SM 556 PDF

SM-556
ESM 12-25
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SERVICE MANUAL
SM556
CONTENTS
GROUP PAGE
Foreword ii
...
How to Use this Manual III
Pictorial Index iv
Safety and Operational Checks iv
Recommended Planned Maintenance
and Lubricatiin Schedule V
Safety Signs and Messages vi
User Safe Maintenance Practices vi
GROUP PAGE
PM Planned Maintenance Program PM-1

’ 12. . Battery Removal & Maintenance 12-01-l
13 Accetkator and Directional Control System 13-01-f
13 Main Pump Motor Switch Check and Adjustment 13-02-l
14 Electrical System and Components 14-01-l
16 Electric Motor General Maintenance 16-01-l
16 Drive Motor 16-02-l
16 Main Pump Motor 16-03-l
16 Steer Pump Motor 16-04-l
16 Drive Motor Overhaul 16-23-l
17 Drive Motor Cut-Cut Switch Check and Adjust 17-01-l
19 Control Panel 19-01-l
19 Control Panel Operation and Troubleshooting 19-02-l
20 Drive Axle 20-01-l
22 Cushion Wheels and Tires 22-01-l
22 Pneumatic Drive Tire and Wheel Maintenance 22-02-l
23 Hydraulic Brake System 23-01-l
23 Brake Master Cyiinder 23-02-l
23 Brake Slave Cylinder 23-03-l
23 Service Brake 23-04-l
25 Steering Gear 25-01-l
26 Steering Axle 26-01-l
26 Power Steering Pump 26-02-l
26 Steer Torque Generator 26-03-l
29 Main Hydraulic Pump 29-01-l
30 Main Hydraulic Valve 30-01-l
31 Hydraulic System 31-01-l
32 Tilt Cylinder 32-01-l
33 Selector Solenoid Valve 33-01-l
34 Upright 34-01-l
34 UprigM Removal 34-9R-1
36 Counterweight 38-01-l
38 Machine Jacking & Blocking 38-02-l
39 Overhead Guard 39-01-l
39 Sheet Metal and Trim 39-02-l
40 Truck Data Plate and Decals 40-01-l
40 Truck Data and Specifications 40-02-l
40 Hydraulic and Electric Diagrams 40-03-l
SM556 i Rev Jan 90
FOREWORD
Clark Equipment Company welcomes you to the growing group of professional people who own, operate
and maintain Clark lift trucks. This manual wiil familiarize you with service maintenance and overhaul
information about your new truck. It has been especially prepared to help you maintain your Clark lift truck
in an efficient and safe operating condition.
Regular, correct maintenance and care of your lift truck is not only important for full and efficient truck life, it
is essential for your safety. A faulty Iii truck is a potential source of danger to the operator, and to other
personnel working near it. The importance of maintaining your Iii truck in a safe operating condii by
servicing it regularly and, when necessary, repairing it promptly cannot be emphasized too strongly.
To assist you in keeping your fii truck in good operating condition, this manual includes an outline of
planned maintenance (PM) procedures that are considered essential to the life and safe performance of
your truck. Brief procedures for inspections, operational checks, deaning, tubncatiin, and adjustments are
included for your reference.
. ,.
Clark recommends that a planned maintenance and safety inspection program (PM) be performed by a
trained and authorized mechanic on a regular basis. The PM program provides the opportunity to make
thorough inspections and checks on the safe condition of your truck. Necessary adjustments and repairs
can be done during the PM, which will increase the life of components and reduce unscheduled downtime.
The need for major adjustments, repairs, or replacements is found and corrections made as required, not
after failure has occurred.
SM556 ii
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 recommended procedures for routine servicing and adjustments as well as for removal and overhaul of
major components of the truck are outlined. It is written to show and describe the adjustment, removal,
disassembly, inspection, repair, and assembly steps that are normally required to service these compo-
nents.
The detailed procedures are arranged in sequence by numbered GROUP and Section. The GROUP
numbers are the same as the component group in the Master Parts Book. Each GROUP has its own Table
of Contents, so that you can find the various topics within more easily. If you cannot find a topic in the Table
of Contents, check the Index at the back of the manual.
Component specifications, information notes and safety messages are included at the proper step of each
procedure. To be better prepared to do the necessary service work, please take time to read the entire
procedure, including any speciaf instructions; before doing anywork.
Speciffcations of selected truck components are included at the back of the manual for easy reference.
Also refer to the Operator’s Manual, located on the truck, for additional information and instructions on the
operation and maintenance of your truck.
If you have need for more information on the care and repair of your truck, please contact your authorized
Clark dealer.
,_ . .
NOTICE - The descriptions and specifications included in this manual were in effectat the time ofprinting. Clark
Equipment Company reserves the right to make improvements and changes in specifications or design, with-
out notice and without incurring obligation. Please check w2h your authorized CLARK dealer for information
on possible updates or revisions.
0 Clark Equipment Company 1989

