CLARK FORKLIFT SPM 626 CWP 20122 SERVICE MANUAL

Service and Parts Manual SPM 626

CWP 20122 SERIAL NUMBER \

ALWAYS GIVETRUCK SERIAL NUMBER WHEN ORDERING PARTS

El!llRH

Material Handling company

BGP Series Walkie Pallet Truck IMPORTANT: Read and understand the contents of this manual before operating the equipment.

RECEIPT INSPECTION This equipment was thoroughly inspected and tested prior to leaving the factory. Before placing the equipment in service it should be thoroughly checked for damage or loss occurring in transit. If any such damage or loss is evident, a claim must be made against the carrier.

Refer to: Damage in Transit information enclosed with the packing slip.

PAGE

CONTENTS

1 . . . . . . . . . . RECEIPT INSPECTION 2 . . . . . . . . . . Decals 3 . . . . . . . . . . PRE-OPERATION INSTRUCTIONS / SAFETY INFORMATION AND OPERATING INSTRUCTIONS 4 . . . . . . . . . . CONTROL SYSTEM 5 . . . . . . . . . . BATTERY DISCHARGE INDICATOR - OPERATION 6 . . . . . . . . . . BODY ASSEMBLY PARTS LIST 7 . . . . . . . . . . BODY ASSEMBLY & LUBRICATION POINTS 8 . . . . . . . . . . DRIVE UNIT PARTS LIST 9 . . . . . . . . . . DRIVE UNIT DIAGRAM 10 . . . . . . . . . . CWP20 PANEL ASSEMBLY & PARTS LIST 11 . . . . . . . . . . CWP22 PANEL ASSEMBLY & PARTS LIST 12 . . . . . . . . . . CWP20 WIRING DIAGRAM / 3 Speed 13 . . . . . . . . . . CWP22 WIRING DIAGRAM / Electronic Controller 14 . . . . . . . . . . PLANNED MAINTENANCE 15 . . . . . . . . . . BATTERY MAINTENANCE 16 . . . . . . . . . . TROUBLE SHOOTING GUIDE

1

CWP20122 ITEM

PART

NUMBER

NUMBER

QTY

DECALS

DESCRIPTION

1 2

2348906

1

Decal - 5” Clark Logo White (Not Shown)

2389040

3

2812621

2 1

Decal - 5” Clark Logo Black (Not Shown) Decal - Operator Warning (Not Shown)

4 5

1747748 2777635

1 1

Decal - Battery Warning (Not Shown) Decal - No Riding (Not Shown)

Page 2

BGP Series Walkie Pallet Truck PRE-OPERATION INSTRUCTIONS 1. Open drive unit cover and check the wiring harness and hydraulic hoses for damage or loose connections.

2. Open the battery compartment and check that all connections are tight. Check that the batteries have not been damaged. Charge battery(s) for one shift. Refer to Battery Maintenance Instructions (page 15).

3. Refer to the Operator’s Manual on unit and check

that the truck operates satisfactorily. Important notice: During initial cylinder assembly, hydraulic fluid is used to lubricate all the components. This assembly fluid may be present, or accumulated in the upper headnut portion of the cylinder during the break-in period or normal use. A small amount of fluid in this area is normal and should not be mistaken for cylinder seal leakage.

4. Complete the Warranty Validation Form provided with this manual and return it to Clark

SAFETY INFORMATION 1. Do not operate this truck unless you have been trained and authorized to do so.

7. Watch swing clearance when turning near walls, racks, pillars or other obstacles.

2. Do not operate this truck until you have checked its condition. Give special attention to tires, battery, controls, lifting systems (including switches), brakes, steering mechanism, guards and safety devices.

8. Start, stop, change direction, travel and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause truck to slide or tip. Be aware that the truck behaves differently without a load than with a load.

3. Report the need for truck repairs to your supervisor promptly. Do not operate the truck. Neglect may cause a minor repair to become a major service problem or cause the truck to become unsafe.

9. Observe applicable traffic regulations and yield right of way to pedestrians. Slow down and sound horn at all aisle intersections and where vision is obstructed.

4. Do not exceed the rated capacity of the vehicle as marked on the nameplate. Do not lift with the fork tips or one fork only, and be sure load is centered.

10.Do not ride on truck unless equipped with a rider platform.

11.Do not carry passengers.

5. Do not handle unstable or loosely stacked loads.

Use special care when handling long, high or wide loads, to avoid tipping, loss of load, or striking bystanders.

12. Before you leave the truck, fully lower lifting mechanism, shut off power and remove the key.

13.Do not leave truck unattended on ramp.

