Clark Forklift PMA 540 SERIAL 540-5001 Planned Maintenance and Adjustment Manual

PMA 540

Parts Book

db

RUBBER TIRED LOADER

SERIAL NUMBERS

540 -5001 a”dw

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Instructions for Binder Inserts

PMA540

This sheet includes two sfy/es of binder inserts:

l

Insert for later poly binder with half window Insert clear insertprotection sheet inlabel holder.

Cuf binder insert on lines indicated and insert behind insetf protection sheet in spine of binder.

m 0 0 R

lnserf for earlier viny/ c/ear window binder Cut binder insert on lines indicated and insert in spine of binder. Discard the front cover binder insert.

--

BBDRESSER@

$ I BDRESSER@

540

540

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

ik DRESSER,

C19Rl4

GROUP 13

6 If the parking brake microswitch does not operate correctly, refer to the following adjustment procedures.

PARKING

BRAKE SWITCH

ADJUSTMENT

Step 1: Turn key switch "OFF".

Step 2: Remove the pylon access cover.

85M510 Step 3: Loosen and remove the hand brake bracket mounting bolt nuts and move hand lever away from pylon for access to switch mounting screws.

85M815 Step 4: Loosen the microswitch mounting s.crews.

Step 5: Move and hold the hand brake lever at a point one-third of the way through its travel from the released position. Move the microswitch until the switch lever makes contact with the actuating stud on hand lever.

Then, tighten the switch mounting screws.

See NOTICE, Page 4.

Code: PMA-540, NOV 85

85M816

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GROUP 13, Section 3, Page 3

CLqRK

GROUP 13 Step 6: Install and tighten the brake lever bracket mounting bolts and nuts.

85Ma15 Step 7: Fully release the parking brake hand lever and check for correct adjustment of the microswitch (see Page '2). Repeat the adjustmen t procedure, if necessary.

NOT CE - The switch body allows only If lim ted movement for adjustment. add tional adjustment is needed, careful y bend the switch lever to contact the stud on hand lever at the correct position.

85M519

Step 8: Install the access cover on pylon.

20283 Step 9: Apply the parking brake, tilt the upright fully back to lower drive wheels to the floor, and remove the blocking under the upright.

85M741

GROUP 13, Section 3, Page 4

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Code: PMA-540. NOV 85

GROUP 13

CLqRK

GROUP

13

SECTION

6 ACCELERATOR

CONTROL MAINTENANCE AND

TROUBLESHOOTING

EV-100 SCR CONTROL SOLID-STATE ACCELERATOR SWITCH ASSEMBLY

Refer to Systems Diagnostic Manual, SDM-542, for additional information on troubleshooting of the accelerator control with the EV-100 SCR control.

BEFORE ANY ADJUSTMENTS, SERVICING, PARTS REPLACEMENT OR ANY ACT IS PERFORMED REQUIRING PHYSICAL CONTACT WITH WORKING COMPONENTS OR WIRING OF THIS COMPONENT: l

RAISE DRIVE WHEELS OFF THE FLOOR,

l

DISCONNECT THE BATTERY, AND

l

DISCHARGE THE CAPACITOR 1C.

Code: PMA-540, NOV 85

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

ELECTRICAL BURNS DISCONNECT THE BATTERY AND REMOVE ALL JEWELRY BEFORE WORKING ON ANY ELECTRICAL SYSTEM. SEVERE BURNS CAN RESULT FROM CONTACT WITH ELECTRICAL SYSTEMS

GROUP 13, Section 6, Page 1

CMRK

GROUP

13 EV-100 SCR CONTROL SOLID-STATE ACCELERATOR CONTROL (SWITCH) ASSEMBLY NOTE: ,NTERWAL NOT SERVICEABLE, THIS “NIT WlLL

ACCELERATING

CONTROL

COMPONENTS ARE OPENING OF VOlD WARRANTY

ASSEMBLY

The accelerator control switch assembly contains: 1

a switch (1MS start switch) which closes at the beginning of shaft travel to energize the control circuit, and

2

a solid-state counter circuit which varies the speed of the truck while in SCR control.

The counter circuit consists of a solid-state infrared light source and a position sensor. As the position sensor moves with respect to the light These signals are converted to an source, digital signals are generated. analog voltage output to provide a linear speed signal to the control.

No parts are adjustab le except the start switch, which should require no adjustment under all normal conditions.

Self-lubricating bear ings are used eliminating the need for any lubrication.

Underwriters' Laboratory Type EE construction, O-ring seal, blind mounting holes, and insulated wire hole grommet all combine to eliminate the need for periodic cleaning.

GROUP 13, Section 6, Page 2

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

Code: PMA-540, NOV 85

CLSRK Speci f i cati

GROUP 13

ons :

1MS start switch should close at [1,9-2,3 mm] .075-.091 in. of shaft travel. SWITCH MUST OPEN BEFORE SHAFT RETURNS TO THE STOP POSITION. Counter Circuit Voltage Output Curve: Linear.

Nominal voltage output: 3.65 volts @ [O-2,1 mm] O-.082 in. travel 0.25 volts 8 [13,5-14,0 mm] .53--55 in. travel NOTICE - ATTEMPT TO REMOVE OR REPAIR CIRCUIT CARDS IN THE SWITCH WILL VOID WARRANTY.

ACCELERATOR

CONTROL CHECKS & TROUBLESHOOTING

Trouble with the accelerator control will normally be investigated in conjunction with troubleshooting of the SCR traction control*.

There are two basic checks that need to be made to troubleshoot the accelerator control.

Check fo;‘: 1 Correct voltage input to the accelerator control circuit.

2 Correct voltage output from accelerator control. *Refer to SDM-542, Control Card Voltage Checks, and Troubleshooting Symptom: 1, 2, 5 and 6.

RAISE THE DRIVE WHEELS OFF THE FLOOR BEFORE DOING ANY TROUBLESHOOTING CHECKS. Refer to GROUP 38, Section 3, Machine Jacking and Blocking.

85M743

Code: PMA-540, NOV 85

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

GROUP 13, Section 6, Page 3

GROUP

13 Check Voltage Input To Accel erator Control Procedure l:* Connect battery.

Turn key switch "ON".

Release hand (parking) bra ke.

Connect volt-ohmmeter (V-O-M) red (+) lead to screw terminal TB3 (wire #65) of the control (oscillator) card on SCR control.

Connect V-O-M black (-) lead to battery negative. (Also see Figure 26543, Page 3.)

26544

With the key switch and hand brake switch closed, the V-O-M must read battery volts.

26545 7 When either the key switch or hand brake switch are opened, the V-O-M must show 0 volts.

17772 8 If the V-O-M measured values are not as given above, check the key switch, hand brake switch, and wiring to the control.

Check control fuse (3FU) and continuity of wire #2, 10, 12, and 65. Repair and/or replace, as necessary.

*Reference SDM-542, Card Voltage Checks, TB3.

Also Symptom: 1.

GROUP 13, Section 6, Page 4

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

Code: PMA-540, NOV 85

CLqRK

GROUP

13

Procedure 2:* Turn key switch "OFF".

Apply hand brake.

Accelerator pedal released.

Connect V-O-M red (+) lead to screw terminal TB2 (wire # 15) of the control card on SCR control.

Connect V-O-M black (-) lead to battery negative.

Control (Oscillate Card Terminal Board (CT81

26544 With the key, hand brake, or 1MS switches open, the V-O-M must show 0 volts.

7 Turn key switch "ON".

8 Release hand brake.

9 Push on accelerator pedal to close 1MS switch.

slightly

10 With the key, hand brake, and 1MS switches closed, the V-O-M must show battery volts.

11 If the V-O-M measured values are not as given above, check the key, hand brake, and 1MS switches.

Also, check control fuse (3FU) and wiring to the control, including continuity of wire #15 (see Repair and/or replace, Procedure 1). as necessary.

*Refer to SDM-542, Also Symptom: 1.

Code:

PMA-540,

NOV 85

Card

Voltage

Check,

TB2.

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

GROUP

13, Section

6, Page 5

GROUP

CLqRK

13 Check Accelerator Control Voltage Output* 1 Turn key switch "OFF".

Disconnect battery.

2 Disconnect wire #29 from screw terminal TBl of the control card on SCR control.

3 Connect V-O-M red (+) lead to wire #29 removed from terminal TBl. 4 Connect V-O-M black (-) lead to battery negative.

Turn key switch "ON".

5 Connect battery.

6 Release the hand brake.

(Oscillator) Card Terminal Board (CTB)

26544 7 With key and hand brake switches closed, and accelerator released (or at creep speed position), the V-O-M must show (3.65 volts nominal rating).

3 - 4 volts.

8 Measure voltage on wire #29 as accelerator control is moved from creep to top speed.

Voltage should change (decrease) from 3 - 4 volts to 0 - .5 volts as accelerator control is moved from creep to top speed.

26546 9 Push

the accelerator

pedal

fully

down.

With key and hand brake switches closed and accelerator control fully depressed, the voltage must decrease to less than 0.5 volts (0.25 volts nominal rating).

26547 10 If the V-O-M does not show the correct voltages as noted above, the accelerator control switch is defective and must be replaced.

11 Turn key switch "OFF".

Disconnect battery.

Reconnect wire #29 to terminal TBl of control card.

Connect battery.

Turn key switch "ON".

Connect V-O-M to terminal TBl and battery negative.

Measure voltage as If voltage does accelerator is moved from creep to top speed position. not change (decrease) from 3-4 volts to O-.5 volts, this indicates a Refer to SDM-542 for additional defective control (oscillator) card. checks.

*Refer to SDM-542, Card Voltage Also Symptom: 2, 4, 5, and 6.

GROUP

13, Section

6, Page 6

Checks,

TBl.

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

Code:

PMA-540,

NOV 85

Cl!‘!‘RK

GROUP 14

GROUP

14

SECTION

1 ELECTRICAL SYSTEM WIRING DIAGRAMS

Code: PMA-540, NOV 85

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

GROUP 14, Section 1, Page 1

GROUP

14

REVERSE SWITCH FORWARD SWITCH

ERING SWITCH

6% HOUR METER

+72

CONTROL

CONTROL

WIRING

13.003

HORN

14.005

HARNESS, DASH END WIRING

l.i.114

WIRING HARNESS, MACHINE

14.146

HARNESS, VALVE SWITCH WIRING

14.864

GROMMET, PARKING SAFETY INTERLOCK SWITCH CONDUCTOR

GROUP 14, Section 1, Page 2

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

14-704

Code: PMA-540, NOV 85

GROUP 14

SEE RECEPTACLE ASSEMBLY VIEW

/’ ,//

rTC-FOS

MOTOR (L)

MOTOR (FU

RECEPTACLE hSSEM BLY

POWER

Code: PMA-540, NOV 85

WIRING

14-703

:4.039 14.040 14.087 14.088 14.089

RECEPTACLE& CABLE, BATTERY RECEPTACLE,BATTERY CONDUCTOR,DRIVE MOTOR (RA-2) CONDUCTOR,DRIVE MOTOR (RA-2) CONDUCTOR,DRIVE MOTOR (RS-1)

14.091 14.347 14.348 14.509 14.522

CONDUCTOR,HYDRAULICPUMP MOTOR (PM-A) CONDUCTOR,STEER PUMP MOTOR (PM-A) CONDUCTOR,STEER PUMP MOTOR (PS-S) CONDUCTOR,HYDRAULICPUMP MOTOR (PM-S) CONDUCTOR,DRIVE MOTOR (Al)

14.606 14.607 14.608 14.609 17.000

CONDUCTOR,DRIVE MOTOR (LA-I) CONDUCTOR,DRIVE MOTOR (LA-2) CONDUCTOR,DRIVE MOTOR (LS-2) CONDUCTOR,DRIVE MOTOR (LS-1) CONTROL PANEL ASSEMBLY

93.951 94.069

NUT, BATTERY RECEPTACLEMOUNTINGFASTENER FASTENER,BATTERY RECEPTACLE

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

GROUP 14, Section 1, Page 3

CMRK

GROUP

14 WIRINGDIAGRAM

>

r2n

2

4 :,: r-l L, t

L

SO-6

SO-I ‘7

PL-1 r-

-z PL-3

’ L* / so-3

2Al

PL-6

I 2A

2

: :

so-10 OPT IONS

>

-266

IOE-

n

,

XLNO

F-----d

I I

3’1 I ;I 3E ii Lv “, so-9

6%

IiA 1 100

PS

Xfl’

-6

7lA-

-

1

15R

-61

15E I

REV SNITCH

-65C

1

LOO 12R

RTTRCHMENT SOLENOID

IN-21706E

GROUP 14, Section 1, Page 4

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Code: PMA-540, NOV 85

GROUP I4

CMRK WIRINGDIAGRAM

-

151

I31

-

RIGHT DRIVE MOTOR

I-

I_

$2 so-a

LEFT DRIVE MOTOR

1

I :

: PL-6 ‘f

I SA

12

L

12FI-

\

NTFICTOR,, NEL v --J

65C +

Ei5c

EV-100 CONTROL

I

-6 -15R -61

158 I

IN-'21706E

Code: PMA-540, NOV 85

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

GROUP 14, Section 1, Page 5

GROUP 14 ELECTRICALCIRCUIT DIAGRAM BRTTERY ‘%%Lrs(

POYEA

2 FU

STEER

MOTOR

PS

d,

23

I

OX osc

CRRO CONNECTOR

I

1 I-

I/

J

I

REC

q-RtCI

I I

RXHT

I

I

-12

13

J KEY SYtTCH

I ‘P

-T3 I l”~TB’

I

,“‘I::::

I

65 I

aosc CAR0 CONNECTOR

1

1,

, 13

13

13

SWITCH

ROURATER

13

13p I2

1

-A

HORN SYITCH

GROUP 14, Section 1, Page 6

IN-21706E Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: PMA-540, NOV 85

GROUP 16

CMRK

GROUP

16

SECTION

1 ELECTRIC

MOTOR MAINTENANCE

GENERAL

PROCEDURES

NOTICE Motor

Insulation

If a change (reduction) in truck (motor) performance has been noted, it may be due to breakdown in motor insulation causing internal grounding or a short circuit.

Failures of motor insulation are due to: 1) contamination, 2) mechanical Contamination includes dirt, moisture, factors, and 3) high temperatures. oily vapors, metal chips, carbon dust from the brushes, etc. Mechanical factors include shock, vibration, overspeed, etc. Operation at prolonged or excessively high temperature will cause the insulation to become brittle and crack leading to premature failure. The insulation condition can be judged both by visual inspection and by test measurements.

Regular, periodic measurements of insulation resistance can give a useful A sudden drop or indication of the rate of insulation deterioration. consistent trend toward low values of insulation resistance give evidence that the insulation is deteriorating and that failure may be imminent.

Code: PMA-540, NOV 85

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

GROUP 16, Section 1, Page 1

GROUP 16 ELECTRIC

MOTOR MAINTENANCE

A planned maintenance program of regular, routine inspections is important for long life and trouble-free operation of electric motors.

Make and keep records of your inspections.

Use these records to help establish the correct P.M. intervals and to indicate maintenance required to prevent major problems from occurring during operation.

TYPICAL

OPERATING

CONDITIONS

NORMAL SERVICE

-

Basically an 8-hour day of mostly material handling operation.

SEVERE SERVICE

-

Extended

EXTREME SERVICE

-

operating

hours,

indoor

or constant

or outdoor

usage.

Dusty or sandy locations, e.g., cement plant, lumber or flour mills, coal dust, or stone-crushing areas. l High temperature areas, e.g., steel mills, foundries, l Sudden temperature changes (continuous indoor-outdoor movement), e.g., refrigeration plant, etc. l

etc.

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

MOTOR

MAINTENANCE/INSPECTION

SCHEDULE

MOTOR POSITION SERVICE INSPECTION FREQUENCY RECOMMENDED (OPERATING TIME) INSPECTION CONDITIONS ~~~-~--------~~~~~~~~~~~--~~~~~~~~~~~~~~~~~~----_--_~~-------_-_-_____________ NORMAL

1000 Hours

Routine

*Motor

installed

Periodic Motor removed As required by inspection -_--------~~~-~~~---~~~~~~~~~~~~~~~~~~~~--~~~~~~~~~~~~~~~~-~-~~~~~~~~~~~~~~~~~ SEVERE

500 Hours

Routine

*Motor

installed

Periodic Motor removed As required by inspection _____________------------_~~~~~~~~~~~~~~~~----------~~~~~~-------------------EXTREME

250 Hours

Routine

*Motor

installed

Periodic Motor removed As required by inspection ____________________~~~~~~~~~~~~~~~~~--~~~~~~~~~~~~~~~-----------------------*As truck

GROUP

design

16, Section

dictates.

1, Page 2

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

Code:

PMA-540,

NOV 85

GROUP 16

Cl!lRK General

Motor Maintenance/Inspection

Procedures

To perform these service procedures, it is recommended that you first:

l

Park truck safely and fu lly lower the upright.

Apply the parking brake.

l

Turn key switch "OFF".

l

Disconnect battery from truck receptacle.

l

Discharge the capacitor.

l

l

l

ELECTRICAL

SHOCK

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

Remove the battery, as necessary, for (GROUP 12, Section 1) access to motors.

Adjust the front battery plate, for (GROUP 38, Section 2) access to motors.

85M862

Motor

Cl eanl i ness

1 Electric motors should be kept clean at all times, to prevent shorting, minimize wear, and for best cooling.

2 Wipe off all dust, dirt, oil, water, etc., from the outer surface of the motor.

3 Remove any debris from cooling air vents and around motor frame to prevent overheating.

85M672

4 Air clean (blow out) open motors using clean, dry (moisture-free) compressed air at [207 kPa] 30 psi maximum pressure. Air clean all inner areas around the commutator and brushes, including the cooling air vents and fan.

5 The presence of any oil on or near the motor could indicate either bad bearings or a leaking hydrau 1 ic system. Determine the cause and repa ir the problem before extensive damage to the motor occurs.

85M708

AIR PRESSURE WEAR EVE PROTECTION (L PROTECTIVE CLOTHING WHEN CLEANING OR DRYING WITH AIR PRESSURE. REDUCE PRESSURE TO [207 kPa] 30 PSI. DEBRIS REMOVED WITH 1 AIR PRESSURE CAN CAUSE INJURY.1

Code: PMA-540, NOV 85

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

GROUP 16, Section 1, Page 3

CLflRK

GROUP 16 Test For Motor Insulation Resistance To Ground Using a 500-volt megger Disconnect the battery.

Disconnect the power cables from all external motor terminals.

Connect one lead of a 500-volt megger to any motor terminal. NOTE- Test all terminals individually or by interconnecting with jumper wires. Connect the other lead to the motor frame. Apply the voltage.

IMPORTANT BE SURE ALL OTHER ELECTRICAL COMPONENTS THAT MIGHT BE DAMAGED BY THE HIGH VOLTAGE ARE DISCONNECTED AND NOT IN THE CIRCUIT.

The resistance should measure at least l,OOO,OOO ohms (1 megohm).

If less than this, the motor should be air cleaned or dried to attempt to increase the insulation resistance.

If, after cleaning, the reading is less than 1 megohm, the motor should be removed from the truck for inspection and repair, as needed.

26548 Test For Motor Insulation Resistance To Ground Using a volt-ohmmeter Use a Simpson 260-6P or equivalent V-O-M, calibrated on the RxlO,OOO scale.

Disconnect the battery.

Disconnect the power cables from all external motor terminals.

Connect the positive lead of the V-O-M to all the motor terminal studs, using jumper wires to connect between the motor terminals. Connect the V-O-M negative lead to the motor frame.

(NOTE - Test all terminals individually, or joined together, as noted.)

26549

The V-O-M must show 1 000,000 ohms (1 megohm) resistance or higher i or a good motor insulation.

If less than 1 megohm is measured, air clean the motor and repeat the test of motor res istance. If air cleaning does not make an improvement the motor will have to be removed from the truck for closer inspection and repair, as needed.

GROUP 16, Section 1, Page 4

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Code: PMA-540, NOV 85

CLSRK

GROUP 16

Brush and Comutator

Inspection

Remove brush cover(s) and remove the brushes from the brush holders. Clean the brushes and holders. Check the brush holders for damage.

7 Check the tension on the brush springs. Spring pressure (load) on all brushes must be equal. Refer to brush spring tension check below.

Inspect the condition of the brushes.

Remove each brush from the brush holder and inspect the brushes and commutator for worn condition and uneven wear, burning, electrical arcing, etc. The brushes should be worn evenly. Refer to brush inspection chart, page 6.

8 Check brush shunt for good contact with brush holder. Be sure shunt is not damaged or burned, since this may cause brush spring to carry current and lose tension.

Clean the commutator surface.

Wipe the commutator with a dry, lintfree cloth. DO NOT USE LUBRICANT OR SOLVENT ON THE COMMUTATOR. Check appearance of commutator surface where the brushes ride. Inspect the commutator bars for burned, damaged, or raised areas. The best signs of good commutation are a dark browncolored, highly-polished commutator and uniform glossy brush-wearing surfaces.

Refer to the COMMUTATOR CHECK CHART at the end of this section.

Measure and make a record of brush length at each inspection. The record will verify the amount of brush wear and indicate if there is enough brush length remaining until the next scheduled inspection.

Brushes must be replaced when worn to approximately half their original length.

BRUSHES MUST BE REPLACED WHEN WORN TO DIMENSION NOTED IN TRUCK SPECIFICATION. REFER TO GROUP 40, SECTION 5.

IMPORTANT NEW BRUSHES MUST BE THE SAME SIZE AND GRADE (MATERIAL SPECIFICATION) AS THE OLD BRUSHES. Observe how brushes are assembled in the brush holders, and position of brush lead (brush shunt). New brushes must be installed in same manner.

Code: PMA-540, NOV 85

9 If brushes do not need to be replaced, and commutator is in good condition, install the brushes and brush springs into brush holders. Be sure brush spring is correctly in place on the brush and that brush slides freely in brush box.

10 Clean and check brush box and connector screws, as applicable.

Tighten if loose. Be sure the brush shunt connection is tight.

Install brush cover on motor case.

11 Check and tighten all motor bolts.

Check the lower nut on each terminal post. It should be installed fingertight, then tighten another l/4-turn with a wrench.

Measuring Brush Spring Tension Put a piece of paper between the brush and commutator.

Use a spring scale with its hook or an adapter fitted around the spring between the brush and spring, at the point where the spring presses on the brush.

Pull the scale to lift the brush spring until the paper under the brush can be moved freely in the direction of rotation of the motor. Measure the tension.

Replace the spring if the tension is too weak (does not meet the spring tension specification).

Refer to GROUP 40, Section 5.

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GROUP 16, Section 1, Page 5

CLSRK

GROUP 16

BRUSH INSPECTION

IF SPRING

TENSION

IS NOT

FOR EACH BRUSH,

REPLACE

THE

SAME

REPLACE

SPRINGS.

REPLACE BRUSH IF PIGTAIL IS LOOSE IN THE BRUSH.

BRUSH

IF OIL

SOAKED

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

* REPLACE BRUSHES WHEN . .m_w WORN TO HtKt.

I

4

NEW

BK USHES

*Refer to motor brush specifications.

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

Continued use of worn-out brushes will result in damage Always replace to commutator and impaired performance. brushes with original equipment parts.

GROUP 16, Section 1, Page 6

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

Code: PMA-540, NOV 85

GEA-7053

SATISFACTORY

LIGHT

TAN

surface

is one

often

seen

FILM

over entire

of many

MOTTLED

commutator

normal

tern

conditions

on a well-functioning

condition

machine.

WATCH

STREAKING beginning brush.

on the commutator of serious

Check

the

COPPER

DRAG,

material,

forms

dition

is rare

metal

char+

below

an abnormal most ohen

but

surface

transfer for

con cause

possible

build-up

at trailing

signals

to the

flashover

the

SLOT

film, appecrs

industry.

related

in

FOR

THESE

THREADING

to resurfacing

metal

PITCH

BAR-MARKING commutator

ings equals

with

transfer

of c~mmu+o+~r

on the

number

in a definite

of conductors

lines

results

occurs. It urualfy

leads

and

produces surface.

to

a slightly

on bars

DANGER

of commutator

excessive

SURFACES

BAR-MARKING,

observed

commutators

causes.

checked.

film pat-

frequently

when

of bar. Con-

if not

of

with random

most

carbon

of commutator

edge

SURFACE

is probably

COMMUTATOR

fine

rapid

brush wear.

low

or burned

The number

of these

half or all the number

of poles

spots mark-

on the motor.

Carbon Products General Electric Company East Stroudsburg.

Pa. 18301 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

HEAVY

darker

area

pa++ern per

tar and,

slot.

FILM

(an

of efficient

and

if uniform,

appear

over

normal is quite

entire

commutaacceptable.

SIGNS

GROOVING by abrasive phere.

is a mechanical material

If grooves

form,

in the

condition brush

caused

or atmos-

s+or+ corrective

action.

CLSRK

GROUP

16

GROUP

16

SECTION

2 DRIVE

Code: PMA-540, NOV 85

MOTOR BRUSH REPLACEMENT

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

GROUP 16, Section 2, Page 1

GROUP 16

NON SERVICEABLE

DRIVE

MOTOR

16.000 16.002 16.004 16.006 16.011

MOTOR ASSEMBLY, DRIVE BEARING, DRIVE MOTOR COMMUTATOR END RETAINER, DRIVE MOTOR COMMUTATOR END BEARING BRUSH HOLDER KIT, DRIVE MOTOR ARMATURE, DRIVE MOTOR

16.014 16.017 16.018 16.029 16.034

COIL SET, DRIVE MOTOR FILED CAFSCREW, DRIVE MOTOR POLE SHOE BRUSH KIT, DRIVE MOTOR SEAL, DRIVE MOTdR ARMATURE SHAFT DRIVE END TERMINAL KIT, DRIVE MOTOR

16.036 16.078 16.079 16.084 15N

FAN, DRIVE MOTOR ARMATURE FRAME ASSEMBLY, DRIVE MOTOR DRIVE END FRAME ASSEMBLY, DRIVE MOTOR COMMUTATOR END COVER, DRIVE MOTOR COMMUTATOR END BEARING USE 16.000 HOUSING, DRIVE MOTOR

GROUP 16, Section 2, Page 2

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

16-069

Code: PMA-540, NOV 85

GROUP .._ lb

DRIVE MOTOR REMOVAL FROM TRUCK Remove the battery from truck (See GROUP 12, Section 1).

Adiust the front batterv elate for maintenance access. Refer to GRO 3 Loosen and remove the drive motor mounting bolts from drive unit mount ing flange.

85M674 4 The bottom motor mounting bolt may be more easily reached with better leverage by using a socket wrench with a long extension from the battery compartment.

85M763 5 Remove power cables from motor terminals.

NOTE - Attach label tags to the cables for easy indentification at assembly.

Replace the nuts on motor terminals to avoid losing them.

85M675 6 Move each motor from the axle towards the rear of truck and into battery compartment.

Motor can be temporarily rested on frame crossmember. NOTE - At this point the brush openings are accessible from the battery compartment and brushes may be inspected or replaced without further removal of the motors. However, the motors may be fully removed from truck, as noted below, for better access to brushes.

85M677

Code: PMA-540, NOV 85

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

GROUP 16, Section 2, Page 3

GROUP 16 NOTE - Motor can be removed either from the battery compartment or up through the center of truck, as shown here.

7 Each drive motor can now be removed from the truck by lifting up through the center of truck.

Drive motor weight: [20 kg] 44 lbs.

Refer to PM Section, and GROUP 16, Section 1, for inspection of drive motor brushes.

85M676 “’

.

1 Remove the plastic brush covers by squeezing or prying the locking tabs from the slots in the sides of opening. Air clean the inside of the motor around the commutator and brushes, using dry (moisture-free) air.

”

,,

,,

,,

,,

_’

,,

”

,,

“’

DRIVE MOTOR BRUSH REPLACEMENT

“,,,

,\ 2

,,

”

_ ,\ ,,

,,

85M717 Brush

Removal

NOT1CE - Observe how brushes are assembled in brush holders and position of brush lead.

New brushes must be installed in same manner.

a. Move brush spring clip from its mounting on brush assembly. b. Disconnect brush assembly lead.

85M719

c. Lift brush assembly from brush holder.

Remove any carbon dust or dirt from brush holder assembly.

85M715

GROUP 16, Section 2, Page 4

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

Code: PMA-540, NOV 85

GROUP 16

Brush Replacement 1 New brush assemblies to be installed by reversing above removal procedure. a. Install brush with the lead wires positioned as when removed. b. Install brush assembly into brush holder.

85M718 c. Connect brush lead assembly.

,_ ,,

d. Install brush spring.

\_

,,

,,‘,.: ,,

_, “,,,:

,,,

”

_) ,,,

“‘,,

,_,, .‘,

,,,.

,’ _,

85M719 2 Repeat brush installation for all brushes.

3 Be sure that all brushes are free (move easily) in the holder.

4 When brush installation is completed, install the brush covers on motor.

85M717 Drive Motor Instal 1ation 1 Install drive mo tors in truck by reversing the procedure of removal. Be sure motor shaft spline and mounting flange is clean and O-ring seal nstalled correctly on pilot flange of motor before installation.

Motor mounting bolt torque: [70-80 N-m] 52-59 lbf.ft.

