALS - DATA PLATE Ensure ANSI / SIA A92.6 Manual of Responsibilities and operator's manual are on the vehicle.

P

F

C

P

F

C

P

F

C

P

F

C

Ensure data plate is in place, secured and legible Ensure all instruction and safety decals are installed, secure and legible.

ADDITIONAL COMMENTS

The undersigned certifies that this machine has been inspected, per each area of inspection, and any and all discrepancies have been brought to the attention of the Owner / User, and that all discrepancies have been corrected prior to any further use of this machine.

OWNER / USER SIGNATURE: DEALER SIGNATURE:

PM-3-3

OWNER / USER PRINTED NAME: DEALER PRINTED NAME:

DATE: DATE:

Group PM

Group 12

Group 12 Battery

Absorbed Glass Mat (AGM) Battery........................... Section 1 Industrial Lead-Acid Battery...................................... Section 2

Group 12 Section 1 Absorbed Glass Mat (AGM) Battery Function and Description CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

The CLARK OSQ 126 and OSQ 162 both use a maintenance-free absorbed glass mat (AGM) battery to power the vehicle. The battery uses an on-board 120V charger to charge the battery. An industrial lead-acid battery is an option.

Battery Dimensions: 29.1" x 7.8" x 26.3" Battery Weight: 360 lb (163 kg)

WARNING Battery service must be done by trained personnel.

Battery acid can cause severe burns and injury. Do not smoke or have open flames around batteries.

Type: AC 24V, 224 Ah

Battery Safety and Handling • The battery should be away from any heat source or location that is nearby sparks or open flame.

• The battery should avoid direct sunlight.

CAUTION Electric truck batteries are heavy and awkward to handle. They are filled with a very hazardous chemical solution. On charge, they give off hydrogen and oxygen which, in certain concentrations, are explosive. Electric truck batteries are also costly. Before you remove, service, or install a truck battery, carefully read the following recommendations and instructions.

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

WARNING Remove all jewelry before working on electrical systems. Severe burns can result from contact with electrical circuits.

12-1-1

• When installing, removing, or servicing the battery wear insulated gloves, aprons, and protective goggles.

• Dirty, corroded, or loose connection(s) may cause battery ignition or damage the battery.

• DO NOT clean the battery case with organic solvent.

• DO NOT use carbon dioxide fire extinguisher to extinguish electrical fires, use only carbon tetrachloride fire extinguisher if available.

• During the use of battery, make sure to tighten the nuts of the terminals to avoid arcing and poor contact.

• Only remove or service storage batteries in an area designated for this purpose.

• Make sure the battery service area has provisions to flush and neutralize spills, ventilate fumes from gassing batteries, and for fire protection.

• This area should be equipped with material handling tools designed for removing and replacing batteries, including a conveyor or overhead hoist. Use lift hooks that have safety latches.

Group 12 • Always use a special lifting device, such as an insulted spreader bar, to attach the hoist to the battery. The width of the spreader bar must be the same as the lifting eyes of the battery, to prevent damage to the battery. Make sure the lift hooks are the correct size to fit the lifting eyes of the battery.

Battery Removal and Installation

• If the battery does not have a cover of its own or has exposed terminals and connectors, cover the top with an insulating (non-conductive) material, such as a sheet of plywood or heavy cardboard, prior to attaching the lifting device.

• Chain hoists or power battery hoists must be equipped with load chain containers to accumulate the excess lifting chain.

• Keep all tools and other metal objects away from terminals.

1

1.

Disconnect the battery connector.

2.

Secure the battery connector out of the way to prevent it from being caught on the vehicle when the battery is removed.

3.

Remove the battery baffle (1) and roll the battery out from the side.

4.

Use an approved lifting device to remove and transport the vehicle battery. Remove the battery and move it to a safe, secure storage location on an approved battery rack or wooden pallet.

5.

Installation is the reverse of removal.

Battery Charging

3

1

AGM Battery Maintenance The CLARK OSQ AGM battery is maintenance-free.

2

AGM Battery Load Test Procedure 1.

Connect voltmeter leads to corresponding positive and negative terminals on the battery.

2.

Record the system battery voltage (V1).

1.

Check all cables and connections for signs of damage.

2.

Make sure the vehicle is powered OFF.

3.

Operate the vehicle by lifting a load or driving the unit.

3.

Follow the safety procedure and regulations as required by the battery and charging station manufacturer(s).

4.

Record the lowest load voltage (V2) when operating the vehicle.

5.

Calculate the voltage drop: VD = ( V1 – V2 ).

4.

Remove the cover plate on the top of the battery.

5.

Remove the plug (1) and connect to the charger plug (2).

6.

Connect the battery plug (3) to the charger and turn the charger ON.

• The maximum allowable voltage drop (VD) under load is 10% of the system battery voltage (V1).

NOTE The condition of a battery can be determined by fully charging the battery, and measuring the load voltage.

12-1-2

Group 12 Section 2 Industrial Lead-Acid Battery Function and Description CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

The CLARK OSQ 192 uses a standard industrial lead-acid battery to power the vehicle. This is an optional battery for the OSQ 126 and 162 models.

Battery Dimensions: 31.4" x 11.0" x 26.3" Battery Weight: 552 lb (250 kg) Type: AC 24V, 280 Ah

WARNING Battery service must be done by trained personnel.

Battery acid can cause severe burns and injury. Do not smoke or have open flames around batteries.

CAUTION Electric truck batteries are heavy and awkward to handle. They are filled with a very hazardous chemical solution. On charge, they give off hydrogen and oxygen which, in certain concentrations, are explosive. Electric truck batteries are also costly. Before you remove, service, or install a truck battery, carefully read the following recommendations and instructions.

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

WARNING Remove all jewelry (watch, rings, bracelets, etc.) before working on electrical systems. Severe burns can result from contact with electrical circuits.

Battery Safety and Handling • The battery should be away from any heat source or location that is nearby sparks or open flame.

• The battery should avoid direct sunlight.

• When installing, removing, or servicing the battery wear insulated gloves, aprons, and protective goggles. .

• Dirty, corroded, or loose connection(s) may cause battery ignition or damage the battery.

• DO NOT clean the battery case with organic solvent.

• DO NOT use carbon dioxide fire extinguisher to extinguish electrical fires, use only carbon tetrachloride fire extinguisher if available.

• During the use of battery, make sure to tighten the nuts of the terminals to avoid arcing and poor contact.

• Only remove or service storage batteries in an area designated for this purpose.

• Make sure the battery service area has provisions to flush and neutralize spills, ventilate fumes from gassing batteries, and for fire protection.

• It is necessary to add water regularly, otherwise damage to the battery may occur.

• Water must be added after the battery is fully charged, adding water before charging is complete can cause electrolyte overflow.

• Only distilled water should be used, do not use tap or mineral water.

• The work area should be equipped with material handling tools designed for removing and replacing batteries, including a conveyor or overhead hoist.

12-2-1

Group 12 • Always use a special lifting device, such as an insulted spreader bar, to attach the hoist to the battery. The width of the spreader bar must be the same as the lifting eyes of the battery, to prevent damage to the battery. Make sure the lift hooks are the correct size to fit the lifting eyes of the battery.

• If the battery does not have a cover of its own or has exposed terminals and connectors, cover the top with an insulating (non-conductive) material, such as a sheet of plywood or heavy cardboard, prior to attaching the lifting device.

• Keep all tools and other metal objects away from terminals.

Battery Charging 1.

Check all cables and connections for signs of damage.

2.

Make sure the vehicle is powered OFF.

3.

Follow the safety procedure and regulations as required by the battery and charger manufacturer(s).

4.

Remove the cover plate on the top of the battery.

5.

Connect the battery plug to the charger and turn the charger ON.

Battery Removal and Installation

Industrial Lead-Acid Battery Maintenance Daily Maintenance: • Charge the discharged battery • Visually inspect for excessive dirtiness and mechanical damage after charging.

Weekly Maintenance: • Check the electrolyte fluid level. If necessary, add distilled water into the electrolyte when fully charged.

Monthly Maintenance: • Before charging is completed, measure and record the voltage of each battery cell.

• After charging is complete, measure and record the electrolyte concentration and temperature of each battery cell.

Normal Battery Condition Normal voltage for a fully charged battery cell is approximately 2.08V. If the voltage of the battery cell is 1.85V or lower then the battery needs replacing.

Normal specific gravity of the electrolyte solution is approximately 1.28. If the specific gravity of the electrolyte solution is 1.05 or lower then the battery cell needs replacing.

Battery Cleaning There are two methods of cleaning a lead-acid battery. One way is to wash it with a low-pressure, cold water spray.

Another is with a solution of 60 ml (1/4 cup) of sodium bicarbonate (baking soda) to 6 L (1.5 gal) of water and then rinsed with clear water.

1

Battery Load Test Procedure 1.

Connect voltmeter leads to corresponding positive and negative terminals on the battery.

Secure the battery connector out of the way to prevent it from being damaged when the battery is removed.

2.

Record the system battery voltage (V1).

3.

Remove the battery baffle (1) and roll the battery out from the side.

3.

Operate the vehicle by lifting a load or driving the unit.

4.

4.

Use an approved lifting device to remove and transport the vehicle battery. Remove the battery and move it to a safe, secure storage location on an approved battery rack or wooden pallet.

Record the lowest load voltage (V2) when operating the vehicle.

5.

Calculate the voltage drop: VD = ( V1 – V2 ).

1.

Disconnect the battery connector.

2.

5.

Installation is the opposite of removal.

• The maximum allowable voltage drop (VD) under load is 10% of the system battery voltage (V1).

12-2-2

Group 13

Group 13 Electrical

Controls........................................................................Section 1 Switches.......................................................................Section 2 Horns and Lights.........................................................Section 3

Group 13 Section 1 Controls CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

5.

Loosen the screw (10) and remove the bolts (11) and washers (12).

6.

Remove the stepper motor (13) from the shaft (14).

7.

Installation is the reverse order of removal.

Right Control Arm Disassembly

7

Left Control Arm Disassembly

9

5 3

1

2 2 10

5 9

6 14

7

4

8

13

10

12 6 4

8

1.

Remove the small cover (1) from the steering tiller (2) with a small, flat screwdriver.

2.

Remove the M10 nut (3) and the steering tiller (2) assembly.

3.

Remove the two screws (4) and separate the top and lower covers (5 and 6) from the left arm (7).

4.

Disconnect the stepper motor harness (8) from the left control arm harness (9).

13-1-1

3

11

1 1.

Remove the screws (1) and separate the upper and lower covers (2 and 3) from the right arm (4).

2.

Disconnect the button switches (5), travel switch harness (6), and key switch (7) connectors from the right control arm harness (8).

3.

Disconnect the spade connectors of the right control arm harness (8) from the emergency stop switch (9).

4.

Replace the button switches (5), travel switch (10), key switch (7), or emergency stop switch (9) as needed.

5.

Installation is the reverse order of removal.

Group 13 Stepper Motor Control Circuit

Stepper Motor Description The stepper motor provides the vehicle with steering input signals. It operates on 5V and is controlled by the steer (EPS-AC0) controller.

• Set the multimeter to ON/OFF. • Check the #27/#28/#29/#30 circuit for conductivity.

Stepper Motor Troubleshooting Problem

• Check for a broken stepper motor circuit using a multimeter:

Possible Cause

When operating the steering tiller, the vehicle does not turn. Alarm code 84 STEER SENSOR KO.

EPS-AC0

• Relearn steering.

• Stepper motor has failed.

28

• Stepper motor circuit is damaged.

30 29 28

27

29

30

27

Checking and Testing Stepper Motor

Emergency Stop Switch Description The emergency stop switch is used to immediately cutoff the power supply to all control circuits. This also the emergency brake feature. It is located on the right control arm. When this switch is in the extended (UP) position, the circuit is connected and normal. When the switch is in the lowered (DOWN) position, the circuit is disconnected.

30

29

28

27

Emergency Stop Switch Troubleshooting Problem

Checking Stepper Motor • Inspect the stepper motor and its harness for damage or shorting and if the connectors are connected securely.

• Check for looseness between steering tiller and stepper motor.

• Check for circuit conductivity.

Testing Stepper Motor

Possible Cause

Emergency stop switch engaged and vehicle continues to operate.

• Emergency stop switch has failed.

Emergency stop switch disengaged and vehicle does not operate.

• Emergency stop switch has failed.

• Emergency stop switch circuit is damaged.

• Emergency stop switch circuit is damaged.

• Enter the TESTER menu using the handset or the display and check stepper motor voltage.

13-1-2

Group 13 Checking and Testing Emergency Stop Switch Checking Emergency Stop Switch • Inspect the emergency stop switch and its harness for damage or shorting and if the connectors are connected securely.

Testing Emergency Stop Switch • Check if emergency stop switch circuit is conducted.

• Check emergency stop switch with a multimeter to check for conductivity.

Emergency Stop Switch Control Circuit • Check for a damaged emergency stop switch circuit using a multimeter: • Set the multimeter to ON/OFF. • Check the #0/F circuit for conductivity.

AC-0 1 0

Checking and Testing Travel Switch Checking Travel Switch • Inspect the travel switch and its harness for damage and if the connectors are connected securely.

Testing Travel Switch • Enter the TESTER menu using the handset or dash display. Go to the BACKWARD SWITCH and FORWARD SWITCH readings and toggle the switch to determine if the voltage changes or not and if the switch is faulty.

• Check travel switch with a multimeter to check for conductivity.

Travel Switch Control Circuit • Check for a damaged travel switch circuit using a multimeter: • Set the multimeter to ON/OFF. • Check the #1/#10/#11/#12/#18 circuit for conductivity.

11

1

12

1 AC-0

0

AF

F

+BATT

18 -BATT

10

1

1

+24V

11

12

10

Travel Switch Description The travel switch provides the forward and backward output signals that are sent to the vehicle's traction (AC-0) controller. It is located on the right control arm of the vehicle.

Travel Switch Troubleshooting Problem

Possible Cause

When the travel switch is toggled, the vehicle does not operate.

• Travel switch has failed.

The vehicle moves forward or backward when the travel switch is not toggled.

• Relearn VACC.

13-1-3

• Travel switch circuit is damaged.

• Travel switch has failed.

Key Switch Description The key switch is used to turn the vehicle ON and OFF. It is located on the right control arm of the vehicle.

Key Switch Troubleshooting Problem

Possible Cause

Key switch turned to ON position and vehicle does not operate.

• Key switch has failed.

Key switch turned to OFF and vehicle continues to operate.

• Key switch has failed.

• Key switch circuit is damaged.

• Key switch is shorting.

Group 13 Checking and Testing Key Switch

Testing Horn Button

Checking Key Switch • Inspect the key switch and its harness for damage and if the connectors are connected securely.

Testing Key Switch

• Energize the horn with 24V, if the horn sounds then it is working correctly. If the horn does not sound, then a replacement is required.

Horn Button Control Circuit • Check for a damaged horn button circuit using a multimeter:

• Check if key switch circuit is conducted.

• Check key switch with a multimeter to check for conductivity.

Key Switch Control Circuit • Check for a damaged key switch circuit using a multimeter: • Set the multimeter to ON/OFF. • Check the #0/#1 circuit for conductivity.

• Set the multimeter to ON/OFF. • Check the #1 circuit, between the horn button and the positive power supply, for conductivity.

• Check the #18 circuit, between the horn button and the negative power supply, for conductivity.

• Check the #38 circuit, between the horn button and the horn, for conductivity

AC-0 1 0

1 38 0

AF

F

KEY SWITCH 1 0

1

Horn Button Description The horn button is used control the horn function. The horn button is a NO (normally open) switch. It is located on the right control arm of the vehicle.

Horn Button Troubleshooting Horn does not sound when button is pressed.

Possible Cause • Horn button has failed.

• Horn has failed.

• Inspect the horn button and its harness for damage and if the connectors are connected securely.

18

18

-BATT

Lower Button Description The lower button is used control the operator's platform lowering function. The lower button is a NO (normally open) switch. It is located on the right control arm of the vehicle.

Lower Button Troubleshooting Problem Platform does not lower when button is pressed.

Possible Cause • Lower button has failed.

• Lower button circuit is damaged.

Checking and Testing Horn Button Checking Horn Button

+BATT AF

+BATT

38

Problem

EMERGENCY STOP SWITCH 0 F

Platform lowers when button is not pressed.

• Lower button has failed.

• Inspect the horn and its harness for damage and if the connectors are connected securely.

13-1-4

Group 13 Checking and Testing Lower Button

Checking and Testing Lift Button

Checking Lower Button

Checking Lift Button

• Inspect the lower button and its harness for damage and if the connectors are connected securely.

Testing Lower Button

• Inspect the lift button and its harness for damage and if the connectors are connected securely.

Testing Lift Button

• Enter the TESTER menu using the handset or dash display. Go to the DESCENT SWITCH and toggle the button to determine if the voltage changes or not and if the switch is faulty.

• Enter the TESTER menu using the handset or dash display. Go to the LIFTING SWITCH and toggle the button to determine if the voltage changes or not and if the switch is faulty.

• Check lower button and its circuit with a multimeter to check for conductivity.

• Check lift button and its circuit with a multimeter to check for conductivity.

Lower Button Control Circuit

Lift Button Control Circuit

• Check for a damaged lower button circuit using a multimeter:

• Check for a damaged lift button circuit using a multimeter:

• Set the multimeter to ON/OFF.

• Set the multimeter to ON/OFF.

• Check the #4/#8 circuit, between the lower button and the traction controller, for conductivity.

• Check the #4 circuit, between the lift button and the traction controller, for conductivity.

AC-0 4 9

4

• Check the #8 circuit, between the lift button and the lifting limit switch, for conductivity.

• Check the #39 circuit, between the lift limit switch and the traction controller, for conductivity.

AC-0

9 4 9

39

Lift Button Description The lift button is used control the operator's platform lifting function. The lift button is a NO (normally open) switch. It is located on the right control arm of the vehicle.

Lift Button Troubleshooting Problem

Possible Cause

Platform does not lift when button is pressed.

