Clark Forklift PMA-541 PHMP 465 (lot 6020 6025 and above) Planned Maintenance and Adjustment Manual

PMA-541 P/HMP 465 (lot 6020 / 6025 and above)

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

Planned Maintenance & Adjustment Procedures

PMA 541 PlHWP 465

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

CLflRK THIS MANUAL INCLUDES PLANNED MAINTENANCE

PM

81 ADJUSTMENT

PROCEDURES

FOR HWP 40-60

AND P 40-60 PALLET LIFT TRUCKS

Code: PM-541, JAN 86

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

Page i

CMRK

PM

TABLE OF CONTENTS 0.0

INTRODUCTION

0.1

HOW TO USE THIS MANUAL

0.2

PICTORIAL

0.4

KNOW YOUR TRUCK

0.16

OWNER SAFE MAINTENANCE

1.1

PLANNED

INDEX

MAINTENANCE

PRACTICES

PROGRAM

GROUPSECTION

TITLE

01-l

LUBRICATION

12-7

ELECTRIC

TRUCK BATTERY

13-1

ELECTRIC

DRIVE MOTOR (BRAKE) CUT-OFF

13-3

LIFT LIMIT CONTROL

16-27

GENERAL

17-l

CONTACTOR

17-2

CONTACTORS

20-l

DRIVE UNIT

23-1

DRIVE WHEEL AND TIRE

23-2

BRAKE

30-l

HYDRAULIC

34-4

LIFT CYLINDER

35-l

TRAIL WHEEL LINKAGE ADJUSTMENT

38-3

TIPPING,

40-l

DECALS -

40-2

TRUCK

40-3

PM INSPECTION AND DRIVERS DAILY INSPECTION EXTINGUISHER RECOMMENDATIONS

40-4

LUBRICATION CHART KEY

Page ii

CHARTS AND SPECIFICATIONS

SWITCH

SWITCH ADJUSTMENT

MOTOR MAINTENANCE PANEL

SYSTEM PRESSURE

CHECK

DRIFT TEST

JACKING AND BLOCKING PLATES -

TRUCK SERIAL NUMBER DATA

SPECIFICATIONS

SPECIFICATIONS

FORMS -

AND RECOMMENDATIONS

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

-

FIRE LUBRICATION

Code: PM-541, JAN 86

PM

CLr(RK

How To Use This Manual

This manual is intended to be used by persons who are trained and authorized to do lift truck maintenance.

The purpose of this manual is to outline the recommended procedures required for doing routine maintenance for your lift truck on a scheduled, periodic basis. It is written to show and describe each step of the inspections, tests, cleaning, lubrication and adjustments that are normally required to maintain your lift truck in an efficient and safe operating condition.

To be better prepared to do the necessary maintenance work, take time to read the subject index, the safety information and the know-your-truck sections. These pages will help you understand your truck and provide instructions for safe maintenance paractices.

After you have read the introductory sections in this manual, you may want to read the Operator's Manual located on the truck. The Operator's Manual can tell you how to start and operate your lift truck safely.

This manual is arranged to first outline the recommended planned maintenance (PM) program. Then, more detailed procedures are presented to give further instructions and information which you will need for lubrication and minor adjustments, replacements or repair. Please be sure to read the entire procedure before doing any work. The detailed procedures are arranged in sequence by numbered GROUP and Section. The GROUP numbers are the same as the component group in the Parts Manual. The GROUP number identification is also the same as used for reference on the PM Report form.

Truck data and other useful information is collected into GROUP 40 at the back of the manual for easy reference.

In this Group you will find a suggested list of tools you will need in a PM program. Also included for your reference are listings of useful specifications for major components, fuel and lubricants, critical fastener (bolt) torques, fill capacities and settings for your truck.

If you have the need for more information on the care and repair of your truck, please contact your authorized Clark dealer.

Code: PM-520, JUN 84

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

Page 0.1

CLSRU

PM

PICTORIAL

INDEX*

GROUP

TITLE

01

LUBRICATION

CHARTS AND SPECIFICATIONS

12

ELECTRIC

TRUCK BATTERY

13

ELECTRIC

DRIVE MOTOR (BRAKE) CUT-OFF

13

LIFT LIMIT CONTROL

16

GENERAL

17

CONTACTOR

17

CONTACTORS

20

DRIVE UNIT

23

DRIVE WHEEL AND TIRE

23

BRAKE

30

HYDRAULIC

34

LIFT CYLINDER

35

TRAIL WHEEL LINKAGE ADJUSTMENT

38

TIPPING,

40

DECALS -

40

TRUCK

40

PM INSPECTION AND DRIVER’S DAILY INSPECTION EXTINGUISHER RECOMMENDATIONS

40

LUBRICATION CHART KEY

SWITCH ADJUSTMENT

MOTOR MAINTENANCE PANEL

SYSTEM PRESSURE

CHECK

DRIFT TEST

JACKING AND BLOCKING PLATES -

TRUCK SERIAL NUMBER

DATA

SPECIFICATIONS

SPECIFICATIONS

*SEE NEXT PAGE FOR PICTORIAL

Page 0.2

SWITCH

REFERENCE

FORMS -

AND RECOMMENDATIONS OF COMPONENT

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

-

FIRE LUBRICATION

AND ITS GROUP NUMBER.

Code: PM-541, JAN 86

PM

CLqRK

12

17 29

16

38

23

01

20

Code: PM-541, JAN 86

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

Page 0.3

ELqRK

KNOW YOUR TRUCK

Operator Controls Truck Data and Safety Plates Product Description Specifications General Data

Page 0.4

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

Code: PM-541, JAN 86

HWP 40 and HWP 60 Hi-Speed, Warehouse, Pallet Truck (4,000 Ibs. [l 800 kg] and 6,000 Ibs. [2 720 kg] Rated Capacity) 1. Directional

and Speed Control Levers.

2. Horn, Lift, Lower and High Speed Controls.

3. Auxiliary

Control Handle.

4. Battery.

5. Pallet (Load) Forks.

6. Load Wheels and Tires.

7. Skid Runner.

8. Spring Loaded Caster (Optional).

9. Rider Platform.

10. Drive Unit Cover.

11. Steering and Brake Control Handle.

P 40, P 60 Pallet Model Trucks (4,000 Ibs. [l 800 kg] or 6,000 Ibs. [2 720 kg] Rated Capacity) 1. Directional

and Speed Control.

2. Steering Control Handle.

3. Battery.

4. Pallet (Load) Forks.

5. Load Wheels and Tires.

6. Drive Unit Cover.

7. Drive Wheel and Tire.

8. Machine Serial Location.

Code: PM-541, JAN 86

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

Page 0.5

PM

Clark P Series and HWP Series (walk/ride) pallet trucks are highly maneuverable, extremely durable, and performance proven in heavy-duty applications. Both are repeatedly selected by users who demand the same reliability from their pallet trucks as from other production equipment.

The HWP walk/ride model is particularly suited for use in large plants where travel distances are a consideration. Operators can ride to distant areas at speeds up to 6 mph. The HWP models offer the operator four speed selections, in both forward and reverse.

The P Series models are ideal for plants where shorter travel distances are required. The P Series models offer the operator three speed selections, in both forward and reverse.

Operator Comfort/Convenience Closed loop handle All controls at fingertips Three speeds forward and reverse on P Series models, and four forward and reverse speeds on HWP models Two-position

brake

Spacious riding platform on HWP models The closed loop handle allows control from either side of the truck, especially spaces.

Non-skid platform and stationary HWP models.

Direction, speed, lift/lower,

important

in tight work

closed loop handle enable the operator to safely step on and ride

horn, brake and steering are all controlled

The directional and speed control is thumb-applied hand operation.

at the handle.

butterfly type; dual designed

The variable forward and reverse speeds, 180 degree steering, application make Clark pallet trucks easy to operate.

for left or right

and smooth up-or-down

brake

A reversing safety switch at the end of the handle is spring loaded and designed to override the directional control, automatically reversing the truck on contact. This feature is designed to help prevent the operator from being pinned in cramped quarters.

Motors Drive motor is 6.5-inch diameter high speed, series wound. Its design enables high torque at low travel speeds, critical for moving heavy loads up ramps or across dock plates. Drive motor is integral with the drive line to assure positive alignment. The motor is fan cooled, ventilated, and equipped with sealed ball bearings for long service life.

Hydraulic motor is 4.5inch diameter, heavy-duty horizontally mounted and integral with pump and reservoir. This design assures positive alignment with maximum strength and rigidity of all components.

Electrical System . 12-Volt l

Single or double row industrial

battery

Battery removal is quick and easy. Simply disconnect the battery and lift it from the truck using an insulated spreader bar and hoist. The truck is equipped with an Anderson gray SB-2 connector.

Page 0.6

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

Code: PM-541, JAN 86

PM

CLflRK Drive Line l

Double reduction

l

Totally enclosed

l

Protected location

spur gears

Power from the horizontally mounted drive motor is transmitted through 22-to-1 double reduction spur gears to the drive wheel axle. The gears are mounted on ball bearings, are in constant mesh and operate totally enclosed in a bath of oil. Fluid volume is 1 pint (.473 L). Drive tire is cushion rubber on cast iron wheel, spline fitted to the axle shaft for maximum service life and easy tire replacement.

Brakes l

Double acting

l

Self-adjusting

Gradual movement of the control handle up or down provides smooth, precise braking control. An external shoe-type brake on the end of the drive motor multiplies effective brake force through final gear reduction by approximately 22-to-l.

Shoes are self-centering to provide smooth operation and even possibility of rivets scoring the drum. As the brake is applied, a breaks the control circuit. The truck does not operate when the position. Additional electric braking is available by reversing the

wear. Bonded linings eliminate the switch is actuated which automatically handle is in the vertical or lowered directional control.

Hydraulic System The hydraulic motor pump, fluid reservoir, pressure relief valve and control valve are assembled into a compact unit centrally located between two self-aligning lift cylinders. Lift and lowering of the forks is regulated by push buttons located on the truck control handle.

The system is protected from impurities by an internal return line filter and suction line screen. A fill plug in the top of the reservoir allows easy inspection of fluid level. Hydraulic sump fluid volume is 1.6 quarts (1.514 L).

Steering l

Handle rotates drive unit 180 degrees

l

Design assures positive control

The tubular steel steering handle, mounted on the drive assembly, pivots the drive wheel 90 degrees left or right for maximum truck maneuverability. A large barrel-type roller bearing supports the drive unit and effectively counteracts load forces to promote easy, low effort steering.

Frame and Chassis The truck frame and load forks are fabricated from plate and bar steel, formed to shape and electrically welded into a unit structure, providing strength and rigidity with minimum weight. The fork elevating channels are integral with the frame. Load wheel rollers are mounted under the ends of the forks and are connected to the elevating linkage.

This linkage is so arranged that when the forks are lifted vertically the wheelbase is shortened and under clearance is increased. Pallet forks are heavy steel plate formed into tubular sections for rigidity; cast steel toes are electrically welded to these sections. The toe of each fork is provided with pallet rollers for entry and exit from double faced pallets.

Code: PM-541, JAN 86

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

Page 0.7

CLSRK Features and Options P SERIES l

l

Standard equipment: Electric horn, grease fittings at all pivot points, single row battery compartment, 48-inch forks, roller uprights with sealed bearings, operator’s manual, warning Finish is high-visibility Clark green.

Options: Power key switch, double row battery compartment, pallet handling, SCR, stability casters, hour meter.

labels.

various fork lengths for special-size

HWP SERIES l

Standard Equipment: Electric horn, grease fittings at all pivot points, roller uprights with sealed bearings, 48-inch forks, operator’s manual, warning labels. Finish is high-visibility Clark green.

l

Options: Double row battery compartment for Model HWP 40, various fork lengths for special-size pallet handling, SCR, stability casters, power.

ANSI and Insurance Classification Standard truck meets all applicable mandatory requirements of Part II - ANSI B56.1 1969 and 1975 Safety Standard for Powered Industrial Trucks and Underwriters Laboratories requirements as to fire hazard for “E” classification. For further information contact a Clark representative.

1 P 40 MODEL

PRODUCT SPECIFICATION General Information

4,000 Lb.

Load Capacity

1 P 60 MODEL

1

1HWP 40 MODEL 1HWP 60 MODEL 4,000 Lb.

6,000 Lb.

12-Volt Electric

Power Unit

Pallet Walk

Vehicle Type

Pallet Walk/Ride Urethane/Rubber

Tire Type Load/Drive Wheels Front/Rear (X = Driven) Basic Dimensions

6,000 Lb.