85M688

Code: PMA-540, NOV 85

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

GROUP 16, Section 2, Page 5

GROUP 16

CLqRK

GROUP

16

SECTION

4 STEER MOTOR BRUSH REPLACEMENT

Code: PMA-540, NOV 85

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

GROUP 16, Section 4, Page 1

GROUP

CMRK

16

16.211,

__.._....^.___ . .._ mru,n

\\

r-r/\\

KII

INCLUDES ITEMS

16.233

16.208,

!

/

fl

_,'

16.212-j..

L16.251

NON SERVICEABLE ITEMS

116.239

i$J

STEER PUMP

MOTOR

16-300

16.200 16.208 16.209 16.211 16.212

MOTOR ASSEMBLY, STEER PUMP BEARING, STEER PUMP MOTOR DRIVE END ARMATURE, STEER PUMP MOTOR BEARING, STEER PlJMF MOTOR COMMUTATOR END SPRING WASHER, STEER PUMP MOTOR COMMUTATOR END BEARING

16.218 16.223 16.231 16.232 16.233

BRUSH KIT, STEER PUMP MOTOR COVER, STEER PUMP MOTOR BRUSH HOLE CONDUCTOR, STEER PUMP MOTOR CROSS COVER, STEER PUMP MOTOR BRUSH HOLE FASTENER, STEER PUMP MOTOR BRUSH HOLE COVER

16.234 16.238 16.239 16.251 16.258

TERMINAL KIT, STEER PUM-PMOTOR BRUSH HOLDER KIT, STEER PUMP MOTOR FASTENER, BRUSH HOLDER MOUNTING RING FASTENER, STEER PUMP MOTOR COMMUTATOR END FRAME FRAME, STEER PUMP MOTOR DRIVE END

16.259 92.550 18N

FRAME, STEER PUMP MOTOR COMMUTATOR END NUT, STEER PUMP MOTOR BRUSH HOLE COVER FASTENER USE 16.200 BODY, STEER PUMP MOTOR

GROUP 16, Section 4, Page 2

MARKED “N”

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

Code: PMA-540, NOV 85

CLARK

GROUP 16

STEER PUMP AND MOTOR REMOVAL FROM TRUCK NOTICE - Inspection of the steer pump motor requires removal of the sump filter mounting bracket, disconnection of the hydraulic lines from pump, and removal of the motor from its mounting on the front battery plate.

1 Adjust front battery plate for maintenance access.

(Refer to GROUP 38, Section 2.)

85M861 2 Loosen and remove the nuts from the mounting bolts, then remove hydraulic oil filter mounting bracket from the battery plate.

85M707 3 Put the bracket, with hydraulic lines and filter attached, aside out of the way.

85M682 4 Loosen the clamp and remove intake hose from pump.

85M695

Code: PMA-540, NOV 85

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

GROUP 16, Section 4, Page 3

GROUP 16 5 Disconnect the high pressure hydraulic line from pump.

Put caps on all fittings for their protection.

85M696 6 Be careful to avoid losing or damaging the O-ring seal in the tube fitting.

85M697 7 Disconnect the power cables from motor terminals. Attach label tags to the cables for easy identification at assembly.

85M880 8 Loosen and remove motor mounting nuts (four) from bolts, at front side of battery plate.

NOTE - Wrench clearance is limited at the outer (L.H.) side by the frame. Wrench must be turned and re-positioned frequently while removing and installing the nuts. DO NOT LOOSEN OR ATTEMPT TO REMOVE THE SOCKET-HEAD BOLTS FROM THE BATTERY COMPARTMENT SIDE. They are fastened in place with locknuts (spacers) at front side of battery plate under the motor mounting plate flange.

GROUP 16, Section 4, Page 4

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

25465

Code: PM-540, NOV 85

CL~Rw

GROUP 16

9 Steer motor may now be removed. Raise motor and pump assembly up and out of truck.

85M698 STEER MOTOR BRUSH INSPECTION/REPLACEMENT Brush

Removal

NOTICE - Observe how brushes are assembled in brush holders and position of brush lead.

New brushes must be installed in same manner.

85M701 1 Remove the brush cover band by removing the clamping screw and prying the cover pins out of engagement in the motor housing.

Also, see Figure 85M699, Page 7.

Air clean the inside of motor around the brushes and commutator, using dry (moisture-free) compressed air.

85M700 2 Brushes should be removed, as follows: a. Move brush spring clip from its mounting on brush assembly. b. Disconnect brush assembly lead.

85M702

Code: PMA-540, NOV 85

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

GROUP 16, Section 4, Page 5

GROUP 16 c. Lift brush assembly from brush holder.

3 Remove any carbon dust or dirt from brush ring assembly.

4 Inspect the condition of the brushes.

85M703

Remove each brush from the brush holder and inspect the brushes and commutator for worn condition and uneven wear, electrical arcing, etc. Refer to GROUP 16, Section 1, for more information on motor maintenance and brush inspection.

5 Replace the brushes (complete set), as needed.

Brush

Rep1 acement

1 New brush assemblies to be installed by reversing above removal procedure. a. Install brush with the lead wires positioned as when removed. b. Install brush assembly into brush holder.

85M703 c. Connect brush lead assembly.

85M702

GROUP 16, Section 4, Page 6

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

Code: PMA-540, NOV 85

GROUP 16

cl!mw 2 Repeat brush installation for all brushes.

3 Be sure that all brushes are free (move easily) in the holder.

4 When brush installation is completed, install the brush covers on motor.

85M699 STEER MOTOR INSTALLATION 1 Install steer motor to the battery plate, by reversing the procedure for removal.

Be sure motor mounting nuts are tightened completely and correctly.

25465 2 Connect hydraulic lines to pump.

Check that both hose and tube connections to the pump are tightened correctly.

Check that the pump mounting bolts are tightened correctly.

Corrrect tightening torque is [40-45 N-m] 29-33 lbf.ft. for pump bolts.

85M696 3 Connect the power cables to steer motor.

85M880

Code: PMA-540, NOV 85

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

GROUP 16, Section 4, Page 7

CLqRK

GROUP 16 4 Install the hydraulic oil filter mounting bracket to the battery plate.

Check that the hydraulic line connections to the filter are all tightened correctly.

85M642

GROUP 16, Section 4, Page 8

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

Code: PMA-540, NOV 85

GROUP 17

CMRIIC

GROUP

17 SECTION

4 STEER AXLE TRUNNION MICROSWITCH

CHECK AND ADJUSTMENT

(DRIVE MOTOR CUT-OUT)

To perform this service procedure, it is recommended that you first: l

l

l l

Park the truck on a level surface and fully lower the upright.

Return all controls to neutral, and turn key switch to the "OFF" position.

Apply the parking brake.

Lift and block the truck up to raise the steer and drive wheels off the floor.

Refer to GROUP 38, Section 3, Machine Jacking and Blocking.

85M777

Code: PMA-540, NOV 85

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

GROUP 17, Section 4, Page 1

GROUP 17

.812

DRIVE

MOTOR

CUT-OUT

17-371

13.192 13.489 13.682 13.683 13.684

BRACKET, SWITCH HANGER BRACKET, CONTROL SWITCH MOUNTING SWITCH, DRIVE MOTOR STEERING INTERLOCK FASTENER, STEERING INTERLOCK SWITCH BRACKET, STEERING INTERLOCK SWITCH

13.685 15.342 60.231 60.232 65.476

FASTENER, STEERING INTERLOCK SWITCH BRACKET HARNESS, POWER STEERING INTERLOCK WIRING PIVOT, STEERING INTERLOCK SWITCH BRACKET SPRING, STEERING INTERLOCK SWITCH BRACKET SUPPORT, STEERING INTERLOCK SWITCH BRACKET

93.411 93.412 93.812 94.199 94.201

WASHER, STEERING INTERLOCK SWITCH MOUNTING BRACKET FASTENER NUT, STEERING INTERLOCK SWITCH MOUNTING FASTENER RETAINER, STEERING INTERLOCK SWITCH BRACKET PIVOT FASTENER, STEERING INTERLOCK SWITCH BRACKET SUPPORT WASHER, STEERING INTERLOCK SWITCH BRACKET SUPPORT FASTENER

GROUP 17, Section 4, Page 2

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

Code: PMA-540, NOV 85

GROUP 17

Steer Axle Trunnion Switch Check 1 Be sure that truck is parked and blocked up correctly to raise the steer and drive wheels Page 1. off the floor. See CAUTION, 2 Turn key switch "ON". Release parking brake.

3 Put direction lever in "FORWARD" and push on accelerator pedal. Both drive wheels must now be turning.

85M479

4

Slowly turn the steering handwheel to make a right turn. Each drive wheel must stop rotating (cut off) when the steering. trunnion (steer axle wheel) is turned at an angle of 41.5 degrees from center (straight-ahead).

Check the right-hand drive wheel to know when it stops. Check the steering trunnion or steer axle wheel to determine the angle of turn from center when drive wheel stops rotating.

85M507

5 Repeat test for left turn. Check left-hand drive wheel and steer axle wheel, as above.

85M524 6 If the respective (right and left) drive motor does not cut off (stop) correctly, or if the turning angle of the steer axle wheel differs from that specified, the steering trunnion microswitches require repair or adjustment.

Refer to the following adjustment procedure.

The steering trunnion microswitches are located at the top of the steer axle trunnion in the SCR controls compartment.

NOTICE-

Code: PMA-540, NOV 85

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

GROUP 17, Section 4, Page 3

GROUP

CLqRK

17 Switch Assembly Description and Adjustment Requirements The plastic cam plate for actuating the switches is mounted to the top of steer axle trunnion shaft.

The switches are mounted on a hinged, spring-loaded bracket assembly which allows the switches to move vertically as they contact the cam.

This bracket also has a "tab" projection on its bottom front edge. This tab is designed to limit the minimum clearance between switches (switch rollers) and the cam plate on axle.

The switch bracket assembly is mounted to an L-shaped bar which is held in place with two bolts that also mount the contactor panel of the traction control. This bar locates the switches over the center of the steering trunnion.

All mounting and attachment bolt holes in the switch bracket parts are elongated or are oversize for location adjustment of the switches.

The switches must be centered over the cam plate on axle for actuation at equal right and left turn steering angles.

The switches must be adjusted vertically for correct travel of the switch lever rollers when actuated by the cam.

The switch bracket assembly is designed to require minimum adjustment when installed correctly.

GROUP 17, Section 4, Page 4

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

Code: PMA-540, NOV 85

GROUP 17

Steer Axle Trunnion Switch Adjustment Step 1: Open the battery compartment cover.

NOTICE - Access to the switches will be made much easier when the battery is removed from truck.

85M616 Step 2: Turn the steer axle wheel to the straight-ahead pos ition.

(Shown in partia lly-turned position.)

Refer to illustrations, Pages 2 and 4.

85M774 Step 3: For centering of the SW itches over the cam plate on axle, loosen the mounting screws and 1) adjust the L-shaped bar (13.489) at its attachment to the contactor panel, and/or 2) the switch bracket (65.476) at its attachment to the L-bar. Tighten mounting screws.

26534 Step 4: For correct height of switch rollers to contact cam plate, loosen mounting screws and adjust the hinged switch bracket assembly (13.684 and 13.192) vertically at its attachment to mounting bracket (65;476) on L-bar.

26535

Code: PMA-540, NOV 85

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

GROUP 17, Section 4, Page 5

GROUP 17

Switch bracket is in the correct position when switches are actuated correctly as verified by test operation of the steer wheel and cam plate.

Refer to test procedure, page 3.

Switch Assembly Removal Refer to Page 2 and Figure 26537, Page 4.

1 Disconnect plug in wiring harness between switches and contactor panel of traction control.

85M832 2 Loosen and remove the two mounting bolts holding L-bar bracket to the contactor panel.

85M828 3 Remove the L-bar bracket, with switch bracket assembly and switches attached, from the truck.

Switch Assembly Installation 1 Install switch bracket assembly by reversal of removal procedure.

85M834

After installation, check for correct operation of switches (see Page 3).

GROUP 17, Section 4, Page 6

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

Code: PMA-540, NOV 85

CMRK

GROUP 19

GROUP

19 SECTION 1 EV-100 SCR CONTROL GENERAL

ARRANGEMENT AND

COMPONENT

INFORMATION

Code: PMA-540, NOV 85 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP 19, Section 1, Page 1

CLSRU

GROUP 19 EV-100

SCR TRACTION

CONTROL ASSEMBLY

1

SCR PANEL

2

CONTACTOR PANEL

3

ACCELERATOR

NOTE: 1 When installing SCR panel, apply a coating (thin, uniform layer) of thermal compound, Clark Part No. 1801480, to area shown.

CONTROL

2 Torque mounting bolts to [ZO-25 N.m] 177-221 lbf.in.

B

GROUP 19, Section 1, Page 2

NOTE 2

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

Code: PMA-540, NOV 85

CLflRK

GROUP 19

EV-100 SCR CONTROL POWER AND CONTROL WIRING

TC-A27 TCTC-PS

-

TC-LS2-7 TC-LSl

\ \/I

/

\

/

TC-RS2 TC-RSl TC- RAl

SEE RECEP TACLE ASS EM BLY VIEW

Code: PMA-540, NOV 85

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

GROUP 19, Section 1, Page 3

CLflRK

GROUP 19

EV-100 SCR CONTROL PANEL COMPONENTS ARRANGEMENT (For reference only)

.5OOI12.71 DIA. MOUNTING HOLES. ISCR PANEL) 13)

.625l15.861 DIA MOUN HOLES. (CONT. PANEL)

I

PART 4 9 10 11 12 14 15

NAME BASE ASSEMBLY SCR CONTROL PANEL CONTACTOR (FA, Rk) CONTACTOR (FB, RB) CONTACTOR (1A) CONTACTOR (P) CONTACTOR (PS) ) I (4REC) SINK (4REC) IINSUL. (4REC) ,u"3rlllYu : BLOCK (

1 ;; I L"

rlNG13)

I

NAME PART 1 25 1 CONT. DRIVER

1

IILnI

GROUP 19, Section 1, Page 4

52 53

BUS BAR (FB-DC) BUS BAR (PS-FU4)

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

Code: PMA-540, NOV 85

CLclRlrC

GROUP 19

EV-100 SCR CONTROL PANEL WIRING (For reference only)

ZONNECT. %l. Al (REC-B. 30NNECT.

SEO. f116BK

1

259A92G9P16BK

TOP

C3 SEO. #18BK

259A9269PlRBK

w1. c7 SCR-TBS. FAIPOSI. FBIPOSI. C6 SCR-TB6.

RAIPOSI. RLXPOS). c5 SCR-7B4.

C2 PINEC). 4REC-B SCR-TB2.

B3 PUTD-3.

01 SlREC-1.

D2. SCR-PB6 PUTD-4.

05 PIPOS). Cl lAD-3.

IAINEGI 30REC-2.

D4 XREC-2.

D3 REINEGI, 30REC-3 FBINEGI, JOREC-1 FAfNEG). 32REC-1 RAINEC). 32REC-3 PSD-3.

PStNEGl PSTD-1.

PSD-1 SCR-TB3.

PSTD-4. lA(POSI. PSIPOS).

PSTD-3.

C4 DCD-3.

DCMGI CONNECT.

ARRANGEMENT

SEO. #I~GY

SCRMGI. PMTD-2.

SCRINEGI. El SCR-PB4.

PMTD-1 SCR-TBl. 82 DCD-1.

31REC-3 SCR-PB5, lAD-1

s CABLE

CONNECT.

SEO.

2GY

259A9887PZGY

BOT DCIPOS).

801

B4

259A9269PlBGY

lAD-2.

Code: PMA-540, NOV 85

PSTD-2.

PSD-2.

DCD- 2

VIEW “A”

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

GROUP 19, Section 1, Page 5

CMRK

GROUP

19 EV-100 SCR PANEL TYPICAL PHYSICAL ARRANGEMENT AND COMPONENTS

IDENTIFICATION

IAl

1)

GROUP

(Oscil lator)

Control

Card

(11)

Plugging

Diode SCR

Connection

(3)

Card

Connector

(7. Plug)

(12)

Charging

(4)

Card

Connector

(B Plug)

(13)

Filter

(ZZREC)

(5)

Control

Card Adjustment

(14)

Filter

(23REC)

(6)

Thermal

Protector

(15)

Filter

(24REC)

(7)

Commutating

(161

Filter

(25REC)

(8)

Main

(1REC)

(17)

Reactor/Choke

(9)

Turn-Off

SCR

(18)

Motor

(TP)

Capacitor

(ZREC)

1, Page 6

Trimpots

(1C)

6

Diode

Card

19, Section

1 Thru

Flyback

(2)

SCR

Terminals

( 3REC)

(10)

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

Current

Code:

(4REC)

(5REC)

Sensor

PMA-540,

NOV 85

GROUP 19

DOES NOT INCLUDE ITEMS MARKED “F”

T

L

17.756 91.604 91.132

-19.934

91.314 w- 94.481

90.203-c& 91.543-Y& 17.014-a

g-

&.A+.--

94.49 92.540 65.200

~E=G501

I

91.600

-

90.186F

17.000 17.014 17.094 17.224 17.750

PANEL ASSEMBLY, ELECTRIC TRUCK CONTROL FASTENER, CONTROL PANEL CONDUCTOR FASTENER, CONTACTOR PANEL FASTENER, TERMINAL CABLE SCR PANEL ASSEMBLY

91.132 91.314 91.481 91.511 91.543

WASHER, TRANSFORMER TERMINAL FASTENER LOCKWASHER, SCR CONTROL PANEL TERMINAL FASTENER LOCKWASHER, CONTROL PANEL TERMINAL FASTENER WASHER, SCR CONTROL PANEL CABLE FASTENER WASHER, CONTROL PANEL CONDUCTOR FASTENER

17.756 17.792 19.501 19.934 65.200

FASTENER, TRANSFORMER TERMINAL BOLT, CONTROL PANEL FASTENER, CONTROL PANEL TERMINAL FASTENER, SCR CONTROL PANEL TERMINAL WASHER, CONTROL PANEL CONDUCTOR FASTENER

91.600 91.604 92.540 93.346 93.347

LOCKWASHER, SCR CONTROL PANEL TERMINAL FASTENER LOCKWASHER, TRANSFORMER TERMINAL FASTENER LOCKWASHER, CONTROL PANEL TERMINAL FASTENER FASTENER, HEAT SINK TERMINAL LOCKWASHER, HEAT SINK TERMINAL FASTENER

65.705 90.079 90.186 90.203

COVER, CONTROL PANEL LOCKWASHER, CONTACTOR PANEL FASTENER LOCKWASHER, CONTROL PANEL FASTENER LOCKWASHER, CONTROL PANEL CONDUCTOR FASTENER

93.349 94.449 94.451 94.481

WASHER, HEAT SINK TERMINAL FASTENER FASTENER, CONTROL PANEL TERMINAL WASHER, CONTROL PANEL TERMINAL FASTENER WASHER, SCR PANEL TERMINAL FASTENER

Code: PMA-540, NOV 85

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

GROUP 19, Section 1, Page 7

CLflRK

G Rp9U P

n

17.023 7

lg.874

94.198

2

,.

.d,

65.474

65.472

3

-*

91.093 91.098

--b

--ga

sb

65.193

v

_/u/(

Y

17.018 i

-65.45;

I

19.598 ’ 1

19.853; ASSEMBLY

COMPLETE

(Continued)

33.047

_17.000

-

CONTROL

PAN EL 19-582

17.000 17.007 17.008 17.018 17.023 17.221 17.222 17.224 17.537 18.070 19.073 19.074 lg.598 19.600 19.624 19.716 19.853 19.859 19.860 lg.873 lg.874 65.193 65.457 65.472

CONTROL PANEL ASSEMBLY (CONTINUED) CONTACTOR ASSEMBLY, 1A FASTENER, 1A CONTACTOR ASSEMBLY ANGLE, CONTACTOR TERMINAL CONTACTOR ASSEMBLY, PUMP CONDUCTOR, HYDRAULIC PUMP CONTACTOR FASTENER, HYDRAULIC PUMP CONTACTOR CONDU(:TOR FASTENER. TERMINAL CABLE FASTENER, HYDRAULIC PUMF CONTACTOR CLIP, CONTROL PANEL WIRING HARNESS DRIVER, 1A CONTACTOR FASTENER, CONTACTOR DRIVER CONDUCTOR, PLUGGING CONTACTOR CONTACTOR ASSEMBLY, PLUGGING FASTENER, PLUGGING CONTACTOR MODULE, STEER PUMF RELAY TIME DELAY FASTENER, PLUGGING CONTACTOR TERMINAL ANGLE BRACKET, PLUGGING CONTACTOR MOUNTING FASTENER, PLUGGING CONTACTOR MOUNTING BRACKET DRIVE, POWER STEERING CIRCUIT SCREW, POWER STEERING CIRCUIT DRIVER DRIVER, HYDRAULIC PUMP CONTACTOR DIODE, DRIVE MOTOR PLUGGING #4 (A) REC. CONTROL PANEL

GROUP 19, Section 1, Page 8

65.473 65.474 65.475 65.784 90.073 90.074 91.093 91.098 91.481 92.210 92.394 92.530 92.531 93.047

HEAT SINK, CONTROL PANEL 114 (A) REC INSULATOR, CONTR PANEL 04 (A) REC HEAT SINK FAST INSULATOR, CONTROL PANEL 14 (A) REC HEAT SINK DIODE, DRIVE MOTOR PLUGGING CONTACTOR LOCKWASHER, HYDRAULIC PUMP CONTACTOR FASTENER LOCKWASHER, 1A CONTACTOR FASTENER NUT, CONTACTOR PANEL CONDUCTOR FASTENER LOCKWASHER, CONTACTOR PANEL CONDUCTOR FASTENER LOCKWASHER. CONTACTOR PANEL TERMINAL FASTENER WASHER, HYDRAULIC PUMP CONTACTOR CONDUCTOR FAST LOCKWASHER. PLUGGING CONTACTOR FASTENER LOCKWASHER, CONTACTOR DRIVER FASTENER WASHER, CONTACTOR DRIVER FASTENER LOCKWASHER. DRIVE MOTOR PLUGGING CONTROL FAST

93.591 94.196 54.197 94.198 94.451 95.189 95.190 95.191

LOCKWASHER. CONDUCTOR TERMINAL FASTENER FASTENER, CONTROL PANEL 84 (A) REC HEAT SINK LOCKWASHER, CONTR PANEL 84 (A) REC HEAT SINK FAS WASHER, CONTROL PANEL 14 (A) REC HEAT SINK FAST WASHER, CONTACTOR PANEL TERMINAL FASTENER FASTENER, DRIVE MOTOR PLUGGING DIODE LOCKWASHER, DRIVE MOTOR PLUGGING DIODE FASTENER WASHER, DRIVE MOTOR PLUGGING DIODE FASTENER

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

Code: PMA-540, NOV 85

CLARK

GROUP a9

ASSEMBLY

COMPLETE

(Continued)

go.471 91.096 -17.341

&,7.362

17.538-i

17.036 1

-m

-i -2

*w

17.015

--J&

7l 0

NOTE: NON SERVICEABLE ITEMS

MARKED-N”

1N

,“I_

I

DA&ICI rMlYLL

19-583

7.000 4.294 7.015 7.029 7.032

PANEL ASSEMBLY, ELECTRIC TRUCK CONTROL (CONT'D) FUSE, POWER STEERING CIRCUIT CONTACTOR ASSEMBLY, FORWARD 6 REVERSE RH CONDUCTOR, CONTROL PANEL FWD 6 REV CONTACTOR CAPSCREW, CONTACTOR PANEL POWER FUSE MOUNTING

65.304 90.059 90.076 90.193 90.194

CONTACTOR ASSEMBLY, FORWARD & REVERSE LH LOCKWASHER, POWER FUSE FASTENER LOCKWASHER, RJD 6 REV CONTACTOR FASTENER LOCKWASHER, FWD 6 REV CONTACTOR DIODE FASTENER WASHER, RJD 6 REV CONTACTOR DIODE FASTENER

7.033 7.035 7.036 7.041 7.269

CONTACTOR ASSEMBLY. POWER STEERING PUMP FASTENER, CONTACTOR PANEL PWR STRG PUMP CONTACTOR CONDUCTOR, CONTACTOR PANEL PWR STRG PUMP CONTACTOR FUSE, POWER DIODE, FORWARD 6 REVERSE CONTACTOR

90.471 91.096 91.483 91.852 91.862

LOCKWASHER, POWER FUSE FASTENER WASHER, MAIN FUSE MOUNTING FASTENER NUT, CONTACTOR.PANEL POWER FUSE MOUNTING FAST LOCKWASHER, CONTACTOR PANEL POWER FUSE MTG BLOCK LOCKWASHER. POWER STRG PUMP CONTACTOR MTG FAST

r.362 7.411 7.530 3.215 3.449

BLOCK, MAIN FUSE MOUNTING STUD, CONTACTOR PANEL POWER FUSE MOUNTING BLCCK FASTENER, FORWARD & REVERSE CONTACTOR DIODE WIRING HARNESS, CONTACTOR PANEL CAPSCREW, FORWARD 6 REVERSE CONTACTOR ASSEMBLY

91.992 92.532 92.533 93.093 93.094

WASHER, CONTACTOR PANEL POWER FUSE MOUNTING FAST CAPSCREW, CONTACTOR PANEL PWR STRG CIRCUIT FUSE WASHER,CONTACTOR PANEL PWR STRG CIRCUIT FUSE FAS FASTENER, FORWARD & REVERSE CONTACTOR BASE LOCKWASHER, FWD 6 REV CONTACTOR BASE FASTENER

3.496 i.082 5.373

BASE, FORWARD 6 REVERSE CONTACTOR LOCKWASHER, PWR STRG CIRCUIT FUSE CONN COND FAST BRACKET, POWER STEERING CONTACTOR MOUNTING

93.334 93.335

FASTENER, POWER STEERING CONTACTOR LOCKWASHER, POWER STEERING CONTACTOR BRKT FAST BASE, CONTACTOR PANEL

Code: PMA-540, NOV 85

1N

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

GROUP 19, Section 1, Page 9

GROUP

19

3.323 3.810

r17.750

/$5/ _~-~1

SCR

17.750 14.056 15.129 17.057 17.751 17.753 17.756 17.757 17.759 17.775 17.780 17.850 65.280 65.283 65.284 65.285 65.309 65.310 65.366 65.537 65.544

SCR PANEL ASSEMBLY FASTENER, TERMINAL BLOCK CONDUCTOR CONDUCTOR, #5 RECTIFIER FASTENER, CONTROL PANEL CONDUCTOR TERMINAL TRANSFORMER, SCR PANEL FASTENER, SCR PANEL TRANSFORMER FASTENER, SCR PANEL TRANSFORMER TERMINAL 14 REC, SCR PANEL #3 REC, SCR PANEL 12 REC, SCR PANEL #S REC. SCR PANEL SHUNT, CURRENT LIMITING HEAT SINK, SCR PANEL 14 REC CONDUCTOR, SCR CONTROL PANEL CONDUCTOR, SCR PANEL CONDUCTOR, SCR PANEL FASTENER; SCR PANEL REC LOCKWASHER. SCR PANEL MAIN POWER VALVE SW FAST INSULATOR, SCR PANEL 84 REC HEAT SINK INSULATOR, SCR PANEL #4 REC HEAT SINK FASTENER HEAT SINK, SCR PANEL VOLTAGE SENSOR

GROUP 19, Section 1, Page 10

ASSEMLYPLETE

PANEL

90.197 90.198 90.323 91.089 91.091 91.132 91.604 92.768 92.769 93.195 93.196 93.20s 93.346 93.352 93.587 93.810 94.197 94.225 94.759 94.760

LOCKWASHER, TERMINAL BLOCK CONDUCTOR FASTENER WASHER, TERMINAL BLOCK CONDUCTOR FASTENER LOCKWASHER, SCR PANEL TRANSFORMER FASTENER LOCKWASHER, CONTROL PANEL CONDUCTOR FASTENER WASHER, CONTROL PANEL CONDUCTOR FASTENER WASHER, SCR PANEL TFANSFORMER TERMINAL FASTENER LOCKWASHER, SCR PANEL TRANSFORMER TERMINAL FAST WASHER, SCR CONTROL PANEL MOUNTING HEAT SINK FAS LOCKWASHER, SCR PANEL MOUNTING HEAT SINK FAST FASTENER, SCR PANEL 14 REC HEAT SINK WASHER, SCR PANEL 114REC HEAT SINK FASTENER WASHER, CURRENT LIMITING SHUNT FASTENER FASTENER, HEAT SINK MCKWASHER, CURRENT LIMITING SHUNT FASTENER WASHER, CURRENT LIMITING SHUNT FASTENER WASHER, SCR CONTROL PANEL TRANSFORMER FASTENER LOCKWASHER, CONTROL PANEL REC HEAT SINK FASTENER FASTENER, CURRENT LIMITING SHUNT LOCKWASHER, CURRENT LIMITING SHUNT FASTENER FASTENER, CURRENT LIMITING SHUNT

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

Code: PMA-540, NOV 85

GROUP

CLflRK

1 COLOR

CODE

@-lg.046

17.764

’

I

(

(.____)L

17.763

1N

5.542

-2 27 SCR

PANEL

19-464

17.750 14.054 17.763 17.764 17.765

SCR PANEL ASSEMBLY (CONTINUED) BLOCK, TERMINAL CAPACITOR, SCR PANEL COMMUTATING BRACKET, SCR PANEL COMMUTATING CAPACITOR MOUNTING FASTENER, COMMUTATING CAPACITOR MOUNTING BRACKET

65.542 65.623 65.630 65.631 90.195

INSULATOR, SCR PANEL REC FILTER, PUMP SCR PANEL f/3REC FILTER, PUMP SCR PANEL 115 REC FILTER, PUMP SCR PANEL #2 REC LOCKWASHER, TERMINAL BLOCK FASTENER

17.776 17.700 19.046 19.072 19.079

$1 REC, SCR PANEL FILTER, SCR PANEL 114 FASTENER, SCR PANEL COMMUTATING CAPACITOR COND THERM0 CUT-OUT, SCR PANEL 111REC WIRING HARNESS, SCR PANEL

90.196 90.343 90.344 90.345 93.155

WASHER, TERMINAL BLOCK FASTENER LOCKWASHER, SCR PANEL CAPACITOR CONDUCTOR FAST WASHER, SCR PANEL COMMUTATING CAPACITOR COND FAS LOCKWASHER, CAPACITOR MOUNTING BRACKET FASTENER FASTENER, OSCILLATOR SPEED CONTROL UNIT

65.062 65.063 65.197 65.198 65.311

SCREW, MAIN POWFR VALVE THERMAL CUT-OUT LOCKWASHER, MAIN POWER VALVE THERMAL CUT-OUT FAST FASTENER, SCR PANEL illREC LOCKWASHER, SCR PANEL 111REC FASTENER WASHER, SCR PANEL illREC FASTENER

93.156 93.661 93.870 94.476 94.514

LOCKWASHER, OSCILLATOR SPEED CONTROL UNIT FAST FASTENER, TERMINAL BLOCK WASHER, SCR PANEL TERMINAL BLOCK FASTENER FASTENER, SCR PANEL FILTER LOCKWASHER, SCR PANEL FILTER FASTENER

65.347

CONTROL UNIT, OSCILLATOR SPEED

1N

BASE, SCR PANEL

Code: PMA-540, NOV 85

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

GROUP 19, Section 1, Page 11

GROUP 19

CLflRK

GROUP

19

SECTION

2 EV-100

SCR CONTROL

GENERAL MAINTENANCE

Code: PMA-540, NOV 85

INSTRUCTIONS

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

GROUP 19, Section 2, Page 1

GROUP 19

EV-100

CLflRK SCR CONTROL

GENERAL MAINTENANCE

NOTICE - Any controls that will be used in ambients of [40 C] 100 F or over should be brought to the attention of the truck manufacturer (CLARK).

