CLARK Service Update Teleconference Notes

August 12th, 2008

Attendees: Clark Simpson, Sales Engineer, CLARK Material Handling Company.

Glen Wood, Tech Pub Manager, CLARK Material Handling Company.
Mark Dyster, Truck Product Manager, CLARK Material Handling Company.
Russ Davies Elect. Truck Product Service Manager, CLARK Material Handling Company.
Dave Nicolette, Technical Trainer, CLARK Material Handling Company.

84 of 104 North American (US, Canada, and Mexico) Dealerships participated

in the Teleconference.

Two separate Teleconferences were conducted, one at 10:00AM Eastern Time for the Eastern
and Central Time Zones, and the second Teleconference at 1:00PM Eastern Time for the
Mountain and Pacific Time Zones.

The next Service Update Teleconference will be conducted during the week of
October 20th to the 24th, 2008, the exact date and time will be announced in September.

TOPICS THAT WERE DISCUSSED

I.C. PRODUCT – CLARK SIMPSON

PartsPRO:
Mostly used by Service Manager’s and Shop Foreman, very few Technicians have easy access to
PartsPRO. PartsPRO has become a part of all the training courses CLARK conducts both here in Lexington
and at the Dealership Location. PartsPRO is both a Parts and Service Tool, there is a lot of information
within the PartsPRO Program that Technicians should be made aware of and given access too, 90% of all of
the items discussed during the Teleconference have already been explained in different sections of PartsPRO.

All Mitsubishi engines with hydraulic lifters.

Use only 10W30 motor oil. Use of straight 30 weight or 15-40 will generally cause the lifters to float
at high rpm’s due to excessive oil pressure. Refer to page 00(G)-3-2 or PS-1-2 in SM-709 for Engine Oil
Specified, disregard any other recommendations.

All Engines
The Positive Crankcase Ventilation Valve is an Emissions Control Device that routes unburned
crankcase blow by gases back into the intake manifold where they can be re-burned. The PCV system is
one of the oldest Emission Control Devices, and also one of the most beneficial. Besides totally eliminating
Crankcase Emissions as a source of Air Pollution, the constant recirculation of air through the crankcase
helps remove moisture which otherwise would cause sludge to form. Thus the PCV Valve extends the life
of the oil and engine. The PCV valve requires little maintenance but should be checked, cleaned, or
replaced every 12 months or 2000 hour intervals, failure to do so has resulted in several instances when the
Woodward Emission Control System (Tier II and Tier III) malfunctioned and the “Check Engine Light” has
been illuminated resulting in a Service Call, because a plugged PCV Valve will introduce oil vapors into the
Mixer. The oil can get into the Vacuum Lines to the Regulator and then plug the Fuel trim Valves.

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 CLARK Service Update Teleconference Notes
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Tier II and Tier III Software
Still getting a lot of calls where the Technician does not have the latest software in his computer.
The latest software is:
TIER II:
Display: MI_4_Diagnostic_Display_revF.dis (Current Display)
SECM: VARSPEEDRBAL

TIER III:
Display: MI07_RevP.dis
SECM: MI07SEQ62VO5

TIER II and TIER III Software Updates:

PartsPRO has the newest TIER II and TIER III Software Upgrades, all upgrades are available in the
EPA 2007 File. The Software Updates are as follows:

TIER II - EPA 2004 Software has been updated to VARSPEEDRBAL. This update addresses a random
problem where there was difficulty connecting to the SECM after a system upgrade.

TIER III - EPA 2007 has been upgraded to (MI07SEQ062V05_****_C_T_P_100mfu). This upgrade
addresses 3 issues with the system.
1.) The New Key On-Engine Off (KOEO) Test Page at the end of Manual Override Pages in the
Service Display (NEW MI-07 Rev M Display) and the Key On-Engine Off (KOEO)
component testing software that enables the Key On-Engine Off (KOEO) Test Page to operate
the components. Dealers now have the ability to verify proper Injector Operation, Spark
Ignition, Electronic Throttle Operation, and Fuel Trim Valve Operation. In order to use the
Key On-Engine Off (KOEO) Test Page for these components, the Dealers/Technicians will
have to use the new MI07 Rev M Display also included in the Software Upgrade.

2.) The range used to determine “MAP_IR_Hi” faults has been adjusted to prevent premature or
false “351” Fault Codes.

3.) The Gas Adaptive Gains used to determine “GasFuelAdaptRangeLo” have been adjusted to
prevent premature or false “721” Fault Codes.

4.) The New MI07_RevP Display. In order to properly run and monitor the KOEO Test Page
Component Testing Software you will require this Display.