SM556 iii
PICTORIAL INDEX
1. Control Handle
2. Traction Control Panel
3. Lift Pump & Motor
4. Steer Pump & Motor
5. Service Brake
6. Drive Motors (2)
7. SumpTank
8. Battery
5 9. Steer Axle & Housing
1O.Steer Torque Generator
6 11. Brake Reservoir
12. Steer Control and Valve
SAFETY AND OPERATIONAL CHECKS

Daily Inspection . - CMWV
_-_. J S-10 hours ABCDE
Checktruckforobvic__ XIS damage
__...__ and leaks 0
Check / clean battery terminals Q
Check electrolyte level
Check capacity, wamina plates. decal I II I I
Check condition of ti,res and wheels and 0
remove embedded objects I I I
Check wheel lug nuts
bn and bolts
tration and other warning
V
devices
Check steering operation 0
Check brake operation 0
.
Check directional and speed control
operation
Check lift, tilt, aind aux.
_._ operation
Check upright, lift ch(ains and fasteners
Check load backrest extension and forks
SM556 iv
RECOMMENDED PLANNED
MAINTENANCE and LUBRICATION
SCHEDULE
Recommended Planned Maintenance Interval

A = 8-l 0 hours daily
B = 50-250 hours or every month
c= 450-500 hours or every 3 months
D = 900-l 000 hours or every 6 months
E = 2000 hours or every year
Rev Jan ‘96 Copyrighted