- All external components having inductive coils must be filtered.

Refer to truck manufacturer (CLARK) for specifications.

Control

Maintenance

Procedures

l The control should not be steam cleaned.

In dusty areas, use lowpressure air to blow off the control.

In oily or greasy areas, a mild solution of detergent or denatured alcohol can be used to wash off the control and then blow completely dry with low-pressure air.

The control can also be cleaned with Freon TF degreaser (Clark Part No. 1801146).

The SCR control, like all electrical apparatus, does have some thermal The semiconductor junctions losses. have finite temperature limits above which these devices may be damaged.

For these reasons, normal maintenance should guard against any action which will expose the components to excessive heat, such as steam cleaning; or which will reduce the heat dissipating ability of air the control, such as restricting flow.

GROUP

19, Section

'2, Page

2

INSTRUCTIONS

l For the SCR panel to be most effective, it must be mounted against the counterweight or frame of the truck.

The counterweight or truck frame, acting as an additional heat sink, will give improved truck performance by keeping the SCR control package cooler.

The use of a heat-transfer grease (Dow Corning 340, GE Versilube G-350-M, or equivalent) is recommended. l Terminal boards and other exposed SCR control parts should be kept free of dirt and paint that might change the effective resistance betwen points. l Do not hipot (or megger) the Unless the terminals of each control. semiconductor and card are connected together, the control may be damaged.

Refer to control manufacturer before hipotting. l Use a lead-acid battery with the voltage and ampere-hour rating specified for the vehicle.

Follow normal battery maintenance procedures, recharging before 80-percent discharged and with periodic equalizing charges.

IMPORTANT The truck should not be plugged when the truck is jacked up and the drive wheels are off the floor in a free-wheeling position.

The higher motor speeds can create excessive voltages that can be harmful to the control.

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

Code:

PMA-540,

NOV 85

GROUP 19

GROUP

19

SECTION

3 CONTROL CARD ADJUSTMENT TUNEUP

FOR NEW OR MISTUNED

(EV-100

CARD

SCR CONTROL)

NOTICE Control panels as originally a particular motor and truck When a new control must be preadjusted truck control.

installed are factory adjusted for and should not need adjustment.

(oscillator) card is required, each trimpot before installing the new card into the

The values noted are nominal settings which may require additional tuning to match the specific truck performance requirements.

Refer

to GROUP

19, Section

7, for removal/installation

of card.

Refer to System Diagnostic Manual SDM-542 for additional information on operation and troubleshooting of EV-100 SCR control.

Code:

PMA-540,

NOV 85

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

GROUP

19, Section

3, Page

1

GROUP

CLqRK

19

ADJUSTMENT PROCEDURES FOR NEW OR MISTUNED CONTROL (OSCILLATOR)

CARD

NOTE - The card is equipped

with single-turn potentiometers with internal The box has "dial" marks for setting each potentiometer. stops.

The trimpots are located at the top edge of the card and enclosed by a sliding cover.

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

For exampl'e, CW adjustment increases creep speed, acceleration rate (C/A Pot), C/L, 1A Time, and stiffness of plug.

Refer to System Diagnostic Manual SDM-542 for additional procedures on operation and troubleshooting of EV-100 SCR control panel.

CREEP

0 1

CIA

C/L

1

1

1A TIME

PLUG

1

25470

turn all trimpots fully counterclockwise to the "1" dial setting.

Then, adjust each pot to the dial setting specified below:

1 With a new card,

(Creep (Controlled

speed)

CREEP

acceleration) (Current

limit)

(1A time)

See

GROUP

3, Page 2

C/A

:

5

C/L

:

9

:

1-2

PLUG

:

7

Page 3 for additional

19, Section

4-5

:

1A Time

(Plugging)

(CCW)

information.

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

Code:

PMA-540,

NOV 85

GROUP 19

2 The control card is located at the front edge (in truck) of the EV-100 control.

(Shown separate in Figure 85M725.)

Refer to GROUP 19, Section 5 for removal of card from SCR control.

: ‘,,, ‘,

_,

‘, ‘,

_,

,,,, ,:\ ,,,_ ,__,,‘_ ,_’ __’ ,:, \’ ,:‘ \_ \ ‘,, _ \

85M725 3 A sliding cover encloses the trimpots at the top edge of card. Move (slide) this cover to the rear (in truck) of the card to expose the pots.

85M728 4 Use a small screwdriver to adjust the trimpots.

85M729 5 Adjustment of the control card when in the truck is shown by Figure 85M740.

85M740

Code: PMA-540, NOV 85

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

GROUP 19, Section 3, Page 3

CLSRK

GROUP 19

GROUP

19

SECTION

4 EV-100 SCR CONTROL OPERATION

(See circuit

Code:

PMA-540,

NOV 85

diagram,

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

page

6)

GROUP

19, Section

4, Page

1

CMRK

GROUP 19

EV-100 SCR CONTROLOPERATION

Basics

of

Circuit

OperatSons

The control circuit is energized by closing the key switch, hand brake switch and seat switch (optional) and moving the forward or reverse (directional control) lever to either position and then depressing the accelerator closing the start (1MS) switch.

This applies power to the control card turning on the PMT driver, which will close the selected directional contactor and complete the circuits to the drive motor.

(See circuit diagram, page 6.)

opposes the battery current through 1REC so that the resultant current is zero.

With reverse voltage across lREC, 1REC !q turned off.

Current continues to flow in the 2REC, lC, motor and battery loop until the capacitor (card terminal 14) is fully-charged negative.

This charge exceeds battery voltage by an amount which is a function of peak motor current, and 2REC turns off.

Figure 25467 illustrates the pulsing of current from the battery.

The control card then supplies a gate pulse to ZREC turning it on to a conducting state, allowing current to flow from the battery through lC, 1X, ZREC, motor field, motor armature, sensor, and back to the battery.

After 1C charges ZREC shuts off, due to lack of holding current.

The control card checks that 1C is charged and unlocks the gate to 1REC and 5REC. The control card then supplies a gate pulse to 1REC turning it on to a conducting state, allowing current to flow from the battery through lREC, motor field, motor armature, sensor, and back to the battery.

5REC turns on and allows current to flow to T-4-T3, lC, lREC, 5REC to T4-T3.

This current charges the bottom of 1C positive with respect to the battery positive bus.

This charging cycle occurs in less than 1 millisecond (-001 set) and 5REC shuts This charge is now stored on the off. capacitor until it is time to turn off

1REC. Current continues to flow in 1REC until the control card fires ZREC. When 2REC conducts, capacitor 1C discharges around the circuit composed of lC, 2REC, 1X, and 1REC. This discharge current

GROUP

19, Section

4, Page 2

CZAR CURREM

AVERAGL - CURRENt

rc TlMC

Bottwy

wmnt 25467

During the off time, the energy stored in the motor, by virtue of the motors' inductance, will cause current to circulate through the motor around the loop formed by 3REC. Thus, providing what is called "flyback current".

Figure 25468 shows the nature of the motor current which is composed of both battery current and the inductive It should be noted flyback current. that the average motor current measured will be greater than the average battery current.

The SCR control, in effect, converts battery current at battery volts into a higher motor current and a lower motor volts.

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

Code:

PMA-540,

NOV 85

GROUP 19

Cl!!RK

800%

m -

c t

E

z

50%

ON OFT ON

-

oft

AVEIIAGE - CUnnL*l

be reversed (short OFF time, long ON time}.

This variation of ON and OFF time of the oscillator produces the optimum frequencies through the SCR The frequency curve of the range. oscillator is shown in Figure 25469.

ON OFF

25468 The time for the next ON and OFF cycle to start is determined by the time that the control card takes to oscilThis frequency of oscillation is late. controlled by the counter circuit in the accelerator and automatic circuitry in Slow speed is obtained by the card. having maximum volts in the acceleraAs the voltage in the accelerator tor. decreases, the speed of the motor The SCR circuit is capable increases. of delivering approximately 95% speed.

For full speed operation, the 1A contactor is closed to apply full battery voltage across the motor.

Control

Features

l Oscillator - the oscillator section of the card has two adjustable features and one fixed feature.

With the accelerator counter circuit at maximum volts, the creep speed can be adjusted by the "creep" trimpot on the card.

Top speed is fixed by card design, and is obtained with the accelerator counter circuit at minimum volts.

The XON time has a range of approximately 5 to 95 percent.

The center operating condition of the oscillator is at 50 percent ON time with a nominal 1.8 milliseconds ON time and 1.8 milliseconds OFF time.

This corresponds to a maximum operating frequency of about 300 hertz.

At creep, the ON time will decrease to approximately 0.8 milliseconds while OFF time will become in the order of 20 milliseconds.

At full SCR operation, this condition will

Code:

PMA-540,

NOV 85

25469 The rate at which the oscillator may increase its % ON time is limited by "Controlled Acceleration".

The minimum time required to go from creep speed to 80-85% ON time point may be varied by trimpot (C/A) on the card, adjustable from approximately 0.5 seconds to 3.5-4.5 seconds. l Current Limit - This circuit monitors motor current by utilizing a sensor in series with the armature.

The information detected across the sensor is fed back to the card so current ma.y be limited to preset value.

If heavyload currents are de t ected, this circuit and limits the overrides oscillator average current to a value set by the C/L adjustment pot.

The C/L setting is based on the maximum thermal rating of 1REC and the peak vo tage on the capacitor.

Because of the flyback current through 3REC, the motor current usually runs 2 to 3 times battery The current limit is set with current. the "C/L" trimpot on the card.

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

GROUP

19, Section

4, Page 3

GROUP

CLqRK

19 l Plugging - Slow down is accomplished when reversing by providing a small amount of retarding torque for deIf the vehicle is moving celeration. and the directional control lever is moved from one direction to the other, the motor field is reversed.

The plug signal is initiated by the fact that the directional switch has moved from one direction to the other.

The motor armature, driven by the inertia of the This vehicle, acts as a generator. generated current passes through 4REC The oscillator circuit and the sensor. regulates at a plug current limit level as set by the plug trimpot on the This controls the pulse control card. rate 1REC to regulate the generated motor current and bring the truck to a smooth stop and reversal.

The accelerator counter circuit input will modulate plugging current.

With the accelerator counter circuit at minimum voltage, the plugging trimpot will enable adjustment of plugging current from max to min current level.

With the accelerator counter circuit at maximum voltage, the plugging current will be reduced. l Ramp Start - this feature provides full SCR torque to restart a vehicle on The memory for this funcan incline. tion is the directional switch.

When stopping on an incline, the directional switch must be left in its original or off position to allow the control to assure full power when restarted.

The accelerator control input will modulate ramp start current. l Full Power built-in feature sition from SCR accomplished by pulse until the close.

GROUP

Transition - this provides smooth tranto 1A bypass.

This is the SCR continuing to 1A contactor power tips

19, Section

4, Page 4

l

modes

1A Control

- the contactor of control:

has two

1) Timed Pickup - this feature works with the counter circuit in the acWhen the accelerator control celerator. is activated so that accelerator voltage is reduced to 0.5 volt or less, the 1A time is enabled.

The time delay pickup of 1A is provided by a circuit in the This allows the truck to card. accelerate through the SCR range until 1A picks up, even if the accelerator control is actuated immediately.

This time delay is adjustable by means of a 1A Time trimpot on the card.

2) If motor current is reduced during cutback to a point where 1A pickup would cause a severe torque increase, the 1A timed pickup function will be disabled. l Static Return to Off (SRO) - this built-in feature of the control is set up to make the driver return the directional control lever to neutral any time he leaves the truck and returns.

If the seat switch (optional) or key switch is opened, the control will shut off and cannot be restarted until directional lever is returned to neutral.

A time delay (.75 second) is built into the seat switch input, to allow momentary opening of the seat switch if a bump is encountered. l Coil Driver Modules - these modules are located typically on the contactor portion of the control.

They are the power devices that operate F, R, and 1A contactor coils.

These modules open or close these coils on command from the control card.

All modules are equipped with reverse battery polarity protection in that if the battery is connected incorrectly, none of the contactors controlled can be closed electrically.

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

Code': PMA-540,

NOV 85

GROUP 19

CLWK

l Thermal Protector (TP) - this temperature-sensitive device is mounted in the 1REC heat sink.

If the 1REC temperature begins to exceed the design limits, the thermal protector will lower the maximum current limit and not allow 1REC to exceed its temperature limits.

Even at a reduced current limit, the vehicle will normally be able to reach sufficient speed for full 1A operation, thereby allowing the panel to cool.

As the panel cools, the thermal protector will automatically return the control to full power.

l Must Pulse To Time - this feature prevents the 1A timer from timing if the oscillation pulse rate has not reached a particular level of operation. l Low Voltage - batteries under load, particularly if undersized or more than 80-percent discharged, will produce low voltages at the SCR control terminals.

The EV-100 control is designed for use down to 50 percent of the nominal batLow battery volts may cause tery volts. the control to not operate correctly but the PMT should open the F or R contactor in the event of a commutation failure.

l 1A Thermal Hold Off - this feature prevents the 1A contactor from closing when the truck is in severe thermal When the cutback to avoid torque jumps. control goes into severe cutback, the "must pulse to time" will inhibit the 1A timer.

Code:

PMA-540,

NOV 85

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

GROUP

19, Section

4, Page

5

GROUP 19

CLflRK

EV-100 SCR CONTROLCIRCUIT DIAGRAM

I2

I SE!”

GROUP 19, Section 4, Page 6

IN-21706E

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

Code: PMA-540, NOV 85

CLSRK

GROUP 19

GROUP

19

SECTION

5 EV-100

SCR CONTROL

TROUBLESHOOTING

INSTRUCTIONS

Refer to Systems Diagnostic Manual SDM-542, TM 36-volt, EV-100 Sequence of Operation and Troubleshooting Guide, for additional detailed information on troubleshooting of the EV-100 SCR control.

Code:

PMA-540,

NOV 85

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

GROUP

19, Section

5, Page

1

GROUP 19 EV-100

SCR CONTROL

SUMMARY OF BASIC TROUBLESHOOTING STEPS When diagnosing and correcting the cause of trouble with an SCR control, do not begin by disassembling components.

Instead, start by analyzing the complaint or symptoms.

Make a preliminary investigation of the trouble.

Then, systematically determine the probable cause.

The following points are fundamental to troubleshooting an SCR system: Never start your troubleshooting until you Talk with the operator and review the work Operate to find

the truck out where

to determine to start.

what's

get the facts. order.

wrong

with

it and

Perform basic checks.

Check the battery and test for grounds and shorts in the truck.

Don't ever try to take any shortcuts by assuming that these things don't have to be done.

It is possible to avoid useless work by diagnosing trouble accurately on the basis of the preliminary and the information in the troubleshooting guide. necessary for sufficient preliminary investigation.

the cause of the investigation Take the time

Using the symptoms indicated by the trouble, locate the proper symptom diagnosis chart in the troubleshooting guide.

You may also want to use the sequence of operation manual as a diagnostic tool.

Proceed to find the problem by using the flow chart in the troubleshooting guide which defines the symptom and its possible causes and solutions.

Locate the trouble by a process of elimination.

The cause is usually simple, rather than mysterious and complicated.

AND MOST IMPORTANT, USE THE ELECTRICAL SCHEMATIC DIAGRAM YOU ARE WORKING ON. YOU MUST BE ABLE TO TRACE THE: 0 POWERCIRCUITS which consist of the heavy and main power components in the truck.

CONTROLCIRCUITS which and controlled

control plugging.

DIRECTIONAL CIRCUITS which

speed,

control

battery

1

indicator,

19, Section

5, Page 2

SHOULD

delay,

the forward

control components, and hourmeter.

! CAUTION - ALL TESTING

GROUP

cables

time

ACCESSORYCIRCUITS which

BE DONE

WITH

FOR THE TRUCK

and reverse

including

DRIVE

WHEELS

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

contactors.

the horn,

RAISED

OFF THE FLOOR.

Code:

PMA-540,

NOV 85

I

GROUP 19

Before troubleshooting: l

Park truck safely.

l

Raise drive wheels off the floor.

85M743 l

Turn key switch "OFF".

DISCONNECT THE BATTERY AND REMOVE ALL JEWELRY BEFORE WORKING ON ANY ELECTRICAL SYSTEM. SEVERE BURNS CAN RESULT FROM CONTACT WITH ELECTRICAL SYSTEMS

l

l

85M482

Open the hood.

Disconnect the battery from truck receptacle.

NOTE - Reconnect the battery as needed for the specific check.

85M541 l

Discharge the capacitor.

Use an insulated tool, e.g., a screwdr iver with a plastic or wood handle, to short between the termina 1s.

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

Code: PMA-540, NOV 85

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

85M620

GROUP 19, Section 5, Page 3

GROUP 19

EV-100

SCR CONTROL

TROUBLESHOOTING

NOTES

Troubleshooting is based on using a voltmeter to determine if the proper voltages are available to permit the control to operate properly.

All troubleshooting is written to check all outside devices and eliminate them as the source of symptoms.

The conclusion then being that the control card is faulty.

The pulsing of the main SCR is too fast for conventional instruments to measure.

When the control is functioning properly, a low hum can be heard (audible hum).

Before proceeding with any testing, visually check for loose wiring, misadjusted linkage to accelerator switch, signs of overheating of components, etc.

If capacitor 1C terminals are not accessible, discharge connecting from SCR POS terminal to 2 REC anode.

capacitor

by

Check resistance with a V-O-M from frame to SCR power and control terminals.

A resistance of less than 20,000 ohms can cause misleading If less than 20,000 ohms resistance is measured, conduct symptoms. further tests to eliminate short circuit/ ground fault condition.

Resistance less than 1000 ohms should be corrected first.

Malfunctions of the SCR will generally fall into one of two categories.

They are either: 1) no power, or 2) full power, when operating in the SCR control

range.

An index of symptoms of the most common and typical EV-100 SCR control troubles is shown on Page 5 as an aid in defining a specific control problem.

! CAUTION

GROUP

- ALL TESTING

19, Section

5, Page 4

SHOULD

BE DONE WITH

DRIVE

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

WHEELS

RAISED

OFF THE FLOOR.

Code:

PMA-540,

NOV 85

GROUP 19

CLsRw EV-100

TROUBLESHOOTING

SCR CONTROL

SYMPTOM INDEX I

SYMPTOM

DESCRIPTION

1

Directional

contactors

2

Directional contactors Truck inoperative with

close.

No power.

No audible accelerator in SCR range.

3

Directional contactors Truck inoperative with

close.

No power.

Audible accelerator in SCR range.

Directional immediately

!

I

Directional contactors and then remain open.

6

1A contactor

7

Stiff

plug

not close.

(Contactors

do not pickup) SCR hum.

SCR hum.

contactors close.

Full SCR hum and power with accelerator in creep position.

1

5

will

will and/or

close once PMT trips.

or twice

not close. plugging

distance

will

not adjust.

Refer to Systems Diagnostic Manual SDM-542, for detailed information sequence of operation and troubleshooting of the EV-100 SCR control.

This manual provides simple and easy-to-follow flow charts which outline the various symptoms and the corrective action to be taken.

Tools l l l l l l

and test equipment

6-volt lamp 6-volt battery Two Al4 diodes (1 amp 400V) Clip leads Volt-ohm meter (VOM)* (20,000 General hand tools

*NOTE

on

are:

ohms/volt)

- A digital Model tests

Code:

required

I

PMA-540,

NOV 85

VOM, such as the Simpson Digital Multi-Meter, 461, or equivalent is recommended for all electrical and control testing.

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

GROUP

19, Section

5, Page 5

GROUP 19

CLSRK

GROUP

19 SECTION

7 CONTROL PANEL REMOVAL (EV-100

SCR CONTROL)

Control Card SCR Panel 0 Contactor Panel l l

Refer to GROUP 19, Section 1, for Control Panel General Arrangement and Component Information.

To perform this service procedure, recommended that you first: l

l

l l

Park truck safely and fully lower the upright.

Return all controls to neutral turn key switch "OFF".

Apply the parking brake.

Block the drive wheels.

it is

and

l

Remove the battery from truck.

Refer to GROUP 12, Section 1, Battery Removal.

l

Discharge

Code:

PMA-540,

ELECTRICAL

SHOCK

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

the capacitor.

NOV 85

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

GROUP

19, Section

7, Page

1

CMRU

GROUP 19 CONTROL (OSCILLATOR) CARD REMOVAL

Plugs

Screw Terminals 1 thru 6

z Plug /

Mounting' Screw

Mounting Screw

SCR

PANEL

IMPORTANT TO PREVENT DAMAGE TO PLUG AND LOCKING'TABS, ALWAYS REMOVE A, B AND Z PLUGS BY PRESSING DOWN ON CENTER TAB OF PLUG WITH A WIDE-BLADE SCREWDRIVER, THEN ROTATE SCREWDRIVER 90° (WHILE PRESSING DOWN) TO PRY (JACK) THE PLUG OUT OF ITS SOCKET. WHEN INSTALLING PLUGS, BE SURE PLUGS ARE PRESSED COMPLETELY INTO SOCKET AND LOCKING TAB POSIT VELY ENGAGED. I

J

26533

GROUP 19, Section 7, Page 2

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

I

Code: PMA-540, NOV 85

GROUP

19

Removal Of Control Card Only Refer to illustration, Page 2.

Disconnect battery (if not removed).

Discharge capacitor.

Remove (disconnect) control wires from screw terminals 1 thru 6 at top of card.

Suggestion: Make a sketch and attach label tags to these wires for correct indentification at assembly.

85M730

Disconnect (unplug) Z plug (large plug at inboard end of card) by pressing down on tab with a wide-blade screwdriver and rotating the screwdriver 90" to pry the plug out of its socket.

85M731 5 Disconnect (unplug) the B plug (small plug near outboard end of card) also by pressing down on tab with a wide-blade screwdriver and rotating the screwdriver 90" to pry the plug out of its socket.

85M733 6 Remove the two mounting screws at base of card (one each end).

85M734

Code: PMA-540, NOV 85

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

GROUP 19, Section 7, Page 3

7 Raise the card slightly and move it towards the center of truck (to clear frame bracket), then remove card from truck.

85M735 IMPORTANT Do not attempt to remove circuit board from black plastic card box which protects it.

85M727 Installation of Control Card 1 Install control card by reversal of above procedures:

l

Put the card in position on the SCR control panel.

l

Install and tighten the card mounting screws.

l

Connect the Z and B plugs. Be sure each plug is pressed completely into the socket and locking tab engaged.

85M732

0 Connect control wires on screw terminals 1 thru 6 and check that they are connected correctly.

GROUP 19, Section 7, Page 4

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

Code: PMA-540, NOV 85

GROUP 19

CMRK SCR CONTROL PANEL ASSEMBLY

REMOVAL

26540

26541 1 Disconnect power cables from their terminals on the SCR panel, and two control wires from Batt Neg terminal at rear corner of SCR panel.

(5 places)(6 cables, 2 wires).

For this procedure, the cables left attached to the terminals contactor panel.

may on

be

2 Remove (disconnect) control wires (in wiring harness attached to contactor panel) from screw terminals 1 thru 6 at top of control card.

Attach label tags to these Suggestion: wires for correct indentification at assembly.

26539

Code:

PMA-540,

NOV 85

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

GROUP

19, Section

7, Page

5

GROUP 19

3 Disconnect (unplug) the B-plug (small plug near outboard end of card) by pressing down on tab with a wide-blade screwdriver and rotating the screwdriver 90' to pry the plug out of its socket.

85M733 4 Loosen and remove the three mounting bolts from base of panel.

85M823 5 Move cable ends out of the way. Then, raise the SCR control panel up and tilt towards the rear to clear frame bracket at the front of control.

85M824 6 Remove the SCR control panel assembly from the truck.

7 Install SCR panel by reversal of above procedures.

IMPORTANT - When installing SCR panel, apply a coating of heat transfer grease to the bottom of the heat sink (SCR panel base) before mounting to counterweight.

85M825

See GROUP 19, Section 1, Page 2.

GROUP 19, Section 7, Page 6

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

Code: PMA-540, NOV 85

GROUP 19 CONTACTOR PANEL ASSEMBLY

REMOVAL

26542 1 Disconnect (unplug) connector in wiring harness from steer trunnion cut-off switches to contactor panel.

85M832

Code: PMA-540, NOV 85

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

GROUP 19, Section 7, Page 7

C19RK

GROUP 19 2 Remove the three bolts mounting contactor panel to the counterweight.

Two of these mounting bolts also hold the steering cutoff switch bracket bar noted below.

85M828 3 Remove the L-shaped bracket bar (with steering cutoff switch bracket and switches attached).

IF SCR CONTROL PANEL NOT REMOVED (OR TO BE LEFT IN TRUCK), the following 4 additional steps (marked *) must also be taken.

Otherwise, proceed to Item 8.

85M834

For removal of contactor panel with SCR panel not removed: *4 Remove (disconnect) control wires from screw terminals 1 thru 6 at top of control card on SCR control.

Suggestion: Attach label tags to these wires for correct indentification at assembly.

1 26539

*5 Disconnect (unplug) the B-plug (small plug near outboard end of control card on SCR control) by pressing down on tab with a wide-blade screwdriver and rotating the screwdriver 90° to pry the plug out of its socket (see page 2).

85M733

GROUP 19, Section 7, Page 8

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

Code: PMA-540, NOV 85

C19RK

GROUP 19

*6 Disconnect two wires (part of wiring harness attached to contactor panel) from Batt Neg terminal on rear corner of SCR panel.

85M737 *7 Disconnect 4 power cables (connected to SCR panel terminals) from terminals on contactor panel.

For this procedure (SCR panel not removed), these cables may be left attached to the terminals on SCR panel.

85M738

TC-RS2 TC-RSl TC- RAl

/’ Code: PMA-540, NOV 85

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

-TC-

LA1

GROUP 19, Section 7, Page 9

GROUP 19 8 Disconnect, from the contactor panel, the power cables which must remain in the truck. Power cables which can be moved with the contactor panel need not be removed.

(9 cables to contactor panel) (‘2 cables to SCR panel, if also removed)

85M83t 9 Disconnect the two power cable leads of the truck receptacle from their terminals on the contactor panel.

26537 10 Disconnect the three wiring harness plug connectors at right hand side of contactor panel.

26538 11 When all necessary power cables have been removed, the contactor panel may be removed from the truck. Raise the panel up and tilt to clear the frame brackets.

(NOTE - Figure 85M831 shows removal of contactor panel after SCR panel has been removed.)

12 Install contactor panel by reversal of above procedures.

GROUP 19, Section 7, Page 10

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

85M831

Code: PMA-540, NOV 85

CLflRls

GROUP 19

GROUP

19

SECTION

8 EV-100 CONTACTOR

l l

Refer to

SCR CONTROL MAINTENANCE

1A CONTACTOR LIFT PUMP CONTACTOR

Systems Diagnostic Manual, SDM-542,

for information on troubleshooting tors with the EV-100 SCR control.

