CLARK FORKLIFT SPM 642 CTT 3 SERVICE MANUALS

Service and Parts Manual SPM 642

CTT 3

SERIAL NUMBER ALWAYS GIVE TRUCK SERIAL NUMBER WHEN ORDERING PARTS

C l!!lRK

Material Handling Company

TT-500 Series Tow Tractor 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 4 . . . . . . . . . . OPERATING INSTRUCTIONS 5 . . . . . . . . . . GENERAL MATERIAL HANDLING GUIDELINES PLANNED MAINTENANCE 6 . . . . . . . . . . PLANNED MAINTENANCE CON'T 7 . . . . . . . . . . OPERATOR CONTROLS LUBRICATION 8 . . . . . . . . . . BODY ASSEMBLY 10 . . . . . . . . . . DRIVE UNIT ASSEMBLY 12 . . . . . . . . . . STEERING UNIT ASSEMBLY 14 . . . . . . . . . . STEERING COLUMN ASSEMBLY 16 . . . . . . . . . . WIRING DIAGRAM

Page 1

CTT3DECALS ITEM

PART

NUMBER

NUMBER

QTY

DESCRIPTION

1

3798346

2

Decal - 3” Clark Logo (Not Shown)

2

2348906

1

Decal - 5” Clark Logo (Not Shown)

3

1747748

1

Decal - Battery Warning (Not Shown)

4

2783039

1

Decal - No Riding (Not Shown)

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TT-500 Series Tow Tractor SAFETY INFORMATION Important: All designated operators of this equipment MUST read and understand the contents of this manual before operating the equipment.

• Do not operate this Tow Tractor unless you have been trained and authorized to do so.

• Extreme caution must be used when towing loosely stacked / packaged loads.

• Do not operate this Tow Tractor until you have checked its condition. Give special attention to the tires, battery, controls, switches, brakes steering mechanism, guards, and safety devices.

• Watch clearance when turning near walls, racks, pillars and other obstacles.

• Report the need for repairs to your supervisor immediately and do not operate the Tow Tractor until the repairs are made. Neglect may cause a minor repair to become a major service problem and cause the Tow Tractor to become unsafe.

• Operate this Tow Tractor from a seated position only.

Do not operate Tow Tractor while standing.

• Start, stop, change direction, travel, and brake smoothly. Slow down for turns on uneven or slippery surfaces. Be aware that the Tow Tractor behaves differently without a load than with a load.

• The Tow Tractor is designed for level surface use only.

• Yield right of way to pedestrians. Slow down and sound the horn at aisle intersections and where vision is obstructed.

• Do not exceed the rated capacity of the Tow Tractor as marked on the nameplate.

• Do not carry passengers.

• Always look in the direction of travel. Use caution when load interferes with visibility.

• Before you leave the truck unattended, apply the parking brake and shut off all power.

PRE-OPERATION INSTRUCTIONS • Complete the warranty validation form included with the manual and return to Clark Warranty coverage may be void if the validation form is not returned completed to Clark.

• Remove any packing material and check the unit for visible damage • Open the drive unit compartment and inspect the wiring harness for damage and loose connections

• Open the battery compartment and check that all connections are tight. Check that the battery or cables have not been damaged. The battery should be fully charged before the vehicle is placed into service.

• Refer to the operating instructions and confirm the Tow Tractor operates properly before use.

REMEMBER: A SAFE OPERATOR IS A SMART OPERATOR

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TT-500 Series Tow Tractor OPERATING INSTRUCTIONS Reference: Figure 1 Horn: Horn push-button is conveniently located on the left side of the operators compartment floorboard or on the center of the steering column.

Travel control: The direction controls are located on the right side of the dash panel. The Tow Tractor is equipped with and electronic speed control and has variable speed selection regulated by depressing the throttle control located on the operators compartment floor board.

Brakes: The brakes are either a mechanically or hydraulically applied disk brake. The brake pedal is located on the operators compartment floorboard. The parking brake is applied by pulling the parking brake lever, located on the right hand side of the dash panel, to the locked position. The parking brake is released by moving the lever to the unlocked position.

Steering controls Turning the steering wheel in the direction desired controls steering. Steering limits are imposed on the mechanism and any attempt to force the steering beyond the turning limits will damage the unit. The steering column is adjustable in both tilt angle and telescopic height. A lever located on the right side of the column controls the position. Pressing the lever down will allow the column to be tilted forward or backward. Releasing the tilt lever will lock the unit into the desired position. Lifting the lever up will allow the column to slide vertically. Releasing the lever will lock the column at the desired height.

GENERAL MATERIAL HANDLING GUIDELINES This section is intended to remind you of generally applicable principles of material handling. Recognizing that your employer may have specific guidelines, and that unique applications may require special guidelines. It is not intended that this section be interpreted as covering all possible guidelines. See your employer for additional instruction.

Trained operators only: It is imperative that you receive adequate training in general workplace safety practices, as well as training in the use of material handling equipment.