24-Volt Electric

211x (1)

Pallet Forks Lift Height to Top of Fork

9.25 in.

Lowered

3.25 in.

Height

Fork Thickness

2.38 in.

Fork Width

9.25 in.

48.0 in.

Fork Length (2) 28.5 in. (3)

Length to Fork Face

34.0 in.

39.5 in.

64.6 in. (4)

71.6 in.

77.1 in.

68.8 in. (5)

78.4

83.9

27.0 in.

Fork Spread

33.75 in.

Chassis Height, Forks Lowered Turning Radius, Forks Raised Right Angle Stack Aisle (With 40 x 48 in. Pallet Size) Performance

(1) 2.713.7

2.613.7

4.015.5

4.516.0

7.213.3

7.813.9

7.213.3

5.213.9

1.813.7

1.013.7

1.813.7

1.813.7

1,624 Lb.

1,654 Lb.

With Load FrontiRear

3,550 Lb.1 2,074 Lb.

5,065 Lb.1 2.589 Lb.

3,391 Lb.1 2,259 Lb.

5,068 Lb.1 3.172 Lb.

Without Load Fronti Rear

550 Lb.1 1,074 Lb.

565 Lb.1 1,089 Lb.

550 Lb.1 1,100 Lb.

660 Lb.1 1,580 Lb:

Max. Travel Speed (MPH) With Load/Without Lift Speed (Seconds) With Load/Without Lower Speeds (Seconds) Weicthts (1)

With Load/Without

Service Weight With Min. Battery Weight

Load

Load Load

I 1

1

1,650 Lb.

1

2,240 Lb.

Axle Loading, Lowered

Page 0.8

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

Code: PM-541, JAN 86

PM

CLflRK

t PRODUCT

1 P 40 MODEL

SPECIFICATION

1 P 60 MODEL

1HWP 40 MODEL 1HWP 60 MODEL1 I

1 Chassis (1) 2/l

Number of Tires Front/Rear

10.5 x 6.0 x 6.5 in.13.38 x 2.63 in.

Tire Size Front/Rear

60.17 in.

Wheelbase .87 in.

I

1 Min. Ground Clearance

.63 in.

I

Service Brakes

Drum and Shoe

Parking Brakes

Spring Applied

I

Pivot Arm

Steerina Drive Line (1)

Lead Acid

Batterv Tvoe I Batterv Cabacitv

(6 hr. Rate), Max. -

KW.h/A.h

I

I I

6.91600 (6) 365 Lb. (6)

I Battery Weight, Min.

1

810 Lb.

6.5 in.

Drive Motor Diameter

4.5 in.

Hvdraulic Motor Diameter

Resistor

I Drive Motor Control 3-Step

Speed Control

4-Step On/Off

Hydraulic Motor Control

1950 psi

Hydraulic Pressure (1) (2) (3) (4) (5) (6)

I

13.821600 430 Lb.

Specifications are shown for Model HWP 40 with single row battery; HWP 60 with double row battery.

Other fork lengths available, see general data information following.

Dimension is for truck models with single row battery compartment. Dimension for double row compartment Dimension is for truck models with single row battery. Dimension for double row battery is 70.1 in.

Dimension is for truck model with single row battery. Dimension for double row battery is 74.3 in.

Specifications are for standard single row battery.

Battery Compartment

is 34.0 in.

Dimensions Vehicle Type

II

Dimension

I I

P Series Sinale Row Bkery

I

I

P Series Double Row Battery

HWP 40

I

I

HWP 60

31.63 in.

Width 8.13 in.

Lenoth

13.38 in.

8.13 in. (1)

13.38 in.

Accepts All Heights

I Heiaht (1) Add 5.5 in. for optional

I

double row battery.

Code: PM-541, JAN 86

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

Page 0.9

1

PM

Fork Lengths and Pallet Dimensions

Fork Lengths and Pallet Dimensions

1ST PALLET

t

2ND PALLET

A-l

Fork Lgths.

Pallet Lenoth

&a/l Load Lenqth

A Bottom Board Width

inches

inches

inches

inches

inches

:

:

15

96

6

15

c

Fork Lgths.

C Pa//et Length

&an Load Length

BOt0m Board Width

inches

inches

inches

inches

For Single Pallet Handling 36 *t;

36 42 46

54 60

2

Page 0.10

B Minimum CleafanC8 for y$‘&P of Pa//et

0 Minimum Clearance for y$$JP of Pallet

For Double Pallet Handling

z

72

t

:

46

‘Standard fork length

inches Performance may vary +5% or -10% due to motor, tire, drive unit, and hydraulic efficiency tolerances and battery weight.

Clark products and specifications

are subject to change without notice.

Clark is a registered trademark of Clark Equipment Company.

OClark Equipment Company 1965.

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

Code: PM-541, JAN 86

CMRK

PM

P Series Dimensions

4!

\

64.6 IN TURNING RADIUS WITH FORKS RAISED’

\

-_

I I

270 IN

I

rmr,u’

I

I

I

42.0 IN 3AD IDTH

_ -\ 66.6 :N RIGHT ANGLE STACK AISLE*

10.5 x 6.0

65

LOAD WHEELS-DUAL 3 30 x 263 URETHANE

‘ADD 5.5 INCHES FOR TRUCKS WITH OPTIONAL “OTHER

Code: PM-541, JAN 86

FORK LENGTHS

AVAILABLE.

SEE CHART

DOUBLE UNDER

ROW BAllERY GENERAL

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

RAISED

COMPARNENT.

DATA.

Page 0.11

PM

HWP Series Dimensions

HWP

Series Dimensions

/

TURNING RADIUS WITH FORKS RAISED’

48.0 IN STANDARD”

1

t-

---_---

21,: I

c

i4.63

(1.. L

DRIVE TIRE 10.5 x co x 6.5 RUBBER /

IN

LENGTH TO _ FORK FACE

925 IN 1

11; I

i 1 3.25 IN

i----

ILOAD WHEELS-DUAL

73 IN LOWERED 11.9 IN RAISED

3u.&%s

‘SEE SPECIFICATIONSCHART FOR INFORMATION. “OTHER FORK LENGlHS AVAILABLE. REFER TO GENERAL DATA.

Page 0.12

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

Code: PM-541, JAN 86

PM

CLclRU OWNER SAFE MAINTENANCE Powered industrial trucks may become hazardous if adequate maintenance is not done.

Therefore, maintenance facilities, personnel and procedures must be provided.

5. Before Starting To Operate The Truck: A. Be in operating

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

C. Before operating truck, check functioning of lift systems, directional and speed controls, steering, warning devices, brakes, and any attachment (if used).

6. Avoid fire hazards and have fire protection equipment available. Do not use an open flame to check level, or for leakage, of fuel, electrolyte or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.

7. Provide ventilation

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

3. Before Leaving The Truck: A. Stop Truck.

B. Fully lower the load engaging C. Apply the brake by releasing handle.

D. Turn off power, or disconnect

means.

8. Brakes, steering mechanisms,

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

the battery.

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

4. Before Working On Truck:

9. All parts of lift mechanisms

and frame members must be carefully and regularly inspected and maintained in a safe operating condition.

A. Raise wheels free of floor or disconnect power source.

B. Use blocks or other positive truck positioning devices.

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

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

Code: PM-541, JAN 86

position.

B. Turn on power, or connect battery.

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

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

PRACTICES

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

11. All hydraulic systems must be regularly inspected and maintained in conformance with good practice. Lift cylinders, valves, and other like parts must be checked to make sure that “drift” has not developed to the extent that it would create a hazard.

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

Page 0.13

OWNER SAFE MAINTENANCE 12. Capacity, operation and maintenance instructions plates, tags, or decals must be maintained in legible condition.

13. Batteries, motors, controllers, limit switches, protective devices, electrical conductors and connections must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of electrical insulation.

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

Page 0.14

PRACTICES (CONT.)

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

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

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

Code: PM-541, JAN 86

INDUSTRIAL

TRUCK DIVISION

SAFETY SIGNS AND SAFETY MESSAGES STAY ALERT! Follow safety rules, regulations and procedures. Accidents can be avoided by recognizing dangerous procedures or situations before they occur.

Improper or careless techniques will cause accidents.

Don't take chances with incorrect or damaged tools and equipment. WORK SAFELY and follow the safety signs and their messages.

READ and understand the procedures for safe lubrication, adjustments and maintenance outlined in this manual.

Safety signs and messages are also put on the forklift truck to provide instructions and to identify specific areas where potential hazards exist.

Study and follow the instructions, signs and messages.

Serious injury or death to you or other persons may result if these messages are not followed.

IMPORTANT

NOTICE

--

-----

This message is used when special precautions should be taken when dis-assembling or assembling components to avoid damage or malfunction.

This message is used when special instructions or identification is required relating to tools, pressure readings, capacities and other special data.

CAUTION

----

This message is used as a reminder of safety practices which can result in personal injury if proper precautions are not taken.

WARNING

----

This message is used when a hazard exists which can result in injury or death, if proper precautions are not taken.

DANGER

-----

This message is used when an extreme hazard exists which will result in death or serious injury if proper precautions are not taken.

Copyrighted Material 1322-Z JUN Intended for CLARK dealers only Do not sell or distribute

84

PM

CLSRK ! SAFETY q

MESSAGES

p&Eq

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

q

WARNING

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

1

WARNING

~1 TERIES.AN EXPLOSION CAN RESULT

cl!

WARNING

SULFURIC ACID WITH DAMAGED OR LOST CECALS AND NAMEPLATES. REPLACE THEM IMMEDIATELY. THEY CONTAIN IMPORTANT INFORMATION.

!

WARNING EJ PERSONAL

INJURY

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

UNLESS YOU ARE TRAINED AND AUTHORIZED AND KNOW THE CORRECT MAINTENANCE PROCE-

_.

D

WARNING

BATTERY

SERVICE

BATTERY SERVICE MUST BE DONE

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

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

INDUSTRIAL

TRUCK DIVISION

SAFETY SIGNS AND SAFETY MESSAGES

STAY ALERT! Follow safety rules, regulations and procedures. Accidents can be avoided by recognizing dangerous procedures or situations before they occur.

Improper or careless techniques will cause accidents. Don't take chances with incorrect or damaged tools and equipment. WORK SAFELY and follow the safety signs and their messages.

READ and understand the procedures for safe lubrication, adjustments and maintenance outlined in this manual.

Safety signs and messages are also put on the forklift truck to provide instructions and to identify specific areas where potential hazards exist.

Study and follow the instructions, signs and messages.

Serious injury or death to you or other persons may result if these messages are not followed.

IMPORTANT

NOTICE

--

-----

This message is used when special precautions should be taken when dis-assembling or assembling components to avoid damage or malfunction.

This message is used when special instructions or identification is required relating to tools, pressure readings, capacities and other special data.

CAUTION

----

This message is used as a reminder of safety practices which can result in personal injury if proper precautions are not taken.

WARNING

----

This message is used when a hazard exists which can result in injury or death, if proper precautions are not taken.

DANGER

-----

This message is used when an extreme hazard exists which will result in death or serious injury if proper precautions are not taken.

Copyrighted Material 1322-Z JUN Intended for CLARK dealers only Do not sell or distribute

84

CMRK

PM

0!

SAFETY MESSAGES

1

!m

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

YOU REMOVE THIS PART FROM THE TRUCK. SEVERE BURNS CAN RESULT FROM CONTACT WITH ELECTRICAL

Bx

EXPLOSNE

GASES

-1

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

TERIES.AN EXPLOSION CAN RESULT

.n !

0!

WARNING SULFURIC ACID

& 1 TANCE.

CAUTION

NAMEPLATES

THE BATTERY CONTAINS CORROSIVE

0!

-I

8 DECALS

1

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

I

WARNING SAFETY AND YOU

J

0!

WARNING AIR PRESSURE

WEAR EYE PROTECTION & PROTECTIVE CLOTHING h!iENCLEANING OR DRYING WITH AIR PRESSURE. REDUCE PRESSURE TO [207 kPa] 30 PSI. CEBRIS REMOVED WITH AIR PRESSURE CAN CAUSE INJURY.

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

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

I

PM

PM

-

PLANNED

MAINTENANCE

PM Report

PROGRAM

Form

1

Visual

Inspection

2

Operational

3

Air

4

Critical

5

Lubrication,

Checks

/ Test

Drive

Cleaning Fastener

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

1323-Z

Filters

JUN 84

Torque

Checks

& Fluid Level

Checks

GROUP

CMRK

I

of this form.'

