Clark Forklift PMA-510 ECAEPA Planned Maintenance and Adjustment Manual

PMA-510 ECA/E

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

CONTENTS 1 2 4 5 6

TRUCK MODEL ILLUSTRATIONS SUBJECT/PICTORIAL INDEX SAFETY INFORMATION FOREWORD PM- PLANNED MAINTENANCE PROGRAM

GROUP SECT. PMA - PLANNED MAINTENANCE ADJUSTMENT PROCEDURES PM REPORT FORM LUBRICATION CHARTS 01 1 SEAT CONTROL ROD ADJUSTMENT 02 1 DIRECTIONAL CONTROL LEVER ADJUSTMENT 06 1 HORN AND STEERING HANDWHEEL ADJUSTMENT 06 2 ELECTRIC TRUCK BATTERY MAINTENANCE 12 1 ELECTRIC TRUCK BATTERY STANDARD U.L. 583 12 2 ELECTRIC MOTOR MAINTENANCE 16 1 DRIVE MOTOR BRUSH REPLACEMENT - GE 16 2 DRIVE MOTOR BRUSH REPLACEMENT - PRESTOLITE 16 3 EV-1 #l CARD INITIAL ADJUSTMENT SETTINGS 19 3 PUMP AND TRACTION CONTROL LED CHECK 19 4 DRIVE UNIT MAINTENANCE 20 1 PNEUMATIC TIRE AND WHEEL MAINTENANCE 22 1 PARKING BRAKE RELEASE 23 1 BRAKE BLEEDING PROCEDURE 23 3 STEER WHEEL BEARING MAINTENANCE 26 2 POWER STEERING RELIEF PRESSURE CHECK 26 3 HYDRAULIC SUMP FLUID AND FILTER CHANGE 29 1 HYDRAULIC SYSTEM RELIEF PRESSURE CHECK AND ADJUSTMENT 30 1 HYDRAULIC SYSTEM SCHEMATIC DIAGRAM 31 1 TILT CYLINDER ADJUSTMENT 32 1 TILT CYLINDER DRIFT TEST 32 2 UPRIGHT LIFT CHAIN CHECK AND ADJUSTMENT 34 1 34 3 UPRIGHT DOWNDRIFT TEST FORK WEAR INSPECTION 34 4 LIFT CHAIN MAINTENANCE 34 7 -REFERENCE 40 1 40 2 40 3 40 4 40 5 40 17 40 18

Page i

INFORMATION

TRUCK DATA PLATES AND DECALS SUGGESTED EQUIPMENT FOR ELECTRIC TRUCK P.M. FIRE EXTINGUISHER RECOMMENDATIONS LUBRICANT SPECIFICATIONS AND RECOMMENDATIONS TRUCK SPECIFICATIONS MEASURING VOLTAGES WITH THE V-O-M MEASURING RESISTANCE WITH THE V-O-M WIRING DIAGRAM - TRUCK ELECTRICAL SYSTEM

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PM-510, REV FEB 84

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

OWNER

SAFE

MAINTENANCE

Powered industrial trucks may become hazardous if adequate maintenance is not done. Therefore, maintenance facilities, personnel and procedures must be provided.

Maintenance and inspection of all powered industrial trucks should be done in agreement with the recommendation in this manual and the following practices.

1.

Only qualified and authorized personnel should be permitted to maintain, repair, adjust, and inspect industrial trucks.

3.

Before Leaving The Truck: Stop Truck.

B.

Fully lower the load engaging means.

C.

Put blocks under the load engaging means, inner-mast(s), or chassis before working under them.

Before working on engine fuel system of LP gas powered trucks, close LP gas cylinder valve and run engine until there is no more fuel in the system and engine stops running.

5.

Put directional controls in neutral.

Before Starting To Operate The Truck: A.

Be in operating position.

B.

Push clutch (or brake pedal on automatic transmission and electric trucks).

D.

Apply the parking brake.

E.

Stop the engine or turn off power.

C.

Put the directional controls in neutral.

Lock the control or ignition circuit.

D.

Start engine or turn on power.

E.

Before operating truck, check functioning of lift and tilt systems, directional and speed controls, steering, warning devices, brakes, and any attachment.

(If used)

F.

Release parking brake.

F.

G.

4.

Use blocks or other positive truck positioning devices.

Operation to check performance of the truck or attachments must be done in a clear, authorized, safe area.

A.

C.

B.

Before working on engine fuel system of gasoline powered trucks with gravity feed fuel systems, make sure fuel shutoff valve is closed.

A scheduled preventive maintenance, lubrication, and inspection system must be followed.

2.

PRACTICES

Put blocks at the wheels if truck is on a ramp, or being worked on.

Before Working On Truck: A.

Raise wheels free of floor or disconnect power source.

- continued Copyrighted Material

1023-Z REV dealers SEP only 83 (FRONT) Intended for CLARK Do not sell or distribute

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

OWNER

SAFE

MAINTENANCE

6.

Avoid fire hazards and have fire protection equipment available.

Do not use an open flame to check level, or for leakage, of fuel, electrolyte or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.

7.

Provide ventilation to the work area, vent exhaust fumes, and keep shop clean and floor dry.

8.

9.

Handle LP gas cylinders with care.

Do not drop, dent, or damage in any way.

Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, lift overload devices, guards and safety devices must be inspected regularly and maintained in a safe operating condition.

10. All parts of lift and tilt mechanisms and frame members must be carefully and regularly inspected and maintained in a safe operating condition.

11. Special trucks or devices designed and approved for hazardous area operation must receive special attention to make sure that maintenance keeps the original, approved safe operating features.

12. Fuel systems must be checked for leaks and condition of parts.

Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected.

PRACTICES

(CONT.)

13. All hydraulic systems must be regularly inspected and maintained in conformance with good practice.

Tilt cylinders, valves, and other like parts must be checked to make sure that "drift" has not developed to the extent that it would create a hazard.

14. Capacity, operation and maintenance instructions plates, tags, or decals must be maintained in legible condition.

15. 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.

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

17. Modifications and additions which affect capacity and safe truck operation must not be done by the customer or user without manufacturers prior written approval. Capacity, operation and maintenance instruction plates, tags or decals must be changed accordingly.

18. Care must be taken to make sure that all replacement parts are interchangeable with the original parts and of a quality equal to that provided in the original equipment.

Copyrighted Material Intended for CLARK dealers only 1023-z REV 83 (BACK) Do notSEP sell or distribute

PM

CA 17,20,22,25,27,30

A 20,22,25,27,3

PM-510, DEC 80

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Page 1

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

SUBJECT INDEX

Symbol -Refer 12 11 2 : : 3 1: 10 7 7 9 1; 10 4 5 : 11 6 8 8 9 1

to Pictorial Index

Find in

GROUP Section

BRAKE BLEEDING PROCEDURE DIRECTIONAL CONTROL LEVER ADJUSTMENT DRIVE MOTOR BRUSH REPLACEMENT - GE DRIVE MOTOR BRUSH REPLACEMENT - PRESTOLITE DRIVE UNIT MAINTENANCE ELECTRIC TRUCK BATTERY MAINTENANCE ELECTRIC MOTOR MAINTENANCE EV-1 #l CARD INITIAL SETTINGS FIRE EXTINGUISHER RECOMMENDATIONS FORK WEAR INSPECTION HORN AND STEERING HANDWHEEL ADJUSTMENT HYDRAULIC SUMP FLUID AND FILTER CHANGE HYDRAULIC SYSTEM RELIEF PRESSURE CHECK & ADJUSTMENT HYDRAULIC SYSTEM SCHEMATIC DIAGRAM LIFT CHAIN CHECK AND ADJUSTMENT LIFT CHAIN MAINTENANCE LUBRICATION CHARTS LUBRICANT SPECIFICATIONS AND RECOMMENDATIONS MEASURING VOLTAGE WITH THE V-O-M MEASURING RESISTANCE WITH THE V-O-M' PARKING BRAKE RELEASE PNEUMATIC TIRE AND WHEEL MAINTENANCE PM REPORT FORMS (See following page 42) POWER STEERING RELIEF PRESSURE CHECK PUMP AND TRACTION CONTROL LED CHECK SEAT CONTROL ROD ADJUSTMENT STEER WHEEL BEARING MAINTENANCE SUGGESTED EQUIPMENT FOR ELECTRIC TRUCK PM TILT CYLINDER ADJUSTMENT TILT CYLINDER DRIFT TEST TRUCK DATA PLATES AND DECALS TRUCK SPECIFICATIONS UPRIGHT DOWNDRIFT TEST UL-583 STANDARD FOR ELECTRIC TRUCK BATTERIES WIRING DIAGRAM - TRUCK ELECTRICAL SYSTEM * * (See at back of manual) PM - PLANNED MAINTENANCE PROGRAM ............

Visual Inspection ..................

Operational Checks .................

Battery Removal ...................

Air Cleaning Drive Unit Flui; ie;ei Chick . 1 1 1 : 1 1 1 1 1 1 1 1 Hydraulic Sump Fluid Level Check ..........

Check Torque of Critical Fasteners .........

Electrical Tests ..................

Page 2

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23 3 06 1 16 2 16 3 20 1 12 1 16 1 19 3 40 3 34 4 06 2 29 1 30 1 31 1 34 1 34 7 01 1 40 4 40 17 40 18 23 1 22 1 26 19 02 26 40 32 32 40 40 34 12

3 4 1 2 2 1 2 1 5 3 2

Page 6 6 13 23 26 30 34 37 41

Code: PM-510, REV FEB 84

PM

CLSRK

PICTORIAL INDEX

PM-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Page 3

INDUSTRIAL

TRUCK DIVISION

CUSTOMER SERVICES GROUP

lX!E FOLLOWLNG IS A LIST OF ‘CAUTIONS CONNECTED WITH THE OPERATION AND MAlNTmAhKE OF TRUCKS EQUIPPED WlTH SOLID SlYATE CONTROL.

WELDING ON TRUCKS 1. ::

Make sure truck has no grounds.

Disconnect truck battery.

Protect electrical wiring and components If the trical

above is not followed components on a solid

from

. . . damage can state controlled

weld

splatter

with

result to wiring truck.

shield.

and

elec-

DO NOT STEAM CLEAN Do not steam clean a solid state interfere with proper operation

controlled of the solid

truck state

as excessive components.

moisture

will

CHECK POLARITY Battery

Polarity

must

be correct

or

the

truck

wi 11 not

operate.

USE THE TRUCK BATTERY ONLY Do not use this truck

a motor generator as serious damage

unit such as may occur.

i

1 ONLY

APPROVED

1 SHOULD DISCONNECT BATTERY BEFORE HANDLING ELECTRICAL COMPONENTS

1

4

move and/or

check

f

...

USE

00

DEGREASER,

OR THE

EQUIV4LENT

I

MS-180

FREON

;

AND 1-----m----m

to

TO CLEAN

I

L

Page

BE L--J p1801146

power

SOLVENTS

SCR COMPONENTS CLARK

POLARITY MUST BE CORRECT TO PREVENT DAMAGE

ready

TF

NOT

CLEAN

COMPONENTS

TO . . .

I

DEGREASER

OR

ELECTRICAL

WITH

SOLVENT

STEAM

1

CLEANER.

J

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

II

PM-510: DEC 80

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

SAFETY

MESSAGES

PLEASE READ AND UNDERSTAND THE SAFETY MESSAGES SHOWN BELOW BEFORE YOU DO ANY WORK ON A LIFT TRUCK

LIFT DO NOT OPERATE A LIFT TRUCK WITH DAMAGED OR LOST DECALS AND NAMEPLATES. REPLACE THEM IMMEDIATELY. THEY CONTAIN IMPORTANT INFORMATION.

PERSONAL

TRUCK

M

DO NOT WORK ON THIS TRUCK UNLESS YOU ARE TRAINED AND AUTHORIZED AND KNOW THE CORRECT MAINTENANCE PROCEDURES.

INJURY

AIR PRESSURE

WEAR EYE GLASSES, SAFETY SHOES AND CORRECT FITTING CLOTHING WHEN WORKING ON LIFT TRUCKS. INJURY CAN RESULT IF YOU DO NOT WEAR PROTECTION.

I

DO NOT WALK OR STAND UNDER RAISED FORKS. THE FORKS CAN FALL AND CAUSE INJURY OR DEATH.

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WEAR EYE PROTECTION & PROTECTIVE CLOTHING WHEN CLEANING OR DRYING WITH AIR PRESSURE. REDUCE PRESSURE TO [207 kPa] 30 PSI. DEBRIS REMOVED WITH AIR PRESSURE CAN CAUSE INJURY.

DO NOT USE YOUR HANDS TO CHECK FOR HYDRAULIC LEAKAGE. FLUID UNDER PRESSURE CAN PENETRATE YOUR SKIN AND CAUSE SERIOUS INJURY.

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

SAFETY

MESSAGES

PLEASE READ AND UNDERSTAND THE SAFETY MESSAGES SHOWN BELOW BEFORE YOU DO ANY WORK ON A LIFT TRUCK

ELECTRICAL DISCONNECT THE BATTERY AND DISCHARGE THE CAPACITOR BEFORE HANDLING SOLID STATE COMPONENTS. INJURY CAN RESULT FROM AN ELECTRICAL SHOCK.

EXPLOSIVE

GASES

DISCONNECT THE BATTERY BEFORE YOU REMOVE THIS PART FROM THE TRUCK. SEVERE BURNS CAN RESULT' FROM CONTACT WITH ELECTRICAL SYSTEMS.

I

SULFURIC

ACID

THE BATTERY CONTAINS CORROSIVE ACID WHICH CAN CAUSE INJURY. IF ACID CONTACTS YOUR EYES OR SKIN, FLUSH IMMEDIATELY WITH WATER AND GET MEDICAL ASSISTANCE.

SMOKE OR HAVE OPEN FLAMES OR SPARKS IN BATTERY CHARGING AREAS OR NEAR BATTERIES.AN EXPLOSION CAN RESULT AND CAUSE INJURY OR DEATH,

BATTERY

BURNS

SERVICE USE AN ADEQUATE LOCKING DEVICE TO HOLD SPRINGS IN COMPRESSED POSITION. EYE OR BODILY INJURY CAN RESULT FROM FLYING SPRINGS.

BATTERY SERVICE MUST BE DONE

BY TRAINED PERSONNEL. BATTERY ACID CAN CAUSE SEVERE BURNS AND INJURY. I

Copyrighted Material Intended for CLARK dealers only 1316-ZDo not FEB sell or84distribute

I

PM

INTRODUCTION Clark Equipment Company welcomes you to the growing group of professional people who own, operate and maintain Clark lift trucks. We take great pride in the long tradition of quality products and superior value that the Clark name represents.

This manual has been written to help you maintain your Clark lift truck in an efficient and safe operating condition.

Regular maintenance and care of your lift truck is not only important for economy and utilization reasons, it is essential for your safety. A faulty lift truck is a potential source of danger to the operator, and to other personnel working near it.

Operator Inspection Lift trucks should be inspected daily by the operator, or at the start of each shift. Complete the Operator's Daily Checklist carefully. Be sure that all Use the daily inspection safety items are checked and in good operating condition. sheet as a check list and a record for your findings. This form is illustrated in the Operator's Manual located on the truck.

Planned Maintenance Program In addition to the daily operator inspection, Clark recommends that a planned maintenance and safety inspection program be performed on a regular basis.

The program will provide an opportunity to make a thorough inspection of the safety and operating condition of your lift truck. Necessary adjustments and repairs can be done during the PM which will increase the life of components and reduce unscheduled downtime. The PM can be scheduled to meet your particular application and lift truck usage.

This manual outlines the procedures with instructions for a periodic planned maintenance program which covers inspections, operational checks, cleaning, lubrication and minor adjustments. Also shown is the PM report form which can be obtained from your local Clark dealer. They are prepared to help you with a Planned Maintenance Program with trained service personnel who know your lift truck and can keep it operating safely and efficiently.

PM-510, REV FEB 84

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Page 5

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

PM

-

PLANNED

MAINTENANCE

PROGRAM

P.M. CHECK SHEET SPECIAL CODING SYSTEM -- as the P.M. is performed, a check is made on the check sheet to indicate (1) if a component or truck system is O.K., (2) a potential problem or (3) needs urgent repair.

Whenever a system or component is faulty or unsafe, it must be noted on the P.M. check sheet. And, it must be reported to the designated authority at the conclusion of the P.M.

Fig. 12618

WHAT SHOULD A COMPLETE ELECTRIC TRUCK P.M. INCLUDE? The best answer is to go through a P.M. based on the knowledge and experience of the P.M. men, service managers, engineers, Customer Services Engineering personnel, and Training Department.

Fig. 12619 REMOVE ALL JEWELRY BEFORE examining electrical components.

Disconnect battery from truck.

Fig. 12704

Visual

Inspection

Check for OIL LEAKS. Make sure a quick overall inspection for oil leaks is If oil leaks are found (at this made. time, or later in the P.M.), correct the minor leaks and report other leakage as major repairs on the P.M. check sheet. tIORTANT

1

Check all DECALS AND NAMEPLATES. Make sure none are missing.

Page 6

Fig. 22150

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PM-510, REV FEB 84

PM

Inspect BATTERY COVER. Any damage should be noted on the P.M. check sheet. Make sure that the battery cover operates freely and latches securely when closed.

Fig. 22151 Inspect OVERHEAD GUARD for damage.

Make sure there are no missing bolts and make certain the mounting bolts are secure. See Page 39 for tightening instructions.

Fig. 22152 Examine the LOAD BACKREST EXTENSION. Be sure all bolts are in place and tight. Make a report of any damage on the P.M. check sheet.

Fig'. 22164 Check UPRIGHT LIFT CHAINS for equal Inspect CARRIAGE AND RAIL tension.

LIFT CHAIN CONDITION. Refer to GROUP 34, Section 7 for Lift Chain maintenance.

Fig. 22153

PM-510, REV FEB 84

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Page 7

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Check CARRIAGE CHAIN ADJUSTMENT. Check roller tracing patterns on the rails. Approximately l/2 - 3/4 inch of unused rail indicates correct chain adjustment.

If patterns are not correct, adjust the carriage chains.

Refer to GROUP 34, Section 1, Upright Lift Chain Check and Adjustment Procedure.

Fig. 17643 Inspect LIFT CHAIN ANCHORS at both ends of chain. Be sure both nuts, for each chain anchor are in place. Be sure there is a cotter key located in the end of each anchor.

Fig. 22225 Check all LIFT LINE HYDRAULIC CONNECTIONS for leaks. If necessary, raise the carriage for access to the fittings.

BE SURE TO PLACE BLOCKING UNDER THE CARRIAGE AND UPRIGHT RAILS. See Fig. 22154, Page 9.

DO NOT WALK OR STAND UNDER RAISED FORKS. THE FORKS CAN FALL AND CAUSE INJURY OR DEATH.

84M253

Check LIFT CYLINDER RETAINING BOLTS to be sure they are in place and tight.

Refer to GROUP 40, Section 5 for torque specification.

Note: When carriage is raised and blocked, the oil level in drive axle may also be checked. Refer to Page 30 and 31.

Fig. 22155

Page 8

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PM-510, REV FEB 84

PM

Inspect the entire upright assembly.

Be sure all safety guards are in place and not damaged. Also that all chain retainers are in place. Check to see that carriage stops are in place, and the top cylinder bolt is in place.

Check all welded connections.

Fig. 22156 If carriage was blocked up for previous inspections, raise carriage slightly and remove the blocking. Lower the carriage.

FALLING

FORKS

DO NOT WALK OR STAND UNDER RAISED FORKS. THE FORKS CAN FALL AND CAUSE INJURY OR DEATH.

Fig. 22154 INSPECT THE LIFT FORKS: Shown here are new forks. Push forks together, as shown and check for the following.

Forks should rest l/4-inch off the floor.

Fig. I8046

PM-510, REV FEB 84

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Page 9

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Inspect LIFT FORKS for cracks, breaks, bending and excessive wear. Neither fork tip should be more than l/4 of an inch higher than the other. Check the amount of wear at the heel of the forks.

Refer to Group 34, Section 4, Fork Wear Inspection.

Fig. 17796 Inspect FORK LATCHES. The latches are spring loaded. Be certain they are not broken or damaged.

Fig. 18132 Check FORK LATCHES to be sure they operate freely and lock properly.

Fig. 17795

Check fork stop pins for security of mounting.

Fig. 19507

Page 10

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PM-510, REV FEB 84

PM

Check condition of DRIVE AND STEER TIRES. Remove objects from the tire tread. Check tires for excessive wear and chunking. Also, check the air pressure in pneumatic tires. See GROUP 40, Section 5 for specifications.

Fig. 12917 Make sure the DIRECTIONAL CONTROL LEVER is mounted securely, and operates freely. Check that the lever positively stays or "holds" in each position (park, forward, and reverse).

Report any malfunction.

Do not attempt to operate the truck until repair has been made. Refer to Group 06, Section 1 for adjustment of directional control lever.

Fig. 22158 Check the HYDRAULIC CONTROL LEVERS for freedom of operation and securitv of mounting.

Make sure that valve iever knobs are attached securely to the lever and screws are tight. Refer to Group 40, Section 5 for torque specifications.

Fig. 22159

PM-510, REV FEB 84

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Page 11

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Inspect condition of the BATTERY CONNECTOR. Check the spring-loaded terminal and retaining tab for poor connection due to burning, bad crimp, or loose or broken retainer.

Check the molded body for damage from overheating, burning and chips or cracks.

Inspect the SPRING LOADED CONNECTORS in the Truck Battery Receptacle.

Look for looseness, burned parts and other damaged areas due to excessive heat.

Refer to checks noted above.

If any of the above conditions are evident, replace the connectors.

Connect the battery to the truck.

Page 12

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PM-510, REV FEB 84

PM

Operational

Checks

Check PARKING BRAKE operation:

1.

Put the truck on a level surface and block the wheels.

Fig. 22160 2.

Put directional control lever in the "NEUTRAL" position and get off the truck.

3.

Turn key switch to the "ON" position, and push the seat down.

You should hear the hydraulic pump motor start operating.

Fig. 22161 4.

At the left front side of the truck under the cowl, watch the operation of the parking brake piston rod.

It should release the parking brake by moving the piston rod out of the cylinder (towards the front of truck).

Fig. 22162

PM-510, REV FEB 84

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Page 13

PM

5.

Now place the directional control lever into the "PARK" position, or let up on the seat.

Fig. 22163 6.

_’

The hydraulic pump motor should stop operating and the parking brake should apply as the piston rod of the parking brake cylinder moves towards the rear of truck.

Fig. 22162

Check operation of RETURN-TO-NEUTRAL: 1.

Get into the driver's seat and turn key switch to "ON" position.

Fig. 22161

Page 14

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PM-510, REV FE9 84

PM

2.

Place directional control lever in "NEUTRAL". Hydraulic pump motor should operate.

3.

Move directional control lever to the "FORWARD" position.

Fig. 22167

4.

Get off of the seat. The directional lever should automatically return to neutral position, and the hydraulic pump motor should stop operating.

5.

Repeat test with directional control lever in the "REVERSE" position.

Report any malfunction of the control lever or seat action. Refer to GROUP 02, Section 1 for return-toneutral adjustment procedure.

Fig. 22168

Get into the driver's seat. Check SEAT MOUNTING and SEAT ADJUSTER for proper forward and back operation and positive locking in place.

Fig. 22170 Check the operation of the spring-operated seat release.

It should release the seat when pushed by hand and return to its original position.

Fig. 22169

PM-510, REV FEB 84

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Page 15

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

operation of the TILT STEERING COLUMN LATCH. Pull up on column release latch operating handle.

The steering column can then be adjusted to any of five positions. The latch should hold securely in all positions.

Fig. 22171 Check SERVICE BRAKE SYSTEM. Push down on the brake pedal. The pedal should feel firm. It must not feel spongy or drift when pushed. If such a condition exists, report it to the designated authority for repairs. Refer to Overhaul Manual OH-510, GROUP 20, Section 13 for drive axle overhaul.

Also see OH-510, GROUP 23, Section 26 for master cylinder overhaul. Refer to GROUP 23, Section 3 for brake bleeding procedure.

Fig. 17592

Check PUMP MOTOR operation: While in the driver's seat, or with seat held down, put directional control lever in "NEUTRAL". Turn key switch "ON" and check hydraulic pump motor The pump motor should operation. operate in the "FORWARD", "NEUTRAL" and "REVERSE" positions; and it should stop operating when directional lever is placed in the "PARK" position.

Fig. 22161 Check the BATTERY DISCHARGE INDICATOR. It should register in the green when the key switch is in the "ON" position.

If not, note condition on the P.M. check sheet.

Also check that the HOUR METER is operating. Sit in the seat, turn key switch to the "ON" position. The indicator in the far right hand dial opening should be moving.

Fig. 22172

Page 16

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PM-510, REV FEB 84

PM

Check the operation of the INDICATOR LIGHTS in the instrument panel.

Turn key switch all the way to the right ("TEST" position).

The lights should al 1 illuminate with the key switch in the "TEST" position.

Drive Motor *ABrush Wear Indicator B - Control Temperature Pump Motor *cBrush Wear Indicator D - Control Temperature * Brush wear indicator lights are optional equipment.

’

A

B

r

1tfil

pq

pq

c

D 1

.1irf? p@j

ppq

Fig. 22173

Check HORN operation. The horn should operate at all times that a properly charged battery is connected at the truck receptacle.

If horn does not operate, or if a rubbing noise or squeaking is heard when turning steering handwheel, adjustment of the clearance between handwheel hub and shift quadrant may be required.

Refer to GROUP 06, Section 2 for horn and steering wheel adjustment.

Check PUMP MOTOR SPEED operation: With key switch still on, move the tilt lever in either "FORWARD" tilt or "BACK" tilt position.

Pump motor will sound slightly different in "FORWARD" tilt than in "BACK" tilt.

Fig. 22161 Move the lift lever to the "RAISE" position. You should be able to hear a definite increase in pump motor speed.

Fig. 22159

PM-510, REV FEB 84

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Page 17

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Check the BRAKE LIMIT (DRIVE MOTOR SHUT-OFF) SWITCH: Move truck forward in CREEP SPEED.

Fig. 22175 Depress the brake pedal while holding the accelerator in creep speed. The braking action should interrupt power to the motor and stop the truck. Upon release of the brake pedal the truck should move forward.

Fig. 14175

Check the POWER STEERING SYSTEM while driving forward in creep speed.

Make a full turn to the right. for unusual steering noise.

Listen

Fig. 22176 Now, make a full turn to the left.

Again listen for unusual steering noise.

NOTE You will hear the power steering operate over relief while making a full cramp turn in either direction.

Fig. 22177

Page 18

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PM-510, REV FEB 84

NOTE Refer to Book No. 59-854-0005, System Diagnosis SCR Controls, ECA/EPA 17 thru 30, for instructions on operation and troubleshooting of GE Model EV-1 solid-state controls.

Refer to GROUP 40, Section 5 for Electrical Test Specifications.

Check CREEP SPEED, ACCELERATION, AND TOP TRAVEL SPEED for the following See next page for additional testing procedures. conditions.

1.

CREEP SPEED should be obtained as the 1MS switch just closes.

2.

ACCELERATION: Truck should adequately accelerate in the SCR RANGE so that a smooth transition from SCR to 1A RANGE can be obtained.

As the 1A contactor closes (providing direct battery current to the drive motor), there should be very little surge as the truck goes out of the SCR range and into 1A. 3.

FIELD WEAKENING is standard equipment for truck applications where more speed is desired than available with the motor directly across the battery (with 1A contactor closed). There should be very little surge as the truck goes out of 1A into the field weakening mode.

Check REVERSE CREEP SPEED Check ACCELERATION Check TOP TRAVEL SPEED Drive truck in "REVERSE" in a straight line of travel. Listen for unusual drive train noise.

STOP TRUCK with the service brakes.

Note any unusual reaction in braking performance or adjustment.

Refer to GROUP 20, Section 1 for Brake Disc Wear Check. Refer to GROUP 23, Section 3 for Brake Bleeding Procedure.

Fig. 22178

PM-510, REV FEB 84

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Page 19

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

CREEP SPEED Check ACCELERATION Check TOP SPEED Drive truck line of drive train

"FORWARD" in Listen for

straight

Stop truck the service Note unusual reaction in braking adjustment.

Refer GROUP 20, 1 Brake Disc GROUP 23, 3 Check. Refer Brake Bleeding Procedure.

Check REGENERATIVE BRAKING

,4

__ ,_ ,”

Fig. 22175

VARIABLE PLUGGING.

During the check normal operation the service brakes, and also check Variable Plugging. 'Variable means that accelerator position determines plugging distance.

Variable Plugging is checked in both directions.

It is a combination of regenerative braking and plugging. These two functions are inter-related and must be adjusted at the same time.

Drive at a SLOW SPEED in reverse and then move the directional lever into forward position while your foot is still depressing the accelerator pedal. The truck should slow to a smooth controllable stop and accelerate in the opposite direction.

If it does not, refer to Card Adjustments in GROUP 19, Section 3 and reset regenerative braking and plugging trimpots.* Check Variable Plugging at slow speed forward, high speed reverse, and high speed forward. * Regenerative braking trimpot is labeled C/L. Refer to Book No. 59-854-Q005, System Diagnosis SCR Controls, ECA/EPA 17 thru 30, for instructions on operation and troubleshooting of GE EV-1 solid-state controls.

Make a BATTERY LOAD TEST Turn key switch to the "ON" position.

Place directional lever in "NEUTRAL".

Put the hydraulic lift control lever in "RAISE" position and hold it there.

When the system operates over relief, watch the needle of the battery charge indicator. The needle should not go into the RED. If it does, battery does not have sufficient charge for proper truck operation.