BEFORE ANY ADJUSTMENTS, SERVICING, PARTS REPLACEMENT OR ANY ACT IS PERFORMED REQUIRING PHYSICAL CONTACT WITH WORKING ELEMENTS OR WIRING OF THESE COMPONENTS:

Code:

l

RAISE DRIVE WHEELS OFF THE FLOOR,

l

DISCONNECT THE BATTERY, AND

l

DISCHARGE THE CAPACITOR 1C.

PMA-540, NOV 85

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

of contac-

ELECTRICAL BURNS DISCONNECT THE BATTERY AND REMOVE ALL JEWELRY BEFORE WORKING ON ANY ELECTRICAL SYSTEM. SEVERE BURNS CAN RESULT FROM CONTACT WITH ELECTRICAL SYSTEMS

GROUP 19, Section 8, Page 1

Cl!!RK

GROUP 19 EV-100 SCR CONTROL LIFT PUMP AND 1A CONTACTORS

(Refer

to GROUP

19, Section

1, for additional

information.)

17.222 -8

PUMP

@2

CONTROL

GROUP

19, Section

8, Page

2

PAN EL

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

19-582

Code:

PMA-540,

NOV 85

GROUP 19

DOES NOT INCLUDE ITEMS MARKED “F”

17.007

CONTACTOR

ASSEMBLY,

1A

17.008

CAPSCREW,

1A CONTACTOR

17.101

COIL,

MOUNT I NG

1A CONTACTOR

17.105

SPRING,

1A CONTACTOR

17.112

CONTACT

SET,

17.115

SPRING,

1A CONTACTOR

17.116

SEAT,

1A CONT

17.120

SUPPORT,

17.533

RETAINER,

17.972

LOCK,

17.977

GUIDE,

INSULATOR,

19.494

ARMATURE,

19.919

SHIM,

CONT

ARMATURE

CONT

ARMATURE

1A CONTACTOR

STAT

CONT

1A CONTACTOR

19.516

MOVABLE

1A CONTACTOR

17.979

RETURN

MOVABLE

1A CONTACTOR

BASE,

ARMATURE

1A CONTACTOR

SPRING

ARMATURE

COIL

MOVABLE

CORE

MOVABLE

1A CONTACTOR

STAT

TIP CONT

SUPPbRT

1A CONTACTOR 1A CONTACTOR

1A CONTACTOR 1A CONTACTOR

CORE

65.237

SCREW,

65.238

LOCKWASHER,

1A CONT

90.461

LOCKWASHER,

1A CONTACTOR

91.545

LOCKWASHER,

1A CONT

91.546

WASHER,

1A CONTACTOR

1A

INSULATOR

STAT

TIP

SUPPORT

STAT

TIP

SUPP

MOUNTING

MOVABLE MOVABLE

CORE CORE

INSUL

INSUL

FAST

FASTENER FASTENER FASTENER

CONTACTOR

19-135

Code:

PMA-540,

NOV 85

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

GROUP 19,

Section

8,

Page

3

GROUP

19

17.896

7.899

lg.841 -

92.542

-

lg.637

lbl

17.023

CONTACTOR

17.161

COIL,

17.165

SPRING,

PUMP

17.169

CONTACT

SET,

PUMP

17.172

SPRING,

PUMP

CONTACTOR

17.173

SEAT,

17.182

SUPPORT,

17.534

RETAINER,

ASSEMBLY,

PUMP

PUMP

CONTACTOR

PUMP

CONTACTOR

MOVABLE MOVABLE

CONTACTOR

PUMP

STATIONARY

CONTACTOR

LOCK, GUIDE,

PUMP

CONTACTOR

MOVABLE

17.899

SCREW,

PUMP

CONTACTOR

STAT

19.495

BASE,

19.637

ARMATURE

PUMP

ASSEMBLY, PUMP

19.944

SHIM,

CONTACTOR

LOCKWASHER,

91.551

WASHER,

92.542

LOCKWASHER,

PUMP

MOVABLE

PUMP

INSULATOR,

91.550

CONTACT

CORE CONTACT

CONT

SUPP

INSULATOR

CONTACTOR

19.841

PUMP

SPRING

COIL

17.891

CONTACTOR

CONTACT CONTACT

17.896

PUMP

RETURN

CONTACTOR

CONTACTOR

PUMP

CONTACT

PUMP

PUMP

STATIONARY

CORE

INSULATOR

CONTACTOR

MOVABLE

CONTACTOR P/C

CONTACTOR

CONTACTOR

STAT

MOVABLE CONTACT

CONT

CORE

CORE SUPP

SUPP

FAST

FASTENER

INSUL

FAST

CONTACTOR 19-139

,495

GROUP 19,

Section

8,

Page

4

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

Code:

PMA-540,

NOV 85

GROUP 19

CONTACTOR MAINTENANCE LIFT PUMP AND 1A CONTACTORS

To perform these service procedures, it is recommended that you first: Park truck safely and fully lower the upright.

Apply the parking brake.

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

Turn key switch "OFF".

Disconnect battery from truck receptacle.

Discharge the capacitor 1C. Remove the battery, as necessary, for access to contactor panel. (GROUP 12, Section 1)

85M620 1 Inspect the contactor assemblies.

2 Use an insulated tool, e.g., the handle of a hammer or screwdriver, to push in on the armature shaft and movable contact assembly.

Check for restrictions to movement in the return spring or contact set.

3 Inspect the contact tips for wear and damage. Check for welded tips. Check for dirt, paper and other contaminants or blockage that could disable the tips, i.e., hold the tips separated or unable to make correct electrical contact.

The contact set must be replaced before the contact tips have worn through to the copper base.

IMPORTANT

85M736 IMPORTANT DO NOT STEAM CLEAN ELECTRICAL COMPONENTS. ONLY APPROVED SOLVENTS SHOULD BE USED TO CLEAN CONTROLS AND SCR COMPONENTS. USE CLARK #1801146 DEGREASER (OR THE EQUIVALENT TO MS-180 FREON TF DEGREASER AND CLEANER). PROTECT ELECTRICAL EQUIPMENT WITH CONQUER SPRAY AND SPRAY KOTE.

DO NOT FILE OR USE SANDPAPER ON CONTACTOR TIPS. REPLACE WHEN WORN.

Code: PMA-540, NOV 85

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

GROUP 19, Section 8, Page 5

CLqRK

GROUP 19 CONTACT SET REPLACEMENT To replace contact tips it is not necessary to remove contactor assembly from control panel.

1A Contactor Disconnect power cables (3) from 1A fixed contact set bar terminals. Remove or move other power cables, as necessary, for access to contactors.

85M829

Remove bus bar (lA-P) that connects 1A and pump contactor terminals.

Pump Contactor Also remove power cable (1) from fixed contact set bar terminal, and Remove bolt holding the FUl (500 amp) fuse to pump contactor contact terminal.

(NOTE - Loosen bolt connecting FUl and FU2 fuses, to allow fuse to be moved.)

Refer to GROUP 14, Section 1, and GROUP 19, Section 1, for additional information.

GROUP 19, Section 8, Page 6

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

Code: PMA-540, NOV 85

GROUP 19

CLflRK Removal

of Contact

Tips

Loosen and remove the retaining lock nut, lockwasher, flat washer, spring seat, and spring from the armature bolt of the center movable contact tip set.

Remove

the movable

contact

Loosen evenly the four long bolts that hold the fixed contact set and insulators in assembly.

Observe the position of the short and long contact tip bus bar terminals.

Installation

of Contact

contact

retaining

'

nut

Movable contact

tip set.

Remove the bolts and lockwashers, and two contact tips.

Movable

Fixed contacb

insulators,

Fixed contact1 support

Tips

1 Install new contact tips by reversing above procedure.

Check for correct position of short and long fixed contact bus bar terminals.

2 Tighten the four long bolts of the fixed contact set evenly and gradually until firmly seated.

(Tighten each bolt gradually in sequence to avoid unequal loading and damage to insulator bars.) DO NOT OVERTIGHTEN.

Armature, coil assembly, and base

3 Tighten the armature and movable contact assembly retaining nut firmly.

DO NOT OVERTIGHTEN.

4 Check the armature for free movement.

and movable

contact

set

5 Install FUl power fuse and bus bar (lA-P) that connects 1A and pump contactor terminals.

Connect power cables.

Check all connections for correct installation and tightness.

26536

Code:

PMA-540,

NOV 85

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

GROUP

19, Section

8, Page

7

CLflRU

GROUP

19

GROUP

19 SECTION

9 EV-100

SCR CONTROL

CONTACTOR MAINTENANCE

0 0 0

FORWARD & REVERSE (FA, RA; FB, RB) POWER STEERING CONTACTOR PLUGGING CONTACTOR

Refer to Systems Diagnostic Manual, SDM-542, for information on troubleshooting of contactors with the EV-100 SCR control.

BEFORE ANY ADJUSTMENTS, SERVICING, PARTS REPLACEMENT OR ANY ACT IS PERFORMED REQUIRING PHYSICAL CONTACT WITH WORKING ELEMENTS OR WIRING OF THESE COMPONENTS: l

RAISE DRIVE WHEELS OFF THE FLOOR,

l

DISCONNECT THE BATTERY, AND

l

DISCHARGE THE CAPACITOR 1C.

Code: PMA-540, NOV 85

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

ELECTRICAL BURNS DISCONNECT THE BATTERY AND REMOVE ALL JEWELRY BEFORE WORKING ON ANY ELECTRICAL SYSTEM. SEVERE BURNS CAN RESULT FROM CONTACT WITHELECTRICAL SYSTEMS

GROUP 19, Section 9, Page 1

GROUP

CLSRK

19

EV-100 SCR CONTROL FORWARD AND REVERSE, POWER STEERING, AND PLUGGING CONTACTORS

(Refer to GROUP 19, Section 1, for additional information.)

19.496-J

1

_

19-503

CO.NTROL PAN EL

GROUP 19, Section 9, Page 2

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

Code: PMA-540, NOV 85

GROUP 19

17.532

17.085

17.015

CONTACTORASSEMBLY,FORWARD 6 REVERSE RR

17.017

FASTENER,FWD6 REV CONTACTOR STAT CONT SUPPORT

17.018

CONDUCTOR,FORWARDL REVERSE CONTACTOR

17.020

FASTENER.CONTACTORTERMINAL ANGLE

17.030

FASTENER,i%D 6 REV CONTACTOR STAT CONT COND

17.070

SUPPORT.FWD 6 REV CONTACTOR STATIONARY CONT

17.073

COIL, FORWARD6 REVERSE CONTACTOR

17.084

CONTACT SET, FORWARD 6 REVERSE CONTACTOR

17.085

FASTENER,FWD h REV CONTACTOR STATIONARY CONT

17.087

SPRING, FWD 6 REV CONTACTORMOVABLE CONTACT

17.366

FASTENER,EWD b REV CONTACTOR CONDUCTOR

17.532

CONDUCTOR,FORWARDh REVERSE CONTACTOR

17.589

INSULATOR,FWD h REV CONTACTOR KOUNTING

19.511

ARMATURE,FORWARD C REVERSE CONTACTOR

65.785

CAP,

65.787

GUIDE, FORWARDC REVERSE CONTACTOR ARUATURE

90.192

LOCKWASHER.FUD iiREV CONTACTOR STAT CONT FAST

91.103

LOCRWASRER.FWD C REV CONT STAT CONT SUPP FAST

91.110

LOCKWASRRR.m

93.582

IJXKWASHER.FWD 6 REV CONT CONNECTORBUS FAST

CONTACT INCLUDES

KIT ITEMS

17.087 2 C

FORWARD6 REVERSE CONTACTOR COIL

FORWARD

b REV CONT STAT

AND REVERSE

CONTACT FAST

CONTACTOR

RH

19-17s

Code: PMA-540, NOV 85

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

GROUP 19, Section 9, Page 3

GROUP 19

17.532

65.384

65.787

$-

1

65.384

CONTACTORASSEMBLY,FORWARD 6 REVERSE LB

17.017

FASTF.NER.FWD h REV CONTACTOR STAT CONT SUPPORT

17.018

CONDUCTOR,

17.020

FASTENER,CONTACTORTERMINAL ANGLE

17.030

FASTENER,Ml 6 REV CONTACTOR STAT CONY COND

17.070

SUPPORT,FWD 6 REV CONTACXOR STATIONARYCONT

17.073

COIL, FORWARD6 REVERSE CONTACTOR

17.084

CONTACT SET, FORWARD 6 REVERSE CONTACTOR

17.085

FASTENER,PdD 6 REV CONTACTOR STATIONARYCONT

17.087

SPRING,FWD 6 REV CONTACTORMOVABLE CONTACT

17.366

FASTENER,FWD 6 REV CONTACTOR CONDUCTOR

17.532

CONDUCTOR.FORWARD 6 REVERSE CONTACTOR

17.589

INSULATOR,FUD 6 REV CONTACTORMOUNTING

19.511

AMTURE,

65.785

CAP, FORWARD 6 REVERSE CONTACTOR COIL

65.787

GUIDE, FORWARD 6 REVERSE CONTACTORARMATURE

90.192

LOCRWASHBR,RJD 6 REV CONTACTOR STAT CONT FAST

91.103

LOCKWASHER,FWD 6 REV CONT STAT CON-TSUPP FAST

91.110

LOCKWASAER,FWD 6 REV CONT STAT CONTACT FAST

93.582

LOCKWASHER.FWD 6 REV CONT CONNECTOR BUS FAST

FORWARD 6 REVERSE CONTACTOR

FORWARD 6 REVERSE CONTACTOR

17.030

FORWARD

AND REVERSE

CONTACTOR

LH

19-176

GROUP 19, Section 9, Page 4

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

Code: PMA-540, NOV 85

GROUP 19

.581

17.033

CONTACTOR ASSEMBLY. POWER STEERING

17.230

COIL, POWER STEERING CONTACTOR

17.240

CONTACT SET, POWER STEERING CONTACTOR

17.243

SEAT, POWER STEERING MOVABLE CONTACT SPRING

17.244

SPRING, POWER STEERING CONTACTOR MOVABLE CONT

19.899

ARMATURE, POWER STEERING CONTACTOR

65.052

INSULATOR, P/S CONTACTOR STAT CONTACT SUPPORT

90.080

LOCKWASHER, POWER STEERING CONTACTOR FASTENER

91.539

LOCKWASHER, PWR STRG CONTACTOR CONDUCTOR FAST

91.581

SCREW, POWER STRG STAT CONTACT SUPP INSULATOR

93.145

NUT, POWER STEERING CONTACTOR CONDUCTOR

93.146

NUT, POWER STEERING PUMP CONTACTOR

go.080

--

17.2’10

-

POWER

STEERING

lg.899

PUMP CONTACTOR

19-168 17.230

CONTACT POWER

SET

STEERINQ

CONTACTOR

Code: PMA-540, NOV 85

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

GROUP 19, Section 9, Page 5

CLSRW

GROUP 19

19.621 -

cl

9.623

c 92.396

-4

-65

.279

65.275

-

19.600

CONTACTOR ASSEMBLY. PLUGGING

19.602

COIL. PLUGGING CONTACTOR

19.615

CONTACT SET, PLUGGING CONTACTOR

19.621

FASTENER, PLUGGING CONTACTOR STAT CONDUCTOR

19.623

SCREW, PLUGGING CONT STAT CONT SUPP INSULATOR

19.849

ARMATURE ASSEMBLY, PLUGGING CONTACTOR

65.275

SEAT, PLUGGING CONT MOVABLE CONT ARMATURE SPRG

65.276

SPRING, PLUGGING CONT MOVABLE CONTACT ARMATURE

65.279

INSULATOR, PLUGGING CONT STAT CONTACT SUPPORT

92.393

LOCKWASHER, PLUGGING CONT STAT CONT COND FAST

92.396

LOCKWASHER. PLUGGING CONT STAT CONT SUPP FAST

93.115

NUT, PLUGGING CONTACTOR CONDUCTOR FASTENER

lg.849

PLUGGING

CONTACTOR

19-167

lg.600

CONTACT SET

-1

ASSEMDLY COMPLETE

CONTACTOR

GROUP 19, Section 9, Page 6

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

Code: PMA-540, NOV 85

CLARK

GROUP 19

CONTACTOR MAINTENANCE FA, RA; FB, RB; POWER STEERING, AND PLUGGING CONTACTORS

To perform these service procedures, it is recommended that you first: l

l

Park truck safely and fully lower the upright.

Apply the parking brake.

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

85M620 1 Inspect the contactor assemblies.

Inspect the contact tips for wear and damage. Check for welded tips. Check for dirt, paper and other contaminants or blockage that could disable the tips, i.e., hold the tips separated or unable to make correct electrical contact.

The contact set must be replaced before the contact tips have worn through to the copper base.

IMPORTANT DO NOT FILE OR USE SANDPAPER ON CONTACTOR TIPS. REPLACE WHEN WORN.

Code: PMA-540, NOV 85

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

IMPORTANT DO NOT STEAM CLEAN ELECTRICAL COMPONENTS. ONLY APPROVED SOLVENTS SHOULD BE USED TO CLEAN CONTROLS AND SCR COMPONENTS. USE CLARK #1801146 DEGREASER (OR THE EQUIVALENT TO MS-180 FREON TF DEGREASER AND CLEANER). PROTECT ELECTRICAL EQUIPMENT WITH CONQUER SPRAY AND SPRAY KOTE.

GROUP 19, Section 9, Page 7

GROUP

19 CONTACT SET REPLACEMENT To replace contact tips it is not necessary to remove contactor assembly from control panel. l

Forward and Reverse Contactors (Single-Pole,

Double-Throw

Type

Assembly)

1 Disconnect power cables from top terminals.

Remove or move other power cables, as necessary, for access to contactors.

2 Remove all bus bars contactors.

from

terminals

on

Refer to GROUP 14, Section 1, and GROUP Section 1, for additional information.

19,

Replacing the Fixed and Moving Contacts Disassemble both sections (F,R) of each contactor to replace contact tips.

Before disassembly, take note of each assembly and the position (orientation) of the components and how each part is placed in the assembly.

26553

Upper Fixed Contacts Loosen and remove the two cover mounting screws from coil frame.

Remove the cover.

Be careful not to lose the return spring fitted under the cover.

Loosen and remove the lock nut and lockwasher from each contact stud and remove contact studs from the top cover.

Put new contact studs into top cover, install lockwasher and tighten lock nut firmly on each stud.

26550 I.

GROUP

19, Section

9, Page 8

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

Code:

PMA-540,

NOV 85

CLflRK

GROUP 19

Moving Contacts 4 To replace the moving

the moving contacts, contact assembly.

lift out

5 Hold

(grip) stem of moving contact stud, remove the lock nut, lockwasher, return spring insulator, insulator retaining washer, and the moving contact assembly.

Be careful not to disassemble or lose other parts under the contact tips on armature shaft.

6 Fit new moving contact set on armature shaft, and install insulator retaining washer, return spring insulator washer, lockwasher, and lock nut.

Tighten lock nut firmly.

Lower Fixed Contacts 7 Remove

the lower fixed contacts from the insulator cover on coil, and replace with new contact tips.

Observe position of long and short contact tip bus bars and connecting terminals.

Reassembly 8 Reassemble

the contactor by putting moving contact assembly armature shaft into coil plunger, with return spring on top of armature shaft.

Put top cover over the spring and install cover mounting screws Be sure that return spring into coil frame. is fitted correctly onto the top of moving contact assembly and into recess in the top cover.

Tighten the cover mounting screws.

NOT1CE - When assembling

top covers to the bases, care should be taken to ensure that positive sign (+) markings are facing inwards, i.e., FA/RA (+) towards FB/RB (+), and that contact tip bus bars are placed correctly.

26551

Code:

PMA-540,

NOV 85

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

GROUP

19, Section

9, Page

9

GROUP

CLSRK

19 CONTACT SET REPLACEMENT Power Steering Pump Contactor (Single-Pole, Single-Throw Type Assembly) Remove power cable from top terminal.

Remove bus bar and FU2 (50 amp) fuse connection.

Loosen connecting bolts of the fuses to allow fuses to be moved, or removed, as necessary.

26554

Plugging Contactor (Single-Pole, Single-Throw Type Assembly) Remove power cables and bus bars from top terminals.

Refer to GROUP 14, Section 1, and GROUP 19, Section 1, for additional information.

Replacing the Fixed Contacts Loosen and remove the two cover mounting screws from coil frame. (Observe position of positive sign (+) marking on cover.)

Remove the cover. Be careful not to lose the return spring fitted under the cover.

Loosen and remove the lock nut and lockwasher from each contact stud and remove contact studs from the top cover.

Put new contact studs into top cover, install lockwasher and tighten lock nut firmly on each stud.

Replacing the Moving Contacts 4 To replace the moving contacts, lift out the moving contact assembly.

5 Remove the lock ring from armature shaft and remove the moving contact tips.

Be careful not to disassemble or lose other parts under the contact tips on armature shaft.

26552

GROUP 19, Section 9, Page 10

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

Code: PMA-540, NOV 85

GROUP

CL!!WU

19

6 Fit new moving contact set on armature shaft, and install lock ring.

Reassembly: 7 Reassemble the contactor by putting moving contact assembly armature shaft into coil plunger, with return spring on top of armature shaft. Put top cover over the spring and install cover mounting screws into coil frame. Be sure that return spring is fitted correctly onto the top of moving contact assembly and into recess in the top cover. Tighten the cover mounting screws.

NOTICE - When assembling top cover to the base, care should be taken to ensure that cover is installed with positive sign (+) markings located correctly.

8 When contact tip replacement is completed, instal! all bus bars, etc., and connect power cables. Check all connections for correct installation and tightness.

Code: PMA-540, NOV 85

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

GROUP 19, Section 9, Page 11

GROUP 20

GROUP

20 SECTION

1 DRIVE

Code: PMA-540, NOV 85

AXLE MAINTENANCE

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

GROUP 20, Section 1, Page 1

CWRK

GROUP 20 DRIVE AXLE MAINTENANCE/INSPECTION Access To The Drive Axle

Refer to GROUP 38, Section 3 Machine Jacking and Blocking.

The best procedure to use for access to the drive axle drain plug, and oil level check/ 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.

1 When suitable equipment is available, the truck may be raised by jacking or hoisting up and placed in a level position on wheel cradles to allow access under the axle.

NOTE - Typical truck view shown.

2 Otherwise, when it is necessary to service the drive axle from the front of the truck, the upright carriage may be raised and blocked up to provide access to the axle. Raise the carriage only as high as necessary. l

l

APPLY THE PARKING BRAKE AND BLOCK THE WHEELS. BE SURE TO PUT BLOCKING UNDER THE CARRIAGE AND UPRIGHT RAILS.

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

85M630 NOTE - Cut blocking to the correct length to suit.

" 85M627

GROUP 20, Section 1, Page 2

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

Code: PMA-540, NOV .85

CLSRK DRIVE

AXLE FLUID

GROUP 20

LEVEL

CHECK

Check the drive axle fluid level with: NOT1 CE Truck on a level surface.

0 Oil at operating temperature. l

Check the planned maintenance interval (operating hours), or the condition of the oil to determine if the drive axle fluid needs to be changed.

1 Remove the fluid level inspection/fill plug located in the front surface of each drive unit housing (two places).

2 The oil level is correct (FULL) when the oil reaches to the lower edge of the inspection plug opening.

85M876

IMPORTANT 3 Add recommended fluid only, as required.

Refer to GROUP 40, Sections 4 & 5, for drive axle recommended oil specifications.

After adding oil to the drive axle, wait several minutes until the oil has distributed evenly throughout the unit, and check for correct oil level. DO NOT OVERFILL.

85M874

4 Inspect each fill plug for damage.

Replace as necessary.

5 Install and tighten the plugs.

85M875

Code: PMA-540, NOV 85

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

GROUP '20, Section 1, Page 3

GROUP 20 DRIVE

AXLE FLUID

CHANGE NOTICE

It is recommended to: l

Drain and replace the drive axle fluid every 1000 operating hours.

Extending the recommended intervals at which drive axle fluid is change should be considered only after careful evaluation of your operating conditions and/or analysis of the condition of the oil.

To change oil in the drive axle: l

l

l

l

Frequent changes of lubricant is an inexpensive way to protect and prolong the safe operating life of an essential and relatively costly major component such as the drive axle.

The oil should be drained when it is warmed to operating temperature.

Put the truck in a level position.

Apply the parking brake and block the wheels to prevent the truck from moving.

Turn key switch "OFF" and disconnect battery from truck receptacle.

NOTE - 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, raise the fork carriage only high enough to provide access clearance to the axle. Please refer to procedure described above in "Access To The Drive Axle", page 2.

GROUP 20, Section 1, Page ci

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

Refer to GROUP 38, Section 3, Machine Jacking and Blocking.

Code: PMA-540, NOV 85

C19Rl4

GROUP 20

1 Place a low, flat drain pan beneath the drive units. The pan capacity should be more than [6.6 L] 14 pints (drive axle total capacity).

85M629 2 Remove drain plugs (two) from bottom of drive units, and fill plugs (two) from front of drive units.

85M625 3 While the drive units are draining, check the breather vents (two) to be sure they are open and not damaged. Vents are located in the top front corners of the drive units.

85M633 4 After drive units have drained, install drain plugs. Fill each drive unit to the bottom edge of fill plug opening with recommended fluid.

5 Remove drain pan. lower carriage.

Remove blocking and

85M874

Code: PMA-540, NOV 85

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

GROUP 20, Section 1, Page 5

CLsRw

GROUP

22

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

Cl!!RK

GROUP

22

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

CLqRK MAINTENANCE

GROUP

22 FOR PNEUMATIC TIRES: 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 TIRE TREAD. REMOVE DEBRIS

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

CHECKING, MINOR REPAIR & CLEAN-UP:

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:

q !

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

rd

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.

4 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 THFi 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

GROUP

CLARK

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. I8314 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 ma llet 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.

l-

Fig. 13985 WARN ----

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

CLERK

GROUP

22

////r --

AIR GAUGE

RELIEF

SAFETY CAGE

E/_\

Y/f

--

SHUTOFF VALVE

\\

I I I II,\

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 airhose 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 valve and check the pressure in the tire by reading the gauge. Do not put too much pressure into the tire.

4.

Continue to fill the tire to the correct caoacity.

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

RT

Ai'lT

PUT EQUAL AIR PRESSURE IN BOTH TIRES OF A DUAL ASSEMBLY. DO NOT PUT AIR INTO A TIRE THAT IS FLAT WITHOUT FIRST INSPECTING IT AND THE WHEEL FOR DArqAGE.

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 1123 [1,103 kPa] or 160#\ [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

GROUP

CLSRW

22

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.

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 Fill the tire with nitrogen. pressure.

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

Fig. 18324

Code: PMA-270, REV JUL 80

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

Section 1, Page 11

GROUP

22 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.

! q

CAUTION

USE A LONG HANDLED GAUGE SO THAT YOUR HAND DOES NOT GO INSIDE THE CAGE, OR IN FRONT OF ANY COMPONENT OF A MULTI-PIECE WHEEL.

Section 1, Page 12

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

Code: PMA-270, REV FEB 84

GROUP

CLARK

22

PROCEDURES FOR ADDING AIR PRESSURE TO MOUNTED TIRE AND WHEEL ASSEMBLIES: 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 (Fig. 13761) hub.

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

INDUSTRIAL 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.

PR&CEDURES

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

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 one 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.

12. Do not use undersized rims. the right 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 1142-Z REV only JUL Intended for CLARK dealers 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 long enough to permit the person filling the tire with air to stand to the side of the tire, not in front or in back of the tire assembly.

Always stand to one side when you apply hydraulic pressure.

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

16. 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 lo0 to keep it firmly in place. If it slips off, it can fly with enough force to kill.

1143-ZCopyrighted REV JUZ; 80 Material Intended for CLARK dealers only Do not sell or distribute

GROUP 23

cl!!mw

GROUP

23 SECTION

3 BRAKE BLEEDING

PROCEDURE

(REMOVAL OF AIR FROM BRAKE SYSTEM)

To perform this service procedure, it is recommended that you first: l l l l l

Park truck on a level surface.

Return all controls to neutral and turn key switch to the "OFF" position.

Disconnect battery from truck receptacle.

Apply the parking brake.

Block the wheels.

85M626

Code: PMA-540, NOV 85

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

GROUP 23, Section 3, Page 1

GROUP 23 HYDRAULIC

BRAKE FLUID

AND BLEEDING

INFORMATION

1. Do not mix different types or brands of brake fluid.

12. Before bleeding, make all necessary adjustments to pedal travel and repairs on lines, hoses, cylinders, etc.

2. Do not use brake fluid which is contaminated.

3. Do not use brake fluid that is cloudy, opaque, an emulsion, separated into layers, or contains any moisture.

13. Clean off bleeder screws before bleeding brakes.

14. Do not use brake bleeding equipment for any other purpose.

4. Always store brake fluid in the orig inal container and keep airtight.

15. Use only pressure bleeders which prevent aeration of fluid.

5. Clean the top and cap of brake fluid containers before opening.

16. Be sure that pressure bleeder is in safe operating condition.

6. Do not use (reuse) brake fluid containers for any other purpose.

17. Before attaching pressure bleeder to master cylinder, fill cylinder completely full, and also fill the bleeder hose with fluid.