1320-ZCopyrighted MAR 84 Material Intended for CLARK dealers only Do not sell or distribute

Use this form for making a record of

PM

PM -

PLANNED MAINTENANCE

PROGRAM

As an aid in performing and documenting the PM inspections, Clark has prepared a “PLANNED MAINTENANCE REPORT” form. See previous page. Copies of this form may be obtained from your authorized Clark dealer. We recommend that you use this form as a checklist and to make a record of your inspection and truck condition.

This manual is intended to be used in conjunction with the PM Report form. It is arranged by groupings of items of work that are done in a logical and efficient sequence.

PM Report Form A check mark or entry is made on the PM Report form when the PM is performed. Please note the special coding system for indicating the importance of needed repairs and/or adjustments.

When you have finished the PM inspections, be sure to give a copy of the report to the designated authority or the person responsible for lift truck maintenance.

Do not make repairs or adjustments unless authorized to do so.

For safety, it is good practice to:

Fig. 12618

Remove all jewelry (watch, rings, bracelets, etc.) before working on the truck.

Disconnect the battery connector before working on electrical components.

Always wear safety glasses. Wear a safety (hard) hat in industrial plants and in special work areas where protection is necessary or required.

ELECTRICAL

SHOCK

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

Fig. 12704

LIFT

TRUCK

MAINTENANCE

DO NOT WORKON THIS TRUCK UNLESS YOU ARE TRAINED AND AUTHORIZEDAND KNOWTHE CORRECTMAINTENANCEPROCEDURES.

Code: PM-541, JAN 86

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

Page 1.1

PM

1 VISUAL INSPECTION

The objective of the visual inspection is to be sure that all components of the lift truck are: 1) in place 2) attached securely 3) in a safe and efficient operating condition Be sure to make a thorough inspection of the critical components that handle or carry the load.

Page 1.2

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

Code: PM-541, JAN 86

CLsRK

PM

First, make a quick overall inspection for oil leaks. If oil leaks are found due to a loose fitting, tighten the fitting.

Report other leakages as major repairs on the PM report form.

Check for a missing or damaged rating plate or decals.

Replace the decals or plate if necessary.

Fig. 25488

IMPORTANT If the truck is modified, capacity may be affected. Contact an authorized Clark dealer for a new plate showing the revised capacity.

Inspect the sheet metal and covers. Any change to the truck since the last PM should be noted on the PM report form.

Remove the hydraulics cover and the drive unit cover.

Fig. 25552 BATTERY AND CABLES Check battery and cable condition. Inspect the cables, connectors and terminals for corrosion, fraying and damage. Remove any minor corrosion damage from the battery.

IMPORTANT Do not wash the battery when it is installed in the truck.

Fig. 25491 Check the condition of the spring loaded battery connector.

Severely burned terminals should be noted on the PM report form.

Fig. 25553

Code: PM-541, JAN 86

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

Page 1.3

PM

If so equipped, check the battery stops for damage and correct adjustment and installation.

NOTICE Depending on the length, some battery stops are equipped with wooden blocks. Check the wooden blocks for damage and proper installation. Battery stop blocks should be installed so battery movement is (13 mm) l/2 inch maximum horizontal movement.

Fig. 12676 GAUGES, LIGHTS AND INDICATORS TESTS

AND ELECTRICAL

Check the condition of all wiring and cables. Make sure all terminals and connections are tight. Make sure electrical plugs are correctly connected. Check wiring for correct routing. Inspect insulation for breaks, cuts and fraying.

HYDRAULIC

FLUID PRESSURE

DO NOi "SE YOUR HANDS TO CHECK FOR HYDRAULIC LEAKAGE. FLUID UNWER PRESSURE CAN PENETRATE YOUR SKIN ANU CAUSE SERIOUS INJURY.

HYDRAULIC

Fig. 25540

SYSTEM

Check the hydraulic unit, lift cylinders, piping and hoses for leaks. Make sure all hydraulic fittings are tight. Check lift cylinder rods for scratches and damage. Check cylinder packings for leaks.

Fig. 25554

Page 1.4

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

Code: PM-541, JAN 86

PM

MOTORS Drive Motor

Remove the inspection band from the drive motor and check the condition of the brushes and commutator. Refer to Group 16, Section 27, General Motor Maintenance for commutator conditions. Brushes that are chipped, broken or oil soaked should be checked on the PM report form as a replacement item.

NOTICE

The brushes and commutator should be checked every third PM. Pump Motor

To inspect the pump motor brushes and commutator, the hydraulic unit must be removed and the end cap removed from the motor. Refer to Group 16, Section 27, General Motor Maintenance, for commutator conditions. Brushes that are chipped, broken or oil soaked should be checked on the PM report form as a replacement item.

NOTICE

Check the brushes every 2,000 operating hours or once a year, whichever comes first.

Fig. 21814

WHEELS AND TIRES

Check the condition of the drive (A), load or trail (B) and caster wheels (C). Remove any embedded objects. Inspect the tires for excessive wear, breaks, separation or “chunking.”

Fig. 25543

Code: PM-541, JAN 86

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

Page 1.5

CLSRU 2 OPERATIONAL

CHECKS/TEST

YOU MUST BE TRAINED

DRIVE

AND AUTHORIZED

TO OPERATE A LIFT TRUCK.

Be sure that all: l

components

l

controls

l

systems

l

safety equipment

are functioning

Code: PM-541, JAN 86

correctly

and in safe operating

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

condition.

Page 2.1

PM

CLSRK

OPERATION CHECKS/TEST

DRIVE

NOTICE Battery must be fully charged before performing tional checks.

opera-

Connect the battery. Move the steer handle through the full right and full left turn positions and check for smooth travel.

If binding or roughness is encountered, check the drive unit thrust rollers and/or radial thrust bearing. Report conditions on the PM report form.

Fig. 25490 Make sure the forward/reverse directional control and the lift/lower button are tightly fastened and operate freely in the steer handle. On HWP models, also check the lift/lower button and the high speed button in the auxiliary handle.

Fig. 25555 Drive the truck in a straight line in the first point of power.

Raise or lower the steer handle to operate the brakes. If the brake and drive unit operation issatisfactory, drive the truck at high speed and check for any unusual drive train noise or vibration. Note any unusual operation on the PM report form.

Fig. 25500 Stop the truck. Drive the truck in reverse at high speed and any check for unusual drive unit noise or vibration:Note unusual operation on the PM report form.

1 Fig. 25497

Page 2.2

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

Code: PM-541, JAN 86

With the truck moving forward, press the Reverse Safety Switch Control Button on the end of the steer handle. The truck should stop and move in the reverse direction until the button is released. Pull the button out to the reset position.

Fig. 23686 On P and HWP trucks, press the lift/lower button on the steer handle and check fork operation. On HWP trucks, press the lift/lower button on the auxiliary handle and check fork operation. If operation is sluggish, refer to Group 34, Section 4, Lift Cylinder Drift and Speed Tests. If fork operation is uneven, refer to Group 34, Section 5, Lift Cylinder Adjustment.

Fig. 23681 Press the lift button and make sure the hydraulic pump motor shuts off at (152 mm) 6.0 inches of fork travel. If not to this specification, refer to Group 13, Section 3, Lift Limit Cut-Off Switch Adjustment.

Fig. 23680 Disconnect the battery. Remove the drive unit cover and check brake components to be sure the cut-off switch, bracket and brake linkage are correctly fastened and not damaged.

Fig. 12685

Code: PM-541, JAN 86

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

Page 2.3

PM

Check the operation of the brake cut-off switch. Slowly raise the handle to the BRAKE ON (full up) position. The switch should deactivate with an audible click just before the brake shoes contact the drum.

Fig. 2554; Then, slowly lower the handle. The shoes should move away from the drum. Continue lowering the handle to the BRAKE ON (full down) posjtion. The switch should deactivate with an audible click just before the brake shoes contact the drum. If the brake system does not operate as described, refer to Group 13, Section 1, Electric Drive Motor (Brake) Cut-Off Switch and/or Group 23, Section 2, Brake.

Fig. 25550 GAUGES, LIGHTS, INDICATORS

Connect the batterv. Insert and turn the kev (if equipped) clockwise to the Of? position Press the horn‘buttbn’ on the handle and check operation.

Fig. 23354 Make sure the hour meter operates (if equipped).

NOTICE

Check to make sure the hour meter starts when the battery is connected and key switch (if equipped) turned to the “ON” position.

Fig. 14015

Page 2.4

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

Code: PM-541, JAN 86

CLflRK

PM

Check the battery discharge indicator (if so equipped).

With the battery connected and key (if equipped) in the ON position, the indicator needle should point to the green area. If not, it should be indicated on the PM report form.

Fig. 12989 BATTERY AND CABLES After the test drive, perform a battery load test. Remove the hydraulic cover and bypass the lift limit switch with a jumper wire.

1 Fig. 25556 Operate the hydraulic lift until the forks are in maximum height position and the hydraulic system operates in the bypass mode. The battery discharge indicator needle should not drop into the red area. If the needle points to the red area, the battery is not sufficiently charged for operation.

I

IMPORTANT

Do not operate the hydraulic system in the bypass mode with the lift limit switch bypassed any longer than necessary to take a reading. Remove the bypass jumper wire.

Fig. 12989

ELECTRICAL TESTS AND PERIODIC ELECTRICAL TESTS Do electrical tests with a volt-ohmmeter and a shunt type ammeter.

Fig. A0959

Code: PM-541, JAN 86

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

Page 2.5

CMRW

PM

Remove all jewelry before handling

electrical

components.

DISCONNECT THE BATTERY BEFORE YOU REMOVE THIS PART FRON THE TRUCK. SEVERE BURNS CAN RESULT FRO,, CONTACT WITH ELECTRICRL

Fig. 12704 Jack up the truck and put blocks under the frame at both sides of the drive unit. (The steer handle is at the front of the truck.)

Fig. 25557 Disconnect the battery.

Fig. 25553 Do a ground test, using the volt-ohmmeter. With the ohmmeter on the RxlO,OOO scale, connect one ohmmeter lead to the positive (+) side of the truck battery receptacle, and the other ohmmeter lead to the truck frame. Keep a record of the resistance on the PM report form.

Then, connect one ohmmeter lead to the negative (-) side of the truck battery receptacle and the other ohmmeter lead to the truck frame. Keep a record of the resistance on the PM report form.

There should be a minimum resistance of 30,000 ohms for used trucks or 50,000 ohms for new trucks on both tests.

Page 2.6

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

Fig. 12705

Code: PM-541, JAN 86

PM

CMRU Check the power cable end crimp (A) and the terminal connections at the contactor panel for tightness.

Fig. 25558 Check the control wire (B) condition terminals for tightness.

and the control wire

Fig. 25559 Check all contactor assemblies (C) for freedom of movement by pushing the moveable contact tips. Also, check the contact tips for arcing.

NOTICE If there are indications of severe arcing on the contact tips, remove and replace the tips.

Fig. 25560 When current draw tests are to be performed, the specific gravity of the battery fluid must be checked. Using a hydrometer, check at least six battery cells. The specific gravity should not be less than 1.250. If less than 1.250, charge the battery.

Fig. 17593

Code: PM-541, JAN 86

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

Page 2.7

PM

Check the battery electrolyte level (especially before charging). The level should be slightly below the lower lip of the vent fill hole. Add water as necessary but DO NOT OVERFILL. Overfilling causes loss of electrolyte.

BATTERY SERVICE MUST BE DONE

BY TRAINED PERSONNEL. BATTERY ACID CAN CAUSE SEVERE BURNS AN0 INJURY.

1

Fig. 12677 Check the battery vent caps for obstructions. The vent hole must be open at all times.

Fig. 12913 Connect the ammeter as shown to do the motor current draw tests.

Fig. 12709 Check the pump motor current draw. Bypass the lift limit switch. Turn the key (if equipped) clockwise to the ON position. Operate the hydraulic control until the system operates in the bypass mode. Check the motor amperage draw and record the reading on the PM report form. On P40, P60 and HWP 40 trucks, the reading should be 200 amps. On HWP 60 trucks, the reading should be 165 amps.

IMPORTANT Do not operate the hydraulic system in the bypass mode with the lift limit switch disconnected any longer than necessary to take a reading.