Battery should be fully charged. A fully-charged battery should be used before performing Electrical Tests. Also make a battery load test by operating system in back tilt hydraulic by-pass.

Page 20

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 22159

PM-510, REV FEB 84

PM

CL9RK

The ELECTRIC TRUCK BATTERY is the heart of an electric lift truck. Because the battery is such an important part of electric truck operation, it requires its own specialized maintenance program. This program should include a complete battery cleaning and inspection.

Refer to GROUP 12, Section 1 in this manual for specific instructions.

Check TILT CYLINDER ROD ADJUSTMENT: Put the upright in FULL FORWARD TILT. The upright should not twist as the tilt cylinders reach the end of their travel.

Fig. 22179 Next, put the upright in FULL BACK TILT position.

Again, the upright should not twist as the tilt cylinders reach the end of their travel.

If upright twists at full cylinder stroke, the cylinder ROD ENDS require adjustment.

Refer to GROUP 32, Section 1 for adjustment procedures.

Fig. 22 180 Raise, then lower UPRIGHT RAILS. Check for looseness, binding and damage.

If there is excessive free play between the rails and channels, the need for upright roller adjustment is indicated.

If the rails or carriage bind or hesitate upon being lowered, this indicates either damaged rollers or improper roller adjustment.

NOTICE IF OPERATIONAL TESTS INDICATE UPRIGHT LOOSENESS, THE ROLLER SHIM ADJUSTMENT SHOULD BE CHECKED FOR THE TOP AND BOTTOM ROLLERS IN ALL LIFT POSITIONS.

PM-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 22227

Page 21

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Check the TILT and LIFT cylinders for too much drift.

Refer to GROUP 32 for Tilt Drift Testing and refer to GROUP 34 for Lift Cylinder Drift Test Procedures.

12 TO 15 INCHES

Fig. 18264

Tilt Cylinder Drift should not exceed specifications in GROUP 40.

Down-drift must not exceed specifications in GROUP 40.

Fig. 17797 IMPORTANT

CLEANING, INSPECTION AND LUBRICATION DO NOT CLEAN ELECTRICAL COMPONENTS WITH STEAM. ONLY APPROVED SOLVENTS SHOULD BE USED TO CLEAN SCR COMPONENTS. USE CLARK #1801146 DEGREASER (OR THE EQUIVALENT TO MS-180 FREON TF DEGREASER AND CLEANER).

Page 22

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PM-510, REV FEB 84

PM

Battery

Removal

Disconnect battery from truck receptacle.

Fig. 17590 Raise the seat and lock the hydraulic control levers by pushing them forward. This allows the battery to be removed without interference from the seat or hydraulic controls.

NOTICE ALL CONTROL LEVERS MUST BE PUSHED FORWARD TOGETHER AT THE SAME TIME AND LOCKED. IF NOT, ANY INDIVIDUAL LEVER LOCKED IN POSITION WILL RELEASE WHEN ANOTHER LEVER IS PUSHED FORWARD.

Fig. 22181

Raise the battery cover.

Fig. 22151 Remove the battery from truck. Refer to GROUP 12, Section 1 for battery removal and safety instructions.

BATTERY SERVICE MUST BE DONE

BY TRAINED PERSONNEL. BATTERY ACID CAN CAUSE SEVERE BURNS

Fig. 22182

PM-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Page 23

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Check rear battery retainers for damage or missing bolts. Check that all bolts are tight.

Fig. 22183 Check front battery proper adjustment. retainer is secured on each side of the bolts are tight.

retainer for damage, and Check that front battery in position by two bolts truck. Check that all

Check to make sure that all holes and openings that could allow leakage from the battery compartment down into traction control and pump motor compartments are sealed with RTV-type silicone sealer (arrows).

Fig. 22184 Check battery cover hinges, springs and rollers for damage, and security of mounting.

Fig. 22185

Fig. 14028

Page 24

Now, with the battery out of the truck, check BATTERY CABLES for fraying and damage. Clean off minor deposits of corrosion on the batterv. *

DO NOT SMOKE OR HAVE OPEN FLAMES OR SPARKS IN BATTERY CHARGING AREAS OR NEAR BATTERIES.AN EXPLOSION CAN RESULT AND CAUSE INJURY OR DEATH.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PM-510, REV FEB 84

PM

CLflRK NEVER WASH THE BATTERY WHILE IT IS IN THE TRUCK BATTERY SAVER and CLEANER, Clark Part No. 886398, may be used to clean and protect the truck battery.

NEW TRUCK BATTERIES: Spray a light coat of BATTERY SAVER and CLEANER over the entire battery surface. Do not wipe off.

OLD TRUCK BATTERIES:

Apply a coat of BATTERY SAVER and CLEANER to entire battery surface. Allow to set for approximately 30 seconds, then wipe thoroughly with a rag. Chemical reaction will dissolve corrosion and rust. After cleaning, apply a second coating for protection.

This will prevent the start of corrosion on cables and terminals.

Check BATTERY VENTS for obstruction.

Cap vents must be open at all times.

If cap vents are plugged, they may be washed in a solution of baking soda.

Fig. 12913

SULFURIC

ACID

THE BATTERY CONTAINS CORROSIVE ACID WHICH CAN CAUSE INJURY. IF ACID CONTACTS YOUR EYES OR SKIN, FLUSH IMMEDIATELY WITH WATER AND GET MEDICAL ASSISTANCE.

PM-510, REV FEB 84

Check SPECIFIC GRAVITY of battery fluid.

Be sure to check at least six battery cells with a hydrometer.

Specific gravity should be no less than 1.250.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 17593

Page 25

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Remove floorboard fasteners and floorboards from the truck.

Fig. 22186 Open the traction controller compartment door. Check the controller mounts for damage.

Fig. 22187 Open the hydraulic pump motor compartment door. Check hydraulic pump intake and high pressure hose lines for signs of leaking, wear and obstruction from sharp bending or kinking. Check that the electrical system air cooling fan housing, intake screen, housing-tomotor seal and housing bolts all are in place and tight.

Fig. 22188

Air Clean

The

Truck

Use an extension on the air hose similar to that shown here. Use clean, dry air and restrict air pressure to [207 kPa] or 30 P.S.I. Wear suitable eye protection and protective clothing.

Fig. 15301

OR DRYING WITH AIR PRESSURE. REDUCE PRESSURE TO [207 kPa] 30 PSI. OEiiRIS RtMOVEO WITH AIR PRESSURE CAN CAUSE INJUR

Page 26

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PM-510, REV FEB 84

PM

Air clean the area under the floorboards. Clean off the accelerator, seat linkage and all other linkages.

Also air clean the fins on the bottom of the pump control.

Fig. 22189 Air clean the drive motor and air ventilation screen openings.

Check all motor electrical connections for tightness. Refer to GROUP 40, Section 5 for torque specification.

Also check for worn or frayed power cables and obvious signs of loose connections, such as burned terminals.

Fig. 22190 Air clean the battery compartment, and front and rear of drive motor.

Fig. 22191 Remove the mounting bolt and swing out the traction control. Air clean the outside of the control box, all terminals and all cooling openings and passages. Air clean field weakening resistor and terminals, if installed.

Note: The rear cover panel snaps in place for easy removal for cleaning of heat sink cooling fins.

Refer to Fig. 22193, Page 28.

Fig. 22192

PM-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Page 27

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

If traction control cooling fins are excessively dirty, remove the fin cover and air clean the fins.

Fig. 22193 Make sure the foam cooling air duct seal is in place. Air clean it and the entire traction control compartment.

NOTE If cooling air duct is extremely dirty, it is recommended when air cleaning that the pump motor in right hand side compartment also be swung out to make sure that dirt is not blown into cooling fan and fan housing.

See Fig. 22197, Page 29.

Fig. 22194

AIR CLEAN THE UPRIGHT.

Fig. 22195 NOTE A CABLE ADAPTER connected between truck battery and truck is required if it is necessary to extend the lift cylinder. THIS ADAPTER SHOULD NOT BE USED TO PERFORM ELECTRICAL TESTS. ITS PURPOSE IS TO OPERATE TRUCK WITH BATTERY REMOVED.

Fig. 17675

Page 28

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PM-510, REV FEB 84

Air clean the drive axle.

Fig. 22196 Air clean the hydraulic pump compartment.

Make sure that rical system cooling fan air screen (arrow) is cleaned of entrapped dirt and debris.

motor and the electintake all

"C$

NOTE

It is recommended to swing the pump motor out at the fan end for air cleaning of the cooling air duct.

Refer to Fig. 22194, Page 28.

Blow dust from vented motors.

If the vent bands are excessively dirty, remove the bands and clean them before cleaning the motor.

83M485

NOTICE ON ENCLOSED MOTORS, REMOVE THE NON-VENTED BANDS EVERY THIRD P.M. AND AIR CLEAN THE MOTORS.

Air clean the hydraulic valve, linkage and fittings.

Fig. 22198

PM-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Page 29

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Air clean the steer axle and steer cylinder.

Drive Unit Fluid Level Check

Fig. 22199

ACCESS TO THE DRIVE AXLE The best method to use for reaching the drive axle check points (oil level plug, filler plug and brake inspection plugs) is dependent upon the style of upright, carriage and attachments on the truck.

If the upright and carriage is of an open construction, the check points can be reached through, or behind the carriage, with the forks on the floor.

Tilt the upright full forward for more room.

If the upright, carriage, or attachments block access to the drive axle, the best procedure is to raise the carriage to allow reaching the drive axle check points from the front of the truck. Raise the carriage only high enough to provide easy access to the drive axle. BE SURE TO PLACE BLOCKING UNDER THE CARRIAGE AND UPRIGHT RAILS.

Fig. 22154

DO NOT WALK OR STAND UNDER RAISED FORKS. THE FORKS CAN FALL AND CAUSE INJURY OR DEATH.

Page 30

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PM-510, REV FEB 84

CL!WK

PM

The drive axle inspection and service plug openings are shown by Figure 24925.

1 2 3 4 5

Fill/oil level dipstick plug Drain plug Vent Inspection/fill plug Brake inspection plugs Fig. 24925

Check DRIVE AXLE FLUID LEVEL with truck on flat level surface.

Remove fluid level plug at lower front of axle center housing. Check condition of fluid. Change or add recommended fluid as specified in GROUP 01, Section 1 Lubrication Charts in this manual.

84M233

Check DRIVE AXLE VENT. Vent must be open at all times. NOTE: Vent is located on top front center of drive motor adapter (differential pinion bearing carrier) on drive axle assembly. Refer to Figure 24925.

Remove blocking if used, from upright and carriage. Lower lift carriage to the floor.

Fig. 22201

PM-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Page 31

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Inspect tilt cylinder mounts for security, and hydraulic connections for leaks.

Fig. 22202 Check tilt cylinder yokes for security of mounting.

83M440 Check tilt cylinder piston rods for nicks and scoring.

Fig. 22204 Check parking brake cylinder mount for Be sure that retainer pin, security. on the under side of the mount, is in place. Also check connections for leaks.

Fig. 22205

Page 32

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PM-510, REV FEB 84

PM

Check parking brake cylinder piston rod for nicks and scoring.

83M442 At lower end of steering column, check priority valve on steering unit and steering hydraulic connections for leaks.

NOTE THE DIAGNOSTIC CHECK PORT QUICKDISCONNECT FITTING (WITH CAP) FOR MAKING HYDRAULIC SYSTEM PRESSURE CHECKS IS ALSO SHOWN (ARROW).

83M443

PM-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Page 33

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Check accelerator control mounting bolts to be sure they are all in place and tight.

Fig. 22208 Check master cylinder for leaks, and check for pedal linkage-to-master cylinder excessive looseness and wear.

Hydraulic

Sump Fluid Level Check

83M444

Check HYDRAULIC SUMP TANK FLUID LEVEL. Lubricant specifications are located in GROUP 40, Section 4.

-IMPORTANT BEFORE CHECKING FLUID LEVEL, THE UPRIGHT MUST BE VERTICAL, THE LIFT CARRIAGE FULLY DOWN, WITH THE TRUCK SETTING ON A FLAT LEVEL FLOOR.

Remove dip stick.

Check condition of the fluid.

If contaminated, the sump tank and fluid filter should be serviced. Refer to GROUP 29, Section 1 for Hydraulic Sump Fluid and Filter Change.

83M446

Page 34

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PM-510, REV FEB 84

PM

FLUID LEVEL should be at the FULL MARK on the dip stick.

If low, add fluid as required. Note: Remove or pull dipstick part way out to vent air from tank while filling.

NOTE One gallon of hydraulic fluid is required to fill from the "Low" mark on the dipstick to the "Full" mark.

1

I

Fig. 24917

Check the fill cap/breather for contamination and damage. Replace at each 6 months or 1000 hours interval.

NOTE The truck should be scheduled for a hydraulic sump filter and fluid change every 2000 operating hours or once a year, whichever comes first.

83M447 To change the hydraulic sump oil filter and/or sump breather: 1.

2.

3.

4.

5.

6.

Remove the rear floorplate.

Remove used hydraulic oil filter.

Install new oil filter.

Remove the used sump breather.

Install new sump breather.

Install rear floorplate.

Put a jack under the frame at axle mount and raise the rear of truck until both steer wheels are off the floor. DO NOT RAISE TRUCK BY THE COUNTERWEIGHT. Put blocks under the frame for support.

IMPORTANT TO AVOID DAMAGE TO THE SUMP TANK, DO NOT LIFT OR PUT BLOCKS UNDER IT.

PM-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 22212

Page 35

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Check steering cylinder piston rod for nicks, scoring and leaks. Move steer wheels from full right to full left turn to facilitate complete inspection.

Fig. 22213 Check STEER WHEEL BEARINGS to see if they are loose. Grasp wheel and try to move it back and forth. If wheels move [6 mm] g inch or more, bearings require service. Refer to Overhaul Manual OH-510, GROUP 26, Section 17 for axle overhaul.

Fig. 22214 Turn STEERING HAND WHEEL until steer wheels are in the straight-ahead Get behind the truck and position. look to see if the steer wheels line up with the frame. If not, steering Refer to linkage must be adjusted.

Overhau Manual OH-510, GROUP 26, Section 17 for axle overhaul. fTizF----

Fig. 22215

COR ECT ALIGNMENT ADJUSTMENT OF THE STEER WHEELS IS REQUIRED FOR BEST SPEED PERFORMANCE AND MINIMUM POWER CONSUMPTION OF THE TRUCK. Grease the truck, and lubricate miscRefer to Lubricellaneous linkages. cation Charts in GROUP 01.

After lubricating the steer axle, slightly raise truck, remove blocking and lower truck to the ground.

Page 36

NOTE Lubricant specifications and lubrication recommendations are located in GROUP 40, Section 4.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PM-510, REV FEB 84

Close compartment doors. Install floorboards.

Fig. 22187 FOR TRUCKS EQUIPPED WITH SPARK-ENCLOSED (EE) 0~ WITH POLYURETHANE TIRES:

commucTIor4

Check GROUND STRAP for security of attachment and wear damage.

Fig. 24918

Check

Torque

Of Critical

Fasteners

See GROUP 40, Section 5 for torque specifications.

Raise drive wheels off the floor. With upright in full back tilt, place wood blocking beneath outer rails of upright.

Place a metal plate on top of each block and tilt the upright forward, raising wheels off the floor. Remove drive wheels.

WOOD

BLOCKING'F&

‘STEEL

PLATE

Fig. 14099

Check DRIVE AXLE MOUNTING BOLTS AND NUTS for proper torque. Tighten each bolt to correct torque specifications.

IIMPORTANT] MOUNTING BOLTS, NUTS, WASHERS AND HOLES ARE NOT TO BE LUBRICATED. IMPACT WRENCHES TO BE USED ONLY TO SNUG UP FASTENERS. TORQUE MEASURING WRENCH MUST BE USED TO OBTAIN FINAL TORQUE VALUES.

PM-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 22216

Page 37

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Check bolts. tion.

trunnion to correct

Fig. 22217 Check BOLTS.

MOUNTING TRUNNION

17691 Tighten the

trunnion cap specification.

to

Fig. 22226 Now,

the drive

Lower truck wheels to blocking.

floor and

22219

Page

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

~~-510, REV FEB

PM

Tighten drive wheel lug nuts to correct specification.

Fig. 22220 Tighten steer wheel lug nuts to correct specification.

Fig. 22221 Tighten tilt cylinder yoke clamp bolts to correct specification.

Tighten tilt cylinder pin lock bolts to correct specification.

Fig. 22222 Tighten all overhead guard bolts to correct specification.

Fig. 22223

PM-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Page 39

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Tighten outside counterweight bolt to specification.

Fig. 22224 Tighten the inside counterweight-tospacer mounting bolts to specification. Tighten the auxiliary counterweight bolts, if installed.

Fig. 22185 Tighten battery compartment to frame mounting bolts to specification.

83M450 Tighten the load backrest mounting bolts to specification.

Fig. 22157

Page 40

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PM-510, REV FEB 84

PM

CLflRK

Electrical

Tests

When electrical tests are required, refer to GROUP 40, Section 5 for Truck Specifications.

Refer to GROUP 40, Sections 17 and 18 for voltage and resistance measuring.

Refer to Book No. 59-854-0005, System Diagnosis SCR Controls, ECA/EPA 17 thru 30, for instructions on operation and troubleshooting of GE Model EV-1 Solid-State Controls.

Perform ELECTRICAL TESTS with a voltohm meter.

1

IMPORTANT _j

THE BATTERY MUST BE FULLY CHARGED BEFORE DOING ELECTRICAL TESTS.

Fig. 22236 Be sure to REMOVE ALL JEWELRY before handling electrical components.

I

Fig. 12704 Disconnect the battery from truck receptacle.

DISCHARGE THE CAPACITOR BEFORE HANDLING SOLID STATE COMPONENTS. INJURY CAN RESULT FROM AN ELECTRICAL SHOCK.

Fig. 17590

PM-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Page 41

INDUSTRIAL MARKETING

TRUCK DIVISION TRAINING

DEPT.

Perform a test for GROUND FAULT CONDITION: -

GROUND USED

TEST

TRUCKS

Make a record of the resistance on the P.M. check sheet. MAKE SURE THAT TRUCK BATTERY IS DISCONNECTED. Note: Truck resistance varies widely depending Values shown are on condition and cleanliness.

However, values ranging down to typical.

20,000 ohms may be found on some trucks, without a problem. Values below 20,000 ohms must be further investigated.

See below.

Fig. 17736

Set meter on Rx10,OOO scale. Turn key switch to "OFF" position and check for ground fault condition as follows:

Fig. 17737 1.

Connect RED lead to POSITIVE (+) of truck receptacle and connect BLACK (-) lead to the truck frame. Make a record of the resistance.

IF LESS THAN 20,000 OHMS RESISTANCE IS MEASURED, CONDUCT FURTHER TESTS TO ELIMINATE SHORT CIRCUIT/ GROUND FAULT CONDITION.

2.

Fig. 14860

Connect RED lead to NEGATIVE (-) of truck receptacle and leave BLACK lead connected to truck frame. Make a record of the resistance.

IF LESS THAN 20,000 OHMS RESISTANCE IS MEASURED, CONDUCT FURTHER TESTS TO ELIMINATE SHORT CIRCUIT/ GROUND FAULT CONDITION.

Page 42

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 14861

PM-510, REV FEB 84

PMA

- PLANNED MAINTENANCE ADJUSTMENT PROCE

PM Report

Copyrighted Material 1318-Z MARonly 84 Intended for CLARK dealers Do not sell or distribute

Form

ELECTRIC TRUCK PLANNED MAINTENANCE REPORT

*SEE

MAINTENANCE

INTERVAL

IN $_~kW,2~;4fiiW$~

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SECTION

1 LUBRICATION

CHARTS

AIR CLEAN THE TRUCK PRIOR TO PERFORMING THE CHECKS AND LUBRICATION INSTRUCTIONS

BEFORE APPLYING A GREASE GUN WIPE GREASE FITTINGS CLEAN

REFER TO GROUP 40, SECTION 4 FOR LUBRICATION SPECIFICATIONS UNLESS OTHERWISE NOTED

Code: PMA-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1,

Page 1

GROUP 01 LUBRICATION

CHART

SERVICE TIME INTERVAL: EVERY 50 TO 250 OPERATING HOURS.

MS-107C

MS- 107 B

Section

1, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

GROUP

01 LUBRICATION SERVICE TIME INTERVAL: EVERY 50 TO 250 OPERATING HOURS.

CHART

LUBRICATE MISCELLANEOUS LINKAGES WITH DRY FILM TYPE LUBRICANT

CHECK HYDRAULIC SUMP =-

& CABLE LUBE, CLARK i/886399.

CHECK FLUID LEVEL DRIVE CLEAN BATTERY EVERY OPERATING HOURS WITH BATTERY CLEANER, CLARK 11886398.

DRIVE UNIT FLUID LEVEL. SHOULD BE EVEN WITH THE PLUG OPENING OF UNIT.

Recommended fluid: TEXACO 8570 ATF or Clark Part No. 962669

INSPECT BATTERY CONDITION, SPECIFIC GRAVITY AND BATTERY WIRING. KEEP VENTS OPEN.

Code: PMA-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 3

GROUP

01 LUBRICATION

CHART

SERVICE TIME INTERVAL: EVERY 2000 OPERATING HOURS OR ONCE A YEAR.

DMIN

HYDR4ULIC FLUID

FILL WITH MS-68 HYDRAULIC FLUID, CLARK l/885385.

n REPLACE HYDRAULIC TANK BREATHER EVERY 1000 OPERATING HOURS.

/

DRAIN AND REFILL \ DRIVE UNIT

LUBRICATE AT EACH OVERHAUL 1

Recommended fluid: TEXACO 8570 ATF or Clark Part No. 9626697 REPLACE HYDRAULIC SYSTEM FILTER

Section 1, Page 4

v

MS-107B

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

C19R

GROUP 01

COLD STORAGE APPLICATIONS

NOTE

High moisture-exposure operation in such as freezers or caustic atmosphere can cause premature failure of SCR control cards.

Encapsulated cards or potted cards are no longer available for use in problem areas and CONQUER Spray Coating must be used.

CLEAN THE SCR CONTROL. If the SCR control is oily or greasy, use "Freon TF Degreaser", CLARK Part No. 1801146.

IMPORTANT The instructions written on the spray can of CONQUER suggests that parts be cleaned with an agent'called "SYNCRONATE." We do not recommend the use of this cleaning agent as it may damage the card. Any cleaning of controls should be with a mild detergent solution. Then blown dry with clean, moisture-free compressed air at low pressure.

To protect the cards, spray them all over with CONQUER Spray Coating, CLARK Part No. 1801145.

CONQUER is an electrical moistureproofing spray coating for contactors, SCR panels, solid state control cards, #1 timer and oscillator cards.

CONQUER spray should be applied in accordance with the following recommendations: TRUCK EXPOSURE

RE-APPLICATION

Indoors Outdoors Freezer or Cold Storage

Every Every Every

ELECTRICAL SWITCHES, WIRING & TERMINALS should be sprayed with SPRAY COATING, CLARK Part No. 886784.

12 Months 4 Months 4 Months

Also each time the control is cleaned during a normal planned maintenance, the card should be re-sprayed.

Code: PMA-510, REV FEB 84

NOTE

CYCLE

SPRAY COATING is a clear acrylic plastic protective coating which acts as an insulator and a corrosion preventative.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 5

IMRK

PM

OTES

1146-Z REV DEC 83

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP

02

SECTION

SEAT CONTROL ROD (RETURN-TO-NEUTRAL) ADJUSTMENT

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 1

GROUP

02 SEAT CONTROL ROD (RETURN TO NEUTRAL) ADJUSTMENT Proper operation of the return-to-neutral function when the seat is raised (driver not in seat) depends on correct adjustment of the accelerator & direction control rod which connects the seat to the accelerator & direction control cover assembly.

Movement of the seat is transmitted by the control rod to rotate the direction selector cam lever in the accelerator control cover assembly.

Proper and full travel (rotation) of the cam lever is necessary to engage and disengage the "Neutral" control switch. Also, the seat control rod must be adjusted properly to match the travel limits of the seat.

Refer to illustration on Page 4.

To adjust the seat control rod: 1.

First, determine whether rod needs to be shortened or lengthened.

Assuming all other truck systems are operating correctly, if directional control lever does not return to neutral when seat is raised, the rod needs to be shortened.

If hydraulic pump does not start when seat is held down, rod needs to be lengthened.

Also, see note on Page 4 regarding switch actuator adjustment.

2.

Turn key switch to "Off" position and disconnect battery from truck receptacle.

3.

Remove the floorboards.

4.

Pull up on steering column latch to release and move tilt steering column fully forward.

5.

Block the seat plate down or have someone sit in the seat. Seat must be held fully in the down position.

6.

Remove nut (A) holding the control rod to the lever on seat plate.

Pull rod end out of the lever.

7.

Loosen lock nut (B) on rod end while holding rod from turning.

Section 1, Page 2

Fig. 22171

Fig. 24919

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

GROUP

02 8. Make sure that the direction selector cam lever (C) in the accelerator control cover assembly is rotated fully and held lightly against the stop (D) on bottom of the control cover assembly, by pushing on the seat control rod. When cam lever is against the stop, rod is adjusted correctly when the free end of the rod aligns with the center of the hole in seat lever. Otherwise, further adjustment is necessary.

Fig. 24920

9. Turn rod end clockwise to shorten.

Counterclockwise to lengthen.

Adjust one full turn at a time.

Insert rod end back into seat lever and check seat movement for correct Repeat until correct adjustment. adjustment is obtained.

J

Fig. 24919 10. Check to make sure that directional control lever operates freely.

If lever "drags" or moves too hard it is because the seat control rod is adjusted too long and cam lever is forced too tightly against the stop on the accelerator control cover.

Seat control rod must be re-adjusted until directional control lever operates freely. Cam lever (C) should just lightly touch the stop (D) when the seat is fully down.

Fig. 22167

11. Tighten lock nut (B) on rod end.

12. Install nut (A) to fasten rod end to seat lever.

-3. Proper operation of the return-toneutral function depends also on correct adjustment of the directional control lever. Refer to GROUP 06, Section 1 for directional control lever adjustment.

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 3

GROUP

02

02.284~11

65_,20’g3] ,,” /

65-426-,.,\,

m13.400-

,

PC//i

ACCELERATOR

PEDAL

AND

LINKAGE

02-214

32.270 02.280 02.281 02.282 02.283

LEVER, ACCELERATOR PEDAL PEDAL, ACCELERATOR PIN, ACCELERATOR PUSH ROD ROD, ACCELERATOR PUSH PIVOT, ACCELERATOR PEDAL

65.427 65.428 65.429 65.500 65.720

SPRING, ACCELERATOR & DIRECTION CONTROL ROD ACTUATOR, HYDRAULIC PUMP SWITCH LEVER, ACCELERATOR & DIRECTION CONTROL ROD ROD END, ACCELERATOR & DIRECTION CONTROL BOOT, ACCELERATOR & DIRECTION CONTROL COVER

02.284 02.286 02.313 02.320 02.321

RETAINER, ACCELERATOR PEDAL PIVOT RETAINER, ACCELERATOR PUSH ROD PIN, ACCELERATOR LEVER BRACKET, ACCELERATOR LEVER FASTENER, ACCELERATOR LEVER BRACKET

65.743 90.670 90.956 90.957 91.766

CLAMP,ACCELERATOR & DIRECTION CONTROL COVER BOOT RETAINER, ACCELERATOR CONTROL ROD WASHER, ACCELERATOR LEVER PIN RETAINER, ACCELERATOR LEVER PIN WASHER, ACCELERATOR PUSH ROD RETAINER

13.400 13.448 19.302 65.418 65.426

CONTROL ASSEMBLY, ACCELERATOR & DIRECTION FASTENER, ACCELERATOR & DIRECTION CONTROL ASSEMBLY ACTUATOR, DIRECTION SWITCH COVER ASSEMBLY, ACCELERATOR b DIRECTION CONTROL ROD, ACCELERATOR & DIRECTION CONTROL

93.724 93.725 93.726 94.331

FASTENER, ACCELERATOR & DIRECTION CONTROL ROD FASTENER, ACCELERATOR & DIRECTION CONTROL COVER WASHER, ACCELERATOR PEDAL PIVOT RETAINER LOCK, ACCELERATOR & DIRECTION CONTROL ROD END

NOTE:

The direction switch actuator and hydraulic pump switch actuator is a twopiece friction-fit assembly designed to self-adjust upon joining of the accelerator & direction control assembly and the accelerator & direction If the operating linkage is improperly adjusted, control cover assembly. overtravel can cause the actuator to fully compress and no longer function.

In this case, the actuator must be replaced and assembled at the maximum assembled (extended) height position.

Section 1, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

GROUP

06

06 SECTION

1 DIRECTIONAL CONTROL LEVER ADJUSTMENT

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 1

GROUP

06 DIRECTIONAL CONTROL LEVER ADJUSTMENT Proper operation of the directional control lever depends on the correct adjustment of the directional control rod at the bottom of the steering column which connects the lever to the accelerator & direction control cover assembly. The detents for the directional control lever positions are in the accelerator & direction control cover assembly.

Refer to illustration on Page 5.

To adjust the directional control rod: 1.

Turn key switch to "Off" position and disconnect battery from truck receptacle.

2.

Remove the floorboards.

3.

Move the tilt steering column fully to the forward position.

4.

Block the seat plate down or have someone sit in the seat. Seat must be held fully in the down position.

Fig. 22171

5.

Remove nut (E) holding the directional control rod to the direction selector cam lever (C) on the accelerator & direction control cover assembly. Pull rod end out of the cam lever.

6.

Loosen lock nut (F) on rod end while holding rod from turning.

Fig. 24921 7.

Push on cam lever (C) to move it into accelerator control cover as far as it will go and release.