6. Always look in direction of travel. Keep a clear view and when load obstructs visibility, travel with load trailing (except when climbing ramps).

OPERATING INSTRUCTIONS Refer to OPERATOR'S MANUAL enclosed in the pouch on the control handle. If OPERATOR'S MANUAL is missing contact your authorized Clark distributor for Parts & Service Department. (see page ¢ for part number).

REMEMBER: A safe operator is a smart operator!

3

BGP Series Walkie Pallet Truck CONTROL SYSTEM If your new CLARK CWP Series Walkie Pallet Truck is equipped with an electronic travel speed control, some features included are:

Current multiplication:

Plug braking:

One of the most intriguing aspects of the electronic travel speed controller is the fact that during acceleration, or reduced speed operation, it allows more current into the motor than what it takes out of the battery. This is possible because the controller acts like a D.C. transformer, i.e.: it takes in high voltage (the full battery voltage) and low current, and puts out low voltage and high current.

Thus for these conditions the battery only has to supply a fraction of the current otherwise required by a standard resistor type controller (in which the battery current and motor current are always equal).

The result is a dramatic improvement in the vehicle’s efficiency, ie. greater driving range per battery charge!

In most applications of these controllers, the vehicle motor will be of the series wound type. If a series wound motor is reversed while the vehicle is moving, an efficient form of electrical braking called plug braking will slow the vehicle down. When the motor is reversed the armature acts as a generator. Generated armature current goes through a “plug diode” built into the controller. The controller regulates the current in the motor field winding to give an appropriate level of plug braking torque.

The vehicle brakes smoothly to stop, then automatically accelerates in the other direction if controls are not released.

The plugging current is factory set, but can be field adjusted to suit special applications.

Controller The electronic motor speed controller, being a sealed, solid state unit, requires almost no maintenance.

It is, however, recommended that the following items be checked occasionally, as required.

WARNING

Before doing any work on the vehicle disconnect the battery and depress horn button to discharge capacitors.

a) Make sure that the electrical connections to the controller (as well as those to the motor, batteries, etc.) are tight. When checking the controller bus bar connections for tightness, be sure to use the double-wrench technique to avoid applying torquing stress on the bus bars which could crack the seals around them.

4

b) Remove from the terminal areas any corrosion or accumulations of dirt, acids, grease, oil, etc.

It is very important that the controller terminal face be free of these substances, since their presence may lead to electrical leakage and cause faulty operation. The controller may be wiped clean. In either case, power must be removed during this cleaning.

BGP Series Walkie Pallet Truck BATTERY DISCHARGE INDICATOR (BDI) - OPERATION Some units may be equipped with a battery discharge indicator that may include a lift lockout feature. When the battery is severely discharged the lifting circuit will automatically be disabled. To avoid this, the operator must return the unit for charging after the last light / bar is activated. The travel circuit will remain operational to return the unit to the charging area.

Although, several different style meters are available as options, their basic function is identical.

The lift lockout feature will ensure that the battery and electrical components are not subject to premature wear due to operating with a discharged battery.

Always check the battery indicator, if equipped, in the event that the lifting circuit is not operational. General operation of a battery discharge indicator with or without the lift lockout feature, if equipped, is outlined on the drawing below.

OPTIONAL PARTS 1 2 3 4

032-211 032-229 032-244 026-511

5

026-516

Hour meter Combo BDI-hour meter BDI with lift lockout Combo BDI-hour meter with lift lockout Harness for 026-511

All lights ON: Battery: - fully charged Voltage: - more than 110% of nominal

Four lights ON: Battery: - fully charged Voltage: - between 110% and 100% of nominal

Three lights ON: Battery: - partially discharged Voltage: - between 98% and 100% of nominal

Two lights ON: Battery: - partially discharged Unit should be promptly returned for charging

One light ON: Battery: - fully discharged Lift will be disabled after several minutes of continued service.Unit must be returned for charging immediately!

5

BGP Series Walkie Pallet Truck BODY ASSEMBLY PARTS LIST

ITEM 1 2 3 4 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21 21 22 23 24 25 26 27 27 28 29 30 31 32 32 33 34 35 36

QTY 1 1 1 2 2 2 2 8 2 2 2 8 4 4 2 2 1 1 4 1 1 1 1 1 1 1 1 2 2 2 1 1 2 2 2 2 1 1 2 2 1 1

PART NUMBER 122-0016 014-060 107-196 791-409 791-410 791-411 790-426 018-001 106-172 300-019 106-170 013-010 106-046 018-500 300-000 788-928 791-429 791-428 031-501 032-427 782-385 025-977 032-229 032-216 032-342 038-076 124-0000 123-5007 013-010 107-096 121-5000 785-615 013-010 107-196 018-013 018-001 791-408 791-407 020-560 020-060 037-061 037-063 * — Not Shown