If you have not received this training or believe you need additional training. See your supervisor.

Load handling: • Handle stable and safely arranged loads.

• Handle loads within the machine’s capacity.

• When maneuvering, always watch your clearance.

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Maneuvering: • When maneuvering, be aware of all obstacles and pedestrians.

• Sound horn at blind spots or when entering intersection aisle.

• Keep people off the Tow Tractor, and load(s).

Do not carry or transport passengers.

• Always have a clear view of the direction of travel.

• Travel very slowly during all turns.

Parking the truck: • Never park the Tow Tractor on a grade or slope.

• Never park the Tow Tractor on a dock leveler or in a trailer.

• Before leaving the Tow Tractor, you must set the parking brakes, and turn the key to the off position and if possible remove the key to prevent use by unauthorized personnel.

TT-500 Series Tow Tractor PLANNED MAINTENANCE Planned maintenance is a program in which inspection, minor adjustments and lubrication are performed on a scheduled and systematic basis. A solid PM program should incorporate a method of record keeping which enables you to better determine PM schedules and enables you to track the maintenance cost per machine.

An effective PM program should incorporate two procedures.

1) A pre-operation check by the driver or maintenance personnel at the beginning of each shift.

2) A planned maintenance routine based on operating hours, with the interval being determined by operating condition.

Records will tell you how often PM should be done. If an operation is clean and/or involves low operating time per day, a PM interval can be extended. If an operation is extremely dirty and/or involves high operating time per day, the PM interval may have to be reduced. Thus the PM interval can be tailored to answer the needs of the operation.

If the PM is religiously followed, needs for repair, major adjustment and component replacement will be discovered automatically and such work will be done as needed.

The PM Objective: 1) To reduce costly unscheduled downtime.

2) Reduce maintenance costs.

3) Increase equipment productivity.

4) Above all, to increase personal safety of operators and other personnel.

Inspection intervals outlined are for normal conditions.

More frequent inspections are necessary for adverse conditions such as: temperature extremes, several operators, dusty atmosphere, etc.

RECOMMENDED PM INTERVALS:

WARNING

Disconnect the battery and discharge the system before attempting inspection or service

Daily: Operating Controls Safety Devices Battery Inspect the following systems for proper operation.

Brake system, direction control for proper orientation and function. seat switch for proper operation, horn and steering system for proper operation, visibility of all decals and warning labels. The battery charge should be noted and consideration should be made in order to determine if enough charge is available to begin the shift. Care must be taken to assure that the Tow Tractor is not subjected to towing loads with low battery coditions.

Note: Units with the optional low battery high speed interrupt option will automatically have the travel speed reduced to 50% when the battery charges reaches 80% discharge.

This function will help prevent operation during low battery conditions.

Quarterly / Every 250 hrs: Electrical systems Drive Unit Mechanical parts Battery Compartment: The battery compartment should be inspected for corrosion and cleaned with a mixture of water and bicarbonate of soda (one pound of soda to a gallon of water) then rinsed with clear water. Any exposed metal should be repainted.

Wire and cables: All wires and cables should be in good condition, firmly attached to their terminals and bundled neatly so as to prevent being snagged or chaffed by the operation of steering and drive systems.

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TT-500 Series Tow Tractor PLANNED MAINTENANCE Cont'd Traction Motor: Use only clean, dry compressed air to remove dust and particles from the traction motor. Remove the brush guards and inspect the brush leads for burning or damage. The brush length should be measured and the brushes should be replaced when half (1⁄2 ) the brush is worn away. Traction motor brushes are 1-1⁄4 ” long when new and 5⁄8” long at the replacement point. If the brushes are not at the replacement point but it is determined that the brushes will reach the replacement point before the next inspection interval, the brushes should be changed. Inspect the motor commutator for damage.

Repair all damage to the commutator before the new brushes are installed. The traction motor requires no lubrication.

Direction Contactors: Inspect the Direction contractor tips. Darkening and pitting is normal however replacement should be made when the contact material is burnt away or will be burnt away before the next inspection interval.

Mechanical Parts: Inspect and lubricate the steering column universal joints, the steering center shaft bearings and wheel axle bearings. The universal joints are oilable and can be lubricated with lightweight motor oil. All other grease points use standard automotive wheel bearing grease. See Figure 2

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Drive Unit: Check the condition of the drive belt. If cracked or damaged replace the belt. The belt tension is correct when a ten (10) pound force applied midway between the pulleys deflects the belt 1⁄2 ”. Excessive belt tension will result in damage to the input bearings on the transaxle. Axle mounting bolts are to be tightened to 47 ft/lb. Check the Drive Wheel lug nuts for proper torque (58-66 lbs•ft).

Check the oil level in the transaxle. If low add oil to the proper level. Use SAE 85W140 oil or equivalent.

Initial oil change must be done at 500hrs of operation and every 1000 hours thereafter.