It will return to the "REVERSE" position detent. Then, pull the cam lever out until it snaps into the next detent position' ("FORWARD"), and release.

Fig. 24922

Section 1, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

GROUP

CLeaK

86 8 . Yove directional control lever to the "Forward" position.

Flake sure that the front edge of the lever is held all the way forward and touching against the edge of the quadrant opening.

Check to see that lever is not lifted up into the "Park" position.

Fig. 22167 9. Adjust length of directional control rod (G).

Turn rod end (H) clockwise to shorten.

Counterclockwise to lengthen.

Rod is adiasted correctly when the rod end aligns wit!1 t'ne center of the hole in Carl lever and can be easily asse!%led into the cam lever without forcing.

Check to make sure that the directional control lever is in position as noted above.

Fig. 24921 10. Insert directional control rod end (H) into ca;7 lever and install nut (E) to fasten rod end to car! lever.

I!. Tigiiten lock nut

3 .I_

.

13.

(F) on rod end.

C+eck the o;:;'-'r:itif3q an:! feel of directioqa? contrill lever. l-ever should $e held hy the detent !\li th a :i:?sitive feel ih "Forl,jard" no s i t i0 r!.

Release the seat.

The lever siimld return to "/:leutral". %l:? seat ?c?!l!l.Move directional cil?:trol ?eve;- to "Reverse" position aqd CilC?Cl; f:?t?! for positive detent ~r>oaqe!~e~jt I .. Release the scat.

The 1 e;er s!i$:llri return tc! ":'Geiltral 'I.

Code : P%'V-51.!),Ft'ii84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig.

Section

2215G

1, Page 3

GROUP

06 14. With seat released (up), move control lever to "PARK" position.

The lever should lock in the "PARK" detent.

Fig. '22163 15

Move tilt steering column fully to the rear position. Check operation of directional control lever as described above.

16

Check to make sure that directional control lever operates freely.

Proper operation of the control lever and of the return-to-neutral function when the seat is raised (driver not in seat) depends also on correct adjustment of the seat control rod. Refer to GROUP 02, Section 1 for seat control rod adjustment.

Section 1, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 22168

Code: PMA-510, FEB 84

GROUP

06

06.143

-v

fig, ;,,@ 06.108-J

DIRECTIONAL

CONTROL

,-‘-+ACCELERATOR CONTROL cb6.915

7,'

LINKAGE

06-420

06.034

FASTENER, DIRECTIONAL CONTROL LEVER KNOB

06.131

FASTENER, DIRECTIONAL CONTROL SHAFT BRACKET

06.053

BEARING, DIRECTlONAL CONTROL PIVOT

06.143

BRACKET, DIRECTIONAL COmOL

06.055

PIN, DIRECTIONAL CONTROL LEVER SPRING

06.170

ARM, DIRECTIONAL CONTROL SHAFT

06.084

SEAT, DIRECTIONAL CONTROL LEVER SPRING

06.171

FASTENER, DIRECTIONAL CONTROL SHAFT ARi'l

06.101

LEVER, DIRECTIONAL CONTROL

06.786

SPRING, DIRECTIONAL CONTROL LEVER

06.103

BRACKET, DIRECTIONAL CONTROL STEERING COLUMN

06.911

KNOB, DIRECTIONAL CONTROL LEVER

06.104

CAP, DIRECTIONAL CONTROL STEERING CGLUHN BRACKET

06.915

FASTENER, DIRECTIONAT, CONTROL ROD END

06.105

FASTENER, DIRECTIONAL CONTR STRG COLUMN BRKT CAP

44.068

CUSHION, DIRECTIONAL CONTROL LEVER

06.108

ROD END, DIRECTIONAL CONTROL

44.069

WASHER, DIRECTIONAL CONTROL LEVER CUSHION

06.110

ROD, DIRECTIONAL CONTROL

91.693

NUT, DIRECTIONAL CONTROL SHAFT ARM FASTENER

06.115

LOCK, DIRECTIONAL CONTROL ROD END

92.861

COTTER, DIRECTIONAL CONTROL LEVER PIN

06.126

PIN, DIRECTIOhXL CONTROL LEVER

93.313

NUT, DIRECTIONAL CONTROL LEVER KNOB FASTENER

06.128

SHAFT, DIRECTIONAL CONTROL LEVER

93.721

COTTER, DIRECTIONAL CONTROL LEVER SPRING PIN

roclf? : ?Wb-51n,

FEti 34

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SKAFT

Section

1,

Page 5

PM

NOTES

Material 1146-Z Copyrighted REV DEC 83

Intended for CLARK dealers only Do not sell or distribute

GROUP

Ct!fIRK

06

2 HORN AND STEERING HANDWHEEL ADJUSTMENT

Code: PMA-510, FE9 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 2, Page 1

HORN AND STEERING HANDWHEEL ADJUSTMENT Improper clearance between the bottom of the steering handwheel hub and the top of the shift lever quadrant housing may cause horn not to operate (too much clearance) or may cause a rubbing or squeaking noise when steering handwheel is turned (too little clearance).

ADJUSTMENT PROCEDURE: 1.

Loosen the Allen-head bolts holding the shift quadrant housing (directional control steering column bracket) to the steering column.

Fig. 24923 2.

Adjust the position of the shift quadrant housing up or down until [l,O mm] 0.040 inch clearance is measured between the bottom of steering handwheel hub and the top surface of shift quadrant housing casting.

wHEEL2!!zITh STEER 11, 01.059-J---

--

10,921 ,037 v

SHIFT QUADRANT CASTING

Fig. 24924 3.

Tighten the Allen-head bolts holding the shift quadrant housing.

The torque on these bolts is [23-25 N.m] '203-221 lbf. in.

4.

After adjustment, check for proper horn and steering handwheel operation.

Section 2, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

GROUP

12

0

12 SECTION

1 ELECTRIC

PMA-510, DEC 80

TRUCK

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

BATTERY

Section 1, Page 1

GROUP

12 BATTERY: With the KEY SWITCH in the ON position, the BATTERY CHARGE INDICATOR will show the available battery voltage.

HANDLING STORAGE BATTERIES: 1.

Change or service storage batteries only in an area designated for this purpose.

2.

Be sure this area has provisions:

Fig. 22172

- to flush and neutralize spillage - to ventilate fumes from gassing batteries - for fire protection.

Before attempting to change or charge a storage battery, the truck shall be positioned in the designated battery service area and the brake(s) applied (locked) so that the truck cannot move.

3.

4.

Be sure the area is equipped with material handling equipment designated for the purpose of removing and replacing batteries such as a conveyor or overhead hoist. Make certain the overhead hoist is equipped with safety hooks.

When using overhead battery hoist, be sure an insulated spreader bar or similar lifting device is used so that the lifting stresses are vertical . . . neither outward or inward pressure must be exerted at In other words, the the battery. width of the lifting device shall be the same width of the battery at the lifting eyes, so that the lift is immediately upward. Also, make certain the lifting hooks are not so large that pressure is exerted on the lifting eyes of the battery.

Section 1, Page 2

5.

If the battery does not have a cover of its own, then cover the battery with a non-conductive material (sheet of plywood) prior to attaching a battery lifting device.

6.

When using a power battery hoist, be sure the hoist is equipped with a chain container to accumulate the excess of lifting chain.

7.

When a hand hoist is used, an uncovered battery shall be covered with a non-conductive material to prevent the hand chain from shorting on the cell connections or terminals.

8.

Keep all tools and other metallic objects away from the terminals.

9.

Personnel maintaining storage batteries shall wear protective clothing such as face shield, long sleeves and gauntlet gloves.

10. Due to hydrogen emission from charging batteries, no smoking shall be allowed in the charging area. Do not check the electrolyte level with an open flame.

Precautions shall be taken to prevent open flame, sparks or electric arcs in battery charging area.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PMA-510, DEC 80

12 If the battery is to be serviced, be sure that there are provisions to flush and neutralize spillage to disperse (ventilate) fumes from gassing batteries on charge. And be sure there are provisions for handling electrolyte.

11.

12.

2.

Position truck in the designated area, place directional lever in park position, turn off the key switch, and disconnect the battery.

3.

Raise the seat and lock the hydraulic control levers by pushing them forward. All control levers must be moved forward together at the same time for positive locking.

4.

Raise the battery cover to expose battery. Note: This may vary depending on the truck being serviced.

5.

If the battery to be handled is uncovered, cover the battery with a non-conducting material prior to attaching a lifting device, refer to Item 5, "Handling Storage Batteries".

6.

Now, attach lifting device and spreader bar (previously described) to the battery .. . be sure the device is equipped with load safety hooks as shown in Fig. 22182.

7.

Remove the battery.

13.

14.

15.

. . . carefully

install read

the previous instructions.

1.

Check the designated service and charging area for fire protection, and be sure all sources of ignition are from the area. DO NOT SMOKE. Be sure all previously listed equipment is in the area, in good repair and working properly.

Code: PMA-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 22182

Section 1, Page 3

GROUP

12 BATTERY CLEANING:

2.

Lift only with a carefully constructed lifting device which will not put pressure on the battery tray.

3.

Battery shall be checked before each charge for electrolyte level.

Add water before charge, but DON'T OVER DO this. Overfilling causes loss of electrolyte.

The level should be slightly below the lower lip of the filling vent hole.

4.

KEEP BATTERY CLEAN AND DRY. down as needed.

5.

Don't overcharge.

6.

Keep battery records as indicated herein.

7.

Keep metal objects and tools away from top of battery to prevent explosions.

With battery out of truck ...

The easiest and most satisfactory method of cleaning a battery is to wash it occasionally with a low pressure cold water spray. The top can also be washed off with a solution of baking soda (add a box of baking soda to a pail of water and stir until dissolved) and rinsed with clear water.

It is wise to have this solution around a battery room at all times.

Of course, during the above cleaning operation, THE CAPS MUST BE TIGHTLY IN PLACE!

Wash

BATTERY MAINTENANCE: Refer to the BATTERY VENDOR-for their recommended procedures.

KEEPING BATTERY RECORDS :

INSTALL BATTERY:

Some type of records shall be kept to get the best service out of your battery and truck. Select a pilot cell, take readings of specific gravity and temperature before and after charging, and record with the date. It is best to change the pilot cell occasionally to distribute any electrolyte loss over the battery in taking readings.

Every 2 to 3 months, take complete battery readings .. . check specific gravity, temperature and voltage ... and record them.

1.

Install lifting device as explained previously.

2.

Correctly locate the battery in the truck and secure it in position.

HOW TO GET MAXIMUM LIFE FROM BATTERY: 1.

Only Don't add acid to a battery. a qualified BATTERY REPRESENTATIVE should determine if this is necessary.

Section 1, Page 4

NOTE Some trucks are equipped with battery stops or blocks while others do not require them at all. If the truck being serviced is equipped with one or the other, check to be sure If they they are not missing. are, replace them. If they are of the adjustable type, be sure they are adjusted to the battery and tightened securely.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PMA-510, DEC 80

GROUP 12

ELqR

SECTION

2 ELECTRIC INDUSTRIAL STANDARD

Code: PMA-510, REV FEB 84

POWERED TRUCK FOR

SAFETY

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

BATTERIES UL583

Section 2, Page 1

GROUP 12 ELECTRIC POWERED INDUSTRIAL TRUCK BATTERIES STANDARD FOR SAFETY - UL 583

11. BATTERY COMPARTMENT AND ENCLOSURE 11.1 Support and protection shall be provided for the battery by means of a noncombustible enclosure.

11.2 A metal battery enclosure shall not be less than 0.053 inch (1.35 mm) thick. A metal battery enclosure shall be flanged not less than l/2 inch (12.7 mm) on all sides or shall be provided with a construction that gives equivalent strength.

11.3 The cover of a battery enclosure shall remain closed by the force of gravity or shall be provided with a fastener.

11.4 A metal cover for a battery enclosure shall: A.

B.

Have such strength and rigidity that, in conjunction with an air spacing provided between it and the battery terminals, the battery terminals are not shortcircuited when a 250-pound (IllO-newton) force is applied to any one-square-foot2(930square centimeters (cm )) area of the cover; or Have insulation secured to the inner surface designed to prevent short-circuiting of the battery terminals.

11.5 The battery enclosure shall be provided with means for ventilation that minimizes the possibility of accumulation of explosive hydrogen-air mixtures above the battery.

Section 2, Page 2

11.6 Means shall be provided as a part of the truck to restrain a battery of nominal voltage rating and representative of maximum ampere-hour capacity rating from moving more than a total of l/2 inch (12.7 mm) in a horizontal direction.

12. BATTERY 12.1 A battery furnished with a noncombustible tray and cover intended to form the ultimate enclosure for the battery shall comply with the requirements in paragraphs 11.1 - 11.5.

12.2 Cells employing metal containers such as alkaline batteries, shall be insulated from one another and from a metal tray or metal battery compartment.

Insulation of wood or other material shall be (1) treated or painted to minimize deterioration by the battery electrolyte, and (2) constructed to minimize the risk of damage to the insulation in the normal operation and maintenance of the truck.

12.3 The connections shall be such that the potential between any two adjacent cells cannot be more than 24 volts nominal.

13. BATTERY LEADS 13.1 A battery lead shall be of a size and capacity acceptable for the application.

It shall be (1) neopreneinsulated or insulated with an equivalent material, (2) resistant to acids or alkalies, and (3) able to withstand flexing, handling and impact at temperatures between 54°C (13OOF) and minus 29°C (minus 20°F).

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

GROUP

CMRK

12

The average insulation thickness shall not be less than 0.060 inch (1252 mm) for a No. 8-2 AWG (8.4-33.6 mm ) wire and shall not be less than 0.080 inch (2.03 mm) for 2 No. l-4/0 AWG (42.4-107.2 mm ) wire.

14. BATTERY CONNECTORS 14.1 A truck shall be equipped with a battery connector located to provide mechanical protection as required for other electrical parts of the truck.

14.2 One part of the connector shall be permanently mounted to either the truck or the battery enclosure. The length of the cable attached to the free part of the connector shall be as short as practicable, without interfering with the disconnecting operation and without placing stress on terminals.

14.3 Live parts shall be recessed from the face of the connector to minimize the possibility of shorting.

14.4 The removable portion of the connector shall be provided with means for being grasped during removal.

PMA-510, DEC 80

14.5 A battery connector shall have the proper rating for use in its particular application,

36. BATTERY ENCLOSURE 36.1 The battery enclosure shall be provided with a cover with means for locking cover in the closed position to deter opening by unauthorized persons.

Insulation designed to prevent shorting of battery terminals shall be secured to inner surface of a metal enclosure, over the terminals.

36.2 All upper openings shall be covered with a heavy-gauge wire mesh, expanded metal, or a perforated cover complying with Table 36.1. If the distance between an uninsulated live part and an opening is less than or equal to 4 inches (102 mm), the size and shape of the opening shall prevent passage of a rod having a diameter greater than l/2 inch (12.7 mm). If the distance between an uninsulated live part and opening is greater than 4 inches, the opening may be larger than previously mentioned, provided no opening passes a rod having a diameter greater than 3/4 inch (19.0 mm).

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 2, Page 3

cMRK

GROUP 12

TABLE 36.1 COVER FOR UPPER OPENINGS IN BATTERY ENCLOSURE

Minimum Acceptable Wire-Diameter of Screen or Thickness of Sheet Steel, Inch (mm)

Type of Covering

1. Screen

Covering Having Openings or Perforati ns l/2 Square !?

Inch (3.2 cm ) or Smaller in Area

Covering Having Openings or Perforations Larger2than l/2 Square Inch (3.2 cm ) in Area

0.051 (1.30)

0.081 (2.06)

A. Uncoated

0.042

0.080

B. Zinc-Coated

0.045 (1.14)

2. Perforated sheet steel employed for expanded metal mesh:

Section 2, Page 4

(1.07)

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

(2.03)

0.084 (2.13)

PMA-510, DEC 80

GROUP

16

SECTION

1 ELECTRIC BRUSH

Code: PMA-510, REV FEB 84

MOTOR REMOVAL

MAINTENANCE AND

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

INSPECTION

Section 1, Page 1

GROUP 16 MOTORS A ROUTINE MAINTENANCE SCHEDULE WITH RECORDED FINDINGS IS THE BEST WAY TO REDUCE COSTLY DOWNTIME AND PREVENT THE REPAIR OF EQUIPMENT DURING OPERATING HOURS.

THE

GOAL OF ANY MAINTENANCE PROGRAM, LONG-LIFE AND TROUBLE-FREE OPERATION, IS RELATED TO THE TIME SPENT MAKING INSPECTIONS AND CORRECTING MINOR PROBLEMS AS THEY OCCUR.

TYPICAL OPERATING CONDITIONS: NORMAL SERVICE ... basically, an eighthour day of mostly indoor br outdoormaterial handling.

EXTREME SERVICE . . . 1.

SEVERE SERVICE . .. extended operating hours. or constant usage:

Dusty or sandy locations, i.e., cement plant, lumber or flour mills, coal dust or stone-crushing areas.

2.

High temperature areas; i.e., steel mills, foundries, etc.

3.

Sudden temperature changes (continuous indoor-outdoor movement) i.e., refrigeration plant, etc.

Since the operating environment of lift truck motors varies widely, the above descriptions should be applied as actual conditions dictate.

ROUTINE INSPECTIONS:

ALWAYS DISCONNECT BATTERY BEFORE DOING ANY WORK ON ELECTRIC MOTORS.

CLEANLINESS

... Wipe off dust, dirt, oil, water, etc., from surface of motor. .. . Remove any debris from air vents and around motor frame to prevent overheating. . .. Blow out open motors with clean, dry compressed air at [207 kPa] 30 PSI maximum pressure.

The presence of oil could indicate bad bearings or a leaking hydraulic system. Uetermine the cause and correct before extensive damage occurs.

Section 1, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

GROUP

16 BRUSH REMOVAL AND INSPECTION:

8.

MOTOR IN THE TRUCK

IMPORTANT

BRUSHES MUST BE REPLACED WHEN WORN TO DIMENSION GIVEN IN TRUCK SPECIFICATION.

THE DRIVE MOTOR BRUSHES CAN BE REPLACED WITHOUT REMOVING THE DRIVE MOTOR FROM THE TRUCK OR DRIVE AXLE.

1.

Turn key switch to "Off" position.

2.

Disconnect the battery.

3.

Remove the battery from the truck.

4.

The drive motor brush holders on end of motor are accessible through the opening in front of battery The floorboards may compartment. also be removed for better visibility and access.

5.

6.

7.

Remove the brush holder assemblies from end of drive motor.

Refer to the detailed instructions for Drive Motor Brush Replacement for General Electric and Prestolite motors in GROUP 16, Sections 2 and 3.

Clean the brushes and holders.

Wipe the commutator with a dry, lint-free cloth. DO NOT USE A LUBRICANT OF ANY KIND ON OR AROUND THE COMMUTATOR. Check appearance of commutator and the brush riding surfaces. The best signs of good commutation are dark, brownish, highly polished commutator and uniform glossy brush wearing surfaces. Refer to the COMMUTATOR CHECK CHART following Page 5 in this section.

Code: PMA-510, REV FEB 84

Measure and record the brush length at each inspection. The record will indicate brush wear and will determine if there is enough brush length remaining until the next inspection.

IMPORTANT NEW BRUSHES MUST BE SAME SIZE AND MATERIAL SPECIFICATION AS THE OLD BRUSHES.

9.

Check brush shunt for good contact with brush holder. Make certain shunt is not damaged or burned.

This may cause pressure spring to carry current and lose tension.

10. If brushes do not need to be replaced, lift the brush spring and put brush into brush box. Make sure pressure spring is on the brush hammer plate and brush slides freely in brush box.

11. Clean and check brush box and cross connector screws. Tighten if loose.

12. Install brush holders into motor per instructions noted in GROUP 16, Sections 2 and 3.

13. Check and tighten all motor bolts.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 3

CLflRK

GROUP

16 INSPECTION CHART

SERVICE CONDITIONS

NORMAL

SEVERE

EXTREME

Section 1, Page 4

RECOMMENDED INSPECTION

MOTOR LOCATION

1000 Hours

Routine

Motor in truck

As required by inspection.

Periodic

Motor removed

500 Hours

Routine

Motor in truck

As required by inspection.

Periodic

Motor removed

250 Hours

Routine

Motor in truck

As required by inspection.

Periodic

Motor removed

INSPECTION FREQUENCY (OPERATING TIME)

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FE5 84

Cl!!R

GROUP 16 BRUSH INSPECTION

BRUSHES

WORN

UNEVEN

IF SPRING

TENSION

IS NOT

FOR EACH BRUSH,

REPLACE

THE SAME

REPLACE BRUSH IF PIGTAIL IS LO,OSE IN THE BRUSH.

i

REPLACE

SPRINGS.

BRUSH

IF OIL

SOAKED

IF BRUSH PIGTAIL IS LOOSE AT THE BRUSH HOLDER TIGHTEN SCREW.

* REPLACE BRUSHES WHEN WORN TO HERE.

NEW

BRUSHES

* Refer to motor brush specifications.

Measurement should be taken to the longest side on commutator contour.

Code: PMA-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 5

0

-I

m

cn

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GEA-7053

SATISFACTORY

LIGHT

TAN

surface

is one

often

seen

FILM of

over many

entire

commutator

norm.1

MOTTLED

conditions

on a well-functioning

tern

machine.

condition

WATCH

STREAKING beginning

on the commutator of serious

Check

brush.

the

COPPER

DRAG,

material,

forms

dition

is rare

metal

char+

below

an abnormal most ohen

but

can

surface

transfer for

cause

possible

build-up

at trailing flashover

signals

to the

the

SLOT

industry.

related

FOR

THESE

THREADING

of

excessive

to resurfacing

PITCH

BAR-MARKING commutator

Carbon Products General Electric East Stroudsburg,

with

transfer

of commutator

and

The

half or all the number

Company Pa. 18301

number

in a definite

of conductors

fine

lines

results

occurs. It usually

produces surface.

to

a slightly

on bars

DANGER

commutator

metal

on the

ings equals

BAR-MARKING,

film, appears

in

causes.

checked.

film potobserved

commutators

when

of bar. Con-

if not

of

with random

most frequently

carbon

of commutator

edge

SURFACE

is probably

SURFACES

COMMUTATOR

rapid

brush wear.

low

or burned

number

of these

of poles

leads

spots mark-

on the motor.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

darker

HEAVY

pattern per

area

slot.

FILM

can

of efficient

tar and,

qppeor

and

if uniform,

over

norm4

entire

commute-

is quite

acceptable.

SIGNS

GROOVING

is a mechanical

by abrasive phere.

material

If grooves

HEAVY

SLOT

etching

of trailing

tern

is related

form,

in the start

BAR-MARKING edge

to number

condition brush

caused

or otmor-

corrective

can

of commutator of conductors

action.

involve bar.

Pat-

per

slot.

GROUP 16

cl!!wM

GROUP

1

SECTION

2 DRIVE MOTOR BRUSH REPLACEMENT General Electric Drive Motors

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 2, Page 1

GROUP 16 DRIVE MOTOR BRUSH REPLACEMENT (General Electric Drive Motors) IMPORTANT DRIVE MOTOR IN THE TRUCK: 1.

Turn key switch to the "Off" position.

2.

Disconnect battery from truck receptacle.

3.

Remove the battery from the truck.

THE DRIVE MOTOR BRUSHES CAN BE REPLACED WITHOUT REMOVING THE DRIVE MOTOR FROM THE TRUCK OR DRIVE AXLE.

1

NOTE The drive motor brush holders on end of motor are accessible through the opening in front floor of battery compartment.

The floorboards may be removed for better visibility and access.

4.

To remove brush holders: (Fig. 83M465) 83M45i

1)

Loosen the hex head lock nut (A) on brush retaining screw.

2)

Tighten the brush retaining screw (C) against the brushes.

This clamps and holds the brushes from dropping out of position and being damaged from striking the commutator during removal and installation through the motor end bell.

DO NOT OVERTIGHTEN!

3) Remove the two Allen head screws (B) that hold each brush holder assembly.

83M465

4) Carefully remove the brush holder from end bell of motor.

5.

Loosen the brush retaining screw (C) to free up the brushes.

6.

Inspect the brushes. Refer to GROUP 16, Section 27 for brush wear check.

Section 2, Page 2

83M434

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

CLflRK 7.

GROUP

16

To change brushes:

1)

Remove screw holding brush shunt terminal.

2)

Remove brush spring. Grasp edges of spring between thumb and forefinger.

Press down, then incline spring towards center of brush box. Spring will pop free.

83M435

3) Remove old brushes.

4) Install new brushes and connect brush shunt terminal.

5) Replace springs. Hold spring with thumb on top and forefinger under spring coil. Insert spring into pocket and engage tab on spring with brush holder.

Release the spring.

6) Repeat until all brushes are changed.

83M436

8. With brushes and springs in place, push down on holder assembly until bottom of holder is flush with brush face.

9. Tighten the brush retaining screw (C). This clamps and holds the brushes in the retracted position while installing into motor to avoid damage to the brushes from striking on commutator of motor.

DO NOT OVERTIGHTEN.

83M433

10. Carefully install each brush holder assembly back into the motor end.

11. Install and tighten the Allen screws (B).

12. Loosen and back out the brush retaining screw (C) until it stops and will turn no more.

13. Tighten the hex lock nut (A) on brush retaining screw.

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

83M465

Section 2, Page 3

GROUP 16 14. Remove wrap-around cover over top of commutator from motor.

15. Connect battery adapter cable to truck receptacle.

16. Raise the drive wheels off the floor (wheels up).

17. Using the truck controls, operate the drive motor. Push down on accelerator pedal approximately halfway. This will run drive motor at a speed between 1000 RPM and 1300 RPM. 18. Apply seating stone to commutator.

Check brush fit after 30-second run. Brushes should have 100 per cent circumferential fit. Correct brush fit will normally be indicated by a full shiny surface on face of brushes, and uniform clean, bright look on the motor commutator.

19. Continute until brushes are seated to the contour of the commutator.

20. Air clean the brushes and commutator using dry, non-oiled air.

CAUTION Eye protection is necessary.

OR DRYING WITH AIR PRESSURE. REDUCE PRESSURE TO [207 kPa] 30 PSI. DEBRIS REMOVED WITH

21. Lower drive wheels.

Disconnect battery adapter cable from truck receptacle.

22. Install wrap-around cover on motor.

Section 2, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

GROUP

16

SECTION

3 DRIVE MOTOR BRUSH REPLACEMENT Prestolite Drive Motors

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 3, Page 1

CMRK

GROUP 16 DRIVE MOTOR BRUSH REPLACEM.ENT (Prestolite Drive Motors) DRIVE MOTOR IN THE TRUCK: 1.

Turn key switch to "Off" position.

2,

Disconnect battery from truck receptacle.

3.

Remove the battery from the truck.

IMPORTANT THE DRIVE MOTOR BRUSHES CAN BE REPLACED WITHOUT REMOVING THE DRIVE MOTOR FROM THE TRUCK OR DRIVE AXLE.

NOTE The drive motor brush holders on end of motor are accessible through the opening in front of battery compartment floor. The floorboards may be removed for better visibility and access.

For easy identification it may be noted that Prestolite motors are painted black color.

4.

Fig. 22184

To remove brush holders: NOTE Early models of Prestolite drive motors have brush retainment screws to clamp the brushes in a retracted position during removal and installation.

Except for the use of this screw the brush holder removal for either style of motor is the same.

1)

For motors with brush retainment screw (A), remove screw from the "Store" position (marked on brush holder) and place in "Clamp" position. Turn clockwise to clamp the brushes.

Finger tighten only.

2)

Loosen and remove the two bolts (B) that hold brush holder in place.

Section 3, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

83M472

Code: PMA-510, FEB 84

GROUP

16 3) Carefully remove the brush holder from end of motor.

Rotate holder as necessary for brushes to clear opening.

83M437 5.

Loosen the brush retainment screw (A) to free up the brushes.

6.

Inspect the brushes. Refer to GROUP 16, Section 27 for brush wear check.

Fig. 21854 7.

To change brushes: 1) Remove screws (C) holding brush shunt terminals.

2) Pull spring away from top of brush and pull brush out of brush box.

3) Remove all old brushes.

4) Install new brushes. Hold spring out of way and insert brush into brush box. Release spring against top of brush.

Connect brush shunt terminal.

83M438

5) Repeat until all brushes are changed.

83M439

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 3, Page 3

8.

With brushes and springs in place, push face of brushes up until brush is flush with bottom of brush box.

9.

Finger tighten the brush retaining screw (A) to clamp the brushes in place. DO NOT USE WRENCH.

83M438 10. Carefully install each brush holder assembly back into the motor end.

For motors without brush clamp screw, the brushes may be rested against the motor commutator to push the brushes into brush box while brush holder is rotated until the mounting screw holes line up.

83M437

11. Install and tighten the brush holder mounting bolts (B). The torque on these bolts is [8-9 N.m] 6-7 lbf. ft. DO NOT OVERTIGHTEN. Note: The brush holders are made of non-metallic material and may be damaged if bolts are overtightened.

12. Loosen and remove clamp screw (A) from "Clamp" position and install Finger in "Store" position. tighten only. DO NOT USE WRENCH.

Section 3, Page 4

83M472

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

CMRK

GROUP

16

13. Remove inspection plate over top of commutator from motor.

14. Connect battery adapter cable to truck receptacle.

15. Raise the drive wheels off the floor (wheels up).

16. Using the truck controls, operate the drive motor. Push down on accelerator pedal approximately halfway. This will run drive motor at a speed between 1000 RPM and 1300 RPM. 17. Apply seating stone to commutator.

Check brush fit after 30-second run.

Brushes should have 100 per cent circumferential fit. Correct brush fit will normally be indicated by a full shiny surface on face of brushes, and uniform clean, bright look on the motor commutator.