SM556Material
v
Safety Signs and Safety Messages User Safe Inspection Practices
lmproperorcareless techniques cause accidents. Don’t The following instructions have been prepared from
take chances with incorrect or damaged equipment. current industry and government safety standards
READ and UNDERSTAND the procedures for safe applicable to industrial truck operations and
driving and maintenance outlined in this manual. maintenance. They are listed hereforthe reference and
safety of all workers during inspection / maintenance
STAY ALERT! Follow safety rules, regulations and operations. When in doubt of any inspection /
procedures. Accidents can be avoided by recognizing maintenance procedures, please contact your local
dangerous procedures or situations before they occur. CLARK dealer.
DRIVE AND WORK SAFELY and follow the safety 1.Powered industrial trucks can become hazardous if
signs and their messages displayed on the truck and in maintenance is neglected. Therefore, suitable
this manual. maintenance facilities, trained personnel and procedures
shall be provided.
SAFETY SIGNS and MESSAGES are placed in this
manual and also on the lift truck to provide instructions 2. Maintenance and inspection of all powered industrial
and to identify specific areas where potential hazards trucks shall be done in conformance with the
exist and special precautions should be taken. Be sure manufacturers recommendations.
you know and understand the meaning of these instruc-
tions, signs and messages. Damage to the truck or 3. A scheduled planned maintenance, lubrication and
death or serious injury to you or other persons may inspection system shall be followed.
result if these messages are not followed.
4. Only trained and authorized personnel shall be
NOTICE permitted to maintain, repair, adjust and inspect industrial
This message is used when special informa- trucks and in accordance with the manufacturer’s
tion is required to clarify procedures or identify specifications.
components pertaining to the truck.
5. Properly ventilate work area, vent exhaust fumes,
keep shop clean and floor dry.
IMPORTANT
This message is used when additional atten-
6. Avoid fire hazards and have fire protection equipment
tion is required for proper operation or mainte-
present in the work area. Do not use an open flame to
nance of the truck.
check electrolyte level. Do not use open pans of fuel or
flammable cleaning fluids for cleaning parts.
A ! CAUTION
This message is used as a reminder of safety
7.Before Starting To Work On Truck:
a) Raise drive wheel free of floor or disconnect power
practices which can result in personal injury if source and use blocksorother positive truck positioning
proper precautions are not taken. devices.
b) Put blocks under the load-engaging means,
A WARNING
This message is used when a hazard exists
innermast( or chassis before working on them.
c) Disconnect battery before working on the electrical
system.
which can result in injury or death, if proper
precautions are not taken. 8. Operation of the truck to check performance must be
conducted in an authorized, safe, clear area.
A 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
SM556 vi Material Rev Jan ‘96
9. Before Starting to Drive the Truck: connections must be inspected and maintained in
a) Be in operating position. conformance with good practices. Special
b) Turn on power. attention must be paid to the condition of electrical
c) Check functioning of lift and tilt systems. insulation.
d) Check directional and speed controls.
e) Check steering. 17. To avoid injury to personnel or damage to the
9 Check brakes. equipment, consult the manufacturers procedures
g) Check warning devices. in replacing contacts on any battery.
h) Check any load handling attachments.
18. Industrial trucks must be kept in a clean
10. Before Leaving the Truck: condition to minimize fire hazards and help in the
a) Stop truck. detection of loose or defective parts.
b) Fully lower forks or attachment device.
c) Allow directional control to return to neutral. 19. Modiiiations and additions that affect capacity
d) Turn off the control / ignition switch. and safe truck operation must not be done without
e) Chock wheels if truck must be left on an the manufacturer’s prior written approval.
incline. Capacity, operation and maintenance instruction
plates, tags or decals must be changed
11. Brakes, steering mechanisms, control accordingly.
mechanisms, warning devices, lights, lift overload
devices, guards and safety devices, lift, reach and 20. Care must be taken to assure that all
rotation mechanisms, and frame members must be replacement parts, including tires, are
carefully and regularly inspected and maintained in interchangeable with the original parts and of a
a safe operating condition. quality at least equal to that provided in the original
equipment. Parts, including tires, are to be
‘12. Special trucks or devices designed and installed per the manufacturers procedures.
approved for hazardous area operation must Always use genuine CLARK or CLARK - approved
receive special attention to ensure that parts. ;
maintenance preserves the original, approved safe
operating features. 21. When removing tires, follow industry safety
practiced. Most important, deflate pneumatic tires
13. All hydraulic systems must be regularly completely prior to removal. Following assembly
inspected and maintained in conformance with of tires on multi-piece rims, use a safety cage or
good practices. Tilt and lift cylinders, valves and restraining device while inflating.
other similar parts must be checked to assure that
“drift” or leakage has not developed to the extent 22. Use special care when removing heavy
that it would create a hazard. components from the truck, such as
counterweight, upright, etc. Be sure that lifting and
14. When working on hydraulic system, be sure handling equipment is of the correct capacity and
the battery is disconnected and upright is in its fully in good condition.
lowered position, and hydraulic pressure relieved
in hoses and tubing.
/\ ! WARNING
Always put blocks under the carriage and
upright rails when necessary to work with
upright in an elevated position.
15. The truck manufacturer’s capacity, operation

and maintenance instruction plates, tags or decals
must be maintained in legible condition.
16. Batteries, motors, controllers. limit switches,

protective device, electrical conductors and
SM556 vii
Planned Maintenance
GROUP PM
PLANNED MAINTENANCE
Visual Inspection .............................................................................. 2

Functional Tests ................................................................................ 5
Test Drive The Truck ........................................................................ 7
Air Cleaning ..................................................................................... 9
Brake Adjustment ........................................................................... 10
Critical Fastener Torque Checks .................................................... 10
Lubrication, Fluids and Filters ....................................................... 10
SM 556, Jan ‘96

