Clark Forklift PMA 525 PW Planned Maintenance and Adjustment Manual

Planned Maintenance & Adjustment Procedures

PMA 525 PW

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

PM

OWNER

SAFE

MAINTENANCE

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

5.

PRACTICES

Before Leavina The Truck: 1) Stop truck.

2) Fully lower the load engaging means.

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

3) Put directional

control in neutral.

4) Apply the parking brake.

I.

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

5) Stop the engine or turn off power.

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

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

6) Lock the control or ignition circuit.

6.

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

4.

Before Startina To Drive The Truck: 1) Be in operating

Before Workina On Truck: 1) Raise wheels free of floor or disconnect power source.

2) Use blocks or other positive truck positioning devices.

position.

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

3) Put blocks under the load engaging means, innermast( or chassis before working under them.

4) Start engine or turn on power.

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

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

8. 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.

3) Put directional

control in neutral.

6) Release parking brake.

Copyrighted Material 1023-2.1 REV only OCT 86 Intended for CLARK dealers Do not sell or distribute

PM

CLSRK OWNER

SAFE

MAINTENANCE

PRACTICES

9. 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.

16. All hydraulic sytems 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.

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

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

11.

18. 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.

Handle LP-gas cylinders with care.

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

12. 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.

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

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

20.

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

14. 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.

15. 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.

21. Care must all replacement with the original to that provided

Copyrighted Material Intended for CLARK dealers 1023-2.2 REV OCT 86only Do not sell or distribute

be taken to make sure that parts are interchangeable parts and of a quality equal in the original equipment.

PM

CLflRK TABLE

CONTENTS OF (By Group Number)

Use of Manual and PM Information Electric Truck Safety Messages Illustration of Machine Pictorial Index Planned Maintenance Procedures

GROUP

1300-z 1299-z Page 3 Page 4 Pages 5 - 19

Section

01

1

Lubrication Charts

12

1

Electric Truck Battery

12

2

Electric Battery Powered Industrial Trucks - U.L. 583

12

3

Charging Procedures - Electric Truck Battery Pack

16

27

20

1

Drive Unit

29

1

Hydraulic Tank - Drain, Clean, Fill

34

3

Lift Cylinder Drift Test

40

1

Decals, Nameplates, and Serial Number Data

40

2

Suggested Equipment for Electric Truck P.M.

40

3

PM Inspection and Driver's Daily Inspection Forms

40

3

PM Safety and PM Cautions - Fire Extinguisher Recommendations

40

3

Safety Instructions for Maintaining Industrial Trucks

40

4

Lubrication Chart Key - Lubrication Specifications

40

5

Truck Specifications

Electric Motor Maintenance

Electrical Schematic Diagram (See rear of manual) Hydraulic Schematic Diagram (See rear of manual)

Code :

Copyrighted Material

PM-525, DEC 81 P.S.L. Intended for CLARK dealers only Do not sell or distribute

Page 1

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

TABLE

OF CONTENTS (Alphabetical Order)

GROUP

Section

Charging Procedures - Electric Truck Battery Pack

12

3

Decals, Nameplates, and Serial Number Data

40

1

Drive Unit

20

1

Electric Battery Powered Industrial Truck - U.L. 583

12

2

Electric Motor Maintenance

16

27

12

1

Hydraulic Tank - Drain, Clean; Fill

29

1

Illustration of Machine

Page 3

Lift Cylinder Drift Test

34

3

Lubrication Charts

01

1

Lubrication Chart Key - Lubrication Specifications

40

4

PM Inspection and Driver's Daily Inspection Forms

40

3

PM Safety and PM Cautions - Fire Extinguisher Recommendations

40

3

Safety Instructions for Maintaining

40

3

Electrical Schematic Diagram (Rear of manual) Electric Truck Battery Hydraulic Schematic Diagram (Rear of manual)

Industrial Trucks

Safety Messages

1299-z

Pictorial Index

Page 4

Planned Maintenance Procedures

Pages 5-19

Suggested Equipment for Electric Truck P.M.

40

2

Tr?.ck Specifications

40

5

Use of Manual and P.M. Information

1300-z

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

Code: PM-525, DEC 81 P.S.L.

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

PLANNED MAINTENANCE PROCEDURES

This manual provides detailed instructions for performing Planned Maintenance Procedures which include: minor adjustments, lubrication, system fluid and filter changes, and truck specifications.

WHY A PLANNED MAINTENANCE PROGRAM? Planned Maintenance is a program designed to reduce major failures and costly downtime by scheduling periodic inspections, lubrication, adjustments and testing on a schedule determined by your use and application of your lift truck.

A good PM program will alert you of the need for minor adjustments and repairs and will greatly reduce the potential for a major failure in the future.

An

effective

program

must

include

the

following

daily

and

periodic

functions:

1.

A daily inspection, prior to each shift which will include a visual inspection for damage, leakage, fluid levels and safety items.

2.

A scheduled monthly or 250 hour program based on your operating conditions and performed according to the instructions in this manual.

INSPECTION FORMS Daily and monthly inspection forms are an IMPORTANT part of your PM program and will provide you with the necessary details for keeping accurate records on the condition and service requirements of your truck. Inspection forms can be obtained from your (See GROUP 40 for sample forms). local Clark dealer.

Copyrighted Material Intended for CLARK dealers only 1300-z Do not sell or distribute

DEC 81

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.

q !

q

CAUTION

!

AIR PRESSURE

WEAR EYE PROTECTION AND APPROVED CLOTHING WHEN CLEANING WITH AIR PRESSURE. REDUCE AIR PRESSURE BELOW [207 kPa] OR 30 P.S.I.

q !

CAUTION HYDRAULIC PRESSURE

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

CAUTION

CAUTION

DECALS AND NAMEPLATES

BATTERY

DO NOT OPERATE A LIFT TRUCK WITH MISSING OR DAMAGED DECALS OR NAMEPLATES. REPLACE THEM IMMEDIATELY.

DISCONNECT THE BATTERY AND DISCHARGE THE CAPACITOR, IF EQUIPPED, BEFORE WORKING ON OR NEAR ELECTRICAL COMPONENTS.

IMPORTANT IMPORTANT

STEAM CLEANING

ELECTRICAL TESTS

DO NOT STEAM CLEAN SOLID STATE -COMPONENTS. MOISTURE AND CHEMICALS CAN DAMAGE ELECTRICAL COMPONENTS.

DO NOT USE A MOTOR GENERATOR OR ANY KIND OF READY-POWER UNIT TO MOVE OR TEST THIS TRUCK. TRUCK OR COMPONENTS CAN BE DAMAGED.

IMPORTANT WELDING

IMPORTANT

1. BE SURE TRUCK HAS NO GROUNDS 2. DISCONNECT TRUCK BATTERY 3. PROTECT WIRING AND COMPONENTS FROM WELD SPLATTER 4. DO NOT WELD NEAR BATTERY VENT CAPS. 5. SEE S.I.-34-87-81R FOR PROPER WELDING PROCEDURES. COMPONENTS OR WIRING CAN BE DAMAGED IF THESE INSTRUCTIONS ARE IGNORED.

I /

CHECK BA::i::OzT' TRUCK WILL / NOT OPERATE IF POLARITY IS INCORRECT

IMPORTANT USE CLARK DEGREASER TO CLEAN SOLID STATE COMPONENTS. SOLVENTS CAN DAMAGE ELECTRICAL COMPONENTS.

Copyrighted Material

1299-z Intended for CLARK dealers DEC only 81 Do not sell or distribute

PM

CLclRK

PW 186 Models 15/18 [1500 Kg and 1800 Kg.] 3300 lb. and 4000 lb. Rated Capacity

Code: PM-525, DEC 81 P.S.L.

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

Page 3

P

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

PICTORIAL INDEX

35

2o

.

;

12 - Battery 13 - Switches, Accelerating Control Assy 16- Motors (Electrical) 17/19 - Contactors/Controls 20 - Drive Axle 23 - Brakes Wheels/Tires 25 - Steering Linkage 29 - Hyd. Pump, Sump & Filte:r 34 - Lift Cylinder 39 - Covers

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

Code: PM-525, DEC 81 P,S.I;.