7. Use only new brake fluid for bleeding and cleaning of brake system parts.

8. Never save or reuse brake fluid once it has been in any brake system.

18. Follow brake bleeding procedures exactly as described.

9. Clean the filler cap and top of master cylinder or reservoir before removing cap.

10. Do not open master cylinder in a dusty area or where rain, snow and other contaminants can enter the fluid.

11. Drain and flush the entire brake system if the fluid in the master cylinder or reservoir looks dirty, cloudy, is emulsified, separated into layers, or contains water or other foreign liquid.

GROUP 23, Section 3, Page 2

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

Code: PMA-540, NOV 85

CLflRl4

GROUP 23

BRAKE BLEEDING NOTICE

PROCEDURE

- The service brake system on this truck model uses conventional SAE/DOT 3 heavy duty automotive hydraulic brake fluid only.

Normally a minimum of brake bleeding will be required. The brake system is designed to place the master cylinder reservoir at the highest point in the circuit. This ensures that the major part of any air that has entered the system will flow upwards and vent into the reservoir. The recommended brake bleeding procedure outlined below is intended to dislodge and remove any entrapped air from the circuit.

IMPORTANT

- Service brake pedal free play must be correctly adjusted before bleeding brakes.

Check frequently and keep master cylinder reservoir filled during bleeding.

Refer to Page 7 for illustration of brake lines installation.

1 Iiemove floorboard.

NOTICE - More space will be available if brake bleeding is performed when battery is removed and front battery plate is adjusted for service access.

Refer to GROUP 38, Section 2, Front Battery Plate Adjustment. ‘,

85M506 2 Remove access cover from pylon.

85M510

Code: PMA-540, NOV 85

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

GROUP 23, Section 3, Page 3

GROUP 23

Clean all dirt and contamination from the reservoir and cap. Check fluid level.

Fill the reservoir and add fluid, as needed, to keep reservoir full during bleeding.

Check brake lines and connections for leakage. Be sure all connections are tightened correctly.

85M645 Release the parking brake during the bleeding procedure.

Check brake pedal for correct adjustment.

Adjust pedal stop screw, as necessary, to provide "free play" of [l,O-3,0 mm] .040--118 inch clearance measured at the stop screw.

85M621 7 Clean the brake bleeder screw.

Brake bleeder screw is located at the top of brake caliper assembly.

85M672 8 It is recommended to install a temporary bleed drain line on the bleeder screw. Use an adequate length of flexible tubing (e.g., clear plastic tubing) having an inside diameter to fit tightly over the bleeder screw opening (to prevent air from entering). This will allow bleeding to be done quickly and cleanly.

If drain line is not used, the bleed screw must be alternatively opened and closed in sequence while bleeding the system, as noted below.

GROUP 23, Section 3, Page 4

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

Code: PMA-540, NOV 85

GROUP 23

CMRK 9 Install bleed drain line on bleeder screw.

Fit the drain line tube only over the outer end of the bleeder screw, leaving wrench clearance at the bottom.

Immerse the open end of the drain line in a jar partially filled with clean hydraulic fluid. Put the jar of fluid in a position above the level of the bleeder screw, and where you can watch for air bubbles in the fluid.

AIR 'BUBBLES

9746 10 Loosen and open the bleeder screw.

(Shown without drain line for ciar ity.)

Al ternate Bleeding Procedure - When bleed drain lines are not installed, the bleed screw must be opened during brake pedal downward movement, and closed before and during brake pedal upward movement, to prevent air from entering the system during pedal return stroke.

85M673 11 Push ("pump") the brake pedal fully down slowlv several times (5-6 times minimum).

When moving the brake‘pedal, be sure tha t the open end of the bleed drain line is always immersed in the jar of hydraulic brake fluid to prevent air from re-enter ing the system. Watch for air bubbles escap ing from the bleed drain line.

Check and fill brake reservoir with recommended hydraulic brake fluid.

85M480

12 Continue brake bleeding until all air is removed from the brake system.

When the bleeding fluid appears to be free of air bubbles, close (tighten) the bleeder screw, and test the brake pedal action.

85M673

Code: PMA-540, NOV 85

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

GROUP 23, Section 3, Page 5

GROUP 23

13 Push on the brake pedal and hold in the fully-down position. Check for a feeling of solid resistance when the brake pedal stops. The pedal must feel firm and not move down farther after it stops.

85M480 14 If the brake pedal motion or feel is not correct: l First, push the pedal fully down several times, with the bleed screw closed. This will give movement to the brake fluid and brake cylinder pistons to aid in dislodging any remaining entrapped bubbles of air.

Wait several minutes. l Then, repeat the bleeding procedure, above. l Test the.brake pedal action.

15 If necessary, repeat the brake bleed ing procedure, until brake pedal action is correct.

NOTICE - If a faulty condition cant inues to exist, a complete inspection and repair of the ,brake system must be made.

See PM Section, Page 5.9, for service brake inspection.

Refer to Overhaul Manual OH-540 for brake removal and overhaul.

16 When brake bleeding is completed satisfactorily: l

Remove bleed drain line and tighten the brake bleeder screw.

l

Check and fill brake reservoir with recommended hydraulic brake fluid.

l

Install the pylon access cover.

Install front battery plate (as req'd).

Install the floorboard.

l l

85M645

GROUP 23, Section 3, Page 6

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

Code: PMA-540, NOV 85

GROUP 23

CLqRK

.23.186

23.175-

HYDRAULIC BRAKE LINES

Code: PMA-540, NOV 85

22.338 22.357 23.150 23.173 23.174

CLAMP, BRAKEFLUID RESERVOIR CAP, RRAKRFLUID RESERVOIR BRAKEtasrRR CYLIRDRR ASSrnLY FITTING, BRAKEHASTER CYLINDER 0Ul’LF.T SW, BRME MASTERCYLINDER OUTLET FITTING

23.175 23.176 23.186 23.225 23.227

FITTING BOLT, BRAKEHASTJiR CYL1NDF.ROUTLRT SEAL, BRMR ffASTER CYLIRTER OUTLFiTFITTING LINR, BRAKRMASTERCYLINDER OUI’LRT FITTING, BOLT, SERVICE BRAKE INLRT SW, SERVICK RRAKE INLET FITTING

23.229 23.231 23.792 23.793 23.194

FITTING, SERVICE BRAKE INLRT SW, SERVICE BRAKRINLRT FITTING FUMRVDIR, BRAKKFLUID FASTENER,BRAKEFLUID RESERVOIR LIRR, BRAKRMSTRR CYLINDER INLET

91.170

NW.

23-262

EIWR FLUID RESERVOIR FASTENER

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

GROUP 23, Section 3, Page 7

GROUP

CLSRU

23

GROUP

23 SECTION

4 PARKING

BRAKE ADJUSTMENT

To perform this service procedure, it is recommended that you first: l l l l l

Park truck on a level surface.

Return all controls to neutral and turn key switch to the "OFF" position.

Disconnect battery from truck receptacle.

Apply the parking brake.

Block the wheels.

Code: PMA-540, NOV 85

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

85M626

GROUP 23, Section 4, Page 1

EMRK

GROUP 23 PARKING

BRAKE ADJUSTMENT

1 Raise and block up the upright carriage, for access to the parking brake adjusting screws. l

BE SURE TO PUT BLOCKING UNDER THE CARRIAGE AND UPRIGHT RAILS.

If you are unfamiliar with this procedure please refer to GROUP 38, Section 3, Machine Jacking and Blocking.

I

85M630

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

Parking

Brake

Caliper

(Puck)

Adjustment

Step 1: Put brake hand lever in released position.

85M519

Step 2: Turn adjusting screw at end of lever counterclockwise to fully release cable tension.

85M648 Step 3: Loosen lock nuts (1) on each adjusting screw (2) on brake caliper body.

Step 4 Adjust screw (2) until brake pads (pucks) just touch brake discs (rotors).

Step 5: Back off adjusting screw (2) one full turn, to give running clearance of brake pad at rotor.

Step 6: Tighten lock nuts (1) securely;

GROUP 23, Section 4, Page 2

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

21189

Code: PMA-540, NOV 85

CLqRw

GROUP 23

Parking Brake Lever Adjustment Step 1: Put lever in released position.

Step 2: Rotate adjusting screw at end of lever clockwise to tighten (increase) cable tension.

Step 3: Test for correct cable tension by applying and releasing lever while adjusting.

85M648 Step 4: Tighten adjusting screw to increase cable tension until lever snap-locks easily into the over-center, brake-applied position.

85M512 Parking Brake Test 1 Test the function of the parking brake after adjustments are completed.

Refer to PM-M section, page 2.6.

A

CAUTION

PARKING BRAKE MUST HOLD TRUCK WITH RATED CAPACITY LOAD ON A 15% GRADE.

NOTICE - If a faulty parking brake condition continues to exist, a complete inspection and repair of the brake system must be made.

See PM section, Page 5.9, for brake inspection.

Refer to Overhaul Manual OH-540, GROUP 23, Section 17, Brake Caliper Assembly Overhaul.

Code: PMA-540, NOV 85

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

GROUP 23, Section 4, Page 3

CLclRW

GROUP

25

GROUP

25 SECTION

5 PYLON

RELEASE

LEVER

Copyrighted Material

Code: PMA-501, MAR 82 P.S.L. Intended for CLARK dealers only Do not sell or distribute

ADJUSTMENT

Section 5, Page 1

CLqRK

GR&up LEVER ADJUSTMENT: 1.

Slowly pull up on the release lever. It must release the pylon when the lever has moved [25,40-31,75 mm] 1.00-1.250 inch from its lock position.

If this distance is not correct, remove the pylon cover.

Fig. 20294 2.

Hold the cable end, and adjust the release lever position by adjusting the nut on the top of the cable. Loosen the lock nut on the release cable. If the lever moves less than [25,40-33,75 mm] 1.00-1.250 inch turn back the adjusting nut. If the lever moves more than this distance, tighten the adjusting nut. Adjust until within specifications, then tighten the lock nut and install the pylon cover.

Fig. 19477

3.

Check the adjustment by raising the release lever when the lever is at the specifications given above. The pylon must move forward by spring action with no restriction. Pull the pylon back to its operating position.

It must lock into position by itself. Install the pylon cover.

Fig. 20283

THE PYLON TILT IS TO GIVE ENOUGH SPACE TO REMOVE THE BATTERY. DO NOT OPERATE THIS MACHINE UNLESS THE PYLON IS LOCKED IN THE FULLY BACK POSITION.

Section 5, Page 2

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

Code: PMA-501, MAR 82 P.S.L.

GROUP 26

cL!ww

GROUP

26 SECTION

1 STEER AXLE TRUNNION

BEARINGS

CHECK AND ADJUSTMENT

To perform this service procedure, it is recommended that you first: l

l

l l

Park the truck on a level surface and fully lower the upright.

Return all controls to neutral, and turn key switch to the "OFF" position.

Apply the parking brake.

Lift and block the truck up to raise the steer axle wheel off the floor.

Refer to GROUP 38, Section 3, Machine Jacking and Blocking.

Code: PMA-540, NOV 85

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

85M775

GROUP 26, Section 1, Page 1

Cl!!!!RK

GROUP 26

DRIVE

STEERING

GROUP 26, Section 1, Page 2

MOTOR

CUT-OUT

LINKAGE

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

Code: PMA-540, NOV 85

CLSRK

GROUP 26

26.224

STEERING

Code: PMA-540, NOV 85

AXLE

26-752

26.224 26.227

FORK. STEER AXLE SEAL, STEER AXLE FORK HOUSING

26.228 26.229 26.234 26.235 26.238

CONE, STEER AXLE FORK LOWER CUP, STEER AXLE FORK LOWER CUP, STEER AXLE FORK UPPER CONE, STEER AXLE FORK UPPER FASTENER, STEER AXLE FORK UPPER BEARING

26.239

SEAL, STEER AXLE FORK COVER

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

GROUP '26, Section 1, Page 3

GROUP 26

STEER AXLE TRUNNION

BEARINGS

CHECK

1 Be sure that truck is parked and blocked up correctly to raise the steer wheel off the floor.

See

CAUTION

note, Page 1.

2 Inspect the steer axle and trunnion for damage and wear.

85M765 3 Check the steer axle trunnion bearings for excessive free-play or looseness.

Hold the steer wheel with both hands and try to move the entire steer axle in the trunnion bearings. Be sure that any movement that you feel is not due to wheel bearing clearance free-play.

If the trunnion bearings have excessive looseness, the bearings require adjustment. Refer to following procedures.

85M747 STEER TRUNNION

BEARING

ADJUSTMENT

1 Open the hood (seat deck/battery compartment cover).

85M616 2 Remove battery from truck, for best access to top of steer.axle trunnion.

Refer to GROUP 12, Section 1, Battery Removal.

85M750

GROUP '26, Section 1, Page 4

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

Code: PMA-540, NOV 85

GROUP 26

3 It is not necessary to remove the hood and counterweight.

However, access to the steer trunnion bearings will be much eas ier if this work is done when the CWT 'and SCR controls are removed.

Some of the following figures show the steer trunn ion with counterwe ight removed for clarity.

85M807 4 If counterweight and SCR controls have not been removed, remove the drive motor cut-out switch assembly which is mounted over the top of the steer trunnion:

1

NOTE - If SCR contra 1s have been removed, proceed to Step 5.

26528 1) Disconnect (unplug) connector in control wiring harness leading from cut-out switches to contactor panel.

85M832 2) Loosen and remove the two mounting bolts, which hold the L-shaped cut-out switch bracket assembly to the contactor panel base plate.

26529

Code: PMA-540, NOV 85

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

GROUP 26, Section 1, Page 5

GROUP 26 3) Remove the L-shaped bracket bar (with steering cut-out switch bracket and switches attached).

85M834 5 Then, remove the cotter pin, loosen and remove castellated nut from rod end ball stud in steering arm, and disconnect steering cylinder rod end from steering arm. This will allow the steer axle to be moved (rotated) freely while adjusting the trunnion bearings.

J

26530 6 Remove mounting bolt which holds drive motor cut-off switch cam plate to top of steer axle trunnion shaft.

7 Remove cam plate from top of trunnion shaft.

85M803

26531

85M804

GROUP 26, Section 1, Page 6

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

Code: PMA-540, NOV 85

CL~RU

GROUP 26

8 Loosen and remove lock nut, then loosen the steer axle trunnion shaft retaining (adjusting) nut.

(Figure 17089 shows typical TM procedure) Loosen the, bearings by rotating the trunnion shaft and/or shaking the steer wheel from right to left. This will unseat or free the bearings from their running position.

85M805

17089

26532 9 Now, tighten the retaining nut to [15-20 N.m] 11-15 lbf.ft. torque (Figure 19498 shows typical TM procedure). Hold steer axle from turning from below while tightening the nut.

Check for free movement of the trunnion shaft and bearings by turning (rotating) the steer axle to the right and left.

19498 10 Check trunnion bearing preload.

Put a torque wrench on the retaining nut.

It should require [Z-3 N.m] 1.5-2.0 lbf.ft. rolling torque to rotate the steer axle in the trunnion bearings. Tighten or loosen the retaining nut to obtain correct preload torque.

19498

Code: PMA-540, NOV 85

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

GROUP 26, Section 1, Page 7

CMR#

GR206UP 11 Install steering cylinder rod end ball stud to steering arm. Tighten nut to [89-103 N.m] 65-75 lbf.ft. torque.

Install cotter pin, spread and bend the ends over.

26530 12 When trunnion bearing preload has been set correctly, install lock nut on trunnion shaft. Tighten to [15-20 N-m] 11-15 lbf.ft. torque. Reference Figure 19498.

85M805 13 Install drive motor cut-out switch cam plate. Be sure dowel pin is correctly positioned in hole in trunnion shaft.

14 Install cam plate mounting bolt. Tighten bolt to [ZO-23 N-m] 15-17 lbf.ft. torque.

85M803 15 Install CWT and SCR controls, if removed.

16 Install the drive motor cut-out switch bracket assembly over center of cam plate on trunnion shaft. Tighten mounting bolts to [ZO-25 N.m] 15-18 lbf.ft. torque.

Refer to GROUP 13, Section 4, if further adjustment of the cut-out switch mounting is required.

17 Connect wiring harness (from cut-out switches to contactor panel).

18 Install battery.

26528

Close the hood.

GROUP 26, Section 1, Page 8

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

Code: PMA-540, NOV 85

GROUP 26

CMRU

GROUP

26 SECTION

2 STEER WHEEL BEARING

MAINTENANCE

To perform this service procedure, it is recommended that you first: Park the truck on a level surface and fully lower the upright.

Return all controls to neutral, and- turn key switch to the "OFF" position.

Apply the parking brake.

Lift and block the truck up to raise the steer axle wheel off the floor.

Refer to GROUP 38, Section 3, Machine Jacking and Blocking.

Code: PMA-540, NOV 85

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

85M775

GROUP 26, Section 2, Page 1

GROUP 26

26.143 26.141 /-

26.224

26.133 26.134 26.135 26.136 26.138

SEAL, STEER WHEEL HUB CONE, STEER WHEEL HUB BEARING (INNER) CUP, STEER WHEEL HUB BEARING (INNER) HUB, STEER WHEEL CUP, STEER WHEEL HUB BEARING (OUTER)

26.139 26.141 26.143 26.224

CONE, STEER WHEEL HUB BEARING (OUTER) FASTENER, STEER AXLE HUB CAP, STEER WHEEL HUB FORK, STEER AXLE

STEER AXLE & HUB ASSEMBLY

26-752

26519 GROUP 26, Section 2, Page 2

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

Cc&r

PMA-540, NOV 85

GROUP 26

STEER WHEEL BEARING

MAINTENANCE

1 Be sure that truck is parked and blocked up correctly to raise the steer wheel off the floor. NOTE - It is optional to raise and block up entire truck.

See CAUTION,

Page 1.

Refer to PM section, Page 6.9, for additional steer axle inspection notes.

26520 2 To check the steer wheel bearings for excessive free play or looseness, hold the wheel with both hands and try to move it by a rocking motion from side to side. Also, try to pull it in and out along the wheel spindle.

There should be a small amount of free movement. The maximum allowable end play is [0,08 mm] -003 inch. If the wheel has excessive end play, the bearings require additional service and/or adjustment.

85M747 Steer

Wheel

Bearing

Adjustment

The steer wheel bearings are retained and adjusted by a self-locking bearing nut.

Step 1: Remove hubcap by tapping lightly on the outer edge of hubcap. (Reference Figure 85M883, shown here with wheel removed).

85M883 Step 2: Loosen spindle (bearing adjusting) nut.

NOTICE - After spindle nut is loosened, hit the top of wheel (tire) to loosen (unseat) the bearings. This moves the bearings free of their seated, running position.

IMPORTANT - Spindle nut should be replaced with a new one each time it is removed because holding torque capability is partially destroyed with each removal.

Code: PMA-540, NOV 85

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

85M892

GROUP 26, Section 2, Page 3

GROUP 26

Step 3: Then, tighten spindle nut to the correct tightening torque while rotating the wheel by hand: Steer Wheel Spindle Nut Torque: [230-244 N.m] 170-180 lbf.ft.

(Reference Figure 21185, showing typical view using torque wrench.)

NOTICE The steer wheel bearings are designed to be correctly adjusted by the specified torque on the self-locking spindle nut.

Overtightening will cause drag and result in lower travel speed and higher power consumption. The specified torque value may require adjustment for some bearing installations.

See Step 5 below.

Step 4: Install the hub cap by tapping into place with a rubber or plastic-faced hammer (Reference Figure 85M891, shown with wheel removed).

85M891 Step 5: Check for correct bearing adjustment by rotating the wheel by hand. Wheel should rotate freely or with only slight "drag". Readjust bearings, as necessary.

85M748

GROUP 26, Section 2, Page 4

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

Code: PMA-540, NOV 85

CLflRK

GROUP 26

Steer Wheel Bearing Lubrication (Clean, repack and adjust bearings) 1 Be sure that truck is parked and b locked up correctly to raise the steer wheel off the floor.

Refer to pages 1 and 3 for additional information.

26519 2 Remove the wheel and tire assemb lY. (Place a block of wood under the tire to prevent rotation of the whee 1 when loosening the lug bolts. Use a pry bar under the tire to help move the wheel on and off the wheel hub.)

85M882 IMPORTANT Because of the heavy weight of the wheel and tire, it is recommended to first remove the wheel when servicing the bearings to avoid damage to the grease seal when the wheel hub is moved on the spindle.

It also makes the work simpler and easier.

85M885 3 Remove hub cap from wheel hub.

4 Clean the excess grease from around the spindle nut.

85M883

Code: PMA-540, NOV 85

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

GROUP 26, Section 2, Page 5

GROUP 26

5 Loosen and remove the spindle nut.

85M884 6 Remove the outer bearing cone.

85M886 7 Pull the wheel hub off the spindle.

Hold the hub firmly to avoid dragging the grease seal at the back side across the threads on spindle end.

85M887 8 Clean the old grease out of center of wheel hub.

9 Clean and inspect the bearing cups and cones for wear and other damage. Replace if necessary. Replace damaged bearing cups and cones as a set.

NOTE - If bearings require lubrication only, repack bearings as noted in Item 1'2, Page 7.

Inspect the grease seal for wear and damage.

Replace as necessary. Refer to Items 10 and 13, Page 7.

GROUP 26, Section 2, Page 6

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

85M888

Code: PMA-540, NOV 85

GROUP 26

CMRK 10 If bearings require replacement, remove

the grease seal and the inner bearing cone, using a brass drift pin or rod to drive the bearing and seal out of the hub.

Grease seal may be first removed by using a puller or prying out of the bore in hub (damage is unimportant; install new seal at assembly). Use a standard puller to remove the bearing cups.

(Figure 26526 shows bearing and seal installation for reference.)

26526

11 Install new bearing cups by pressing into wheel hub. Be sure cups are fully seated in bearing bore.

26521 12 Pack the bearings with grease and install the inner bearing in the hub.

Recommended greasing procedure: 1) Use Grade No. 1 Lithium soap base multipurpose grease, Clark MS-9B or equivalent.

2) Pack bearings with grease before assembly.

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

26527 .3 Install a new grease 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 install seal in hub bore. Carefully tap grease seal into place with a soft-faced mallet until seal face is flush with end of hub.

85M889

Code: PMA-540, NOV 85

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

GROUP 26, Section 2, Page 7

GROUP 26 14 Put the hub on the spindle. Be careful not to damage seal lip when moving the hub over the end of spindle and threads.

85M887 15 Install the outer wheel bearing after it has been packed with grease.

See Item 12, greasing procedure.

16 Install new spindle nut.* *IMPORTANT- Always replace with a new bearing nut. The self-locking capability is partially destroyed when nut is removed.

85M886

17 Tighten spindle nut, while rotat ing the hub by hand, to a torque of: ['230-244 N.m] 170-180 lbf.ft DO NOT OVERTIGHTEN!

85M890 NOTICE - The steer wheel bearings are designed to be correctly adjusted by the specified torque on the spindle nut.

Overtightening will cause drag and result in lower travel speed and higher power consumption. The specified torque value may require adjustment for some bearing installations. See Step 21, Page 9.

GROUP 26, Section 2, Page 8

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

Code: PMA-540, NOV 85

GROUP 26

18 Carefully install the hub cap by lightly tapping into place with a rubber or plastic-faced hammer. Be sure that cap is fully seated. Avoid damage or bending that may cause loose fit.

85M891 19 Install the steer wheel and tire assembly. Use a pry bar under the tire to help move the wheel onto the hub while the lug bolts are being started into place.

85M882 20 Tighten the wheel lug bolts to the correct tightening torque: [255-275 N.m] 188-203 lbf.ft.

(Place a block of wood under the tire to prevent rotation when tightening the mounting bolts.)

85M881 21 Check for correct bearing adjustment by rotating the wheel by hand. Wheel should rotate freely or with only a slight drag felt on the wheel. Readjust bearings, as necessary.

I

22 Remove the blocking and lower the steer wheel to the floor.

85M748

Code: PMA-540, NOV 85

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

GROUP 26, Section 2, Page 9

GROUP 26

GROUP

26 SECTION

3 POWER STEERING RELIEF

SYSTEM

PRESSURE

CHECK

To perform this service procedure, it is recommended that you first: l l l l l

Park the truck on a level surface and fully lower the upright.

Put blocks under the upright rails, and Raise the drive wheels off the floor.

Return all controls to neutral, and turn key switch to the "OFF" position.

Apply the parking brake.

Refer to GROUP 38, Section 3, Machine Jacking and Blocking.

85M743

Code: PMA-540, NOV 85

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

GROUP '26, Section 3, Page 1

GROUP 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 service 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 Overhaul Manual OH-540, GROUP 25, Section 7 for overhaul of power steering control. Also, refer to GROUP 26, Section 14 for overhaul of power steering pump.

1 The power steering system relief valve pressure setting may be checked with a MICO QUADRIGAGE (Clark Part No. 1800106), or a conventional pressure gauge with pressure range scale from [O-20,700 kPa] O-3000 psi.

11156 2 Remove the access cover from the front of the pylon. Use a screwdriver to release the l/4-turn fastener.

85M510 3 The power steering system pressure is checked at the left (L) steer port (upper right-hand side as you face the valve from front of truck) of the control valve located in the steering column pylon.

85M635

GROUP '26, Section 3, Page 2

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

Code: PMA-540, NOV 85

C19RR

GROUP 26

4 Disconnect the steer line from elbow fitting on valve.

5 Remove the elbow fitting and install a temporary Tee, or equivalent fittings (e-g., Clark Part No. 3798165 and 12K5H fittings) in the valve port. ALTERNATE: Install a Tee fitting between the elbow and the steer line.

6 Install the steer line.

85M647

7 Install a diagnostic check gort with quick-disconnect adapter fitting, Clark Part No. 3798166, in the Tee fitting.

(Similar to Figure 19284.)

8 Connect the pressure gauge to the check port fitting.

NOTE - Use quick-disconnect adapter fitting, Clark Part No. 3797029.

& 19284

9 Turn key switch to "ON" position.

10 Release the parking brake.

11 Move direction control lever from neutral to either "FORWARD" or "REVERSE" position.

The steer pump should begin operating.

85M495 12 Turn the 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.

IMPORTANT DO NOT OPERATE SYSTEM OVER RELIEF ANY LONGER THAN NECESSARY TO READ THE PRESSURE GAUGE. 85M524

Code: PMA-540, NOV 85

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

GROUP 26, Section 3, Page 3

GROUP 26 13 When the relief pressure reading has been obtained: 14 Turn key switch "OFF".

15 Move direction control lever to neutral.

16 Apply parking brake.

17 Disconnect pressure gauge, remove the temporary Tee fitting, and install elbow and steer line as initially installed.

Be sure to correctly tighten all fittings.

85M635 18 Install access cover on pylon.

20283 19 Remove blocking from under the upright.

NOTICE - If steering system relief pressure setting is not correct, refer to Overhaul Manual OH-540, for correct maintenance procedures.

GROUP 26, Section 3, Page 4

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

Code: PMA-540, NOV 85

CLqRK

GROUP 26

GROUP

26 SECTION

4 STEER

CYLINDER

LINKAGE

CHECK AND ADJUSTMENT

To perform this service procedure, it is recommended that you first: l

l

l l

Park the truck on a level surface and fully lower the upright.

Return all controls to neutral, and turn key switch to the "OFF" position.

Apply the parking brake.

Lift and block the truck up to raise the steer axle wheel off the floor.

85M774

Refer to GROUP 38, Section 3, Machine Jacking and Blocking.

Alternate Procedure: Also remove the counterweight to facilitate access to and inspection of the steer linkage.

Refer to GROUP 38, Section 1, Counterweight Removal.

85M806

Code: PMA-540, NOV 85

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

GROUP 26, Section 4, Page 1

GROUP 26

26.023 26.01

26.018

---‘-@,*

n

26

25.394 LZb.OSb

STEERING

LINKAGE

25-196

25.080 25.122 25.162 25.387 25.390

ARM, STEERING DRAG LINK ASSEMBLY, STEERING CONTROL LUB FITTING, STEERING LEVER PIVOT, STEERING ARM BEARING, STEERING ARM PIVOT

26.025 26.026 26.028 26.049 26.056

SHIELD, CYLINDER ROD END DUST FASTENER, CYLINDER ROD END ROD END ASSEMBLY, CYLINDER (PISTON ROD END) BALL STUD, CYLINDER ROD END (PISTON ROD END) RETAINER, BALL STlJDHOUSING PLUG

25.391 25.393 25.394 25.443 26.000

BEARING, STEERING ARH PIN, STEERING LINK PIN, STEERING LINK AXLE LEVER, INTERLOCK SWITCH ACTUATOR CYLINDER ASSEMBLY, STEERING

26.057 26.082 26.246 92.745 93.315

LIJB FITTING, STEERING CYLINDER ROD END COVER, CYLINDER ROD END DUST COVER, CYLINDER BALL STUD DUST SHIELD COTTER, POWER STEERING CYLINDER BALL RUT FAST FASTENER, STEERING INTERLOCK SWITCH ACTUATOR

26.015 26.018 26.019 26.020 26.021

SEAT, BALL STUD LUB FITTING, BALL STUD ROUSING STUD, BALL SHIELD, CYLINDER BALL STUD DUST FASTENER, BALL STUD

93.316 93.317 93.318 93.319 93.793

DOWEL, STEERING INTERLOCK SWITCH ACTUATOR RETAINER, POWER STEERING CYLINDER BALL NUT, STEERING LINK PIN (STEERING ARM) NUT, STEERING LINK PIN (AXLE END) WASHER, STEERING ARM PIVOT FASTENER

26.023 26.024

PLUG, BALL STUD HOUSING LOCK, CYLINDER BALL STUD HOUSING PLUG

94.295 95.169 95.170

FASTENER, STEERING ARM PIVOT PIN WASHER, STEERING LINK PIN WASHER, STEERING LINK AXLE PIN

GROUP 26, Section 4, Page '2

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

Code: PMA-540, NOV 85

CLflRl4

GROUP 26

STEERINGLINKAGEINSPECTION Inspect steer cylinder for any damage to rod ends, cylinder barrel, piston rod and rod wiper. Check for excessive looseness in the ball joints. Inspect hydraulic hoses, fittings and connections for leaks and damage. Excessively damaged parts must be repaired or replaced before further adjustments are made.