18. Continue until brushes are seated to the contour of the commutator. lg. Air clean the brushes and commutator using dry, non-oiled air.

CAUTION Eye protection is necessary.

1 AIR

PRESSURE

CAN CAUSE

INjURY.

20. Lower drive wheels. Disconnect battery adapter cable from truck receptacle.

21. Install inspection plate on motor.

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 3, Page 5

PM

OTES

11146-ZCopyrighted REV DECMaterial 83 Intended for CLARK dealers only Do not sell or distribute

CLsRw

GROUP

9

OUP 19

SECTION

3 TUNEUP FOR NEW OR MISTUNED GE EV-1 SCR #1 CARD INITIAL ADJUSTMENT PROCEDURES FOR EV-1 NUMBER ONE CARD SERVICE REPLACEMENT

IMPORTANT WHEN A NEW #l OSCILLATOR CARD IS REQUIRED, EACH TRIMPOT MUST BE PREADJUSTED BEFORE INSTALLING THE NEW CARD INTO THE TRUCK CONTROL. NOTICE These are preliminary nominal settings which may require additional tuning to match the truck performance requirements.

Control panels as originally installed are factory adjusted for a particular motor and truck and should not need adjustment.

The SCR card is equipped with single turn potentiometers with internal stops. The box has "Dial" marks for setting each potentiometer.

Turning the pots clockwise (CW) increases the particular function.

For example, CW adjustment increases creep speed, acceleration rate (C/A Pot), C/L (Regenerative Braking), 1A Time, 1A DO, Plugging (stiffness), FW PU, and FW DO. Refer to Book No. 59-854-0005, System Diagnosis SCR Controls, for instructions on operation and troubleshooting of GE Model EV-1 solid-state controls.

Code: PMA-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 3, Page 1

GROUP

19 INITIAL ADJUSTMENT PROCEDURES FOR GE EV-1 SCR #l CARD SERVICE REPLACEMENT NOTICE Turn all trimpots fully counterclockwise (CC\) to the "1" dial setting. Then adjust each potentiometer to the dial setting specified below.

Fig. 18639

Adjust the creep speed potentiometer clockwise to dial setting 4.

Adjust the controlled acceleration (C/A) potentiometer clockwise to dial setting 5.

Fig. 18640 Adjust the regenerative braking (C/L) potentiometer clockwise to dial setting 4.

Fig. 18641 Adjust the 1A time potentiometer clockwise to dial setting 2.5.

Fig. 18652

Section 3, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

GROUP

9 Adjust the 1A drop out (1A D.O.) potentiometer clockwise to dial setting 9.

Fig. 18653 Adjust the plugging (plug) potentiometer clockwise to dial setting 3.

Fig. 18654 Adjust the field weakening pick up (FW P.U.) potentiometer clockwise to dial setting 4.

Fig. 18655 Adjust the field weakening drop out (FW D.O.) potentiometer clockwise to dial setting 4.5.

Fig. 18656

PMA-510, DEC 80

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 3, Page 3

PM

NOTES

1146-Z REV DEC 83

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP 19

ou

19, SECTION

4

PUMP

AND

TRACTION

L.E.D.

PUMP

MOTOR CARD

PM&510, REV JAN 82

CONTROL CHECK

SPEED

CONTROL

ADJUSTMENT

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 4, Page 1

CMRU

GROUP

19 TRACTION

CONTROL

ANC L.E.D.

RAISE DRIVE !JHEELS OFF THE upright in full back tilt, blocking beneath the outer upright.

CHECK FLOOR. CJith place wood rails of the

Place a metal plate on top of each block, then tilt upright forward, raising izlheels off the floor.

WOOD

TEEL

BLOCKING

PLATE

Fig. 14099 TURN

key s!*litchto "Off"

3ISCOWiECT the battery

position.

at truck

receptacle.

OPEN the traction ment door.

REMOVE the fuse control.

control le!- cxl~xrt-

box cover

on traction

83M455 Set V.9.M. on Rxl scale.

Check for ?I.9.!~1. reading should he :1:7erl fuses. !iear c! phr?s.

Fig. 22228

REMOVE ALL JEWELRY BEFORE WORKING ON ANY ELECTRICAL SEVERE BURNS CAN RESULT FROM CONTACT WITH

Section

4, Paqe

2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code:

PMA-510,

REV FEB 84

GROUP

CLqRK

19

To test (verify) that instrument panel indicator lights are functioning properly: Turn key switch to extreme right ("Test") position.

Fig. 22161 Red indicator lights on overhead instrument panel should illuminate.

Fig. 22173 To test (verify) that traction control L.E.D. indicator lights are functioning properly: L.E.D. lights are mounted on outside top edge of traction control.

Push the button labeled "L.E.D. Test Switch" to check L.E.D. lights. All four L.E.D.'s should illuminate.

83M457 CHECK "P" (PUMP) L.E.D.: Turn key switch to "On" position.

Fig. 22161

Code: PMA-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 4, Page 3

GROUP 19

CMRK

Place directional lever in "Neutral" position.

Fig. 22158 Hold the driver's seat down.

Fig. 22230 The "P" (Pump) L.E.D. should illuminate and the pump motor should begin to operate.

Place directional lever in "Forward" position.

Fig. 221G7

Section 4, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PfvlA-510,REV FEB 84

GROUP

19 Depress accelerator pedal partially down .

Fig. 22167 The "F" (Forward) L.E.D. should illuminate.

Repeat the above test for "Reverse" direction.

Place directional lever in "Reverse" oosition. Depress accelerator pedal partially down.

The "R" (Reverse) L.E.D. should illuminate.

83M468

CHECK "1A" L.E.D: (Trucks w/field weakening) Place directional lever in either forFully deward or reverse direction.

"1A" L.E.D. should press accelerator. light within 3 seconds.

This test check includes the '2MS switch.

"1A" L.E.D. will not illuminate if the truck is not equipped with field weakening (optional).

83M469

CHECK ACCELERATOR OUTPUI: Set V.O.M. on 1OV. scale. Connect Creep meter leads as in Fig. 83M458. position should give a meter reading of 4 volts (t 1 volt). With pedal fully deoressed, the meter reading should be 0 volts (+ 0.5 volt).

83M458

Code: PMA-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 4, Page 5

Cl!!RK

GROUP 19 PUMP CONTROL: Make certain "P" (Pump) L.E.D. illuminates in traction control by turning key switch to "On" position, placing directional lever in "Neutral", and holding the driver's seat down.

83M467 Check "lift/aux" L.E.D., located in pump control box. It should not be illuminated when the Economy-Performance switch (1) is in the "Economy" position.

Note: The "ECON-PERF" switch uses the AUX 1 card circuitry. Therefore, the LED light is on anytime the pump control is operated in the "PERF" mode or "Lift" mode.

83M479

The "lift/aux" L.E.D. should be illuminated under the following conditions.

1.

With switch in performance position, seat down, directional lever out of park position and key switch in-on position.

2.

With switch in economy position, seat down, directional lever out of park position, key switch in on position and lift and/or aux valve lever actuated.

83M479

hl

11

n

u

1-

I

r

c

When troubleshooting the pump control, the "ECONOMY" mode.

In this mode the LED will This will assist lift switch is actuated. the switch or the electronics are at fault to operate.

Section 4, Page 6

switch should be in the only indicate when the in determining whether should the lift fail

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FE9 84

GROUP

MRK

19

Check #7 fuse located in pump control box for continuity.

83M479 Set V.O.M. on 100-volt scale. Measure voltage between "PC-P" and "PC-Neg" terminals. Meter reading should be battery volts.

83M479

Code: PMA-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 4, Page 7

PM

WIRK

NOTES

1146-Z REV DEC 83

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP

20

SECTION

1 DRIVE

Code: PMA-510, REV FEB 84

UNIT

MAINTENANCE

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 1

GROUP

CLflRK

20 DRIVE UNIT CRANKCASE LUBRICATION: Drain and refill the drive unit once a year or every 2,000 operating hours, whichever comes first.

Park truck on a flat level surface .

DRAIN DRIVE UNIT WHEN FLUID IS ~~~

Fig. 22175 The best procedure to use for access to the drive axle drain plug, oil level check plug and filler plug is dependent upon the style of upright, carriage and attachments on the truck, as well as the shop facilities available.

It can generally be best determined by looking at your specific truck model.

When suitable equipment is available, the truck may be raised or hoisted up and placed in a level position on wheel cradles to allow access under the axle. Otherwise, if it is necessary to reach the axle from the front of the truck, raise the carriage only high enough to provide access to the axle. BE SURE TO PLACE BLOCKING UNDER THE CARRIAGE AND UPRIGHT RAILS. Also refer to PMA Section, Page 30.

DO NOT WALK OR STAND UNDER RAISED FORKS. THE FORKS CAN FALL AND CAUSE INJURY OR DEATH.

Fig. 22154

Place directional lever in park position.

Turn key switch to the "Off" position.

Disconnect battery from truck receptacle.

Fig. 22163

Section 1, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

GROUP

20 Place a low flat drain pan beneath the drive unit.

The pan capacity should be more than [3.785 litres] 8 pints (drive unit capacity).

Fig. 20518 Remove drain plug (2) and fill/oil level dipstick plug (I). Uhile the drive unit is draining, check the vent (3) to be sure it is open and not damaged.

After drive unit has drained, install drain Plug (2). Remove the large inspection/filler plug (4) in top center of axle. Fill the drive unit to the bottom edge of fill/oil level plug opening (1) with recommended fluid (noted

be1 ow) : IUPORTANT The following drive axle lubricant is recommended for best operation of the disc brakes: TEXACO 8570 ATF or Clark Part No. 962669

Fig. 24925

Install fill/level plug.

84M233 Install large filler plug on top of axle.

Remove drain pan. Remove blocking and lower carriage.

84M256

Code: PMA-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 3

GROUP

20 BRAKE DISC tiEAR CLEARANCE CHECK The purpose of this check is to determine the "worn" thickness of the inner (friction) brake discs. The remaining thickness of the inner plates is readily determined by measuring the space (clearance) between two steel outer discs.

The minimum allowable "worn" thickness of the inner friction discs is [2,6 mm] 0.104 inch. Measurable wear of the steel outer discs is normally not expected.

The brakes must be fully applied during this check to make sure that all of the operating running clearance is removed.

1.

Put blocks on each side of the drive wheels to prevent truck from moving.

2.

Lower the lift carriage to the floor and tilt upright fully forward. Alternate procedure: Raise the upright and carriage, to give access to drive axle.

(Fig. 22154)

PUT POSTS UNDER THE UPRIGHT AND CARRIAGE AS SHOWN IN FIGURE 22154 TO KEEP IT FROM FALLING AND CAUSING PERSONAL INJURY.

Fig. 22154 3.

Remove the brake inspection plugs (5) from top of drive axle housing.

Fig. 24925

Section 1, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

GROUP

EL9RK 4.

20

Apply parking brake or push down on the brake pedal and maintain 100 PSI force against the pedal while checking the brake discs.

Fig. 17592 5.

Brake disc gauge (6) dimensions are shown by Figure 20716.

I------[152]

6.0

-

h31 0.25

-I-

D5.41 1.0

1

ri-

L+

Fig. 20716 6.

Insert the gauge into the axle through the brake inspection plug opening (5). Try to put the brake disc clearance gauge (6) between two steel discs (8), Figure 24982.

Minimum disc clearance is [2,6 mm] 0.104 inch.

Fig. 21977 7.

The gauge (6) should go between the outer discs (8). If it does not, the brake inner (friction) discs (7) are worn and require replacement.

Refer to Overhaul Manual OH-510, GROUP 20, Section 13 for drive axle overhaul.

Fig. 24982

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 5

z

0 I-J )-L

e

-I

m

cn

R

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute N

GROUP

22

SECTION

1 PNEUMATIC

Code: PMA-270, REV JUL 80

TIRE

&

WHEEL

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

MAINTENANCE

Section 1, Page 1

GROUP

22

I

FOR YOUR SAFETY AND THE SAFETY OF OTHERS! BEFORE YOU DO TIRE OR RIM MAINTENANCE: READ THE OSHA RULES REGARDING OWNER RESPONSIBILITY. DO NOT WORK ON TIRES OR RIMS UNLESS YOU HAVE BEEN TRAINED IN THE CORRECT PROCEDURES. READ AND UNDERSTAND ALL MAINTENANCE AND REPAIR PROCEDURES ON TIRES AND RIMS. SERIOUS INJURY OR DEATH CAN RESULT IF THE SAFETY MESSAGES ARE IGNORED.

"The Occupational Safety and Health Act (OSHA) specifies required procedures for servicing multi-piece rim wheels in 29 CFR Section 1910.177.

It is the owners responsibility to comply with OSHA

In accordance with OSHA, the owner must provide a training program to train and instruct all employees who service multi-piece rim wheels in the hazards involved and the safety procedures to be followed.

Do not let anyone mount, demount or service multi-piece rim wheels without correct training.

The owner should obtain and maintain in the service area current copies of the United States Department of Transportation, National Highway Traffic Safety Administration publications entitled 'Safety Precautions for Mounting and Demounting Tube-Type Truck/Bus Tires' and 'Multi-Piece Rim/Wheel Matching Chart' or other similar publications applicable to the types of multi-piece rim wheels being serviced.

,

The following instructions supplement the OSHA requirements.

In the event of any conflict or inconsistency between these instructions and the OSHA requirements, the OSHA requirements shall be controlling."

Section 1, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-270, REV FEB 84

GROUP 22

CLsRK MAINTENANCE

FOR PNEUMATIC TIRES: !

13

WARNING -----__

REMOVE THE AIR FROM THE TIRES BEFORE YOU REMOVE THE WHEELS FROM THE TRUCK.

Check the tire air pressure. Low tire pressure can decrease stability of the truck.

(Refer to the truck PMA Manual GROUP 40 for the correct tire pressure specifications.)

Fig. 21523

IMPORTANT CHECK WHEELS AND TIRES FOR CHECK TIRE PRESSURE. MAKE DIRT CAN GET INTO CUTS AND REMOVE DEBRIS TIRE TREAD.

DAMAGE EVERY TIME YOU REPAIRS WHEN NEEDED. CAUSE DAMAGE TO THE FROM ALL CUTS.

CHECKING, MINOR REPAIR & CLEAN-UP: 7

1.

2.

3.

4.

5.

6.

7.

8.

9.

Check tires for cuts and breaks.

Check for loose nuts or nuts not in position.

Check the surface of the wheels for bent flanges.

Check the nuts or bolts for damage.

Check all parts for rust or corrosion.

Mark the damaged areas with chalk so that the parts can be removed from operation.

Remove all parts that have damage and install new parts in the same position.

Replace parts with the correct sizes and types. See your parts manual.

Include your truck serial number when ordering replacement parts.

Fig. 21521

Fig. A0821

TIRES INSTALLED ON LOCK RING TYPE WHEELS: WARNING ------_ BEFORE YOU LOOSEN THE WHEEL MOUNTING BOLTS OR NUTS, REMOVE THE AIR FROM THE TIRE. FAILURE TO REMOVE THE AIR FROM THE TIRE CAN RESULT IN INJURY. Remove valve core from the valve stem.

Code: PMA-270, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 18631

Section 1, Page 3

INDUSTRIAL

TRUCK DIVISION

CUSTOMER SERVICES GROUP

After you remove air from the tire, then loosen and remove the wheel bolts or nuts.

Remove the wheel.

Fig. 18924 Remove lock ring.

Remove wheel wedge.

Fig. 18630

Fig. 18316 Remove tire from wheel.

Remove the rubber tube protector.

Repair tire and/or tube.

Fig. 18314

CRACKS IN THE WHEEL ARE CAUSED BY: 1.

2.

3.

4.

Fig. 18629

Check for cracks in the wheel.

Deep rim tool marks.

Too much load on wheels.

Too much air pressure in the tires.

Using the wrong size tires.

Fig. 18304

Section 1, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-270, REV JUL 80

q N

GROUP

22

CRACKS IN THE LOCK RING ARE CAUSED BY: 1.

2.

3.

4.

Deep rim tool marks.

Too much load on wheels.

Too much air pressure in the tires.

Using the wrong size tires.

Check for cracks in the lock ring.

Fig. 18305 CRACKS ARE CAUSED BY: 1.

2.

3.

Check for cracks between the stud holes in the wheel.

Loose wheel nuts.

The wheel was not installed correctly.

The wrong size or type of parts were used.

Fig. 18306

TOO MUCH TORQUE ON THE WHEEL FASTENERS.

TOO LITTLE TORQUE ON THE WHEEL FASTENERS.

If the wheel mounting parts are too tight, the studs or bolts can break, causing cracks in the wheel between the stud holes.

If the wheel mounting parts are too loose, damage to parts and tire wear will result.

Check wedge ring for wear or damage.

TOO MUCH CORROSION WILL. CAUSE WEAR AND DAMAGE TO THE WHEEL WEDGE RING.

Q

Fig. 18307

Code: PMA-270, REV JUL 80

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 5

INDUSTRIAL

TRUCK DIVISION

CUSTOMER SERVICES GROUP

Clean the wheels. Remove rust and dirt.

Clean the tire bead seat area.

Remove all rust and rubber.

Fig. 18308

Fig. 18309

Clean wedge and lock rings. Make sure the seating surface and bead seat areas are clean.

Fig. 18310 Apply paint to the tire rim with a brush.

Or, use an aerosol can of metal primer.

The parts must be clean and dry before you apply the paint. Make sure to apply paint to the outside or tire side of the rim. This is important because air is on the metal surface of the tire side of the rim.

Fig. 18311 Apply lubricant on the tire side of the rim base. Do not use a lubricant that has water or solvent which will cause damage to the rubber.

CLARK DEALERS CAN SUPPLY THB CORRECT LUBRICANT WHICH CONTAINS A RUST INHIBITOR.

Fig. 18311

Section 1, Page 6

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-270, REV JUL 80

'd

GROUP

22 Put the tube into the tire.

Install washer '22.095 on tube over valve stem before flap is installed, if specified.* Put the rubber tube protector (flap) over the tube.

Fig. 18629 Install the tire onto the wheel rim, against the bead seat area.

Fig. 18314 Put the wheel wedge over the rim.

Install the wheel wedge.

Fig. 18317

Fig. 18316

Put the side ring over the rim and install the lock ring as shown.

Fig. 18627

Code: PMA-270, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 7

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

Connect air chuck and put [21 kPa] or 3 PSI of air into the tire.

Turn wheel to the other side.

Check to make sure lock ring is in correct location.

Fig. 16142

Fig. 18318

Use a mallet and hit the ring to make sure the ring is fully installed.

Disconnect the air chuck.

Fig. 18636 Put the tire in an OSHA approved safety cage.

Follow the procedures on the next two pages when you put air into your tires. If your air supply does not have enough pressure to fill the tire, you can use a nitrogen cylinder to get the correct tire pressure.

Connect a nitrogen cylinder to the valve stem with the use of an air chuck. TIRE IS STILL IN SAFETY CAGE! Refer to pages 11 and 12 on "How to adjust the regulator on the nitrogen cylinder".

WARNING -_----MAKE SURE THE EQUIPMENT USED (NITROGEN CYLINDER, GAUGES, REGULATOR, HOSES) ARE ALL IN GOOD CONDITION. MAKE SURE THE EQUIPMENT IS U.L. APPROVED. USE THE CORRECT REGULATOR AND HOSE FOR THE PRESSURES THAT ARE NECESSARY.

Fig. WARN ----

,398

ING ---

USE NITROGEN ONLY. DO NOT USE OXYGEN OR ANY OTHER GAS TO FILL YOUR TIRES.

Section 1, Page 8

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-270, REV JUL 80

GROUP

22

TY AIR GAUGE \

RELIEF VALVE I

SHUTOFF VALVE

SOURCE OF AIR SUPPLY

Fig. 9702

Typical Tire Filling Procedure

Filling Tires With Air All wheel and tire assemblies must be filled in a safety cage. The chose and components should be arranged as shown in Fig. 9702. The hose must have an adapter that can be connected to the valve stem.

1.

2.

3.

At intervals, close the control _I I I I .I . .. valve ana cnecK tne pressure in tne tire by reading the gauge. Do not put too much pressure into the tire.

4.

Continue to fill the tire to the correct capacity.

Attach an air hose to valve stem.

Open the control valve which will let compressed air into the tire.

Code: PMA-270, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

I M PO

RTANT

PUT EQUAL AIR PRESSURE IN BOTH TIRES OF A DUAL ASSEMBLY. DO lilOTPUT AIR INTO A TIRE THAT IS FLAT WITHOUT FIRST INSPECTING IT AND THE WHEEL FOR DAMAGE.

Section 1, Page 9

INDUSTRIAL

TRUCK DIVISION

CUSTOMER SERVICES GROUP

RELIEF VALVE Model 250V [6.35 mm] or l/4-INCH NPT Humphrey Products P.O. Box 2008 Kilgore at Sprinkle Road Kalamazoo, Michigan

AIR PRESSURE GAUGE MARSHALTOWN f23 [1,103 kPa] or 160 lb.

[6.35 mm] or l/4-INCH NPT [63.5 mm] DIAMETER or 2-l/2-INCH DIAMETER Kendall Industrial Supplies, Inc. 702 North 20th Street Battle Creek, Michigan -49016-

SHUT-OFF CONTROL IMPERIAL #77E [6.35 mm] or l/4-INCH NPT

SAFETY CAGE (OSHA APPROVED) Meyers Tire Supplies 6400 Epworth Blvd.

Detroit, Michigan

CLIP-ON

AIR

CHUCK

NOTICE: YOU CAN ORDER PARTS FROM THE DEALERS LISTED ABOVE OR FROM ANY SUPPLIER.

Section 1, Page 10

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code

PMA-270, REV JUL 80

HOW TO ADJUST THE REGULATOR ON THE NITROGEN CYLINDER: Be sure cylinder valve is closed.

Turn the regulator valve counterclockwise until you can feel no resistance from the regulator.

This will adjust the regulator pressure to a low pressure near zero.

Fig. 18324

Slowly turn the cylinder valve counterclockwise to open position.

I

/

The tank gauge will now show tank pressure.

Fig. 18324

Fig. 18324

Turn the regulator valve clockwise until the regulator gauge reads the correct tire pressure. Fill the tire with nitrogen.

Fig. 18324 Turn the tank valve clockwise and close the valve.

//

I

I

Fig. 18324

Code: PMA-270, REV JLJL 80

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 11

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Disconnect the air chuck from the valve stem.

Fig. 16141 Turn the regulator valve counterclockwise the off position.

to

Use a tire pressure gauge to check the tire If necessary, put more air into the pressure. tire. Do this as many times as necessary to reach the correct tire pressure.

Fig. 18324

CAUTION USE A LONG HANDLED GAUGE SO THAT YOUR HAND DOES NOT GO INSIDE THE CAGE, OR IN FRONT OF ANY COMPONENT OF A Fig. 21523

MULTI-PIECE WHEEL.

Section 1, Page 12

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-270, REV FEB 84

GROUP

22

PROCEDURES FOR ADDING AIR PRESSURE TO MOUNTED TIRE AND WHEEL ASSEMBLIES: A !

WARNING ---_---

BEFORE YOU ADD AIR PRESSURE TO THE TIRE, MAKE SURE THE LOCK RING IS CORRECTLY POSITIONED IN THE RIM AND SIDE RING. THE LOCK RING CAN SEPARATE FROM THE RIM WITH ENOUGH FORCE TO CAUSE INJURY OR DEATH. Fig. 18924 Attach a clip-on air chuck to valve stem.

Stand by the side of the wheel and put the correct air pressure in the tire.

Fig. 21524 If your air supply does not have enough pressure to fill the tire, you can use a nitrogen cylinder to get the correct pressure.

Put a clip-on type air chuck on the nitrogen cylinder hose and attach it to the valve stem.

Follow the procedures on pages 11 and 12 for adjustment of the nitrogen cylinder valves.

WARNING ------USE NITROGEN ONLY TO FILL YOUR TIRES. DO NOT USE OXYGEN OR OTHER GAS. Fig. 18927

Code: PMA-270, REV JUL 80

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 13

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

SPLIT WHEEL ASSEMBLIES: WARNING -----__ BEFORE REMOVING TIRES FROM SPLIT WHEEL ASSEMBLIES, REMOVE ALL AIR PRESSURE FROM THE TIRES. BEFORE YOU PUT AIR PRESSURE INTO TIRES WITH SPLIT WHEEL ASSEMBLIES, MAKE SURE THE SPLIT WHEEL ATTACHING BOLTS ARE INSTALLED AND TIGHTENED TO PROPER TORQUE VALUE. ALWAYS USE A SAFETY CAGE WHEN INFLATING TIRES.

Fig. 13761

Outside (A) bolts hold split wheel together.

Inside (B) bolts hold wheel assembly on the hub.

(Fig. 13761)

DIRECTIONAL TREAD TIRES: All directional tread tires are to be mounted in the correct position with respect to the arrow cast on the side of the tire as explained below.

Fig. 6422 Directional tread dual tires: 1.

Inside dual tire arrow to point in the direction of forward rotation, see Fig. 6422.

Rotate wheel to bring arrow on tire above the wheel. Arrow must point toward front of truck.

2.

Outside dual tire arrow to point in the direction of rearward rotation, see Fig. 6423.

Fig. 6423

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

Directional Tread Single Drive Tires: 1.

Tire arrow to point in the direction of forward rotation, see Fig. 6422.

Rotate wheel to bring arrow on tire above the wheel. Arrow must point toward front of truck, see Fig. 6422.

Section 1, Page 14

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 6422

Code: PMA-270, REV JUL 80

lNDUSTRlA9. TRUCK DIVISION CUSTOMER SERVICES GROUP

SAFETY

1.

Never attempt to weld on an inflated tire/rim assembly.

2.

Always remove all air from a single tire and from both tires of a dual assembly prior to removing any rim components, or any wheel components, such as nuts and rim clamps.

Make sure to remove the valve core and remove all air from the tire.

PROCEDURES

7.

Mixing parts of one manufacturer's rims with those of another is potentially dangerous. Always ask manufacturer for approval.

8.

Do not overload rims. Ask your rim manufacturer if special operating conditions are required.

9.

Do not fill a tire with air that has been run flat without first inspecting the tire, rim, and wheel assembly.

Remove the valve cores from both tires of a dual assembly.

Double check the lock ring for damage . . . make sure that it is secure in the gutter before filling the tire with air.

Check the valve stem by inserting a piece of wire through the stem to make sure it is not plugged.

3.

Check rim components periodically for fatigue cracks. Replace all cracked, badly worn, damaged and severely rusted components.

4.

Clean rims and repaint to stop detrimental effects of corrosion.

Be very careful to clean all dirt and rust from the lock ring gutter.

This is important to secure the lock ring in its proper position.

A filter on the air filling equipment to remove the moisture from the air line prevents a lot of corrosion. The filter should be checked periodically to make sure it is working properly.

5.

6.

Make sure correct parts are being assembled. Ask your distributor or the manufacturer if you have any doubts.

Double check to make sure all the components are properly seated prior to filling tire with air.

10. Never run a vehicle on ane tire of a dual assembly. The carrying capacity of the single tire and rim is dangerously exceeded, and operating a vehicle in this manner can result in damage to the rim.

11. Do not be careless or take chances.

If you are not sure about the proper mating of rim and wheel parts, consult a wheel and rim expert. This may be the tire man who is servicing your fleet, the rim and wheel distributor in your area, or the CLARK dealer.

1%. Do not use undersized rims. the rig'nt rims for the job.

Use

13. Do not seat rings by hitting with a hammer while the tire is filled.

Do not hit a filled or partially filled tire/rim assembly with a hammer.

14. Do not let anyone mount or demount tires without proper training.

Copyrighted Material Intended for CLARK dealers 1142-Z REVonly JUL Do not sell or distribute

80

INDUSTRIAL

TRUCK DIVISION

CUSTOMER SERVICES GROUP

SAFETY

PROCEDURES

15. Never sit on or stand in front of a tire and rim assembly that is being filled with air. Use a clip-on chuck and make sure hose is loq enough to permit the person fillinb the tire with air to stand to the side of the tire, not in front or in back of the tire assembly.

16.

Always stand to one side when you apply hydraulic‘pressure.

21. When using a cable or chain sling, stand away ... it might break.

Do not, under any circumstances, attempt to rework, weld heat, or braze any rim components that are cracked, broken or damaged. Replace with new parts or parts that are not cracked, broken, or damaged, which are of the same size, type and make.

17. Fill the tire with air in a safety cage.

18. Regardless of how hard or firm the ground appears, put hardwood blocks under the jack.

19. Block the tire and wheel on the other side of the vehicle, before you place the jack in position.

Place blocks under the truck frame as near as possible to the jack to prevent the truck from falling, if the jack should fail.

20. Remove the bead seat band slowly to prevent it from dropping off and crushing your toes. Support the band on your thigh and roll it slowly to the ground. This will protect your back and toes.

21. Bead breakers and rams apply pressure to bead flanges. Keep your fingers away from the bead flanges. Slant bead breaker about 10' to keep it firmly in place. If it slips off, it can fly with enough force to kill.

Copyrighted Material Intended for CLARK dealers only 1143-Z Do REV JUL 80 not sell or distribute

CLflRK

GROUP

23

ROUP

23 SECT10

PARKING

PMA-510, JAN 82

BRAKE

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

RELEASE

Section 1, Page 1

GROUP

23 PARKING BRAKE RELEASE: The parking brake is spring applied and in normal operation is released by hydraulic pressure.

If the truck must be moved and there is no hydraulic pressure, follow the instructions below to release the parking brake.

Disconnect the battery.