NOTE: We have had several incidents, reported by Dealers, of problems while using the “Crypt
Token Update”. The Update will permit you to get through the first two “Run Menu’s” and up to the
“Update Token Menu”, when you click on the “Update Token Button” you get an Error Message that
states “This application has failed to start because XTP9510Lib.dll was not found. Re-installing the
application may fix this problem”. Re-installing the application does not fix the problem; we have
found that the problem is not with the Update Software. The Computer being used to update the
Crypt Token has been placed in a “Secured Mode” and will not permit all of the Software to upload.
You must make sure your IT/IS Department Personnel have unlocked all security to the Computer
before utilizing the Software Updates from PartsPRO. If you have any problems of this nature please
contact Billy Marksbury at 1-859-422-6409 here at CLARK.

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Dash Display Error Codes:
Error Codes displayed in the Hour Meter Display on the Clark Semi Circular Dash. The Numeric
Codes indicate the Dash Connector Pin Number for the circuit in which the Electrical Malfunction occurred.
All of this information can be found in Service Bulletin Number SI-39-783-04, which can be downloaded
and/or printed from PartsPRO.

Static Ground Chain on IC trucks

Even though we do not normally put a Static Strap / Ground Chain on Pneumatic or I.C. Lift Trucks
with Black Tires which have Carbon in them, there may situations where the Lift Truck is generating /
absorbing enough Static Electricity to cause Electrical System Problems or is giving a Static Electricity
Shock to the operators. Also, floors that have a heavily coated Poly Seal on them, and environments where
plastic may be snagged and drug along by the underside of the Lift Truck may also generated large amounts
of Static Electricity. In these situations a Static Strap or Ground Chain may be required.

GM 4.3L Engine Starter Failures:

Replace with Starter Part #935180 and install Bracket Kit #1813285, this Bracket Kit has just been
revised for easier installation.

Head Lamp Bulbs:

If you are having a problem with H3 Halogen Head Lamp Bulbs on the GEN2 Models, replace the
Bulbs with Part #935617 this is a heftier filament and is a 50 Watt / 14.5 Volt Bulb. We also have
replacement assemblies (New Part Number #2827443) for Part Number #8001692 and #8001828 that have
the Long Life Bulb and also an improved Vibration Mount. The Old Lights are the same except for the
Lens orientation, so you can service both with the New Number by just adjusting the Lamp so the beam
shines where you want it. We will cross both of these to the Ne Part Number #2827443 when our stock is
used up.

Spark Plugs:
If you have been experiencing a Rough Idle, Sputtering after Idling then Rapid Acceleration, or
Random Misfire on Acceleration, you may be experiencing a Spark Plug Problem. If you are on site and do
not have the proper Spark Plugs, but want to verify the Spark Plug Problem, usually Re-Gapping the Spark
Plugs to .015-.018in. will correct the problem. If the Spark Plugs are the cause, then the recommendation is
to replace the Spark Plugs with Platinum Tipped, Resistor Spark Plugs, and Gapped at .035in. Also see SI-
00-794-07 in PartsPRO.

On all TIER II and TIER III Engines, Spark Plugs should be checked every 1,500 hours, or if the
Engine begins to misfire or stumble on acceleration. ONLY USE Platinum Tipped, Resistor Spark Plugs on
all TIER II and TIER III Engines. Spark Plug Gap on all TIER II and TIER III Engines is .035in., and must
be checked when replacing the Spark Plugs. On all TIER II and TIER III Engines the Spark Plugs should be
RELACED when the Electrode Gap has worn to .045in. or greater. Coat all Spark Plug Threads with
Anti-Seize before installing the Spark Plugs into an Aluminum Head.

To order Platinum Tipped Resistor Spark Plugs us the following Part Numbers and ensure the Plugs
are stamped with the appropriate Manufactures Numbers:
Mitsubishi 2.0 / 2.4L use a 934881 which is a DENSO P16R or a BOSCH WRW8DP+ Spark Plug.
General Motors 4.3L uses a 923702 which is a AC DA-JCB which is manufactured in China,
or AC 41-932 which is manufactured in the USA.

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Neutral Shift Controller:
On GEN2 C232, P232, C152, P152, and CGC470’s with the Neutral Shift Controller Part Number
#8041257, if you experience any of the following symptoms:
1.) The Transmission won’t engage with the Parking Brake released, or may only engage in Forward
and not in Reverse, or may only engage in Reverse and not Forward, or may not engage at all.
2.) Engine will not Crank to Start unless the Parking Brake is set.
3.) Engine will not Crank to Start unless the Parking Brake is released.
4.) Neutral Shift Warning Horn beeps continuously.
5.) The Engine will Crank but will not Start, and there is no Voltage at the Ignition Coil.
It is recommended you replace the 8041257 Neutral Shift Controller with an 1833118 Relay Kit; this Relay
Kit does not work on the CMP Series Lift Trucks. See SI-39-793-07 in PartsPRO.