85M808 Check the condition of steering linkage for bent parts and signs of stress or unusual wear. Check the condition of all steer linkage pivot pins for binding or excessive wear. Repair or replace any parts, as necessary, before making further adjustments.

85M802 3 Check the two pivot pin bolts in each end of the steering link for correct torque.

Tightening torque is [ZO-25 N.m] 177-221 lbf.in.

85M801 4 Check the steering arm pivot bolt mounting steering arm to truck frame for correct torque.

Tightening torque is [240-270 N-m] 177-199 lbf.ft.

85M795

Code: PMA-540, NOV 85

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

GROUP 26, Section 4, Page 3

GROUP 26 5 Check torque on adjustment plug of ball stud on steer cylinder base end.

Remove cotter pin from ball stud housing end, and torque adjustment plug to [25 N.m] 220 lbf.in. Then, back off to first cotter pin hole. Install new cotter pin, spread and bend the ends over.

85M799 6 Check torque on adjustment plug of ball stud on rod end of cylinder.

Remove cotter pin from ball stud housing end, and torque adjustment plug to [lo N.m] 90 lbf.in. Then, back off to first cotter pin hole. Install new cotter pin, spread and bend the ends over.

85M796 7 Check ball stud bolt and nut at each end of the steer cylinder for tight fit and correct torque. Correct nut tightening torque is [89-103 N-m] 65-75 lbf.ft.

Be sure to install the ball bolt and nut, at the base end of cylinder, with the cotter pin in vertical position.

(Also see Figure 85M796 above.)

85M866 8 Check for wear and looseness of the steering arm pivot bearing. Apply an upward and downward force at the steer cylinder rod end attachment to the steering arm. There must be very little or no free movement or looseness of the steering arm relative to the pivot pin or trunnion. If there is, the pivot bearing is worn or damaged and must be replaced.

85M795

GROUP 26, Section 4, Page 4

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

Code: PMA-540, NOV 85

GROUP 26

STEER CYLINDER

ADJUSTMENT

If there is a problem with steering geometry, check the steer cylinder rod end adjustment for correct installed-length of steer cylinder.

, J 25473

1 Move (turn) steer wheel to the left so steer cylinder is fully extended. Measure from the centers of the two ball studs.

Overall length between when cylinder is fully [700 mm] 27.5 inches. is not correct adjust steer cylinder rod.

ball stud centers, extended, should be If installed length the rod end on the

(See Page 6 for enlarged view of linkage.)

85M807

2 Loosen the clamp bolt of rod end on piston rod. Rod end has right-hand thread.

Rotate piston rod to extend or shorten rod end position until correct installed length is obtained.

85M798 3 Tighten clamp bolt in rod end to secure rod end to piston rod, when adjustment is completed. Torque clamp bolt to [40-45 N-m] 30-33 lbf.ft. Be sure grease fitting nipple on rod end is directed toward rear of truck.

Code: PMA-540, NOV 85

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

GROUP 26, Section 4, Page 5

GROUP 26

CLflRK

25473

GROUP '26, Section 4, Page 6

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

Code: PMA-540, NOV 85

GROUP 29

GROUP

29 SECTION

1 HYDRAULIC

SYSTEM

FLUID

AND FILTER

CHANGE

To perform this service procedure, it is recommended that you first: Park truck on a level surface.

Put the upright in a vertical position and lower the lift carriage fully down.

Return all controls to neutral and turn key switch to the "OFF" position.

Apply the parking brake.

Block the wheels.

1 2 3 4 5

85M626

Open the hood.

Remove floorboard.

Remove valve cover from main valve.

Remove battery from truck.* Adjust front battery plate for access.* *See NOTICE, page 3.

85M642

Code: PMA-540, NOV 85

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

GROUP 29, Section 1, Page 1

CMRK

GROUP 29

II

/I

29.728-

3

II

29.768-

,/ 0<\

HYDRAULIC

SUMP

PARTS

29.701

TANK, HYDRAULIC SUMP

29.702

FASTENER, HYDRAULIC SUMP TANK

29.728

CAP, SUMP FILTER

29.766

COVER, SUMP TANK

29.767

SEAL, SUM-P TANK COVER

29.768

FASTENER, SUMP TANK COVER

29.798

SCREEN, HYDRAULIC SUMP PRE-FILTER

29.809

DIPSTICK, SUMP LEVEL

GROUP '29, Section 1, Page 2

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

29-166

Code: PMA-540, NOV 85

C19RK HYDRAULIC

SYSTEM FLUID

GROUP 29

AND FILTER

CHANGE

Please refer to Planned Maintenance Program, PM-540, Pages 6.3, 6.4 and 6.5 for other important information on hydraulic sump tank fluid level check and fluid change. Also refer to GROUP 01, Section 1, Recommended Planned Maintenance Schedule.

There is no drain plug in the hydraulic sump tank. Unless the sump tank is to be removed for other repair or maintenance, the hydraulic fluid can be changed by one of the following methods: A. Removal of the hydraulic sump cover assembly and pumping the fluid out by suction using a separate pump and hose.

B. Pumping the fluid out by using the truck hydraulic system. This method, described below, may be used most easily and satisfactorily for routine changes of the fluid.

1 Remove the floorboard for access to the hydraulic sump and filter.

85M506 2 Remove the cover enclosing the main hydraulic valve for access to the hydraulic system pressure diagnostic check port located on outer right-hand s ide of valve.

NOTICE - Servicing of the hydraulic fluid filter is more eas ily done when the battery is removed and bat tery plate adjusted to the maintenance position. This action moves the filter up where it is more readily accessible.

Refer to PM section, Page 5.8; and GROUP 38, Section 2, Battery Plate Adjustment.

Code: PMA-540, NOV 85

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

85M849

GROUP 29, Section 1, Page 3

GROUP 29 3 Remove the snap-on cap and connect a suitable drain hose line to the diagnostic check port fitting located on side of main hydraulic valve. NOTE - Use quick-disconnect adapter fitting, Clark Part No. 3797029.

85M552

4 You will need a drain pan of [9.8-17 L] '2.6-4.5 gal minimum capacity, or other method of disposal, for collecting the used oil.

Be sure the outlet end of the drain line is directed into the drain pan and held from moving when pressurized.

NOTICE - If battery is removed, use an adapter cable connected between battery and truck receptacle to power hydraulic system.

5 Turn key switch to "ON" position.

6 Move tilt control lever to the back tilt position to start the lift pump. Hold tilt lever in this position until sump tank is emptied. See below.

A steady stream of used hydraulic oil should flow from the drain line.

85M489 7 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.

IMPORTANT BE CAREFUL WHEN SUMP IS NEARLY EMPTIED. WATCH FOR SIGNS OF PUMP CAVITATION. DO NOT OPERATE PUMP AFTER CAVITATION OCCURS.

8 Release the tilt lever immediately when pump cavitation occurs.

GROUP '29, Section 1, Page 4

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

Code: PMA-540, NOV 85

GROUP

CLSRK

29

9 Turn key switch to "OFF" position.

10 Disconnect drain hose from the truck.

11 Replace cap on the hydraulic valve pressure check port fitting.

85M552 12 Remove used hydraulic oil filter.

(Shown with battery plate adjusted for maintenance access.)

13 Install a new oil filter.

IMPORTANT ALWAYS USE GENUINE CLARK PARTS. 85M641 14 Remove the used sump fill cap/breather.

15 Fill sump tank with new fluid.

Hydraulic Sump Tank Capacity, Useable Volume: [9.84 L] '2.6 gal.

Total Volume: [17.0 L] 4.5 gal.

NOTE - Remove or pull dipstick part way out to vent air from tank while filling.

DO NOT OVERFILL. IMPORTANT USE RECOMMENDED FLUID ONLY. Refer to GROUP 40, Sections 4 & 5, for hydraulic oil specification.

Code: PMA-540, NOV 85

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

GROUP 29, Section 1, Page 5

GROUP 29 16

Install

new sump breather cap.

NOTICE - If truck battery is removed and battery plate adjusted for access, install the battery plate. Use an adapter cable for powering the truck when battery is removed (see Page 4).

85M863 17 Turn key switch to "ON' position.

18 Operate the truck hydraulic system.

Cycle the hydraulic system several times.

Raise the lift carriage to the highest position and lower fully down. Check for leaks.

BE SURE THERE IS ADEQUATE OVERHEAD CLEARANCE BEFORE RAISING UPRIGHT. 85M865

19 Turn key switch to "OFF" position.

85M482 20 Check hydraulic sump fluid level again.

Add fluid as required to fill sump to the "FULL" level on dipstick. DO NOT OVERFILL.

21 Install cover enclosing main hydraulic valve.

22 Install floorboard.

23

Install

battery,

as applicable.

85M848

GROUP 29, Section 1, Page 6

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

Code: PMA-540, NOV 85

GROUP 30

CUWW

GROUP

30 SECTION

HYDRAULIC

SYSTEM RELIEF

PRESSURE

CHECK AND ADJUSTMENT

To perform this service procedure, it is recommended that you first: Park truck on a level surface and fully lower the upright.

Put blocks under the upright rails, and Raise the drive wheels off the floor.

Return all controls to neutral and turn key switch to the "OFF" position.

Apply the parking brake.

Refer to GROUP 38, Section 3, Machine Jacking and Blocking.

Code: PMA-540, NOV 85

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

GROUP 30, Section 1, Page 1

GROUP

C19RK

30

HYDRAULIC SYSTEM RELIEF PRESSURE CHECK AND ADJUSTMENT Following is the general procedure for checking and setting main hydraulic valve lift/tilt and auxiliary relief prssure, for all TM 15-20 36-volt trucks.

Refer to GROUP 40, Section 5 for relief pressure specifications.

IMPORTANT IF ADJUSTMENT IS NECESSARY, DO NOT EXCEED THE RELIEF PRESSURE SETTING SPECIFIED FOR THE TRUCK MODEL CAPACITY RATING. CHANGING THE PRESSURE WILL NOT INCREASE LIFTING CAPACITY OR LIFTING SPEED.

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

Hydraulic system relief pressure setting may be checked with a MICO QUADRIGAGE (Clark Part No. 1800106), or with a conventional pressure gauge having a suitable pressure range scale.

To cover all models including TM 20 model with the highest pressure setting, a gauge with a capacity range of [O-27,580 kPa] O-4000 psi minimum, is recommended.

11156 2 First, remove floorboard.

3 Then, remove the enclosing cover from main hydraulic control valve for access to the hydraulic system pressure diagnostic check port located on outer right-hand side of valve. Loosen and remove the two bolts at top front of cover and lift cover out of the truck.

85M534

GROUP 30, Section 1, Page 2

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

Code: PMA-540, NOV 85

CLflRU

GROUP 30

4 Remove the snap-on cap and connect the pressure gauge to the check port fitting on outside of main hydraulic control valve.

NOTE - Use quick-disconnect adapter fitting, Clark Part No. 3797029.

85M552 5 Turn key switch to "ON" position.

85M483 6 Move tilt control lever to the full backtilt relief position. Hold tilt lever in relief position until pressure reading is obtained, and then release.

IMPORTANT DO NOT OPERATE SYSTEM OVER RELIEF ANY LONGER THAN NECESSARY TO READ THE PRESSURE GAUGE. 85M551 If relief pressure is not correct, refer to the following adjustment procedure.

Relief Pressure Adjustment 1 On the main valve, the hydraulic system relief valve (1) and auxiliary relief valve (2) adjustment screws are shown in Figure 83M477.

83M477

Code: PMA-540, NOV 85

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

GROUP 30, Section 1, Page 3

GROUP 30 2 The relief-pressure adjustment screws are located at the top front side of the main hydraulic valve.

To adjust, loosen the lock nut, reset and tighten lock nut. Turn adjustment screw clockwise to increase pressure. Turn counterclockwise to decrease pressure.

85M851 3 When either main hydraulic system or auxiliary relief pressure needs to be adjusted: Step 1: Loosen the lock nut.

Step 2: Hold the respective (tilt or aux) control lever in relief position.

85M489 Step 3: Turn the relief pressure adjustment screw until pressure gauge reads the correct relief pressure setting.

Step 4: Tighten the lock nut.

85M550 4 Check relief pressure setting. Move the tilt lever to relief position and read the pressure gauge. This is to verify that relief pressure setting has not been changed during tightening of the lock nut.

85M551

GROUP 30, Section 1, Page 4

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

Code: PMA-540, NOV 85

CLsRK

GROUP 30

5 If relief pressure setting is not correct, repeat the adjustment procedure.

85M550 6 When relief pressure setting is correct, turn key switch to "OFF" position and disconnect the pressure gauge. Put the cap on quick-disconnect fitting.

85M851 7 Install the cover enclosing the main valve.

8 Install floorboard.

85M617

Code: PMA-540, NOV 85

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

GROUP 30, Section 1, Page 5

CL9RK

GROUP 31

GROUP

31

SECTION

1

Code: PMA-540, NOV 85

HYDRAULIC

SYSTEM

SCHEMATIC

DIAGRAM

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

GROUP 31, Section 1, Page 1

GROUP

CLqRK

31

HYDRAULIC SYSTEMSCHEMATIC DIAGRAM TM 15-20 36-Volt

STEER I

CYLINDER I

m,FT

’

HI-VIS

STD

CYLINDER

-------

LIFT CYLINDER

TILT CYLINDER

i ~~~~~~-_~--_____--~-L

i___

-OUTLET

r

-.-I

JLET

P

,TEER

PUMP

r-

INLE

iI

LIFT PUMP

k )(

r--

,”

)(

SUMP

TANK

_;

1

UTI

I

c

STD. TRUCK DIAGRAM TWO SPOOL VALVE

IN-19169B

GROUP 31, Section 1, Page 2

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

Code: PMA-540, NOV 85

GROUP

31

31.028 U ONLY)

MAIN

HYDRAULIC

AND

LIFT

LINES

31-618

31.036

FITTING, HYDRAULIC VALVE INLET PORT

LINE, HYDRAULIC PUMP INLET

31.037

FITTING, HYDRAULIC VALVE DISCHARGE PORT

31.007

LINE, PUMP INLET

31.038

SEAL. HYDRAULIC VALVE DISCHARGE FORT

31.008

FITTING, HYDRAULIC PUMP INLET PORT

31.109

LINE, HYDRAULIC VALVE DISCHARGE

31 .OlO

SEAL, HYDRAULIC PUMP INLET PORT

31.195

LINE, VALVE TO SUMP RETURN

31.013

SEAL, HYDRAULIC PUMP OUTLET PORT

31.200

FITTING, HYDRAULIC VALVE LIFT PORT

31.014

FITTING, HYDRAULIC PUMP OUTLET PORT

31.387

CLAW,

31.018

LINE, HYDRAULIC PUMP OUTLET

31.395

CAP, LIFT CYLINDER VENT SUMP INLET

31.023

SEAL, HYDRAULIC VALVE INLET PORT

31.421

SEAL, PUMF OUTLET PORT FITTING

31.026

SEAL, HYDRAULIC VALVE LIFT PORT

31.627

SEAL, LIFT VALVE RETURN PORT

31.028

CLIP, VALVE OUTLET LINE SUPPORT

31.628

SEAL. LIFT VALVE INLET PORT

31.030

LINE, HYDRAULIC VALVE LIFT

28.838

SEAL,

31.006

HYDRAULIC VALVE LIFT PORT FITTING

Code: PMA-540, NOV 85

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

VALVE TO SUMP RETURN LINE

GROUP 31, Section 1, Page 3

GROUP

CLqRK

POWER

!6.652 28.500 28.760 26.795 28.801 20.839 28.840 29.000 29.002 29.014 29.015 31.043 31.044 31.047 31.050 31.098 31.100 31.102 31.104 31.115 31.120 31.122 31.138 31.139 31.147 31.149

STEERING

FASTENER, POWER STEERING LINES CLAM HOSE COUPLING, FILTER INLET LINE SEAL, STEER VALVE OUTLET PORT PROTECTOR, POWER STEERING LINES SEAL, HTDRAULIC PUMP OUTLET FORT FITTING SEAL, STEER CYLINDER ROD PORT FITTING SEAL, STEER CYLINDER ANCHOR PORT FITTING FILTER, HYDRAULIC OIL FASTENER, HYDRAULIC OIL FILTER BRACKET, HYDRAULIC OIL FILTER MOUNTING FASTENER, HYDRAULIC OIL FILTER MOUNTING BRACKET FITTING, HYDRAULIC OIL FILTER INLET PORT SEAL, HYDRAULIC OIL FILTER INLET PORT SEAL, HYDRAULIC OIL FILTER OUTLET PORT FITTING, HYDRAULIC OIL FILTER OUTLET PORT CLAMP, STEER PUKF INLET HOSE LINE, STEER PUMF INLET FITTING, STEER PUMF INLET PORT FITTING, STEER PUMP OUTL.ETPORT LINE, STEER PUW OUTLET LINE, SUMP RETURN HOSE COUPLING. POWER STEERING RETURN LINE FITTING, STEER VALVE OUTLET PORT FITTING, STEER VALVB OUTLET PORT LINE, STEER PUMP INLET FITTING, STEER VALVE INLET PORT

GROUP 31, Section 1, Page 4

LINES

31.150 31.164 31.373 31.399 31.449 31.460 31.461 31.462 31.465 31.466 31.479 31.499 31.606 31.664 31.666 31.667 31.668 31.669 31.670 31.749 31.793 31.885 90.764 93.275 93.276 93.277

26-144

FITTING, STEER VALVE DISCHARGE PORT LINE, STEER VALVE DISCHARGE SFiAL,STEER PUKF OUTLET PORT SEAL, STEER VALVE DISCHARGE PORT SEAL, STEER PUMP INLET PORT SEAL, POWER STEERING INLET PORT SEAL, STEER VALVE DISCHARGE PORT SEAL. STEER VALVE OUTLET PORT SEAL, STEER VALVE OUTLET PORT SEAL, STEER VALVE INLET PORT CLAXP. POWER STEERING LINES FASTENER, POWER STEERING LINES CLAMP LINE, STEER PUMP INLET LINE, STEERING CYLINDER ANCHOR END FITTING. STEERING CYLINDER ANCBOR FORT SEAL, STEERING CVLINDER ANCHOR PORT LINE. STEERING CYLINDER ROD END FITTING, STEERING CYLINDER ROD PORT SEAL. STEERING CYLINDER ROD PORT CLAMP, POWER STEERING LINES CLAKF, FOVER STEERING LINES HOSE COUPLING, STEER PUMF RETURN NUT, POWFiRSTEERING LINE CLAMF FASTENER NUT, HYDRAULIC OIL FILTER MOUNTING BRACKET FAST NUT, HYDRAULIC OIL FILTER FASTENER NUT. POWER STEERING LINES CLIP FASTENER

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

Code: PMA-540, NOV 85

CLSRK

GROUP

32

GROUP

32 SECTION

1 TILT

Code: PMA-500, FEB 80

CYLINDER

ADJUSTMENT

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

Section 1, Page 1

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

TILT CYLINDER RACKING ADJUSTMENT: 1.

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 racking adjustment.

Fig. 20280 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 racking. Forward racking must be adjusted before backward racking. If forward adjustment is not needed, continue with Step 5.

: s h,

Fig. 19495 3.

Loosen rod end clamp bolt, on the tilt cylinder, that extends the farthest, and turn piston rod.

4.

Continue to turn rod into rod end until upright racking is corrected. Tighten rod end clamp bolt.

5.

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.

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.

7.

After the excess space is taken up by the adjusting shims, test the full forward and backward tilt for proper adjustment.

Section 1, Page 2

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

Fig. 19496

Fig. 19497

Code: PMA-500, AUG 80 REV

GROUP

ELfIRK

32

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

CMRK

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, tiien 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

El!‘VlK

34

GROUP

34 SECTION

1 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 1

GROUP

CMRK

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:

!

•1

WARNING __-----

TO AVOID INJURY, DO NOT GET UNDER THE LOAD AND CARRIAGE WHEN CHECKING THE CHAINS OR MAKING ADJUSTMENTS.

1.

Elevate carriage to about [1219 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 C12.7 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

GROUP

clmu

34

GROUP

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

C19RK

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 a roximately 1 degree from vertical) Shut off the truck. itP!he same time .

Turn key switch to the "OFF" position.

I

I & 12 TO 15 INCHES t

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.

Section 3, Page 2

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

Fig. 14887

Code: PMA-510, REV FEB 84

CLqRK

GROUP 34

GROUP

34 SECTION

4 FORK MAINTENANCE

FORKS ARE AN IMPORTANT SAFETY ELEMENT OF THE LIFT TRUCK. THEY MUST BE CAREFULLY INSPECTED AT EACH PM INTERVAL AND ALWAYS MAINTAINED IN A SAFE CONDITION. FORKS THAT ARE BENT OR TWISTED WILL CAUSE THE LOAD TO SHIFT OR SLIDE OFF AND BE DROPPED. FORKS THAT ARE CRACKED OR WORN EXCESSIVELY CAN BREAK SUDDENLY AND CAUSE SEVERE INJURY OR DEATH.

Code: PMA-540, NOV 85

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

GROUP 34, Section 4, Page 1

GROUP 34

FORK MAINTENANCE 1 Inspect the lift forks for cracks, breaks bending, and wear. Check for cracks and wear all around the fork heel area.

Move the fork blades together (side-byside). Check the fork blades for bent or twisted condition, with respect to each other and also to the fork shank.

18046 2 The fork surfaces should be level and even with each other. The height difference between both fork tips should be no more than [6mm] 0.25 inch maximum.

25455 3 Inspect the forks carefully for twists and bends. Put a 2"x4"~24" metal block on the blade of the fork with the 4" surface against the blade. Put a carpenter's square on the top of the block and against the shank of the fork. Check the fork 18" above the blade to be sure it is not bent more than specified in the chart below.

lade

25456 Fork

Blade

Bending

Chart Allowable "Y" value (inches) for fork blade lengths 60" blade 54" blade 48" blade 42" blade

Fork Size Cross-section

I

I

GROUP 34, Section 4, Page 2

I

l-15/16 31132

l-9116 25132

l-1/4 518

15116 I/2

1-1/2x4 1-3/4x5

I

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

1

I

Code: PMA-540, NOV 85

C19RK

GROUP 34

FORK WEAR INSPECTION NOTICE - At each planned maintenance interval, an inspection and measurement of the forks must be made to check for wear.

REFER TO FIGURE 25457 BELOW.

25457

1

Allowable wear of fork thickness at the heel of the fork is as follows: Forks must be scheduled for replacement.

10% WEAR (90% thickness remaining): With 10% wear, the forks are adequate for only 80%,of rated capacity. Forks may by used only until replacements are available.

20% WEAR (80% thickness remaining): from service immediately.

Forks are unsafe and must be removed

WEAR FACTOR CHART * NEW * Standard Fork Thickness, inches 1.25 1.50 1.75 2.00 2.25 2.50

** REPLACE ** Nominal 10% Wear Thickness, inches 1.12 1.38 1.56 1.81 2.00 2.25

*** SAFETY HAZARD *** Nominal 20% Wear Thickness, inches 1.00 1.19 1.38 1.62 1.81 2.00

NOTE - The percent capacity reductions are based upon wear only.

Other factors such as cracks, cuts, holes, etc., may further reduce fork capacity.

Code: PMA-540, NOV 85

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

GROUP 34, Section 4, Page 3

C19RK

GR304

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 1

CMRK

GR304UP CONTENTS: LIFT CHAIN INSPECTION II. LIFT CHAIN LUBRICATION III. LIFT CHAIN REPLACEMENT IV. CHECK LIST

I.

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 Chains need periodic mainresult of poor maintenance. tenance to give maximum service life.

Section 7, Page 2

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

PMA-416, REV MAR 82 P.S.L

C19RK I.

GROUP

34

LIFT CHAIN INSPECTION:

Inspect and lubricate the lift chains every truck PM (50-250 hours). See Section II for lubrication details.

When operating in corrosive environments, inspect the cha ns every 50 hours.

The maintenance person doing the inspection should look for the following chain condit ons.

1. Wear __ 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 corroIt is sion causes sideplate cracking. 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.

Intended for CLARK dealers only Code: PMA-416, REV FEB 84 P.S.L. 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.

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.

Applications where corrosion is 3. 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 dealers only Code: 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 Peening of plate edges may components. be caused by worn sheaves, very heavy loads, or the chains sliding past a Such conditions guide on the upright. 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.

Example 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 See Fig. 23831. are no longer aligned.

Chains with turned or raised pins must be replaced immediately. -Do not repair the chain by pushing pins back into the chain.

Fig. 23831

Code: PM&416,

Copyrighted Material

Intended for CLARK dealers only REV MAR 82 P.S.L. Do not sell or distribute

Section 7, Page 5

GROUP

CLflRK

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.

8. 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.

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: Keep joint wear (chain wear) to a 1. 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.

C19RK

GR304

Use Clark Chain and Cable Lube f/886399 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.

I

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.

Copyrighted Material

Section view of leaf chain showing bearing surface (area between O.D. of pin and I.D. of plate holes).

Fig. 18384

Code: PMA-416, REV MAR 82 P.S.L. Intended for CLARK dealers only Do not sell or distribute

Section 7, Page 7

GR304UP 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 available 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 #886399.

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 Paint will help prevent installation. 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 Tight Joints 4.

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 8886399 Lubricate full length of all 2. strands.

C.

LIFT CHAIN REPLACEMENT: 1 All chains must be replaced if 1. any strand has wear of 3% or more or if any of the conditions listed in Section I are found during inspection.

Order replacement chains from 2. your Clark Dealer.

Replace all chains as a set.

3.

Do not remove lubricant or 4. 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 Code: only FM&416, Do not sell or distribute

REV MAR 82 P.S.L.

GR304

CLSRH

ROLLER AND ROLLERLESS CHAIN Rollerless Chain No.

Roller Chain No.

40 50 60 80 100 120 140 160 200

45 55 65 85 105 125 145 165 205

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

Worn Chain Length

Span inch inch inch inch inch inch inch inch inch

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]

Span

0.500 inch 0.625 inch 0.750 inch 1.000 inch 1.250 inch 1.500 inch 1._750inch 2.000 inch

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 CHAIN LENGTH - The distance from the first pin counted to the last pin counted in a span while the chains have lifted a small load.

Copyrighted Material Intended for CLARK dealers only Code: PMA-416, REV MAR 82 P.S.L. Do not sell or distribute

Section 7, Page 9

PROCEDURE TO CHECK FOR CHAIN WEAR: (See Page 11, also) 1.

2.

3.

4.

EXAMPLE OF THE CHECK FOR CHAIN WEAR:

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.

C. Count the number of pins needed 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 dealers only Code: Do not sell or distribute

PMA-416, REV MAR 82 P.S.L.

CLSRK

GROUP

34

Measuring BL846

1.

2.

chain for wear, using tape measure Fig. 23832

New Chain Length Worn Chain Length

3.

4.

Span Pitch

Copyrighted Material

Code: PMA-416,

REV MAR 82

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

Section 7, Page 11

GROUP 38

CMRK

GROUP

38 SECTION

1 COUNTERWEIGHT

REMOVAL

IMPORTANT The counterweight must be in good condition and securely attached to the lift truck.

Because of its heavy weight and bulky mass, the counterweight must be carefully supported and handled.

Always store counterweights at floor level in a stable position to be sure they will not fall or tip causing either damage or injury.

REMOVING THE COUNTERWEIGHT CAN CAUSE LIFT TRUCK TO BE UNSTABLE. DO NOT OPERATE A LIFT TRUCK OR HANDLE LOADS WITH THE COUNTERWEIGHT REMOVED. FAILURE TO FOLLOW THIS MESSAGE CAN RESULT IN SEVERE INJURY OR DEATH.

To perform this service procedure, it is recommended that you first: l l l l l

Park truck on a solid, level surface.

Lower forks or attachment fully down.

Put all controls in neutral and turn key switch to the "OFF" position.

Apply the parking brake.

Put chocks at the drive wheels.

Code: PMA-540, NOV 85

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

85M626

GROUP 38, Section 1, Page 1

GROUP 38

FRAME

GROUP 38,

Section

1,

AND

COUNTERWEIGHT

38.020

FRAME ASSEMBLY

38.869

COUNTERWEIGHT, REAR

38.870

FASTENER, COUNTERWEIGHT

38.871

FASTENER, COUNTERWEIGHT

38.876

FASTENER, AUXILIARY COUNTERWEIGHT

38.886

COUNTERWEIGHT, AUXILIARY

30.895

RETAINER, AUXILIARY COUNTERWEIGHT

91.204

NUT, COUNTERWEIGHT FASTENER

Page 2

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

38-194

Code: PMA-540, NOV 85

CUIRK

GROUP 38

NOTICE The following components must be disassembled or removed before counterweight can be removed.