PM

PLANNED MAINTENANCE

(P.M.) CHECK SHEET:

As the Planned Maintenance (P.M.) is being done, put a check on the check sheet to indicate; (1) if a component or truck system is operating correctly, (2) a possible future problem or (3) needs immediate repair. When a component or system does not operate correctly, or is not safe, a note must be made on the Planned Maintenance (P.M.) check sheet, and a report made to the person responsible for lift truck maintenance, at the end of the Planned Maintenance (P.M.).

Fig. 12618

REMOVE ALL JEWELRY AND DISCONNECT THE BATTERY FROM THE TRUCK BEFORE CHECKING OR WORKING NEAR ELECTRICAL COMPONENTS.

Fig. 12704 VISUAL INSPECTION Check for oil leaks.

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

Fig. 23700

Inspect the battery cover and the front cover. Make sure decals and nameplates are in position.

Fig. 23356

Code: PM-525, DEC 81 P.S.L.

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

Page 5

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Inspect the forks for damage.

NOTE Lift linkages are not adjustable.

Fig. 23701 Inspect the load wheels and pallet exit rollers.

Fig. 23702 Inspect the drive wheel and tire.

Fig. 23357 OPERATIBNAL TESTS: (Battery must be connected.)

Make sure tightly, full left must move

the control handle is mounted Move the control handle from turn to full right turn. It smoothly.

Fig. 23703

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

Code: P&525, DEC 81 P.S.L.

PM

CLARK

Make sure the "horn", "lift" and "lower" buttons operate correctly.

Hydraulic functions must operate smoothly.

Fig. 23351 Check the operation of the Mechanical Reversing Switch (Make this test in an area free from other trucks or objects.)

1.

2.

Move the truck in forward direction Permit the red mechanical (toward you). reversing switch to make contact with your body (or hand), which pushes the switch in half way, and turns off power to the drive motor.

Fig. 23685

Pull the mechanical reversing switch out to reset.

Fig. 23686 3.

Again, move the truck in forward direction.

Push the mechanical reversing switch again, but harder, pushing the switch all the way in. The truck will move away frcm you for a moment, and the switch will return to the half way position, turning off power to the truck. Reset the switch.

Fig. 23685

Code: PM-525, REV JUN 84

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

Page 7

INDUSTRIAL

TRUCK DtVlSlON

MARKETING TRAINING DEPT.

Check the brake components. Make sure the brake switch and cam are not damaged.

Fig. 23704 Check the amount of wear on the brake pads.

Fig. 23705 CHECK THE BRAKE SWITCH OPERATION:

1.

Slowly raise the control handle to full "up" position (brake is applied), and at the same time listen for the brake switch to open while watching for the brake shoe to make contact with the brake drum.

2.

The brake switch must open just before the brake show makes contacmth the brake drum.

Drive the truck in a straight line, forward direction, in the first speed. Check the brake operation. Brakes must apply with the handle in the fully raised position, and fully lowered position. The brake switch arm may be bent a small amount for adjustment purposes.

If the brake operation is acceptable, then drive the truck at high speed, check brake operation again, and listen for any noises from the drive unit that may be an indication of component wear or failure.

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

Fig. 23678

Fig. 23353

Code: PM-525, REV JUN

84

CLSRK

PM

Drive the truck in reverse direction at high speed. Again, listen for noises from the drive unit.

Put a capacity load on the forks. Check the lift cylinder drift per instructions in GROUP 34. Drift must not exceed specifications in GROUP 34 for your machine.

Fig. 23699 BATTERY AND CABLES: Clark Battery Saver and Cleaner may be used to clean and protect the truck battery.

New Truck Batteries: Apply a thin layer of Battery Saver and Cleaner Part 11 886395, over the battery surface. Do not clean off.

Old Truck Batteries: Apply a layer of Battery Saver and Cleaner to the battery surface. Permit it to set for approximately three minutes.

Clean off with a rag. Battery Saver and Cleaner dissolves rust and corrosion. After cleaning, apply a second layer for protection.

This will prevent corrosion on cables and terminals.

(For more information on battery maintenance, see GROUP 12 in this manual.)

1.

Loosen the knob, rotate the retainers, and remove the battery cover.

Code: PM-525, DEC 81 P.S.L.

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

Page 9

INDUSTRIAL

TRUCK DIVISION

fvlARKETlNG TRAINING DEPT.

2.

Disconnect the battery pack, or the industrial battery (whichever is used). Check the condition of the battery connector for cracks, loose fit, or electrical arcing.

Fig. 17590 3.

Check the battery condition. cables for cracks or damage.

Inspect the

Fig. 12678 Do not wash Clean off deposits of corrosion. -a battery while it is in the truck.

Fig. 19563 Check the battery vent caps. must be open.

The vent holes

Fig. 12913

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

Code: PM-525, DEC 81 P.S.L.

PM

CLsRw 'For those trucks with industrial batteries, check the battery stops for damage, and correct adjustment.

These battery stops can be put in reverse position to fit different size batteries.

NOTE There are no battery stops on trucks with the battery pack.

1. Short Battery

Fig. 23781 2. Long Battery I

1

Check the specific-gravity with a hydrometer.

The specific gravity must be no less than 1.250.

Fig. 17593 Connect the battery.

J

Fig. 17590 AIR CLEAN AND LUBRICATE THE TRUCK: Use an OSHA approved air hose and nozzle. Air pressure must not exceed [207 kPa] or 30 P.S.I. Wear safety glasses and necessary protective clothing.

Fig. 15301

Code: PM-525, DEC 81 P.S.L.

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

Page 11

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Remove the front cover.

Fig. 24336 At this time, raise the forks from the floor.

Visually inspect the lift cylinder for damage or leaks. Lower the forks to the floor.

Fig. 23709 Disconnect the battery.

Fig. 17590 Make sure all control wires are tight.

Fig. 23710

Page 12

Code: PM-525, REV JUN 82 P.S.L. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

PM

CLqRK

Make sure all motor connections are tight.

Fig. 23711 ,, ,*,:

Check control wire and cable terminals. There must be no looseness or corrosion. Also, check the insulation on the control wires and cables for damage.

? ‘;

,<“’

~

,\:.

2

;\.

Fig. 17727 Make sure the hydraulic fittings are tight.

Fig. 23712 Clean and lubricate all grease fittings.

GROUP 01.

See

I

Fig. 10890

Code: PM-525, DEC 81 P.S.L.

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

Page 13

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Park the truck on a level surface to check the drive unit fluid level. Remove the fluid level plug. Check the condition of the fluid, and if necessary, add fluid. (Use only DEXRON.) See GROUP 40, Section 4.

Fig. 23713 Remove the filler cap/breather from the hydraulic unit. Check the fluid level.

You must be able to see the fluid in the filler tube. If needed, fill with MIS-68 hydraulic fluid. Clean the breather (located in the cap itself) in an approved solvent.

Fig. 23714 TIGHTEN IMPORTANT FASTENERS: (See GROUP 40 for specifications.)

Connect the battery.

Fig. 17590 Push the "lift" button to raise the forks.

Fig.

r_

i4

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

23680

Code: PM-525, DEC 81 P.S.L.

PM

Check the torque of the trail wheel mounting bolts.

Fig. 23715 Push the "lower" button to lower the forks.

Fig. 23681 Disconnect the battery.

Y

Fig. 17590 Check torque of the elevating bracket pivot shaft retaining bolts.

Fig. 23726

Code: PM-525, DEC 81 P.S.L.

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

Page 15

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

Check the torque of the lifting link pivot shaft retaining bolts.

Fig. 23716 Check the torque of the lifting link to yoke shoulder bolts.

Fig. 23717 Check the torque of the drive wheel lug nuts.

Tighten the lug nuts in a cross pattern in clockwise rotation.

Fig. 23718 Check the torque of the output gear retaining bolt.

Fig. 23718

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

Code: PM-525, DEC 81 P.S.L.

PM

CLSRK Check the torque of the stabilizer bolts.

Fig. 23719 Check the torque of the control mounting bolts.

handle

Fig. 23727 Check the torque of the lift cylinder anchor bolts.

Fig. 23728 ELECTRICAL TESTS: Make a ground test:

!

WARNING -------

13

- REMEMBER BATTERY IS STILL DISCONNECTED. REMOVE ALL JEWELRY. 1.