Page 2.8

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

Fig. 23680

Code: PM-541, JAN 86

PM

WHEN PERFORMING THE DRIVE MOTOR CURRENT DRAW TESTS, THE TRUCK MUST BE FIRMLY SUPPORTED ON WOOD BLOCKS. THE WOOD BLOCKS MUST NOT CONTACT THE DRIVE WHEEL. Check the drive motor current draw. With the drive wheel off the floor, turn the key (if equipped) clockwise to the ON position. Push the directional control knob for the top free wheeling speed in the forward mode. Repeat this procedure for the reverse mode. Record the readings on the PM report form. On P40, P60 and HWP 40 trucks, the drive motor current draw reading should be 38 amps. On HWP 60 trucks, the reading should be 32 amps.

Fig. 23683

Remove the wood blocks and lower the truck. Install the drive unit cover and the hydraulics cover.

Code: PM-541, JAN 86

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

Page 2.9

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

PM

3 AIR CLEANING

Fig. 25551 Disconnect the battery. Always maintain a lift truck in a clean condition. Do not allow dirt, dust, lint or other contaminants to accumulate on the truck. Keep the truck free from leaking oil and grease.

Wipe up all oil spills. Keep the controls and platform clean, dry and safe. A clean truck makes it easier to see leakage, loose, missing or damaged parts, and will help prevent fires. A clean truck will run cooler.

The environment in which a lift truck operates will determine how often and to what extent cleaning is necessary. For example, trucks operating in manufacturing plants which have a high level of dirt or lint (e.g., cotton fibers, paper dust, etc.) in the air or on the floor, will require more frequent cleaning.

The radiator, especially, may require daily air cleaning to ensure correct cooling. If air pressure does not remove heavy deposits of grease, oil, etc., it may be necessary to use steam or liquid spray cleaner.

Code: PM-541, JAN 86

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

Page 3.1

C19RK

PM

Use an extension on the air hose similar to that shown.

Use clean dry air and restrict air pressure to (207 kPa) 30 PSI. Wear suitable eye protection and protective clothing.

WEAR EYE PROTECTION & PROTECTIVE CLOTHING UHEN CLEANING OR DRYING WITH AIR PRESSURE. REDUCE PRESSURE TO [207 kPa]

1 Fig. 15301 P40-P60 Remove the hydraulics cover and air clean the hydraulic pump and motor assembly and any exposed areas.

I

Remove the drive unit cover. Air clean the contactor panel and brake assembly and blow the dust from the drive motor.

NOTICE Motors with vented bands . . . if dirty, remove the bands and clean them before air cleaning the motor.

Enclosed motors . . . remove the non-vented bands every third P.M. and air clean the motors.

Fig. 25562 HWP40-HWPGO Remove the hydraulics cover. Air clean the hydraulic pump and motor assembly and exposed areas.

Fig. 25563

Page 3.2

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

Code: PM-541, JAN 86

PM

CLSRK Remove the drive unit cover. Air clean the contactor and blow the dust from the drive motor.

panel

Fig. 25540

Code: PM-541, JAN 86

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

Page 3.3

CMRK

PM

4

Critical

Fastener

Torque

Checks

Fig.

14844

All components of the lift truck which are assembled with threaded fasteners are designed to be held in place with a torque that is correct for the application and size of the fasteners.

Fasteners in highly loaded (critical) components can quickly fail if they become loosened; also, loose fasteners can cause damage or failure of the component.

For safety, it is important that the correct torque be maintained on all critical fasteners of components which directly support, handle or control the load, and protect the operator.

Code: PM-520, JUN 84

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

Page 4.1

C19RK

PM

NOTICE

For any component torque specifications not listed below, refer to Group 40, Section 5, Specifications.

Using a torque wrench, check the torque on the bolts and nuts fastening the drive unit collar to the frame. Tighten to (81-95 Nom) 60-70 lb. ft.

Fig. 20411 Check that the drive wheel and stability caster wheels are fastened securely.

Fig. 25564

Page 4.2

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

Code: PM-541, JAN 86

CLARK

PM

5 LUBRICATION AND FLUID LEVEL CHECKS

Fig. 19529

The following pages outline general procedures and recommendations for checking all fluids and fluid levels, including lubrication and inspection of chassis and components. Also refer to Group 01, Section 2, Lubrication Charts, and Group 40, Section 4, Lubricant Specifications and Recommendations.

Code: PM-541, JAN 86

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

Page 5.1

PM

Lubricate fitting (A) on the drive unit radial thrust bearing with the recommended lubricant. Refer to Group 40, Section 4, Lubricant Specifications and Recommendations.

Fig. 25565 Lubricate the linkage pivot points (B) on the steer handle with the recommended lubricant. Refer to Group 40, Section 4, Lubricant Specifica&ns and Recommendations.

Fig. 25566 Clean and lubricate all fittings. Refer to Group 01, Section 1, PM and Lubrication Charts and Group 40, Section 4, Lubricant Specifications and Recommendations.

r J

Fig. 10890 DRIVE UNIT With the truck on a flat, level floor, remove the level plug and check the drive unit fluid level. The fluid level should be slightly below the level plug hole. Add the recommended fluid if the level is low. Refer to Group 40, Section 4, Lubricant Specifications and Recommendations.

NOTICE The drive unit fluid must be changed every 2000 operating hours or once a year, whichever comes first. The fluid change is a repair item and not part of PM.

Page 5.2

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

Fig. 12690

Code: PM-541, JAN 86

PM

CUM Check the drive unit vent. It must be open and free of debris.

!

1 Fig. 25567

HYDRAULIC

I

SYSTEM

I /

With the truck on a-flat, level floor, remove the fill plug and check the hydraulic tank fluid level. The level should be (13 mm) l/2 inch from the top of the fill plug hole. Add the recommended fluid if the level is low. Refer to Ground 40, Section 4, Lubricant Specifications and Recommendations.

Fig. 25549 The hydraulic unit fluid should be changed and the strainer filter cleaned every 2000 operating hours or once a year, whichever comes first. This is a repair item and not part of the PM. Refer to Group 29, Section 1, Hydraulic Sump Tank.

Fig. 25524

Code: PM-541, JAN 86

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

Page 5.3

GROUP

01

GROUP

01

SECTION

1 LUBRICATION

Code: PMA-425, DEC 79

CHARTS

&

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

SPECIFICATIONS

Section 1, Page 1

GROUP

01 P/HWP 40-60 GREASE FITTINGS LUBE POINTS*

* Refer to lubricant

key for lubrication

P/HWP 40-60 HYDRAULIC

\ \_

specifications.

r ?g-l

AND TRANSMISSION

* Refer to lubricant specifications.

// /

Section 1, Page 2

FLUIC; FILL POINTS*

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

key for lubricant Fig. 25568

Code: PMA-541, JAN 86

CMRK NORMAL LUBRICANT

GROUP

01 APPLICATIONS

Grease** at grease fittings every 50-250 operating hours.* Use grade NLGI #2 meeting Clark specification MS-107B.

COLD STORAGE -Grease**

Drain drive unit every 2000 operating hours or one year*, whichever comes first. Use DEXRON (R) or DEXRON-(R) II Automatic Transmission fluid, Clark part number 879804.

Drain hydraulic sump tank every 2000 operating hours or once a year*, whichever comes first. Use hydraulic fluid that meets Clark specification MS-68, Clark part number 885835.

LUBRICANT

APPLICATION

at grease fittings every 50-250 operating hours.’ Use _ specification MIL-G-238274.

Drain drive unit every 2000 operating hours or one year*, whichever comes first. Use DEXRON (R) or DEXRON-( R) II Automatic Transmission fluid, Clark part number 879804.

Drain hydraulic sump tank every 2000 hours or once a year*, whichever comes first. Use hydraulic fluid that meets specification MIL-H-5606A, Clark specification MS-226.

* Time intervals between lubrications are largely determined by operating conditions. For example, operation in sandy, dusty locations requires shorter lubrication intervals than operating in clean warehouses. If your lift truck is used in extreme operating conditions, you must shorten the lubrication intervals accordingly. If truck is operated under severe conditions, such as areas in which brine or caustic solutions are used, grease should be applied daily. ** Wipe fittings clean before applying

grease gun.

Code: PMA-541, JAN 86

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

Section 1, Page 3

CMRK

GRIYp

GROUP

12

SECTION

7 ELECTRIC

TRUCK

BATTERY

Code: PMA-432, DEC 79 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 7, Page 1

INDUSTRIAL

TRUCK DIVISION

CUSTOMER SERVICES GROUP

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

HANDLING STORAGE BATTERIES: 1.

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

2.

Be sure this area has provisions: - to flush and neutralize spillage - to ventilate fumes from gassing batteries - for fire protection.

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

3.

4.

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

When using overhead battery hoist, be sure an insulated spreader bar or similar lifting device is used so that the lifting stresses are vertical . .. neither outward or inward pressure must be exerted at the battery.

In other words, the width of the lifting device shall be the same width of the battery at the lifting eyes, so that the lift is immediately upward. Also, make certain the lifting hooks are not so large that pressure is exerted on the lifting eyes of the battery.

Section 7, Page 2

Fig. 20121

5.

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

6.

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

7.

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

8.

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

9.

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

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

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

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Code: PMA-432, DEC 79

$ V I--' h,

GRP2U

CMRU 11. When handling electrolyte, a carboy tilter or siphon shall be provided.

12. When using electrolyte, acid shall always be poured into water. Water shall never be poured into acid.

- Acid shall be poured into water.

- Water shall not be poured into acid.

Pouring water into acid will cause a dangerous chemical action.

13. When charging batteries, vent caps shall be kept in place to avoid electrolyte spray. Care shall be \ taken to assure the vent caps are functioning.

Vent cap holes must be open to allow battery to breath.

Battery, or compartment cover(s) must be open to dissipate heat.

14. Electrical installations shall conform to the NATIONAL ELECTRICAL CODE (ANSI B56.2, 1974), NFPA505-78, Part "C" and any local ordinances.

2.

Position truck in designated area, turn off key switch, set parking brake and disconnect battery.

3.

Expose battery, remove sheet metal or the doors, etc. This will vary depending on the truck being serviced.

4.

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

5.

Now, attach the lifting device and spreader bar (previously described) to battery and be sure the device is equipped with load safety hooks as shown in Fig. 20412.

6.

Remove the battery.

15. Reinstalled batteries shall be properly positioned and secured in truck prior to releasing for use.

BATTERY REMOVAL: IMPORTANT BEFORE YOU SERVICE, REMOVE OR INSTALL A TRUCK BATTERY ... CAREFULLY READ THE PREVIOUS INSTRUCTIONS. 1.

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

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

Code: PMA-425, DEC 79

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

Fig. 20412

Section 7, Page 3

INDUSTRIAL

TRUCK DIVISION

CUSTOMER SERVICES GROUP

2. Lift only with a carefully

BATTERY CLEANING:

constructed lifting device which will not put pressure on the battery tray.

With battery out of truck ...

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

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

3.

Battery shall be checked before each charge for electrolyte level.

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

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

4.

KEEP BATTERY CLEAN AND DRY. down as needed.

5.

Don't overcharge.

6.

Keep battery records as indicated herein.

Wash

BATTERY MAINTENANCE:

7. Keep metal objects and tools away Refer to the BATTERY VENDOR for their recommended procedures.

from top of battery to prevent explosions.

KEEPING BATTERY RECORDS :

INSTALL BATTERY:

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

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

1.

Install lifting device as explained previously.

2.

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

HOW TO GET MAXIMUM LIFE FROM BATTERY: 1.

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

Section 7, Page 4

NOTE

0

Some trucks are equipped with battery stops or blocks while others do not require them at all. If the truck being serviced is equipped with one or the other, check to be sure they are not missing.

If they are, replace them. If they are of the adjustable type, be sure they are adjusted to the battery and tightened securely.

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

Code: PM&432,

DEC 79

5 'd p h)

INDUSTRIAL SERVICE

TRUCK

ENGINEERING

DIVISION

DEPARTMENT,

BATTLE

GROUP ELEC TRIG (B R A KE)CUT-OFF

DRIVE

SECTION

Code:

PMA-321

JUN

73

CREEK

13 MOTOR SWITCH

1

Section

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

1, Page

1

INDUSTRIAL

TRUCK

SERVICE ENGINEERING

DEPARTMENT,

DIVISION BATTLE CREEK

NOTE Brake switch adjustment is important.

The switch must cut electrical current to the drive motor, before the brake shoes contact brake drum . . . otherwise, excessive lining wear will result and the drive motor will overheat.

1.

Position degrees

2.

Loosen

switch

mounting

3.

Locate audible

switch click

so it just actuates, can be heard.

4.

Tighten

5.

Move steer

6.

Check operation of switch by moving steer control handle from full up position to full down.

Switch should actuate 10 degrees from vertical and again at 10 degrees before full down position.