1 Battery (See GROUP 12, Section 1.).

2 Hood (GROUP 39, Section 2').

85M781

3 Overhead guard (GROUP 39, Section 1).

85M793 4 Disconnect power cables to SCR controls (See GROUP 19, Section 7).

85M739 5 SXR controls (optional depending on need).

I.f counterweight is to be repaired or -eplaced: Refer to GROUP 19, Section 7, lontrol Panel Removal.

NOTE - If counterweight is to be removed only for access to service other components, the SCR controls may be left installed on the CWT. Disconnect power cables only (Item 4 above).

85M831

Code: PMA-540, NOV 85

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

GROUP 38, Section 1, Page 3

GROUP 38

COUNTERWEIGHT

REMOVAL

Cou'nterweiqhts can be removed by one of two methods: 1) Using a hoist or overhead crane, or 2) using another lift truck as a hoist.

BOLTS, SECURE COUNTERWEIGHT FOR REMOVAL. DO NOT REMOVE WITH BLOCKS UNDER COUNTERWEIGHT SUPPORTING TRUCK. FAILURE TO FOLLOW THE PROCEDURES AS SHOWN IN THIS MANUAL CAN RESULT IN SEVERE INJURY OR DEATH. I

See NOTICE, Page 3, for truck components which must be disassembled before counterweight can be removed.

MINIMUM TOOLS REQUIRED: Refer to GROUP 40, Section 2, Suggested Equipment for Electric Truck PM, for information on load capacities for various styles of hoisting chains and slings

Wheel blocks.

Eye bolts.

Lifting chains, sling or spreader bar.

Torque wrench, [O-1356 N.m] O-1000 lbf.ft. capacity.

Overhead hoist, with adequate capacity to lift the load.

I

ALL TOOLS AND LIFTING COMPONENTS USED IN THESE PROCEDURES MUST BE IN GOOD CONDITION, MEET THE LIFTING CAPACITY REQUIREMENTS, AND HAVE OSHA APPROVAL LABELS WHEN REQUIRED.

GROUP 38, Section 1, Page 4

I

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

1

Refer to GROUP 40, Section 5, Truck Specifications, for information on counterweight weights.

Code: PMA-540, NOV 85

GROUP 38

CMRK Counterweight Removal Using A Hoist Or Overhead Crane IMPORTANT Use lifting hooks with safety latches to prevent hook from slipping from the lifting eye.

25432 1 Move the lift truck as required into the correct position under the hoist. APPLY the parking brake and put blocks at the front and rear of drive wheels.

NOTE - Some illustrations show typical procedures as applicable to TM.

25433 2 Install lifting chains, sling or spreader bar on the hoist hook.

J

1

25434 3 Install eye bolts in the lifting holes of the counterweight (overhead guard rear leg mounting holes at top of CWT).

Bolt thread size:

Ml2 [12 mm]

85M809

Code: PMA-540, NOV 85

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

GROUP 38, Section 1, Page 5

CMRK

GROUP 38 4 Attach the lifting chain hooks to eye bolts in counterweight.

Raise hoist as necessary to remove (take up) slack in lifting chain to support the weight of the counterweight.

85M810 5 Remove the counterweight mounting bolts.

Refer to illustration, page 2.

26522 6 Lift counterweight from the truck.

85M811 7 Move counterweight away from the truck.

Refer to Page 10 for counterweight inspection procedure.

85M812

GROUP 38, Section 1, Page 6

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

Code: PMA-540, NOV 85

GROUP 38

8 Move counterweight for storage.

It is recommended to use a load platform (pallet, or equivalent) of adequate (correct) construction and capacity for temporary or permanent storage, and for movement (transport) of the counterweight.

25436 9 Carefully lower the counterweight onto the load platform or floor.

When storing on a platform or the floor, always put the counterweight in a stable condition with the broad, flat side down.

25437 10 Remove the lifting chains or sling.

Remove the eye bolts if counterweight is to be stored permanently (not immediately used).

25438 11 If counterweight must be stored on its curved side for inspection or servicing, be sure to put adequate blocking at each side to prevent rolling or shifting.

Code:

PMA-540,

NOV 85

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

GROUP

38, Section

1, Page 7

GROUP 38 Counterweight Removal Using Another Lift Truck As A Hoist NOTE - It is recommended that this procedure be conducted by a crew of two.

One crewmember should attend the counterweight while the other operates the hoist truck.

Refer to GROUP 40, Section 5, Truck Specifications, for information on counterweight weights.

Be sure that hoist lift truck has enough capacity to lift the counterweight.

Move the lift truck into a convenient position with adequate clearance for maneuvering of the hoist truck.

Be sure that the parking brake is applied and blocks put at the front and rear of drive wheels.

25433 3 Install lifting chains, sling or spreader bar on the forks of the hoist truck. Be sure to wrap chain around the forkbars to prevent hoist chain from slipping off the tip of the fork.

25440 4 Install eye bolts in the lifting holes of the counterweight (overhead guard rear leg mountin_g bolt holes).

85M809

GROUP 38, Section 1, Page 8

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

Code: PMA-540, NOV 85

CLflRK

GROUP 38

5 Attach the lifting chain hooks to the eye bolts in counterweight.

Raise the forks of the hoist truck, as necessary, to take up (remove) slack in lifting chains.

25474 6 Loosen and remove counterweight mounting bolts. Refer to illustration, page 2.

Be sure that forks of hoist truck are adjusted to remove all slack in the lifting chains and pick up (support) the weight of the counterweight before bolts are removed.

85M866 7 Carefully lift counterweight from the truck.

CAUTION- Stand away from the path of the counterweight as it is being lifted and moved. Watch the lifting chains and hooks for any unusual twisting or movement. DO NOT WALK OR STAND UNDER THE FORKS. 25441 8 Move the truck slowly to prevent swinging of the counterweight.

25442

Code: PMA-540, NOV 85

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

GROUP 38, Section 1, Page 9

GROUP 38

9 Refer to previous procedures for moving and storing counterweight, pages 6 and 7.

25438 Counterweight Inspection Perform a complete inspection of the entire counterweight when it is removed from the truck.

The inspection may most easily be made while the counterweight is supported by the hoist during removal. LOWER THE COUNTERWEIGHT TO THE FLOOR. BE CAREFUL WHEN NEAR A COUNTERWEIGHT WHILE IT IS ATTACHED TO A HOIST. DO NOT WALK OR STAND UNDER RAISED FORKS.

25443

Inspect all surfaces for damage and cracks, particularly the inner areas which may be inaccessible when installed. Carefully check all areas around bolt holes, openings and cast-in thread inserts for loose sections of material, looseness of the inserts, and damaged threads. Inspect the mounting bolts for worn condition and damaged threads.

GROUP 38, Section 1, Page 10

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

Code: PMA-540, NOV 85

CLsRK Counterweight

GROUP 38

Installation

1 Apply the parking brake and put blocks at the front and rear of drive wheels.

2 Move and position the counterweight correctly near the truck.

25441 3 Install eye bolts in the lifting holes (OHG mounting holes) of the counterweight.

25446 4 Attach the lifting chain hooks to the eye bolts in counterweight.

Be sure that the lift hooks are correctly installed and latches are undamaged and operating correctly. Raise hoist (or hoist truck forks) to take up (remove) slack in the lifting chains.

25437 5 Carefully operate the hoist (or hoisttruck) to lift and move the counterweight.

Keep the counterweight close to the floor while moving. Move the hoist (or truck) slowly to avoid swinging of the counterweight.

25442

Code: PMA-540, NOV 85

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

GROUP 38, Section 1, Page 11

CLARK

GROUP 38 6 Carefully raise the counterweight into position and align the nounting holes.

IMPORTANT Do not use substitute, defective or incorrect mounting bolts. Be sure that the mounting bolts are undamaged and have the correct material (strength Replace and hardness) specification. worn or defective bolts with genuine Clark parts.

I

FASTENERS WHICH ARE NOT CLARK O.E.M. PARTS MAY NOT HOLD COUNTERWEIGHT SECURELY. USE ONLYORIGINAL EOUIPMENT FASTENERS WHEN INSTALLING CLARK COUNTERWEIGHTS. TORQUE TO SPECIFICATIONS SHOWN IN MANUAL. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SEVERE INJURYOR DEATH.

7 Install the counterweight mounting bolts (one outer and two inner) and tighten sufficiently to draw the counterweight into position. Check the counterweight for correct position and alignment when the bolts are being tightened.

Tighten the inner and outer bolts evenly in sequence to draw the counterweight into place.

26523

GROUP 38, Section 1, Page 12

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

Code: PMA-540, NOV 85

CLflRK

GROUP 38

8 Tighten inner counterweight mounting bolts to correct torque specification.

Mounting Bolt Tightening Torque: [340-380 N.m] 251-280 lbf.ft.

85M650 9 Tighten outer counterweight mounting bolt to correct torque specificatiion.

Mounting Bolt Tightening Torque: [340-380 N.m] 251-280 lbf.ft.

85M649 10 Lower the hoist and disconnect the lifting chains or sling. Remove the eye bolts from counterweight.

85M809 11 Remove the chocks from drive wheels.

12 Install SCR controls, if removed.

13 Connect power cables to SCR controls.

14 Install overhead guard.

15 Install hood.

16 Install battery.

17 Close hood (battery compartment cover).

Code: PMA-540, NOV 85

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

25447

GROUP 38, Section 1, Page 13

GROUP 38

CWRK

GROUP

38 SECTION

2 FRONT BATTERY

PLATE ADJUSTMENT

(FOR MAINTENANCE ACCESS)

To perform this service procedure, it is recommended that you first: 0

0 0

0 0

Park truck safely in the selected maintenance area.

Fully lower the upright.

Return all controls to neutral and turn key switch to the "OFF" position.

Apply the parking brake.

Block the wheels.

85M626

Turn key switch to "OFF" position.

Open battery compartment cover (hood).

Disconnect battery from truck receptacle.

Remove battery from truck.

Remove floorboard. z Remove cover from main valve.

1 2 3 4

See Page 2 for additional details.

Code: PMA-540, NOV 85

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

GROUP 38, Section 2, Page 1

GROUP 38

85M482

85M755

1 Turn key switch to "OFF" position.

4 Remove battery from truck.

Refer to GROUP 12, Section 1.

85M505

85M651

2 Open hood (battery compartment cover).

5 Remove floorboard.

85M541 3 Disconnect battery from truck receptacle.

GROUP 38, Section 2, Page 2

85M849 6 Always remove valve cover before moving battery plate to prevent damage to cover lower flange.

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

Code: PMA-540, NOV 85

/ I \

a. \ \

w

m

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

GROUP 38

Cl!!wK

85M762

85M862

GROUP 38, Section 2, Page 4

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

Code: PMA-540, NOV 85

GROUP 38

FRONT BATTERY

PLATE ADJUSTMENT

FOR MAINTENANCE

ACCESS

The front battery plate is hinged at the bottom and adjustable for maintenance access to drive motors, brakes., hydraulic pumps, motors and piping components installed in the compartment under the floorboard. When this plate is loosened and pivoted towards the rear of truck, added clearance between components is provided and the main hydraulic pump and motor, and hydraulic oil filter are rotated to a position where they may be more easily serviced.

Truck battery must first .be removed, to provide access to the battery plate mounting bolts and to allow movement of the plate into the battery compa.rtment.

See Page 2.

Remove floorboard.

See Page 2.

Remove valve cover. See Page 2.

Always remove valve cover before moving battery plate, to prevent damaging lower flange of cover (fits under frame edge).

85M764

From the battery compartment side, loosen and remove the four (4) bolts which mount the battery plate at its sides to the frame.

Bolt Torque: [40-45 N.m] 30-35 lbf.ft.

The battery plate may now be adjusted to the maintenance position by moving the top of the plate towards the rear of truck.

See NOTICE, Page 6.

85M861

Code: PMA-540, NOV 85

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

GROUP 38, Section 2, Page 5

GROUP 38

NOTICE - Travel of the battery plate is normally limited by the length of the lift line hose from main valve to the upright.

IMPORTANT - The plate may require blocking at the rear to limit its maximum travel, to prevent the valve control levers from striking the SCR controls.

6 To block the batte-ry plate, use a piece of wood, e.g., a Z"x4"xlZ" (approximate length) block, placed behind the rear top side of the plate and against the top front of the counterweight or frame structure.

Place the block where it will be out of the way of the necessary work.

7 Be sure the battery plate is supported securely by the block before starting any maintenance work.

85M760 8 When required, remove the plastic strip (floorboard support), as shown. This strip is held in place by fitting over the tabs projecting from the battery plate.

85M671 9 Install the battery plate in operating position by reversing the above procedure.

Install all four bolts and tighten to the correct torque specification (page 5).

Be sure to install the plastic floorboard support strip by pressing over the tabs on battery plate and adjusting to the width of the frame.

85M666

GROUP 38, Section 2, Page 6

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

Code: PMA-540, NOV 85

CLflRK

GROUP 38

GROUP SECTION

3 MACHINEJACKINGAND BLOCKING TM

Models

To perform these service procedures, it is recommended that you first: Park truck on a hard, level and solid surface, such as a concrete floor with no gaps or breaks.

Put upright in vertical position and fully lower the forks or attachment.

Put all controls in neutral and turn key switch to the "OFF" position.

Apply the parking brake.

85M467

DEFECTIVE EQUIPMENT CAN CAUSE ACCIDENTS ALL TOOLS AND LIFTING EQUIPMENT MUST BE IN GOOD CONDITION, MEET THE LOAD CAPACITY REQUIREMENTS AND HAVE OSHA LABELS WHEN REQUIRED. TOOLS WITH DEFECTS CAN HAVE FAILURES CAUSING SEVERE INJURY OR DEATH.

Code: PMA-540, NOV 85

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

GROUP 38, Section 3, Page 1

GROUP 38 To Raise Drive Wheels Off The Floor This procedure uses the upright as a lever to lift the drive wheels off the floor and prevent accidents due to inadvertent powering of the drive wheels.

1 Park the truck safely.

I

See page 1.

2 Turn key switch "ON" and tilt upright fully back.

85M489 3 Put a solid [100x100 mm] 4x4 inch hardwood block under the front section of each upright rail. Put a [3,1-6,4 mm] .125.250 inch thickness steel plate on top of each block.

Also see Figure 19519, page 3.

85M741 4 With key switch "ON", tilt the upright fully forward. This action should raise the drive wheels off the floor. Release the tilt control lever.

5 Turn key switch "OFF".

85M742

GROUP 38, Section 3, Page 2

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

Code: PMA-540, NOV 85

CLqRK

GROUP 38

6 Check for safe clearance between drive wheels and floor.

85M744 7 Check for stable condition of the truck.

Be sure that the blocks are located securely under the upright rails before operating the drive or working on truck.

85M743 8 Lower the drive wheels to the floor and remove the blocks by reversing the above procedure. l l l

Turn key switch "ON".

Tilt upright fully back.

Turn key switch "OFF".

85M742 9 Remove the blocks from under the upright rails.

(Typical truck view shown.)

Code: PMA-540, NOV 85

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

GROUP 38, Section 3, Page 3

GROUP 38 Blocking The Upright In Raised Position This procedure is used to safely provide clearance for access from the front of truck to components on or near the drive axle.

Park truck safely. See page 1.

Put blocks in front of and behind drive wheels.

Put wooden blocks conveniently near rails before raising the upright. Use two 4x4 hardwood blocks, or equal, of approximate lengths shown in Figure 85M630.

DO NOT STAND UNDER THE FORKS WHEN BLOCKS ARE PUT UNDER THE RAILS. THE FORKS CAN FALL AND CAUSE INJURY OR DEATH TO PERSONNEL.

Turn key switch "ON" and raise the upright carriage.

Hold the tall block against inner rail and lower the upright until carriage rests on block.

85M630 Hold the short block against the outer rail and lower the upright until inner rail rests on the block. NOTE - For STD UPR, block may need length cut to suit.

85M627 7 For HVTSU upright, the carriage may be blocked up, as shown by Figure 85M852.

85M852

GROUP 38, Section 3, Page 4

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

Code: PMA-540, NOV 85

CLflRl4

GROUP 38

To Raise The Rear Of Truck Refer to GROUP 40, Section 5, Specifications for truck weights.

The truck may be raised at the rear by jacking and blocking under the sides near the rear section of the frame.

AN INCORRECTLY INSTALLED COUNTERWEIGHT CAN MOVE OR FALL UNEXPECTEDLY. NEVER LIFT OR BLOCK A TRUCK USING THE COUNTERWEIGHT. FAILURE TO'FOLLOW PROCEDURES OUTLINED IN THIS MANUAL CAN RESULT IN INJURY OR DEATH.

1 Park truck safely (see page 1). Put blocks at front and rear of drive wheels.

NOTICE - When convenient, it is recommended to first remove the battery from truck, to reduce weight for both safer and easier jacking.

85M626 2 Put a floor jack under the rear side of truck frame. NEVER PUT THE JACK UNDER THE COUNTERWEIGHT. NOTE - If there is insufficient clearance under frame for your jack, truck may first be driven onto thin platforms, such as l"x6"x12" pieces of board (shims), to increase the truck frame underclearance.

3 Raise the truck only as high as necessary to perform the maintenance work.

85M780

4 Put blocks at both sides of the truck, fully under the frame main side structure.

Put the blocks in front of but close to the counterweight and steer wheel for best truck stability.

Put an equal amount of blocks under each side of the truck to provide a level Individual pieces of working position. blocking with minimum length equal to the width of the truck are recommended.

Code: PMA-540, NOV 85

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

85M775

GROUP 38, Section 3, Page 5

GROUP 38

5 Lower the truck onto the blocks and remove the jack. Before performing any maintenance work, check the truck for stable condition on the blocking.

6 When maintenance work is completed, lower the rear of truck to the floor by reversing the above procedure. l l l

Put jack under frame and raise truck.

Carefully remove blocks and lower truck.

Remove jack and blocks from drive wheels.

GROUP 38, Secti'on 3, Page 6

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

Code: PMA-540, NOV 85

GROUP 38

To Raise Entire Truck (Front and Rear) Refer to GROUP 40, Section 5, Specifications for truck weights.

1 Park truck safely (see page 1).

2 Check and be sure all tools are in good condition and have enough capacity to lift the loads.

85M777 NOTICE - When convenient, it is recommended to first remove the battery from truck, to reduce weight for safer and easier jacking.

If there is insufficient clearance under frame for your jack, truck may first be driven onto thin shims, e.g., l"x6"xlZ" pieces of board, to increase the truck frame underclearance.

Two jacks (if available) may be used, one on each side of the truck.

3 Put the jack(s) under side frame near the center of the truck.

IMPORTANT - Be sure to put the jack(s) squarely and fully under the main side structure of the frame.

85M780 4 Lift the truck one side at a time, only as high as necessary to do the work and not more than a maximum of 6 inches.

5 Put blocks under the side frame, at each side of the jack. Put (spread) the blocks close to the steer and drive wheels for maximum stability.

85M779

Code: PMA-540, NOV 85

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

GROUP 38, Section 3, Page 7

GROUP 38 6 Lower the truck onto the blocks and move the jack to the opposite side. Repeat the lifting procedure.

7 Put the same size blocks under each side of the truck so it will be level.

85M778

CAUTION- Before performing any maintenance work, check the truck for stable condition on the blocking.

85M776

8

When maintenance work is completed, lower the entire truck to the floor by reversing the lifting procedure.

Lower the truck one side at a time, while carefully removing the blocks. Check to be sure that no tools or equipment are under the truck or wheels.

NOTE - Depending on jack height, shims under the tires may be needed for clearance to allow removal of jack.

GROUP 38, Section 3, Page 8

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

Code: PMA-540, NOV 85

GROUP 38

Raising The Truck With A Hoist 1 When suitable equipment is available, the truck may be raised by means of a hoist and wheel cradles placed under the wheels.

Figure 17053 shows typical TM truck being raised at the front (with upright removed ).

2 Attach a hoist with chains of correct capacity as shown.

NOTE - Watch truck for signs of lateral It may tip sideways. instability.

You may have to support or guide the sides of the truck or overhead guard to prevent tipping.

3 When required to raise only the front of truck, lift truck up and place wheel cradles under the front wheels as shown.

Lower truck onto the cradles.

Typical truck view shown.

4 When working on components other than the steer axle or drive wheels, raise the truck and put stable wheel cradles under all wheels.

Typical truck view shown.

Code: PMA-540, NOV 85

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

GROUP 38, Section 3, Page 9

CLSRK

_

GROUP 39

GROUP

39 SECTION

1 OVERHEAD GUARD REMOVAL

To perform this service procedure, it is recommended that you first:

lPark truck on a hard, level surface in correct position for using an overhead hoist, if available. lFully lower the upright. oReturn all controls to neutral and turn key switch to the "OFF" position. lApply the parking brake. lBlock the wheels.

85M626

oRemove floorboard, for access to OHG front mounting bolts.

oRemove hood.

See Page 3.

lBattery

may also be removed, as in the illustrations shown here.

85M506

Code: PMA-540, NOV 85

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

GROUP 39, Section 1, Page 1

GROUP

C19RK

39

OVERHEAD

GROUP 39,

Section

GUARD

12.170

BUMPER, BATTERY COVER

39.932

GUARD, OVERHEAD

39.933

FASTENER, OVERHEAD GUARD (FRONT LEGS)

39.934

FASTENER, OVERHEAD GUARD (REAR LEGS)

90.963

NUT, OVERHEAD GUARD FASTENER

90.958

DAMPENER, OVERHEAD GUARD VIBRATION

1,

Page

2

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

Code:

PMA-540,

NOV 85

C19RkC

GROUP 39

OVERHEAD GUARD REMOVAL

NOTICE:

CAUTION :

First, remove hood (battery cover) from OHG. If OHG (or hood) needs to be repaired or replace,d, the hood must always be removed from its mounting on overhead guard. Refer to GROUP 39, Section 2, for hood removal.

It is recommended to never attempt to remove the OHG with hood attached because of the difficulty of securing the hood to OHG and the danger of damage or injury from the hood falling.

1 Remove front OHG leg mounting bolts from the frame.

NOTE - Clearance for access to nut or bolt on right-hand side is limited and requires use of a long boxend wrench, or similar tool, at the inside of frame. Best hand access is from the front side at tilt cylinder opening.

Bolt Torque: [70-80 N-m] 52-59 lbf.ft.

85M791 2 Remove rear OHG leg mounting bolts from the counterweight.

Bolt Torque: [70-80 N.m] 52-59 lbf.ft.

85M789 3 Use an approved lifting sling of correct capacity to attach an overhead hoist to the OHG. OHG weight is [68 kg] 150 lbs, approximately.

85M793

Code: PMA-540, NOV 85

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

GROUP 39,'Section 1, Page 3

GROUP 39

4 A large sling may also be placed in the longitudinal position. This may give better balance when positioning or carrying.

84M582 5 Raise OHG assembly up and away from truck.

6 Lower the OHG assembly to the floor and store in a safe position until required for reassembly.

85M794 7 Reverse the above procedure for installation of OHG.

8 Torque mounting bolts to the correct torque specification.

85M618

85M790

GROUP 39, Section 1, Page 4

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

Code: PMA-540, NOV 85

GROUP 39

C19RK

GROUP

39 SECTION

2 HOOD REMOVAL (SEAT DECK/BATTERY COMPARTMENT COVER)

Code: PMA-540, NOV 85

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

GROUP 39, Section 2, Page 1

GRO_UP

R.H. AND LW. PARTS

SHEET

METAL

AND

TRIM 39-325

36.211 31.120 37.312 37.544 38.104

BUSHING, PIVOT PIN PLUG, TILT CYLINDER ACCESS HOLE STOP, TOP UOOD' ANCEIOR. TOP HOOD PROP PLATE, BATTERY COMPARTUFaNT FRONT

39.641 39.643 39.644 39.640 39.653

HANDLE, TOP ROOD LATCH CATCH, TOP LATCH LATCR, TOP ROOD FASTENER, TOP EOOD LATCH CATCU SPRING, TOP BCIOD LATCH

39.475 39.471 39.478 39.497 39.535

PLATE, FRONT FLOOR FASTENER, VALVE COVER PLATE, REAR FLOOR FASTENER, VALVE COVER BRACKET, TOP ROOD MOUNTING LH

39.656 39.662 39.702 39.705

39.978

PIN, TOP HOOD LATCB FASTENER, TOP HOOD LATCH PROP, TOP BOOD FASTENER, TOP ROOD PROP PIVOT, TOP IKIGD

39 -536 39.544 39.564 39.594 39.595

BRACRET, TOP HOOD MOUNTING FH COVER, HYDRAULIC VALVE ACCESS TRIM, BATTERY RECEPTACLE ACCESS HOOD, TOP FASTENER, TOP HOOD

91.269 92.982 93.399 95.179

NUT, TOP ROOD FASTENER WASHER, TOP EOOD LATCR FASTENER FASTENER, TOP HOOD STOP FASTENER, BATTERY COMPARTMENT FRONT PL

GROUP 39, Section 2, Page 2

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

Code: PMA-540, NOV 85

GROUP 39

HOOD REMOVAL

NOTE - Removal of the seat is optional. The weight to be handled will be less if the seat is removed. Hood removal and installaticn is best done by two persons working together.

1 Unlatch and raise hood to the fully-open position.

NOTICE - Discharge the capacitor on SCR control, for safety while working near the controls.

85M505 2 Disconnect both gas spring assist/support cylinders from their attachment to the hood. CAUTION - Be sure to hold and support hood from falling when support cylinders are loosened and removed.

Bolt Torque: [ZO-25 N.m] 117-221 lbf.in.

85M782 3 Loosen and remove gas springs from their mounting on counterweight, if they need to be removed for inspection, repair, or replacement.

Bolt Torque: [ZO-25 N.m] 117-221 lbf.in.

85M783

Code: PMA-540, NOV 85

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

GROUP 39, Section 2, Page 3

GROUP 39

4 Carefully lower the hood to the closed position.

85M476 5 First, loosen the two mounting bolts of one hinge bracket from the tapping block at underside of hood. Then, complete the removal of the mounting bolts. Reach under the hood to hold the tapping block from falling into the SCR controls.

Bolt Torque: [ZO-25 N.m] 117-221 lbf.in.

85M797 6 Remove the hinge bracket by sliding it off the hood hinge pin on OHG leg.

NOTE - It is necessary to only remove one hinge bracket for temporary removal of hood from truck. See below.

85M784 7 Disengage hood from OHG. Lift the hood slightly and move sideways to slide the remaining hinge bracket on opposite side off of its hinge pin on OHG leg.

85M786

GROUP 39, Section 2, Page 4

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

Code: PMA-540, NOV 85

GROUP

CMRK

39

8 The hood may now be removed from truck.

Note - Hinge bracket and tapping block may be temporarily reinstalled on hood for safe storage.

25471 9 If required, remove the hood pivot pins from the OHG legs. Loosen and remove the mounting bolt from each pivot pin.

Put a match-mark on each pivot pin and OHG leg for adjustment of hood when installed.

Bolt Torque: [40-45 N.m] 30-35 lbf.ft.

25472

Hood Install

ation

Reverse the above procedures for hood installation.

1 Lift hood assembly and set it temporarily into place on truck, in the lowered position. Engage hood hinge bracket (attached to hood) to hinge pin on OHG leg.

2 Carefully rest hood in lowered position without latching. Slide the other hinge bracket onto hinge pin on OHG leg (Figure 85M784), install and tighten the two hinge bracket mounting bolts with tapping block (underside of hood).

Bolt torque: [ZO-25 N.m] 117-221 lbf.in.

Code: PMA-540, NOV 85

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

GROUP 39, Section 2, Page 5

GROUP 39 3 Raise hood to the open position, and install both gas springs.

NOTE - The gas springs, when released, will extend slightly. They may require prying to compress them into place when installing. If necessary, the hood hinge brackets may be loosened at the hood mounting, and the hood raised up slightly in the slotted holes in the mounting surface, until the spring mounting bolts can be installed.

85M781

Hood Adjustment Adjustment of hood fit-up when installed is provided for by: 1) Oversize slotted holes in mounting of hinge to top of hood sheetmetal: Loosen the bolts in the hinge brackets when major hood adjustment (fore-and-aft or sideways) is required for alignment at the front edge or along the sides).

2)

85M797

Eccentric hood hinge pins in OHG leg: Loosen the mounting bolts and rotate the hinge pins for further adjustment of the hood (e.g., centering alignment with latch pin at front).

85M785 3) Adjustable hood stop screws which rest against fixed brackets on the frame inside controls/ battery compartment.

The hood stop screws are a type of set screw using a hex wrench for adjustment: Loosen the locknut on underside of hood, and using a hex wrench inserted in the opening on top of hood, adjust each stop screw for correct contact with the stop brackets on frame, for leveling and support of the hood (seat support).

Be sure to correctly tighten all bolts after adjustment of hood.