Fig. 17590 To release the parking brake the parking brake link on the top of the drive axle must be loosened to relieve the tension that applies the brake. The adjustor is on right hand side of axle. Remove the retainer pin (A) in the adjustor bolt. Turn the adjustor bolt (B) counter-clockwise until the bolt is completely loose and free with clearance showing under the head of bolt.

83M459 After the truck has been moved, adjust the parking brake link back to its original condition. Turn the brake adjustor bolt (B) fully clockwise until the parking brake link has been pulled together and completely seated. The torque on this adjustor bolt is [44-57 N'm] 32-42 lbf. ft. Install the spring retainer (A) in adjustor bolt.

Fig. 24926

WARN -----__

I NG

DO NOT OPERATE OR PARK A LIFT TRUCK WITH THE PARKING BRAKE DISCONNECTED. THE TRUCK WILL MOVE WHEN PARKED AND CAUSE INJURY OR DEATH TO PERSONNEL.

Section 1, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

GROUP

CLSRU

23

RO

23 SECTION

3 BRAKE BLEEDING PROCEDURE

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 3, Page 1

GROUP

23 BRAKE BLEEDING PROCEDURE: 1.

Park the truck on a level surface, with the steer whee s turned fully in either direction.

Fig. 22176 2.

Tilt the upright to the full forward position and lower the lift carriage to the floor.

Fig. 22179 3.

Turn key switch to the "Off" position.

Fig. 22161 4.

Put blocks at the front and rear of the drive wheels.

Fig. 22160

Section 3, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

GROUP 23

CMRK

5.

Remove the floorboards from the truck.

Fig. 22186 6.

Install bleed discharge lines on the two bleeder screws (one on the top side of each drive axle end housing).

Place the open ends of the bleed lines fully immersed into a separate container of hydraulic fluid, and open the bleeder screws.

7.

Sit in the operator's seat.

Fig. 24927

8.

Put the directional control lever in the "Neutral" position.

IMPORTANT DO NOT ACTUATE THE BRAKE PEDAL IN AN ATTEMPT TO REMOVE THE AIR FROM THE BRAKE SYSTEM.

9.

Turn key switch to the "On" position.

10.

Reach down and restrict the master cylinder return line by manually pinching the line to prevent hydraulic fluid from returning to the hydraulic tank. Then, turn the steering handwheel at a continuous rate (approximately one turn per second).

Fig. 22167

IMPORTANT MAKE SURE THE OPEN ENDS OF THE BLEED DISCHARGE LINES ARE FULLY IMMERSED IN THE CONTAINER OF HYDRAULIC FLUID OR AIR WILL BE DRAWN BACK INTO THE SYSTEM.

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 24928

Section 3, Page 3

GROUP 23 11. Continue to turn the steer wheels fully from one direction to the opposite direction until no air bubbles are seen in the container of hydraulic fluid.

Fig. 22279 12. Close the bleeder screws, and remove the bleed discharge lines.

Fig. 24927 13. Push on the brake pedal. It must be firm, and hold position. The pedal must not feel spongy or drift under foot pressure.

Fig. 17592 14. Install the floorboards.

15. Remove blocks from the drive wheels.

Fig. 22186

Section 3, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

GROUP

26

SECTION

2 CLEAN, STEER

PMA-fl0, DEC 80

REPACK WHEEL

AND

ADJUST

BEARINGS

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 2, Page 1

GROUP

CLSRK

26 CLEAN, REPACK AND ADJ"JST STEER ',aJHEEL BEARII'IGS: Cushion Tire Model

BE SURE TRUCK IS JACKED UP AND ADEQUATELY BLOCKED BEFORE BEGIi#ING. THIS SECTIO:d SHOI6 THE STEER AXLE REMOVED FRO11THE TRUCK, 1IITH IJHEELS OFF. 1.

Using a hammer and chisel, tap gently around the hub cap.

2.

Carefully loosen the hub cap with a pry bar.

Fig. 20959 3.

Remove the hub cap.

Fig. 20960 4.

Clean the excess 3rease from around the spindle nut.

Fig. 209Gl

Section 2, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: Pk!A-510, REV FEB 84

GROUP

26 5.

6.

7.

8.

Loosen

Remove

the self-locking

the nut

Pull the wheel

from

out,

spindle

nut.

Fig.

20962

Fig.

20963

Fig.

20964

the spindle.

as shown.

Remove the outer bearing.

Clean and inspect the bearing.

Fig. 20965

Code:

PMA-510,

REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section

2, Page 3

GROUP

26 9.

Pull the wheel off the spindle.

NOTE: Later model axles have grease fittings on the sides of the tie rod ends. There is no effect on service procedures.

Fig. 20966 10.

Lay it down with the outer edge !!?*

Fig. 20967 11.

Use a brass rod to drive the bearing and seal out of the wheel.

Fig. 20968 12.

If a brass rod is not available, a pipe the same diameter as the bearing may be used to drive the bearing and seal out of the wheel.

Fig. 20969

Section 2, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

GROUP

26 13.

Lift k~heel u;7 to expose bearing Clean the old grease and seal. out of center of wheel hub.

Fig. 14.

Remove the other hub and in the same manner.

20970

bearings

Clean and inspect the bearing cups and cones for wear and other Replace if necessary. damage.

Replace damaged bearing cups and cones as a set.

‘3 Fig. 20971 15.

Pack the bearings with grease and install the inner bearing in the wheel.

Recommended

greasing

procedure:

1) Use Grade No. 1 Lithium soap base multi-purpose grease, Clark MS-9B or equivalent.

2) Pack bearings iwith grease before assembly.

3) Pack cavity between bearings in hubs one-half full with grease at assembly.

16.

Install

a new grease

Fig. 21022

seal.

Apply coating of Grade No. 1 EP Lithium soap base grease, Clark MS-107C or equivalent to inside diameter of seal lips prior to assembly, then press to bottom of housing bore.

Fig.

Code:

PMA-510,

REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section

21023

2, Page

5

Cl!!!!RK

GROUP

26 17.

Carefully tap grease seal into place with a mallet.

Fig. 21024 18.

Put the wheel on the spindle.

19.

Install the outer wheel bearing after it has been packed with grease.

20.

Install new spindle nut.

IMPORTANT ALWAYS REPLACE WITH A NEW SPINDLE NUT. THE SELF-LOCKING CAPABILITY IS DESTROYED WHEN THE NUT IS REMOVED.

i r

Fig. 20963

Section 2, Page 6

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

GROUP

26 21.

Tighten to a torque of [230-244 N-m] 170-180 lbf. ft.

DO NOT OVERTIGHTEN! NOTE The steer wheel bearings are correctly adjusted by the specified torque on the spindle nut. Overtightening will cause drag and result in lower travel speed and higher power consumption.

23 L.

Fig. 21025

Pack the area around the nut with grease.

Fig. 21026 23.

Carefully and evenly tap the hub cap back on with a plastic or rubber mallet.

Be sure that hub cap is fully seated. Avoid damage or bending that may cause loose fit.

Fig. 21027

Code: PMA-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 2, Page 7

GROUP 26 CLEAN, REPACK AND ADJUST STEER IJHEEL BEARINGS: Pneumatic Tire Model 1.

Be sure truck is jacked up and adequately blocked before beginning.

2.

Grasp steer wheel and move it back and forth. Check free play at wheel bearings or steering knuckle bearings.

3.

Remove hubcap. Loosen self-locking spindle nut and hit top of wheel. This will allow bearings to be moved free of their seated position.

NOTE Refer to previous instructions for Cushion Tire Model for removal of wheels, bearings and seals.

Fig. 21133

4.

Clean, inspect and repack bearings.

If further service is necessary, refer to Overhaul ilanual OH-510, GROUP 26 for axle overhaul. Refer to GIIOUP 40, Section 4 for grease specification.

Also, see previous instructions for rec0iXlended greasing procedure.

5.

Install neii grease seals.

6.

Install bearings, huh and spindle nut.

INPORTAPIT REPLACE SPII'IDLEPaUT E.qCI-: TIilE IT IS REMOVED BECAUSE TORQI!E HOLDI1!G CAPABILITY IS PARTIALLY 3ESTRrjYEi?.

7.

Tighten spindl e nut to a torque of [230-244 N-m] 170-133 lbf. ft. [>$ '4CT The steer wheel bearin;;s OVERTIGHTEM. are correctly adjusted by the specified torque on the snindle nut.

8.

Install the hub cap.

Section 2, Page 8

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

CLSRK

GROUP

26

SECTION

3 POWER RELIEF

Code: PMA-510, FEB 84

STEERING PRESSURE

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SYSTEM CHECK

Sect-ion 3, Page 1

GROU 26 POWER STEERING SYSTEM RELIEF PRESSURE CHECK Refer to GROUP 40, Section 5 for power steering system relief pressure specifications.

The following procedure may be used to check steering system relief pressure only. No adjustment of the pressure can be made.

If relief pressure is not correct, it may be from dirt in the valve or worn parts.

Refer to SDM-510, System Diagnosis - Hydraulics for additional troubleshooting and testing procedures.

Refer to Overhaul Manual OH-510, GROUP 25, Section 9 for overhaul of power steering gear. Also, refer to OH-510, GROUP 29, Section 17 for main hydraulic pump overhaul.

The power steering control relief valve pressure setting may be checked with a MICO QUADRIGAGE (Clark Part No. 1800106), or with a conventional pressure gauge with pressure range calibration from [O-20,700 kPa] O-3000 PSI.

Fig. 11156

1.

Put blocks on each side of the drive wheels to prevent truck from moving.

Fig. 22160 2.

Remove the floorboards from truck.

Fig. 22186

Section 3, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

CLqRK 3.

GROUP

26

The power steering system pressure is checked at the diagnostic check port quick-disconnect fitting (with cap) located on the priority valve of power steering control at lower end of steering column.

Fig. 24933 4.

Remove the cap and connect the pressure gauge to the check port on power steering control.

Use quick-disconnect fitting, Clark Part No. 3797029.

NOTICE Move directional control lever to "NEUTRAL" position, and hold seat down for main pump to operate.

83M478 5.

Turn key switch to "ON" position.

6.

Turn steering handwheel in one direction until steering cylinder reaches its stop (relief position).

Hold steering handwheel in relief position until pressure reading is taken, and then release.

DO NOT OPERATE SYSTEM OVER RELIEF ANY LONGER THAN NECESSARY TO READ THE PRESSURE GAUGE. 7.

If further servicing is not required, turn key switch to "OFF" position. Remove gauge and install floorboards.

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 3, Page 3

TES

1146-Z Copyrighted REV DECMaterial 83

Intended for CLARK dealers only Do not sell or distribute

GROUP

CLqRK

29

GROUP

29 SECTION

1 HYDRAULIC

Code: PMA-510, FEB 84

FILTER

SUMP

FLUID CHANGE

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

AND

Section 1, Page 1

ROUP

LSRK

29 HYDRAULIC SUMP FLUID AND FILTER CHANGE: 1.

Park truck on level surface.

2.

Upright must be vertical and lift carriage fully down.

3.

Turn key switch to "Off" position.

4.

Disconnect battery from truck receptacle.

5.

Remove the battery from the truck.

6.

Remove the rear floorboard.

7.

Disconnect all hydraulic hoses at fittings (A) on hydraulic sump fill tube assembly (hydraulic sump cover). Also, disconnect oil filter return line.

8.

Remove the fastener bolt (B) at top of fill tube assembly.

9.

Remove the two mounting bolts (C) at the bottom of tank (underside of truck) that hold the sump tank in place.

10.

Move the sump tank towards the front of truck as far as possible.

11.

Remove the hydraulic sump fill cover clamp (D) and cover (breather, dipstick and return tube assembly).

12.

Using a separate pump with flexible suction hose inserted into the sump tank through the cover opening, pump out the contents of the sump tank.

13.

Install sump cover and cover clamp (D).

14.

Move sump tank back into place and install the sump tank mounting bolts (C).

Section 1, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

GROUP

29

29.788

HYDRAULIC 29.701 29.702

29.703 29.761

29.762 29.766

29.767 29.768 29.788 29.798 29.809

SUMP

PARTS

TANK, HYDRAULIC SUMP FASTENER, HYDRAULIC SUMP TANX SEAL, sw TANK (OUTLET) PLATE, HYDRAULIC SLIMPMOUNTING FASTENER, KYDRAULIC SUMP MOUNTING PLATE COVER, BYDRALKJC SUMP SEAL, SUMP TANK COVER FASTENER, HYDRAULIC SUMP COVER BREATHER, HYDRAULIC SUMP SCREEN, BYDRA'JLIC SUMP PRE-FILTER

91.067

DIPSTICK, SUMP LEVEL CLAMP, HYDRAULIC SUMP COVER LINE, IWDRAULIC SUMP OUTLET CLAMP, HYDRAULIC SUMP OUTLET LINE NUT, HYDRAULIC SUMP COVER FASTENER

93.697

NLJT,RYDRAULIC SUMF MOUNTING PLATE FASTENER

29.828 31.001 31.002

Code: PMA-510, FEB 84

29-15c

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 3

GROUP

29 15.

Install the fastener bolt (B) at top of fill tube assembly.

16.

Connect the respective hydraulic hoses at the fittings (A) on the fill tube assembly. Also, connect oil filter return line.

17.

Remove used hydraulic oil filter.

Install new oil filter.

18.

Remove the used sump fill cap/ breather.

83M447 19.

Fill sump tank with new fluid.

Refer to Group 40, Section 4 for hydraulic fluid specifications.

NOTE Pull dipstick part of the way out to vent air from tank while filling.

83M446 20.

Install new sump breather.

21.

Install and connect the battery, or use cable adapter, to operate the truck.

22.

Operate the truck hydraulic system.

Cycle the system several times and check for leaks. Check the sump fluid level. Add fluid as required. DO NOT OVERFILL.

23.

Install rear floorboard.

Section 1, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: WA-510,

FEB 84

GROUP

29 HYDRAULIC SUMP FLUID AND FILTER CHANGEALTERNATE METHOD: An alternate method for changing the hydraulic sump oil may be used for routine changing of the fluid. This method uses the truck hydraulic system to pump out the used oil.

1.

Park truck on level surface.

2.

Upright must be vertical and lift carriage fully down.

3.

Remove, the floorboards.

4.

Remove the snap-on cap and connect drain hose line to quick-disconnect fitting at the hydraulic pressure check port on the steering gear priority valve. Provide a drain pan of adequate capacity, or other method of disposal, for collecting the used oil.

5.

Move direction control lever to "Neutral" position. Hold seat down.

6.

Turn key switch to "On" position.

7.

Operate the truck hydraulic system at lowest speed (idle). A steady stream of used oil should flow from the drain line.

8.

Continue operation until the sump tank is emptied. This point will be reached when the pump starts to cavitate. When cavitation occurs the pump speed will increase. A change in pump speed pitch will be heard. Also, watch the drain line. The oil flow will become erratic or will stop when the pump can no longer pick up oil from the sump tank.

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

83M443

IMPORTANT BE CAREFUL WHEN SUMP IS NEARLY EMPTIED. WATCH FOR SIGNS OF PUMP CAVITATION. DO NOT OPERATE PUMP AFTER CAVITATION OCCURS.

Section I, Page 5

GROUP

29 9.

Turn the key switch to "Off" position as soon as pump cavitation is noted.

10.

Disconnect drain hose from truck.

Replace cap on the quick-disconnect fitting at hydraulic pressure check port.

11.

Remove used hydraulic oil filter.

Install new oil filter.

12.

Remove the used sump fill cap/ breather.

83M447 13.

Fill sump tank with new fluid.

DO NOT OVERFILL. Lubricant specifications are noted in Group 40, Section 4.

NOTE Pull dipstick part of the way out to vent air from tank while filling.

83M446

14.

Install new sump breather.

15.

Turn key switch to "On" position.

16.

Operate truck hydraulic system.

Cycle the hydraulic system several times. Raise lift carriage to the highest position and lower fully down. Check for leaks.

Section 1, Page 6

17.

Check hydraulic sump fluid level.

Add fluid as required. DO NOT OVERFILL.

18.

Turn key switch to "Off" position.

19.

Install the floorboards.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

CLqRK

GROUP

30

ROU

30 SECTION

1

HYDRAULIC

SYSTEM CHECK

AND

RELIEF

PRESSURE

ADJUSTMENT

HYDRAULIC

FLUID

PRESSURE

DO NOT USE YOUR HANDS TO CHECK FOR HYDRAULIC LEAKAGE. FLUID UNDER PRESSURE CAN PENETRATE YOUR SKIN AND CAUSE SERIOUS INJURY.

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 1

GROUP

30 HYDRAULIC

SYSTEid RELIEF

PRESSURE -~

CHECK

AND_ADJUST1,1ENT

Following is the general procedure for checking and setting main hydraulic valve lift and auxiliary relief pressure, for all ECA/EPA 36/48 volt trucks, Lot No. 5345 (ECA) and above, with pump control Part No. 2371890.

Refer to Special Procedure for setting relief pressure, for ECA/EPA 30 only, Lot Nos. ECA - 4510 thru 5325, EPA - 4595 thru 5330, with pump control Part No. 2371889.

See Page 5.

Refer to GROUP 40, Section 5 for relief pressure Refer to SDPI-510, System Diagnosis - Hydraulics, shooting and testing procedures.

specifications. for additional

IMPORTANT

trouble-

ilOTICE

IF ADJUSTMENT IS NECESSARY, DO NOT EXCEED THE RELIEF PRESSURE SETTING SPECIFIED FOR THE TRUCK MODEL CAPACITY RATING. CHANGING THE PRESSURE idILL NOT INCREASE LIFTING CAPACITY OR LIFTING SPEED.

The diagnostic check oort quickdisconnect fitting (with cap) for making hydraulic system pressure checks is located on priority valve of power steering control at lower end of steering coluirn.

See Fig. 24933, Page 4.

Hydraulic system relief pressure setting may be checked with a MICO QUADRIGAGE (Clark Part No. 1800106) or with a conventional pressure gauge with suitable pressure range calibration.

To cover all models including ECA/EPA 30 models with the highest pressure settings, a gauge with capacity range of [O-27,580 kPa] O-4000 PSI minimum is recommended.

Fig.

1.

Put blocks on each side wheels to prevent truck moving.

2.

Remove

3.

Remove the outer main valve.

4.

Remove the cap and connect the pressure gauge to the diagnostic check port on power steering control.

Use quick-disconnect adapter fitting, Clark Part No. 3797029.

Section

the floorboards

1, Page

2

cover

11156

of drive from

from

truck.

from

the

83M478

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Cade:

PMA-510,

FEB 84

GROUP

30 NOTICE Move directional control lever to "Neutral" position, and hold seat down for main pump to operate.

5.

Turn key switch to "On" position.

Fig. 22161 6.

Move the lift control lever to raise upright until it reaches the upper stop. CAUTION: MAKE SURE THE UPRIGHT HAS CLEARANCE AT THE TOP. Using the lift control will give maximum pump flow and pressure.

7.

Hold the lift control lever in relief position until pressure reading is taken, and then release.

Fig. 22159

IMPORTANT DO NOT OPERATE SYSTEM OVER RELIEF ANY LONGER THAN NECESSARY TO READ THE PRESSURE GAUGE. 8.

On the main valve, the main hydraulic system relief (1) and auxiliary relief ('2)are shown in Fig. 83M477. To adjust, loosen the lock nut, reset and tighten lock nut. Turn adjustment clockwise to increase pressure. Turn counterclockwise to decrease pressure.

9.

If pressure relief valve needs to be adjusted, loosen the lock nut, hold the lift lever in relief position, and turn the relief pressure adjustment screw until pressure gauge reads the correct relief pressure setting.

10.

Turn key switch to "Off" position, then tighten the lock nut.

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

83M477

83M475

Section 1, Page 3

CLqRK

GROUP

3 11.

Turn key switch to "On" position.

Move the lift control lever to relief position and read the pressure gauge. This is to verify that relief pressure setting has not been changed during tightening of lock nut.

Fig. 22159 12.

If relief pressure setting is not correct, repeat the procedure, Steps 8 and 9.

83M476 13.

When relief pressure setting is correct, disconnect the pressure gauge. Put the cap on quickdisconnect fitting.

Fig. 24933 14.

Install the cover enclosing main valve.

Install floorboards in truck. This completes the procedure for setting relief pressure.

Fig. 22186

Section 1, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

ELqRK

GROUP

30

HYDRAULIC SYSTEM RELIEF PRESSURE ADJUSTMENT - SPECIAL PROCEDURE Following is the special procedure for adjusting hydraulic valve lift and auxiliary relief pressure for ECA/EPA 30 only, Lot Nos. ECA-4510 thru 5325, EPA-4595 thru 5330, with pump control Part No. 2371889.

NOTE:

THIS PROCEDURE SHOULD BE USED ONLY BY TRAINED PERSONNEL.

This special procedure bypasses the speed and current limit circuits in the pump control to allow the main pump motor to develop correct speed and torque

PUMP MOTOR WILL RUN AT HIGH SPEED THE SEQUENCE OF OPERATION MUST BE FOLLOWED TO PREVENT DAMAGE TO THE

Refer to the general procedure for checking relief pressure, Pages 2 and 3.

Hydraulic system relief pressure setting may be checked with a MICO QUADRIGAGE (Clark Part No. 1800106) or with a conventional pressure gauge with suitable pressure range calibration.

To cover all models including ECA/EPA 30 models with the highest pressure settings, a gauge with capacity range of [O-27,580 kPa] O-4000 PSI minimum is recommended.

IMPORTANT IF ADJUSTMENT IS NECESSARY, DO NOT EXCEED THE RELIEF PRESSURE SETTING SPECIFIED FOR THE TRUCK MODEL CAPACITY RATING. 1.

Put blocks on each side of drive wheels to prevent truck from moving.

2.

Remove the floorboards from truck.

Remove the cover enclosing main valve.

3.

Remove the cap and connect the pressure gauge to the diagnostic check port on power steering control, Fig. 24933. Use quickdisconnect adapter fitting, Clark Part No. 3797029.

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 11156

I

Fig. 24933

83M478

Section 1, Page 5

GROUP

30 4.

Turn key switch to "OFF" position and disconnect battery from truck receptacle.

Fig. 17651 5.

Remove the top cover from pump control.

6.

On the pump control terminal strip, disconnect the input power cables from the two terminals marked "P" and "S". Then, connect the two input power cables together (to each other) with a bolt and nut.

Wrap the connection with electrical insulating tape.

7.

On main valve, loosen the lock nut on relief pressure setting screw.

8.

Connect the battery at truck receptacle.

Fig. 24983

NOTICE Move directional control lever to "NEUTRAL" position, and hold seat down for main pump to operate.

83M475 9.

Move the TILT CONTROL LEVER to full back tilt relief position.

THEN, turn key switch to "ON" position.

NOTE: PUMP MOTOR WILL RUN AT HIGH SPEED. Tilt lever must be held in relief position at all times that the key switch is in "ON" position.

Fig. 22245

Section I, Page 6

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

GROUP

30 10.

lJhile holding the iilt control lever in relief position, turn the relief pressure adjustment screw until pressure gauge reads the correct relief pressure setting. Turn adjustment clockwise to increase pressure. Turn counterclockwise to decrease pressure.

DO NOT OPERATE SYSTEM OVER RELIEF ANY LONGER THAN NECESSARY TO MAKE ADJUSTMENTS OR TO READ THE PRESSURE GAUGE. 11.

While holding tilt control lever in relief position, turn key switch to "OFF" position, and then tighten the lock nut on main valve.

Fig. 22161

12.

Move the tilt control lever back to relief position. THEN, turn key slditch to "ON" position and read the pressure gauge.

This is to verify that relief pressure setting has not been changed during tightening of lock nut. Turn key switch to "OFF" position.

Release the tilt control lever.

13.

If relief pressure is not correct, repeat the procedure, Steps 7, 9, 10 and 11.

14.

I/hen relief pressure setting is correct, turn key switch to "OFF" position, release the tilt control lever and disconnect battery at truck receptacle.

Fig. 17653

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 7

GROUP

30 15.

Remove the tape and separate the power cables that were connected together during Step 6. Install the correct cables back to t.te;;;;ls "P" and "S" on pump .

Install the top cover back on pump control.

1 Fig. 24983 16.

Connect the battery at truck receptacle and turn the key switch to "ON" position. The pump motor must run at idle (low) speed.

Fig. 22161 17.

Disconnect the pressure gauge, and install cap on quickdisconnect fitting.

la.

Install the cover enclosing main valve.

19.

Install the floorboards in truck.

This completes the special procedure for setting relief pressure.

Section 1, Page a

Fig. 22186

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

ROUP

CLRR

31

SECTION

1 HYDRAULIC

PMA-510, DEC 80

SCHEMATIC

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

DIAGRAM

Section 1,

Page 1

GROUP 31

HYDRAULIC ECA/EPA

SYSTEM

SCHEMATIC

DIAGRAM

17-30

LIFT CYLINDER ( STANDARD)

1

-o2-

TILT CYLINDERS n n

it-t

I VENT I LINE ALL UPRIGHTS

I

f

i

eI&-6

\.

w 1”l I_--_.____.._-_---____---____t----------, POWER

9

f/l

STEERING

i

1.

2.

3.

4.

5.

6.

7.

Return Line Filter Filter Bypass Valve Hydraulic Pump Priority Demand Valve with Pressure Relief Valve for Steering Power Steering Valve Power Steering Cylinder Main Hydraulic Valve Cdith: Pressure Relief Valve z: Lift, Lowering Spool with Load Check

Section 1, Page 2

C.

d.

8.

9.

10.

11.

12.

13.

Tilt Spool with Counterbalance Valve Auxiliary Spools

Lowering Flow Valve Breather Filter Hydraulic Tank Parking Brake Cylinder Service Brake Master Cylinder Diagnostic Check Port

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PMA-510, REV FEB 84

GROUP

32

SECTION

1 TILT

PMA-510, DEC 80

CYLINDER

ADJUSTMENT

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 1

CMRK

GROUP

32 TILT CYLINDER (UPRIGHT TMSTING) 1.

ADJUSTMENT:

Check condition of the tilt cylinder, rod end, mounting pins, piston rod, rod wiper, cylinder gland, etc., for excessive wear or damage. Make repairs before making twisting adjustment.

Upright twisting (racking) occurs when tilt cylinder strokes are unequal.

8314440

2.

With a capacity load (raised only high enough to clear the floor) slowly tilt upright fully forward, watching both piston rods for equal movement and upright for Forward twisting must be adjusted twisting. before backward twisting.

If forward adjustment is not needed, continue with Step 5.

83M44P 3.

Loosen rod end clamp bolt on the tilt cylinder that extends the farthest, and turn piston rod into rod end to shorten.

NOTE:

4.

5.

Use wrench flat on rod end under spacer. Move spacer for access.

Continue to turn rod into rod end until Tighten upright twisting is corrected. rod end clamp bolt.

83M470

Slowly tilt upright fully backwards while watching piston rods. They should both bottom out at the same time. If they don't, adjust backward tilt as follows.

Fig. 22241

Section 1, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

GROUP

32 6.

Stop the upright when the first tilt cylinder bottoms out against its rod spacer. Use rod shims to fill in the space between the rod end and spacer on the other tilt cylinder.

NOTE Shown is a standard tilt cylinder with spacer. Uprights with MFH of more than [3912 mm] 154 inches use spacers to restrict back tilt.

7.

After the excess space is taken up by the adjusting shims, test the full forward and backward tilt for correct adjustment.

Code: PMA-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

83M441

Section 1, Page 3

PM

NOTES

Material 1146-Z Copyrighted REV DEC 83

Intended for CLARK dealers only Do not sell or distribute

GROUP

32

SECTION

2 TILT

PMA-510, DEC 80

CYLINDER

DRIFT

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

TEST

Section 2, Page 1

GROUP

32 UPRIGHT TILT CYLINDER DRIFT TEST_ To check for drift, a TEST LOAD should be made and the TEST LOAD should be equally distributed on a 48" by 48" pallet. The TEST LOAD should be a full rated capacity load. Refer to the Serial Number Plate on your truck for capacity rating.

The TEST material arranged the TEST

LOAD must be secure on the pallet. The used to make up the TEST LOAD must be (stacked) to provide load stability and LOAD must not extend beyond the pallet.

First, make a TEST LOAD as stated above, then position the load on forks.

1.

Adjust fork width to maximum which will accomodate TEST LOAD. Space forks as wide as possible to provide even distribution of weight.

2.

Keep forks level during pick up.

3.

Enter pallet and TEST LOAD as far as possible.

TEST LOAD and/or pallet should be in contact with load back rest.

4.

Raise carriage and TEST LOAD approximately [305-381 mm] 12-15 inches off the floor.

Tilt the upright to full back position.

Shut off the truck. Turn key switch to "Off" position.

5.

Measure and mark the initial position of the tilt cylinder rod (see Fig. 14886).

An alternate procedure is to measure the change in the inclined angle of the upright, using a protractor and level, or inclinometer.

6.

Let upright with test load stand for the specified test time. Mark the new position of the tilt cylinder rod or upright. Measure the change in dimension or angle from the initial reference mark.

7.

Refer to GROUP 40, Section 5 for tilt cylinder drift specifications.

Section 2, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 14886

Code: PMA-510, REV FEB 84

GROUP 34

ClclR

SECTION

UPRIGHT CHECK

PMA-510, DEC 80

&

LIFT

ADJUSTMENT

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

CHAIN PROCEDURE

Section 1, Page L

GROUP 34 LIFT CHAIN CHECK AND ADJUSTMENT PROCEDURE The lift chains are mounted to the chain anchors on the lift carriage and at the chain anchor rods near the lift cylinder piston head.

If it becomes necessary to adjust the lift chains, proceed as follows:

WARNING ------TO AVOID INJURY, DO NOT GET UNDER THE LOAD AND CARRIAGE WHEN CHECKING THE CHAINS OR MAKING ADJUSTMENTS.