6

DESCRIPTION Front pipe pin Capscrew Clevis pin Connecting rod (36" / 915mm fork) Connecting rod (42" / 1065mm fork) Connecting rod (48" / 1220mm fork) Clevis tee Bushing Clevis axle Hanger axle Load roller axle Spring pin Split ring Bearing Load roller Hanger assembly (c/w bushings) Battery cable set Power cable assembly Battery (6 volt) Charger Battery tray Palm kill switch BDI / Hour meter combination gage BDI with lift lock-out Hour meter Decal Dash board Upper lever weldment Spring pin Clevis pin Cylinder assembly Seal Kit Spring pin Clevis pin Bushing Bushing Front pipe (20¹⁄₂" / 520mm truck) Front pipe (27" / 685mm truck) Caster assembly (optional) Caster wheel c/w bearings Drive unit cover Handle base cover

BGP Series Walkie Pallet Truck BODY ASSEMBLY & LUBRICATION POINTS 19

— Grease

18

17

16

15 Battery cable set

— Motor oil

22

23 21 20 24 25, 26 5 28, 29 4 35 36

3

27

2

32

30

Bushing

31

Bushing

1

14 33

13 12 11 10

34

Caster wheel c/w bearings

6

Bushing 9

10 8 7 HANGER ASSEMBLY DETAIL (Shown from underside for clarity)

Important notice - During initial cylinder assembly, hydraulic fluid is used to lubricate all the components.

This assembly fluid may be present, or accumulated in the upper headnut portion of the cylinder during the break-in period or normal use. A small amount of fluid in this area is normal and should not be mistaken for cylinder seal leakage.

7

BGP Series Walkie Pallet Truck DRIVE UNIT PARTS LIST ITEM 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 41 42 43 44 45 46 47 48

8

QTY 1 1 2 3 4 3 1 4 1 1 1 1 1 1 1 2 4 1 2 1 1 3 2 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 2 2 4 1 1 2 2 2 2 2 1 1

PART NO. 164-5007 164-5007-1 104-5001 010-000 012-210 012-202 122-5001 011-624 018-072 021-315 781-748 781-734 010-036 012-200 018-523 011-060 012-291 021-317 104-355 018-084 021-316 011-508 012-238 164-5001 030-790 013-005 010-057 012-221 120-321 018-507 019-500 120-318 011-599 111-653 780-864 164-5008 018-051 164-0022 011-625 012-224 028-171 025-632 025-561 037-055 012-275 013-033 164-0021 011-053 025-978 783-299

DESCRIPTION CWP20 Handle assembly CWP22 Handle assembly Cam body pivot pin weld Screw Flat washer Lock washer "H" frame weld Cap screw Taper bushing Sprocket Motor bracket Adjustment bracket Screw Lock washer Steel ball Cap screw Washer Belt Key Bushing Sprocket Hex nut Flat washer Brake linkage arrangement Electric motor Spring pin Screw Lock washer Center pin washer Tapered bearing Grease nipple Center pin Lock nut Washer Drive wheel assembly Control handle weldment Bushing Rubber shim Screw Internal lock washer Micro switch CWP20 Direction switch CWP22 Direction switch Thumbwheel Washer External retainer ring Grip handle assembly Bolt Key switch Gear box

BGP Series Walkie Pallet Truck DRIVE UNIT DIAGRAM

See Control Handle Supplement

2 3, 4, 5

6

23 21, 22

7 25, 26, 27

8, 9

24

10 15, 16

28 29, 30

11 12, 13

31 32

14 33

34 17 18

48

19 20

9

BGP Series Walkie Pallet Truck CWP20 PANEL ASSEMBLY & PARTS LIST 8

10

2

3

2

9

5

1

4

11

6,7

ITEM 1 2 3 4 5 6 7 8 9 10 11 12

QTY 2 3 1 1 1 1 1 1 1 2 1 1

PART NO. 116-381 025-717 025-977 025-973 033-738 030-814 030-838 035-208 026-197 026-146 788-927 *032-302 * - Not Shown

DESCRIPTION Resistor Solenoid Palm kill switch Contactor Power pack Motor Brush plate assembly Breather Power fuse Control fuse Hose Horn

BGP Series Walkie Pallet Truck CWP22 PANEL ASSEMBLY & PARTS LIST 8

10

3

2

9

1 6

4

11

6, 7

ITEM 1 2 3 4 5 6 7 8 9 10 11 12

QTY 1 1 1 1 1 1 1 1 1 2 1 1

PART NO. 026-507 025-717 025-977 025-973 033-738 030-814 030-838 035-208 026-197 026-146 788-927 *032-302 * - Not Shown

DESCRIPTION Controller Solenoid Palm kill switch Contactor Power pack Motor Brush plate assembly Breather Power fuse Control fuses Hose Horn

BGP Series Walkie Pallet Truck CWP20 WIRING DIAGRAM / 3 Speed CONTROL WIRE POWER CABLE HYDRAULIC HOSE

6 BLU/BLK

HI

REV.