7.

If switch re-adjust obtained.

steer control from vertical

mounting control

handle position

at 10 and hold.

screws. an

screws. handle

to

up position.

Fig.

12990

Fig.

12714

does not actuate at both points, unti 1 proper adjustment is

JUN 73

Section

1,

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

Page

2

Code:

PMA-321

Cl!!RlS

GROUP

13

GROUP 13 SECTION 3 LIFT LIMIT CONTROL

Code: PMA-541, JAN 86

SWITCH ADJUSTMENT

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

Section 3, Page 1

GROUP 13 LIFT LIMIT CONTROL

SWITCH ADJUSTMENT

Raise the forks to the fully raised position. At six inches of fork upward travel, the lift limit switch (A) should be activated by the lift cylinder (B) and stop electrical current to the pump motor.

Fig. 25544 To adjust the switch, loosen the mounting bolts and nuts (C) and move the switch to the correct position. Tighten the mounting bolts and nuts.

Fig. 25545

Section 3, Page 2

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

Code: PMA-541, JAN 86

GRiiiuP

GROUP

16 SECTION

27 GENERAL

MOTOR

MAINTENANCE

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

Section 27, Page 1

GROUP

CLqRK

16 GEN_ERALMOTOR MAINTENANCE These procedures are intended to provide the technician with direction and specifications to safely and efficiently troubleshoot and repair Clark Electric Lift Trucks.

While some of the methods vary from model to model, the following procedures are of a general nature unless otherwise specified.

Electric Motor Routine Service A. Clean the motor with solvent and dry with compressed air. Inspect the covers for bent or damaged spacers, and for damaged gaskets.

B. Make sure that all covers are tight for good contact with the motor frame at reassembly.

C. Remove end cap from pump motor, or if working on drive motor, remove brush inspection band.

D. Check brush set for wear and replace if necessary.

E. Blow dirt and dust out of motor housing.

Section 27, Page 2

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

Code: PMA-541, JAN 86

GEA-7053

LIGHT

TAN

surface

is one

often

seen

FILM of

over entire many

commutator

normal

MOTTLED

conditions

on a well-functioning

tern

machine.

SURFACE

is probably

condition

of

WATCH

STREAKING

on the commutator

beginning brush.

of serious

Check

the

COPPER

DRAG,

material,

forms

dition

is rare

metal

chart

below

an abnormal most often

surface

transfer for

flashover

signals the

possible

build-up

at trailing

but con cause

to

the

frequently

related

THESE

to reswfocing

excessive

metal

PITCH

BAR-MARKING

on the

comnwtator

ings equals

I

and

The

half or all the number

CarSon Products General Fleciric Company East Stroudsburg, Pa. 38301

on bars

number

a slightly

darker

in a definite

pattern

of conductors

fine

lines

results

occurs. It usually

produces rutface.

to

with

transfer

of commutator

appears

DANGER

of commutator

causes.

checked.

industry.

FOR

when

BAR-MARKING,

film,

in

THREADING

of commutator

SLOT

observed

~ommutotors

carbon

edge of bar. Conif not

random film pat-

with

most

rapid

low

brush

leads wear.

or burned

number of poles

of these

spo+s mark-

on the motor.

L

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

per

HEAVY mea

slot.

FILM

can appear

of efficient

and

tar and, if uniform,

over

normal

is quite

entire

commutaacceptable.

SIGNS

GROOVING by abrasive phere.

HEAVY etching tern

is a mechanical material

If grooves

SLOT

start

BAR-MARKING

of trailing

is related

form,

in the

edge

to number

condition brush

caused

or atmos-

corrective

can

of commutator of conductors

action.

involve bar.

Pat-

per

slot.

CMRK

GROUP 17

GROUP 17 SECTION 1 CONTACTOR

PANEL

WARNING I

ELECTRICAL

BURNS

1

BATTERY AND REMOVE ALL JEWELRY BEFORE WORKSYSTEM. SEVERE BURNS CAN RESULT FROM CONTACT WITH ELECTRICAL SYSTEMS

Code: PMA-541. JAN 86

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

!

WARNING L1 ELECTRICAL

BURNS

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

Section 1, Page 1

GROUP 17

CU’IRK

CONTACTOR PANEL INSPECTION

1. Every time the lift truck is inspected, check the condition of the contactor panel.

2. A thorough inspection may eliminate a future repair.

3. Check that all mounting hardware is in place and

securely tightened. Bolts, nuts, screws, and washers are magnetically attracted to the electrical fields created in the panel area. Replace all missing hardware, and if necessary, coat the bolt threads with a medium grade Loctite before installing.

4. Check the contactor panel for dirt, moisture, or oil, as

they may cause intermittent electrical component operation. Locate and repair all leaks before servicing electrical components.

Fig. 25562

Fig. 25570

Section 1, Page 2

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

Fig. 25569

Code: PMA-541, JAN 86

GROUP 17 5. Disconnect

1

the battery and check the following.

A. Make sure fuse and fuse holder are not damaged.

Check for loose or weak connections. Make sure that all terminal connections are tight.

B. Check enclosed the relay case.

relays for condensation

or dirt in

C. Loose or missing hardware should be tightened replaced if necessary.

and

D. Look for weak electrical connectors and for areas where wires may be pinched or chaffed. Harnesses which are close to sharp metal should be routed to avoid chaffing and shorting to ground.

E. Overall wire insulation should be carefully for cracks, bare spots, and brittleness.

Fig. 25571

inspected

NOTICE If wire terminations are weak or damaged, replace the connector with a comparable size and gauge.

Code: PMA-541, JAN 86

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

Section 1, Page 3

GROUP 17

CLqRK

GROUP 17 SECTION 2 CONTACTORS

Code: PMA-541, JAN 86

Section 2, Page 1 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP 17

CLSRK

CONTACTOR INSPECTION

IE’

A. Check contact surfaces for burns and contact surface wear. If contacts are dirty and pitted, clean with “00” sandpaper, to remove surface defects. Spray the contact with Clark contact spray, Clark part #1801145.

B. Operate the moveable contact assembly making sure it moves smoothly.

C. Check all connections

to make sure they are tight.

D. Check contact tip gap and tip alignment to see if adjustment is needed. To adjust lower contact (normally open) gap, shims (metal washers) are used. Increase the number of shims to increase the gap. Remove shims to decrease the gap. To adjust the upper contact (normally open) gap, remove shims (non-metal) washers to increase the gap. Increase the number of shims to decrease gap.

Section 2, Page 2

s

mechanically,

A. TIP GAP B. SHIMS C. CONTACT SURFACE

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

Code: PMA-541, JAN 86

CL’RK

GR200

GROUP

20 SECTION 1

DRIVE

UNIT

Code: PMA-321, REV JUN 82 P.S.L. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Section 1, Page 1

GROUP

20

DRIVE UNIT LUBRICATION: Drain and fill the drive unit once a year or every 2,000 operating hours, whichever comes first. Use Dexron.

NOTE The drive unit capacity is approximately [,24 Litres] l/2 pint. Drain the drive unit when the lubricant is at operating temperature.

Fig. 22297 1.

2.

Level plug Drain plug

3.

4.

5.

Grease fitting Bushing Roller

THRUST ROLLER GREASE FITTINGS: Lubricate all grease fittings every 50-250 operating hours. The time interval must be according to operating conditions.

Fig. 12023

Section 1, Page 2

Code: PMA-321, REV JUN 82 P.S.L. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

INDUSTRIAL SERVICE

TRUCK

ENGINEERING

DIVISION

DEPARTMENT,

BATTLE

GROUP DRIVE

23

WHEEL

&

SECTION

Code:

PMA-321

JUN

73

CREEK

TIRE

1

Section

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

1, Page

1

GROUP

23 DRIVE WHEEL REMOVAL AND INSTALLATION 1. Raise the front of the truck with a chain hoist to gain access to the axle shaft. Securely block the truck in the raised position.

MAKE SURE THAT THE TRUCK IS ADEQUATELY BLOCKED IN THE RAISED POSITION BEFORE DOING ANY WORK ON IT.

2. Remove the stud from the exposed end of the driveshaft.

Fig. 12997 3. Remove the snap ring that holds the axle shaft to the drive unit.

4. Support the wheel with wood blocks to remove as much weight as possible from the axle shaft. Using a similar type puller as shown in Fig. 9984, pull the axle shaft out of the drive unit housing and the wheel hub.

Fig. 9984

Section 1, Page 2

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

Code: PMA-541, JAN 86

GROUP

23 DRIVE WHEEL INSTALLATION

Reverse the REMOVAL procedure to install the drive wheel.

IMPORTANT

Coat the splines of the axle shaft with graptiite grease prior to installation.

Fig. 13001 PRESSED-ON ASSEMBLY Disassembly

TYPE DRIVE WHEEL AND TIRE and Reassembly NOTICE

A press of at least 30-ton capacity is required to press a tire off and on the wheel.

When installing a new tire . . . be sure the tire is pressed on with an EQUAL DlMENSlON on both sides of the wheel.

Code: PMA-541, JAN 86

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

Section 1, Page 3

GR203U

CLflRH

GROUP

23 SECTION

2 BRAKE

Section 2, Page 1 Code: PMA-425, DEC 79

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

INDUSTRIAL

TRUCK DIVISION

CUSTOMER SERVICES GROUP

1.

Position steer handle in operating range and hold.

Fig. 12714 2.

Adjust set screw stop for brake shoe clearance of .015" to .020" on left hand shoe.

Fig. 12712 3.

Adjust clevis rod between brake arms to .015" to .020" on opposite shoe.

Fig. 12713

Section 2, Page 2

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

Code: PMA-425, DEC 79

GROUP

23

4.

Take steer handle from operating range and position it 10" from vertical and hold.

Fig. 12672 5.

Check to see if the Cam Follower (C) is correctly positioned on Cam Surface (D) as shoti. If not, with handle at 10" from vertical: (A) Loosen JAM Nut (A) (B) Back out Set Screw (B) (C) Loosen Cam Follower (C) and correctly position the roller cam surface as shown at (D), tighten cam hollower.

Now, rotate Set Screw (B) until it makes contact with the cam follower shaft .. . tighten Jan Nut (A).

Fig. 12715

6.

Set brake switch to make contact just after brake shoe on switch side has released.

The mounting bolt holes are elongated for switch adjustment.

Refer to GROUP 13 for procedure.

IMPORTANT The switch must be set to actuate (shut off) just prior to the brake shoes contacting the brake drum.

Fig. 12716

Code: PMA-425, DEC 79

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

Section 2, Page 3

GROUP

23 7. Adjust brake holding torque by raising drive tire from floor and adjusting nut “A” until torque wrench “T” reads rating shown in table below.

Fig. 12718

TRUCK MODEL

WEIGHT

LOADED

“T” POUND-INCHES TORQUE SPECIFICATIONS 22-1

P40

5,500 Ibs. or 2495 kg

175 lb. in. or 20 N*m

P60

7,500 Ibs. or 3402 kg

240 lb. in. or 27 N*m

HWP-40

5,600 Ibs. or 2537 kg

180 lb. in. or 20 Nom

HWP-60

7,940 Ibs. or 3597 kg

185 lb. in. or 21 Nom

*NOTE: Brake must hold truck with full rated capacity load on a 15% grade.

Section 2, Page 4

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

Code: PMA-541, JAN 86

GROUP

cww

30

GROUP 30 SECTION 1 HYDRAULIC

SYSTEM PRESSURE

CHECK

Section 1, Page 1 Code: PMA-541, JAN 86

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

CMRK

GRtcYp CHECKING

SYSTEM PRESSURE

Hydraulic system pressure may be checked with a Mica Quadrigage (Clark Part No. 1800106) or with a conventional pressure gauge with a O-4,000 PSI scale. Pressure is checked at the high pressure fluid line.

If a Schroeder Hydraulic Circuit Tester (Clark Part Number 1800106) is available, the relief valve setting and the rate of flow being delivered by the pump may be checked as described by the instructions provided with the tester.

When using a Mica Quadrigage or conventional gauge, use the following procedure.

pressure

1. Remove one of the high pressure fluid lines (A) from the “T” fitting in the center of the hydraulic unit.

2. Install another “T” fitting between the hydraulic unit “T” fitting and the high pressure fluid line removed in Step 1.

3. Connect the Quadrigage “T” fitting.

or conventional

tester to the

i

Fig. 25573

Section 1, Page 2

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

Code: PMA-541, JAN 86

CLqRK

GROUP

30

4. Use a jumper wire to bypass the lift limit switch (A).

5. Turn power key switch on (if so equipped).

Fig. 25574 6. Actuate the lift switch to raise the forks to maximum height. When the forks are full up, the relief valve comes off its seat. Immediately take a reading. Release the lift control. Record the reading.