1.

Elevate carriage to about Cl219 mm] 4 feet.

2.

Apply grease to the innerslide channel as shown in Fig. 8622.

3.

Make sure upright is either vertical or slightly aft of vertical.

4.

Pick up a capacity load. Then, lower load to the fully-down position.

Fig. 6634

NOTE It is important that the chain adjustment check be made with a capacity load to allow for chain stretch.

5.

Remove capacity load.

6.

Raise carriage and measure the distance from where the center of the BOTTOM CARRIAGE ROLLER stopped to the edge of the inner slide. Distance must not be less than [12.7 mm] 0.50 inch.

Adjust lift chains as necessary.

7.

Be sure to wipe grease from rail.

8.

As a check procedure it may also be noted that upright lift carriage chains should be adjusted so that bottoms of forks are [12.1 mm] 0.50 inch above the floor with the upright vertical.

Section 1, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Fig. 8622

PMA-510, REV FEB 84

GROU

34

SECTION

3 UPRIGHT

PMA-510, DEC 80

DOWNDRIFT

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

TEST

Section 3, Page 1

GROUP

34 UPRIGHT DOWNDRIFT TEST To check for drift, a TEST LOAD should be made and the TEST LOAD should be equally distributed on a 48" by 48" pallet. The TEST LOAD should be a full rated capacity load. Refer to the Serial Number Plate on your truck for capacity rating.

The TEST material arranged the TEST

LOAD must be secure on the pallet. The used to make up the TEST LOAD must be (stacked) to provide load stability and LOAD must not extend beyond the pallet.

First, make a TEST LOAD as stated above, then position the load on forks.

1.

Adjust fork width to maximum which will accomodate TEST LOAD. Space forks as wide as possible to provide even distribution of weight.

2.

Keep forks level during pick up.

3.

Enter pallet and TEST LOAD as far as possible.

TEST LOAD and/or pallet should be in contact with load back rest.

4.

Raise carriage and TEST LOAD approximately [305-381 mm] 12 - 15 inches off the floor.

Tilt upright slightly backward (approximately 1 degree from vertical) at the same time. Shut off the truck.

Turn key switch to the "OFF" position.

5.

Stand at one side of the upright, not under the load, and mark all upright rails with a pencil.

6.

Let the upright hold the test load in the raised position for the specified test time.

Then check the movement of the reference mark.

Make new mark on movable rail in line with original mark on fixed rail. Measure distance between marks on rails and make a record of this dimension.

7.

Refer to GROUP 40, Section 5 for upright downdrift specifications.

12 TO 15 INCHES

Fig. 14887

Section 3, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

GROUP

cum

34

UPRIGHT DOWN DRIFT IN 5 MINUTES: TRUCK MODEL

TEMP.

STD.

HILO

TSU

QUAD

17, 2@

[26.7'C] 80°F

[8.Omm] 0.31 inch

[6.Omm] 0.24 inch

[6.Omm] 0.24 inch

[8.Omm] 0.31 inch

[37.8"C] lOOoF

[13.Omm] 0.52 inch

[lO.Omm] 0.39 inch

[lO.Omm] 0.39 inch

[14.Omm] 0.55 inch

[48.9'C] 120°F

[19.Omm] 0.75 inch

[14.Omm] 0.55 inch

[14.Omm] 0.55 inch

[21.Omm] 0.83 inch

[26.7'C] 80°F

[9.Omm] 0.35 inch

[7.Omm] 0.27 inch

[7.Omm] 0.27 inch

[37.8"C] 100°F

[15.Omm] 0.59 inch

[12.Omm] 0.47 inch

[12.Omm] 0.47 inch

[48.9'C] 120°F

[23.Omm] 0.91 inch

[17.Omm] 0.67 inch

[l'l.Omm] 0.67 inch

[26.7"C] 80°F

[ll.Omm] 0.43 inch

[8.Omm] 0.31 inch

[8.Omm] 0.31 inch

[37.8'C] 100°F

[18.Omm] 0.71 inch

[14.Omm] 0.55 inch

[14.Omm] 0.55 inch

[48.9'C] 120°F

[28.Omm] 1.10 inch

[21.Omm] 0.83 inch

[21.Omm] 0.83 inch

22, 25

27, 30

*

U.S. equivalents

PMA-510, DEC 80

(inch) are approximate values.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 3, Page 3

M

C

NOTES

1146-Z REV DEC 83 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP

34

SECTION

4 FORK WEAR INSPECTION

Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 4, Page 1

GROUP

34 FORK WEAR INSPECTION 1.

At each planned maintenance interval, an inspection and measurement of the forks must be made to check for wear.

2.

Allowable wear of fork thickness at the heel of the fork is as follows: 10% Wear Forks must be scheduled for replacement. With 10% wear, the forks are adequate for only approximately 80% of rated capacity.

Forks may be used until replacements are available.

20% Wear Forks are unsafe and must be removed from service immediately.

WEAR FACTOR TABLE

Standard Fork Thickness, inches 1.25 1.50 1.75 2.00 2.25 2.50

Nominal 10% Wear Thickness, inches (Replace) 1.12 1.38 1.56 1.81 2.00 2.25

Nominal 20% Wear Thickness, inches (Safety Hazard) 1.00 1.19 1.38 1.62 1.81 2.00

The percent caoacity reductions are based upon wear only.

Other factors such as cracks, cuts, holes, etc., may further reduce the capacity of the fork.

Section 4, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, FEB 84

GROUP

34

SECTION

7 LIFT

CHAIN

MAINTENANCE

Copyrighted Material

Code: PMA-416, REV MAR 82 P.S.L. Intended for CLARK dealers only Do not sell or distribute

Section 7, Page B

CLqRK

GR34up CONTENTS: I. II. III. IV.

LIFT CHAIN INSPECTION LIFT CHAIN LUBRICATION LIFT CHAIN REPLACEMENT CHECK LIST

FOREWORD: Lift chains are very important components on fork lift trucks. The chain system on your upright was designed for efficient, reliable transmission of lifting force from hydraulic cylinder to the forks. Safe use of your lift truck with little down-time, depends on the correct care and maintenance of the lift chains.

Most complaints of unacceptable chain performance are a result of poor maintenance.

Chains need periodic maintenance to give maximum service life.

Section 7, Page 2

Copyrighted Material Intended for CLARK dealersCode: only Do not sell or distribute

PMA-416, REV MAR 82 P.S.L.

GROUP

34 I.

LIFT CHAIN INSPECTION:

Inspect and lubricate the lift chains every truck PM (50-250 hours). See Section II for lubrication details.

When operating in corro sive environments, inspect the chai ns every 50 hours.

The maintenance person doing the inspection should look for the following chain conditi ons.

Wear 1.

As the chain rolls on and off the sheaves, the joints wear very slowly.

This increased length that occurs in a chain in service is caused by material being worn off the bearing joints.

Chain wear can be measured by using a steel tape (Fig. 23832). When chains have worn 3%, they must be discarded.

For example, [305 mm] one foot of BL634 chain contains 16 pitches (links).

When 16 pitches measure [314,6 mm] 12.375 inches, the chains must be replaced. When checking chain wear, make sure you measure a segment of chain that moves over a sheave. Do not repair chains by cutting out the worn section and joining a new piece. If part of a chain is worn, replace all the chains on the truck.

2. Rust and Corrosion Corrosion will reduce the load carrying capacity of lift chain because corrosion causes sideplate cracking.

It is very important to protect lift chains from corrosion whether in service or in storage. The factory lubrication on chains is a very good rust and corrosion inhibitor. The factory lubrication is applied in a hot dip tank to make sure there is complete penetration into the joint. After the chain has been put in service, there must be additional lubrication so there is a layer of oil on the chains at all times.

Heavy motor oil is used both as a

Copyrighted Material

--&__ 0 Fig. 23830 A.

B.

C.

lubricant and corrosion inhibitor.

During inspection, check for a layer of oil on the external chain surfaces.

Under some operating conditions it will be necessary to lubricate chains between P.M-.'s.

Code: PMA-4 16, REV FEB 84 P..S Intended .L. for CLARK dealers only Do not sell or distribute

Leaf Chain 1. Inner Linkplate 2. Outer Linkplate 3. Riveted Pin Roller Chain 4. Riveted Pin 5. Roller 6. Bushing Pin ;: Inner Linkplate 9. Outer Linkplate Rollerless Chain 10. Riveted Pin 11. Bushing 12. Pin 13. Inner Linkplate 14. Outer Linkplate

Section 7, Page 3

GROUP 34

In all instances, the external surface of the chain must be protected with a layer of oil. Chains with corrosion must be inspected for cracked plates.

Outside plates are especially susceptible to stress-corrosion cracking.

If chains have heavy rust or corrosion they must be removed from the upright for a complete inspection for cracked plates. If the plates are cracked, all chains on the truck must be replaced. Lubricate chains when they are installed on the upright.

3. Cracked Plates The most common cause of plate cracking is fatigue failure. Fatigue affects most metals and many plastics. After many repeated heavy loads the plates will crack and the chains will break.

Fatigue cracks are almost always found through the pitch holes, perpendicular to the pitch line. Compare this failure to the failures caused by stress(See Fig. 18376). corrosion cracking.

I Fig. 18376 Typical examples of stress-corrosion cracks on the lift chain. Similar cracks are sometimes caused by: 1. Sub-zero applications 2. Applications where acid vapors are present.

3. Applications where corrosion is present.

Cracked plates can also be found where chains are subjected to: 1. Chemical vapors 2. Sub-zero temperatures If cracks are found, replace all chains on the truck. Many plates that appear good may be ready to crack, making chain failure very likely.

4. Strength Failure This type of failure is caused by overloads that far exceed the truck design.

Chains subjected to such loading must Do not try to repair be replaced. -them. ,5. Tight Joints All lift chain joints must flex freely.

Tight joints resist flexing and increases internal friction, which increases chain tension needed to lift a given load. Increased tension accelerates wear and fatigue problems.

Section 7, Page 4

Cracked plates resulting from fatigue failure Fig. 18377

Copyrighted Material Intended for CLARK dealersCode: only Do not sell or distribute

PMA-416, REV MAR 82 P.S.L.

In roller or rollerless chains, tight joints are caused by rust or inside plates moving outward on the bushing.

Loosen chains with rust by lubricating heavily.

If tight joints, due to plate "walking" are found, it is recommended that chains be replaced, not repaired. This type of link plate displacement is accelerated by poor lubrication. Most roller and rollerless chains with tight joints have been found to have operated with little or no lubrication.

Broken plate caused by overload.

Fig. 18378

Tight joints in lift chains can be caused by: 1. Bent pins or plates 2. Rust in the joints 3. Peened plate edges Lubricate chains that have rust, and replace chains with bent or peened components.

Peening of plate edges may be caused by worn sheaves, very heavy loads, or the chains sliding past a guide on the upright.

Such conditions must be corrected to prevent damage to replacement chains, also.

6. Raised or Turned Pins Heavily loaded chains operating with little lubrication generate friction between pin and plates (pin and bushing in roller and rollerless chain). In some instances, the torque created in the joint can turn pins in the outside plates.

Examp 1e of how tight joints prevent flexing of rollerless chain.

Fig. 18379

If chain is permitted to operate in this condition, the pins slowly work out of the chain, causing chain failure. Turned pins can be easily seen because the flats on the "V" heads are no longer aligned.

See Fig. 23831.

Chains with turned or raised pins must be replaced immediately. -Do not repair the chain by pushing pins back into the chain.

Fig. 23831

Copyrighted Material Intended for CLARK dealers only Code: PMA-416, REV MAR 82 P.S.L. Do not sell or distribute

Section 7, Page 5

GROUP

34

7. Chain Side Wear A wear pattern on the pin heads and outside plates indicates poor alignment. This condition damages chain and sheaves, as well as increasing internal friction in the chain system.

Chain Anchors and Sheaves Check chain anchors for wear, damage, and alignment that is not correct.

Anchors with worn or broken fingers must be replaced. Anchors must be adjusted to remove twisting or poor alignment in the chain. When chain is poorly aligned, the load is not balanced among the plates. Long periods of operation will result in fatigue failure.

8.

Bent or peened plates on lift chain can cause tight joints and prevent flexing Fig. 18380

Sheaves with badly worn flanges and outside diameter must be replaced.

Heavy wear on the flanges indicates poor alignment of the chains.

II.

LIFT CHAIN LUBRICATION:

The most important consideration in field maintenance of lift chains is lubrication. Hard working, heavily loaded chains cannot give acceptable wear life without periodic lubrication.

As with all bearing surfaces, the joint-wearing surfaces need a layer of oil between mating parts to prevent wear.

Keeping a layer of oil on all chain surfaces will: 1. Keep joint wear (chain wear) to a minimum 2. Prevent or reduce the rate of corrosion (see Section 1) 3. Reduce the chance of pin turning 4. Keep tight joints in roller and rollerless chains to a minimum number 5. Help give smooth, quiet chain action 6. Lower the chain tension by reducing internal friction in the chain

Section 7, Page 6

Raised pins caused by heavy loading of chain without enough lubrication.

Fig. 18381

Copyrighted Material Intended for CLARK dealers only Code: Do not sell or distribute

PMA-416, REV MAR 82 P.S.L.

CLsRK

GR304

Use Clark Chain and Cable Lube 8886399 for lubrication of chains. Heavy motor oil is also a very good lubricant.

Whatever method is used, the lubricant must penetrate into the chain joint to prevent wear. Applying lubricant to external surfaces will prevent rust, but the lubricant must flow into the bearing surfaces for maximum chain life.

The frequency of lubrication will change with the operating conditions and the environment.

The best lubrication time is during each P.M. (50-250 hours or four weeks maximum actual truck operating time). Trucks that are parked outdoors, or in very severe service, may need lubrication more often to keep a layer of oil on all chain surfaces.

LUBRICANT

Section view of roller chain showing path of lubrication to bearing surface (area between O.D. of pin and I.D. of bushing).

Fig. 18383

In dirty operating conditions, lubricated chain will gather dirt. Even under these conditions chain life will be increased by periodic lubrication.

Joints get a "paste" of oil and dirt, but joint wear will still be much less than if the chain is permitted to operate dry with metal-to-metal contact between pins and plates (pin and bushing in roller chain).

In dirty operating conditions, leaf chain can be more easily lubricated than roller and rollerless chain.

The plates in leaf chain gives more paths for the lubricant to reach the pin (See Fig. 18384). At every P.M., or four week intervals, clean the chains in kerosene or mineral spirits to remove dirt. Lubricate immediately after the chain is dry. Steam cleaning is not recommended because some cleaning solutions contain chemicals which can cause linkplates to crack.

Code: PMA-416, REV MAR 82

Section view of leaf chain showing bearing surface (area between O.D. of pin and I.D. of plate holes).

Fig. 18384

Copyrighted Material Intended for CLARK dealers only P.S.L.Do not sell or distribute

Section 7, Page 7

III.

LIFT CHAIN REPLACEMENT:

Find the manufacturer's stamped number on the links of the chain. Your Clark Dealer will need this number to make sure you are getting the correct chain for, your truck. Leaf chain is available in lengths up to [7,62 m] 25 ft.

Short sections of leaf chain must never be j\oined together to form a longer length. Roller and rollerless chain is alailable in [3,05 mm] 10 ft. sections.

Never join new chain sections to old chain sections.

Lift chains must always be replaced as pairs. It is impossible to keep a balanced load between chains if a new chain is put into service opposite an old chain. The joints in the old chain may have worn through the hardest layer of the case-hardened pins, and the old chain will wear much faster than the new chain, causing problems keeping chain tension equal. Also, the new chain will wear more slowly, causing it to hold most of the load, resulting in early wear and failure.

Do not remove the lubricant from new chains. The manufacturer's lubricant helps prevent wear and corrosion.

If the original factory lubrication has dried or been removed, apply Clark Chain and Cable Lube f886399.

After the old chains have been removed from the upright, very carefully inspect the chain anchors and sheaves.

Broken, cracked, or worn anchors must be replaced. Replace worn sheaves, and check the sheave bearings for wear.

Do not paint new chain before or after installation.

Paint will help prevent corrosion, but will also prevent lubricant from reaching the pin surface for good joint lubrication.

Section 7, Page 8

Use new anchor pins when installing new chains. Old pins may contain fatigue cracks that could cause failure. After the chains have been connected to the anchors, adjust the chain tension.

Correct chain installation and upright adjustment will increase chain service life.

CHECK LIST LIFT CHAIN MAINTENANCE A.

LIFT CHAIN INSPECTION: Every truck PM (50-250 hours) check for: 1. Cracked Plates 2. Rust and Corrosion 3. Turned Pins 4. Tight Joints 5. Wear - measure portion of chain that flexes over sheaves using a steel tape.

B.

LIFT CHAIN LUBRICATION: Every truck PM (50-250 hours) 50 hrs. in corrosive environment 1. Apply Clark Chain and Cable Lube f886399 2. Lubricate full length of all strands.

C.

LIFT CHAIN REPLACEMENT: 2 1.

All chains must be replaced if any strand has wear of 3% or more or if any of the conditions listed in Section I are found during inspection.

2. Order replacement chains from your Clark Dealer.

3. Replace all chains as a set.

4. Do not remove lubricant or paint new chains.

5. Replace anchor pins and worn or broken anchors when installing new chains.

6. Adjust tension on new chains.

Copyrighted Material Intended for CLARK dealers only Code: Do not sell or distribute

PMA-416, REV MAR 82 P.S.L.

CLSRK

GR304 ROLLER AND ROLLERLESS CHAIN

Rollerless Chain No.

Roller Chain No.

40

45 55 65 85 105 125 145 165 205

50 60 80 100 120 140 160 200

Pitch [12,70 [15,87 [19,05 [25,40 [31,75 [38,10 [44,45 [50,80 [63,50

mm] mm] mm] mm] mm] mm] mm] mm] mm]

0.500 0.625 0.750 1.000 1.250 1.500 1.750 2.000 2.500

Span inch inch inch inch inch inch inch inch inch

Worn Chain Length

25 21 17 13 11 9 8 7 6

[314,32 [327,02 [314,32 [314,32 [327,02 [314,32 [320,67 [314,32 [327,02

mm] mm] mm] mm] mm] mm] mm] mm] mm]

12.375 12.875 12.375 12.375 12.875 12.375 12.625 12.375 12.875

inch inch inch inch inch inch inch inch inch

LEAF CHAIN Chain No. BL400 BL500 BL600 BL800 BLlOOO BL1200 BL1400 BL1600

Pitch [12,70 [15,87 [19,05 [25,40 [31,75 [38,10 [44,45 [50,80

mm] mm] mm] mm] mm] mm] mm] mm]

0.500 inch 0.625 inch 0.750 inch 1.000 inch 1.250 inch 1.500 inch 1._750inch 2.000 inch

Span 25 21 17 13 11 9 8 7

Worn Chain Length [314,32 [327,02 [314,32 [314,32 [327,02 [314,32 [320,67 [314,32

mm] mm] mm] mm] mm] mm] mm] mm]

12.375 12.875 12.375 12.375 12.875 12.375 12.625 12.375

inch inch inch inch inch inch inch inch

PITCH - The distance from the center of one pin to the center of the next pin.

SPAN - The number of pins in the length of chain to be measured.

WORN SHAIN LENGTH - The distance from the first pin counted to the last pin counted in a span while the chains have lifted a small load.

Code: PMA-416, REV MAR 82

Copyrighted Material Intended for CLARK dealers only P.S.L.Do not sell or distribute

Section 7, Page 9

EXAMPLE OF THE CHECK FOR CHAIN WEAR:

PROCEDURE TO CHECK FOR CHAIN WEAR: (See Page 11, also) 1.

2.

3.

4.

Find the pitch of the chain. a. Measure from the center of one chain pin to the center of the next chain pin.

Locate the specifications (Page 9). a. Locate the pitch of the chain. b. Find the number of pins to be counted (span).

Find the maximum worn length of C. a selected span.

Select an area of chain to be measured. a. Use a section of chain which moves over sheaves. b. Lift a small load.

Count the number of pins needed C. for a length measurement.

Measure the chain. a. Use a steel tape to measure from the first pin counted to the last pin counted. b. The length measurement must be more than the actual span of the chain section being measured.

C. Any chain span which is worn to the length measurement or beyond must be replaced.

Section 7, Page 10

A mechanic measures from the center of one pin to the center of the next pin and finds the PITCH of the chain to be [25,40 mm] 1 inch. After looking at the chain charts, he must align the end of the steel tape with the center of one pin, and counting to the thirteenth pin (counting the pin he started with as number one) measures the length to the center of the thirteenth pin and finds it to be [316,0 mm] 12.437 inch.

Again, looking at the chart, he finds the maximum worn length to be [314,32 mm] 12.375 inch. From this he decides that both chains on this truck must be replaced.

Copyrighted Material Intended for CLARK dealersCode: only Do not sell or distribute

PMA-416, REV MAR 82 P.S.L.

Measuring BL846 chain for wear, using tape measure Fig. 23832 1.

2.

New Chain Length Worn Chain Length

Copyrighted Material

Code: PMA-416, REV MAR 82 P.S.L. Intended for CLARK dealers only Do not sell or distribute

3.

4.