SPEED RESISTORS

A2

S2

A1

S1

5 FWD.

2ND.

TRACTION MOTOR

OR/ BLK

MOTOR CONTACTORS

BLACK DEADMAN SWITCH

WHITE

SOLENOID LOWERING VALVE

1

2

3

4

5

RED

RED/BLK

BLUE

GREEN

OR/ BLK

BLUE

ORANGE

BLACK/WHITE

RED

CONTROL FUSE

EMERGENCY DISCONNECT SWITCH

6

8

7

9

10

HORN

11

ORANGE BLK/W W/BLK BLU/BLK

8

9 POWER FUSE

MOTOR CNTR. LIFT CYLINDER

HYDRAULIC GEAR PUMP

OIL RESEVOIR PUMP MOTOR

BATTERY CONNECTOR POWER PACK

KEY SWITCH

WHITE BLACK

RED

RED/BLK

RED

4 REV.

3 FWD.

6

ORANGE

GREEN BLUE BLUE / BLACK

RED

HI BLUE GREEN/BLK

CONTROL HANDLE

BLUE

SAFETY REVERSE BUTTON

ORANGE / BLACK RED

5 2ND.

ORANGE

1

WHITE / BLACK RED / BLACK 10

NOTE: ALL CONTROL WIRING IS 18 GA. UNLESS OTHERWISE INDICATED.

HORN

7 DOWN

2

8 UP

BLACK / WHITE

BGP Series Walkie Pallet Truck CWP22 WIRING DIAGRAM / Electronic Controller CONTROL WIRE POWER CABLE HYDRAULIC HOSE HORN

OPTIONAL HOUR METER BATTERY CONNECTOR

10

BDI HOUR METER COMBO 5

6

4 3

10

11

12

ORANGE

9

W/BLK

8

BLACK

7

ORANGE

6

BLK/WH

5

R/B

12

4

OR/ BLACK

3

WHITE

2

GREEN

1

BLACK

RED

BLUE

CONTROL FUSES

SOLENOID LOWERING VALVE

RED / BLACK

1 2

POWER FUSE

W/BLK

BLK/WH

OR/ BLK

WHITE

BLACK

RED WHITE RED

RED/BLK

GREEN

EMERGENCY DISCONNECT SWITCH

GRN/BLK BLUE

WHITE / BLACK

DEADMAN SWITCH WHITE

LIFT CYLINDER BLACK

BLACK

ORGE/BLK

2 MOTOR CONTACTORS

GRN 2

HYDRAULIC GEAR PUMP A2

3 6

OIL RESEVOIR

B+

7

REV

11 12

BLUE

FWD

13

BLACK

M-

14

GRN/BLK

15

RED RED/BLK

16

M-

CURTIS 1207 CONTROLLER BLUE 3

PUMP MOTOR

B-

B1 KEY SWITCH

SOLID STATE CURTISS THROTTLE

A2

ORGE. BLACK GREEN WH/BLK WHITE WH/BRN

BLUE / WHITE RED / WHITE ORANGE / BLACK WHITE GREEN RED

SAFETY REVERSE BUTTON

GREEN / BLACK

BLUE WHITE / BLACK RED

BLACK

NOTE: ALL CONTROL WIRING IS 18 GA. UNLESS OTHERWISE INDICATED.

RED / BLACK

4

12

10 HORN

DOWN

11 UP

ORANGE BLACK / WHITE

B2

A1

BGP Series Walkie Pallet Truck PLANNED MAINTENANCE Spotting trouble before it happens can prevent costly down-time and extensive repairs. Inspection intervals outlined are for normal conditions. More frequent inspections are necessary for adverse conditions ie: rough floor, temperature extremes, multiple operators, dusty environment, etc.

INSPECTION INTERVALS Daily: - Operating controls (SAFETY), see OPERATORS MANUAL - Battery Quarterly: - Electrical system - Hydraulic system - Drive unit, motor brushes and moving mechanical parts

WARNING

Disconnect the battery and depress horn button to discharge capacitors before attempting inspection or service.