• Lift button has failed.

Platform lifts when button is not pressed.

• Lift button has failed.

13-1-5

4

• Lift button circuit is damaged.

8

39

LIFT LIMIT SWITCH

Group 13 Foot Switch Function and Description

M4 Bolts (2x)

The foot switch (dead man's switch) functions as the vehicles operator presence system. The foot switch must be pressed to allow the vehicle to operate any functions.

When released, the foot switch also activates the emergency brake. The foot switch is located on the floor of the operator's platform.

Switch Cover

Screws (2x)

Foot Switch Replacement Washers (2x)

Lock Washers (2x) M6 Bolts (3x)

Foot Switch Assembly

Nuts (2x)

6.

Remove the two small screws and the foot switch cover.

7.

Remove the two M4 bolts securing the foot switch to the plate.

8.

Remove the foot switch.

9.

Installation is the reverse order of removal.

Foot Switch Troubleshooting Lock Washers (3x)

Washers (3x) Nuts (3x)

1.

Raise and support the operating platform. Refer to Group SA, Section 2 of this manual.

2.

Turn the key switch to OFF and disconnect the battery.

3.

Disconnect the foot switch connector.

4.

Remove the three M6 bolts, washers, and nuts securing the foot switch assembly to the bottom of the operator's platform.

5.

Remove the foot switch assembly.

Problem

Possible Cause

When the foot switch is not depressed, the vehicle can still travel and/or operate the hydraulics.

• Foot switch has failed.

When the foot switch is depressed, the vehicle does not have travel or hydraulic function.

• Foot switch has failed.

• Foot switch control circuit is damaged (shorted).

• Foot switch control circuit is damaged (shorted).

Checking and Testing Foot Switch Checking Foot Switch • Inspect the foot switch and its harness for damage or shorting and if the connectors are connected securely.

• Check that the foot switch resets correctly.

13-1-6

Group 13 Display

Testing Foot Switch • Enter the TESTER menu using the handset or dash display. Go to the HANDLE/SEAT SW and toggle the switch to determine if the voltage changes or not and if the switch is faulty.

• Check foot switch and its circuit with a multimeter to check for conductivity.

Foot Switch Control Circuit • Check for a damaged foot switch circuit using a multimeter: • Set the multimeter to ON/OFF. • Check the #4/#17circuit, between the foot switch and the traction controller, for conductivity.

4

17

4

1

3

4

5

6

7

2

AC-0

Item 1 2 3 4 5 6 7

Component Screen Keypad Low Battery Fault Alarm Temperature Alarm Operator Presence Emergency Brake

(2) Function Keypad: Use the LEFT button to change the Speed Mode. Use the DOWN button to select the Driving Mode.

(3) Low Battery Alarm: Activates when the nominal battery voltage is too low. Replace with a fully charged battery or charge the battery to prevent the battery from over-discharging.

(4) Fault Alarm: Activates when a fault condition occurs. The fault lamp will illuminate and the specific fault code will be displayed on the screen.

13-1-7

Group 13 (5) Temperature Alarm:

(1) Battery Discharge

Activates when the temperature of the drive or steering motor is too high. The lamp will illuminate and a fault code will be displayed. Stop operation of the vehicle to prevent damage to the motor(s).

Displays the level of charge remaining in the battery. Each bar represents 10% of total battery charge. Ex. The image shows an 80% charge level.

(6) Foot Switch Alarm:

(2) Steer Direction

Activates when the foot switch is NOT engaged. The foot pedal lamp will illuminate and the vehicle will not operate until the switch is activated.

Displays the current direction that the drive (steer) wheel is pointed. The drive wheel has a 180° travel radius.

(7) Parking Brake Alarm:

(3) and (4) Driving Modes

Activates when the emergency / park brake is engaged. The fault lamp will illuminate and the vehicle will immediately stop operation.

Displays either HIGH or LOW (turtle) speed mode. The vehicle remains in HIGH speed mode unless the operator platform is raised approximately 22 inches (56 cm) or higher.

Screen

(5) Speed Mode

6

7

5

Displays the four speed ranges that are available in both HIGH and LOW (turtle) Driving Modes. Mode 1 indicates the slowest speed and Mode 4 indicates the highest speed.

(6) Vehicle Information

4

1 Item 1 2 3 4 5 6 7

2

3 Component Battery Discharge Steer Direction Driving Mode (High Speed) Driving Mode (Low Speed) Speed Mode Vehicle Information Travel Speed

Displays vehicle warnings and faults. Report any warnings or faults immediately to your supervisor or a qualified service technician.

(7) Travel Speed Displays the actual vehicle speed in either miles per hour or kilometers per hour.

Group 13 Section 2 Switches Tilt Switch Calibration CAUTION

Cover

Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

Tilt Switch Function and Description The OSQ is equipped with a tilt switch that signals a buzzer if the vehicle is operated on a slope of 5.0° or greater when the operator's platform is raised at least 22" (56 cm). The switch will send an output signal to the traction controller and the traction controller will control the buzzer to make an alarm. The hydraulic operation of this vehicle is designed and intended for firm, level surfaces. The tilt switch is located on the lower chassis frame, underneath the operator's platform.

Tilt Switch Replacement

Screw (4X)

1.

Raise and support the operating platform. Refer to Group SA, Section 2 of this manual.

2.

Remove the four screws and the cover of the tilt switch.

IMPORTANT!

The vehicle must be parked on a firm, level surface to allow for correct calibration of the tilt switch.

Green LED

Tilt Sensor 1.

Raise and support the operating platform. See Group SA, Section 2.

2.

Turn the key switch to OFF and disconnect the battery.

3.

Disconnect the tilt switch connector.

4.

Remove the four bolts securing the tilt switch.

5.

Remove the tilt switch.

6.

Installation is the reverse order of removal.

7.

Calibrate the switch. Refer to Group SA, Section 2 of this manual.

13-2-1

Switch

3.

Press and hold the small switch until the green LED light blinks rapidly, then release the switch. This indicates that calibration is complete.

Group 13 Tilt Switch Troubleshooting Problem

Limit Switches - Function and Description

Possible Cause

When traveling with the operator's platform raised past the 1st stage speed limit switch and on a slope of 5.0°, the buzzer alarm does NOT sound.

• Tilt switch not calibrated.

• Tilt switch failed.

• Tilt buzzer failed.

• Control circuit damaged.

Checking and Testing Tilt Switch Checking Tilt Switch • Inspect the tilt buzzer, tilt switch and wiring harness for damage or shorting and if the connectors are connected securely.

Limit Switch

Testing Tilt Switch • Check the tilt switch and tilt buzzer circuit for conductivity.

• Test the buzzer by energizing the tilt buzzer with 24V. • If no sound is made, then replace the buzzer.

• If sounds is made, then replace the switch.

Determine if the motor windings are operating normally by measuring the resistance (Ω) between U, V, and W and the steer motor housing as described in the table below.

Tilt Switch Control Circuit • Check the tilt switch circuit using a multimeter: • Set the multimeter to ON/OFF. • Check for conductivity between the tilt switch and the controller (#1/#18/#43/#48 circuit).

The OSQ is equipped with six variable roller lever limit switches. There are two gate safety switches, three speed reduction switches (one for each section of the 3-stage upright), and a lift limit switch.

The limit switches have four terminals each, one pair is NO (normally opened) and the other pair is NC (normally closed). The switch is operated between open and closed by toggling the roller lever to control the connection of the switch terminals.

EPS-AC0 43 18 48 48 43 1 +BATT

-BATT 48

18

18

-BATT

13-2-2

Group 13 Safety Gate Switch Location

Limit Switch Location (2/2)

Safety Gate Switch

Speed Reduction Switch - 1st Stage

Limit Switch Locations (1/2)

Limit Switch Replacement 5

Lift Limit Switch

7 8 6

Speed Reduction Switch - 3rd Stage

1

3 Speed Reduction Switch - 2nd Stage

13-2-3

1

2 4

1.

Remove the three screws (1) and the cover (2) from the limit switch seat (3).

2.

Route the harness ring connectors through the protective ring (4) and install the terminals on the limit switch seat (3).

3.

Install the cover (2) to the limit switch seat (3) with the three screws (1).

Group 13 Limit Switch Adjustment

Lift Limit Switch

• To adjust the direction of the roller lever seat (5), use the adjustment screw (6).

• To adjust the distance of the roller lever (7), use the adjust screw (8).

Limit Switch Troubleshooting

The speed reduction switches are NO (normally open). Terminals 3 and 4 are used to connect to the vehicle harness.

Problem The lifting mechanism can not lift.

Possible Cause • Lift limit switch is disconnected.

• Lift limit switch circuit is damaged.

Lifting mechanism does not stop after being lifted to the top.

4

1

3

Speed Reduction Switches

4

3 (NO)

2 1

The speed reduction switches are NO (normally open).

Terminals 3 and 4 are used to connect to the vehicle wiring harness.

Problem

2 (NC)

Safety Gate Switches The gate safety switches are NC (normally closed). Terminals 1 and 2 are used to connect to the vehicle harness.

Problem

• Lifting limit switch has not reset and is in a continuously closed state.

Possible Cause

Vehicle travels or raises and lowers with safety gate(s) up.

• Safety gate switch is closed.

Vehicle does not travel or raise and lower when the safety gate(s) are down.

• Safety gate switch has not reset and is in a continuously OFF state.

• Safety gate switch circuit is damaged.

When speed reduction switch is activated, the speed is not reduced.

Possible Cause • The speed reduction switch has not reset and is in continuous closed state.

Checking and Testing Limit Switch Checking Limit Switch • Inspect the limit switch and its wiring harness for damage or shorting and if the connectors are connected securely.

• Check for debris blocking the roller wheel.

Testing Limit Switch • Check the limit switch using the TESTER menu in the display or by using the Zapi® Smart Console.

• Test the limit switch using a multimeter to check for conductivity. Toggle the switch to check that the switch operates properly.

13-2-4

Group 13 Limit Switch Control Circuits

Speed Reduction Switch (Stage #1)

Safety Gate Switches • Check for a damaged safety gate switch circuit using a multimeter:

• Check for a damaged speed reduction switch circuit using a multimeter: • Set the multimeter to ON/OFF. • Check for conductivity between the speed reduction switch and the traction controller (#1/#43 circuit).

• Set the multimeter to ON/OFF. • Check for conductivity between the safety switches and the traction controller (#4/#21/#40 circuit).

(NC) 1

2

21

AC-0

(NC)

4

1

40

2 40

4

(NO)

AC-0

4

3

1

43

21

Speed Reduction Switch (Stage #2)

Lift Limit Switch • Check for a damaged lift limit switch circuit using a multimeter:

• Check for a damaged speed reduction switch circuit using a multimeter: • Set the multimeter to ON/OFF.

• Set the multimeter to ON/OFF.

• Check for conductivity between the speed reduction switch and the traction controller (#46/#47 circuit).

• Check for conductivity between the lift limit switch and the traction controller (#8/#39 circuit).

(NO)

(NO) AC-0

4 4

39

13-2-5

1

43

4

3

47

46

AC-0

46

3

8

8

4

39

47

Group 13 Speed Reduction Switch (Stage #3) • Check for a damaged speed reduction switch circuit using a multimeter: • Set the multimeter to ON/OFF. • Check for conductivity between the speed reduction switch and the traction controller (#44/#45 circuit).

(NO)

4

44

AC-0 45

3

45

44

13-2-6

Group 13 Section 3 Horns and Lights Tilt Buzzer CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

The tilt buzzer is used to produce an alarm sound when the vehicle is operated on a slope of greater than approximately 5.0°. It is actuated by the tilt switch. The switch will send voltage to the buzzer and an alarm is heard. The tilt buzzer is located on the front left side of the vehicle near the drive assembly and can be accessed by removing the front cover.

Lowering / Gate Buzzer

Horns and Buzzers Lowering / Gate Buzzer

Tilt Buzzer

The lowering and safety gate buzzer is used to produce an alarm when one or more of the safety gates is in the UP position and the vehicle's operator platform is raised above the approximately 22" (56 cm). It also produces an alarm whenever the operator's platform is lowered to alert any bystanders or pedestrians. It is actuated by either the gate safety limit switch or the speed reduction switches on the upright. A switch sends 24V voltage to the buzzer and an alarm sound is heard. This buzzer is located on the front left side of the vehicle near the drive assembly and can be accessed by removing the front cover.

Lights Front Warning Light

Horn Horn The horn is controlled by the operator and actuated by depressing the horn button located on the right control arm. When the button is pressed, voltage (24V) is applied to the horn and a sound is heard. The purpose of the horn is to alert nearby coworkers and/or pedestrians that the vehicle is being operated and to use care. It is located on the front left side of the vehicle near the drive assembly and can be accessed by removing the front cover. It is not controlled by either Zapi® controller.

13-3-1

Front Light

Group 13 Warning Light Control Circuit

Rear Warning Light

• Check for a broken warning light circuit using a multimeter: • Set the multimeter to ON/OFF. • Check the #1/#18 circuit for conductivity.

18

1

1

0

0

F

+BATT AF

18

-BATT

Rear Light

The OSQ has two warning lights mounted in the rear and front of the vehicle. They are activated when the vehicle is turned ON.

Warning Light Troubleshooting Problem When vehicle is turned ON, the warning lights do not light up.

Possible Cause • Warning light failure.

• Warning light circuit is damaged.

Checking and Testing Warning Lights Checking Warning Light • Inspect the warning light and it's harness for damage or shorting and if the connectors are connected securely.

Testing Warning Light • Check if the warning light circuit has conductivity.

• Test the light by energizing the warning light with 24V. • If the light does not turn ON, replace the light.

• If the light turns ON, then the light is OK.

13-3-2

Group 15

Group 15 Wiring

Wiring Diagrams..........................................................Section 1 Wiring Schematic........................................................Section 2 Fuses............................................................................Section 3

Group 15 Section 1 Wiring Diagrams Wiring Diagram 12

+

—

P+

1 FUSE 1

PUMP MOTOR

FUSE 2 P-

2

3 4

W

DRIVE MOTOR

U B+

V

V

AC-0 CONTROLLER

BU

5

W 9

6 7

EPS-AC0 CONTROLLER

W

STEER MOTOR

V

V 10 U

W

B-

8

11

U B+

Number

Description

Number

1

Pump Motor Cable (PA+)

7

Steer Motor Cable (V)

2

Pump Motor Cable (PA-)

8

Steer Motor Cable (U)

3

Drive Motor Cable (W)

9

D-AC0 Cable (Negative)

4

Drive Motor Cable (V)

10

D-EPS Cable (Negative)

5

Drive Motor Cable (U)

11

EPS-AC0 Cable (Positive)

6

Steer Motor Cable (W)

12

Battery Connector

15-1-1

Description

Group 15

Connector Diagram

MAIN WIRING HARNESS

+BATT PUMP CONTACTOR

-BATT

MC

WARNING LIGHT

PUMP BATTSOLENOID VALVE COIL

LIMIT SW.

EM

PROXIMITY SW. LOWERING BUZZER

TRACTION MOTOR

TILT BUZZER

TILT SW.

STEER MOTOR HORN

RIGHT ARM HARNESS MULTI-CORE CABLE HARNESS

E-STOP SW.

TRAVEL SW.

HORN SW.

DISPLAY

LOWERING SW.

LIFTING SW.

KEY SW.

DOOR SAFETY SW.

LEFT ARM HARNESS STEPPER MOTOR

15-1-2

Group 15 Section 2 Wiring Schematic Wiring Schematic (1/2)

15-2-1

Group 15

Wiring Schematic (2/2)

15-2-2

Group 15 Section 3 Fuses Fuse Locations CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

Power Fuses Fuse #1

CAUTION Always disconnect the battery before performing any service or maintenance on the vehicle's electrical system.

Fuse #2

Function and Description Fuse #1 (200A)

Main Contactor

Fuse #2 (200A)

The main power fuses are located on the controller mounting plate on the left side of the vehicle. The front cover must be removed to access the fuses.

Control Fuse

Traction Controller Fuse #3

Steer Controller

The OSQ has three (3) fuses, a low power and two main power fuses. The two main power fuses are rated to 200A each and the control fuse is rated to 10A. The purpose of the vehicle's fuses are to prevent damage to the motors, pumps, controllers, and other electrical components due to excessive current. When there is a fuse failure, the vehicle may not run properly or at all.

15-3-1

The control fuse is located in-line on the main harness near the controller mounting plate. The front cover must be removed to access the fuse.

Group 15 Checking and Testing Fuses Checking • Check the fuses for damage or failure.

• Check the connectors at the terminal lugs for looseness or poor lead connection.

Testing NOTE Check that the vehicle is OFF with key removed and the battery is disconnected before testing.

• Set the multimeter to measure resistance (Ω) and connect the black negative (–) probe to one end of the fuse and the red positive (+) probed to the opposite end of the fuse.

• Refer to the table below to determine if the fuse is functioning properly.

Measurement (Ω)

Description

0Ω

Normal

∞Ω

Fuse Failure (Replace the fuse)

Troubleshooting Function Fuse #1 Fuse #2 Fuse #3 Drive Lift / Lower Steering Controllers Display Horn Light Tilt Buzzer

Component Status Fuse #1

○ ♦ ♦ ○ ○ ○ ○ ♦ ♦ ♦ ○

Fuse #2

♦ ○ ♦ ○ ○ ○ ○ ○ ○ ○ ○

Fuse #3

♦ ○ ♦ ○ ○ ○ ○ ○ ○ ○ ○

♦ = Normal ○ = Failure

15-3-2

Group 16

Group 16 Motors

Drive Motor...................................................................Section 1 Steer Motor...................................................................Section 2

Group 16 Section 1 Drive Motor Drive Motor Assembly CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

EM-Brake M8 Bolt (6x) Lock Washer (6x)

Function and Description The drive motor is a three-phase AC motor with class F insulation. The electronic control uses variable frequency to control the speed of the motor. The external U, V, and W connections are easily accessible from the side of the motor.