TIER III SECM Fault Codes 481, 711, 712, 717:

If you have a TIER III CLARK Lift Truck that Fault Codes 481, 711, 712, & 717 are re-occurring
Faults for no apparent reason contact Mike Michalski at 1-859-422-6423. Woodward is aware of this
problem and is currently researching software solutions for it.

Upright Lift and / or Tilt Drift Problems:

Consult SI-30-792-07, found in PartsPRO.

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ELECTRIC PRODUCT – RUSS DAVIES & MARK DYSTER

Fault Codes 31, 110, & 173 (VMN High) on CLARK TMX, ECX, & ESX:
These Fault Codes indicate that there is higher than 50% Battery Voltage at one or more of the AC
Stator Windings prior to the Drive Control Frequency. The High Voltage can generally be traced back
through the frame of the Lift Truck to a Dirty or Corroded Battery and Compartment or a bad Key Switch.
The solutions are if the Key Switch is the problem, replace it, if the Battery Voltage is leaking to the frame
then clean the Battery and Compartment.

CLARK TMX Fault Code 85,

CLARK ECX No Fault Code on the Dash, the Lift Truck is ready to Operate but there is little or no
movement when the Accelerator is depressed:
On both the TMX and ECX the Lift Truck may begin to move but then Traction Motor dies. We
have found that occasionally, when the Battery Voltage Setting is changed, or the battery has been
disconnected for a long period of time, the ZAPI AC Controller may loose its calibration for the Accelerator.
Using the ZAPI Handset, go to the Left Side Menu and “Relearn the Accelerator” using the Program VACC
Menu. After Re-Learning the Accelerator, if the Lift Truck still does not work the Accelerator may have to
be replaced.

CLARK ESX Fault Code 248 (EM Brake Open):

This Fault Code is meant to inform the Technician there is a problem with the Parking Brake System,
it may or may not indicate and electrical problem. This Fault Code could be set if the Lift Truck were
sitting still, with the Key Switch turned to the “ON” Position, and the truck is bumped by another vehicle
causing the Lift Truck to move ever so slightly. If the Lift Truck is bumped and moved with the Key Switch
turned “ON”, the Traction Motor Encoders will send a signal to the Controller telling it the Drive Wheels are
turning. The Controller knows there is no one in the Operator Compartment and there is no demand from
the Accelerator so the Lift Truck should not be moving, but since the Lift Truck is moving the Parking Brake
must be bad, and the Controller Displays a Fault Code 248.

To clear the 248 Fault Code, using the ZAPI Handset, access the Right Side Menu and scroll to the
“Set Options” Menu. Enter the “Set Options” Menu and scroll to the “EM Brake Test” Option, select the
“EM Brake Test” Option and turn it “ON”, then save it. After saving the “EM Brake Test” Option “ON”,
move the Multifunctional Control Handle to the “FULL Forward” Position and hold it there for
approximately ten (10) seconds. If the Parking/EM Brakes are good the Fault Code 248 will disappear, if
there is a problem with the Parking/EM Brake the Fault Code will remain on.

After concluding the “EM Brake Test” you must go back into the “Set Options” Menu and turn the
“EM Brake Test” “OFF”.

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CLARK ESX Upright Drift with Load:

If there is no load on the Forks you may experience a slight drift in the Upright, however once the
Forks have engaged and lifted a load there should be no drifting.

The few instances we have had were caused by contamination in the Hydraulic Oil that became stuck
in the Lowering Valve or the Lowering Compensator Valve. In order to clear the contamination, remove the
Lowering Valve and the Lowering Compensator Valve, clean them with Brake Clean, and Re-Install both
Valves.

For other Upright Lift and Tilt Drift problems consult SI-30-792-07 found in PartsPRO.

CLARK TMX & ECX Intermittent Electrical Problems:

If you are experiencing a large number of Intermittent Electrical Problems on these units our
recommendation is to remove the 12 Volt Negative Wires (to include the Negative Wire from the 12 Volt
Converter) from the Chassis Stand-Off and tie them together with a bolt, making sure they remain isolated
from the Chassis. We have had some success with this fix, if you have tried this fix and it did not work
contact Russ Davies at 1-859-422-6421.

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