AVOID HOLDING LIFT CONTROL ANY LONGER THAN NECESSARY TO CHECK READING ON PRESSURE GAUGE. 7. System pressure should be (IO 341 kPa) 1500 PSI. Adjust system pressure using the following procedure.

Fig. 23680 ADJUSTING SYSTEM PRESSURE 1. Remove the exterior Allen plug (A) from the relief valve to expose the internal adjusting screw.

2. Turn the internal adjusting screw until the correct pressure is obtained. Turn the screw clockwise to increase system pressure. Turn the screw counterclockwise to decrease system pressure.

3. When the correct pressure is obtained, replace the exterior Allen plug.

Fig. 25575

Code: PMA-541, JAN 86

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

Section 1, Page 3

GROUP 34

CMRH

GROUP 34 SECTION 4 LIFT CYLINDER

DRIFT TEST

Section 4, Page 1 Code: PMA-541, JAN 86

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

GROUP 34 LIFT CYLINDER

CLflRK DRIFT TEST

*

&

1. Put a capacity load on the forks.

2. Raise the forks to the maximum inches).

height position (6.0

3. Standing to one side of the load, measure the distance from the bottom edge of the forks to the floor.

4. Drift should not exceed l/4 inch in a five period. If drift exceeds this specification, hydraulic system for leaks. If necessary, 30, Group 4, Hydraulic System Pressure

Section 4, Page 2

(5) minute check the refer to Section Checks.

1

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

I

\

\

Fig. 25576

Code: PMA-541, JAN 86

GROUP

el!!Rw

35

GROUP 35 SECTION 1 TRAIL WHEEL LINKAGE ADJUSTMENT

Code: PMA-541, JAN 86

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

Section 1, Page 1

CLSR#

GROUP 35 INSPECTION 1. Visually inspect trail wheel linkage for wear. Replace parts if necessary.

2. Check all bearings (A) for looseness or binding or a break in the bearing seal. If bearing replacement is necessary, lubricate the inner diameter of the trail wheel before installing the bearing. Drive on bearing outer race only when installing the bearing.

3. Make sure that all retaining position.

pins (B) are firmly in

LUBRICATION Refer to Section 01-1, Lubrication Points and Specifications, for lubrication points and specifications.

TORQUE SPECIFICATIONS 1. Apply Loctite to trail wheel setscrews (34-38 N-m) 25-28 lb.-ft.

2. Tighten lift linkage adjusting 190-220 lb.-ft.

(C) and tighten to

nut (D) to (260-300 N*m)

3. Tighten pull rod clevis pin locknut (E) to (300-330 Nom) 220-245 lb.-ft.

Section 1, Page 2

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

Code: PMA-541, JAN 86

CLqRK LIFT CYLINDER

GROUP

35 ADJUSTMENT

1

1.

Raise the forks and put blocks under them as shown.

2.

Release the hydraulic

pressure.

Fig. 25578 3.

Remove the nut (A) and washers clevis pin (C).

4.

Drive the clevis pin from the yoke.

(B) from each yoke

Fig. 25579 5.

Loosen the locknuts (A). Rotate the yokes (B) so the trail wheels retract evenly. The lifting brackets should just touch the forks when the trail wheels are completely retracted.

6. Tighten the locknuts to (260-300 Nom) 190-220 lb.-ft.

7.

Position the yokes on the lift bar. Install the clevis pin so the grease fittings face inboard and the “D” spacer flat rests on the roll pin.

a.

Install the washers and nut. Tighten Nom) 125140 lb.-ft.

nut to (170-190 Fig. 25580

Code: PMA-541, JAN 86

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

Section 1, Page 3

GROUP

CMRK

38

GROUP 38 SECTION 3 TIPPING, JACKING

!

•J

AND

BLOCKING

IRS-

WARNING

LIFT TRUCK MAINTENANCE

- --

DO NOT WORK ON THIS TRUCK

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

UNLESS YOU ARE TRAINED AND AUTHORIZED AND KNOW THE CORRECT MAINTENANCE PROCEDURES.

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-541,

JAN

86

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

Section

3, Page

1

GROUP 38 TIPPING TRUCK 1. Remove the battery. When using an overhead battery hoist, be sure an insulated spreader bar or similar lifting device is used so that the lifting stresses are vertical. Neither outward nor inward pressure must be exerted at the battery.

Fig. 25581

2. Secure control handle so that drive unit and control handle do not swing as truck is tipped.

Fig. 25582

3. Put wood blocks on the floor next to the truck to protect the sheet metal when truck is resting on its side.

Fig. 25583

4. Install an eye bolt in the hole on one side of the lower truck frame. Using an overhead hoist of suitable capacity, put the hook of the overhead hoist chain through the eye bolt.

WARNING Make sure that the overhead hoist and chain are of sufficient capacity to lift the truck. Serious injury or death may result if this warning is ignored.

Fig. 25584

Section 3, Page 2

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

Code: PMA-541, JAN 86

GROUP

CLSRK

38

5. On the side opposite the eye bolt, connect a 48 inch stability chain in the slot on the frame bottom.

Fig. 25585

6. Connect the opposite end of the stability chain to the hoist chain 18 inches (A) from the center of the eye bolt.

Fig. 2558;

7. Carefully raise the overhead hoist chain to tip the truck on its side.

Fig. 25587

8. To return the truck to the upright position, remove and connect the stability chain to the (B) overhead hoist chain 13 inches from the center of the eye bolt.

Carefully raise the chain to tip the truck to the upright position.

Fig. 25588

Code: PMA-541, JAN 86

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

Section 3, Page 3

CMRK

GROUP

38 BLOCKING LIFT FORKS 1. Raise the forks fully using the hydraulic system.

2. Put wood blocks under the forks at the points (A).

Lower the forks onto the blocks.

IMPORTANT Make sure that the forks, not the lift linkage, rest on the blocks.

Fig. 25590 JACKING TRUCK 1. Put a jack under the truck frame. Jack up the truck and put blocks under the frame. Lower the truck onto the blocks.

MAKE SURE THAT THE TRUCK IS SECURELY SUPPORTED ON THE BLOCKS BEFORE PERFORMING ANY WORK ON THE VEHICLE.

Section 3, Page 4

Fig. 25557

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

Code: PMA-541,

JAN 86

GROUP 40

Cl!!RK

GROUP 40 SECTION 1 TRUCK

DECALS - PLATES SERIAL NUMBER

DATA

!

CAUTION CI NAMEPLATES 8 DECALS DONOT OPERATE A LIFT TRUCK

WITH DAMAGED OR LOST OECALS AND NAMEPLATES. REPLACE THEM IMMEDIATELY. THEY CONTAIN IMPORTANT I NFORMAT ION.

Code:

PMA-541,

JAN 86

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

Section

1, Page

1

GROUP 40 Know the location of the capacity data plate (A) (Model Capacity and Serial Number).

Know the location of the machine serial number (A) stamped on the vehicle frame.

Fig. 25592 HOW TO READ THE CAPACITY

DATA PLATE

1. Truck model number 2. Truck type 3. Truck serial number 4.

Load capacity WARNING

b0

not exceed maximum specified load capacity

5. Truck weight without battery 6. Truck weight with maximum battery 7. Maximum battery weight 8. Minimum battery weight 9. Battery I.D. number

10. Battery DC voltage 11. Battery maximum ampere hours 12. I.D. plate part number IMPORTANT

If the truck is modified, capacity may be affected. Contact your authorized Clark dealer for a new plate showing the revised capacity.

Section 1, Page 2

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

Fig. 25593

Code: PMA-541, JAN 86

GROUP

40

DECAL

L

Code: PMA-541, JAN 86

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

I

Section 1, Page 3

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

CMRK

GROUP1 40 12 BATTERY System Voltage and Ground:

P40, P60, HWP40: 12 Volt, Negative Ground 24 Volt, Negative Ground HWPGO

Battery: Type: Lead Acid Capacity (6hr. rate) Max., kWh/Ah: P40, P60, HWP40: 6.9/600 : 13.82/600 HWPGO Weight-Minimum:

P40, P60: 365 Ibs. HWP40: 430 Ibs. HWPGO: 810 Ibs.

Specific Gravity-Minimum: 1.250 Specific Gravity-Fully Charged: 1.275 Battery Connector: Anderson SB-21175 Amp

13 CONTROLS Electric Drive Motor (Brake) Cut-Off Switch Adjustment: handle 10” from full up and full down positions.

Move switch so motor stops with steer

Auxiliary Handle (HWP only) and Steer Handle Controls: Drive Motor Control: Resistor Speed Control: P-Series: 3 Step HWP-Series: 4 Step Hydraulic Motor Control: On/Off Lift Limit Control Switch Adjustment: Move switch to contact lift cylinder tab so hydraulic motor stops operation at 6.0 inches maximum fork travel.

Section 2, Page 2

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

pump

Code: PMA-541, JAN 86

GROUP

40 16 GENERAL MOTOR MAINTENANCE Ground Test-Meter Scale Rxl0,OOO: Used Trucks-30,000 Ohms Minimum New Trucks-50,000 Ohms Minimum l

For Drive Motor Specifications,

l

For Hydraulic

refer to 20 Drive Unit

Pump Motor Specifications,

refer to 29/30 Hydraulic

System

17 CONTACTOR PANEL AND CONTACTORS Fuse: AGC 15 Amp In-Line Wiring Harness P40, P60 Contactors F and R

1A

Normally Open Tip Gap

0.065-0.075 inch (1.65-l .90 mm)

0.1 lo-O.130 inch (2.79-3.30 mm)

Normally Closed Tip Gap

0.065-0.075 inch (1.65-l .90 mm)

Initial Tip Pressure (Normally Open and Closed)

Armature Pressure

Minimum Wipe (Normally Open and Closed)

*Reduced

0.33-0.50 lb.

(0.15-0.23 kg)

0.33-0.50 lb.

(0.15-0.23 kg)

1.40-2.10 lb.* (0.64-0.95 kg)

1.00-l .60 lb.

(0.45-0.74 kg)

0.045 inch (1.14 mm)

0.050 inch (1.27 mm)

by 0.88-1.30 lb. (0.40-0.59

Code: PMA-541, JAN 86

kg) when normally closed contacts are closed.

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

Section 2, Page 3

GROUP 40

C19RK

17 CONTACTOR PANEL AND CONTACTORS (CONT’D.) .

I

HWP40, HWPGO Contactors

Normally Open Tip Gap

F and R

IA

0.112-0.128 inch (2.85-3.25 mm)

0.112-0.128 inch (2.85-3.25 mm) 0.112-0.128 inch (2.85-3.25 mm)

Normally Closed Tip Gap

Initial Tip Pressure (Normally Open and Closed)

Armature Pressure

Coil Resistance at 77°F (25°C)

2.30-2.82 lb. ft.

(10.24-I 2.54 N)

0.97-l .19 lb. ft.

(4.32-5.29 N)

3.37-4.11 lb. ft.

(14.99-l 8.28 N)

2.79-3.41 lb. ft.

(12.41-15.16 N)

5.1-6.3 (HWP40) 21 .l-25.7 (HWPGO)

5.0-6.2 (HWP40) 20.2-24.8 (HWPGO)

20 DRIVE UNIT Type: Clark, 6.5 inch diameter, two spur gear reduction type, 22:1 ratio Fluid Capacity: 1 pint (0.473 liter) Fluid Level: Even with bottom of fill plug hole Fluid Recommendation:

DEXRON@ or DEXRON II@, Clark Part No. 879804

Current Draw-Top

Speed, Free Wheeling:

P40, P60: 38 Amps HWP40: 38 Amps HWPGO: 32 Amps

Brush Replacement

Length: 0.562 inch (14.3 mm)

Brush Spring Tension: 30-35 oz. (8-10 N) Drive Unit Collar and Roller Recommended Lubricant: Normal Operation: General Purpose Grease meeting specification MS-107B Cold Storage Operation: Low Temperature Grease meeting specification MIL-G-23827A

Section 2, Page 4

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

Code: PMA-541, JAN 86

CMRK

GROUP

40

23 DRIVE WHEEL AND TIRE Front Tire Size: 10.5x6.0x6.5

inch

23 BRAKE Drum-to-Shoe

Clearance:

0.015-0.020

inch (0.38-0.51 mm)

Brake Holding Torque: P40 (5,500 Ibs. weight loaded) 175 lb. in. (20 P60 (7,500 Ibs. weight loaded) 240 lb. in. (27 HWP40 (5,600 Ibs. weight loaded) 180 lb. in.