The drive motor has a built-in thermistor which constantly monitors the motor temperature and sends this information to the main (traction) controller. This sensor is a non-serviceable part. Should it sense that the motor is approaching the temperature limit, the control will cutback motor current until the temperature decreases.

Locking Key

Proximity Sensor

Washer (6x) Drive Gear

M12 Nut

Planned Maintenance Apply grease to the steering ring gear every 150 hours or monthly. Refer to Planned Maintenance, Section 2 in this manual.

Steering Bearing

Steering Ring Gear

Drive Unit

16-1-1

Group 16 Drive Motor Removal 1.

Remove the front cover.

2.

Remove the steer motor. Refer to Group 16, Section 2 in this manual.

3.

Disconnect the following connectors:

Speed Encoder

• Electromagnetic brake 24

• Encoder sensor • Temperature sensor 4.

Remove the U, V, and W cables from the drive motor.

5.

Remove the six M8 bolts securing the drive motor to the drive mounting base.

6.

Remove the drive motor.

25 26

GND

23 +12V

Speed Encoder

Drive Motor Installation IMPORTANT! When installing the drive motor, be sure to: • Make sure the locking key is fully seated on the drive motor gear.

• Make sure the drive motor gear fully engages with the drive unit. Check for correct operation before securing drive motor in place.

Speed Encoder Description The speed encoder's purpose is to detect the speed of the drive motor and convert it into a signal to send to the controller.

Speed Encoder Replacement 1.

Remove the front cover.

1.

Install the drive motor.

2.

Disconnect the connector from the vehicle harness.

2.

Install the six M8 bolts to secure the drive motor to the mounting base.

3.

Remove the screw and the speed encoder.

4.

Installation is the reverse order of removal.

3.

Torque tighten the M8 bolts.

Checking the Speed Encoder

M8 Bolt Torque: 140 Nm (103 ft-lb) 4.

Install the U, V, and W cables to the drive motor.

5.

Connect the following connectors: • Electromagnetic brake • Encoder sensor • Temperature sensor

6.

Install the steer motor. Refer to Group 16, Section 2 in this manual.

7.

Calibrate the steering. Refer to Group 19, Section 4 in this manual.

8.

Install the front cover.

• Check that the cable and connections are in good condition and securely connected.

• Check the sensor surface for wear or damage.

Testing the Speed Encoder • Check for a broken speed encoder circuit: • Set the multimeter to ON/OFF. • Measure voltage between #23 and #24; this should be 12V. • Check if #25 and #26 are reversed.

• Check ENCODER reading on TESTER menu of service display or use handset.

16-1-2

Group 16 Temperature Sensor

Problem

Temperature Sensor

Possible Cause

Motor is rotating slowly or in reverse.

• U, V, or W cables installed incorrectly

Abnormal noise and/or vibration

• Uneven clearance between stator and rotor • Bearing failure • Loose fasteners

19

20

Smoke or burning smell.

• Stator short circuit or motor burnt

Excessive motor temperature.

• Stator short circuit • Bearing failure • Cooling blockage by foreign body • Overuse

Motor speed is slow.

Temperature Sensor Description

• U, V, or W cable damaged

The temperature sensor's purpose is to monitor the temperature of the drive motor. The temperature sensor is a non-serviceable component.

Checking the Temperature Sensor Using a multimeter, measure the resistance (Ω) between #19 and #20. Use the table below to determine if the sensor is operating properly.

Measurement (Ω)

Description

0Ω

Sensor short circuit (Replace the drive motor)

∞Ω

Sensor open circuit (Replace the motor)

Drive Motor Troubleshooting Problem Motor does not rotate.

Possible Cause • U, V, or W cable is broken or loose connection • Stator coil open circuit • Motor bearing damage • Speed encoder or its circuit has failed

16-1-3

• Low battery voltage

• Speed encoder failure

Checking and Testing Drive Motor Checking the U, V, and W Terminals (Resistance) Determine if the motor windings are operating normally by measuring the resistance (Ω) of the U-V, V-W, and U-W circuits as described in the table below.

NOTE Be sure to set the multimeter to a low range when measuring the resistance of the motor windings.

Measurement (Ω)

Description

Low Reading

Normal *

0Ω

Internal motor winding shorting (Replace the drive motor)

∞Ω

Coil breaking (Replace the drive motor)

* The difference between the measured resistance values at the U, V, and W terminals should not be greater than 2%.

Group 16 Checking the U, V, and W Terminals (Leakage Current) Determine if the motor windings are operating normally by measuring the resistance (Ω) between U, V, and W and the steer motor housing as described in the table below.

Measurement (Ω)

Description

0Ω

Leakage current occurring (Replace the drive motor)

∞Ω

Normal **

** For a normal operating drive motor, the U, V, and W terminals are insulated from the housing.

Drive Motor Control Circuit • Check for a broken drive motor circuit: • Set the multimeter to ON/OFF. • Check for conductivity between the motor encoder and the controller (#23/24/25/26 circuit).

• Check for conductivity between the temperature sensor and the controller (#19/#20 circuit).

U V

W

W U V AC-0

GND

24 25

GND

19

20

26

23 +12V

20

19

23

24

Group 16 Section 2 Steer Motor Planned Maintenance CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

Apply grease to the steer motor gear every 150 hours or monthly. See Planned Maintenance, Section 2 of this manual.

Function and Description The steer motor drives the large ring gear attached to the drive unit, enabling the vehicle to be steered. The drive unit can be rotated a full 180° (90° in either the left or right direction). The steer motor is controlled by the EPS-AC0 controller via the U,V, and W cables. It has two sensors: a temperature sensor and a speed encoder. The encoder is serviceable and the temperatures sensor is non-serviceable.

U

Speed Encoder

16-2-1

V W

Temperature Sensor

Steer Motor Removal 1.

Remove the front cover.

2.

Remove the M6 bolt, lock washer, and flat washer.

3.

Remove the steer motor gear.

4.

Disconnect the encoder and temperature sensor connectors from the harness.

5.

Remove the U,V, and W cables from the steer motor.

6.

Remove the four M8 bolts.

7.

Remove the steer motor.

Group 16 Speed Encoder

Steer Motor

Speed Encoder

30 GND

35

34

33 +5V

Speed Encoder Description

Gear

M8 Bolt (4x)

Washer Lock Washer M6 Bolt

Steer Motor Installation NOTE When installing the steer motor, be sure the motor is positioned correctly in the groove of the motor mounting base.

1.

Install the steer motor.

2.

Install the four M8 bolts.

3.

Install the U, V, and W cables to the steer motor.

4.

Connect the encoder and temperature sensor connectors.

5.

Install the steer motor gear and secure with the M6 bolt, lock washer, and flat washer. Tighten the bolt.

6.

Calibrate the steering. See Group 19, Section 4 of this manual.

7.

Install the front cover.

The speed encoder's purpose is to detect the speed of the steer motor and convert it into a signal to send to the controller.

Speed Encoder Replacement 1.

Remove the front cover.

2.

Disconnect the connector from the vehicle harness.

3.

Remove the screw and the speed encoder.

4.

Installation is the reverse order of removal.

Checking the Speed Encoder • Check that the cable and connections are in good condition and securely connected.

• Check the sensor surface for wear or damage.

Testing the Speed Encoder • Check for a broken speed encoder circuit: • Set the multimeter to ON/OFF. • Measure voltage between #30 and #33; this should be 5V. • Check if #34 and #35 are reversed. The alarm code 83 BAD ENCODER SIGN will be present.

• Check ENC SPEED reading on TESTER menu of service display or use handset.

16-2-2

Group 16 Temperature Sensor

Problem

Possible Cause

Motor is rotating slowly or in reverse.

• U, V, or W cables installed incorrectly

Abnormal noise and/or vibration

• Uneven clearance between stator and rotor • Bearing failure • Loose fasteners

32

31

Smoke or burning smell.

• Stator short circuit or motor burnt

Excessive motor temperature.

• Stator short circuit • Bearing failure • Cooling blockage by foreign body • Overuse

Motor speed is slow.

Temperature Sensor Description The temperature sensor's purpose is to monitor the temperature of the steer motor. The temperature sensor is a non-serviceable component.

Checking the Temperature Sensor Using a multimeter, measure the resistance (Ω) between #31 and #33. Use the table below to determine if the sensor is operating properly.

Measurement (Ω)

Description

With Readings

Normal

0Ω

Sensor short circuit (Replace the drive motor)

∞Ω

Sensor open circuit (Replace the motor)

Steer Motor Troubleshooting Problem Motor does not rotate.

Possible Cause • U, V, or W cable is broken or loose connection • Stator coil open circuit • Motor bearing damage • Speed encoder or its circuit has failed

16-2-3

• Low battery voltage • U, V, or W cable damaged • Speed encoder failure

Checking and Testing Steer Motor Checking the U, V, and W Terminals (Resistance) Determine if the motor windings are operating normally by measuring the resistance (Ω) of the U-V, V-W, and U-W circuits as described in the table below.

NOTE Be sure to set the multimeter to a low range when measuring the resistance of the motor windings.

Measurement (Ω)

Description

Low Reading

Normal *

0Ω

Internal motor winding shorting (Replace the steer motor)

∞Ω

Coil breaking (Replace the steer motor)

* The difference between the measured resistance values at the U, V, and W terminals should not be greater than 2%.

Group 16 Checking the U, V, and W Terminals (Leakage Current) Determine if the motor windings are operating normally by measuring the resistance (Ω) between U, V, and W and the steer motor housing as described in the table below.

Measurement (Ω)

Description

0Ω

Leakage current occurring (Replace the steer motor)

∞Ω

Normal **

** For a normal operating steer motor, the U, V, and W terminals are insulated from the housing.

Steer Motor Control Circuit • Check for a broken steer motor circuit: • Set the multimeter to ON/OFF. • Check for conductivity between the motor encoder and the controller (#30/33/34/35 circuit).

• Check for conductivity between the temperature sensor and the controller (#31/#32 circuit).

U V

W

U V W EPS-AC0

GND

30 35

34 33

GND

32

31

31 35

33

30 32

34

+5V

16-2-4

Group 17

Group 17 Contactors

Main Contactor............................................................Section 1 Pump Contactor...........................................................Section 2

Group 17 Section 1 Main Contactor with the contact connected, so the circuit is disconnected.

CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

CAUTION Always disconnect the battery before performing any service or maintenance on the vehicle's electrical system.

Function and Description

When the contactor coil is powered OFF, the magnetic force stops and the pressure plate is released along with the release of spring. The contact returns to normally opened, the circuit is now disconnected.

CLARK recommends replacing non-working contactors versus repairing. During excessive use the contactor can become hot and distort the cover enough to change the clearance between moving contact and stationary contact tips.

If repairing a contactor, always make sure you have the same clearance on each.

Before attempting to disassemble a contactor, to install a new contact set, be sure to note the location and orientation of each component.

Main Contactor Location

Main Contactor

Main Contactor

The OSQ main contactor is a dual contactor with normally opened (NO) contacts. The ON and OFF function of the main contactor is controlled through the main controller.

When the contactor coil is energized, the coil current will create a magnetic field, causing the static stator core to produce a steady magnetic force to absorb the core and drive the contactor actions. The contactor coil is normally opened

17-1-1

The main contactor is located on the controller mounting plate on the left side of the vehicle. The front cover must be removed to access the contactor.

Group 17 Main Contactor Removal and Disassembly 1.

Remove the front cover.

NOTE

NOTE

Always replace contact assemblies in pairs.

Record the layout and orientation of the cables and wiring harnesses attached to the contactor before disconnecting to aid in reassembly.

2.

Main Contactor Assembly and Installation

Remove the fasteners and disconnect the cables, buss bars, and wiring harness connectors from the posts of the contactor.

3.

Remove fasteners securing the contactor to the controller mounting plate and remove the contactor.

4.

Loosen the screws and remove the top cover of the contactor.

5.

Remove the contact assemblies and springs from the coil assembly.

1.

Replace any damaged or worn components.

2.

Installation is the reverse order of removal. Do not overtighten the screws or the fasteners used to secure the contactor to the mounting plate.

Checking and Testing Main Contactor Visual Inspection • Check the surface of the contactor for scratches, stains, or other damage.

• If damaged, replace the contactor.

Checking Contactor • Disconnect the connectors from the contactor.

Coil Assembly

• Measure the resistance (Ω) of the coil as shown below using a multimeter.

Positive (+) Red

Contacts

Fastener (4x) Spring (2x) Negative (–) Black

Cover

• Use the table below to diagnose the issue.

Screw (2x) Fastener (4x)

Measurement (Ω)

Description

≈ 52 Ω

Normal

0Ω

Coil shorting (Replace the contactor)

∞Ω

Coil breaking (Replace the contactor)

17-1-2

Group 17 Checking Contacts • Check the surface of the contacts, making sure they are smooth and symmetrical and not worn or eroded.

• Apply voltage (24V) from another source and check if the contact absorbs the stator core. Replace the contactor if it does not operate properly.

• Check that the contacts move freely.

• Check for rusted or corroding springs.

• Inspect for tip welding.

• Any damage to tips requires replacement. Do not sand or file tips.

Testing Main Contactor Circuit • Check for a broken circuit between the main (traction) controller and the main contactor using a multimeter: • Set the multimeter to ON/OFF. • Check for conductivity between the #2 and #3 circuit as shown. #2

17-1-3

AC-0 #3

Group 17

Group 17 Section 2 Pump Contactor CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

CAUTION Always disconnect the battery before performing any service or maintenance on the vehicle's electrical system.

to absorb the core and drive the contactor actions. The normally opened contactor coil C and D is connected, so the circuit is disconnected.

When the contactor coil is powered OFF, the magnetic force disappears and the pressure plate is released along with the spring. The contact returns to normally opened and contact C and D disconnect, so the circuit is now disconnected.

CLARK recommends replacing non-working contactors versus repairing. During excessive use the contactor can become hot and distort the cover enough to change the clearance between moving contact and stationary contact tips.

When repairing you should always make sure you have the same clearance on each.

Before attempting to disassemble a contactor to in-stall a new contact set, be sure to note the location and orientation of each component.

Function and Description

Pump Contactor Location

Pump Contactor

Pump Contactor The OSQ pump contactor is a DC contactor with normally opened (NO) contacts. The ON and OFF function of the pump contactor is controlled through the main controller.

When the contactor coil between A and B is energized, the coil current will create a magnetic field. This causes the static stator core to produce a steady magnetic force

17-2-1

The pump contactor is located on the pump motor on the right side of the vehicle. The front cover must be removed to access the contactor.

Group 17 Pump Contactor Removal 1.

Remove the front cover.

NOTE

Record the layout and orientation of the cables and wiring harnesses attached to the contactor before disconnecting to aid in reassembly.

2.

Disconnect the cables and wiring harness connectors from the posts of the contactor.

3.

Remove fasteners securing the contactor to the pump motor assembly.

4.

Checking the Contactor • Perform ON/OFF test to determine is contactor is functioning properly. If not, continue with testing.

• Disconnect the connectors from the contactor.

• Measure the resistance (Ω) of the coil at A and B as shown below using a multimeter.

C

B Positive (+) Red

A

D

Remove the contactor.

Negative (–)

Negative (–) Black

Positive (+)

• Use the table below to diagnose the issue. If reading is normal, continue with testing.

• Apply voltage (24V) to A and B (from another source) and check if the contact absorbs the stator core when energized. Replace the contactor if it does not operate properly.

Pump Contactor Installation 1.

Installation is the reverse order of removal.

2.

Do not overtighten the fasteners used to secure the contactor to the pump motor assembly.

• If the contact is absorbed and contact C and D are conducted, then the contactor is working properly.

Measurement (Ω)

Description

≈ 24 Ω

Normal

Checking and Testing Pump Contactor

0Ω

Coil shorting (Replace the contactor)

Visual Inspection

∞Ω

Coil breaking (Replace the contactor)

• Check the surface of the contactor for scratches, stains or other damage.

• Check the electrical connections for corrosion or damage. Repair as needed.

• If excessively damaged, replace the contactor.

17-2-2

Group 17 Checking the Contacts • Check the surface of the contacts, making sure they are smooth and symmetrical and not worn or eroded.

• Check that the contacts move freely.

• Check for rusted or corroding springs.

• Inspect for tip welding.

• Any damage to tips requires replacement. Do not sand or file tips.

Testing Pump Contactor Circuit • Check for a broken circuit between the main (traction) controller and the pump contactor using a multimeter: • Set the multimeter to ON/OFF. • Check for conductivity between the #13 and #14 circuit as shown.

AC-0 # 13

B A

17-2-3

# 14

Group 17

Group 19

Group 19 Controllers

Controllers...................................................................Section 1 Controller Settings......................................................Section 2 Controller Alarms........................................................Section 3 Basic Controller Programming.................................. Section 4

Group 19 Section 1 Controllers Controller Removal CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

1.

Remove the front cover.

2.

Remove the wiring harness, cables, and straps from the controller.

3.

Remove the four bolts securing the controller to the mounting plate.

4.

Remove the controller.

D

CAUTION Always disconnect the battery before performing any service or maintenance to the controllers.

E C

Function and Description

D

B

Main Contactor

B

C

Fuses

Traction Controller

E

A

Steer Controller

A

The CLARK OSQ uses a Zapi® AC-0 traction controller and a EPS-AC0 steering controller to operate the vehicle functions. Both controllers are AC current powered. The traction (main) controller controls the drive and hydraulic pump motor. The steer controller mainly controls the steer motor. Both controllers have built-in thermal protection that will reduce output current if temperature nears the thermal limit.

19-1-1

Controller Installation 1.

Apply thermal paste to the back of the controller.

2.

Install the controller and secure using the bolts.

3.

Install the wiring harness, cables, and straps to the controller.

4.

Install the front cover.