Calibrate the ohmmeter on the Rx 10,000 scale.

Code: PM-525, DEC 81 P.S.L.

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

Fig. 17737

Page 17

INDUSTRIAL

TRUCK DIVISION

MARKETING TRAINING DEPT.

2.

Connect the positive lead of the ohmmeter to the positive (+) of the truck receptacle.

Connect the negative lead of the ohmmeter to the truck frame. Keep a record of the resistance.

Fig. 14860 3.

The resistance values between the frame and the positive (+) terminal of the truck receptacle must be: - 30,000 - 50,000

ohms or higher for used trucks. ohms or higher for new trucks.

There is a positive ground in the system if values are not as given above.

Fig. 22236 4.

Connect the positive lead of the ohmmeter to the negative (-) of the truck receptacle.

Leave the negative lead connected to the truck frame.

The frame is connected to the negative terminal of the truck battery receptacle through the field terminal of the hydraulic unit: The resistance value must be 0 ohms. Keep a record of the resistance. Disconnect the meter leads.

Make a short circuit test: 1.

n..u

Fig. 14861

Calibrate the ohmmeter on the Rx1 scale.

18

I

I

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

RX1

Code: PM-525, DEC 81 P.S.L.

PM-

C19RK

2.

Connect the positive lead of the ohmmeter to the positive side of the truck receptacle.

Connect the negative lead of the ohmmeter to the negative side of the truck receptacle.

The resistance must be near infinity.

If the resistance is less than 30 ohms, it is an indication that there is a short circuit which must be found before connecting the battery.

1 Fig. 14448

Install the front cover.

Fig. 24336 Install the battery cover.

Fig. 23691 Install the cover retainers.

Fig. 24337

Code: PM-525, REV JUN 82 P.S.L.

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

Page 19

GROUP 01

GROUP

01

SECTION

1 LUBRICATION

Code: PMA-525, DEC 81 P.S.L.

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

CHARTS

Section 1, Page 1

GROUP 01

CMRK

MAINTENANCE

ITEM

SCHEDULE

HOURS OF OPERATION 250 500

50

Battery

Electrolyte - Check

1000

X

Drive Unit Pivot - Lubricate

X

Drive Unit Level - Check

X

Drive Unit - Drain and Fill

X

Hydraulic Unit Level - Check

X

Hydraulic Unit Breather - Clean

X

Hydraulic Unit Breather - Replace

X

Hydraulic Unit - Drain and Fill

X

Hydraulic Tank Strainer - Clean

X

411 Lift Linkages - Lubricate

X

Lift Cylinder Anchor - Lubricate

X L

C^_L2

_

..GA1, Page 2

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

Code: PMA-525, DEC 81 P.S.L.

CLflRK

GROUP 01

SEE THE MAINTENANCE SCHEDULE ON PAGE 2 FOR LUBRICATION INTERVALS. SEE GROUP 40, SECTION 4 FOR LUBRICATION SPECIFICATIONS.

111

11.200 CHECK ELECTROLYTE LEVEL AND SPECIFIC GRAVITY.

CHECK HYDRAULIC FLUID LEVEL, FLUID MUST BE UP EVEN WITH THE FILLER TUBE. DRAIN AND FILL AS SPECIFIED. CLEAN OR REPLACE BREATHER. \

INKAGE SIDE

LIFT LINKAGE 4 EACH SIDE

CHECK DRIVE UNIT FLUID LEVEL. FLUID LEVEL MUST BE EVEN tiITH FILL/LEVEL PLUG OPENING. DRAIN AND FILL AS SPECIFIED.

Code :

Copyrighted Material

PMA-525, DEC 81 P.S.L.Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 3

GROUP 12

Cl!!RK

GROUP

12

SECTION

1 ELECTRIC

Code: PMA-5~5, DEC 81 P.S.L.

TRUCK

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

BATTERY

Section 1, Page 1

GROUP

12

WARNING -----___ BATTERY MAINTENANCE

BATTERY ACID, FUMES AND ELECTRICAL POTENTIAL CAN CAUSE SERIOUS INJURY OR DEATH. READ AND UNDERSTAND THESE PROCEDURES BEFORE WORKLNG ON BATTERIES.

1.

DO NOT SMOKE OR ALLOW OPEN FLAME OR SPARKS NEAR BATTERIES OR IN BATTERY CHARGING AREAS.

2. WEAR PROTECTIVE CLOTHING, GLOVES AND A FACE SHIELD WHEN WORKING ON BATTERIES,

3.

KEEP ALL METAL OBJECTS AWAY FROM BATTERIES.

4. HANDLE ACID WITH CARE.

FOUR ACID INTO

WATER AND NEVER POUR WATER INTO ACID.

5. BATTERIES ARE VERY HEPiVY, HANDLE THEM WITH THE CORRECT LIFTING DEVICES..

6. BATTERY CHARGING AREAS MUST CONFORM TO FEDERAL REGULATIONS.

7. DO NOT PERFORM BATTERY SERVICE UNLES,SYOU ARE TRAINED AND QUALIFIED.

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

PM&525,

DEC 81 P.S,L,

GROUP

Cl!!lRU

12

HANDLING STORAGE BATTERIES: 1.

Change or service storage batteries only in a battery service area.

2.

Make sure this area has the equipment: - to flush and make neutral any acid that may spill.

- for ventilation of fumes from batteries.

- for fire protection.

to prevent the chain from making a short circuit on the cell connections or terminals.

8.

Before trying to remove, install, or charge a storage battery, the truck must be in the battery service area with the brake(s) applied so that the truck cannot move.

3.

4.

Make sure the area has material handling equipment made for the purpose of removing and installing batteries, such as an overhead hoist. Make sure the overhead hoist has safety hooks.

When an overhead hoist is used, make sure an insulated spreader bar or similar device is used. The width of the spreader bar must be the same width of the battery at the lifting eyes, so that it is lifted immediately upward. Also, make sure the lifting hooks are not so large that pressure is put on the lifting eyes of the battery.

5.

If the battery does not have a cover, put a non-conductive material (plywood, cardboard, etc.) over the battery before attaching a battery lifting device.

6.

When a power chain hoist is used, make sure the hoist has a chain container to hold the amount of chain not used.

7.

When a hand hoist is used, a battery without a cover must have a non-conductive material put over it

Keep all tools and other objects made of metal away from the terminals.

10. Because of hydrogen

gas from batteries that are being charged, no smoking will be permitted in the battery area. Do not check electrolyte level with an open flame.

No open flames, sparks, or electric arcs will be permitted in the battery charging area.

11. When handling electrolyte, a carboy tilter or siphon must be used.

12. When using electrolyte, ACID MUST ALWAYS BE POURED INTO WATER. WATER MUST NEVER BE POURED TNT0 ACT---- Pouring water into acid will cause a dangerous chemical action.

13. When batteries are being charged, the vent caps must be kept in position to prevent electrolyte spray. The vent holes in the cap must be open. The battery, or battery compartment cover(s) must be open to permit the battery to cool and fumes to escape.

14. Electrical installations must follow the National Electrical Code (ANSI B56.2, 1974), NFPA 505-78, Part "C" and any local ordinances.

15. Batteries that are installed must be correctly put in position and held in the truck before the truck is put into use.

Copyrighted Material for CLARK dealers only Code: PMA-525, DEC 81 P.S.L. Intended Do not sell or distribute

Section 1, Page 3

GROUP

12

BATTERY REMOVAL:

n !

5 _----_ ARNING

5.

Attach the lifting device and spreader bar to the battery. See Fig. 23843.

6.

Remove the battery.

See Fig. 23843.

BEFORE YOU DO SERVICE WORK OR REMOVE OR INSTALL A TRUCK BATTERY, READ THE FOLLOWING INSTRUCTIONS CAREFULLY.

FAILURE TO FOLLOW THESE

INsT~ucrIoNs CAN

RESULT IN SERIOUS

PERSONAL INJURY.

1.

2.

Check the service and charging area for fire protection, and make sure there are no flames or heat in the area. Do not smoke. Make sure all necessary equipment is in the area, in good repair, and operating correctly. If service is to be done on the battery, make sure there is equipment to flush and make neutral any acid that may spill, ventilation to carry fumes from the battery, and equipment to handle electrolyte.