HWPGO (7,940 Ibs. weight loaded) 185 lb. in.

Nom) N*m) (20 Nom) (21 N*m)

25 CONTROL HANDLE Pivot Recommended Lubricant: Normal Operation - General Purpose Grease meeting specification MS-107B Cold Storage Operation: Low Temperature Grease meeting specification MIL-G-23827-A

29/30 HYDRAULIC SYSTEM Fluid Capacity: 0.40 gallon (1.514 liter) Fluid Level: l/2 inch (13 mm) from the top of the fill plug hole Fluid Recommendation:

Normal Operation - Hydraulic Fluid, Clark Part No. 885385 Cold Storage Operation - Hydraulic Fluid, Clark Part No. MS-226 meeting specification MIL-H-5606A

Hydraulic System Pressure:

1950 psi

Pressure Relief Valve Setting:

1500 psi

Pump Motor Current Draw (at bypass) P40, P60, HWP40: 200 Amps : 165 Amps HWPGO Brush Spring Tension: 32-40 oz. (9-11 N) Brush Length (Worn): 0.25 inch (6 mm)

Code: PMA-541, JAN 86

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

Section 2, Page 5

Cl!!RlS

GROUP

40 34 LIFT CYLINDER

Lift Cylinder Drift (in 5 minutes): 0.25 inch (6.35 mm) Maximum Speed Test (Lifting and Lowering Times) I

Lifting Time (In Seconds) Model

Lowering Time (In Seconds)

Empty

Loaded

Empty

Loaded

P40

5.0

7.0

7.4

5.8

P60

5.0

8.0

7.4

5.0

HWP40

5.0

7.0

7.4

5.7

HWPGO

2.6

5.0

7.4

2.4

35 TRAIL WHEELS Wheel Size: 3.38 x 2.63 inch Tire Type = Urethane Fitting Recommended Lubricant: Normal Operation - General Purpose Grease meeting specification MS-107B Cold Storage Operation - Low Temperature Grease meeting specification MIL-G-23827-A

Section 2, Page 6

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

Code: PMA-541, JAN 86

CLqRK

GROUP 40

TORQUE SPECIFICATIONS

Specification

Description Trail wheel setscrew

(1)

25-28 lb-ft 34-38 Nom

Lift linkage adjusting

nut

190-220 lb-ft 260-300 Nom 220-245 Ib-ft 300-330 Nom

Clevis to pull rod nut and bolt Auxiliary

handle to frame nut and bolt

25-28 Ib-ft 34-38 Nom

Pull rod to bar bolt

65-70 lb-ft 85-95 N*m

Pallet entry roller bracket to frame

25-38 lb-ft 34-38 Nom 125-l 40 lb-ft 170-l 90 Nom

Pallet entry roller to bracket nut Drive unit collar to frame nut and bolt

60-70 lb-ft 81-95 Nom

Brake arm to drive motor plate hex head bolt

37-41 lb-ft 50-56 Nom

Brake drum to drive motor shaft nut (2)

200-250 lb-ft 271-298 Nom

Drive wheel to axle shaft bolt

200-220 lb-ft 271-300 Nom

Stability caster to frame nut and bolt

95-l 20 lb-ft 129-l 63 N*m

Access cover to drive unit bolts

1O-l 5 lb-ft 14-20 N*m

Stability skid to frame nut and bolt

25-28 lb-ft 34-38 Nom

Access cover to drive unit bolts

lo-15 lb-ft 14-20 N*m

Pinion cover to access cover bolts

22-25 Ib-ft 31-34 N*m

Pinion to drive motor shaft nut (2)

200-250 lb-ft 271-298 N*m

Drive gear to bearing nut (3)

200-256 lb-ft 271-298 Nom

1) Apply Loctite to trail wheel setscrews.

2) Tighten to specified torque, advance to next castellation 3) Use new nut, tighten to specified torque and stake nut.

Code: PMA-541, JAN 86

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

and install cotter pin.

Section 2, Page 7

C19RK

GROUP

40

GROUP

40 SECTION

3 PM INSPECTION AND DRIVERS DAILY INSPECTION FORMS FIRE EXTINGUISHER RECOMMENDATIONS

Code: PMA-424, SEP 83

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

Section 3, Page 1

CMRK

GROUP 40

Cl!!RK

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

CHECK

ONE:

0

GAS,

LPG OR DIESEL

TRUCK

TRUCK NO.

0

ELECTRIC

OPERATOR:

START OF DAY HOUR

METER

TRUCK

SUPERVISOR’S OK

ENDOF DAY

HRS. FOR DAY

READING:

fl

Boxes Accordingly

HYDRAULIC

REMARKS: (EXPLAIN ALL ITEMS NEEDING Al-rENTION

CONTROLS

OR REPAIR)

FORM NO. 59770.2937 NOV SO

Section 3, Page 2

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

Code: PMA-424, SEP 83

00 8 ..

CUSTOMER

CL!WlS

INSPECTOR

I

ELECTRIC TRUCK PLANNED MAINTENANCE REPORT

.sPEClAL !NSTRdCTIONS

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

GROUP

40

FIRE EXTINGUISHERS AND SOLID STATE CONTROL EQUIPMENT: Approved Fire Extinguishers: There are two types of fire extinguishers that are approved for use on trucks having solid state controls.

They are:

1.

Dry chemical for 'B' and 'C' applications.

The chemical used in the dry type extinguishers is either sodium bicarbonate or potassium bicarbonate which has been made water resistant.

After using, the control must be completely cleaned and dried. THE BATTERY MUST BE DISCONNECTED BEFORE CLEANING AND MUST NOT BE CONNECTED AGAIN UNTIL THE CONTROL DRIES COMPLETELY. General Electric's recommendation is the Ansul dry type fire extinguisher.

FIRE EXTINGUISHERS NOT APPROVED:

2.

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

When carbon dioxide is used, cleaning is not necessary.

Carbon dioxide only replaces the oxygen in the area of the fire and extinguishes the flames. The danger in using this type of fire extinguisher is in small areas where a large amount of carbon dioxide could replace so much oxygen that persons in this area can fall down from too little oxygen.

Section 3, Page 4

Pyrene fire extinguishers are not approved for use on trucks having solid state control.

General Electric has found that the chemicals in pyrene extinguishers destroys the insulation on the cables and has a bad effect on the solid state controls.

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

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

CLSRK

GROUP

40

GROUP

40 SECTION

4 LUBRICANT AND

SPECIFICATIONS RECOMMENDATIONS

LUBRICATION

Code: PMA-322, FEB 84 REV

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

CHART

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 CLARK does not follow regarding approval of their use in CLARK products. a formal test and approval procedure for specific branded products.

Rather it is CLARK policy to establish basic specifications for oils which have demonstrated suitable performance for the application.

In general these specifications follow the recommendations of the major component manufacturer, such as engines and hydraulic pumps. Any oil which meets the respective specification is considered acceptable for use in CLARK products.

Component operation should not be affected as long as the oil meets the stated specification and the recommended oil and filter change intervals are followed. For EXTENDED OIL DRAIN INTERVALS, periodic It is the oil analysis by a reputable testing laboratory should be made. responsibility of the manufacturer or supplier of the oil to insure that his product meets the specifications and gives the expected performance.

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

Section 4, Page 2

__------

----a--__--------------------------___------------

American Gear Manufacturers Association American Petroleum Institute American Society for Testing Materials Engine Manufacturers Association Military Specification Natural Gas Processors Association National Lubricating Grease Institute Society of Automotive Engineers

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

Code: PMA-322, JUN 80 REV

CLqRl4

GROUP 40

LUBRICATION CHART KEY LUBRICANT SPECIFICATIONS & RECOMMENDATIONS PRODUCTS AVAILABLE UNDER CLARK PART NUMBER Page Ref No's

FILTERS

4

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

a

8. Ignition Distributor Cams 9. Starter, Generator Frame Bearings

Page Page

8 8

10. High Temperature

Page

a

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

GROUP 40

CMRK DESCRIPTION

SYMBOL

CLARK PART NUMBER

HYDRAULIC BRAKE FLUID

1801167 850487

1 - case of 12-ounce cans 1 - case of 6 one-gallon cans

HYDRAULIC SYSTEM FLUID

1800236 1802155

1 - case of 24 one-quart cans 1 - case of 6 one-gallon cans

AUTOMATIC TRANSMISSION FLUID

1802200 1802154 962669

1 - case of 24 one-quart cans 1 - case of 6 one-gallon cans 1 - five-gallon can

BATTERY CLEANER

886398

1 - case of 12 one-pint cans

LUBRICANT - INNERSLIDE

886396

1 - case of 12 one-pint cans

PENETRATING OIL

886397

1 - case of 12 one-pint cans

1800078

1 - case of 12 one-pint cans

BELT DRESSING CHAIN & CABLE LUBE

886399

1 - case of 12 one-pint cans (Roller & Leaf Chain Lube)

886785

1 - case of 12 16-ounce cans (Black Heavy-Duty "EP" Lubricant.)

DEGREASER

1800330

1 - case of 12 one-pint cans

CONQUER SPRAY*

1801145

1 - case of 12 16-ounce cans

886784

1 - case of’ 12 16-ounce cans (Transparent Protective Insulating Sealer with Clear Lube.)

DEGREASER***

1801146

1 - case of 12 16-ounce cans

SCR HEAT CONDUCTIVE THERMAL COMPOUND

1801480 1742787

1 - carton of 4 5-ounce tubes 1 - 5-pound can

SPRAY LUBE FOR OPEN GEARS

SPRAY KOTE**

*HIGH MOISTURE EXPOSURE ... Protective Spray Coating for SCR Cards. **HIGH MOISTURE EXPOSURE . ..Protective Spray Coating for Electrical Switches, Contactors and Ignition Systems. ***Oily or Greasy SCR Control . . . CLARK #1801146 Degreaser (or the equivalent to MS-180 Freon TF Degreaser).

Section 4, Page 4

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

Code: PMA-322, FEB 84 REV

Cl!!RU

GROUP 40

CRANKCASE IMOTOR OIL

CLARK PART NUMBER

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

1802152 1802153

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

LOW TEMPERATURE OPERATION (MULTI-VISCOSITY OILS) ____________________~~~~~~~~~~~~~~~~~~~~~~~~~~~~ IT IS RECOMMENDED THAT MULTI-VISCOSITY OIL CONDITIONS, COMBINED WITH HIGHER OPERATING SUPPLIER SHOULD ASSUME FULL RESPONSIBILITY MULTI-VISCOSITY OIL AT BOTH LOW AND NORMAL

BE USED ONLY WHERE COLD STARTING TEMPERATURES MAKE IT NECESSARY. THE OIL FOR SATISFACTORY PERFORMANCE OF THE ENGINE OPERATING TEMPERATURES.

SERVICE CONDITIONS _-----_---________ OIL PERFORMANCE WILL REFLECT ENGINE LOAD, TEMPERATURE, FUEL QUALITY, ATMOSPHERIC kJHERE OIL PERFORMANCE PROBLEMS ARISE OR ARE DIRT, MOISTURE 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

2.

r3 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" Sulfated ash content per SAE Report 5183 and/or *MIL-L-2104B. 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.

API

ENGINE CRANKCASE OIL

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

SERIES 3

e n

API

CD

MIL-L-45199B MIL-L-2104C

3.

ENGINE CRANKCASE OIL

FOR . . . TURBOCHARGED DIESEL ENGINES OR DIESEL ENGINES USING HIGH SULFUR CONTENT FUEL (OVER 0.5% SULFUR).

SPECIFICATION TO MEET API Service Classification "CD" per SAE Report 5183 and equivalent Series 3 and/or MIL-L-45199B Specifications. Also MIL-L-2104C when applicable.

Sulfated ash content 1.65% maximum.

FOR ALL OPERATIONS WITHIN NOMINAL RANGES, THE USE OF SINGLE-GRADED OILS IS RECOMMENDED.

SAE 1OW SAE 20/2ow SAE 30

SAE 30 OIL OF MIL-L-2104B PERFORMANCE LEVEL IS RECOMMENDED FOR YEAR AROUND USE IN DETROIT DIESEL ENGINES ...

(Limitations - Zinc 0.10% maximum, The use of sulfated ash 1.0% maximum).

Multi-grade oils in Detroit Diesel engines is not recommended.