LUBRICATION (based on normal, single shift usage) The transmission (gearbox) oil, hydraulic oil should be changed after the truck has been in service for six months, then minimum once a year, for normal single shift usage.

Every month: - Apply engine oil (SAE 10) or grease to all points as shown on page 7, including handle pivot points.

Every three months: - Remove breather cap (item8, page 10,11) check oil level is 1" (25mm) below the top of the reservoir and add approved oil, if necessary. High oil level may cause leakage during rapid braking. The breather cap should be cleaned with a suitable cleaning solvent and blown dry (safety glasses must be worn) before you reinstall. Check gearbox oil level (item 48, page 8).

Every six months: - Clean drive unit swivel bearings and wheel bearings, check for smooth operation and lubricate using high quality lithium based EP type grease.

Yearly: - Remove reservoir, discard used oil and clean reservoir. Clean and inspect strainer and replace if damaged. Reinstall and add oil to 1" (25mm) below the top. For operation at normal (room) temperatures use only approved hydraulic oils such as: ISO 32 Sunvis 832 Esso Polar 32 Shell Tellus 29 Texaco Rando Oil HD32(150) Dextron II transmission fluid or equal.

For transmission (gearbox) oil use: Gulf Harmony 68 Esso Teresso 68 Shell Covil 68 or equal.

For low temperature operation consult the manufacturer for recommended hydraulic and transmission oils.

BGP Series Walkie Pallet Truck BATTERY MAINTENANCE Do not discharge below specific gravity of 1.150 or there will be a permanent loss of capacity.

CAUTION

Equalizing charge In order to equalize all the cells once a week, following a normal charge, the battery should be given a second charge, continued until there is no improvement between two consecutive hydrometer readings of each cell. This is actually a continuation of the regular charge at a low rate.

Charging industrial battery with remote charger Refer to charger manufacturer's operating directions and manual.

Charging with built-in charger / battery pack Plug charger cord into electrical outlet (115/1/60).

Charging will start and stop automatically.

Electrolyte level Only distilled water should be added to each cell as often as necessary after charging, to keep the electrolyte to the bottom of the vent well. Do not over fill. Normally water is required no more than once a week. Excessive water use may indicate over-charging or high charging rates, defective battery or an under rated battery/charger package.

Charging with GNB 'Champion' power pack Refer to manufacturers operating directions and manual.

WARNING Insure that battery charger electric plug cannot come into contact with battery terminal posts.

General The top of the battery should be kept clean and dry. Wash off with clean water and baking soda when necessary. Good ventilation should be provided during charging. Do not allow electrolyte temperature to exceed 110oF (43oC).Keep open flames away from battery. Never add acid to cells. Batteries used at temperatures below or above normal (room) temperature will have reduced capacity.

WARNING Disconnect the SB battery connector from the machine prior to charging to prevent accidental vehicle movement.

Records A weekly record should be kept showing hydrometer readings of pilot cell at start and at end of charge. Change to a different pilot cell monthly.

Once a week after the battery has received an equalizing charge, record the hydrometer readings of all cells

BATTERY CABLE CONNECTIONS (for built-in battery / charger pack)

WARNING

Make sure of battery voltage and polarity before making connection

CABLING ARRANGEMENT FOR 4 - 12 VOLT BATTERIES (IN SERIES/PARALLEL)

+

-

+

12V

-

+

-

+

12V

+

12V

-

12V

-

12V

BGP Series Walkie Pallet Truck

TROUBLE SHOOTING GUIDE

PROBLEM NO LIFT (Motor does not run)

POSSIBLE CAUSE • • • • •

Faulty wiring from fuse to lift switch in handle.

Faulty lift switch Faulty wiring from lift switch to pump contactor.

Faulty lift contactor Faulty wiring from battery positive terminal to pump contactor, or from pump contactor to pump motor • Burned out brushes in pump motor • Defective control circuit fuse

NO LIFT (motor runs)

• Low hydraulic pressure caused by: - Pressure relief valve needs adjustment - Pump check valve stuck open - Faulty solenoid valve • Check oil level if forks do not raise fully • Check hydraulic pump operation • Defective control circuit fuse

FORKS WILL NOT LOWER

• Faulty lowering switch on steering handle • Faulty wiring from lowering switch to solenoid valve • Faulty solenoid coil • Defective control circuit fuse

NO ELECTRICAL POWER (no travel)

• No electrical power caused by: - Key switch in "OFF" position - Emergency disconnect button depressed - Faulty SB connector (or unplugged) - Loose battery connections - Blown control or power fuse • Faulty wiring from fuse to travel control switch • Faulty travel control switch • Faulty wiring from travel control switch to direction contactor • Faulty contactor