Put the truck in the battery area, turn the key switch to the "off" position, apply the parking brake or put the directional lever in park position, and disconnect the battery.

3.

Remove sheet metal, or doors, etc., for access to the battery.

4.

If the battery has no cover, a nonconducting material must be put over the battery before a lifting device is attached.

See item 5, "Handling Storage Batteries".

Fig. 23843

BATTERY CLEANING: 1,

Clean the battery only when .it is removed from the truck,

2.

Vent caps must be in position during cleaning.

Section 1, Page 4 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-445, JUN 82 P.,S..L.

CL9RK

GRIYp

3.

Wash the battery with low pressure cold water.

4.

'Ihe top of the battery can also be washed with a solution of sodium bicarbonate (put a box of sodium bicarbonate in a pail of water and mix). Rinse with clean water.

6.

Keep battery records.

7.

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

INSTALL THE BATTERY: 1.

Attach lifting device as described earlier.

2.

Correctly locate the battery in the truck and adjust battery stops.

BATTERY MAINTENANCE: See the battery vendor for recommendations.

NOTE KEEP BATTERY RECORDS: Records must be kept to get the best service from your battery and truck.

Select a pilot cell, and read the specific gravity and temperature before and after charging, and make a record of them, with the date. Change the pilot cell periodically.

Every 2 or 3 months, make a complete battery check of specific gravity, temperature and voltage and keep a record of them.

Some trucks have battery stops, or blocks, while others do not.

Replace them if they are missing.

If they are the adjustable stops, make sure they are adjusted to the battery, and tightened.

TO GET MAXIMUM LIFE FROM THE BATTERY: 1.

Do not add acid to a battery. Only a person from the battery manufacturer should decide if this is necessary.

2.

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

3.

Check the level of the electrolyte before charging. Add water before charging, but do not overfill. The level should be just below the lower lip of the fill hole.

4.

Keep the battery clean and dry.

5.

Do not charge except when necessary.

Code: PMA-525, DEC 81 P.S.L.

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

Section 1, Page 5

GROUP

CLsRw

12

GROUP

12

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 pro ided with means for ventilation that minimizes the possibility of accumulation of explosive hydrogen-air mixtures above the battery.

I;nrtinn

. 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 (130°F) 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 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 The truck or the battery enclosure. 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

WIRH

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

Covering Having Openings or Perforatiyns 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 (1.07)

0.080

B. Zinc-Coated

0.045 (1.14)

0.084 (2.13)

1. Screen 2. Perforated sheet

steel employed for expanded metal mesh:

Section 2, Page 4

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

(2.03)

PMA-510, DEC 80

GROUP

E19RK

12

GROUP

12

SECTION

3 PROCEDURES

CHARGING ELECTRIC

TRUCK

Copyrighted Material

BATTERY

Code: PMA-525, DEC 81 P.S.L.Intended for CLARK dealers only Do not sell or distribute

PACK

Section 3, Page 1

CHARGING OPERATION:

BATTERY CHARGING TO AVOID PERSONAL INJURY BATTERIES MUST BE CHARGED IN AN APPROVED CHARGING AREA AND CHARGED ACCORDING TO APPROVED PROCEDURES.

0!

CAUTION

DO NOT OPERATE THIS CHARGER UNLESS IT IS CONNECTED TO THE BATTERIES.

1.

Remove the battery cover.

Fig. 23691 2.

Disconnect the battery from the truck receptacle and turn the timer to the "off" position.

Fig. 23693 3.

Connect the A.C. cord to a 115V. A.C. outlet line (or a 230V. A.C. outlet, according to type of charger).

Fig. 23694

. 3. Paw

3

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

Code: PMA-525. DEC 81 P.S.L.

Cl!!RK 4.

Connect the battery receptacle to the charger.

Fig. 23695 5.

Turn the timer dial to the "on" position.

The pilot light and ammeter show the charger is "on" and charging. When the charger is turned to the "on" position, the charger will run for 12 hours maximum, or as set.

NOTE The charger may stay connected to the batteries for long periods of time without damage to the charger, and without discharging the batteries.

Fig. 23696

IMPORTANT WEEKLY CHECK:

Code: PMA-525, REV JUN 84

AFTER CHARGING, CHECK THE HEIGHT OF ELECTROLYTE IN EACH BATTERY CELL. ADD DISTILLED WATER IF NECESSARY. THEN, AFTER BATTERIES HAVE BEEN CHARGED, CONNECT THE BATTERIES TO THE CHARGER AND SET THE TIME CLOCK POINTER TO #4 ON THE TIMER DIAL. THIS ADDED CHARGING TIME WILL KEEP THE CELLS EQUAL TO ONE ANOTHER AND HELP KEEP THE BATTERIES IN GOOD CONDITION. WEEKLY CHECKS ARE TO BE MADE ONLY BY TRAINED AND AUTHORIZED BATTERY MAINTENANCE PERSONNEL.

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

Section 3, Page 3

CL!WK

GR12u

GROUP

16

SECTION

27 GENERAL

MOTOR

MAINTENANCE

Copyrighted Material Code: OH-500, REV FEB 81 P.S.L. Intended for CLARK dealers only Do not sell or distribute

Section 27, Page 1

GROUP

16 GENERAL MOTOR MAINTENANCE: 1.

Clean the motor with solvent. with compressed air.

3.

Connect one lead to all motor field terminal studs. Leave the other lead on the motor frame and read the ohms scale.

4.

Connect one lead to all motor armature terminal studs. Leave the other lead on the motor frame and read the ohms scale.

5.

A reading of l,OOO,OOO ohms or higher is needed for small motors.

Dry

AIR PRESSURE 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..

NOTE If less than l,OOO,OOO ohms and cleaning with air pressure does not help, remove the motor from the truck for closer inspection.

2.

Inspect the covers for bent or damaged spacers.

3.

Inspect the covers for bent or damaged gaskets.

6.

Assemble covers in the original position.

MOTOR INSULATION CHECK:

4.

NOTE ENCLOSED MOTORS: Make sure the openings are completely covered and the cover is tight for good contact with the motor frame.

Connect the terminal leads.

1.

Disconnect the battery.

2.

Disconnect the outer motor terminals.

IMPORTANT SEMI-CONDUCTORS, SMALL TRANSFORMERS, VOLTAGE REGULATORS AND OTHER COMPONENTS THAT MIGHT BE DAMAGED BY THE HIGH VOLTAGE MUST NOT BE IN THE CIRCUIT.

GROUND TEST: Test motor for a ground. Use a V-O-M, Simpson 260-6P or a meter with equivalent specifications.

The V-O-M will show the condition of the insulation.

3.

1.

Disconnect the battery.

2.

Disconnect the outer motor terminals and make a note of their positions if necessary.

Connect one lead of a 500 volt megger to any motor terminal.

Connect the other lead to the motor frame and apply the volta,ge.

NOTE Set the meter on the Rx10,OOO scale.

Section 27, Page 2

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

Code: OH-5,0,0,REV FE8 84

CLsRK

GROUP

16

4.

A reading of one megohm or higher is needed for small motors.

5.

If the reading is less than one megohm, the motor should be removed from truck for inspection.

6.

Connect the terminal leads.

TERMINALS. BOLTS AND COVERS:

NOTE If the operator has felt changes in the operation of the truck, it is possible for the motor to have a short circuit.

1.

Clean and check brush box for damage. Tighten cross-connector screws.

2.

Tighten all capscrews around motor frame.

3.

Inspect drip-proof type covers for bent or broken spacers.

4.

Inspect enclosed type covers for damaged insulating gaskets.

5.

Assemble covers and gaskets in the original position.

6.

Check terminals for tight connections.

TERMINAL STUD REPLACEMENT: Generally, it will not be necessary to take apart terminal assemblies from the drive motor body unless one of these assemblies becomes damaged.

In case of damage to a terminal on a drive motor, follow the procedure for removing the motor from the truck and for taking the drive motor apart until you get access to the terminal.

If the threads of the brass insert are damaged, replace the insert and insulator. Install to the correct depth.

The insulator should have Chemlok 304 or 305 applied to the surface. This is the inside hole in the drive motor body Install the just before installation. insert in the correct position and let it set over night. Make sure Chemlok 304 or 305 has made a complete seal all around the terminal.