Oil Change Intervals ... a helpful guide in determining the intervals is an engine oil analysis made several different times. Local oil distributors offer this service. And by using it you can set P.M. intervals with greater certainty.

Ref. 2

::: ...

0" to 32" F. 33" to 75" F. above 75" F.

ENGINE CRANKCASE OIL

FOR . . . MISCELLANEOUS LINKAGE 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

CL9RIC

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 #l per MS-107B

6.

LOW TEMP

MIL-G-23827A

LOW TEMPERATURE GREASE COLD STORAGE OPERATION

For ... GENERAL CHASSIS GREASE UPRIGHT MOUNTING UPRIGHT LIFT CHAINS ALL MOVABLE PARTS EQUIPPED WITH GREASE FITTINGS BRAKE (AND CLUTCH) PEDAL LINKAGE (Narrow Aisle Trucks & Powrworkers) DRIVE UNIT FITTINGS PANTOGRAPH CASTER WHEELS STEER CHAIN, ROLLERS & SPROCKETS LOAD WHEELS WITH FITTINGS SPECIFICATION An extreme low temperature aircraft quality grease meeting Specification MIL-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.

7 MOLY GREASE

FOR ... STRADDLE CARRIERS EQUALIZING LINKAGE HOOK & HANGER BUSHINGS HOIST MECHANISM SPECIFICATIONS A smooth high quality grease of refined mineral oil base with a lithium soap thickener or equal compounded with corrosion and oxidation inhibitors and containing 1 to 3% moly (molybdenum disulfide). NLGI i/2

8.

lrLL.> MOLY GREASE

SPECIFICATIONS

CLARK PART NUMBER 1800636

See above.

SPECIAL GREASE

FOR ... DELCO STARTER BEARINGS *GENERATOR/ALTERNATOR END FRAME BEARINGS SPECIFICATIONS

10.

HIGH TEMP

SPECIAL GREASE

FOR ... DISTRIBUTOR CAMS

9.

BLG. G.B.L. MOLY GREASE

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 ti 0

SPECIFICATIONS A high temperature grease of refined mineral oil base with a lithium soap thickener or equal compounded with additives to give high load-carrying ability and resistance to water and high temperature.

To withstand temperatures of -20" F. (to) +300" F. NLGI Grade No. 2.

NOTE:

Section 4, Page 8

Commercial products meeting MIL-G-3545C also meet this requirement.

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

Code: PMA-322, JUN 80 REV

CLflRK

GROUP 40

11.

SPLINE GREASE

FOR 1.. 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, FE9 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 i/l 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.

EC1

U

ELECTRICAL CABLE LUBRICANT

FOR . . . LEVEL WINDING OF ROS CABLES ON REEL SPECIFICATIONS A silicone jelly or equivalent to provide nonsticking lubrication of external cable surfaces during rewinding on reel.

16.

SPECIAL LUBRICANT

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

17.

API GL-4

Use an approved Dry Film Type Lubricant or the

DRIVE AXLE GEAR LUBRICANT

FOR . . . DRIVE AXLES, HEAVY DUTY DIFFERENTIALS, PLANETARY WHEEL ENDS SPECIFICATIONS Extreme pressure type gear lubricant with sulfurchlorine-lead (SCL) "EP" additive for API GL-4 service per SAE Report J308a. To meet CLARK Specification MS-8.

Below 0 to -10" F. Normal Temperature 100" F. and above

MS-8

Section 4, Page 10

NOTE:

----

SAE 80 SAE 90 SAE 140

SAE 80 and SAE 140 viscosities, when used, should contain like additives as specified by MS-8 (SAE 90). DO NOT ADD (MIX) DIFFERENT TYPES OF LUBRICANT.

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

Code: PMA-322, JUN 80 REV

EP LUBE MIL-2105B

18.

TRANSMISSION LUBRICANT

FOR . . . STANDARD MANUAL SHIFT (SYNCHROMESH) TRANSMISSION f 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

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

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

20.

TRANSMISSION FLUID

FOR ... HYDRAULIC SYSTEM AND DRIVE UNITS, POWRWORKERS, NS, NSP, NST TRUCKS, ELECTRIC RIDER TRUCKS, POWER STEERING RESERVOIRS.

DEXRON II

SPECIFICATIONS DEXRON II* ATF (Automatic Transmission Fluid) containing zinc or equivalent anti-wear additive sufficient to pass the requirements of ASTM D-2882 pump wear test, with 50 mg total weight loss maximum. Container must carry GM approval number (C-xxxxx/DEXRON II.)

Code: PMA-322, AUG 81 REV

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

Section 4, Page 11

CAUTION

; CORD f=l

L TWR

21.

TRANSMISSION FLUID - FORD

FOR ... ALL FORD AUTOMATIC TRANSMISSIONS AND CONVERTERS

“VI

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

TYPE "F" CAUTION:

22.

HYDRAULIC

BRAKE FLUID

HYDRAULIC BRAKE FLUID

FOR . . . HYDRAULIC BRAKE SYSTEMS EXCEPT WHEN SPECIFIED DIFFERENTLY ON THE LUBRICATION CHART(S) AND NOT USED FOR COLD STORAGE.

CLARK PART NUMBER 884677

SPECIFICATIONS Use only heavy-duty Hydraulic Brake Fluid which meets or exceeds the requirements of SAE 51703 Specification, or alternatively, Type DOT-Brake Fluid, Grade DOT 3, as specified

by Federal Motor Vehicle Safety Standard No. 116 (FMVSS 116).

Non-petroleum type.

23.

COLD STORAGE

DEXRON AND TYPE "A" FLUIDS ARE NOT COMPATIBLE WITH TYPE "F" FLUIDS AND SHOULD NOT BE MIXED. DEXRON FLUID OR TYPE "A" FLUID SHOULD NOT BE USED IN FORD TRANSMISSIONS AND CONVERTERS (CTA "E" MODELS) TO DO SO WILL RUIN CLUTCH DISC FACINGS.

HYDRAULIC BRAKE FLUID -COLD STORAGE OPERATION-

FOR . . . HYDRAULIC BRAKE SYSTEMS, WHEN SPECIFIED SEPARATELY ON LUBRICATION CHART(S).

SPECIFICATION Use Fluid per CLARK Specification MS-92: Recommended Fluid: 85% by volume, Isopropyl Alcohol: 15% by volume.

PRE-BLENDED BRAKE FLUID

Section 4, Page 12

ALTERNATE: Fluid meeting SAE 51702, Motor Vehicle Brake FluidArctic, or Federal Specification MIL-H-13910, as available.

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

Code: PM&322, AUG 81 REV

CLflRlt

GR&u 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

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

2 g I&.

0

CL!WU

GROUP 40 CLARK PART NUMBER 1801146 FOR ELECTRICAL & SCR COMPONENTS IMPORTANT DO NOT CLEAN ELECTRICAL COMPONENTS WITH STEAM. ONLY APPROVED SOLVENTS SHOULD BE

0

USED TO CLEAN SCR COMPONENTS ...

NOTE

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,

0 NOTE

valves and other components as well as engines . . . may be used on paint.

Code: PMA-322, FEB 84 REV

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

Section 4, Page 15

ELECTRICAL SCHEMATICS AND DIAGRAMS

Code: PMA-541, JAN 86

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

The models covered in the electrical

section are:

P. 1 & 2. P-40/P-60 (12 volt) P. 3 & 4. HWP 40/60 (12 or 24 volt) P. 5 & 6. HWP 60 (24 volt) P. 7 & 8. HWP 60 (24 volt), S.C.R. System Several notes are provided to add clarification

to the wiring diagrams

0 “Lift” and “Lower” components

and as such are marked accordingly

l

“Forward” and “Reverse”

l

Some switches

l

If component

are identified

components

are identified

replacement

are identified

and schematics. on diagrams.

by “F” and “R”.

by function while others are initialed by function.

is necessary,

use only Clark parts.

The following wiring color code is provided to aid in electrical troubleshooting COLOR CODE 0

BLACK

1

BROWN

2

RED

3

ORANGE

4

YELLOW

5

GREEN

6

BLUE

7

VIOLET

8

GRAY

9

WHITE

Numbers in ( ) denote wire color. In two digit numbers the second digit is the wire color.

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

and wire replacement.

CMRU 1. P4O/P60 -

12 VOLTS -

DC -

LADDER SCHEMATIC

BATTERY ->-+11w\\ 12 VOLTS

PUMP

MOTOR

FIELD

5

fl

l

+----

IRIVE

MOTOR

RESISTOR

1FU F -----I ----_I

EMERGENCY MOMENTRRY

*KEY /.SWI TCH

S2

F

REVERSE SNITCH

22 BRFlKE SWITCH 22-_4-28

l-l

-22-i-43--

LIT

I

LOWER

-22-w

Llrlll

SWITCH

us-:"-13

LOWER u7p"-13 i

0

HORN

HORN 25--13

227

I I HOUR METER I +-_------_22_-------_$M'+-------_13_--------1 I -1 I I

BATTERY

OISCHRRGE

INOICATOR

L_________22________~B~~~______---13_--------J -1

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

--I I I I I I

2. ~401~60-

12 VOLTS -

DC -

WIRING ~IAGWWI

BRTTERI OISCHRRGE INDICRTOR

BARKE

SWITCH

__-i RESISTOR

r

I

L__ VI

-_

CONTRCTOR ORIVE

HOTOR

L

tl,

L

I

-_-

HRNO

CONTROLLER

--

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

I

-

PRNEL

3. HWP 4O/HWP 60 -

12/24 VOLTS -

DC -

LADDER SCHEMATIC

BRTTERY >~llc;--(< 12/24 VOLTS

PUMP

MOTOR

FIELD

DRIVE

MOTOR

-JYTmg-

EMERGENCY HOtlENTRRY

REVERSE SWITCH

.---, .---q’s

S;::CH

I

-22-

BRAKE WITCH

2 SECOND

32

-32132’t----13R% Y -22

“;;I:;;”

RUX LIFT SUITCH

-

114

s-;-13-

r LIFT

-224

W;,:~;‘”

-22

-rq*’ LOUER

LONER 13-

u7

-22-J

HORN -22

HORN

-v

2Spy13HOUR

BRTTERY .--

_________

22 _____

r.

METER

DISCHARGE

0

INOICRTOR

-__-~~~;~__________~3_-_-------J

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

I

CMRK 4. HWP 40/HWP 60 -

12/24 VOLTS -

DC -

WIRING DIAGRAM

I.-_;

BRTTERT RECEPTRCLE

HOUR METER

BRTTERY OISCHRRCE INOICRTOR

LIMIT SWITCH

ORIVE

L ~__

15--z __-

HRNO

MOTOR

REYEI

CONTROLLER

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

CMRR 5. HWP 60 -

24 VOLTS -

DC -

LADDER SCHEMATIC

HWPGO 24 V/DC

BRTTERY ?i%z~

PUMP

MOTOR

DRIVE

MOTOR

F

12 EMERGENCY MOMENTRRY

KEY SWITCH

REVERSE SWITCH

@

22-4 BRRKE SNITCH

t

c c

212

-32-l32&---13-

95:-*3-

22 -7’”

22-

c

22

LIFT LIMIT SWITCH

RUX LIFT SWITCH

LIFT

4s 1

AUX LOUER SNITCH

22--q*, LOWER

LOWER 13-

47

22-4 t HORN

HORN 2S,-13-

227 212

HOUR

METER

@

~~~__~______~~__~~_____~~N’~___~___~~_~3__~~___~~~ , I

L--_--_-----22

‘*

_, BRTTERY _________

OISCHRRCE

1’3

INDICRTOR

_~B~~~----__--__~3_-_-______J

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

I

I

Cl!QRK 6. HWP 60 -

24 VOLTS -

DC -

WIRING DIAGRAM

B-pj BRTTERY

III

RECEPTRCLE

TIP

BRTTERY DISCHRRGE INOICRTOR //zk

LIMIT SNITCH

BRRKE

i4 SWITCH

L15

i__ HRND

CONTROLLER

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

CMRK 7. HWP 60 -

24 VOLTS -

DC -

SCR SYSTEM -

LADDER SCHEMATIC

I I

-22

tlORN

=v13+

w

2'2 nw*_n;m *__-_-_---__---___22._______________.~~~~---------------_~3_--------_________+ _A I I

BRiTERf

DISCH_n?GE

lND,CRTOR

L_________________zz_-------------_--(BoI~_---------__----_13_-----------------i

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

13 I I

8. HWP 60 -

24 VOLTS -

DC -

SC SYSTEM -

I::

I_ -1 --

0

-----_ --

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

WIRING DIAGRAM