Planned Maintenance
PM - PLANNED MAINTENANCE PROGRAM

A planned maintenanceprogramof regular,routine inspectionsand
lubrication is important for long life and trouble-free operation of
A WARNING
Failure to perform these checks and adjustments
your lift truck. Make and keep records of your inspections. Use will cause a loss of brakes and may result in prop-
these records to help establish the correCtPM intervals for your erty damage, and/or severe or fatal bodily injury.
applicationand to indicate maintenancerequired to prevent major
problems from occurring during operation. HOW TO PERFORM THE PM PERIODIC
INSPECTIONS AND MAINTENANCE
PM REPORT FORM
Asanaid in performing and documenting your PM inspections,
Clark has prepared an “ELECTRIC TRUCK PLANNEDMAIN-
TENANCE REPORT”form. Copies of this form may be obtained
from your authorizedCLARKdealer. We recommend that you use
this form as a checklist and to make a record of your inspectionand
truck condition.
The periodic maintenanceprocedures outlined in this manual are

intended to be used with the PM report form. They are arrangedin
groupings of maintenance work that are done in a logical and
efficient sequence.
AcheckmarkorentryismadeonthePMReportFormwhenthePM
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 VISUAL INSPECTION
of the report to the designatedauthorityor thepersonresponsiblefor First, perform a visual inspection of the lift truck and its
lift truck maintenance. components. Walk around the truck and take note of any
obvious damage and maintenance problems. Check for loose
Do not make repairs or adjustments unless au- fasteners and fittings.
thorized to do so. For safety,it is good practice to:
Check to be sure all capacity, safety, and warning plates or
Remove all jewelry (watch, rings, bracelets, etc.) before decals are attached and legible.
working on the truck.
Disconnect battery from truck receptacle before work- IMPORTANT
ing on electrical components. NAMEPLATES & DECALS
Always weaf safety glasses. Wear a safety (hard) hat in Do not operate a lift truck with damaged or missing
industrial plants and in special work areas where protec- decals and nameplates. Replace them immediately.
tion is necessary or required. They contain important information.
IMPORTANT Inspect the truck for signs of external leakage of transmission

The ESM brakes are not self adjusting, but need to be fluid, etc. Check for hydraulic oil leaks and loose fittings. DO
periodically inspected and adjusted accordingly. If NOT USE BARE HANDS TO CHECK OIL. Oil may be hot
adjustments are not made as required, the slave or under pressure.
cylinder can run out of stroke, and the springs will
not apply the brakes. This condition will not be a
sudden event, but will result in a gradual loss of
braking capability. If the brakes begin to get “soft”,
this is an indication that the slave cylinder may be
A WARNING
HYDRAULIC FLUID PRESSURE
“bottoming out” and the brakes have not been ad- Do not use your hands to check for
justed as needed. Checking the brake adjustment hydraulic leakage. Fluid under pres-
setting in addition to the driving test must be part of sure can penetrate your skin and cause
the Planned Maintenance program. When the covers serious injury.
are removed for air cleaning the travel controls, the
brake arm positioning and lining wear must be in-
spected, recorded and corrected as necessary.
PM-2 Copyrighted Material SM 556, Jan’ 96

Planned Maintenance
A
Be sure that the driver’s overhead guard, load backrest
extension, finger guards, and any other safety devices are in DANGER
place, undamaged, and attached securely. Uprights can drop suddenly. Look at the up-
right, but keep hands out.
IMPORTANT
For trucks equipped with spark-enclosed (EE) con- Check the upright assembly. Inspect the upright rails, car-
struction, or with polyurethane tires, check the riage rollers, lift chains, lift and tilt cylinders. Look for
ground strap for wear and secure attachment. obvious wear, and damaged or missing parts. Check for any
loosepartsorfittings. Checkforleaks,anydamagedorloose
Check all of the critical components that handle or carry rollers, and rail wear (metal flaking). Carefully check the lift
the load. chains for wear, rust and corrosion, cracked or broken links,
stretching, etc. Check that the lift and carriage chains are
correctly adjusted to have equal tension. Check that the lift
chain anchor fasteners and lccking means are in place and
tight.
Be sure all safety guards and chain retainers are in place and
not damaged. Inspect the carriage stops and cylinder retainer
bolts. Check all welded connections.
Inspect all lift line hydraulic connections for leaks. Check the
lift cylinder rods for wear marks, grooves, and scratches.
Check the cylinder seals for leaks.
IMPORTANT
. Uprights and lift chains require special attention
and maintenance to maintain them in safe oper-
ating condition. Refer to Lift Chain Mainte-
nance section for additional information.
Check the overhead guard for damage. Be sure that it
is properly positioned and all mounting fasteners are in
Forks
place and tight.
Inspect the load forks for cracks, breaks, bending and wear.
The fork top surfaces should be level and even with each
Check the load backrestfordamage. Inspect the welds
other. The height difference between both fork tips should be
on the carriage and load backrest for cracks. Be sure
no more than 0.25 inch (6mm).
that the mounting fasteners are all in place
and tight.
IMPORTANT
Ifload backrest has been removed,
a bolt and washer must be in place
on each end of the top fork bar to
act as a fork stop.
max. wear
Check the amount of wear at the heel of the fork.
A WARNING
If the fork blade at the heel is worn down by more
than lo%, the load capacity is reduced and the fork
must be replaced. Do not attempt to fill with weld.
Copyrighted Material PM-3