I

Fig. 23734 Sectional View of Terminal 1. Capscrew 2. Lockwasher 3. Milled brass inserts internal threads

4. Motor body 5. Insulator 6. Chemlok seal

When the Chemlok has set, remove the tape.and check the internal threads of the.brass insert with a capscrew inside and outside the body.

Copyrighted Material Intended for CLARK dealers only Code: OH-500, REV DEC 81 P.S.L. Do not sell or distribute

Section 27, Page 3

GRliiup BRUSH WEAR CHECK: 1.

Remove the brush covers.

2.

Lift the brush springs and remove the brushes.

NOTE Do not remove the shunt screw unless new brushes are needed.

3.

4.

Clean the brushes and holders.

Clean the commutator with a dry cloth.

06

Check the commutator and the brush surfaces. The best indication of a good commutator are dark, highly smooth commutator and an even surface. (See the Commutator Check Chart at the back of this section.)

5.

Check the brush length.

6.

Check the brush shunt for good contact with the brush holder.

Make sure the shunt is not damaged or burned. This may cause the pressure spring to carry current and have lower tension.

7.

If the brushes do not need to be replaced, lift brush spring and put the brush into the brush box.

\

Fig. 23731 1. Pull the scale in line with the brush 2. Spring scale 3. Coil spring 4. Leather loop 5. Brush holder box 6. Rotation 7. Paper

MEASURING SPRING PRESSURE: 1.

Put a piece of paper between the brush and commutator.

2.

Put a spring scale between the pressure spring and brush.

3.

Lift the spring scale until the paper moves freely in the direction of rotation.

4.

Replace the spring if the pressure is too weak.

Soc-:;n 27 , Page 4

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

OH-500, REV DEC 81 P.S.L.

CLSRK

GRlfY p

BRUSH REPLACEMENT: Some brushes can be replaced without removing the motor from the truck.

(If not, remove the motor.)

1.

Disconnect the battery.

2.

Remove brush covers.

3.

Remove the shunt screw and remove the brush from the box.

4.

Install a new brush.

NOTE The new brushes must be the same size and grade as the old brushes.

Fig. 23730

COMMUTATOR MAINTENANCE: If it is Inspect the commutator. burned or damaged, it must be turned on a lathe and some mica removed.

1.

Put armature in a lathe and turn down the commutator until it is round. Make sure the cut is not made on the commutator riser bars as solder will be removed and weaken the coil connections.

Stay about [4,7 mm] ,187 inch from the riser bars.

2.

Remove the mica down to [0,76 mm] .030 of an inch. The area removed must be the width of the mica and flat at bottom.

3.

Remove any burrs left with number 00 sandpaper.

4.

Check the armature on a growler for short circuits.

1.

1. Brush shunt Pressure spring Commutator Hammer plate Brushes Shunt retaining screw Cross connector screw Brush box retaining screw Pressure spring 10. Brush box 11. Brush box retaining screw 2.

3.

4.

5.

6.

7.

8.

9.

r

L

Fig. 22337 2.

CORRECT WAY TO CUT MICA A. Segments B. Mica C. Commutator

Copyrighted Material Intended for CLARK dealers only Code: OH-500, REV DEC 81 P.S.L. Do not sell or distribute

WRONG WAY TO CUT MICA A. Segments B. Mica C. Commutator

Section 27, Page

5

GROUP

16

ARMATURE TESTS: 1.

Test for short circuits. (Fig. 23732) Check the armature for short circuits by putting it on a growler. Rotate the armature with a steel rod. If the blade moves, the armature has short circuits in an area of the core below the moving blade.

Clean out the slots in the commutator bars.

Cover all bare wires with insulation.

If a short circuit cannot be corrected, the armature must be replaced.

2.

Fig. 23732

Test for open circuits.

Open circuits in an armature may be caused by a bad connection in the commutator bars or by a broken wire in an armature coil.

Either will cause sparks at the brushes.

Bad connections and broken wires can often be found visually. When this is not possible, test for open circuits as follows: J

Put the armature on the growler as Test the top shown in Fig. 23732. two bars with an a-c Millivoltmeter.

Rotate the armature and test the next bars. When the millivoltmeter bridges the two bars connected to the open coil, the meter pointer will not be moved. All other bars will give movement.

3.

Bar-to-meter test.

(Fig. 23733)

This way of finding an open coil is also correct.

(a>

Put armature on "V" blocks and connect a source of direct current to the commutator. Use the circuit in Fig. 23733.

Fig. 23733 1. Coil broken in slot 2. Lamp The meter completes the circuit. .4. To test the armature for grounds, put a probe of the test lamp on the armature core or shaft and put the other probe on the commutator bars.

If the lamp illuminates, the armature has a ground and must be repaired or replaced.

FIELD COIL GROUND TEST: 1.

(b)

Test the bar with the millivoltmeter leads as shown.

cc> The

meter will not show a reading until it is connected between bars 6 and 7 as an example shown in Fig. 23733.

27. Paqe 6

To test for grounds in the fields, put one probe of a test lamp on the motor body and the other probe on the field terminal. If a lamp illuminates, the field coils have grounds and must be replaced.

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

OH-500, REV DEC 81 P.S.L.

GROUP

CMRK 2.

16

Paint the field coils and the inside of the motor frame with Class "F" air drying varnish. The armature coils, core, the end of commutator bars, and the mica cone ring can be painted with Class "F" varnish.

IMPORTANT DO NOT USE SILICONE BASE VARNISHES.

INSPECTION OF COMPONENTS: Motor maintenance should include the following inspections.

1.

Field coil insulation. burns and worn areas.

2.

Inspect for burning, Armature windings. looseness and damage.

3.

Commutator bars. Inspect for burned, damaged or raised areas. Refer to Page 5 for maintenance.

4.

Cooling fan and blades. or loose sections.

Code: OH-500, REV FEB 84

Inspect for cracks,

Inspect for broken

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

Section 27, Page 7

CLqRK

GR*%u

GROUP

20 SECTION

1

DRIVE

Code: PMA-525, DEC 81 P.S.L.

UNIT

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

Section 1, Page 1

GR200UP DRIVE UNIT LUBRICATION: Drain and fill the drive unit every 1000 operating hours or once a year, whichever comes first. Drain the drive unit when the fluid is at operating temperature.

Park the truck on a flat surface.

Fig. 23678 Put a flat pan under the drive unit.

Fig. 23782 Remove the drain plug and the fill/level Plug*

Fig. 23782 After the drive unit has drained, install the drain plug. Fill the drive unit to the fill/level plug opening.

(Use only DEXRON.) See GROUP 40, Section 4 for fluid specifications.

Fig. 23782

f

1.

Penn

3

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

COdP t

PMA-575.

DEC

81

J’-S.L.

CLflRK

GR*~u

GROUP

29 SECTION

1

HYDRAULIC DRAIN,

Code: PMA-525, DEC 81 P.S.L.

TANK CLEAN,

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

FILL

Section 1,

Page 1

GROUP

29

DRAIN. CLEAN AND FILL HYDRAULIC TANK:

11.

1.

Lower the forks to the floor.

2.

Remove the battery cover and disconnect the battery.

3.

Remove the front cover.

4.

Disconnect the hydraulic hose and electrical wiring.

5.

Remove the hydraulic unit mounting bolts (29.762).

6.

Remove the fill cap/breather (29.728) from the hydraulic tank.

7.

Install the hydraulic tank to the pump and motor assembly.

12. Install the hydraulic unit onto the truck. Tighten the mounting bolts to specifications.

13. Install the electrical wiring and hydraulic hose to the hydraulic unit.

14. Fill the hydraulic tank with [0,82 L] 0.22 gallons of MS-68 hydraulic fluid. See GROUP 40, Section 4 for fluid specifications.

15. The fluid level must be up to the filler tube.

Drain the hydraulic fluid into a container.

16. Connect the battery. Raise and lower the forks several times to remove air from the lines and into he reservoir.

J

8.

After the hydraulic tank (29.701) has drained, separate it from the pump and motor assembly.

9.

Clean the inside and outside of the hydraulic tank. Clean the filter assembly (29.738), the inlet filter (29.726), and the load lowering valve (29.164) in an approved solvent.