GROUP 39, Section '2, Page 6

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

Code: PMA-540, NOV 85

CLSRK

GROUP 40

GROUP

40 SECTION

1 TRUCK DATA PLATES

Code: PMA-540, NOV 85

AND DECALS

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

GROUP 40, Section 1, Page 1

Cl!lRK

GROUP

40

40.024 L-40.000

ho.089

TM 40.014 _/

0 40.145 7 .amC_lI__-."U,".--.-v--m

L 40.008

DATA PLATES

AND

\ kO.062

DECALS 40-195

37.205 40.000 40.001 40.006 40.008

TRAY, LITERATURE LEGEND, CAPACITY & SERIAL NUMBER FASTENER, CAPACITY 6 SERIAL NUMBER LEGEND, PATENT LEGEND, UPRIGHT CONTROL LEVER

40.010 40.012 40.014 40.024 40.025

DECAL, CLARK LOGO DECAL, CLARK LOGO DECAL, MODEL NAME PLATE, UNDERWRITERS LABEL FASTENER, UNDERWRITERS LABEL PLATE

40.049 40.062 40.071 40.089 40.130

LEGEND, INSTRUCTIONS DECAL, DRIVERS WARNING LEGEND, SAFETY PARKING BRAKE DECAL, WARNING DECAL, CAUTION FORKS

40.131 40.138 40.145 40.163 93.575

DECAL, HANDS OFF DECAL, WARNING LEGEND, WARNING DECAL, VALVE LEVER LOCK FASTENER, LITERATURE TRAY

GROUP 40, Section 1, Page 2

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

Code: PMA-540, NOV 85

CMRK

GROUP 40

WARNING

DECAL

L

PYLON

RELEASE

,, ,

MANUAL

\

OPERATOR

CASE

INSTRUCTIONS

NOTE: ADD INFORMATIONAL PACKETS TO MANUAL CASE, FOR OPTIONAL EQUIPMENT USED ON TRUCK.

Code: PMA-540, NOV 85

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

\

UL CLASSIFICATION

CLARK LOGO- BOTH SIDES OF HOOD. PLATE

GROUP 40, Section 1, Page 3

CLSRW

GROUP 40

LETTERS LETTERS

/

L

WIDTHS FLOOR,

POSITION DECAL ON EMBOSSED OF OVERHEAD GUARD

(2)-CENTER DECAL ON RAIL POSITION LETTER”C”NEAREST BOTH SIDES OF UPRIGHT

CENTER ON TIE BAR

REQ’ D

/

CENTER DECAL ON OUTERRAIL WIDTH BOTH SIDES OF UPRIGHT.

TM152 REQ’D TM 17-2REQ’D TM 20-2 REQ’D

1200 FkOM FLOOR AND WITH FORKS DOWN

GROUP 40, Section 1, Page 4

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

Code: PMA-540, NOV 85

GROUP 40

C19RK

GROUP

40 SECTION

2 EQUIPMENT

SUGGESTED FOR ELECTRIC

PMA-510, DEC 80

TRUCK

P.M.

Section 2, Page 1 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP

C19RW

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 ] [O-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

RECORDINGS BELOW ARE: mm reads in Kg inches read in Lbs.

Fig. (A)

Fig. (B)

Fig. Fig. Fig. Fig. Fig. Fig. (C) (A) (A) (B) (C) (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 1885 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 31%" 6500 13000 4850 11300 9150 6500 14100 11500 8100 16900 13800 9800 ________-___-~_--~~-_._--____.-___--~~---~--~-~-_---_---~---~-----~_--~~~---~---~~~--~~-13mm 4990 9980 3745 8665 7075 4990 10795 8800 6260 12975 10570 7485 l/2" 11000 22000 8250 19100 15600 11000 23800 19400 13800 28600 23300 16500 _______________,--__-_.__-____.-___--__---~__--___,--~_---~__---__---_----__---__--~__---_16mm 7400 14745 5535 12745 10435 7400 15965 13020 9210 19145 15650 11079 51%" 16300 32500 12200 28100 23000 15300 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 25310 9890 22770 18600 13155 28485 23270 16465 34155 27895 19730 718" 29000 58000 21800 50200 41000 29000 62800 51300 36300 75300 51500 43500 --~---.~~---~~~~~~~~~.-~----~.~--~~-~------~-----~------~----~----~~~---~~~-------~-----25.4mm 17375 34700 13020 30255 20000 17375 37560 30660 21680 45090 36790 25035 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 85500 _____________~_-----_.---___~-__-~-_----__--~~-_~~___--~----__-~~~---------~-~~~~---~~-38.4mm 35380 70760 26535 51235 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)

!

Fig. (B) Fig. (C)

Section 2, Page 4

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

PMA-510, DEC 80

CLSRK

GROUP

40

GROUP

40 SECTION

3 FIRE EXTINGUISHER RECOMMENDATIONS

Code: PMA-510, FEB 84

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

Section 3, Page 1

CUIRK

GROUP 40 SAFETY

EQUIPMENT

FIRE EXTINGUISHERS FOR TRUCKS WITH SOLID-STATE CONTROLS APPROVED FIRE EXTINGUISHERS: Two types of fire extinguishers are approved for use on trucks with solid-state controls: 1.

CO2 (carbon dioxide)

CO fire extinguishers are best used fog Class 'C' fires (*) in electrical wiring and controls. Carbon dioxide 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, however, from using a CO fire extinguisher in small, eZ 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 EXTINGUISHERS NOT APPROVED:

DO NOT ENTER OR WORK IN AN AREA WHERE A CO FIRE EXTINGUISHER HAS BEEN USED UNTIL THE SPACE HAS BEEN COMPLETELY VENTILATED. 2.

Dry chemical

(~~;;:)'B' and 'C' *

The chemical used in the dry-type extinguishers is either sodium bicarbonate or potassium bicarbonate, which has been made water-resistant.

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.

"Class A fires" are fires in ordinary combustible materials, such as wood, 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 equipment. The use of a fire extinguishing material that does not conduct electricity is important.

*1>

Section 3, Page 2

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

Code: PMA-510, FEB 84

CLSRK

GROUP 40

GROUP

40 SECTION

4 LUBRICANT AND

SPECIFICATIONS RECOMMENDATIONS

LUBRICATION

Code: PMA-322, FE9 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 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 Component operation should not be affected as long as in CLARK products. 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

__------

-------_------_--------------------__-----__-----_

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

GROUP 40

CLSRK LUBRICATION CHART KEY LUBRICANT SPECIFICATIONS & RECOMMENDATIONS PRODUCTS AVAILABLE UNDER CLARK PART NUMBER Page Ref No's

4

FILTERS 1. System Filters-Oil & Fluid

Page

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

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

CMRK

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

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

CMRK

40

CRANKCASE MOTOR OIL

CLARK PART NUMBER

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

IT IS RECOMMENDED THAT MULTI-VISCOSITY OIL CONDITIONS, COMBINED WITH HIGHER OPERATING SUPPLIER SHOULD ASSUME FULL RESPONSIBILITY MULTI-VISCOSITY OIL Al- BOTH LOW AND NORMAL

1802152 1802153

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

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 WHERE OIL PERFORMANCE PROBLEMS ARISE OR ARE DIRT, MOISl-URE AND MAINTENANCE. 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 r

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.

6 API

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

SERIES 3

3.

ENGINE CRANKCASE OIL

FOR . . . TURBOCHARGED DIESEL ENGINES OR DIESEL ENGINES USING HIGH SULFUR CONTENT FUEL (OVER 0.5% SULFUR).

MIL-L-45199B MIL-L-2104C

SPECIFICATION TO MEET API Service Classification "CD" per SAE Report 5183 and equivalent Series 3 and/or MIL-L-45199B Sulfated ash Specifications. Also MIL-L-2104C when applicable. 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 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

&

0

CLflRU

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 & BUSHINGS POWRWORKER & NARROW AISLE TRUCKS - ALL POINTS *RECOMMENDATION Use Grade NLGI 111per 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 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 #2

8.

r.,.,.p MOLY GREASE

FOR . . . DISTRIBUTOR CAMS SPECIFICATIONS

9.

eSG.L&L. MOLY GREASE

CLARK PART NUMBER 1800636

See above.

SPECIAL GREASE

FOR ... DELCO STARTER BEARINGS *GENERATOR/ALTERNATOR END FRAME BEARINGS SPECIFICATIONS

10.

HIGH TEMP

SPECIAL GREASE

CLARK PART NUMBER 1800574

See above.

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 To withstand temperatures of -20' F. water and high temperature. (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

$ z g &

Code: PMA-322, JUN 80 REV

CLqRK

GROUP 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 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 111 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.

._ 6

16.

SPECIAL LUBRICANT

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

St

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

GR%u EP LUBE MIL-2105B

18.

TRANSMISSION LUBRICANT

FOR ...

swmm

mufa

SHIFT (SYNCHR~MESH) TRANSMISSION c

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.)

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 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

CAUTION *: FORD

TYm?" 6

21.

TRANSMISSION FLUID - FORD

FOR ... ALL FORD AUTOMATIC TRANSMISSIONS AND CONVERTERS SPECIFICATIONS Automatic Transmission Fluid, Type "F", which meets FORD MOTOR COMPANY Specification: ESW-~2~33~ (RED DYED)

TYPE "F" CAUTION:

22.

HYDRAULIC

m

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

EMIRU 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

La MS-48

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:

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: PMA-322, JUN 80 REV

GROUP

40 CLARK PART NUMBER 1801146 FOR ELECTRICAL Px SCR COMPONENTS IMPORTANT DO NOT CLEAN ELECTRICAL COMPONENTS WITH STEAM. ONLY APPROVED SOLVENTS SHOULD BE

0 NOTE

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 #1800330

Degreaser may be used to clean outer surface of cylinders,

cls NOTE

Code: I'MA-322, FEB 84 REV

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

valves and other components as well as engines . . . may be used on paint.

Section 4, Page 15

GROUP 40

GROUP

40 SECTION

5 TRUCK SPECIFICATIONS

NOTICE Clark products and specifications are subject to improvements and changes without notice or obligation.

Code:

PMA-540,

NOV 85

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

GROUP

40, Section

5, Page

1

C19RK

GROUP 40 Truck Specifications

12

POWER SUPPLY - BATTERY 36 volt

Max Size & Rating

18 cell, 17 plate, 38.9 kWh, 1120 amp-hr @ 6 Hour rating

Battery, Fully Charged: Discharged: Recommended Battery Fluid:

16

1.275 specific gravity 1.120 II II

(1.310

Exide Load Hog)

Distilled water only

MOTORS: DRIVE 36v 6.64 in. diameter Series Wound.

Weight: [24.5 kg] 54 lb Open Rating (60 Min.): 34.8 v, 2160 rpm, 5.5 hp, 143 amps No. per Holder: 1 Nc per Motor: 4 Brush Grade: Morganite HlOO Brushes: L [35 mml1.38 in, W [32 mml1.26 in, T [1;,65 mm].498 in Worn Length: [14,5 mm] -57 inch on longest side Brush spring tension (force per brush) NEW: [935-1077 g] 33-38 oz WORN: [453 g] 16 oz LIFT

Weight: [42.2 kg] 93 lb 36v 7.15 in. diameter Series Wound.

Open Rating (15% Time): 33.18 v, 1170 rpm, 11.8 hp, 360 amps No. per motor: 8 Brush Grade: Morganite HlOO No. per holder: 2 Brushes: L [35 mml1.38 in, W [25,3 mm].997 in, T [13,9 mm].548 in Brush Worn Length: [14,5 mm] .57 in. on longest side Brush spring tension (force per brush) NEW: [935-1077 g] 33-38 oz WORN: [453 g] 16 oz

STEER 36v 6.5 in. diameter Permanent Magnet. Weight: [19.3 kg] 43 lb Enclosed Rating (Continuous): 36 v, 1351 rpm, 0.95 hp, 28.1 amps Brush Grade: Stackpole 2192 No. per Holder: 1 No. per motor: 4 Brushes: L [28,7 mml1.13 in, W [20,6 mm].812 in, T [9,35 mm].368 in Worn Length: [lo,65 mm] .420 inch on longest side Brush spring tension (force per brush) NEW: [782-870 g] 27.6-30.7 oz WORN: [326-357 g] 11.5-12.6 oz

GROUP 40, Section 5, Page 2

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

Code: PMA-540, NOV 85

CLSRK

GROUP 40

Truck

19

ELECTRICAL

COMPONENT/TEST

Specifications

SPECIFICATIONS

(M inimum resistance) *30,000 ohms.

50,000 ohms.

Used Truck: New Truck: *Used truck resistance values may range from 20,000 to 30,000 ohms, When below 20,000 ohms, further testing must be conducted. w/o problem.

GROUND

TEST:

CURRENT DRAW VALUES: (t/- 15% Tolerance, Warm Truck, 36-volt 1) Drive Motor - (1A Freewheeling, Less Pump Mtr Idle Curr.) @ Battery: 75 amps 8 amps 2) Lift Motor - Idle Current @ Battery:

battery)

SCR CURRENT LIMIT: (t/- 15% Tolerance, Cold Truck) 1) Drive Motor - 250 amps motor current

CREEP

SPEED:

1A PICKUP

POWER

TIME

STEERING

1.6 volts

DELAY:

TIME

FUSES: 1FU 2FU 3FU

Code:

PMA-540,

NOV 85

to 3.6 volts

1.5

(+/-

DELAY:

5.0

@ motor

-5) seconds

(+/-

-5) seconds

Rating

Function

500 amp 50 amp 15 amp

Drive, Pump Power Steer Control

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

GROUP

40, Section

5, Page 3

CMRK

GROUP 40

Truck 20

Specifications

DRIVE UNITS (TWO) Recommended Oil Specification: Drive Unit Oil Capacity, Each: Overall Ratio:

23

23

WHEELS & TIRES: (Tire sizes are common Drive

Tire

Size

- Cushion - Pneumatic

Steer

Tire

Size

- Cushion - Pneumatic

to all models,

Trans

except

Fluid

as noted)

18x7x12.12 (TM15) 18x8x12.12 18x7 - 8 16-ply Tire Pressure - [970 kPa] 140 psi

(TM17,20)

18x7x12.12 18x7 - 8 16-ply Tire Pressure - [970 kPa] 140 psi

BRAKES Recommended

Master 26

DEXRON II ATF Automatic [3.81 L] 8 pints 23.386:1 Reduction

Brake

Cylinder:

Heavy-duty hydraulic brake fluid, SAE J1703b specification, or Type DOT, Grade DOT 3. in Dia. x 0.787 in Stroke

Fluid:

0.75

STEERING SYSTEM: Recommended

Power

Steering

Fluid:

Uses main

hydraulic

Power Steering System Relief Pressure Setting:

29/30

Steer

Cylinder

Diameter:

Steer

Handwheel

Turns,

2.00

sump oil supply.

[8620 kPa] 1250 psi

inch

Lock-to-Lock:

5 (Cyl extending ), 4 (Cyl retract'g)

HYDRAULIC SYSTEM: Recommended

Sump Tank

Hydraulic

Capacity,

Fluid:

Usable Total

Clark Specification MS-68 w/anti-wear additives

Volume: Volume:

[9.84 [13.6

TM 17: [18620-19306 TM 20: [20340-21030

GROUP

Relief

40, Section

Pressure

5, Page 4

Setting:

Oil

L] 2.6 gal L] 3.6 gal

Main Hydraulic Valve (Lift & Tilt) Relief Pressure Setting: TM 15: [16890-17580

Aux Valve

Hydraulic

Adjustable attachment

kPa] kPa] kPa]

2450-2550 2700-2800 2950-3050

psi psi psi

- Refer to specifications.

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

Code:

PMA-540,

NOV 85

CMRK

GROUP 40

Truck

32

Specifications

TILT CYLINDERS: Tilt

Cylinder

Tilt

Speed,

[76.2

Diameter:

Nominal:

Thru Above

TILT DRIFT, in 5 minutes, Temperature [26_7C] 80F [37.8C] 1OOF [48_9C] 12OF

3.00 in

mm]

151 MFH 151 MFH w/rated Drift

- 3.2 to 3.9 deg/sec - 2.4 to 2.8 deg/sec load, [mm]

new truck: Drift (degrees) N/A N/A N/A

34 UPRIGHTS UPRIGHT

SPEEDS:

TM15-Loaded Empty

Nominal performance for UPR at cut-off MFH HI-VIS TSU HI-VIS STD Lowering Lowering Lifting Lifting m/s ft/min m/s ft/min m/s ft/min m/s ft/min 0.32 63 0.48 95 0.43 85 '0.30 60 0.51 101 0.41 80 0.47 93 0.41 80

TM17-Loaded Empty

0.30 0.51

59 100

0.48 0.41

95 80

0.28 0.47

56 92

0.43 0.41

85 80

TM20-Loaded Empty

0.28 0.51

55 100

0.48 0.41

95 80

0.26 0.47

52 92

0.43 0.41

85 80

MAXIMUM FORK DRIFT, in 5 Minutes Temperature

with

capacity

HI-VIS

STD

load,

new truck: HI-VIS

TSU*

TM15

[26.7 [37.8 [48.9

C] 80 F C] 100 F C] 120 F

TM17

[26.7 [37.8 [48.9

C] 80 F C] 100 F C] 120 F

[16.5 [28.5 [42.0

mm] mm] mm]

-65 in 1.12 in 1.65 in

[14.0 mm] [23.0 mm] [33.5 mm]

-55 in -91 in 1.32 in

TM20

[26.7 [37.8 [48.9

C] 80 F C] 100 F C] 120 F

[18.5 [31.5 [47.0

mm] mm] mm]

.73 in 1.24 in 1.85 in

[15.5 mm] [25.5 mm] [37.5 mm] * Primary

.61 in 1.00 in 1.48 in stage only

Code:

PMA-540,

NOV 85

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

GROUP

40,

Section

5, Page

5

CMRK

GROUP 40

Truck

40

Specifications

RATED LOAD CAPACITY TM 15 . . . . [1360 TM 17 . . . . [1590 TM 20 . . . . [1815

@ Load Center: kg @ 600 mm] kg @ 600 mm] kg @ 600 mm]

Note: Rated capacity and including: HVSTD

40

applies when using uprights with maximum MFH [3835 mm] 151 in / HVTSU [3875 mm] 152 in

up to

[521 mm] 20.5 in [985 mm] 38.8 in [787 mm] 31.0 in

SERVICE WEIGHTS Note:

Model,

(With minimum

battery

weight

[1175

kg] 2590

w/UPR

& MFH

Drive

Steer

Total

1416 3122

3268 7205

LDD Dr Axle

TM15

STD [3835 mm] 151 in

kg: lbs:

1852 4083

TM17

STD [3835

kg: lbs:

1850

1676

3526

4580

4079

3695

7774

10097

1847 4072

1920 3695

3767 7774

4966 10948

TM20

lbs)

Maximum battery weight allowed is [1352 kg] 2980 lbs.

For batteries weighing less than [1175 kg] 2590 lbs, slab aux weights are to be used under the battery.

mm]

151 in

40

lbs @ 24 in lbs @ 24 in lbs @ 24 in

BATTERY COMPARTMENT SIZE: Length Width Height

40

3000 3500 4000

STD [3835 mm] 151 in

kg:

4184 9224

COUNTERWEIGHT WEIGHTS TM 15: TM 17: TM 20:

GROUP

40, Section

[385 kg] 849 lbs [645 kg] 1422 lbs [885 kg] 1951 lbs

5, Page 6

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

Code:

PMA-540,

NOV 85

GROUP 40

CMRIK

Truck

40

TORQUE

CHART

Cri ti cal GRP 16 Steer 19

20

Fastener

motor

Torque

mounting

Speci f i cati ons :

nuts

Motor cable connections Traction control panel cable

torque,

(Dry)

]

:z:,.4

connections

[ 10-12 [ 11-14

] ]

90-110 100-120

bolts

[550-6001

unit to frame mounting motor mounting bolts

23

Drive

wheel

26

Steer wheel mounting bolts Steer wheel spindle (bearing) nut Steer axle trunnion retaining nut Steering handwheel retaining nut

mounting

Tightening

[ z25

Drive Drive

29

Specifications

[ 70-80

bolts

lbf.in. lbf.in.

406-443

]

[255-2751

52-59 188-203

[255-2751

188-203

[230-2441 [ I..-;; 3

170-180 11-15 35-40

Main hydraulic valve mounting bolts Control lever knob mounting bolts

[ 4;:;;

3

30-33 71-88

lbf.in.

32

Tilt Tilt

[ 20-25 [ 20-25

] ]

177-221 177-221

lbf.in. lbf.in.

34

Upright cylinder retaining bolts Load backrest extension mounting

38

39

cylinder cylinder

Seat mounting Counterweight Overhead

NOTE:

Code:

guard

yoke clamp bolts pin retainer bolts

bolts mounting mounting

bolts

bolts bolts

[170-1901 [240-2701

125-140 177-199

[ 20-25 ] [340-3801

177-221 251-280

[ 70-80

52-59

]

lbf.in.

1) When checking tightness of major fasteners on new trucks, the values may be less than the recommended specification due to metal deformation and fastener stretch.

This is a normal occurrence and does not indicate that the fasteners were not correctly tightened during assembly.

Tighten to recommended specifications.

PMA-540,

NOV 85

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

GROUP

40, Section

5, Page

7

CLSRK

GROUP 40 Truck Specifications LUBRICANTSPECIFICATIONS

Engine crankcase oil Upright latch, Control rods, Miscellaneous linkage Transmission fluid Drive axle Hydraulic fluid Hydraulic sump Normal temp application Cold storage

Multi-purpose grease Axle ends, Wheel bearings

Steering linkage, Upright mast & carriage rollers, Trunnion bushings, Tilt cylinder rod ends, Brake pedal shaft Chain lube Upright lift chains Dry-film lubricant Side shifter, Attachments, Clamp slides

Low temperature grease Co1 d storage general purpose grease

API "CC", MIL-L-2104B, MIL-L-46152

DEXRON II ATF Automatic Transmission Fluid Clark Specification MS-68 Hydraulic oil Clark Specification MS-226 Hydraulic oil

NLGI Grade No. 1 Lithium soap base grease, Clark Spec MS-9B and MS-107B, or equivalent.

NLGI Grade No. 2 Lithium soap base grease, Clark Spec MS-9B and MS-107C, or equivalent.

Clark #886399 Chain and Cable Lube, or equivalent Dow Corning Molykote 321 Bonded Lubricant, Graph-0-Kote #220, Molub-Alloy #369 Dry Lube, or equivalent Low temperature grease, MIL-G-23827A, or equivalent

Protective spray coating Wiring, terminals, switches after assembly

Clark #886784 Spray Coating

Moistureproofing spray coating Contactor panels, SCR cards

Clark #1801145 Spray Coating

Battery

Distilled water

NOTICE - Refer to GROUP 40, Section 4, Lubricant Specifications and Recommendations for further information.

GROUP 40, Section 5, Page 8

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

Code: PMA-540, NOV 85

CLqRK

GROUP 40

GROUP

40

MEASURING VOLTAGES WITH THE VOLT-OHM

SECTION

METER

( V-O-M

)

17

RESISTANCE SCALE Refer to Section 18.

VOLTAGE

THIS

Code:

SCALE

SCALE

NOT ‘USED.

PMA-336, REV JAN 77

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

17, Page 1

INDUSTRIAL TRUCK DIVISION CUSTOMER

USING

SERVICES GROUP

THE

Connect

METER:

Leads:

RED TEST LEAD in jack marked + BLACK TEST LEAD in jack marked-

Insert Insert

A typical volt meter is equipped with several voltage ranges to provide accurate readings over a wide voltage range.

In the absense of a specified range to use, be sure to use a range sufficiently higher than the voltage to be measured to avoid damaging the meter.

Meter

When measuring voltage, be sure the truck battery is connected, and be sure to observe voltage polarity when connect ing the meter leads.

Unless directed to do so, do not disconnect wiring to parts being tested.

THE MOST ACCURATE READING OF ANY METER IS TOWARD THE CENTER OF ITS IMPORTANT: FOR EXAMPLE, WHEN READING VOLTAGES UP TO 2.2, USE THE 2.5V RANGE, HOWEVER, SCALE. THIS BRINGS THE READING NEARER THE WHEN READING 2.5 VOLTS, USE THE 1OV RANGE. IT ALSO PROTECTS THE CENTER OF THE SCALE AND PROVIDES A MORE ACCURATE READING. METER FROM POSSIBLE DAMAGE IN THE EVENT VOLTAGES READ EXCEED 2.5.

4 I

VOLTAGE TO BE MEASURED

from

0

to

I

RAN GE SW I TCH SETTING

,5D*

O-

2.5V

2.5V

or

loo

or

l.oo*

HERE

RANGE

Section

SWITCH

17, Page 2

I

USE DC VOLTAGE WITH FIGURES

SETTING:

THE

2.5V

150

or

METER

1.50+

READS

Read

1 st

I

READING

SCALE BELOW

THE

METER

JcMove‘the decimal point two places to the left.

250

200

2.2.5V

Row of

or

or

250 or 2050~

2.004

24V

Figures

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

with

Code:

the

DC Scale.

PMA-336,

REV JAN

77

CLflRK

GR4%u

VOLTAGE TO BE MEASURED

from from from

RANGE SWITCH SETTING

USE DC VOLTAGE SCALE WITH FIGURES BELOW

1ov 50V

0 - 10 0 - 50 O250

2.9 to 1OV 1OV to 50V 50V to 25OV

250V

READING

Read Read Read

10 V RANGE

METER Fig.

THE METER

directly directly directly

SWITCH

READS

SETTING

3 VOLTS

17229

Fig. .16015

__.__. ___1” _“ll-.“_“x.I”

.x-_.

.I”._

RANGE SWITCH SETTING: 50V AC/DC DIAL SETTING: +DC

50 V RANGE

SWITCH

SETTING

READ 2nd ROW FIGURES WITH DC SCALE. METER Fig.

Fig.

READ 1st ROW FIGURES WITH DC SCALE. *

Code:

15 VOLTS

17229 RANGE SWITCH SETTING: 250V AC/DC DIAL SETTING: +DC

Fig.

READS

250 v wwx

METER

SWITCH

READS

SETTING

75 VOLTS

17229

PMA-336, JAN 77

Fig.

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 .1--l/4 VOLTS I

1.00 OR 1V 0.75

4.25

1.50 OR l-1/2V 1.75 OR l-3/4V

OR 3/4V

OR 1/4V

2-l/2

VOLTS

2.5 VOLT SCALE

Section

17, Page 4

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

Code:

PMA-336,

JAN 77

GROUP

C19RK

40

GROUP MEASURING

RESISTANCE

WITH

THE

40

VOLT-OHM

SECTION

METER

( V-O-M

)

18

Black

RESISTANCE

VOLTAGE SCALE Refer to Section 17.

THIS

Code:

~~1-336,

SCALE ‘NOT

USED

REV JAN 77

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

18,

Page 1

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

CONNECT METER LEADS: Insert RED TEST LEAD in jack marked (+).

Insert BLACK TEST LEAD in jack marked (-).

USING THE METER: To insure accurate ._ readings, and prevent possible damage to the meter, be sure to disconnect Also, disconnect one truck battery. connection of any part being tested from the circuit to prevent other circuits from affecting resistance readings.

SETTING THE METER: Meter settings referred to in the PM procedures are: Set the center Rxl, RxlOO, RxlO,OOO. meter function switch to the specified If measuring an UNresistance range.

KNOWN RESISTANCE use the Rx100 range If the indicator points near first. center scale, then use this scale for reading.

However, if the indicator drops to O-ohms, then use the Rx1 scale.

If the indicator stays at or near the infinity mark then use the RxlO,OOO scale.

TOUCH

TEST

LEADS ACROSS

Resistance Value Measured

UNKNOWN

Being

Range

ZERO to 200 OHMS 200 to 20,000 OHMS 20,000 to INFINITY

ADJUST METER TO READ ZERO OHMS: Meter must be calibrated each time it is set to the ohms scale, and each time it is changed from one ohms scale to another.

To do this, connect the leads together and adjust ZERO OHMS KNOB for exactly 0 on the ohms scale.

RESISTANCE Switch

AND

Setting

READ \

VALUE,

USING

Reading

THIS

CHART.

The Meter

’

Read ohms scale directly.

Multiply ohms scale by 100.

Multiply ohms scale by 10,000

Rx1 Rx100 RxlO,OOO

With the RANGE SWITCH set as indicated, the scale examples are read as follows:

Refer to ITEM 1 in opposite With meter i 1 lustration. indicator in this position, the meter would be read as follows:

Rx1 Rx100 Rx10,OOO

50 OHMS 5000 OHMS 500,000 OHMS

10 OHMS 1000 OHMS 100,000 OHMS

5 OHMS 500 OHMS 50,000 OHMS

RANGE SWITCH SETTING: Rx1 Read Scale from right to left.

The meter reads 12 OHMS. RANGE SWITCH SETTING: Rx100 Read scale from right to left.

The meter reads 1200 OHMS. RANGE SWITCH SETTING: RxlO,OOO Read scale from right to left.

The meter reads 120,000 OHMS.

REFER

Section

TO THE OPPOSITE

18, Page 2

PAGE

FOR METER

SCALE

BREAK

DOWN OF DIFFERENT

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

Code:

RANGE

PMA-336,

SETTINGS.

REV

JAN

77

CLqRK

GR400UP OHMS

(SCALES)

RxlO,OOC

y? p $5 ‘0 $9 $2 2y 9

* * * .* * 6o,ooo 50,000

2000 G ?G 5 600 500 400

40,000

300

30,000

200

20.000 10,000 30,000

Code:

WA-336,

JAN 77

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

Section

18,

Page 3