SM 556, Jan ‘96
Planned Maintenance
Inspect the forks for twists and bends. To check, put a IMPORTANT
2”x4”~24” long block on the blade of the fork with the 4” Personnel working on wheels and tires must be
surface against the blade. Put a 24” carpenters square on the trained and qualified to do wheel and tire maiu-
top of the block and against the shank. Check the fork 18” tenance.
above the blade to be sure it is not bent more than 1 inch
maximum. Pneumatic Tires
Carpenter Square Check for the correct air pressure on trucks with pneumatic
\
tires.
Blade -
them inspected by a trained maintenance person

before operating the truck.
A ! CAUTION
Check tire pressure from a position facing the
tread of the tire, not the side. Use a long-handled
gauge to keep your body away from the side. If
tires are low, don’t add air. The tire may require
removal and repair. Have the tire and wheel
inspected by a person trained and authorized to
do tire and wheel maintenance. Low tire pres-
sure can reduce the stability of your lift truck
and cause it to tip over.
Inspect the fork latches. Be sure they are not damaged or
broken and operate freely and lock correctly. Check the fork Inspect pneumatic tires and wheels carefully for:
stop pins (or bolt and washer) for secure condition. Damaged tire.
Damaged wheels or loosening of the locking rings on
multi-piece rims.
Wheels and Tires Loosening of the clamping bolts and nuts on two-piece,
Check the condition of the drive and split-rim wheels.
steer wheels and tires. Remove Low inflation pressure.
A DANGER
objects that are embedded in the
RIM SEPARATION
Remove the air from tires before doing any work
on tires or rims. Multi-piece rims cans separate
with enough force to cause injury or death.
Check all wheel mounting bolts to
be sure none are loose or missing.
Replace missing bolts and tighten
loose bolts to the correct torque
before operating the truck.

Planned Maintenance
FUNCTIONAL TESTS
Operate the control handle in the travel, lift, and lower

positions. The control handle should operate smoothly and
return to the neutral position when released. If there is any
binding or sticking, have the problem corrected before oper-
ating the truck.
Check to make sure all controls and systems are functioning
Before operating a lift truck, make sure it is in a safe
correctly.
condition.
Test all warning &vices, horn, lights, and other safety
equipment and accessories. Be sure they areproperly mounted
Check to see that:
and working correctly.
l Forks are fully lowered to the floor.
l You are familiar with how all the controls function.
Press the horn button to check horn l All controls are in neutral or other correct position.
function. If the horn does not operate,
report the failure and have it repaired Turn key switch ON, but do not depress brake pedal.
beforethetruckisputbackintoopera-
tion.
Check hourmeter operation. With key switch ON, rotate the

control lever to the FWD or REV travel position. The steer
pump and hourmeter should begin operating. Watch for
movement of the indicator in the right-hand dial opening.
Note any malfunction or damage.
Return control handle to NEUTRAL.
Write the hourmeter reading on the PM report form.