17. Check the fluid level. if necessary.

Add fluid,

18. Install the fill/cap breather.

19. Install the battery cover and front cover.

10. Install a new tank seal (29.703).

- 1, Paee 2

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

Code: PMA-525, DEC 81 P.S.L.

GROUP

CLSRK

29

I

r

u

ASSEMBLY COMPLETE

416.500

29.762 r- 29.858

.29.100

0

L

29.700

HYDRAULIC UNIT ASSEMBLY

16.500

MOTOR ASSEMBLY, HYDRAULIC PUMP

29.100

PUMP, HYDRAULIC

29.164

VALVE, LOAD LOWERING

29.701

TANE, HYDRAULIC SUMP

29.702

FASTENER, HYDRAULIC SUMP TANK

29.703

SEAL, HYDRAULIC SUMP TANK

29.704

ACTUATOR, LOAD LOWERING VALVE

29.126

FILTER, HYDRAULIC PUMP INLET

29.727

FITTING, SUMP FILLER

29.728

CAP, SUMP FILLER

29.738

FILTER ASSEMBLY, HYDRAULIC SUMP

29.743

SEAL, HYDRAULIC SUMP FILTER

29.755

SCREEN, HYDRAULIC SUMP FILTER

29.761

PLATE, HYDRAULIC UNIT MOUNTING

29.762

FASTENER, HYDRAULIC UNIT MOUNTING PLATE

29.826

FITTING, LOAD LOWERING VALVE MANIFOLD

29.827

MANIFOLD, LOAD LOWERING VALVE

29.828

INSULATOR, HYDRAULIC UNIT LEAD

29.858

SPACER, HYDRAULIC UNIT MOUNTING PLATE

31.006

LINE, HYDRAULIC PUMP'INLET

31.050

LINE, HYDRAULIC SUMP RETURN

29.761 ,31.050 29.82

r&”

-

29.726

702

HYDRAULIC

Code: PMA-525, DEC 81

UNIT

Copyrighted Material Intended for CLARK dealers only P.S.L. Do not sell or distribute

Section

1, Page 3

CLflRK

GR3rp

GROUP

34 SECTION

3 LIFT

CYLINDER

Copyrighted Material

Code: PMA-525, DEC 81 P.S.L.Intended for CLARK dealers only Do not sell or distribute

DRIFT

TEST

Section 3, Page 1

LIFT CYLINDER DRIFT TEST: 1.

Put a capacity load (see the capacity plate on the control handle) on a [1219 mm x 1219 mm] 48" x 48" pallet.

2.

as Enter the pallet and load as f possible. Raise the load to rull height.

3.

Stand to one side of the load. Measure the distance from the bottom of the forks to the floor.

4.

Drift must not exceed the specifications below.

LIFT CYLINDER DRIFT in five minutes Truck Model PW 15 PW 18 PW 15 PW 18 PW 15 PW 18

Oil Temperature [27'C] 80°F [27'C] 80°F [38'C] 100°F [38'C] lOOoF [49"C] 120°F [49"C] 120°F

_ 3. Pave 2

Drift [1,3 mm1 .050 inch [l,O mm] .040 inch [2,C mn-4 .080 inch [1,8 ml .070 inch [3,2 mm] .125 inch [2,5 mm] .lOO inch

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

-

Code: PMA-525.

DEC 81 P-S-L.

GROUP

CLflRK

40

GROUP

40 SECTION

1

DECALS, SERIAL

NAMEPLATES, NUMBER

Copyrighted Material

Code: PMA-525, DEC 81 P.S.L.Intended for CLARK dealers only Do not sell or distribute

AND DATA

Section 1, Page 1

GROUP 40

Know the location of your machine serial number printed on the truck frame.

Fig. 23729 Know the location of the truck data and capacity plate. See below also.

Fig. 23697 Know the rated capacity of your lift truck.

Never exceed this rated capacity.

Read the rated capacity on the data plate, and read and know areas 1 through 11 as shown in the illustration.

Truck model 1.

2. Type 3. Serial number 4. Capacity 5. Truck weight without battery 6. Truck weight with maximum battery 7. Battery weight - maximum 8. Battery weight - minimum 9. Battery type ) 10. Voltage 11. Maximum amp hours

Fig. 23721

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

Cnrl~:PMA-575

nef!

81

P.S.T..

GROUP 40

CLSRK

Read and understand the warning decal on the front cover, and make sure the Underwriters Laboratories (U.L.) label is in position.

Fig. 23698 Also, make sure the operator's decal and the "No Riding" decals are in position on the front cover.

Fig. 23698

Code: PMA-525, DEC 81 P.S.L.

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

Section 1, Page 3

CLqRw

GR&u

GROUP

40 SECTION

2 SUGGESTED

EQUIPMENT FOR

ELECTRIC

TRUCK

Copyrighted Material

Code: PMA-525, DEC 81 P.S.L. Intended for CLARK dealers only Do not sell or distribute

P.M.

Section 2, Page 1

GROUP 40

Perform electrical tests with a volt-ohmmeter (V.O.M.). Make sure the meter is calibrated each time a different scale is used.

Fig. 22236 Have a set of tools which include combination wrenches, screwdrivers, socket set, pliers, allen wrenches, etc.

Fig. 19523 Use a set of torque wrenches, which are calibrated correctly.

Fig. 14844 You will need a hydrometer, a battery water filler, a post and terminal tool, battery pliers and Clark Battery Saver for battery maintenance.

Fig. 19526

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

G-lrlD

!

PMA-575

l-X-W

Rl

P..S_T..

CLSRCC

GR&uP

An air hose and gun with extension is needed to air clean the truck.

Fig. 15301 For lubrication you will need grease, grease gun, oil and suction gun, automatic transmission fluid and hydraulic fluid.

Fig. 19529 Check hydraulic pressure with a MICO quadrigage, or a single function gauge, [O-27580 kPa] O-4000 P.S.I.

Fig. 11156 Approved floor jacks, hardwood blocks, and approved wheel blocks are needed to jack up the truck.

Fig. 19531

Code: PMA-525, DEC 81 P.S.L.

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

Section 2. Page 3

GROUP

’

40

RECORDINGS BELOW ARE:

Fig. (A)

nm reads in Kg

inches read in Lbs.

Fig. (B)

Fig. Fig. Fig. Fig. Fig. Fig. (C) (A) (B) (C) (A) (B) See figures below for chain spread.

Fig. (C)

*These capacities are only this high when load is equally distributed to each leg.

6.5mm 1250 2500 930 2160 1770 1250 2700 2200 1545 3245 2655 la85 l/4" 2750 5500 2050 4750 3900 2750 5950 4850 3400 7150 5850 4150 _---_-._-----~-~~--~~.---____~.------------~~-~~~~~~~~~~~~~~~~~~~~~-~~~~~~~~~~~~~~~~~~~~~~ 1Omm 2950 5900 2200 5125 4150 2950 6400 5215 3675 7665 6260 4445 318" 6500 13000 4850 11300 9150 6500 14100 11500 8100 16900 13800 9800 _____________________~_______I______________________--_______________~.~~~~~-~~~~~~~~~~~~~ 13mm 4990 9980 3745 a665 7075 4990 10795 8800 6260 12975 10570 7485 112" 11000 22000 a250 19100 15600 11000 23800 19400 13800 28600 23300 16500 _---~~I_-----~------~.---~--_.---~--------------~,--_--------_---------------------~---~~16mm 7400 14745 5535 12745 10435 7400 15965 13020 9210 19145 15650 11070 5/a!' 16300 32500 12200 28100 23000 16300 35200 28700 20300 42200 34500 24400 ~~~---._-----~----~~_.-----_~________________~~~.~~~~~~~-~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 19mm 10205 20410 7665 17690 14425 10205 22090 18055 12745 26535 21635 15330 314" 22500 45000 16900 39000 31800 22500 48700 39800 28100 58500 47700 33800 _-----.~--_--~~.-----~.~~~~~-~.~~-~~---~-~~~~~_--~.---------------------------------------22.5mm 13155 26310 9890 22770 la600 13155 28485 23270 16465 34155 27895 19730 718" 29000 58000 21800 50200 41000 29000 62800 51300 36300 75300 61500 43500 ---___.________,_-__~_._____________~~~~~~_--~,-------------------_-----------~~~-----25.4mm 17375 34700 13020 30255 20000 17375 37560 30660 21680 45090 36790 26035 111 38300 76500 28700 66200 54100 38300 82800 67600 47800 99400 81100 57400 _~----.~-~--^~-------.~-----_,-----______________)_____~~~-~~~~~~-~-~~-~~~~~-~---~-------~ 32mm 25855 5170 19415 44770 36595 25855 55790 45810 32340 67130 54885 38780 l-1/4" 57000 11400 42800 98700 80600 57000 123000 101000 71300 148000 121000 a5560 ~~~~-~.~----~~----~~-.-----__,_-------~---------~~~~~~~~~~~~~~~~~~~-~~~~~~~~~~~~~~~~~~~~~~ 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)

I

Fig. (B) Fig. (C)

.- 2, PaRe 4

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

Code: PMA-525, DEC 81 P.S.L.