Group 19 Controller Function Diagram Emergency Stop Switch

Steering Tiller Stepper Motor

Foot Switch

Travel Switch

Buzzer Warning Light

Horn

Pump Motor

EMBrake

PM

U, V, W

Traction Controller (AC-0)

DM

Limit Switch

Display

Steer Controller (EPS-AC0)

U, V, W

SM

Proximity Switch

19-1-2

Group 19 Traction Controller Interface Function AC-0 Interface A : 20-Pin

AC-0 Interface B : 12-Pin

Interface A

19-1-3

Pin

Name

Description

A1

NMC

Negative of main contactor coil.

A2

PMC

Positive of main contactor coil.

A3

NEB

Output for EM-brake, drives load to -Batt. Maximum current is 3A.

A4

NPC

Negative of pump contactor.

A5

PPC / PEV

Positive of pump contactor and lowering valve coil.

A6

NEV

Negative of lowering valve coil.

A7

CAN LOW

Low level CANBUS voltage I/O.

A8

-BATT

Negative battery.

A9

ENC +

Encoder positive supply; +5V or +12V.

A10

ENC -

Encoder negative supply.

A11

HM (+B)

Output for hour meter.

A12

-BATT

Negative battery.

A13

MOT TH

Motor thermal sensor input.

A14

SR2

Speed reduction 2 input.

A15

SR1

Speed reduction 1 input.

A16

+12V

Output provides a +12V signal for MDI PRC.

Group 19 Interface A Pin

Name

Description

A17

CAN HIGH

High level CANBUS voltage I/O.

A18

CPOTB

Brake potentiometer wiper.

A19

ENC A

Encoder channel A.

A20

ENC B

Encoder channel B.

Interface B Pin

Name

Description

B1

KEY SW

Connected to key switch. 10A fuse.

B2

CM

Public ports, provides starting voltage.

B3

TILLER SW

Tiller request input. Must be connected to the tiller microswitch; active high.

B4

H&S SW

Hard and soft request input.

B5

BACKWARD SW

Backward direction request input; active high.

B6

FORWARD SW

Forward direction request input; active high.

B7

BELLY SW

Quick inversion function input; active high.

B8

LOWERING SW

Lowering request input, active high.

B9

LIFTING SW

Lifting request input, active high.

B10

CPOT

Accelerator potentiometer wiper.

B11

NPOT

Negative for accelerator unit.

B12

PPOT

Potentiometer positive.

Interface C (Zapi® Handset Communication Interface) Pin

Name

Description

C1

PCLRXD

Positive serial reception.

C2

NCLRXD

Negative serial reception.

C3

PCLTXD

Positive serial transmission.

C4

NCLTXD

Negative serial transmission.

C5

GND

Negative console power supply.

C6

+12V

Positive console power supply.

C7

FLASH

Must be connected to C8 for flash memory programming.

C8

FLASH

Must be connected to C7 for flash memory programming.

19-1-4

Group 19 Steer Controller Interface Function EPS-AC0 Interface A : 14-Pin

EPS-AC0 Interface B : 8-Pin

Interface A

19-1-5

Pin

Name

Description

A1

DRIVE SWITCH

Traction travel demand input.

A3

SW1

First toggle switch.

A4

NK1

Safety switch lower voltage point.

A5

K1

Safety switch higher voltage point.

A6

CANL

CANBUS low. Connected to traction controller.

A7

KEY

Key switch signal input port.

A8

CPOC2 / QL

Stepper motor Q line.

A9

CPOC1 / DL

Stepper motor D line.

A10

NPOC

Twin SP POT negative supply (GND).

A11

GND

Ground; encoder negative supply.

A12

GND

Ground; SW1 and SW2 negative.

A13

GND

Ground; motor thermal sensor negative.

A14

CANH

CANBUS high; connected to traction controller.

Group 19 Interface B Pin

Name

Description

B2

PPOT

FB POT positive supply.

B3

THMOT

Motor thermal sensor input.

B4

+5VDC

Encoder positive supply.

B6

CPOT

FB POT wiper.

B7

CHB

Phase B of encoder.

B8

CHA

Phase A of encoder.

Interface C (Zapi® Handset Communication Interface) Pin

Name

Description

C1

PCLRXD

Positive serial reception.

C2

NCLRXD

Negative serial reception.

C3

PCLTXD

Positive serial transmission.

C4

NCLTXD

Negative serial transmission.

C5

GND

Negative console power supply.

C6

+12V

Positive console power supply.

C7

FLASH

Must be connected to C8 for flash memory programming.

C8

FLASH

Must be connected to C7 for flash memory programming.

Terminal Studs Pin

Name

Description

-

-B

Negative of battery.

-

+B

Positive of battery.

-

FU, FV, FW

Connection bars of the three phase motor.

19-1-6

Group 19 Section 2 Controller Settings

19-2-1

Group 19 Main Menu IMPORTANT! The default password to access the controller through the dash display is: 55555.

Press 2X +4:+8 6'99=58* E E E E E

Press 5X 6'99=58*

6'99=58* 54 6'99=58* 5,,

@'6/ )54952+

)544+):+* :5 */96 +*@ +6

Display Settings A

)544+):+* :5 ') : (+91 +6

Traction Settings B

)544+):+* :5 +69') ' +6

Steer Settings C

19-2-2

Group 19 Display Settings Menu Display Settings A

*/96 +*@ +6 < '

3'/4 3+4; 6'8'3+:+8 ).'4-+

6

).+)1 ;6 :?6+ 2+<+2#

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6

).+)1 ;6 .5;89

45

3'/4 3+4; 6'8'3+:+8 ).'4-+

Previous Menu 3'/4 3+4; 685-8'3 <'))

Previous Menu **Displays Last 5 Alarms** 3'/4 3+4; '2'839

'

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Alarm Information

N ȭ

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'

Next Page

19-2-3

N ȭ

Time of Alarm Number of Occurances

N ȭ

Controller Temperature

Group 19 Previous Page Previous Menu

3'/4 3+4; :+9:+8

:

:

:

:

:

1+?

5,, -4*

1+?

5,, -4*

1+?

5,, -4*

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1+?

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19-2-4

Group 19 Traction Controller Settings Menu Traction Settings B

') : (+91 +6 < '

3'/4 3+4; 6'8'3+:+8 ).'4-+

6

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Next Page

19-2-5

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Group 19 Previous Page

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6

6

6

6

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6

6

6

Previous Menu

3'> 96++* (')1 .@

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3'> 96++* ,58= .@

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96++* 2/3/: (81 2+<+2#

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2+<+2#

)NGTMK

3'/4 3+4; 685-8'3 <'))

Next Page

19-2-6

Group 19 Previous Page Previous Menu **Displays Last 5 Alarms** '

3'/4 3+4; '2'839

N ȭ

)2+'8 25-(551% ?+9#+4:+8 45#5;: ?+9

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3'/4 3+4; '2'839

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Previous Menu :

3'/4 3+4; :+9:+8

:

:

('::+8? <52:'-+ <

Alarm Information

N ȭ

(;@@+8 5;:6;: 5,, -4*

9:++8 '4-2+ °

Time of Alarm Number of Occurances Controller Temperature

:

:

Next Page

19-2-7

9/*+-':+9 9=/:).

54 <(

);:(')1 9=/:).

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Group 19 Previous Page :

:

:

:

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:

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35:58 :+36+8': ȭ

Next Page

19-2-8

Group 19 Previous Page :

:

:

:

:

:

:

:

:

19-2-9

:+36+8':;8+ ȭ

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35:58 <52:'-+

Group 19 Traction Controller Tester Guide

Parameter

Description

Function

BATTERY VOLTAGE

Check voltage of battery.

Display current voltage (V).

BUZZER OUTPUT

Check status of safety buzzer.

If the function is triggered properly, the value will change.

STEER ANGLE

Check drive wheel angle.

Display current angle (°)

SIDEGATES SWITCH

Check status of door safety switch.

If the function is triggered properly, the value will change.

CUTBACK SWITCH 3

Check status of 3-stage speed reduction switch.

If the function is triggered properly, the value will change.

CUTBACK SWITCH 2

Check status of 2-stage speed reduction switch.

If the function is triggered properly, the value will change.

CUTBACK SWITCH

Check status of 1-stage speed reduction switch

If the function is triggered properly, the value will change.

INCHING BACKWARD

–

–

H·S CUTBACK

–

–

HANDLE/SEAT SW.

Check status of foot switch.

If the function is triggered properly, the value will change.

BACKWARD SWITCH

Check the backward status of travel switch.

If the function is triggered properly, the value will change.

FORWARD SWITCH

Check the forward status of travel switch.

If the function is triggered properly, the value will change.

DESCENT SWITCH

Check the status of lowering switch.

If the function is triggered properly, the value will change.

LIFTING SWITCH

Check the status of lifting switch.

If the function is triggered properly, the value will change.

ACCELERATOR

Check the output voltage of travel switch.

Display current voltage (V).

MOTOR TEMPERAT

Check drive motor temperature.

Display current temperature (°C).

TEMPERATURE

Check the temperature of controller.

Display current temperature (°C).

BATTERY CHARGE

Check the remaining capacity of battery.

Display current capacity (%).

BATTERY CURRENT

Check the current of battery.

Display current value (A).

CURRENT RMS

Check the drive motor current.

Display current value (A).

SLIP VALUE

Check difference between output frequency of controller and the measured frequency.

Display current difference (Hz).

ENCODER

Check the drive motor speed.

Display current speed (Hz).

FREQUENCY

Check the output frequency of traction controller.

Display current frequency (Hz).

VOLTAGE BOOSTER

–

–

MOTOR VOLTAGE

Check the drive motor voltage.

Display current voltage (V).

19-2-10

Group 19 Steer Controller Settings Menu Steer Settings C

+69') ' +6 < '

6

3'/4 3+4; 6'8'3+:+8 ).'4-+

96++* 2/3/: 2+<+2#

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6

6

6

6

6

6

Next Page

19-2-11

2'- ,+ 8+-;2': 2+<+2#

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Group 19 Previous Page

6

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9+49/:/</:?

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N ȭ

Time of Alarm

Previous Menu Number of Occurances 3'/4 3+4; 685-8'3 <'))

Controller Temperature

Previous Menu **Displays Last 5 Alarms** '

3'/4 3+4; '2'839

N ȭ

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Next Page

19-2-12

Group 19 Previous Page

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Alarm Information

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Next Page

19-2-13

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Next Page

19-2-14

Group 19 Previous Page :

:

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Group 19 Steer Controller Tester Guide

Parameter

Description

Function

STEPPER MOTOR

Check voltage of stepper motor.

Display current voltage (V).

READ FBPT AT SW1

–

–

SET POINT POT.

–

–

TRUCK SPEED

–

–

SLOPE PEAK

–

–

WHEEL ANGLE

Check status of 2-stage speed reduction switch.

If the function is triggered properly, the value will change.

ENC COUNT AT 180

–

–

TRUCK MOVING

–

–

SM ALARM SWITCH

–

–

MM ALARM SWITCH

–

–

AUTO IN PROGRESS

–

–

ACW LIMIT LEVEL

–

–

CW LIMIT LEVEL

–

–

ENDSTROKE ACW

–

–

ENDSTROKE CW

–

–

ENC SPEED

Check the speed of steer motor.

Display current frequency (Hz).

MOTOR CURRENT

Check the current of steer motor.

Display current value (A).

MOTOR VOLTAGE

Check the voltage of steer motor.

Display current voltage (V).

SAT FREQ HZ

–

–

FREQUENCY

Check the output frequency of EPS controller.

Display the current frequency (Hz).

MOTOR TEMPERAT

Check the temperature of steer motor.

Display current temperature (°C).

TEMPERATURE

Check the temperature of EPS controller.

Display current temperature (°C).

FEEDBACK ENC.

–

–

FEEDBACK POT.

–

–

19-2-16

Group 19 Section 3 Controller Alarms

19-3-1

Group 19 Traction Controller Alarms Traction Controller Alarm (AC-0) Number Description

8

13

WATCHDOG

EEPROM KO

Possible Cause Occurs when the embedded WATCH DOG protection is not able either to cut off the power stage when not triggered or it is not able to activate the power stage when triggered.

Occurs due to a defect of the non-volatile embedded memory supporting the controller regulations.

Troubleshooting

• Check UVW cables between controller and drive motor.

• If alarm continues, replace controller.

• Attempt to clear code and perform relearn traction VACC. • If alarm continues, replace controller.

• Recharge the battery.

17

LOGIC FAILURE #3

A power or logic failure.

• If alarm continues, check cables between battery and controller.

• If alarm continues, check battery voltage.

• If alarm continues, replace controller.

• Recharge the battery.

18

LOGIC FAILURE #2

The circuit, to compensate for dead times of the sine waves, has failed.

• If alarm continues, check cables between battery and controller.

• If alarm continues, check battery voltage.

• If alarm continues, replace controller.

19-3-2

Group 19 Traction Controller Alarm (AC-0) Number Description

Possible Cause

Troubleshooting • Recharge the battery.

19

LOGIC FAILURE #1

An over or under voltage protection operation has occurred.

• If alarm continues, check cables between battery and controller.

• If alarm continues, check battery voltage.

• If alarm continues, replace controller.

30

VMN LOW

If the top side power mosfets are turned ON before the traction contactor is ON, the controller expects the phase V voltage to increase toward the rail capacitor value. If the phase V does not increase, an alarm occurs.

• Check UVW cables between drive motor and controller.

• If alarm continues, check wires between controller and encoder. Replace encoder if wires OK. • If alarm continues, check resistance between drive motor and frame.

If resistance is 0Ω, replace drive motor.

• If alarm continues, replace controller.

• Check UVW cables between drive motor and controller.

31

VMN HIGH

If the bottom side power mosfets are turned ON before the main contactor is ON, the controller expects the phase V voltage falls toward ground value. If the phase V remains high, an alarm occurs.

• If alarm continues, check wires between controller and encoder. Replace encoder if wires OK. • If alarm continues, check resistance between drive motor and frame.

If resistance is 0Ω, replace drive motor.

• If alarm continues, replace controller.

19-3-3

Group 19 Traction Controller Alarm (AC-0) Number Description

37

38

CONTACTOR CLOSED

CONTACTOR OPEN

Possible Cause If the main contactor is closed when the coil is not driven, the capacitor bank should discharge. If capacitor bank does not discharge, then alarm occurs.

Main contactor coil has been driven by the logic board, but does not close.

Troubleshooting • Clean main contactor and/or replace the contactor spring.

• If alarm continues, replace main contactor.

• If alarm continues, replace controller.

• Clean main contactor and check wires between main contactor and controller.

• If alarm continues, replace main contactor.

• If alarm continues, replace controller.

49

53

60

I=0 EVER

STBY I HIGH

CAPACITOR CHARGE

The current feedback sensor is constantly stuck to 0 when drive motor is running.

• Replace controller.

If the voltage outputs of the current amplifiers is not close to 2.5V (between 2.26V and 2.74V is OK).

• Replace controller.

If the voltage on the rail capacitors (measured on the phase V) is low and does not increase when the main contactor is open.

• Check UVW cables between drive motor and controller.

• If alarm continues, replace controller.

19-3-4

Group 19 Traction Controller Alarm (AC-0) Number Description

61

65

HIGH TEMPERATURE

MOTOR TEMPERAT.

Possible Cause

The controller temperature reached 78 °C or greater. The maximum current decreases proportionally to any temperature increase up to 100 °C. At 100 °C the current is limited to 0 A.

The drive motor temperature is higher than the MOTOR OVERTEMP setting.

Troubleshooting • Stop operation and record controller temperature.

Allow vehicle to cool completely.

If OK, then duty cycle or operating environment is too extreme.

• If alarm continues, replace controller.

• Stop operation and record drive motor temperature.

Allow truck to cool completely.

If OK, then duty cycle or operating environment is too extreme.

• If alarm continues, check wires between temperature sensor and controller.

• If alarm continues, replace sensor.

• If alarm continues, replace controller.

• Charge battery.

66

69

19-3-5

BATTERY LOW

CURRENT SENS. KO

The battery charge is calculated being less than 10% of the FULL charge and the BATTERY CHECK setting is not 0.

Current sensor failed.

• If alarm continues, check battery voltage.

• If battery voltage is less than 22V, replace battery.

• If battery voltage is equal or greater than 24V, then replace controller.

• Replace controller.

Group 19 Traction Controller Alarm (AC-0) Number Description

Possible Cause

Troubleshooting • Clean main contactor and check wires between contactor and controller.

74

DRIVER SHORTED

Occurs when the voltage on the main contactor is higher than the supplied voltage.

• If alarm continues, check or replace contactor spring.

• If alarm continues, replace main contactor.

• If alarm continues, replace the controller.

• Clean main contactor and check wires between contactor and controller.

75

CONTACTOR DRIVER

Occurs when the voltage on the main contactor is lower than the supplied voltage.

• If alarm continues, check or replace contactor spring.

• If alarm continues, replace main contactor.

• If alarm continues, replace the controller.

• CAN #1: Check voltage between main contactor and controller.

76

COIL SHORTED

Occurs when there is an overload on one of the following connections: CAN #1, CAN #3, CAN #4 or CAN #6.

• CAN #3: Check voltage between brake and controller.

• CAN #4: Check voltage between pump contactor and controller.

• CAN #6: Check main contactor voltage.

• If alarm continues, replace the controller.

19-3-6

Group 19 Traction Controller Alarm (AC-0) Number Description

Possible Cause

Troubleshooting • Attempt to clear code and perform relearn traction VACC.

78

VACC NOT OK

CPOT voltage is higher than VACC MIN +1V when the traction enable switch is open.

• If alarm continues, check wires between accelerator and controller.

• If alarm continues, replace accelerator.

• If alarm continues, replace controller.

• Check accelerator and pedal switch, then attempt to operate.

79

INCORRECT START

Incorrect starting sequence.

• If alarm continues, check accelerator switch using handset. If error shows, check wire between controller CAN #3 and CAN #1.

• If alarm continues, replace controller.

80

FORW + BACK

The forward and backward switches are closed together.

• Check forward and backward using handset. If ERROR shows, check wires between controller and accelerator. If NORMAL shows, replace controller.

• If alarm continues, replace accelerator.

• If alarm continues, replace controller.

99

19-3-7

INPUT ERROR #1

PLD device has failed.