Inspect the brake pads and caliper. Both brake pads should be replaced when any one pad is worn 75%.

New pads are 3⁄8” thick when new and 1⁄4 ” when in need of replacement. If the pad will reach replacement thickness before the next inspection interval both pads should be replaced. Check the master cylinder fluid level. If fluid is required use only Dot 3 Automotive fluid.

TT-500 Series Tow Tractor OPERATOR CONTROLS Figure 1

LUBRICATION Figure 2

SAE85W140 Oil

Page 7

TT-500 Series Tow Tractor BODY ASSEMBLY

Page 8

TT-500 Series Tow Tractor BODY ASSEMBLY PARTS LIST

ITEM NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

PART NUMBER

QTY

037-071 037-052 037-066 028-056 035-297 791-248 023-607 300-296 300-289 791-225 020-088 020-087 032-358 025-691 791-262 013-592 023-580 023-615

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

DESCRIPTION Steering Unit Cover Seat (without arm rests) Arm Rest Kit Seat Switch Kit Brake Lever Throttle Assembly Master Cylinder Parking Brake Cable Assembly Drive Unit Cover Floor Board Assembly (9") Steering Wheel Steering Column Horn Button Column Mounted Option Horn Button Floor Mounted Option Shaft Clamp Brake Line Brake Switch Kit

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TT-500 Series Tow Tractor DRIVE UNIT ASSEMBLY

24

Page 10

TT-500 Series Tow Tractor DRIVE UNIT ASSEMBLY PARTS LIST

ITEM NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

PART NUMBER

QTY

901-0008 901-0034

1 2

035-421 023-025 018-072 104-355 018-103 013-128 5350104 023-598 023-613 023-606 5350065 5350068 021-104 791-273 020-093 012-222 011-510 090-931 5350086 012-026 011-642 790-799

1 2 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 .75 gal 1 10 10 1

DESCRIPTION Traction Motor Brush set Not Shown Breather Pulley Bushing Key Bushing Key Belt Brake Lining Fixed Side Brake Lining Live Side Brake Assembly complete with 1 lining Brake Disk Key Key Drive Wheel Hub Drive Tire Washer Nut Gear oil SAE 85W40 Transaxle Stud Nut Filler Tube Assembly

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TT-500 Series Tow Tractor STEERING UNIT ASSEMBLY

Page 12

TT-500 Series Tow Tractor STEERING UNIT ASSEMBLY PARTS LIST

ITEM NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NUMBER

QTY

023-210 018-101 023-039 011-634 013-079 012-303 791-240 300-256 018-500 023-040 018-102 023-329 116-531 791-245 119-461 020-042 119-471 300-305

1 1 1 1 1 1 2 1 2 1 1 2 1 4 2 2 2 1

DESCRIPTION Steering belt Bushing Pulley Nut Cotter Pin Washer Bearing Set Adjuster Assembly Bearing Pulley Bushing U-Joint Wheel Axle Bearing Set Wheel Hub Tire Lock Nut Shaft

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TT-500 Series Tow Tractor STEERING COLUMN ASSEMBLY

Page 14

TT-500 Series Tow Tractor STEERING COLUMN ASSEMBLY PARTS LIST

ITEM NUMBER

PART NUMBER

1 1a 1b 1c 1d 1e 1f 1g 1h 2 3 4

024-004 Part of Item Part of Item Part of Item Part of Item Part of Item Part of Item Part of Item Part of Item 017-068 018-621 023-617

5 6 6a 6b 6c 6d 6e 7 8

091-248 5350025 Part of Item Part of Item Part of Item Part of Item Part of Item 018-622 791-262

QTY 1 1 1 1 1 1 1 1 1

6 6 6 6 6

DESCRIPTION Tilt / Telescopic Lever Assembly Bushing Link Arm Lock Washer Rivet Link Arm Lock Washer Lever Hand Lever Knob Spring Kit includes all 4 springs Bushing Cover Kit, Includes both cover halves, screw and cable tie Rubber Bellows Tilt Lock Devise Kit Screw Tooth Segment Catch Pin Pin Bushing Shaft

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TT-500 Series Tow Tractor ELECTRICAL

Page 16

TT-500 Series Tow Tractor ELECTRICAL PARTS LIST

ITEM NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NUMBER

QTY

026-510 026-521 026-200 026-146 025-984 032-406 025-561 032-211 798-001 032-244 025-525 032-302 032-373 032-372

1 1 1 2 1 2 1 1 1 1 1 1 1 1

DESCRIPTION Electronic Motor Controller Direction Contactor Main Power Fuse Control Power Fuse Low Power Relay Kit SB-175 Battery Connector Key Switch Hour Meter with Lift Lock-out Pilot Light Assembly Battery Discharge Indicator Direction Switch Horn (Not Shown) Head Light Assembly (Not Shown) Brake / Tail Light Assembly (Not Shown)

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TT-500 Series Tow Tractor WIRING DIAGRAM

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