GROUP

40

GROUP

40 SECTION

3 PM INSPECTION AND DRIVERS DAILY INSPECTION FORMS FIRE EXTINGUISHER RECOMMENDATIONS

Code: PMA-424, SEP 83

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

Section 3, Page 1

GROUP 40

CLqRK

DRIVER’S DAILY CHECKLIST Check Before Start Of Each Shift DATE

CHECK

ONE:

@

GAS,

LPG OR DIESEL

TRUCK

TRUCK NO,

0

ELECTRIC

TRUCK

OPERATOR:

SUPERVISOR’S OK

START OF DAY HOUR

METER

HRS. FOR DAY

END OF DAY

READING:

r/

VISUAL

Boxes Accordingly

OK

Needs Attention

CHECKS

OPERATIONAL

SUFFICIENT

REMARKS: (EXPLAIN ALL lTEMS NEEDING ATTENTION

or Repair CHECKS

CHAR

OR REPAIR)

FORM NO. 59770-2937 NOV 80

'q 3, Paae 2

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

Code: PMA-424, SW

83

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

w

A. TEST DRIVE MACHINE a. Drive Train Noise b. Steering Operation c. Service Brake Operation d. Speed Control Creep Speed iA Operation Plugging & Directional Control Relurn to Neutral Hydraulic System Operahon Pedal Pads & Linkages

i

e.

1. g. h.

ELECTRIC TRUCK PLANNED MAINTENANCE REPORT

‘SEE

MAINTENANCE

INTERVAL

IN ;_yM$721dfJNU;;

GROUP 40

FIRE EXTINGUISHERS AND SOLID STATE CONTROL EQUIPMENT: 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.

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.

FIRE EXTINGUISHERS NOT APPROVED:

2.

CO2 (carbon dioxide) which is acceptable for electrical fires.

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 Code: Intended for CLARK dealers only Do not sell or distribute

PMA-377, REV DEC 81 P.S.L.

GROUP

CLARK

40

GROUP

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 DlVlSlON 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 conditions of the individual application.

RESPONSIBILITY for the quality 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 regarding approval of their use in CLARK products.

CLARK does not follow 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 oil analysis by a reputable testing laboratory should be made.

It is the responsibility of the manufacturer or supplier of the oil to insure that his product meets the specifications and gives the expected performance.

TECHNICAL SOCIETIES IN REFERENCE ON FOLLOWING PAGES AGMA API ASTM EMA MIL NGPA NLGI SAE

Section 4, Page 2

-----_-------_-----_--------------__ -_----a-

---___--

American Gear Manufacturers Association American 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

CLflRK

GROUP 40

LUBRICATION CHART KEY LUBRICANT SPECIFICATIONS & 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

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

Joints

Page 10 16. Throwout Bearing Carrier Rails, Attachments, Slides, Bushings GEAR LUBRICANTS 17. Drive Axle, MS-8

Code: PMA-322, FEB 84 REV

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

Page 14

Page 14

Page 14

Page 10

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

Section 4, Page 3

GROUP

CMRK

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

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

CHAIN & CABLE LUBE

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

CLARK

40

CRANKCASE llOTOR OIL

CLARK PART NUMBER

(SE/CD) s.A.E. 30 (SF/CC) S.A.E. lOW30

1802152 1802153

case of 24 one-quart cans case of 24 one-quart cans 1 -

1 -

LOW 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, Al-MOSPHEZIC DIRT, MOIST!JRE 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 I

-

2.

ENGINE CRANKCASE OIL

cc

FOR ... GASOLINE, L P -GAS ENGINES AND NATURALLY ASPIRATED DIESEL ENGINES.

XL-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.

rzl ’

API

*Although Specification MIL-L-2104B has recently been superceded, oils of this quality will continue to be available, and are preferred.

SERIES 3 c --

r.3 API

CD

XL-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, sulfated ash 1.0% maximum).

The use of 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 SPECIFICATION Any good grade of motor oil in SAE 10, 20 or 30 weight as the temperature and conditions dictate.

Section 4, Page 6

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

Code: PMA-322, JUN 80 REV

CLflRK

r

GR&u 4.

GENERAL PURPOSE GREASE

2

MS-107C

GENERAL PURPOSE GREASE

r

FOR . . . STEER AXLE TRUNNION BEARINGS UPRIGHT MAST ROLLERS & SLIDES UNIVERSAL JOINTS WATER PUMP BEARINGS GENERAL CHASSIS LUBRICATION *RECOMMENDATION Use Grade NLGI #2 per 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

1

MS-lc)7B

FOR . . . CLARK AXLE ENDS WHEEL BEARINGS STEERING GEARS JOINTS, LEVERS SCBUSHINGS POWRWORKER & NARROW AISLE TRUCKS - ALL POINTS *RECOMMENDATION Use Grade NLGI Y/lper 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-G-23827A, 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 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 82

8.

SPECIAL GREASE

FOR . . . DISTRIBUTOR CAMS MOLY GREASE

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.

HIGH TEMPERATURE GREASE

FOR ... CLUTCH THROWOUT BEARINGS CLUTCH PILOT BEARINGS DYNATORK PILOT BEARINGS

CLARK PART NUMBER 617410

bP

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

g

Code: PMA-322, JUN 80 REV

GROUP

CLARK

40 11.

SPLINE GREASE

FOR ... MOTOR TO PUMP DRIVE TANG HYDRAULIC PUMP & MOTOR SHAFT SPLINES

MOLY GREASE

CLARK PART NUMBER 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 NUMBER 617410

SPECIFICATIONS A soft density, smooth lith urn 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 #1 TIMER & OSCILLATOR CARD

CLARK PART 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.

SPECIAL LUBRICANT

FOR ... CLUTCH THROWOUT BEARING-CARRIER RAILS, SIDE SHIFTER ATTACHMENT, CLAMP SLIDES, SLIDE BUSHINGS OF ANY TYPE 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

MS-8

Section 4, Page 10

NOTE:

----

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

CLSRK EP LUBE MIL-2105B

GR400 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.)

0 @ G API GL-5

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

CLARK PART NUMBER 879804 FOR ... TORQUE CONVERTERS FLUID COUPLING DRIVES AUTOMATIC TRANSMISSIONS (EXCEPT Fom) POWRSHIFT TRANSMISSIONS POWRSHIFT FORWARD & REVERSE UNIT HYDRATORK TRANSMISSION HYDRACOOL (WET) CLUTCH TRANSMISSION ELECTRIC RIDER TRUCK DRIVE UNITS (WHEN sP~cmm ONLUBE CHARTS) DEXRON* OR DEXRON II*

. rl -

SPECIFICATIONS DEXRON* OR DEXRON II* ATF (Automatic Transmission Fluid).

20.

TRANSMISSION FLUID

Q

,,+’

DEXRON II

FOR ... HYDRAULIC SYSTEM AND DRIVE UNITS, POWRWORKERS, NS, NSP, NST TRUCKS, ELECTRIC RIDER TRUCKS, POWER STEERING RESERVOIRS. SPECIFICATIONS DEXRON II* ATF (Automatic Transmission Fluid) containing zinc orequivalent 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-~~xxx/DEXRON II.)

Code: PMA-322, AUG 81 REV

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

Section 4, Page 11

CLSRK

GR4%uP

*: El

CAUTION

FORD

21.