• Replace controller.

Group 19 Traction Controller Alarm (AC-0) Number Description

230

PUMP CONT. OPEN

Possible Cause

Pump contactor stays closed.

Troubleshooting • Check wires between the pump contactor and controller.

• If alarm continues, replace pump contactor.

• If alarm continues, replace controller.

• Check wires between the pump contactor and controller.

231

PUMP CONT. CLOSED

Pump contactor stays open.

• If alarm continues, clean pump contactor and/or replace contactor spring.

• If alarm continues, replace contactor.

• If alarm continues, replace controller.

232

VACC OUT RANGE

Program VACC required or accelerator has failed.

• Attempt to clear code and perform relearn traction VACC. • If alarm continues, replace accelerator.

• If alarm continues, replace controller.

234

235

EPS RELE OPEN

CAN BUS KO EPS

Electronic power steering (EPS) alarm occurred.

Controller is unable to get information from the EPS controller via CAN.

• Check EPS alarm.

• Check CAN wires between controller and EPS controller.

• If alarm continues, replace EPS controller.

• If alarm continues, replace controller.

19-3-8

Group 19 Traction Controller Alarm (AC-0) Number Description

Possible Cause

Troubleshooting • Check battery voltage.

236

WRONG SET BAT.

The battery voltage is NOT within an acceptable range of the nominal value.

• If less than 22V, replace battery.

• If equal to or greater than 24V or battery replacement did not correct, check battery cables.

• If alarm continues, replace controller.

• Check lift and lower switches with handset.

• If NORMAL displays, replace controller.

238

LIFT LOW. ACTIVE

A lift or lower function is active before key-on.

• If ERROR displays, check wires between controller and lift and lower switches.

• If alarm continues, replace lift and/or lower switch.

• If alarm continues, replace controller.

239

LIFT + LOWER

This occurs when the LIFT and LOWER switch are closed at the same time.

• Do not press the LIFT and LOWER buttons at the same time.

• If alarm continues, check wires between controller and switches.

• If alarm continues, replace controller.

19-3-9

Group 19 Traction Controller Alarm (AC-0) Number Description

Possible Cause

Troubleshooting • Check wires between controller, EPS controller, display, and handset.

248

CAN BUS KO

Controller not receiving signal from CAN bus line.

• If alarm continues, disconnect controller CAN wires. If no alarm, replace controller.

• If alarm continues, disconnect EPS controller CAN wires.

If no alarm, replace EPS controller.

• If alarm continues, disconnect display CAN wires. If no alarm, replace display or replace main harness.

250

THERMIC SENS. KO

The temperature sensor located on base plate, has failed or motor / controller is exceeding thermal limit due to extreme operating conditions. If failed, the sensor output will be greater than 4.95V or lower than 0.1V.

• Record ambient temperature, stop operation, and allow truck to cool.

• If OK, then operating conditions too extreme.

• If alarm continues, check wires between temperature sensor and EPS controller.

• If alarm continues, replace the sensor.

• If alarm continues, replace controller.

252

WAITING FOR NODE

When controller does not receive signal from remote module via CAN bus, a time out occurs.

• Check CAN wires between controller, EPS controller, display, and handset.

• If alarm continues, replace controller.

19-3-10

Group 19 Traction Controller Alarm (AC-0) Number Description

Possible Cause

Troubleshooting • Check that encoder is properly tightened.

253

ENCODER ERROR

Two consecutive speed signal values from the encoder have too great of a difference.

• If alarm continues, check CAN wires between controller and encoder.

• If alarm continues, replace encoder.

• If alarm continues, replace controller.

254

19-3-11

AUX OUTPUT KO

When ON/OFF switch active, the pulse width modulation generated by the controller to supply the EM-brake and the actual feedback voltage on the EM-brake are not the same.

• Check wires between EM-brake and controller.

• If alarm continues, replace EM-brake.

• If alarm continues, replace controller.

Group 19 Steer Controller Alarms Steer Controller Alarm (EPS-AC0) Number Description

6

13

16

17

18

19

Possible Cause

SERIAL ERR #1

Slave microcontroller does not receive the communication from the main microcontroller through this serial interface

EEPROM KO

Occurs if a test to write and read in one location EEPROM fails. The SW expects to read the written value. It occurs also when the hour counter gives different values between the three redundant locations in which it is recorded. It occurs also when the busy bit of the EEPROM does not rise within 12 mS.

Troubleshooting

• Replace EPS controller.

• Clear EEPROM code using handset and relearn steering calibration.

• If alarm continues, replace EPS controller.

LOGIC FAILURE #4

The rest state if the output of the voltage amplifier of the phase Vw-Vv has a drift larger than ±0.25 V.

• Replace EPS controller.

LOGIC FAILURE #3

The rest state if the output of the voltage amplifier of the phase Vu-Vw has a drift larger than ±0.25 V.

• Replace EPS controller.

LOGIC FAILURE #2

The real voltage between phases W and V of the motor is different from the desired.

• Replace EPS controller.

LOGIC FAILURE #1

The real voltage between phases W and U of the motor is different from the desired.

• Replace EPS controller.

19-3-12

Group 19 Steer Controller Alarm (EPS-AC0) Number Description

32

48

53

Possible Cause

VMN NOT OK

The initial rest state after key-on and the outputs of the motor voltage amplifiers are not in the window from 2.2 to 2.8 V.

MAIN CONT. OPEN

The setting CAN BUS is PRESENT. Then the EPS controller waits for information that the traction controller has closed the main contactor. If this information takes more than about 1.5 s, this alarm occurs.

STBY I HIGH

1) If during the initial rest state after key-on, the outputs of the current amplifiers are not within the window 2.2 to 2.8 V. 2) When the outputs of the current amplifiers at rest have a drift greater than ±0.15 V.

61

HIGH TEMPERATURE

The temperature of the controller base plate becomes greater than 75 °C.

Troubleshooting

• Replace EPS controller.

• Check traction controller's alarm for this error. Fix as needed.

• If alarm continues, replace EPS controller.

• Replace EPS controller.

• Stop operation and record ambient temperature. Allow vehicle to cool.

If OK, then duty cycle or operating environment is too extreme.

• If alarm continues, replace EPS controller.

19-3-13

Group 19 Steer Controller Alarm (EPS-AC0) Number Description

65

MOTOR TEMPERAT.

Possible Cause

When DIAG MOTOR TEMP is ON and the motor temperature sensor measures a temperature greater than 65 °C.

Troubleshooting • Stop operation and record ambient temperature. Allow vehicle to cool.

If OK, then duty cycle or operating environment is too extreme.

• If alarm continues, check wires between motor temperature sensor and EPS controller.

• If alarm continues, replace motor temperature sensor.

• If alarm continues, replace EPS controller.

70

HIGH CURRENT

The circuit to limit (via hardware) the current in the motor is either: always active at key-on or repeatedly active when the motor is ON.

• Replace EPS controller.

• Check the main fuses.

71

POWER FAILURE #3

The current in phase V of the motor is 0 and the motor is active.

• If alarm continues, check cables on B+ and B- of EPS controller.

• If alarm continues, check phase V cable between steer motor and EPS controller.

• If alarm continues, replace EPS controller.

19-3-14

Group 19 Steer Controller Alarm (EPS-AC0) Number Description

Possible Cause

Troubleshooting • Check the main fuses.

72

POWER FAILURE #2

The current in phase U of the motor is 0 and the motor is active.

• If alarm continues, check cables on B+ and B- of EPS controller.

• If alarm continues, check phase U cable between steer motor and EPS controller.

• If alarm continues, replace EPS controller.

• Check the main fuses.

73

POWER FAILURE #1

The current in phase W of the motor is 0 and the motor is active.

• If alarm continues, check cables on B+ and B- of EPS controller.

• If alarm continues, check phase W cable between steer motor and EPS controller.

• If alarm continues, replace EPS controller.

83

19-3-15

BAD ENCODER SIGN

A switches' applied frequency (FREQUENCY) and the motor speed (ENC SPEED) have the opposite sign.

• Swap encode channel's CAN bus.

• If alarm continues, change wires back and replace EPS controller.

Group 19 Steer Controller Alarm (EPS-AC0) Number Description

84

85

99

212

218

STEER SENSOR KO

STEER HAZARD

Possible Cause

Troubleshooting

The command potentiometer changes with a jerk larger than MAX SP SLOPE. This alarm occurs when a discontinuity in the voltages of the command potentiometer.

• Replace twin potentiometer.

A warning that the steer controller is limiting the angle in the steering direction. No speed reduction occurs.

N/A

• Check wire between traction controller and EPS controller.

INPUT ERROR #1

The voltage on CAN #4 is greater than 12V before the safety contacts closed.

MICRO SLAVE #8

The encoder counting of the main microcontroller does not match with the encoder counting of the slave microcontroller.

• Replace EPS controller.

CLOCK PAL NOT OK

The main microcontroller sends an analog signal to the slave microcontroller to reset the slave microcontroller on demand. When the slave microcontroller detects this analog signal external to a range of 2.2V to 2.8V and it's not in range to generate the reset on demand, the slave microcontroller raises this alarm.

• Replace the EPS controller.

• If alarm continues, replace EPS controller.

19-3-16

Group 19 Steer Controller Alarm (EPS-AC0) Number Description

219

STEPPER MOTOR MISM

Possible Cause The frequency and the amplitude of the voltages from the stepper motor lines are mismatched.

When the amplitude of the stepper motor lines increases, the frequency of the stepper motor lines must increase too.

Troubleshooting

• Replace the EPS controller.

• Check if the steer motor is installed properly.

220

MOTOR LOCKED

The current in the steer motor stays close to the maximum current longer than 1s.

• If steer motor is installed correctly and alarm continues, replace the steer motor.

• If alarm continues, replace EPS controller.

221

MICRO SLAVE #4

It occurs in one of the following conditions: 1) Open loop application only: if the slave microcontroller detects the stator voltage phasor rotates in the opposite direction with respect to the sign of the stepper motor speed.

2) Closed loop application only: if the slave microcontroller detects the stator voltage phasor rotates in the opposite direction respect to the commanded position.

19-3-17

• Perform relearn of steering calibration.

• If alarm continues, replace EPS controller.

Group 19 Steer Controller Alarm (EPS-AC0) Number Description

Possible Cause

Troubleshooting • Check wires between EPS controller and proximity switch.

222

FB POT LOCKED

This alarm occurs if the feedback encoder counting does not change its value even if commanded to change.

• If alarm continues, check wires between EPS controller and encoder.

• If alarm continues, replace proximity switch.

• If alarm continues, replace encoder.

• If alarm continues, replace EPS controller.

223

225

JERKING FB POT

The feedback potentiometer changes with a jerk larger than 0.3 V in 16 mS. This alarm occurs when a discontinuity in the voltages of the feedback potentiometer.

• Replace feedback potentiometer.

CURRENT GAIN

The parameters to compensate for the gain of the current amplifier have the default values.

• Replace EPS controller.

19-3-18

Group 19 Steer Controller Alarm (EPS-AC0) Number Description

226

227

Possible Cause

Troubleshooting

NO SYNC

Every 16 mS, inside the code cycle, the main microcontroller rises and then lowers an input for the slave microcontroller (SYNC). When the slave microcontroller detects no edge for more than 100 mS on this input, this alarm occurs. This is just a watch dog function: when the main microcontroller does not execute the code cycle it does not update the SYNC signal and the slave microcontroller cuts off the steer and traction.

• Replace EPS controller.

SLAVE COM. ERROR

The main microcontroller does not receive the communication from the slave microcontroller through the serial interface.

• Replace EPS controller.

• Check wires between EPS controller and proximity switch.

228

POSITION ERROR

Error in the redundant test of the feedback sensors.

• If alarm continues, check wires between EPS controller and encoder.

• If alarm continues, replace proximity switch.

• If alarm continues, replace encoder.

• If alarm continues, replace EPS controller.

19-3-19

Group 19 Steer Controller Alarm (EPS-AC0) Number Description

237

238

239

241

Possible Cause

Troubleshooting

WAITING DATA

The EPS controller asks the traction controller to send a list of parameters via CAN bus. From the request until the parameters are correctly relieved, this warning occurs. The steer is not activated yet, and the safety relays remain open when this warning is present.

N/A

EPS NOT ALIGNED

The initial alignment if the straight-ahead condition is not matched within 6sec. Throughout this 6 secs delay, the steer is not activated yet, the safety relays are open and the traction is stopped.

N/A

WAITING FOR TRAC

At key-on the steer controller requires a signal from the traction controller to close the safety contacts and to turn onto operational mode.

Until this signal is received, the warning occurs. The steer is not active and the safety relays remain open while this warning is present.

N/A

ENCODER ERROR

When ENCODER CONTROL is set ON and the real frequency does not reach the set frequency.

• Check for a wrong connection between the two encoder channels.

19-3-20

Group 19 Steer Controller Alarm (EPS-AC0) Number Description

242

Q LINE SENSOR KO

Possible Cause

Occurs when the mean voltage on the quadrature line of the stepper motor is not null.

Troubleshooting • Check wires between EPS controller and steer potentiometer.

• If alarm continues, replace steer potentiometer.

• If alarm continues, replace EPS controller.

243

244

245

19-3-21

D LINE SENSOR KO

Occurs when the mean voltage on the direct line of the stepper motor is not null.

• Check wire between EPS controller and steer potentiometer.

• If alarm continues, replace steer potentiometer.

• If alarm continues, replace EPS controller.

GAIN EEPROM KO

The parameters to compensate for the gain of the current amplifiers are recorded in a not volatile memory (EEPROM) with a redundant handling. In fact every adjustment is recorded in three EEPROM locations. If the values in these three locations are different in between this alarm occurs.

• Replace EPS controller.

DATA ACQUISITION

Occurs when acquiring the motor resistance or when adjusting the parameters to compensate for the gain of the current amplifiers (maximum current factory adjusted).

• Recycle the key-on function.

Group 19 Steer Controller Alarm (EPS-AC0) Number Description

246

247

248

Possible Cause

MICRO SLAVE KO

In stepper motor application, this alarm occurs if the main microcontroller is detecting a direction of the stepper motor not matched with the one that the slave microcontroller is detecting.

In closed loop application, this occurs if the main microcontroller is detecting a direction of the steering error not matched with the one that the slave microcontroller is detecting. Also, this alarm occurs if the main microcontroller is detecting no steering limitation while the slave microcontroller is detecting steering limitation.

CAN BUS KO

Occurs only when the setting CAN BUS is PRESENT: the steer controller must receive the event signal from the traction controller.

If these messages take more than approximately 1s, the alarm occurs.

S.P. OUT OF RANGE

This alarm occurs for a fault on the command potentiometer. When a single command potentiometer is chosen, the alarm occurs if its wiper exits the range from 0.8V to 4.2V. When the twin potentiometer is chosen, the alarm occurs if the sum of the two wiper voltages exits the range from 4.5V to 5.5V.

Troubleshooting

• Replace EPS controller.

• Check CAN wires between traction controller, EPS controller, and handset.

• If alarm continues, replace EPS controller.

• Check the connections of the potentiometer.

19-3-22

Group 19 Steer Controller Alarm (EPS-AC0) Number Description 249

250

251

252

253

254

19-3-23

Possible Cause

Troubleshooting

F.B. OUT OF RANGE

This alarm occurs if the feedback potentiometer exits the range from 0.3V to 4.7V.

• Check the connections of the feedback potentiometer.

MICRO SLAVE

It occurs when the information on the status bus between the main microcontroller and the slave microcontroller is frozen to the 0xFF value (the slave microcontroller does not update the status bus configuration).

• Replace EPS controller.

KM OPEN

This occurs if the slave microcontroller detects the safety contact of the main microcontroller open, instead of being closed.

• Replace EPS controller.

KS OPEN

This alarm occurs if the main microcontroller detects the safety contact of the slave microcontroller open, instead of being closed.

• Replace EPS controller.

KM CLOSED

This alarm occurs at keyon if the slave microcontroller detects the safety contact, of the main microcontroller, closed prior to being opened.

• Check wires between traction controller and EPS controller.

This alarm occurs if the main microcontroller detects the safety contact, of the slave microcontroller, closed prior to being opened.

• Check wires between traction controller and EPS controller.

KS CLOSED

• If alarm continues, replace controller.

• If alarm continues, replace controller.

Group 19

19-3-24

Group 19 Section 4 Basic Controller Programming IMPORTANT! When replacing controllers, only use genuine CLARK parts! Using non-OEM components can cause the vehicle to operate incorrectly or not at all.

IMPORTANT! When connecting to the OSQ, CLARK highly recommends using the Zapi® Smart Console with the 2-pin CAN connecting cable. Using other handsets may cause issues and lead to problems with the vehicle.

Zapi® Smart Console Handset CLARK Part Number: 8118502 2-Pin CAN Jumper Cable CLARK Part Number: 2630295

Introduction A Zapi® Handset is available that is designed specifically for use with the Zapi® controller. It performs multiple functions including: reading diagnostic data, testing vehicle operation, setting options, adjustments, and parameter changes of the controllers. The Zapi® handset is available through your CLARK dealer.

Connecting To Zapi® Smart Console NOTE The following procedures describe how to connect to the OSQ using the 2-pin CAN connector. The Zapi® Smart Console Handset can also be connected using the standard RS232 serial connection ports on the traction and steer controllers.

IMPORTANT! Zapi® Controller to Node Identification: Node 2 = Traction (AC-0) Controller Node 6 = Steer (EPS-AC0) Controller Node 16 = Display

Horn

2-Pin CAN

19-4-1

1.

Remove the front cover.

2.

Locate the 2-pin CAN connector located on the left side of the vehicle near the horn.

3.

Turn the vehicle key switch to the OFF position.

Group 19 VACC Calibration:

UP

POWER

LEFT

RIGHT

DOWN

OK

ESC

1.

Connect to the Zapi® Smart Console.

2.

Select PROGRAM VACC and press OK.

3.

Press OK button to begin calibration.

4.