Span Pktch

Section 7, Page 11

C

PM

NOTES

Material 1146-Z Copyrighted REV DEC 83

Intended for CLARK dealers only Do not sell or distribute

GROUP 40

GROUP

40 SECTION

1 DATA

PLATES, AND

PM&510, DEC 80

UPRIGHT SERIAL

NUMBER

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

DECK

NUMBER,

DATA

Section 1, Page 1

GROUP 40 _“, <*“i

aa, s>

$$; ,,,

I Know the location

~~~g@j$~of

your

machine

_ ,_

serial number stamped in the front battery plate.

Know the location of your Upright Deck Number stamped in the outer rail assembly.

Fig. 23894

Fig. 22239

Know the location of your Original Equipment Name Plate (Model Capacity and Serial Number).

Fig. 22237 TRUCK DATA AND CAPACITY PLATE

Fig. 22244 Know the rated capacity of your truck and its attachments. capacities.

Read the rated capacity on the data plate. in the illustration.

1.

2. :: 5.

Truck model Type Serial number Attachments (when installed) Capacity

Section 1, Page 2

;: 8.

9.

10.

Never exceed these rated

Read and know areas 1 thru 10 as shown

Truck weight w/o battery Truck weight with battery Battery weights Battery compartment length Battery type

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

GROUP

40

40.136 -I 40.040 J 40.137 J OPTION

OPTION

OPTION

L40.006

L

L

40.138

40.131

LL$;__j I‘i

40.049 v' b; J 0 I",5 o"rPnc*D CUARD

,

40.065

1

r

THRU

\

40.139

I-

I~-----!YJ~40~071

140.064

40.139

DATA

PLATES AND

L-O.024

DECALS 40-172

40.000 40.001 40.006 40.010 40.014 40.024 40.025 40.039 40.040 40.049 40.064 40.065 40.069 40.071 40.077 40.069 40.090 40.096 40.108 40.121 40.130 40.131 40.136 40.131 40.138 40.139 94.432

Code: PMA-510, FEB 84

PLATE, CAPACITY & SERIAL NUMBER FASTENER, CAPACITY h SERIAL NUMBER PLATE DECAL, PATENT LEGEND, CLARX DECAL, MODEL NAME PLATE, UNDERWRITERS FASTENER, UNDERWRITERS PLATE DECAL, CLAMP DECAL, ROTATE LEGEND, INSTRUCTIONS PLATE, DRIVER OVERHEAD GUARD FASTENER, DRIVER OVERHEAD GUARD PLATE DECAL, PUSH-PULL LEGEND, SEAT BRAKE DECAL, ELECTRIC TRUCK WARNING PLATE, SAFETY INSTRUCTIONS FASTENER, SAFETY INSTRUCTIONS PLATE DECAL, SIDE SHIFT DECAL, MAINTENANCE INSTRUCTlONS DECAL, BATTERY SPECIFICATION LEGENI), SAFETY LEGEND, SAFETY DECAL, PUSHER DECAL, FORK POSITlONER DECAL, SAFETY DECAL, I%?:-L D!:S!'GNATION WASHER. SAFETY INSTRUCTIONS PLATE FASTENER

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 3

Z

0

-I

m

0

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP 40

SECTION

2 EQUIPMENT

SUGGESTED FOR ELECTRIC

PMA-510, DEC 80

TRUCK

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

P.M.

Section 2, Page 1

CLflRK

GROUP 40

1.

2.

To perform the electrical tests, you will need a volt-ohmmeter (V-O-M). Make sure the V-O-M is recalibrated when choosing different range setting.

For further information refer to GROUP 40, Sections 17 & 18. Also recommended for controls testing: Digital Multi-Meter (Simpson D.M.M. Model 461 or equivalent), two current monitoring shunts (500 amps, 50 mV rating), and digital stop watch (0.01 set resolution).

Fig. 22236 Have a standard set of metric and SAE tools, consisting of combination wrenches, screwdrivers, pliers, socket set, Allen wrenches, etc.

Fig. 19523 3.

Three, torque wrenches will also be required of either metric or SAE calibration.

[O-6 N'm ] CO-339 N'm ] CO-1356 N'm]

O-50 lbf. in.

O-250 lbf. ft.

O-1000 lbf. ft.

Fig. 14844 4.

For battery maintenance, you will need a hydrometer, a battery water filler, battery post, cable terminal cleaners and some Clark Battery Saver, Part No. 886398.

Fig. 19526

Section 2, Page 2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

GROUP

40 5.

An air hose and gun will be required to blow off truck parts. Tire pressure gauge and tire inflation tool will be used to check and adjust pneumatic tire pressure.

Fig. 19528 6.

For lubrication you will need grease, a grease gun, oil and suction gun, brake fluid, hydraulic oil, chain and cable lube spray and an oil can that meets recommendations for oil and grease, from GROUP 40, Section 4.

:‘

‘_

,,, \__

‘,’ ,,‘” ‘, )

‘_

Fig. 19529 7.

To check hydraulic pressure, you will need a MICO quadrigage.

Fig. 11156 8.

For jacking up the truck, you will need an approved floor jack, 4 x 4 hardwood blocks and approved safety wheel blocks.

Fig. 19531

PMA-510, DEC 80

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 2, Page 3

Fig. (A)

XECORDINGS BELOW ARE: nm reads in Kg inches read in Lbs.

Fig. (B)

Fig. Fig. Fig. Fig. Fig. Fig. (C) (A) (B) cc> (A) 0) See figures below for chain spread.

Fig. cc>

*These capacities are only this high when load is equally distributed to each leg.

1250 2500 2160 1770 1250 2700 j.5mm 930 2200 1545 3245 2655 1885 l/4" 2750 5500 2050 4750 3900 2750 5950 4850 3400 7150 5850 4150 ______._----__-______.-------.___________________)_____---~~~~~~~~~-______---__________2950 5900 2200 4150 2950 6400 6260 lOmm 5125 5215 3675 7665 4445 6500 13000 4850 11300 9150 6500 14100 11500 8100 16900 13800 9800 318" ________-----~------~------~~~~~~~~--~--~~~~~~~~----~~~~~--------~ 1~_~-~------~~~~~---9980 3745 8665 7075 4990 10795 8800 6260 12975 10570 13mm 4990 7485 11000 22000 8250 19100 15600 11000 23800 19400 13800 28600 23300 16500 l/2" _----___-----~-.------.-~-----.~~~~~~~~~---~~~~~~_.-----~~~~------------------_-__~-------7400 14745 5535 12745 10435 7400 15965 13020 9210 19145 15650 11079 16mm 16300 32500 12200 28100 23000 15300 35200 28700 20300 42200 34500 24400 j/8" ________------------~.-------.-----~~~~~~~_---~~~.~~~-----~~~~~~-----~~~~~~~~--~~~~~~~~~-~ 10205 20410 7665 17690 14425 10205 22090 18055 12745 26535 21635 15330 19mm 22500 45000 16900 39000 31800 22500 48700 39800 28100 58500 47700 33800 S/4" _-----._---___-~-___--.~~~~~~~~~~~~~_---~~~~~---_.--_______--_____________________ ___ !2.5mm 13155 26310 9890 22770 18600 13155 28485 23270 16465 34155 27895 19730 29000 58000 21800 50200 41000 29000 62800 51300 36300 75300 61500 43500 T/8" _-----.~~~-----------.~~~--~~.~~~~~~~-~~~~~~~~~~-.~~~~~~~-~-~~~~~~~~~--~~~~~~~----~~~~~~-~ !5.4mm 17375 34700 13020 30255 20000 17375 37560 30660 21680 45090 36790 26035 1II 38300 76500 28700 66200 54100 38300 82800 67600 47800 99400 81100 57400 ______._ -------.

------.

-- -----.__

----~~~-~-----

___. ------_-~~~--------~~--------_----------

5170 19415 44770 36595 25855 55790 45810 32340 67130 54885 38780 32m.m 25855 l-1/4" 57000 11400 42800 98700 80600 57000 123000 101000 71300 148000 121000 85500 _--_-___-------------.-~-----.~~~~~______________)_____~--~~~~~~~~~-~-~~~~~~~~~----~~~~~~~ 38.4mm 35380 70760 26535 61235 49895 35380 76660 62500 44225 92080 74843 53070 l-1/2" 78000 156000 58500 135000 110000 78000 169000 138000 97500 203000 165000 117000 Fig. (A)

A

I

Fig. (B) Fig. (C)

60'

Section 2, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PMA-510, DEC 80

GROUP 40

GROUP

40 SECTION

3 FIRE EXTINGUISHER RECOMMENDATIONS

Section 3, Page Code: PMA-510, FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

1

GROUP 40 SAFETY FIRE

EXTINGUISHERS

APPROVED

FOR TRUCKS

WITH

CO2

SOLID-STATE

CONTROLS

FIRE EXTINGUISHERS:

Two types of fire extinguishers approved for use on trucks with solid-state controls: 1.

EQUIPMENT

(carbon

are

dioxide)

CO fire extinguishers are best used fog Class 'Cl-fires (*) in electrical Carbon dioxide wiring and controls. is an inert gas which puts out a fire by replacing the air (oxygen) around the flames.

With CO2, no cleanup is Since carbon dioxide is a gas needed. and leaves no residue, you do not have to clean the controls after using a CO2 fire extinguisher.

There is a danger, fire however, from using a CO extinguisher in small, e k;closed places where a large amount of carbon dioxide gas could be left in place of the clean air needed for people to breathe safely.

Dry-type fire extinguishers work by covering the fire (and controls) with a layer of chemicals.

This shuts out the air (oxygen) needed for burning and smothers the flames.

After using a dry-type fire extinguisher, the chemicals must be cleaned up and washed off the controls.

The controls must be completely cleaned and dried.

CAUTION THE BATTERY MUST BE DISCONNECTED BEFORE CLEANING THE CONTROLS AND MUST NOT BE CONNECTED AGAIN UNTIL THE CONTROLS ARE COMPLETELY DRY.

The Ansul Company dry-type fire extinguisher is recommended by General Electric.

FIRE

DO NOT ENTER OR WORK IN AN AREA WHERE A CO FIRE EXTINGUISHER HAS BEEN USED UNTIL THE SPACE HAS BEEN COMPLETELY VENTILATED.

2.

(fci;;;)'B' and *

Dry chemical

'C'

The chemical used in the dry-type extinguishers is either sodium bicarbonate or potassium bicarbonate, which has been made water-resistant.

EXTINGUISHERS

NOT APPROVED:

Pyrene fire extinguishers are not approved for use on trucks with solid-state controls.

General Electric has found that the chemicals in Pyrene extinguishers destroy the insulation on electrical cables and wiring, and can damage plastic parts of the solid-state controls.

materials, such as wood, "Class A fires" are fires in ordinary combustible cloth, paper and rubber.

2) "Class B fires" are fires in flammable liquids, gases and greases.

3) "Class C fires" are fires which involve "hot" (energized) electrical The use of a fire extinguishing material that does not equipment. conduct electricity is important.

*l)

Section

3, Page

2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code:

PMA-510,

FEB 54

GROUP 40

G.

Properly ventilate work area, vent exhaust fumes and keep shop clean and dry.

H.

Handle LP gas cylinders with care.

Do not drop, dent or damage in any way.

I.

Brakes, steering mechanisms, control mechanisms, lift overload devices, guard and safety devices shall be inspected regularly and maintained in a safe operating condition.

.J. All parts of lift and tilt mechanisms and frame members should be carefully and regularly inspected and maintained in a safe operating Special trucks or condition. devices designed and approved for hazardous area operation should receive special attention to ensure that maintenance preserves the original, approved safe operating features.

L.

Fuel systems shall be checked for leaks and condition of parts. Extra special consideration shall be given in the case of a leak in the fuel system. Action shall be taken to prevent the use of the truck until the leak has been corrected.

M.

All hydraulic systems shall be regularly inspected and maintained in conformance with good practice.

Tilt cylinders, valves and other similar parts shall be checked to assure that "drift" has not developed to the extent that it would create a hazard.

N.

Capacity, operation and maintenance instruction plates, tags or decals shall be maintained in legible condition.

Code: PMA-425, DEC 79

0.

Batteries, motors, controllers, limit switches, protective devices, electrical conductors and connections shall be inspected and maintained in conformance with good practice.

Special attention shall be paid to the condition of electrical insulation.

P.

Industrial trucks shall be kept in a clean condition to minimize fire hazards and facilitate detection of loose or defective parts.

Q-

Modifications and additions which affect capacity and safe truck operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation and maintenance instruction plates, tags or decals shall be changed accordingly.

R.

Care shall be taken to assure that all replacement parts are interchangeable with the original parts and of a quality equal to that provided in the original equipment.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 3, Page 3

GROUP

40

FIRE EXTINGUISHERS AND SOLID STATE CONTROL EOUIPMENT:

The chemical used in the dry type extinguishers is either sodium bicarbonate or potassium bicarbonate which has been made water resistant.

After using, the control must be completely cleaned and dried. THE BATTERY MUST BE DISCONNECTED BEFORE CLEANING AND MUST NOT BE CONNECTED AGAIN UNTIL THE CONTROL DRIES COMPLETELY. General Electric's recommendation is the Ansul dry type fire extinguisher.

Approved Fire Extinguishers: There are two types of fire extinguishers that are approved for use on trucks having solid state controls.

They are: 1.

Dry chemical for 'B' and 'C' applications.

2.

CO2 (carbon dioxide) which is acceptable for electrical fires.

FIRE EXTINGUISHERS NOT APPROVED:

When carbon dioxide is used, cleaning is not necessary.

Carbon dioxide only replaces the oxygen in the area of the fire and extinguishes the flames. The danger in using this type of fire extinguisher is in small areas where a large amount of carbon dioxide could replace so much oxygen that persons in this area can fall down from too little oxygen.

Section 3, Page 4

Pyrene fire extinguishers are not approved for use on trucks having solid state control.

General Electric has found that the chemicals in pyrene extinguishers destroys the insulation on the cables and has a bad effect on the solid state controls.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Code:

PMA-377, REV DEC 81 P.S.L.

ELECTRIC TRUCK DRIVER’S DAILY CHECKLIST Check

Before

Start

Of Each Shift

Date _ Truck

No. Supervisor’s

Operator:

Hour

Meter

Start

of Day

OK

Reading: End of Day

Hrs. for Day

Note:

Remarks:

(Explain

All

Items

Needing

Attention

battery indicator while holding tilt lever on full back tilt.

If needle falls to red area, battery

Watch

Or Repair)

Printed

Code: PMA-321, REV MAR 74

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

in

“.%A

Section 3, Page 5

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

ELECTRIC

PLANNED Customer

TRUCK

MAINTENANCE

REPORT

Address

Authorized

Special

Signature

Instructions 1,111,

Hr.

Meter

Reading:

Make,

Mfg.

& Mode

Customer P.

0.

No.

-

-

Racklr

OWE Drift t K. Park,"

Section 3, Page 6

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-321, REV MAR 74

40 SECTION

4 LUBRICANT AND

SPECIFICATIONS RECOMMENDATIONS

LUBRICATION

Code: PMA-322, FEB 84 REV

CHART

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

KEY

Section

4, Page 1

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

FOREWORD

THIS LISTING OF LUBRICATION SPECIFICATIONS HAS BEEN COMPILED FOR THE REFERENCE OF CLARK ENGINEERING AND SERVICE PERSONNEL, DEALERS AND CUSTOMERS. THE LIST OF PRODUCTS IS INTENDED AS A GUIDE IN THE SELECTION OF A LUBRICANT TO MEET THE REQUIREMENTS OF CLARK INDUSTRIAL TRUCK OPERATION. CLARK makes no representation as to the relative merits of any commercial oil product. With the exception of MS-68 Hydraulic Fluid, CLARK has no formal system for approving oil products, but has published herein general specifications which it believes will provide adequate or superior component lubrication and life.

It is the PREROGATIVE of each user to choose suppliers and products as they feel necessary for proper operation of the equipment under the RESPONSIBILITY for the quality conditions of the individual application. of the product and its performance in service must remain with the oil supplier, in agreement with the user.

SYNTHETIC HYDRAULIC FLUIDS AND ENGINE OILS With the recent advertising and promotional emphasis on synthetic engine and hydraulic oils, CLARK EQUIPMENT COMPANY has received many questions CLARK does not follow regarding approval of their use in CLARK products. a formal test and approval procedure for specific branded products.

Rather it is CLARK policy to establish basic specifications for oils which have demonstrated suitable performance for the application.

In general these specifications follow the recommendations of the major component manufacturer, such as engines and hydraulic pumps. Any oil which meets the respective specification is considered acceptable for use in CLARK products.

Component operation should not be affected as long as the oil meets the stated specification and the recommended oil and filter change intervals are followed. For EXTENDED OIL DRAIN INTERVALS, periodic It is the oil analysis by a reputable testing laboratory should be made. responsibility of the manufacturer or supplier of the oil to insure that his product meets the spec:ifications and gives the expected performance.

TECHNICAL SOCIL.TIES IN REFERENCE ON FOLLOWING PAGES AGMA API ASTM EMA MIL NGPA NLGI SAE

Section 4, Page 2

--------------__------------_-------------___----___-----

American Gear Manuf a.cturers Association &norican Petroleum Institute American Society for Testing Materials Engine Manufacturers Association Military Specification Natural Gas Processors Association National Lubricating Grease Institute Society of Automotive Engineers

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-322, JUN 80 REV

C19RK

GROUP 40 LUBRICATION CHART KEY LUBRICANT SPECIFICATTWS & RECOMMENDATIONS

PRODUCTS AVAILABLE UNDER CLARK PART NUMBER Page Ref No's FILTERS 1. System Filters-Oil & Fluid

Page

4

5

ENGINE OILS 2. Gasoline & LPG Engines

Page

6

3. Diesel Engines

Page

6

GREASES 4. General Purpose MS-107C

Page

7

5. General Purpose MS-107B

Page

7

6. Low Temp.-Cold Storage

Page

7

7. Spec Applications-Carriers

Page

8

8. Ignition Distributor Cams 9. Starter, Generator Frame Bearings

Page Page

8 8

10. High Temperature

Page

8

11. Motor Shaft Splines & Drive Tangs

Page

9

12. Slip Tubes, Sleeves, Ball Joints

Page

9

PROTECTIVE SPRAYS 13. Cold Storage & Other Applications

Page

9

14. Contactors & SCR Controls

Page 10

SPRAY LUBRICANTS 15. Cable Lube., Electrical

Page 10

16. Throwout Bearing Carrier Page 10 Rails, Attachments, Slides, Bushings GEAR LUBRICANTS 17. Drive Axle, MS-8

Code: PMA-322, FEB 84 REV

Page 10

18. Transmission, Manual Shift

Page 11

TRANSMISSION FLUIDS 19. Transmission, Power Shift, & Torque Converter

Page 11

20. Special Applications, Powrworker, NS, NSP, NST, Power Steering Reservoirs

Page 11

21. Ford Transmissions

Page 12

BRAKE FLUIDS - LUBRICANTS 22. Hydraulic Brake Systems

Page 12

23. Hydraulic Brake Systems, Cold Storage Applications MS-92

Page 12

24. Power Brake Vacuum Cyl.

Page 13

HYDRAULIC FLUIDS 25. Hydraulic Systems, Normal Applications, MS-68

Page 13

26. Hydraulic Systems, Cold Storage Applications, MS-226

Page 13

27. Hydraulic Systems, Fire Resistant

Page 14

FUELS 28. Gas, LP Gas, Diesel Engines 29. Products & Technical Societies in Reference DEGREASERS 30. For Electrical & SCR Components, For NonElectrical Components

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Page 14 Page 14

Page 14

Section 4, Page 3

GROUP

40 DESCRIPTION

SYMBOL

CLARK PART NUMBER

HYDRAULIC BRAKE FLUID

1801167 850487

1 - case of 12-ounce cans 1 - case of 6 one-gallon cans

HYDRAULIC SYSTEM FLUID

1800236 1802155

1 - case of 24 one-quart cans 1 - case of 6 one-gallon cans

AUTOMATIC TRANSMISSION FLUID

1802200 1802154 962669

1 - case of 24 one-quart cans 1 - case of 6 one-gallon cans 1 - five-gallon can

BATTERY CLEANER

886398

1 - case of 12 one-pint cans

LUBRICANT - INNERSLIDE

886396

1 - case of 12 one-pint cans

PENETRATING OIL

886397

1 - case of 12 one-pint cans

1800078

1 - case of 12 one-pint cans

BELT DRESSING CHAIN & CABLE LUBE

886399

1 - case of 12 one-pint cans (Roller & Leaf Chain Lube)

886785

1 - case of 12 16-ounce cans (Black Heavy-Duty "EP" Lubricant.)

DEGREASER

1800330

1 - case of 12 one-pint cans

CONQUER SPRAY*

1801145

1 - case of 12 16-ounce cans

886784

1 - case of 12 16-ounce cans (Transparent Protective Insulating Sealer with Clear Lube.)

DEGREASER***

1801146

1 - case of 12 16-ounce cans

SCR HEAT CONDUCTIVE THERMAL COMPOUND

1801480 1742787

1 - carton of 4 5-ounce tubes 1 - 5-pound can

SPRAY LUbE FOR OPEN GEARS

SPRAY KOTE**

*HIGH MOISTURE EXPOSURE ... Protective Spray Coating for SCR Cards. **HIGH MOISTURE EXPOSURE . ..Protective Spray Coating for Electrical Switches, Contactors and Ignition Systems. ***Oily or Greasy SCR Control . . . CLARK #1801146 Degreaser (or the equivalent to MS-180 Freon TF Degreaser).

Section 4, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-322, FEB 84 REV

GROUP 40

CLflRK

CRANKCASE llOTOR OIL

CLARK PART NUMBER

(SE/CD) s.A.E. 30 (SF/CC) S.A.E. lOW30

1802152 1802153

1 - case of 24 one-quart cans 1 - case of 24 one-quart cans

~0\r1 TEMPERATURE OPERATION (MULTI-VISCOSITY OILS) ____________________~~~~~~~~~~~~~~~~~~~~~~~~~~~~ IT IS RECOMMENDED THAT MULTI-VISCOSITY OIL CONDITIONS, COMBINED WITH HIGHER OPERATING SUPPLIER SHOULD ASSUME FULL RESPONSIBILITY MULTI-VISCOSITY OIL AT BOTH LOW AND NORMAL

BE USED ONLY WHERE COLD STARTING TEMPERATURES MAKE IT NECESSARY. THE OIL FOR SATISFACTORY PERFORMANCE OF THE ENGINE OPERATING TEMPERATURES.

SERVICE CONDITIONS ----------------_OIL PERFORMANCE WILL REFLECT ENGINE LOAD, TEMPERATURE, FUEL QUALITY, ATMOSPHERIC DIRT, MOISTURE AND MAINTENANCE. WHERE OIL PERFORMANCE PROBLEMS ARISE OR ARE ANTICIPATED, THE OIL SUPPLIER SHOULD BE CONSULTED. WHEN EXTENDED DRAIN PERIODS ARE CONTEMPLATED, HIS ANALYSIS OR THAT OF A REPUTABLE LABORATORY SHOULD DETERMINE THE SUITABILITY OF OIL FOR FURTHER SERVICE.

LUBRICANT SPECIFICATIONS & CHART(S) KEY LUBRICATION CHARTS - SEE GROUP 01 1.

OIL & FLUID FILTERS

FOR .. TRUCK SYSTEM(S) SPECIFICATIONS Replacement parts to be of a quality equal to that provided in original equipment.

Consult CLARK Service Parts Publication(s) for recommended replacement parts.

Oil Filter Cartridge Kits(s) (Reference: Appropriate Parts Manual)

CAUTION The use of other than CLARK approved filters may cause oil pressure or flow changes which could result in damage to the system.

Code: PMA-322, FEB 84 REV

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 4, Page 5

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

MIL-B C‘

2.

ENGINE CRANKCASE OIL

cc

FOR ... GASOLINE, L P -GAS ENGINES AND NATURALLY ASPIRATED DIESEL ENGINES.

MIL-L-2104B MIL-L-46152

SPECIFICATION TO MEET API Service classification "CC" and "SC" per SAE Report 5183 and/or *MIL-L-2104B. Sulfated ash content 1.00% weight maximum.

Zinc content 0.06 to 0.10% weight maximum.

ENGINE CRANKCASE OIL

This specification includes "SE" oils meeting Specification MIL-L-46152 when applicable. Also, API Service "SC"/"SD" (formally "MS") oils may be preferred under stop-and-go or light service conditions.

rl AC1

*Although Specification MIL-L-2104B has recently been superceded, oils of this quality will continue to be available, and are preferred.

i; e

SERIES 3 API CD

MIL-L-45199B MIL-L-2104C

3.

ENGINE CRANKCASE OIL

FOR . . . TURBOCHARGED DIESEL ENGINES OR DIESEL ENGINES USING HIGH SULFUR CONTENT FUEL (OVER 0.5% SULFUR).

SPECIFICATION TO MEET API Service Classification "CD" per SAE Report 5183 and equivalent Series 3 and/or MIL-L-45199B Specifications. Also MIL-L-2104C when applicable.

Sulfated ash content 1.65% maximum.

... ...

FOR ALL OPERATIONS WITHIN NOMINAL RANGES, THE USE OF SINGLE-GRADED OILS IS RECOMMENDED.

SAE 1OW SAE 20/2OW SAE 30

SAE 30 OIL OF MIL-L-2104B PERFORMANCE LEVEL IS RECOMMENDED FOR YEAR AROUND USE IN DETROIT DIESEL ENGINES ...

(Limitations - Zinc 0.10% maximum, The use of sulfated ash 1.0% maximum).

Multi-grade oils in Detroit Diesel engines is not recommended.

Oil Change Intervals ... a helpful guide in determining the intervals is an engine oil analysis made several different times. Local oil distributors offer this service. And by using it you can set P.M. intervals with greater certainty.

Ref. 2

.. .

0" to 32" F. 33" to 75" F. above 75" F.

ENGINE CRANKCASE OIL

FOR . . . MISCELLANEOUS LINKAGE U

Section 4, Page 6

SPECIFICATION Any good grade of motor oil in SAE 10, 20 or 30 weight as the temperature and conditions dictate.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-322, JUN 80 REV

&

0

GROUP 40

MS-107C

GENERAL PURPOSE GREASE

4.

GENERAL PURPOSE GREASE

FOR **.

STEER AXLE TRUNNION BEARINGS UPRIGHT MAST ROLLERS & SLIDES UNIVERSAL JOINTS WATER PUMP BEARINGS GENERAL CHASSIS LUBRICATION

*RECOMMENDATION Use Grade NLGI i/2per MS-107C. *SPECIFICATION A multi-purpose grease of refined mineral oil blended with a lithium soap thickener or equal containing anti-wear, anti-rust and anti-oxidants with EP additives. Per CLARK Specification MS-107.

5.

GENERAL PURPOSE GREASE

FOR . . . CLARK AXLE ENDS WHEEL BEARINGS STEERING GEARS JOINTS, LEVERS & BUSHINGS POWRWORKER & NARROW AISLE TRUCKS - ALL POINTS MS-lL)7B

*RECOMMENDATION Use Grade NLGI fl per MS-107B

6.

LOW TEMP

MIL-G-23827A

LOW TEMPERATURE GREASE COLD STORAGE OPERATION

For ... GENERAL CHASSIS GREASE UPRIGHT MOUNTING UPRIGHT LIFT CHAINS ALL MOVABLE PARTS EQUIPPED WITH GREASE FITTINGS BRAKE (AND CLUTCH) PEDAL LINKAGE (Narrow Aisle Trucks & Powrworkers) DRIVE UNIT FITTINGS PANTOGRAPH CASTER WHEELS STEER CHAIN, ROLLERS & SPROCKETS LOAD WHEELS WITH FITTINGS SPECIFICATION An extreme low temperature aircraft quality grease meeting Specification MIL-G23827A, or equivalent product.

Temperature range - 100 to +250" F.

Code: PMA-322, JUN 80 REV

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 4, Page 7

INDUSTRIAL

TRUCK DIVISION

CUSTOMER SERVICES GROUP

7.

SPECIAL GREASE

FOR ... STRADDLE CARRIERS EQUALIZING LINKAGE HOOK & HANGER BUSHINGS HOIST MECHANISM MOLY GREASE

SPECIFICATIONS A smooth high quality grease of refined mineral oil base with a lithium soap thickener or equal compounded with corrosion and oxidation inhibitors and containing 1 to 3% moly (molybdenum disulfide). NLGI f2

8.

F,,...

MOLY GREASE

SPECIAL GREASE

FOR . . . DISTRIBUTOR CAMS SPECIFICATIONS

9.

See above.

SPECIAL GREASE

FOR ... DELCO STARTER BEARINGS *GENERATOR/ALTERNATOR END FRAME BEARINGS MOLY GREASE

SPECIFICATIONS

10.

HIGH TEMP

CLARK PART NUMBER 1800636

CLARK PART NUMBER 1800574

See above.

E

HIGH TEMPERATURE GREASE

FOR ... CLUTCH THROWOUT BEARINGS CLUTCH PILOT BEARINGS DYNATORK PILOT BEARINGS

CLARK PART NUMBER 617410

&

0

SPECIFICATIONS A high temperature grease of refined mineral oil base with a lithium soap thickener or equal compounded with additives to give high load-carrying ability and resistance to water and high temperature.

To withstand temperatures of -20" F. (to) +300" F. NLGI Grade No. 2.

NOTE:

Section 4, Page 8

Commercial products meeting MIL-G-3545C also meet this requirement.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

2 q

Code: PMA-322, JUN 80 REV

GROUP 40

11.

SPLINE GREASE

FOR ... MOTOR TO PUMP DRIVE TANG HYDRAULIC PUMP & llOT3R SHAFT SPLINES MOLY GREASE

CLARK PART !dUMBER 1800531

SPECIFICATIONS A lithium base or equal multi-purpose grease blended with selected additives to provide high load-carrying capacity with superior protection against corrosion and hightemperature oxidation and containing 3 (to) 5% moly (molydbenum disulfide).

NLGI #2.

NOTE:

12.

Grease products under this specification are suitable for use on ball and roller bearings operating under extreme loads or in severe environments, and for extended lubrication intervals including chassis, sleeve bearings, cams and sliding mechanisms, etc., under heavy loads, shock and vibration.

SPECIAL LUBRICANT HAND APPLIED

For .. . SLIP TUBES, SLEEVES, SPRING APPLIED SLEEVES, LINKAGE BALL JOINTS, ETC.

CLARK PART NU;u!BER617410

SPECIFICATIONS A soft density, smooth lithium base or equivalent grease with extreme pressure properties for use in adverse operating conditions from 0" F. to 250" F. NLGI #l.

13.

PROTECTIVE SPRAY COATING - ELECTRIC TRUCKS IN COLD STORAGE & OTHER APPLICATIONS

FOR .. . ELECTRICAL SWITCHES, WIRING & TERMINALS, AFTER ASSEMBLY.

CLARK PART NUMBER 886784

SPECIFICATIONS A clear acrylic plastic protective coating which acts as an insulator and corrosion preventative.

Code: PMA-322, FEB 84 REV

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 4, Page 9

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

14.

ELECTRICAL MOISTUREPROOFING SPRAY COATING

FOR . . . CONTACTOR/SCR

PANELS SOLID STATE CONTROL CARDS #l TIMER & OSCILLATOR CARD

CLARK FART NUMBER 1801145

SPECIFICATIONS A water displacing moisture-proofing and anticorrosion agent for electrical and electronic equipment. Must not emulsify or harden. Non-insulating.

15.

ELECTRICAL CABLE LUBRICANT

FOR . . . LEVEL WINDING OF ROS CABLES ON REEL SPECIFICATIONS A silicone jelly or equivalent to provide nonsticking lubrication of external cable surfaces during rewinding on reel.

16.

d -

SPECIAL LUBRICANT

RAILS, SIDE SHIFTER FOR ... CLUTCH THROWOUT BEARINGCARRIER ATTACHMENT, CLAMP SLIDES, SLIDE BUSHINGS OF ANY TYPE

SL

SPECIFICATIONS equivalent.

17.

API GL-4

Use an approved Dry Film Type Lubricant or the

DRIVE AXLE GEAR LUBRICANT

FOR . . . DRIVE AXLES, HEAVY DUTY DIFFERENTIALS, PLANETARY WHEEL ENDS SPECIFICATIONS Extreme pressure type gear lubricant with sulfurchlorine-lead (SCL) "EP" additive for API GL-4 service per SAE Report J308a. To meet CLARK Specification MS-8.

Below 0 to -10" F. Normal Temperature 100" F. and above NOTE:

Section 4, Page 10

----

SAE 80 SAE 90 SAE 140

SAE 80 and SAE 140 viscosities, when used, should contain like additives as specified by MS-8 (SAE 90). DO NOT ADD (MIX) DIFFERENT TYPES OF LUBRICANT.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-322, JUN 80 REV

GR&u EP LUBE MIL-2105B

@ G API GL-5

18.

TRANSMISSION LUBRICANT

FOR ... STANDARD MANUAL SHIFT (SYNCHROMESH) TRANSMISSION & GEAR BOXES. SPECIFICATION (1) MIL-L-2105B Extreme Pressure Lubricant for API GL-5 Service per SAE Report J308b is preferred.

(2) Heavy Duty engine oil (API SD or SE) .is satisfactory.

(3) Straight mineral gear oil may be used. (Do not mix lubricant types.)

ABOVE 20" F. -- Grade 90 (SAE 50) BELOW 20" F. -- Grade 80 (SAE 30) FOR 0 to -60" F. -- MIL-L-10324A

19.

TRANSMISSION FLUID

FOR ... TORQUE CONVERTERS CLARK PART NUMBER 879804 FLUID COUPLING DRIVES AUTOMATIC TRANSMISSIONS (EXCEPT FORD) POWRSHIFT TRANSMISSIONS POWRSHIFT FORWARD & REVERSE UNIT HYDRATORK TRANSMISSION HYDRACOOL (WET) CLUTCH TRANSMISSION ELECTRIC RIDER TRUCK DRIVE UNITS (WHEN SPECIFIED ON LUBE CHARTS) DEXRON* OR DEXRON II*

SPECIFICATIONS DEXRON* OR DEXRON II* ATF (Automatic Transmission Fluid).

20.

TRANSMISSION FLUID

FOR ... HYDRAULIC SYSTEM AND DRIVE UNITS, POWRWORKERS, NS, NSP, NST TRUCKS, ELECTRIC RIDER TRUCKS, POWER STEERING RESERVOIRS.

DEXRON II

SPECIFICATIONS DEXRON II* ATF (Automatic Transmission Fluid) containing zinc or equivalent anti-wear additive sufficient to pass the requirements of ASTM D-2882 pump wear test, with 50 mg total weight loss maximum. Container must carry GM approval number (C-xxxxx/DEXRON II.)

Code: PMA-322, AUG 81 REV

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 4, Page 11

,: rl

CAUTION

CORD

21.

TRANSMISSION FLUID - FORD

FOR ... ALL FORD AUTOMATIC TRANSMISSIONS AND CONVERTERS

TYM?"

SPECIFICATIONS Automatic Transmission Fluid, Type "F", which meets FORD MOTOR COMPANY Specification: ESW-~2~33~ (RED DYED)

TYPE "F" CAUTION:

22.

HYDRAULIC

BRAKE FLUID

HYDRAULIC BRAKE FLUID

FOR . . . HYDRAULIC BRAKE SYSTEMS EXCEPT WHEN SPECIFIED DIFFERENTLY ON THE LUBRICATION CHART(S) AND NOT USED FOR COLD STORAGE.

CLARK PART NUMBER 884677

SPECIFICATIONS Use only heavy-duty Hydraulic Brake Fluid which meets or exceeds the requirements of SAE 51703 Specification, or alternatively, Type DOT Brake Fluid, Grade DOT 3, as specified

by Federal Motor Vehicle Safety Standard No. 116 (FMVSS 116).

Non-petroleum type.

23.

COLD STORAGE

DEXRON AND TYPE "A" FLUIDS ARE NOT COMPATIBLE WITH TYPE "F" FLUIDS AND SHOULD NOT BE MIXED. DEXRON FLUID OR TYPE "A" FLUID SHOULD NOT BE USED IN FORD TRANSMISSIONS AND CONVERTERS (CTA "E" MODELS) TO DO SO WILL RUIN CLUTCH DISC FACINGS.

HYDRAULIC BRAKE FLUID -COLD STORAGE OPERATION-

FOR . . . HYDRAULIC BRAKE SYSTEMS, WHEN SPECIFIED SEPARATELY ON LUBRICATION CHART(S).

SPECIFICATION Use Fluid per CLARK Specification MS-92: Recommended Fluid: 85% by volume, Isopropyl Alcohol: 15% by volume.

PRE-BLENDED BRAKE FLUID

Section 4, Page 12

ALTERNATE: Fluid meeting SAE 51702, Motor Vehicle Brake FluidArctic, or Federal Specification MIL-H-13910, as available.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-322, AUG 81 REV

24.

POWER BRAKE VACUUM CYLINDER LUBRICANT

POWER BRAKE FOR . . . BENDIX HYDROVAC UNIT

CLARK PART NO. 377299 (2 oz tube) CLARK PART NO. 377300 (quart can)

SPECIFICATION Bendix Vacuum Power Cylinder Oil or approved equivalent.

LUBRICATION

Apply after installation and periodic maintenance per instruction.

25.

HYDRAULIC FLUID

ra c

,

MI-68

NORMAL APPLICATION

FOR . . . MAIN HYDRAULIC SYSTEMS EXCEPT WHEN SPECIFIED DIFFERENTLY ON THE LUBRICATION CHART(S)

CLARK PART NUMBER 885385

SPECIFICATIONS Use only high quality hydraulic fluid with Zinc or equivalent Anti-Wear additive which meets the requirements of ASTM D-2882 pump wear test with 50 mg total weight loss maximum per CLARK Specification MS-68.

26.

HYDRAULIC FLUID

HYDRAULIC FLUID

HYDRAULIC FLUID -COLD STORAGE OPERATION-

FOR . . . MAIN HYDRAULIC SYSTEMS EXCEPT WHEN SPECIFIED DIFFERENTLY ON THE LUBRICATION CHART(S).

SPECIFICATIONS Use Hydraulic Fluid which meets MIL-H-5606A per CLARK Specifications MS-226.

COLD STORAGE OPERATION

A petroleum base hydraulic fluid with additives to improve viscosity index, oxidation resistance and anti-wear characteristics blended to form a stable product under storage and operational conditions between -65 and +160" F., meeting MIL-H-5606A* per CLARK Specifications MS-226. *The restrictive cleanliness specifications of later revisions is not required.

Code: PMA-322, JUN 80 REV

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 4, Page 13

INDUSTRIAL

TRUCK DIVISION

CUSTOMER SERVICES GROUP

27.

HYDRAULIC FLUID

FIRE RESISTANT

HYDRAULIC FIRE RESISTANT FLUID

FOR . . . SPECIAL APPLICATIONS IN MAIN HYDRAULIC SYSTEMS EXCEPT WHEN SPECIFIED DIFFERENTLY ON THE LUBRICATION CHART(S) SPECIFICATIONS High quality Water-Glycol Fire Resistant Hydraulic Fluid composed of approximately 42% water and 58% glycol with a nominal viscosity of 200 SUS at 100" F. Pour point -35" F. min. To contain proper additive balance to impart optimum stability, lubricity, wear and corrosion protection.

Approved by Factory Mutual Insurance Underwriters.

28.

ENGINE FUEL - GASOLINE

FOR . . . INDUSTRIAL GASOLINE ENGINES SPECIFICATIONS Fuel to be Automotive Quality Regular Grade Gasoline containing a corrosion inhibitor.

Minimum Motor Octane Number - 85

29.

ENGINE FUEL - L P -GAS

FOR ... INDUSTRIAL L P -GAS POWERED ENGINES SPECIFICATIONS Use LPG meeting PROPANE HD-5 (NGPA Specification 2140-62) or ASTM D2154 (Special Duty Propane) requirements.

Minimum Motor Octane Number - 95

30.

ENGINE FUEL - DIESEL

FOR . . . INDUSTRIAL DIESEL POWERED ENGINES SPECIFICATIONS Fuel to be Automotive Quality Diesel Fuel Oil as defined by ASTM D975, Grades No. 1-D and 2-D, and having a sulfur content of less than 0.5% weight.

Recommended Cetane Number - 45 Minimum NOTE:

Section 4, Page 14

AN ASTM NO. 1-D FUEL IS PREFERRED WHERE MINIMUM

SMOKE AND ODOR IS REQUIRED OR WHERE LIGHT LOAD AND SPEED WITH CONSIDERABLE IDLING IS ENCOUNTERED AND FOR COLD WEATHER USE GENERALLY.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-322, JUN 80 REV

GROUP 40

CLSRK

CLARK PART NUMBER 1801146 FOR ELECTRICAL & SCR COMPONENTS I M PO

RTAN

T

DO NOT CLEAN ELECTRICAL COMPONENTS WITH STEAM. ONLY APPROVED SOLVENTS SHOULD BE USED TO CLEAN SCR COMPONENTS

...

USE CLARK #1801146 DEGREASER (OR THE EQUIVALENT TO MS-180, FREON TF DEGREASER).

CLARK PART NUMBER 1800330 FOR NON-ELECTRICAL COMPONENTS FOR use on NON-ELECTRICAL Components.

CLARK X1800330

Degreaser may be used to clean outer surface of cylinders, valves and other components as well as engines . . . may be used on paint.

Code: PMA-322, FEB 84 REV

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 4, Page 15

OTES

1146-Z REV DEC 83

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP 40

G

U SECTION

5 TRUCK

Code: PMA-510, DEC 80

SPECIFICATIONS

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 5, Page 1

ELECTRICAL COMPONENT/TEST SPECIFICATIONS 1.275 Specific Gravity.

1.310 Specific Gravity.

BATTERY FULLY CHARGED:

(Standard Batteries) (Exide Loadhog only)

GROUND TEST: (Minimum Resistance) New Truck: 50,000 ohms. Used Truck:*30,000ohms, *Used truck resistance values may range from 20,000 to 30,000 ohms, w/o problem.

When below 20,000 ohms, further testing must be conducted.

CURRENT DRAW VALUES: (+15% Tolerance, Warm Truck, 36-volt and 48-volt battery) 1) Drive Motor - (1A Freewheeling, Less Pump Mtr Idle Curr.) 0 BATTERY: 60 amps 2) Pump Motor - Idle Current 0 BATTERY: 31 amps SCR CURRENT LIMIT: (?15% Tolerance, Cold Truck) 1) Drive Motor (Less Pump Motor Idle) 0 BATTERY: *@ MOTOR : 2) Pump Motor (Hydraulic Relief) *For both 36-volt and 48-volt battery

REGENERATIVE BRAKING/PLUGGING Drive Motor G.E. 11 inch, Prestolite 11 inch

Truck EC

G.E. 13 inch

DISTANCE:

36 v 220 amps Truck Model 17, 20 22, 25 27, 30

48 v 246 amps Current Draw 440 amps 480 amps 510 amps

(+20% Tolerance)

~~_~o~t4B;t;fjry

FE_lo!t7B;ttmejry

11 - I.6ft

17 - 23 ft

EC

[3.7 - 4.9 m] 12 - 16 ft

[6.1 - 8.0 m] 20 - 26 ft

G.E. 13 inch

EP

[4.6 - 6.1 m] 15 - 20 ft

[6.! ;09F; ml 22

Prestolite 13 inch

EC

[4.6 - 6.1 m] 15 - 20 ft

[6.1 - 8.0 m] 20 - 26 ft

Prestolite 13 inch

EP

[5.8 - 8.0 m] 19 - 26 ft

[8.5 ;51vi7 m] 28 -

CREEP SPEED:

Fixed 0 3.5 motor volts approx.

1A PICKUP TIME DELAY:

1.0 - 2.0 seconds.

FIELD WEAKENING CURRENT: (Less Pump Motor Idle Current) 0 BATTERY For both 36 v and 48 v Battery FUSES: 1 3 5 6

FU, FU, FU, FU,

2 4 6 8

FU FU, 7 FU FU FU

PJIRING DIAGRAM:

Section 5, Page 2

AMP Rating 500 amp 15 amp 15 amp 15 amp

Contactor:

Pick-Up 150 amps*

Drop-Out 325 amps*

*t20 amps Function Pump and Traction Control Control Fuses 12-Volt Converter (In traction Control) IZ-Volt Converter (Remote Mounted)

Refer to the truck wiring diagram supplied with the truck, or to the circuit diagram located in the back of this book.

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV FEB 84

CONTACTOR SPECIFICATIONS: Function Amp Rating

lA, Pump 300

F, R 150

F.W. 150

R.B. 300

N-0. Gap

[3,70 mm] ,146 inch

[3.70 mm] .146 inch

[3.70 mm] .146 inch

[3.70 mm] .146 inch

N.C. Gap

N-0. Tip Wipe

[3.43 mm] .135 inch (minimum) [1.35 mm] .053 inch

[1.35 mm] -053 inch

N.C. Tip Wipe

[3.43 mm] .135 inch (minimum) [1.35 mm] .053 inch

[1.35 mm] .053 inch

[.97 mm] .038 inch (minimum)

[.97 mm] -038 inch (minimum)

Initial Tip Pressure

[16.0-17.8 N] 3.6-4.0 lb

[16.5-19.1 N] 3.7-4.3 lb

[10.2-11.6 N] 2.3-2.6 lb

[16.5-19.1 N] 3.7-4.3 lb

Final Tip Pressure

[48.9-53.4 N] 11.0-12.0 lb

[55.2-62.7 N] 12.4-14.1 lb

[29.8-33.4 N] 6.7-7.5 lb

[55.2-62.7 N] 12.4-14.1 lb

Coil Resistance, Ohms 0 25°C

33.20

19.75

22.90

19.80

PUMP MOTOR BRUSH SPRING TENSION:

New Brushes: Worn Brushes:

PUMP MOTOR BRUSH REPLACEMENT (WORN) LENGTH:

[9.7 N] 35 oz. Minumum [ll.l N] 40 oz. Maximum [5.3 N] 19 oz.

[16 mm] 0.62 inch

DRIVE MOTOR BRUSH SPRING TENSION: G.E. 11 in., 13 in.

New LlO-12N] 36-44 oz.

(New and/or used) Prestolite llin., 13 in.

New [9.7-llN] 35-40 oz.

DRIVE MOTOR BRUSH LENGTH: G.E. 11 in., 13 in.

Worn: L20 mm] .80 in.

New: [44,45 mm] 1.75 in.

Prestolite 11 in., 13 in.

Worn: L16 mm] .62 in.

New: [44,45 mm] 1.75 in.

Code: PMA-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 5, Page 3

GROUP 40 MAXIMUM UPRIGHT DOWNDRIFT IN 5 MINUTES (WITH CAPACITY LOAD) CLARK UPRIGHTS HILO

TRUCK 40DEL

TEMPERATURE

STD

17, 20

[26.7"C] 80°F

[8.5 mm] 0.33 inch

[7.5 mm] 0.29 inch

[7.5 mm] 0.29 inch

[37.8OC] 100°F

[13.5 mm] 0.53 inch

[11.5 mm] 0.45 inch

[11.5 mm] 0.45 inch

[48.9"C] 120°F

[19.5 mm] 0.77 inch

[15.5 mm] 0.61 inch

[15.5 mm] 0.61 inch

[26.7"C] 80°F

19.5 mm] 0.37 inch

[8.5 mm] 0.33 inch

[8.5 mm] 0.33 inch

[37.8"C] 100°F

C15.5 mm] 0.61 inch

[13.5 mm] 0.53 inch

[13.5 mm] 0.53 inch

[48.9"C] 120°F

[23.5 mm] 0.93 inch

[18.5 mm] 0.73 inch

[18.5 mm] 0.73 inch

[26_7"C] 80°F

[11.5 mm] 0.45 inch

[9.5 mm] 0.37 inch

[9.5 mm] 0.37 inch

[37_8"C] 100°F

[18.5 mm] 0.73 inch

[15.5 mm] 0.61 inch

[15.5 mm1 0.61 inch

[48.9"C] 120°F

[28.5 mm] 1.12 inch

L22.5 mm] 0.89 inch

[22.5 mm1 0.89 inch

22, 25

27, 30

VOTE:

TSU

These values are for a ne\$Jtruck.

TILT DRIFT I?45 MINUTES TEYP ("C)

TEMP ("F)

26.7" 37.8" 48.9"

80" 100" 120"

Section 5, Paye 4

DRIFT (mm) 3.0 5.5 8.0

DEGREES -5" -8" 1.2"

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

INCHES (APPROX.) 0.12 0.22 0.31

Code: PMA-510, REV FEB 84

GROUP 40

MAJOR BOLT TORQUE SPECIFICATIONS 1

Steer Wheel Lug Nuts (EP only):

[359-458 N m]

265-338 lbf. ft.

2

Steer Wheel Spindle Nut :

[230-244 N m]

170-180 lbf. ft.

3

Drive Wheel Lug Nuts (EC/EP):

[637-718 N m]

470-530 lbf. ft.

4

Upright Trunnion Cap Bolts:

[75-80 N m]

55-59 lbf. ft.

5

Upright-to-Trunnion

[370-410 N m]

273-302 lbf. ft.

6

Outside Counterweight Bolt:

[630-700 N m]

465-515 lbf. ft.

7

Inside Counterweight Mounting Bolts:

[360-400 N m]

265-295 lbf. ft.

8

Auxiliary Counterweight Mounting Nut:

[185-205 N m]

140-150 lbf. ft.

9

Drive Axle Mounting Bolts (Top):

[500-540 N m]

370-400 lbf. ft.

10

Drive Axle Mounting Bolts (Lower):

[580-610 N m]

430-450 lbf. ft.

11

Drive Motor-to-Differential

[72-80 N m]

53-59 lbf. ft.

12

Axle End to Adaptor Bolts:

[114-142 N m]

84-105 lbf. ft.

13

Steer Axle Mounting Bolts 0 Silent Block:

[ZO N m]

177 lbf. in. max.

14

Tilt Cylinder Yoke Clamp Bolt:

[170-190 N m]

125-140 lbf. ft.

15

Tilt Cylinder Pin Lock Bolt:

[41-45 N m]

30-33 lbf. ft.

16

Overhead Guard Bolts:

[72-80 N n]

53-59 lbf. ft.

17

Battery Compartment-to-Frame

[185-205 N m]

140-150 lbf. ft.

18

Steering Column Adjustor Arm Mounting Bolts:

[lo-15 N m]

7-11 lbf. ft.

19

Steering Hand Wheel Nut:

[47-54 N m]

35-40 lbf. ft.

20

Hydraulic Valve Mounting Bolt:

[41-45 N 171

30-33 lbf. ft.

21

Main Pump-to-Motor Bolts:

[70-80 p;in]

52-59 lbf. ft.

22

Main Pump Motor Mounting Bolts:

[23-25 pim]

203-221 lbf. in.

23

Motor Cable Connections:

[lo-l1 ilm]

90-1ilC lbf. in.

24

Seat Mounting Bolts:

[Zl-23 i‘i m]

180-2l?O lbf. in:.

Bolts:

Code: PMA-510, REV FEB 84

Mounting Bolts:

Bolts:

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 5, Page 5

GROUP 40 25

Traction Control Panel Cable Connections:

D l-14

N m]

loo- 120 lbf. in.

26

Pump Control Panel Cable Connections:

[18-20 N m]

160-175 lbf. in,

27

Lift Cylinder Retaining Bolts:

[65-75 N m]

50-55 lbf. ft.

28

Load Backrest Mounting Bolts:

[240-270 N m]

177-199 lbf. ft.

29

Electric Accelerator Control Mounting Bolts

[lo-12 N m]

84-96 lbf. in.

30

Accelerator Pedal Bracket Mounting Bolts:

[23-25 N m]

203-221 lbf. in.

31

Valve Lever Knob Bolts:

[8-10 N m]

75-85 lbf. in.

TIRE PRESSURE Drive: Steer:

All EPA Models

[827 kPa] 120 PSI (14 ply) [965 kPa] 140 PSI

[930 kPa] 135 PSI (16 ply)

HYDRAULIC SYSTEM Main Valve EC 17, 20; EC 22, 25; EC 27, 30;

Relief Pressures: EP 20: [15858-16547 kPa] 2300-2400 PSI EP 22, 25: [17926-18616 kPa] 2600-2700 PSI EP 27, 30: [20339-21029 kPa] 2950-3050 PSI

Power Steering Relief Pressure:

[5860-6550 kPa] 850-950 PSI

Auxiliary Valve Relief Pressure: (Refer to attachment specifications) Adjustable dependent upon application from [689-13789 kPa] 100-2000 PSI

Hydraulic Filter by-pass Pressure: [69 kPa] 10 PSI RESERVOIR CAPACITIES Drive Axle: Hydraulic Sump Tank: Hydraulic Tank (useable volume):

Section 5, Page 6

[3.785 litres] 8 pints [30.7 litres] 8.1 gallons [22.7 litres] 6.0 gallons

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-510, REV JAN 82

Capacity & Weight

ECA-17 ECA-20

ECA-22 ECA-25

(All weights are with min. battery weight)

Lifting Capacity

Truck Weight

Counter Weight

Battery Weight Min. Max.

1700 kg 3400 lbs

3599 kg 7935 lbs

304 kg 670 lbs

771 kg 1700 lbs

1928 kg 4250 lbs

526 kg 1155 lbs

594 kg 1310 lbs

753 kg 1600 lbs

2000 kg 4000 lbs

3781 kg 8335 lbs

304 kg 670 lbs

952 kg 2100 lbs

1928 kg 4250 lbs

526 kg 1155 lbs

594 kg 1310 lbs

753 kg 1660 lbs

2200 kg 4400 lbs

4051 kg 8930 lbs

414 kg 913 lbs

1066 kg 2350 lbs

1928 kg 4250 lbs

526 kg 1155 lbs

594 kg 1310 lbs

753 kg 1660 lbs

2500 kg 5000 lbs

4225 kg 9315 lbs

524 kg 1155 lbs

1180 kg 2600 lbs

1928 kg 4250 lbs

526 kg 1155 lbs

594 kg 1310 lbs

753 kg 1660 lbs

2700 kg 3400 lbs

4438 kg 9785 lbs

587 kg 1295 lbs

1360 kg 3000 lbs

1928 kg 4250 lbs

566 kg 1245 lbs

625 kg 1380 lbs

793 kg 1750 lbs

3000 kg 6000 lbs

4661 kg 719 kg 10275 lbs 1585 lbs

1360 kg 3000 lbs

1928 kg 4250 lbs

566 kg 1245 lbs

625 kg 1380 lbs

793 kg 1750 lbs

2000 kg 4000 lbs

3851 kg 8490 lbs

300 kg 660 lbs

952 kg 2100 lbs

1928 kg 4250 lbs

526 kg 1155 lbs

594 kg 1310 lbs

753 kg 1660 lbs

2200 kg 4400 lbs

4051 kg 8930 lbs

363 kg 800 lbs

1089 kg 2400 lbs

1928 kg 4250 lbs

526 kg 1155 lbs

594 kg 1310 lbs

753 kg 1660 lbs

2500 kg 5000 lbs

4314 kg 9510 lbs

583 kg 1285 lbs

1134 kg 2500 lbs

1928 kg 4250 lbs

526 kg 1155 lbs

594 kg 1310 lbs

753 kg 1660 lbs

2700 kg 3400 lbs

4581 kg 683 kg 10100 lbs 1505 lbs

1270 kg 2800 lbs

1928 kg 4250 lbs

566 kg 1245 lbs

625 kg 1380 lbs

793 kg 1750 lbs

3000 kg 6000 lbs

4770 kg 683 kg 10515 lbs 1925 lbs

1270 kg 2800 lbs

1928 kg 4250 lbs

566 kg 1245 lbs

625 kg 1380 lbs

793 kg 1750 lbs

ECA-27

ECA-30

EPA-20

EPA-22

EPA-25

EPA-27 EPA-30

Std

Upright Weight HiLo

TSU

IMPORTANT: WEIGHTS LISTED above are approximate weights for trucks with standard They have been rounded off to the next highest figure. Do not reduce equipment. them. Use these weights as a guide to pick an appropriate chain hoist, jacks and/ If the truck is equipped or wheel support stands of the proper rated capacity. with an attachment or device other than standard, this extra weight must also be considered.

Trucks vary in weight with the SIZE and TYPE of UPRIGHT and BATTERY used.

BATTERY WEIGHTS vary by size, type and manufacturer.

First, check you battery case. The battery weight generally is listed near the lifting eye or lifting hole. If not, consult your battery supplier.

Code: PMA-510, REV FEB 84

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section

5,

Page 7

M

OTES

1146-Z REV DEC 83 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP 40

MEASURING

VOLTAGES

WITH

THE

VOLT-OHM

SECTION

METER

( V-O-M

>

17

Black

RESISTANCE SCALE Refer to Section 18.

Code:

~~~-336,

E SCALE

Section 17, Page

REV JAN 77 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

1

INDUSTRIAL

TRUCK DIVISION

CUSTOMER SERVICES GROUP

USING A

THE

typical

several

Connect

METER: volt

meter

voltage

accurate

ranges

readings

range.

is equipped

In the

with

to provide

over

a wide

absense

of

a

Meter

Insert

RED

insert

BLACK

Leads:

TEST

LEAD

TEST

in jack

LEAD

marked

in jack

+

marked-

voltage

specified

range to use, be sure to use a range sufficiently higher than the voltage to be measured to avoid damaging the meter.

When

measuring

truck

voltage,

battery

to observe necting wiring

voltage

the

directed

meter

to

be

sure

is connected,

do

polarity leads.

so,

to parts

and

do

being

not

the be

when

sure

con-

Unless disconnect

tested.

THE MOST ACCURATE READING OF ANY METER IS TOWARD THE CENTER OF IMPORTANT: FOR EXAMPLE, WHEN READING VOLTAGES UP TO 2.2, USE THE 2.9 RANGE, SCALE. THIS BRINGS THE READING NEARER WHEN READING 2.5 VOLTS, USE THE 1OV RANGE. CENTER OF THE SCALE AND PROVIDES A MORE ACCURATE READING. IT ALSO PROTECTS METER

FROM

VOLTAGE

POSSIBLE TO

BE

DAMAGE RANGE

IN THE

EVENT

SWITCH

READ

EXCEED

WITH

4

0 to

2.5V

50 or ,504 = 0.5\!

READING

SCALE

FIGURES

o-

2.5V

100 or l.OOJ = l.OV

THE

2.5.

THE

METER

BELOW *Move

from

THE

USE DC VOLTAGE

SETTING

MEASURED

VOLTAGES

ITS

HOWEVER,

250

two

150 or 1.5036 200 or 2.00* = 2.ov = 1.5v

the

decimal

places

to

point

the

left.

250 or 2.50* = 2.5V

>p=3$07

/GO 'C 0

0‘ a0

/ HERE

RANGE

Section

SWITCH

17, Page 2

SETTING:

THE

2.5V

METER

READS

Read

1st

2.25V

Row

or

of

2&l

Figures

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

with

Code:

the

DC

~~~-336,

Scale.

REV

JAN

77

VOLTAGE TO BE MEASURED

from from from

2.5V to 1OV IOV to 5OV 50V to 25OV

RANGE SWITCH SETTING

USE DC VOLTAGE SCALE WITH FIGURES BELOW

1ov

READING

0 - 10 0 - 50 0 - 250

5ov 25OV

c

RANGE SWITCH SETTING: 1OV AC/DC DIAL SETTING: +DC

Read Read Read

10 V RANGE

THE METER

directly directly directly

SWITCH

SETTING

READ 3rd ROW FIGURES WITH DC SCALE, METER Fig.

READS

3 VOLTS

37229

Fig. .16015 c

RANGE SWITCH SETTING: 50V AC/DC DlAi SETTING: +DC

50 V RANGE

SWITCH

SETTING

READ 2nd ROW FIGURES WITH DC SCALE.

Fig.

17229

Fig. RANGE SWITCH SETTING: 250V AC/DC DIAL SETTING: +DC

READ 1st ROW FIGURES WITH DC SCALE. Fig.

Code:

250 V RANGE

METER

SWITCH

READS

SETTING

75 VOLTS

17229

PMA-336,

Fig.

JAN 77

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

16015

Section

16015

17, Page 3

INDUSTRIAL

TRUCK DIVISION

CUSTOMER SERVICES GROUP

1.25 OR l--l/4 VOLTS 1 .OO OR 1V

I

1.75 OR l-3/4V

(7

?ci5iY 50” 250”

Section

17, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code:

PMA-336,

JAN 77

GROUP 40

MEASURING

RESISTANCE

WITH

THE

VOLT-OHM

SECTION

METER

( V-O-M

)

18

Black

RESISTANCE

VOLTAGE SCALE Refer to Section 17.

THIS

Code:

PMA-336, REV JAN 77

SCALE ‘NOT

USED

Section Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

18, Page 1

INDUSTRIAL

TRUCK DIVISION

CUSTOMER SERVICES GROUP

USING

THE

to

the

CONNECT

METER: To insure accurate and prevent possible damage

readings,

meter,

be

sure Also,

to disconnect disconnect one

METER

LEAD

in jack

TEST

LEAD

LEADS:

Insert

marked

in jack

(+).

RED

TEST

Insert (-).

marked

BLACK

truck battery. connection of any part being tested from the circuit to prevent other circuits

from

affecting

resistance

read-

ings.

SETTING

THE

ferred

to

METER:

Meter

in the

settings

PM procedures

Rxl, RxlOO, RxlO,OOO. meter function switch

Set the center to the specified

If measuring resistance range.

KNOWN RESISTANCE use the Rx100 If the

first. center

if the reading.

However, drops to O-ohms, then use If the

an

UN-

range

indicator points near then use this scale for

scale,

indicator

infinity

re-

are:

mark

stays

then

the or

the

Rx1

be

the

To

RxlO,OOO

do

and

scale.

TEST

Resistance

LEADS

ACROSS

Value

Being

UNKNOWN Range

RESISTANCE Switch

AND

this, the

READ

Setting

READ

ZERO

each

ohms scale, from one ohms

adjust

0 on TOUCH

TO

calibrated

and

to the chanqed

scale.

near

METER

must

indicator

at

use

ADJUST

connect ZERO

ohms

each

the

Meter

it

is set

time

scale

OHMS

it

is

to another.

leads

together

KNOB

for

exactly

THIS

CHART.

Meter

’

scale.

VALUE,

USING

Reading

’

OHMS:

time

The

Measured ZERO

to 200

200

to 20,000

20_000 to

to

ITEM

illustration. indicator in the

OHMS

INFINITY

I

defer

OHMS

meter

this

Read The

be

read

Read

reads

SWITCH scale

meter

REFER

Section

TO

reads

THE

stalk

by

100.

RxlO,OOO

Multiply

ohms

scale

by

10,000

With

the

the

scale

RANGE

SWITCH

examples

1200

set

are

as

read

indicated, as

50

Rx100

5000

Rx10,OOO

500,000

OHMS

10

OHMS OHMS

5 OHMS

OHMS

1000

OHMS

100,000

follows:

500

OHMS

OHMS

50,000 OHMS

left.

to

:[pLTyT

left.

OHMS.

right 120,000

2

Rx1

Rx100

right

OPPOSITE

18, Page

directly.

Rx1

SETTING: from

scale

I

as

right to 12 OHMS.

SETTING: from

meter

RANGE The

SWITCH scale

ohms

position,

SETTING:

Read Scale from The meter reads RANGE

ohms

1 in opposite With meter

would

SWITCH

Read

Multiply

I

follows: 3ANGE

Rx1 Rx100

RxlO,OOO to

left.

OHMS.

PAGE

FOR

METER

SCALE

BREAK

DOWN

OF

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

DIFFERENT

Code:

RANGE

PMA-336,

SETTINGS.

REV

JAN

77

CLqRK

GROUP

QHMS

(SCALES)

* fl I a00 G z -500 -400 -300 200 -

1 120.000

100 -

110,000

000 zCT

JOO,ooo ~,oqo

z 00 Y 50 '00 z-\ c ;0 \ '0 i s ?

$ \ \ \ 2s

Code: PMA-336, JAN 77

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section

18,

Page

3

PM

NOTES

1146-ZCopyrighted REV DEC 83 Material Intended for CLARK dealers only Do not sell or distribute

1.

TO

12

VOLT

POS

TO

12

VOLT

n INDICATES CONNECTION

EXTERNAL

BY CLARK

NEG

4

-!D

---

63.--a=L-.---------_~t-----------_

---

63---~-----_______~----------_

RUX

12

VOLT

SWIT'CHES

TO

NEGRTIVE

64_------64__-_-___

AUX

CIRCUIT

SOLENOIDS

DIQGRflM

=_

-v9zJ AUX

L JUMPER STRNORRO:OMlT WHEN 601 IS USE0

PUMP

GE

CAR0

PUMP

CONTROL

CIRCUIT

36148

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

VOLTS

POWER

1.

n INDICATES CONNECTION

B_RT T E R Y

POS

TO

-l-FI

POS

36-48 CONTROL

PUMP

V. TO

I

L

T

CONTROL

NEG

w

1

18

lfl

PUMP

R2

LEO

R

fll

2

3 23

FIL

+=-I 53

I53

FU

I L

SECTION OF INT.TERMINRL, BORRO.

I I:

v 1

I

12-i

I

EXTERNRL POWER

BY CLFIRK

IC

13

1

iKEY SWITCk

FICCELERATOR

62

MODULE

1’3

13fl-

10

L +-

I SWICH RELRY

12

Y KEY

SWITCH

POS63 0---6?=&+53r)

I

264~~13R-

:: 63 p.

.13---l

RELRY 13

\V/

VOLT

1:

RB

.65 -----IT

62

62~-

r

13

I 361'48

8

FU

+12

VOLT-J' OUTPUT

ii-12

VOLT

NEG

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

VOLTS

liiii+s

TRRCTION

CONTROL

MODULE

ITCI

I

-,o+lr)’

654 -6433) -B-44>;: ----I34 -29-%6B);: -m-b -734 65-b,912,

:W 3ESISTOR

T

ACCELERATOR ---

2);

; ;

5>

:

7 > B>;

! ! ‘_’

r

1

PL2

MODULE

7 i

r

,217 _._._._so2

CONTROL

i ; : : : ! !

L

OPTIONRL mRCK-UP LAMP

SWITCH

r-

r

I I

.--_

5016

PLl6

OPTIONRL

,II

i23r156

r c

12 VOLT CONVERTER

RECEPTRCLE

r

--.

OP SW

IONFlL TCHES

<

UIPER

1 FRN

DRIVE BRUSH

63C

__

LIGHT

1

LIGHTS-

HORN

RERR

LIGHTS

n

I -l3C-+,2,+

PL9 25*

”

1’

-

.p

MOTOR HERR IOPTI

PC

BORRD

DRIVE CONTROLp TEMPERATURE

WRRNING LRMPS

PUMP CONTROL BRUSH HERR IOr PUMP CONTROL TE”PERRTURE

509

1r-<A

-

:@HORN BUTTON

BLRNK

-3 -6

I

63

ST0 NORMRL

, PUMP CONTOL MODULE (PC1

33

OPTIONRL BACK-UP ALARM

SI

52

OPTIONRL

RI

2B

-B9 -63 -63

,

OPTIONRL

FOR

FOOT BRRKE NORMRLLY OPEN

/

BRCK-UP OPTIONFIL HERDLRMP

OPTION

1 TO OPTIONRL BWI HRRNESS

I 611F

R2

I

#-12RPL20

-

TRRCTION MOTOR ITMI

WIRING SHOWN IN PHRNTOM LINE FIRE OPTIONAL EQUIPMENT WIRING.

r

L

PUMP

III

MOTOR IPM)

L Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

II

I

DIRGRRM-WIRING