TRANSMISSION FLUID - FORD

FOR . . . ALL FORD AUTOMATIC TRANSMISSIONS AND CONVERTERS

TY?E"r"

SPECIFICATIONS Automatic Transmission Fluid, Type "F", which meets FORD MOTOR COMPANY Specification: ESW-M2C33F (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

GR&u

CLqRK 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

L2 MI-66

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

! w +P

FOR .. . INDUSTRIAL DIESEL POWERED ENGINES

0

SPECIFICATIONS Fuei 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:

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.

Section 4, Page 14

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

Code: PM&322,

JUN 80 REV

GROUP 40

CLqRlS

CLARK PART NUMBER 1801146 FOR ELECTRICAL & SCR COMPONENTS I M P 0 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 81800330

Degreaser may be used to clean outer surface of cylinders,

cf> NOTE

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

CLflRK

GR&uP

GROUP

40 SECTION

5 TRUCK

Code: PMA-525, DEC 81 P.S.L.

SPECIFICATIONS

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

Section 5, Page 1

CLqRK

GR4%up BATTERY FULLY CHARGED: 1.275 Specific Gravity.

U/L 583 Standard.

See GROUP 12,

CONTACTORS: All

Brush Spring Tension New Brushes (minimum): New Brushes (maximum):

[8,9 N.] 32 oz. [ll,l N.] 40 oz.

FUSES:

Pick-Up V. 11.8*

Drop-Out V. 1.8*

Main Fuse: See Electrical Circuit Diagram Control Fuse: 15 Amps

*At [82"C] 180°F

FLUID CAPACITIES:

CURRENT DRAW TESTS:

Drive Unit: Hydraulic Unit:

Drive Motor (full speed): 24.5 battery volts: 18.5 Amps, wheels on floor, no load

[0,50 L] 0.13 gallon [0,82 L] 0.22 gallon

HYDRAULIC SYSTEM:

Pump Motor ([54"C] 130°F oil, at bypass): 115 Amps at cl7237 kPa] 2500 P.S.I.

Relief Pressure:

BRUSH SPECIFICATIONS - DRIVE MOTOR:

BRAKES:

Brushes Length (new): Width: Thickness: Length (worn):

Holding torque: [203 N'm] 150 lb. ft. at radius of tire

[15,7 mm] 0.62 inch [17,5 mm] 0.69 inch [8,6 mm] 0.34 inch [7,87 mm] 0.31 inch

[16547-17236 kPa] 2400-2500 PSI

Brush Spring Tension New Brushes (minimum): [7,78 N.] 28 oz.

New Brushes (maximum): [9,45 N.] 34 oz.

Worn Brushes (minimum): [5,0 N.] 18 oz.

BRUSH SPECIFICATIONS - PUMP MOTOR: Brushes Length (new): [12,65-13,16 mm] .498-.518 inch Width: [17,50-17,70 mm] .689-.697 inch Thickness: [8,71-8,81 mm] .343-.347 inch Length (worn): [6,35 mm] -250 inch

Section 5, Page 2

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

Code: PMA-525, REV JUN 84

CLsRw

GROUP

40 LOAD CAPACITY AND COMPONENT WEIGHTS:

Truck Weight KCJL

Lifting Capacity Kg lb

Truck Model PW 15 PW I8

1500 1800

Battery Weights Maximum (Industrial Minimum (Battery Pack) Battery) Kg lb Kg=

3300 4000

250 250

550 550

127 127

280 280

259 259

570 570

TORQUE SPECIFICATIONS: .............

Motor Cable Connections .........

Control Panel Cable Connections Drive Motor Mounting Bolts ............

Horn Mounting Bolt ................

Drive Wheel Lug Nuts . . . . . . . . . . . . . . .

Hydraulic Unit Mounting Bolt . . . . . . . . .

.

Control Handle Mounting Bolt . . . . . . . . .

Brake Switch Cam to Handle Assembly . . . . .

Trail Wheel Mounting Bolts . . . . . . . . . .

Elevating Bracket Pivot Shaft - Retaining BoTt Lifting Link Pivot Shaft - Retaining Bolt . .

Lifting Link to Yoke Shoulder Bolt . . . . . .

Lift Cylinder Anchor Bolt . . . . . . . . . .

. . . .

Drive Unit Cover Bolts . .

Drive Unit Fill Level Plug Output Gear Retaining Bolt Stabilizer Bolts . . . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

.

. . . .

. . . . . .

. . . .

2-4 lb. ft.

[3-5 N'm] 2-4 lb. ft.

[3-5 N'm] 8-10 lb. ft. [ll-14 N'm] 6-8 lb. ft. _[8-10 N'm] 91-101 lb.ft. l-123-137 N'mJ (Lubricated) 6-8 lb. ft.

[8-10 N'm] (Apply Loctite 242 to threads.)

60-70 lb. ft.

[81-95 N'm] [0,57-0,90 N'm] 5-8 lb. in.

80-90 lb. ft.

[108-122 N'm] 15-20 lb. ft.

[20-27 N'm] 50-55 lb. ft.

[65-75 N'm] 85-95 lb. ft.

[115-129 N'm] 138-145 lb. ft.

[187-197 N'm] (Lubricated) 8-10 lb. ft. [ll-14 N'm] 35-45 lb. ft.

[48-61 N'm] 91-110 lb.ft.

[123-149 N'm] 138-145 lb. ft.

[187-197 N'm] (Lubricated)

LIFT CYLINDER DRIFT in five minutes: Truck Model PW 15 PW 18 PW 15 PW I8 PW 15 PW 18

w

LI,3 m~~if~50 inch [27"C] [38"C] [38"C] [49"C] [49"C]

80°F 100°F 100°F 120°F 120°F

Code: PMA-525, REV JUN 84

[l,O [2,0 [1,8 [3,2 [2,5

mm] mm] mm] mm] mm]

.040 .080 .070 .125 .lOO

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

inch inch inch inch inch

Section 5, Page 3

I

I

I I

I I I

I I

I

I. I

I I

I

I

I I

I

I I I I

I I I I I I

I I I

I

03

I I I I

04

08 M

05

--

-6 i_______________

I I I

0

:* 3:

Lift Cylinder Check Valve Motor

-. -------------

4.

5.

6.

Pump Filter Hydraulic Tank

________

7.

8.

9.

__A

Relief Valve Lower Valve Filter

2757821

Section 5, Page 4

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

Code: PMA-525, REV JUN 84

24 VOLT

BATTERY

HORN 1‘8 LOWER

SEE INTERNAL HAND CONTROLLER WIRING EMERGENCY

--.

2ND

v

I

L

HYDRAULIC UNIT

EtNAL HAND -CONTROLLER WIRING

13

L 3RD

12

LIFT

43

LIFT

BLACK,

13

13

I

-_II~I-

BATTERY

+$?

LIMIT

-q/r-

COIL

a+

CONTACTOR,(N/O)

-

MOTOR FIELD

-LIMIT

BRAKE SWITCH

sW,(N/O)

RED/WHITE

STRIPE,

sw,(Nm

PW-15 DI 2757798F

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

I

24 VOLT BATTERY (+I

I MAI N FUSE

LIFT CONTACTOR

‘5 HORN

LIFT PUMP MOTOR

A

--

--

r--

<$!&!ji-

’

1 _=

CASE

8

I

LOWER

I

DIRECTIONAL CONTACTORS

SPEED CONTROL RESISTOR AND

!

:

I

L 3 9

EMER. CUT-OFF

G

SEE INTERNAL HAND CONTROLLER WIRING EMERGENCY 13

PACKAGE I

__I

r

(MOMENTARY)

1

I

1

INTERNAL HAND -___CONTROLLER WIRING

13

HURAULIC UNIT

EMERGENCY

BLACK,

13

LIFT

0

LOWER

12

43

LIFT

HORN

1

13

47

1

II 411~

BATTERY

w

LIMIT

+

COIL

q

CONTACTOR.(N/O)

-

MOTOR FIELD

~LIMIT

._--

WHITE.1

SW,(N/O)

RED/WHITE

1 \

L

BRAKE

DRIVE

1

MOTOR

STRIPE

I

I

SWITCH

SW,(N/CI

I

DIAGRAM-CIRCUIT

CmRtt ‘sl 2387692

PW-15 DI 2387692

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

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