Push the accelerator (travel switch) fully forward and then fully backward, holding momentarily in both directions. The voltage readings shown on the handset screen should change and the minimum and maximum values will turn RED.

5.

Press the ESC button when finished.

6.

Cycle the key switch ON/OFF to save changes.

Steering Calibration / Relearn Procedure: 1.

Connect to the Zapi® Smart Console handset.

2.

Select Node 6 (EPS-AC0 steer controller) and press the OK button to connect.

3.

Press OK to enter the MAIN MENU.

4.

Select HARDWARE SETTING and press OK to enter.

5.

Select AUTOTEACHING and change to ON.

6.

Press ESC button, then OK/YES to confirm. The handset screen should return to the MAIN MENU.

7.

Press and hold the POWER button for 3 seconds to turn the handset OFF.

8.

Cycle the key switch ON/OFF to start the automatic steering calibration. DO NOT attempt to operate the vehicle until calibration is complete (drive wheel stops turning).

Cycle the key switch ON/OFF to save calibration.

4.

Press POWER button on Zapi® Smart Console.

5.

Connect handset to 2-pin CAN connector.

6.

Turn key switch to ON position.

7.

Select CAN CONSOLE on handset screen and press OK.

8.

Select the controller to connect to:

9.

• Node 2 = AC-0 Traction Controller

Locking / Unlocking the Display:

• Node 6 = EPS-AC0 Steer Controller • Node 16 = Display 9.

Press OK to connect to the controller.

Clearing EEPROM:

1.

Connect to the Zapi® Smart Console handset.

2.

Select Node 16 (display) and press the OK button to connect.

3.

Press OK to enter the MAIN MENU.

1.

Connect to the Zapi Smart Console handset.

4.

Select SET OPTIONS and press OK to enter.

2.

Select Node 2 (traction controller) and press the OK button to connect.

5.

Select CONSOLE ENABLE and change to ON (display unlocked) or OFF (display locked).

3.

Press OK to enter the MAIN MENU.

6.

4.

Select CLEAR EEPROM and press OK, then OK/YES to confirm. A message should appear on the handset screen indicating that the EEPROM has been cleared.

Press ESC button, then OK/YES to confirm. The handset screen should return to the MAIN MENU.

7.

Press the ESC two time (2X) then cycle the key switch ON/OFF to save.

5.

Cycle the key switch ON/OFF and restart the handset.

®

19-4-2

Group 19 Locking / Unlocking Speed Mode: 1.

Connect to the Zapi® Smart Console handset.

2.

Select Node 16 (display) and press the OK button to connect.

3.

Press OK to enter the MAIN MENU.

4.

Select SET OPTIONS and press OK to enter.

5.

Select PERFORMANCE ENABLE and change to ON (speed mode unlocked) or OFF (speed mode locked).

6.

Press ESC button, then OK/YES to confirm. The handset screen should return to the MAIN MENU.

7.

Press the ESC two time (2X) then cycle the key switch ON/OFF to save.

19-4-3

Group 19

Group 20

Group 20 Drive Axle

Drive Unit.....................................................................Section 1

Group 20 Section 1 Drive Unit Checking Drive Unit Fluid Level CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

1.

Remove the front cover.

2.

Remove fill port plug on the drive unit.

3.

Use finger to check the fluid level: • If the fluid level is at the lower edge of the fill port, then fluid level is normal.

• If the fluid level is below the lower edge of the fill port, then fluid level is low.

4.

CAUTION Possible crushing injury due to heavy component.

Use care when removing the drive unit to prevent injury or damage to the vehicle.

IMPORTANT! The drive unit is a non-serviceable component that cannot be rebuilt if failure occurs. If the drive unit fails, it is necessary to replace the complete unit.

If needed, add fluid until fluid level reaches lower edge of fill port.

Replacing Drive Unit Fluid 1.

Raise and support the vehicle high enough to allow access to the drain and fill ports of the drive unit.

Refer to Group SA, Section 2 in this manual.

2.

Remove the front cover.

3.

Position a catch or drain pan under the drive unit.

Function and Description The CLARK OSQ uses a heavy duty drive unit with double reduction helical spur and spiral bevel gears that operate in a bath of oil. It is a totally enclosed unit and is vertically mounted to the frame. Power is supplied to the drive unit from the drive motor. The drive unit is responsible for transferring power to the ground via the drive wheel. A proximity sensor is used to determine and monitor the position of the drive wheel.

Fill

Drain

Lubrication Schedule and Fluid Capacity Fluid Replacement: Every 2000 hours or yearly

4.

Fluid Type: SAE 80W-90 GL-5 Gear Oil

Remove the fill and drain plugs. Allow the fluid to drain completely.

5.

Install the drain plug. Use a new O-ring.

CLARK Part Number: 1808014 (qt) / 1808015 (gal)

6.

Fill the drive unit.

7.

Check the fluid level.

8.

Install the fill plug. Use a new O-ring.

9.

Lower the vehicle.

Capacity: 1.38 L (1.46 qt)

20-1-1

10. Discard of used fluid appropriately.

Group 20 Drive Unit Removal 1.

Raise and support the vehicle high enough to allow removal of the drive unit. Refer to Group SA, Section 2 in this manual.

2.

Remove the front cover.

3.

Remove the proximity switch. Refer to Group 20, Section 1 in this manual.

4.

Remove the drive motor. Refer to Group 16, Section 1 in this manual.

5.

Remove the six bolts securing the drive unit to the mounting base frame.

6.

Remove the drive unit.

Steering Bearing

M8 Bolt (8x)

Steering Ring Gear

Drive Unit Installation If replacing the drive unit, perform the following: M10 Bolt (6x)

• Install the drive wheel. Refer to Group 22, Section 1 in this manual.

• Install the steering ring gear and the steering bearing.

• Install the bolts to secure the steering ring gear and bearing to the drive unit. Torque tighten the bolts.

Drive Unit If replacing the drive unit, perform the following: • Remove the bolts securing the steering bearing and the steering ring gear to the drive unit.

1.

Install the drive unit.

2.

Secure the drive unit to the mounting base frame with the six bolts.

3.

Install the drive motor. Refer to Group 16, Section 1 in this manual.

4.

Install the proximity switch. Refer to Group 20, Section 1 in this manual.

5.

Calibrate the steering. Refer to Group 19, Section 4 in this manual.

6.

Install the front cover.

7.

Lower the vehicle.

8.

Check for proper operation.

• Remove the steering bearing and the steering ring gear.

• Remove the drive wheel. See Group 22, Section 1.

20-1-2

Group 20 Proximity Switch Location

Proximity Switch Installation and Adjustment

A

Proximity Sensor

1.

Install the proximity sensor.

2.

Adjust the gap distance (A) between the proximity sensor and the large steering ring gear using an appropriate feeler gauge.

Proximity Switch Removal

Proximity Sensor Gap: 1 mm - 2 mm 3.

Tighten the jam nuts when the sensor has been properly adjusted.

4.

Turn the key switch to ON and allow the vehicle to perform a drive wheel positioning test. This should occur automatically.

5.

If the vehicle operates normally without any alarm codes, then installation is complete.

6.

If drive wheel fails to position (continues to rotate) and/or an alarm is displayed, re-adjust the sensor or continue with troubleshooting.

Proximity Sensor Troubleshooting Problem Drive wheel rotates continuously. EPS NOT ALIGNED alarm will appear.

1.

Remove the front cover.

2.

Disconnect the proximity sensor connector from the vehicle harness.

3.

Loosen the jam nuts.

4.

Unscrew and remove the proximity sensor.

20-1-3

Possible Cause • Debris between proximity sensor and steering ring gear.

• Sensor gap not adjusted correctly.

• Proximity switch failure.

• Proximity switch circuit failure.

Group 20 Checking and Testing Proximity Sensor

Proximity Sensor Control Circuit • Check for a broken drive motor circuit: • Set the multimeter to ON/OFF. • Check for conductivity between the proximity switch and the controller (#1/36/37 circuit).

LED Indicator

Inductive Surface

37 GND

1 +24V

EPS-AC0

36

37

1

36

36

37

+24V

Checking the Proximity Sensor • The OSQ proximity sensor is NO (normally open), when there is no signal, the output wire (#36/Black) is not connected with the power supply input wire (#1/Brown).

GND 1

0

0

F AF

+BATT

• The LED indicator (1) will signal when sensor is energized and the inductive surface is facing convex of big ring gear, proximity switch will trigger signal, and #36 wire will be connected with #1 wire.

• Inductive surface (2) distance of 1 to 2 mm.

• Check if proximity sensor harness is in good condition.

• Check if sensor gap is OK. Testing the Proximity Sensor • Adjust the inductive surface of proximity sensor to the large steering ring gear so that it does not function properly. Measure the voltage between pins #37 and #1 with a multimeter.

• If there is no voltage, check if the circuit is connected.

• If there is voltage, continue below.

• Measure the voltage between pins #36 and #1.

• If there is 24V voltage (or the switch is energized under a non-induction state and LED is lit), the switch has been damaged.

• If there is no voltage, move on to the next step.

• Touch the inductive surface to the ring gear to cause it to send signals.

• If there is no voltage between pins #36 and #1, the switch has been damaged.

20-1-4

Group 22

Group 22 Wheels

Drive Wheel..................................................................Section 1 Load Wheels................................................................Section 2 Caster Wheels..............................................................Section 3

Group 22 Section 1 Drive Wheel CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

2.

Remove the front cover.

3.

Rotate the drive assembly to improve access to the drive wheel.

4.

Remove the five M12 flanged lug nuts and conical washers.

5.

Remove the drive wheel from the drive unit.

Drive Unit Drive Wheel

CAUTION Never perform maintenance or service work on a vehicle that seems unstable or has been improperly raised and supported.

CAUTION

Washer Nut (5x) (5x)

Prior to performing any maintenance, check the vehicle for a stable condition on the blocks or jack stands.

Drive Wheel Removal 1.

Raise and support the vehicle high enough to allow removal of the drive wheel. Refer to Group SA, Section 2 in this manual.

22-1-1

Drive Wheel Installation IMPORTANT! Always use genuine CLARK factory parts when servicing the wheel(s) on the OSQ vehicle. Using and installing high quality wheels directly affects the stability and driving performance of your vehicle. If replacement wheels are needed, use original spare parts provided by the equipment manufacturer to maintain the original design performance of the vehicle.

1.

Install the drive wheel to the drive unit.

2.

Install the M12 flanged lug nuts and conical washers to secure the drive wheel.

Group 22 3.

Torque tighten the flanged lug nuts in the sequence shown below.

M12 Lug Nut Torque: 90 Nm (66 ft-lb)

E B C

A

D

Troubleshooting Use the following table to diagnose drive wheel related issues: Problem Drive wheel slipping or jumping.

Possible Cause • Part failure • Foreign body blockage • EM coil failure • Low supply voltage (<24V)

Drive wheel cracking or chucking.

• Foreign body blockage

Excessive vehicle sway during operation.

• Pressure plate not linearly absorbed.

• Mechanical resistance.

22-1-2

Group 22 Section 2 Load Wheels CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

2.

Remove the four M6 bolts and the dust cover.

3.

Remove the lock nut.

4.

Bend the tabs of the locking washer and remove.

5.

Remove the load wheel and the outer bearing. Use a rubber mallet or dead blow hammer to tap on the back of the load wheel if the wheel and bearing is difficult to remove.

NOTE

Use a three-jaw puller to remove the inner bearing.

CAUTION Never perform maintenance or service work on a vehicle that seems unstable or has been improperly raised and supported.

6.

Remove the inner bearing and wheel seal.

7.

Remove and the outer bearing from the load wheel.

Inner Bearing

CAUTION Prior to performing any maintenance, check the vehicle for a stable condition on the blocks or jack stands.

Outer Bearing Seal

Load Wheel Removal 1.

Raise and support the rear of the vehicle high enough to allow removal of the load wheels. Refer to Group SA, Section 2 in this manual.

22-2-1

Load Wheel

Locking Washer

Lock Nut M6 Bolt (4x) Dust Cover

Group 22 Load Wheel Installation IMPORTANT! Always use genuine CLARK factory parts when servicing the wheel(s) on the OSQ vehicle. Using and installing high quality wheels directly affects the stability and driving performance of your vehicle. If replacement wheels are needed, use original spare parts provided by the equipment manufacturer to maintain the original design performance of the vehicle.

1.

Apply grease to the wheel bearings. Refer to Group PM, Section 2 in this manual.

2.

Install the wheel seal. Always use a new part.

3.

Press and install the inner and outer bearings.

4.

Install the load wheel to the vehicle.

5.

Install the lock washer.

6.

Install the lock nut. Tighten the nut and then back it off a 1/4 turn. Bend the locking tabs of the lock washer to secure in place.

7.

Install the dust cover and secure with the M6 bolts.

Torque tighten the bolts.

M6 Bolt Torque: 11 Nm (8 ft-lb)

8.

Check for proper operation of the load wheel.

Troubleshooting Use the following table to diagnose load wheel related issues: Problem Excessive bearing noise.

Possible Cause • Bearing fatigue damage • Foreign body blockage

Abnormal wheel wear (cracking, chunking, gumming)

• Incorrect operating environment or improper use

22-2-2

Group 22 Section 3 Caster Wheels CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

2.

Remove the front cover.

3.

Remove the four M8 bolts, washers, and lock washers.

4.

Remove the shims and the caster wheel.

CAUTION

Shim (2x)

Never perform maintenance or service work on a vehicle that seems unstable or has been improperly raised and supported.

Caster Wheel CAUTION Prior to performing any maintenance, check the vehicle for a stable condition on the blocks or jack stands.

Washer (4x)

Caster Wheel Removal 1.

Lock Washer (4x) M8 Bolts (4x)

Raise and support the vehicle high enough to allow removal of the caster wheels. Refer to Group SA, Section 2 in this manual.

Caster Wheel Installation

22-3-1

1.

Install the caster wheel.

2.

Install the screws and washers to secure the caster wheel.

3.

Tighten the M8 bolts.

Group 22 Caster Wheel Assembly

Caster Wheel Adjustment

Refer to the diagram below when replacing caster wheel components:

During normal operation, the drive wheel will wear and the caster wheels will support more of the weight of the truck leading to a decrease in drive wheel traction. Adjustment of the caster wheels will need to performed to restore proper drive wheel traction and factory steering and stability characteristics.

1 2

To adjust the caster wheels: • Loosen or tighten the M8 nut (5) to adjust the height of the caster wheel.

3 5

4

6

• Adjust the caster wheel so that the caster just contacts the ground.

10

11 7

12

8

9 10

13

14

17 16

15

18

17

15 No.

Description

No.

Description

1

Locking Ring

10

M12 Nut

2

Caster Support

11

Caster Support

3

Bearing

12

M12 Bolt

4

Locking Ring

13

Wheel Bracket

5

M8 Nut

14

M12 Bolt

6

Rod

15

Washer

7

Block

16

Spacer

8

Washer

17

Bearing

9

M8 Bolt

18

Wheel

22-3-2

Group 23

Group 23 Brake System

Electromagnetic Brake...............................................Section 1

Group 23 Section 1 Electromagnetic Brake Electromagnetic Brake Removal CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

1.

Decommission the vehicle.

2.

Block the load wheels to prevent unintended movement of the vehicle.

3.

Remove the front cover.

M5 Bolt (3x)

CAUTION Do not attempt to pull or push the vehicle with the EM-brake engaged. The EM-brake must be manually released before attempting to move a disabled vehicle or damage to the truck will occur.

Spring (3x) Brake Rotor

IMPORTANT! When servicing the braking system, always install chocks or block the load wheels to prevent the vehicle from moving unexpectedly.

Lock Ring (2x)

Pressure Plate Friction Plate Splined Hub

Locking Key

Function and Description The CLARK OSQ uses an electromagnetic (EM) braking system mounted to the top of the electric drive (traction) motor. The brake is mechanically applied using springs and electrically released when current is sent to the electromagnetic brake coils.

When the vehicle is powered OFF, the electromagnetic brake coils do not absorb the pressure plate and the brake rotor and friction plate are forced to contact each other.

This creates a friction force that slows the drive motor and brings the vehicle to a stop.

23-1-1

4.

Disconnect the EM-brake harness connector.

5.

Remove the M5 bolts securing the EM-brake to the drive motor.

6.

Remove the brake.

Electromagnetic Brake Installation 1.

Install the EM-brake.

2.

Install the M5 bolts to secure the EM-brake assembly to the drive motor.

3.

Connect the harness connector to the EM-brake.

4.

Check the air gap. Refer to Group 23, Section 1 in this manual.

Group 23 5.

Install the front cover.

6.

Remove the blocking from the load wheels.

7.

Commission the vehicle.

Manually Releasing Brake

To check the air gap: NOTE When the air gap exceeds 0.4 mm, then replace the brake rotor or replace the EM-brake assembly.

1.

Use a feeler gauge to measure the gap as shown below.

2.

If the gap is between 0.2 mm and 0.4 mm then the brake is OK.

3.

If the gap is greater than 0.4 mm then the brake rotor or the EM-brake must be replaced.

X To disengage the EM-brake for emergency moving of the vehicle, pull up on the handle to release the brake.

Checking the Air Gap The EM-brake is not adjustable and must be replaced if it becomes faulty. Always be sure to check the air gap between the electromagnetic coils and the pressure plate. If the gap becomes too large due to excessive wear of the brake rotor, replace the brake rotor.

Air Gap

Ideal Value

Maximum Value

x

0.2 mm

0.4 mm

NOTE As the brake rotors of the electric brake wear, the air gap will increase until failure of the electromagnetic absorption of the pressure plate occurs.

If the brake coils are energized and the pressure plate is not being absorbed, check the air gap to ensure it is withing correct specification.

Also, after installing a new EM-brake assembly, always check the air gap between the electromagnetic coils and the pressure plate.

23-1-2

Group 23 Troubleshooting the Brake Problem

• Use the table below to diagnose the issue.

Possible Cause

Brake is energized but pressure plate does not absorb.

• Part failure • Foreign body blockage • EM coil failure • Low supply voltage (< 24V)

Power is OFF, but pressure plate will not release.

• Foreign body blockage

Excessive noise after absorption.

• Pressure plate not linearly absorbed.

• Mechanical resistance.

Excessive brake temperature.

• Pressure plate not fully absorbed - brake dragging.

Measurement (Ω)

Description

≈ 30 Ω

Normal

0Ω

Coil shorting (Replace the brake)

∞Ω

Coil breaking (Replace the brake)

Testing Pump Contactor Circuit • Check for a broken brake circuit: • Set the multimeter to ON/OFF. • Check for conductivity between #3 brake circuit (between brake and controller).

• Check for conductivity between #7 brake circuit (between brake and controller).

• Over current to EM-brake coil.

• Coil energized too frequently.

Checking and Testing Brake Checking the Electromagnetic Coils • Turn the vehicle OFF and disconnect the battery.

• Disconnect the connector from the brake.

• Measure the resistance (Ω) of the coil as shown below using a multimeter.

Positive (+) Red

Negative (–) Black

23-1-3

AC-0 #3

#7

Group 23

Group 29

Group 29 Hydraulics

Hydraulic Pump and Motor.........................................Section 1 Solenoid Valve.............................................................Section 2 Accumulator................................................................Section 3 Hydraulic Schematic...................................................Section 4

Group 29 Section 1 Hydraulic Pump and Motor Assembly Specifications CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

WARNING Avoid serious injection injury from high-pressure fluid.

Do not use hands to check for leaks. Relieve the hydraulic system pressure before servicing the hydraulic system.

To relieve the hydraulic system pressure, press the Emergency Lowering Valve to relieve the hydraulic pressure.

Function and Description The hydraulic system pressure is provided by the hydraulic unit system, which consists of a motor, pump, and sump.

The hydraulic assembly is equipped with a relief valve to ensure that the entire system pressure is always within the safe maximum load limit.

• Pump Displacement: 5 cc/rev • Speed: 3000 rev/min • Flow Rate: 5 – 30 L/min • Maximum Relief Pressure: 1450 psi (100 bar)

Planned Maintenance Fluid Replacement: Every 2000 hours or yearly Fluid Type: ISO AW 32 Hydraulic Fluid (MS-68) CLARK Part Number: 1800236 (qt) or 1802155 (gal) Capacity: • OSQ 126 - 6.87 qt (6.5 L) • OSQ 162 - 8.99 qt (8.5 L) • OSQ 192 - 9.94 qt (9.4 L) Filter Replacement: Every 2000 hours or yearly Filter Type: Hydraulic Tank (Sump) Filter CLARK Part Number: 1247772

Checking Hydraulic Fluid Level

The hydraulic pump motor is controlled by the traction controller (AC-0). Upon receiving the input signal from the controller, the motor transmits power to operate the hydraulic pump. The hydraulic pump provides hydraulic pressure to the system and is regulated by the solenoid control valve.

The solenoid valve is used to control the lifting and lowering of the operator's platform. A flow control valve is used to control the lowering speed. The system is equipped with a filter to prevent impurities in the hydraulic fluid from entering the pump.

An explosion proof valve is installed before the hydraulic cylinders to prevent the free falling of a load if a system failure occurs.

29-1-1

Dipstick

1.

Remove the front cover.

2.

Remove dipstick from the top of the hydraulic tank.

3.

Check the hydraulic fluid level.

4.

If needed, add additional fluid.

Group 29 Replacing Hydraulic Fluid 1.

Relieve the hydraulic system pressure by pressing the emergency lowering valve.

2.

Remove the front cover.

3.

Remove the hydraulic pump and motor assembly.

Refer to Group 29, Section 1 in this manual.

4.

Remove and discard of used fluid appropriately. The hydraulic tank does not have drain. a.

Option #1: Use an external vacuum pump.

b.

Option #2: Remove the hydraulic reservoir.

5.

Replace the filter on the end of the pickup tube of the hydraulic pump and motor assembly.

6.

Install the hydraulic pump and motor assembly. Refer to Group 29, Section 1 in this manual.

7.

Fill the hydraulic reservoir.

8.

Operate the vehicle's lift and lower functions to check for proper hydraulic function and purge any air from the system.

9.

Check fluid level using the dipstick, add fluid if needed.

Pump and Motor Assembly Removal

Pump Contactor Solenoid

M6 Bolts (4x)

Hydraulic Hose

1.

Remove the front cover.

2.

Relieve the hydraulic system pressure.

3.

Remove the cables and wires from the solenoid and pump contactor.

4.

Disconnect the hydraulic hose from the lift valve.

Hydraulic Unit

Fill Cap

Washer (4x) Lock Washer (4x) M6 Bolt (4x)

5.

Remove the four bolts, washers, and lock washers securing the hydraulic unit to the sump.

6.

Lift and remove the hydraulic unit from the sump.

Pump and Motor Assembly Installation 1.

Install the hydraulic unit to the sump flange.

2.

Install the four M6 bolts, washers, and lock washers to secure the hydraulic unit to the sump.

3.

Connect the hydraulic hose to the lift valve.

4.

Install the cables and wires to the solenoid and pump contactor.

5.

Check the hydraulic fluid level using the dipstick. Add fluid if needed.

6.

Operate the lift and lower functions to check for correct hydraulic operation.

7.

Check that the emergency lowering function works properly.

8.

Install the front cover.

29-1-2

Group 29 Motor Removal and Installation

Pump and Motor Assembly

1

Bolts (2x)

2

3 4

Brush Motor

5

7

6

8

9 10 12 Valve Block 13 1.

Remove the front cover.

2.

Remove the hydraulic pump and motor assembly.

Refer to Group 29, Section 1 in this manual.

3.

Remove the band clamp and the pump contactor from the motor.

4.

Remove the two long bolts and the motor end cover.

5.

Remove the motor from the valve block.

6.

Check the carbon brushes. If replacement is needed, replace all the brushes, do not replace just one.

7.

Installation is reverse order of removal.

8.

If carbon brushes were replaced, carry out a conduction test. Run the motor continuously to ensure that the fit and function is correct and the motor is properly conducted.

IMPORTANT!

When installing the pump motor, make sure the shaft and coupling on the motor rotor are mated correctly.

WARNING If disassembling the motor, do not place fingers or hand between the rotor and the stator as the magnetic force between creates a pinch hazard.

29-1-3

14

11

15 16 17

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Component Pump Contactor Carbon Brush (4 used) Pump Motor Band Clamp Bushing Coupling Solenoid Valve (lowering) Plug Valve Body Lifting Valve Relief Valve Seal Kit (O-rings) Screen Filter M6 Bolts (4 used) Hydraulic Pump Oil Pickup Tube Pickup Filter

Group 29 Pump and Motor Assembly Troubleshooting Problem Motor does not rotate

Possible Cause

Problem Low system pressure

• Motor bearing damaged or worn

• Pump wear, internal leakage Relief pressure unstable or low

• Relief valve spool worn or blocked

• Insufficient voltage supply • Carbon brushes worn or broken

Checking and Testing Motor

• Bearing worn or damaged

Positive

• Windings are shorting or grounded out Motor operates intermittently

• Damaged or loose power cables • Carbon brush worn or damaged

• Pressure adjustment too loose • Relief valve spring failed

• Carbon brushes worn Motor is rotating slowly

• Lack of fluid • Relief valve failure

• Damaged or loose power cables • Internal circuit damaged or broken

Possible Cause

Negative

• Winding circuit is broken or damaged Motor operates with abnormal noise or vibration

• Uneven clearance between stator and rotor • Bearing failure • Loose fixture fasteners

Excessive motor temperature

• Stator short circuit

Noisy pump

• Lack of hydraulic fluid

• Bearing failure • Wrong fluid type (too high viscosity) • Pickup tube leaking • Filter(s) clogged • Foaming fluid

Hydraulic fluid foaming

• Pump cavitation • Water in fluid

Excessive pump and/or fluid temperature

• Pump cavitation • Valve body internal relief

Checking the Motor • Check if the pump motor and it's cables are in good condition and if the connections are secure.

• Check if the connectors are connected.

Testing the Motor • Remove the cables from the pump motor.

• Perform a conduction (ON/OFF) test to the positive and negative contacts of the motor using a multimeter.

• If conducted, the motor is OK. • If not conducted, the circuit of the motor coils are damaged or the carbon brush is worn. Replace all the carbon brushes if worn.

Group 29 Section 2 Solenoid Valve CAUTION

B

Emergency Lowering Valve

Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

A

WARNING Avoid serious injection injury from high-pressure fluid.

Do not use hands to check for leaks. Relieve the hydraulic system pressure before servicing the hydraulic system.

To relieve the hydraulic system pressure, press the Emergency Lowering Valve to relieve the hydraulic pressure.

Electromagnetic Coil

Solenoid Valve Troubleshooting Problem Solenoid valve is energized but does not function.

Function and Description

When the contactor coil is de-energized, the closing part will be released under the effect of the released spring, the hydraulic fluid cannot form a loop, thus the lifting mechanism cannot be lowered.

Possible Cause • Power supply wires switched.

• Solenoid short circuit.

• Insufficient power supply voltage.

The solenoid valve's function is to control the flow of fluid in the hydraulic system. It is part of the hydraulic motor and pump assembly, which can be accessed by removing the front cover. It is controlled by the main traction controller (AC-0) and operates on 24V voltage. It includes the lift, lower, and relief valve sections. The emergency lowering function is combined in the lowering valve section.

When the solenoid valve coil is energized between A and B. The electromagnetic coil generates an electromagnetic force, causing the spool to move, opening the valve, and lowering the vehicle's operator platform.

Spool

• Spool blocked by contaminants.

• Incorrect hydraulic fluid viscosity.

• Service life exceeded, leading to component failure.

Solenoid valve does not close.

• Internal spool seals damaged and/or leaking.

• Spool blocked by contaminants.

• Return spring deforming or damaged.

• Service life exceeded, leading to component failure.

29-2-1

Group 29 Problem

Possible Cause

Internal spool / valve leakage.

• Damaged seals.

External spool / valve leakage.

• Loose hydraulic connection(s).

Solenoid Valve Control Circuit • Check for a broken solenoid valve circuit:

• Deformed return spring.

• Set the multimeter to ON/OFF. • Check for conductivity between the solenoid valve and the traction controller (#9/#15 circuit).

• Damaged seals.

Noisy valve operation.

• Inconsistent power supply voltage.

• Contamination of valve assembly.

B

15 9

9

15

AC-0

A

Checking and Testing Solenoid Valve Checking Solenoid Valve Check the solenoid valve for loose hydraulic connections or loose electrical leads and connectors.

Testing Solenoid Valve Measure the resistance (Ω) between the solenoid valve coil at contacts A and B. Refer to the table shown below.

Measurement (Ω)

Description

≈ 25 Ω

Normal

0Ω

Solenoid coil shorting (Replace the solenoid valve).

∞Ω

Solenoid coil broken.

(Replace the solenoid valve).

If the coil tests normal, check the solenoid valve for blocking due to impurities or contaminants in the system. Specifically be sure to check the spool fitment as the tolerances are extremely tight. Clean orifices and spool with hydraulic fluid and non-scratching tools.

29-2-2

Group 29 Section 3 Accumulator Accumulator Replacement CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

Accumulator Sealing Washer Fitting Sealing Washer

WARNING

Manifold Block

Avoid serious injection injury from high-pressure fluid.

Do not use hands to check for leaks. Relieve the hydraulic system pressure before servicing the hydraulic system.

To relieve the hydraulic system pressure, press the Emergency Lowering Valve to relieve the hydraulic pressure.

1.

Remove the front cover.

2.

Relieve the hydraulic system pressure.

3.

Remove the fitting and accumulator assembly. Discard the sealing washers.

Function and Description The OSQ uses a diaphragm-type hydraulic accumulator to cushion pressures surges in the hydraulic system.

The accumulator is precharged and is a non-serviceable component.

It consists of a hydraulic fluid section and a compressed gas section, where the hydraulic fluid of the accumulator is connected with hydraulic circuit and held under pressure by the compressed gas.

When the hydraulic system pressure rises, the hydraulic fluid enters the accumulator, the gas is compressed, and the system pressure is held constant. When the system pressure drops, the compressed gas will expand to press the oil into the circuit, thus stabilizing the pressure within the system.

29-3-1

NOTE Use new sealing washers during installation.

4.

Installation is the reverse order of removal.

Accumulator Troubleshooting Problem When raising or lowering the operator's platform, the vehicle shakes and/or shudders during operation.

Possible Cause • The accumulator is leaking either gas or hydraulic fluid.

Group 29

Group 29 Section 4 Hydraulic Schematic

Cylinder Pressure Switch Accumulator

2-Way Solenoid Valve

Safety Valve

Check Valve Relief Valve

Flow Control Valve

Pump Contactor

M Pump Motor

Pump

Filter

Reservoir

29-4-1

Filter

Reservoir

Group 29

Group 34

Group 34 Upright

Platform & Frame........................................................Section 1 Lift Chains....................................................................Section 2 Cylinders......................................................................Section 3

Group 34 Section 1 Platform & Frame Upright Rail and Rollers Inspection CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

WARNING The upright and operator's platform can move unexpectedly. Always follow the service procedures described below: • Do not walk or stand under a raised platform.

• Keep hand away from moving parts of the upright.

• Install blocks or jack to support upright.

• Do not reach through open areas in upright.

• Use a pry bar to align frame rails, do not use hands.

Perform a periodic inspection of the upright rails and rollers at least every 500 hours or 3 months. Visually inspect the upright rails for excessive or abnormal wear. Be sure to also check for cracks, especially at weld and joints. The upright rollers should function smoothly during operation (no sounds or gouging of the rails) and be adjusted properly.

Upright Roller Adjustment NOTE To adjust the upright rollers, at least two technicians are needed. One person to operate the vehicle and the other to adjust the rollers.

1.

Fully raise the operator's platform.

2.

The key to adjusting the upright rollers is start from the lowest and outermost rollers and continue to the highest and innermost rollers. The order of adjustment for the upright rollers is listed below: • 1st Set - Outer upright, upper rollers

Failure to follow the warnings listed above can result in serious injury or death!

Planned Maintenance Lubrication Intervals:

• 2nd Set - Middle upright, lower rollers • 3rd Set - Middle upright, upper rollers • 4th Set - Inner upright, lower rollers 3.

To adjust a set of upright rollers:

• Upright Rails: Every 150 hours or monthly

Locking Tab

• Upright Rollers: Every 250 hours or monthly Rail Lubrication Type: CLARK Innerslide Lube CLARK Part Number: 886396 Roller Lubrication Type: NLGI #2 Grease (MS-107C) CLARK Part Number: VV70133

Screwdriver

a.

34-1-1

Using a small screwdriver, bend back the locking tab on each roller.

Group 34

Hex Key (6 mm)

4.

Repeat the adjustment procedure for each set of rollers.

5.

When adjustment is complete, perform the following checks to ensure proper alignment of the upright: • Operate the lift and lower functions and check for abnormal sounds, upright hangup, and roller wear pattern.

• Push on the front tray of the vehicle to check for play in the operator's platform / upright.

There should be no more than 1/4" (7 mm) of play.

6. b.

Use a 6 mm hex key to loosen both rollers until they are not touching the upright rail, back the adjusting screw off at least one (1) full rotation.

c.

Check that both rollers rotate smoothly.

If the upright is still out of alignment, repeat the adjustment procedure. Replacement of rollers may be required if they are overly worn or damaged.

Thrust Roller Contact Point

Upright Rail

Adjusting Screw

d.

Tighten the adjuster screws so that the thrust rollers just barely makes contact with the upright rail. Do not overtighten the adjusting screws.

e.

Verify the rollers are evenly adjusted by checking the thread depth of the adjusting screws.

f.

When adjustment is complete, bend the locking tabs back to secure adjusting screws.

IMPORTANT!

Always adjust the rollers in pairs to ensure proper function and maximize roller life. Make sure to adjust the rollers evenly on both sides. Use care not to overtighten the adjustment screws.

34-1-2

Group 34 Rear Cover Adjustment

M12 Bolt

The gap between the upright and the rear cover must be adjusted properly to prevent unwanted contact when lifting or raising the operator's platform.

Gap: ≥ 1/2"

3.

Loosen the M12 bolt (B) near the tow hitch (not shown).

4.

Position the rear cover so that the gap meets specification.

5.

Tighten the three bolts (A and B) to secure the rear cover.

6.

Operate the vehicle's lift and lower operation and make sure there is no contact between the cover and the upright.

Operator's Platform Gap Check The gap between the operator's platform and the lower frame must be adjusted properly for correct lift and lower operation.

1.

Use a tape measure or ruler to check the gap between the rear cover and the upright. If the gap is smaller than specification, then adjustment is required.

Rear Cover Gap: Minimum of 1/2" (13 mm)

M16 Bolt (2x)

Gap: ≥ 1/2" 1.

Use a tape measure or ruler to check the gap between the four rubber bump stops and the lower frame. If the gap is smaller than specification, then adjustment is required.

Platform Gap: Minimum of 1/2" (13 mm)

2.

Loosen the two M16 bolts (A) on the rear of the vehicle.

34-1-3

2.

To adjust the height of the operator's platform, the lift chains must be adjusted. Refer to Group 34, Section 2 in this manual.

3.

Operate the vehicle's lift and lower operation and make sure there is no contact between the operator's platform rubber bump stops and the lower frame.

Group 34 Stabilizer Gap Check The gap between the either stabilizer block (located on the front of the frame) must be less than the specification shown. If the gap is greater than the specified value, then the stabilizer must be replaced.

To check the stabilizer gap:

Gap: ≤ 1/2"

1.

Park the vehicle on a firm, level surface.

2.

Use a tape measure or ruler to check the gap between the stabilizer block and the floor. If the gap is smaller than specification, then replacement is required.

Stabilizer Gap: Maximum of 1/2" (13 mm)

34-1-4

Group 34 Section 2 Lift Chains Planned Maintenance CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

WARNING The upright and operator's platform can move unexpectedly. Always follow the service procedures described below: • Do not walk or stand under a raised platform.

• Keep hand away from moving parts of the upright.

• Install blocks or jack to support upright.

• Do not reach through open areas in upright.

• Use a pry bar to align frame rails, do not use hands.

Failure to follow the warnings listed above can result in serious injury or death!

IMPORTANT! When servicing or replacing lift chains, always use the following guidelines: • Only use genuine CLARK replacement lift chains.

• Do not repair chains. If damaged or worn, replace.

• Do not weld on or near lift chains.

• If heat is used to remove, replace lift chains.

34-2-1

Inspection Interval: Every 500 hours or 3 months Lubrication Interval: Every 250 hours or monthly Chain Lubrication Type: CLARK Chain & Cable Lube CLARK Part Number: 886399

Lift Chain Inspection Perform a periodic inspection of the lift chains at least every 500 hours or 6 months. This should be done more frequently during extreme use or severe operating environment.

Fully raise and lower the operator's platform during inspection. Make sure to look for the following wear or damage: Chain Elongation

New (12" or 305 mm) Worn ( >12-3/8" or 315 mm) When a lift chain has been stretched by 3% or more of it's original length, then it is considered worn and must be replaced. Always replace lift chains in pairs.

To determine lift chain stretch, measure the pin centerto-pin center distance between a 12" (305 mm) section of chain. If the measured length is 12-3/8" (315 mm) or greater then the original length, replace the chain. Always measure the section of chain that moves over the sheaves, do not measure the chain near the terminating ends.

Group 34 Edge Wear

Tight Joints

H 5% of H

Check the chain for wear on the link plate edges caused by moving over the sheaves. The maximum amount of wear should not exceed 5% of the original height (H) of the link plate. Use the link plates that do not run over the sheaves to determine the original link plate height. Over worn and damaged link plates can cause tight joints, inhibiting chain flexibility.

Check the flexibility of the lift chains. Tight joints resist flexing and lead to increased friction of the joints. This accelerates wear and fatigue of the lift chains. Initially, attempt to lubricate a stiff joint to loosen the joint. If it is overly corroded or rusted, replace the lift chain.

Turned or Protruding Pins

The lift chain's joint, pin, and plate surfaces require a coating of chain lube or engine oil between all mating parts to prevent accelerated wear. Lubrication of the lift chains must be performed at least every 250 hours or 3 months, or more frequently depending upon usage and operating environment.

Normal

Turned

Lift Chain Lubrication

Regular care and lubrication of the lift chain(s) will: • Minimize joint wear • Improve corrosion resistance Check for pin rotation and pins that are twisting out of the frame. Lift chains that are operated with heavy loads and inadequate lubrication can develop this issue. Do not attempt to repair turned or protruding pins, replace lift chain immediately.

Cracked or Broken Plates

• Reduce the possibility of pin turning • Minimize tightened joints • Ensure smooth, quiet chain operation • Reduce internal friction of the chain To lubricate lift chains, perform the following: • Prepare the chain for lubrication: Use a stiff brush to clean the leaf chain plates. This allows the lubricant to penetrate to the bearing surfaces effectively.

• If using engine oil, apply using a narrow paint brush.

If using chain lube, spray onto chain until covered with lubricant. Chain should be well coated to ensure oil penetrates the joint.

Check for evidence of cracking or stress fracture of the link plates. If any cracks ares found, replace lift chain immediately. Cracks can be caused by overloading, cyclical fatigue, corrosion, and strength failures.

• For difficult to reach locations when applying engine oil, use a high quality pump pressure sprayer.

34-2-2

Group 34 Lift Chain Adjustment

Clevis Pin

Cotter Pin Clevis Pin

Ensure the gap between the rubber stops on the bottom of the operator's platform and the frame are within specification. Refer to Group 34, Section 1 in this manual.

7.

Check operation of the lifting mechanism, if the lift chain is still slack, repeat the adjustment procedure.

Upright Lift Chain Replacement Lift Chain Flat Washer

Cotter Pin

6.

Anchor Bolt

IMPORTANT! When replacing lift chains, always replace in pairs.

1.

Block the load wheels to prevent the vehicle from moving unexpectedly.

2.

Remove static load from the lift chains:

Cotter Pin Lift Chain

Flat Washer

Adjustment Nut

3.

Jam Nut

a.

Raise the inner upright approximately 3' (91.5 cm) or until lift chains are loosened.

b.

Install blocking or use an appropriate lifting device to support the upright.

Check that the upright is properly supported and the lift chains are loose before proceeding.

CAUTION

Possible injury or death due to heavy component.

Make certain that the upright is supported before servicing the lift chains.

Anchor Bolt

4.

Turn the vehicle OFF and disconnect the battery cable.

5.

Loosen and remove the jam nuts on the anchor bolts.

1.

Fully lower the operator's platform and relieve the hydraulic system pressure.

6.

Remove the cotter pin, flat washer, clevis pin, and anchor bolt from the inner upright.

2.

Decommission the vehicle.

7.

3.

Loosen the jam nut on the anchor bolt.

Remove the cotter pin, flat washer, clevis pin, and anchor bolt from the outer upright.

4.

Rotate the adjustment nut up the anchor bolt to tighten the lift chain. Rotate the adjusting nut down the anchor bolt to loosen the lift chain.

8.

Remove the lift chain from the sheave.

9.

Installation is the reverse order of removal.

5.

When the chain is no longer loose or slack, adjustment is complete. Do not overtighten the lift chain.

CAUTION

When lift chain adjustment is complete, a minimum of three (3) full threads must be visible below the jam nut to ensure the assembly is secure. If not enough threads are available, then replace the lift chains.

34-2-3

10. Repeat the procedure for the opposite side.

11. Adjust the lift chains. Refer to Group 34, Section 2 in this manual.

Group 34

B A

Sheave

Sheave

Upright Lift Chain

B A Outer Upright

Inner Upright

Frame

Middle Upright

Upright Lift Chain

34-2-4

Group 34

Operator's Platform Lift Chain

Inner Upright

Sheave

Sheave Operator's Platform Lift Chain

Primary Lift Cylinder

Operator's Platform Lift Chain Replacement CAUTION When replacing lift chains, always replace in pairs.

4.

Turn the vehicle OFF and disconnect the battery cable.

5.

Loosen and remove the jam nuts on the anchor bolts.

6.

Remove the cotter pin, flat washer, clevis pin, and anchor bolt from the operator's platform.

7.

Remove the cotter pin, flat washer, clevis pin, and anchor bolt from the inner upright.

1.

Block the load wheels to prevent the vehicle from moving unexpectedly.

8.

Remove the lift chain from the sheave.

2.

Remove static load from lift chains:

9.

Installation is the reverse order of removal.

a.

Raise the operator's platform until the lift chains are loosened.

10. Repeat the procedure for the opposite side.

b.

Install blocking or use an appropriate lifting device to support the upright.

3.

Check that the upright is properly supported and the lift chains are loose before proceeding.

34-2-5

11. Adjust the lift chains. Refer to Group 34, Section 2 in this manual.

Group 34

Group 34 Section 3 Cylinders Primary Lift Cylinder Replacement CAUTION Before servicing the vehicle, always perform the following decommissioning procedure: • Park vehicle on a firm, level surface.

• Press the emergency disconnect switch.

• Turn the key switch to OFF. • Disconnect the battery.

16

8 9 6

WARNING The upright and operator's platform can move unexpectedly. Always follow the service procedures described below: • Do not walk or stand under a raised platform.

• Keep hand away from moving parts of the upright.

• Install blocks or jack to support upright.

• Do not reach through open areas in upright.

• Use a pry bar to align frame rails, do not use hands.

10

14

13

Avoid serious injection injury from high-pressure fluid. Do not use hands to check for leaks. Relieve the hydraulic system pressure before performing any maintenance on the hydraulic system.

CAUTION Possible injury or death due to heavy component.

Make certain that the upright is supported before servicing the lift chains.

IMPORTANT! Hydraulic fluid can damage vehicle paint and pollute the environment. Be sure to collect used fluid and dispose of in an appropriate manner.

34-3-1

1 3 5

11

15

Failure to follow the warnings listed above can result in serious injury or death!

WARNING

2

4

7

12

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Component M12 Bolt Lock Washer Flat Washer Nylon Sheave Bushing Guard Bracket M12 Bolt Lock Washer Flat Washer Stop Bracket Roller Bracket Primary Cylinder M12 Bolt Lock Washer Flat Washer Inner Upright

Group 34 1.

Block the load wheels to prevent the vehicle from moving unexpectedly.

2.

Support the operator's platform and outer upright using an appropriate lifting device or blocking.

3.

Relieve the hydraulic system pressure by pressing the emergency lowering valve.

4.

Remove the operator's platform lift chains. Refer to Group 34, Section 2 in this manual.

5.

Remove the bolt (1), washers (2 and 3), sheave (4), and bushing (5) from the bracket (6).

6.

Remove the bolt (7), washers (8 and 9), and brackets (6, 10, and 11) from the primary cylinder (12).

OSQ 192 25

26 28

OSQ 126 / 162

17

22

27

Item 25 26 27 28

23 20 24 21 19

18

Item 17 18 19 20 21 22 23 24 7.

23

Component Hydraulic Hose Oil Pipe M8 Bolt Lock Washer Flat Washer Connector Fitting Sealing Washer Safety Valve

For OSQ 126/162 models only: a.

Disconnect the hydraulic hose (17) from the oil pipe (18).

b.

Remove the bolt (19), washers (20 and 21), and the oil pipe (18) from the connector fitting (22).

c.

Remove the connector fitting (22), sealing washers (23), and safety valve (24) from the primary cylinder (12).

8.

9.

Component Hydraulic Hose Oil Pipe Straight Fitting Safety Valve

For OSQ 192 models only: a.

Disconnect the hydraulic hose (25) from the oil pipe (26).

b.

Remove the oil pipe (26) from the straight fitting (27).

c.

Remove the straight fitting (27) and safety valve (28) from the primary cylinder (12).

Secure the primary cylinder (12) to prevent it from falling or moving unexpectedly when removing fasteners.

10. Remove the bolts (13) and washers (14 and 15) securing the primary cylinder (12) to the inner upright (16).

11. Remove the primary cylinder (12).

12. Installation of the primary cylinder (12) is the reverse order of assembly.

13. Install the operator's platform lift chains. Refer to Group 34, Section 2 in this manual.

14. Adjust the lift chains. Refer to Group 34, Section 2 in this manual.

34-3-2

Group 34 15. Fill hydraulic reservoir using CLARK specification hydraulic fluid. Refer to Group 29, Section 1 in this manual.

Item 8 9 10 11 12 13 14 15 16 17 18 19 20 21

16. Operate the lift and lower functions to purge any air from the system and to check for proper hydraulic function.

17. Check proper hydraulic fluid level and for any leaks before returning the vehicle back into service.

Primary Lift Cylinder Overhaul 1 2 3 4

10

Component Bleed Screw Cylinder Barrel Piston Rod Wear Ring Piston Piston Ring Retainer Guide Piston Seal Check Valve O-ring Check Valve Spring Retainer Seal Washer

5

IMPORTANT!

6

Perform any lift cylinder maintenance in a clean environment to prevent hydraulic system contamination.

IMPORTANT!

11 7 12 13

• If the piston rod or cylinder barrel is damaged, replace the entire cylinder.

• Replace all seals and O-rings when disassembling, a seal kit is available.

8 14 15 16 18

9

20

Item 1 2 3 4 5 6 7

34-3-3

17 19 21

Component Wiper Seal Packing Cylinder Cap O-ring O-ring Bleeder Seal

NOTE During reassembly of lift cylinders, use a CLARK recommended hydraulic fluid (as specified in this manual) when cleaning or lubricating cylinder components.

1.

Secure the lift cylinder in a vise, clamping lightly at the base of the cylinder. DO NOT overtighten!

2.

Remove the cylinder cap (4) using an appropriate cylinder wrench.

3.

Remove the wiper (1), seal (2), packing (3), and O-rings (5 and 6) from the cylinder cap (4).

4.

Remove the piston rod (10) assembly from the cylinder barrel (9).

5.

Remove the piston ring (13) from the piston rod (10).

6.

Disassembly the piston rod (10) assembly including components (11-12 and 14-21). Replace all seals and any damaged or faulty components.

Group 34 7.

Apply hydraulic fluid to all new components and seals before reassembling the cylinder.

1.

Block the load wheels to prevent the vehicle from moving unexpectedly.

8.

Reassembly is the reverse order of disassembly procedure.

2.

Support the operator's platform and middle upright using an appropriate lifting device or blocking.

3.

Relieve the hydraulic system pressure by pressing the emergency lowering valve.

4.

Remove the operator's platform lift chains. Refer to Group 34, Section 2 in this manual.

5.

Disconnect the oil pipe (1 or 2) from the straight fitting (3 or 4) in the lower port of the secondary cylinder (5 or 6) to be removed.

6.

Remove the straight fitting (3) and sealing washer (7) from secondary cylinder (5) or remove the straight fitting (4), sealing washers (8 and 9), safety valve (10), and relief valve (11) from the secondary cylinder (6).

Secondary Lift Cylinder Replacement

5

6

3

7 1

11

8

2

Item 1 2 3 4 5 6 7 8 9 10 11

10

9

4

Component Oil Pipe Oil Pipe Straight Fitting Straight Fitting Secondary Cylinder (LH) Secondary Cylinder (RH) Sealing Washer Sealing Washer Sealing Washer Safety Valve Relief Valve

34-3-4

Group 34 11. Install the operator's platform lift chains. Refer to Group 34, Section 2 in this manual.

12 13 14

12. Adjust the lift chains. Refer to Group 34, Section 2 in this manual.

13. Fill hydraulic reservoir using CLARK specification hydraulic fluid. Refer to Group 29, Section 1 in this manual.

14. Operate the lift and lower functions to purge any air from the system and to check for proper hydraulic function.

A A

15. Check proper hydraulic fluid level and for any leaks before returning the vehicle back into service.

Secondary Lift Cylinder Overhaul 1 2 15 3 4 5

10 6 Frame

Item 12 13 14 15

Component M10 Bolt Lock Washer Flat Washer Middle Upright

7.

Secure the secondary cylinder (5 or 6) to prevent it from falling or moving unexpectedly when removing fasteners.

8.

Remove the bolt (12) and washers (13 and 14) securing the secondary cylinder (5 or 6) to the middle upright (15).

9.

Remove the secondary cylinder (5 or 6).

10. Installation of the secondary cylinder (5 or 6) is the reverse order of assembly.

34-3-5

11

7

12 13 8

9

Group 34 Item 1 2 3 4 5 6 7 8 9 10 11 12 13

Component Wiper Packing Cylinder Cap O-ring O-ring Bleeder Seal Bleed Screw Cylinder Barrel M8x30 Bolt Piston Rod Bushing Lock Ring Piston Ring

6.

Replace all seals and any damaged or faulty components.

7.

Apply hydraulic fluid to all new components and seals before reassembling the cylinder.

8.

Reassembly is the reverse order of disassembly procedure.

IMPORTANT! Perform any lift cylinder maintenance in a clean environment to prevent hydraulic system contamination.

IMPORTANT! If the piston rod or cylinder barrel is damaged, replace the entire cylinder.

Replace all seals and O-rings when disassembling, a seal kit is available.

NOTE During reassembly of lift cylinders, use a CLARK recommended hydraulic fluid (as specified in this manual) when cleaning or lubricating cylinder components.

1.

Secure the lift cylinder in a vise, clamping lightly at the base of the cylinder. DO NOT overtighten!

2.

Remove the cylinder cap (3) using an appropriate cylinder wrench.

3.

Remove the wiper (1), packing (2), and O-rings (4and 5) from the cylinder cap (3).

4.

Remove the piston rod (10) assembly from the cylinder barrel (8).

5.

Remove the lock ring (12), bushing (11), and piston ring (13) from the piston rod (10).

34-3-6

Group 40

Group 40 Specifications

Height, Weight, and Speed Specifications................ Section 1 Decal Locations...........................................................Section 2

Group 40 Section 1 Height, Weight, and Speed Specifications

20.5"

E C

D

A

42.6"

B 30.7"

G

F

13.6"

H

40-1-1

21.4"

26"

Group 40 Load Collapsed Extended Work Tray Chassis Height Height Height Height Height Weight Lift

A

B

C

D

E

126"

62.6"

178.6"

159"

203"

2268 lb

162"

82"

236"

195"

239"

2610 lb

192"

83"

264"

225"

269"

3160 lb

Wheel-to-Wheel Vehicle Vehicle Minimum Turning Distance Width Length Turn Aisle Radius Width F

G

H

45.2"

59"

31.5"

52.5"

72"

45.2"

59"

31.5"

52.5"

72"

49"

63.3"

34"

56"

72"

OSQ 126

OSQ 162

OSQ 192

Maximum Travel Speed (Optional)

5.0 mph (8.0 km/h)

5.0 mph (8.0 km/h)

5.0 mph (8.0 km/h)

< 24"

< 24"

< 24"

Maximum Travel Speed (Standard)

3.4 mph (5.5 km/h)

3.4 mph (5.5 km/h)

3.4 mph (5.5 km/h)

< 24"

< 24"

< 24"

2.3 mph (3.7 km/h)

2.3 mph (3.7 km/h)

2.3 mph (3.7 km/h)

24" – 76"

24" – 76"

24" – 76"

1.5 mph (2.5 km/h)

1.5 mph (2.5 km/h)

1.5 mph (2.5 km/h)

76" – 102"

76" – 102"

76" – 102"

0.6 mph (1 km/h)

0.6 mph (1 km/h)

0.6 mph (1 km/h)

102" – 126"

102" – 162"

102" – 192"

126"

162"

192"

Speed Cutback #1 Speed Cutback #2 Speed Cutback #3 Cutout Height

40-1-2

Group 40 Section 2 Decal Locations

40-2-1

Group 40

700 Enterprise Drive Lexington KY 40510 © CLARK Material Handling Company 2020