Operate the brake pedal. If there is any binding or sticking,
have the problem corrected before operating the truck. For
Check battery discharge indicator. The indicator should
further brake checks see pages 7 and 10.
register in the green area when key switch is ON. Also, check
Travel function of battery discharge indicator when making the
Forward battery load test below.
Travel
Reverse
SM 556, Jan ‘96 Copyrighted Material PM-5

Planned Maintenance
Battery Load Test The main pump motor should start to run as the lever moves
from the neutral position and upright should rise. Return the
Battery Indicator
Tilt Control control handle to the neutral position. Pump motor should
stop. Push control handle forward into the LOWER position
until upright starts to lower.
If control handle movement is excessive before the pump

starts, or if pump does not stop running when control handle
returns to neutral, the microswitches need adjustment or
replacement.
Check the battery condition by holding the tilt lever in full
Test function of control handle TILT and AUX push-buttons
back-tilt position, allowing main pump to run against load of
and control valve solenoids. Depress the TILT push-button
bypass relief pressure valve for a few seconds. Watch the
and slowly pull back the control handle. The main pump
battery discharge indicator. The needle should stay in the
should start and the upright should tilt back. Return the
green area. If needle falls into the red area, the battery is
control handle to the neutral position. The pump should stop.
faulty or charge level is low and battery must be recharged
With the TILT push-button still depressed, push the control
before completing other electrical tests and performance
handle forward Thepump should start and the upright should
parts of the PM. Turn key switch OFF.
tilt forward. Repeat this test for each AUX push-button
installed. If truck does not function properly, have the prob-
Refer to Group 12, Battery Maintenance, for additional
lem corrected before operating.
information.
Test function of the power steering pump switch and system.
Battery Disconnect Turn key switch ON, and depress the brake pedal. Rotate the
control handle from neutral to either FORWARD or RE-
VERSE position. The steer pump motor should begin oper-
ating.
With the truck not moving, check the steering system by

moving the steering handwheel in a full right turn, and then
in a full left turn. Return the truck steer wheels to the straight-
ahead position. The steering components should operate
smoothly when the steering wheel is turned. Listen for the
steering pressure reliefvalve to bypass when the steer wheels
are fully turned. The steer pump and motor should not stall or
exhibit excessive loading. If it does, the power steering
system relief pressure valve may be malfunctioning.
Check the battery disconnect by pulling back the disconnect Return control handle to NEUTRAL. Steer pump motor
lever. The connector should separate smoothly. If it does not, should stop.
have it repaired.
IMPORTANT
Before Driving The Truck, Do These Tests: The steering system and steer axle should be
inspected periodically for wear, leaking seals,
etc. Check for any changes in steering action.
Hard steering, excessive freeplay (looseness) or
unusual sounds when turning or maneuvering
indicates a need for inspection and servicing.
Never operate a truck which has a steering sys-
tem fault.
Test function of mainpump motor switches on control handle

in LIFT position. Turn key switch ON. Slowly pull the
control handle back into the LIFT position.

Planned Maintenance
TEST DRIVE THE TRUCK Check the accelerator control while conducting the speed
range tests. It must move easily and smoothly throughout the
IMPORTANT acceleration stroke, andreturn withoutbinding. There should
It is recommended that these tests be conducted be no restriction to movement on either acceleration or
with a rated capacity load, if possible. deceleration.
Operate ONLY in a pedestrian and traffic free aisle. An Test the service brake (drive motor cut-off) switch. Drive the
empty parking lot with a smooth, level surface is also a good truck FORWARD (or in REVERSE) at creep speed. While
operating location. holding the control handle steady in creep-speed position,
release brake pedal. The braking action should interrupt
Test the truck for proper operation and drive train function power to the drive motor and stop the truck. Depress the
by driving the truck in both the forward and reverse direc- brake pedal. The drive motors should again start moving the
tions. Drive first in a straight line and slowly through a series truck.
of full right and left turns.
Test for correct function of the SCR control.
Check CREEP SPEED, 1A RANGE, and PLUGGING.
1. Check CREEP SPEED and 1A RANGE while driving

the truck in a straight line in both FORWARD and
REVERSE directions. CREEP SPEED should be ob-
tained at the beginning of SCR RANGE after slightly Test brake operation by depressing and releasing the brake
rotating the control handle and closing 1MS switch. 1A pedal several times while driving the truck. The brakes
RANGE - When the control handle is rotated farther and should bring the truck to a smooth stop, without pulling,
then completely, the truck should accelerate in SCR squealing, or shuddering. Have the brakes adjusted or re-
RANGE and make a smooth transition into 1A RANGE paired as necessary.
for maximum travel speed. As the 1A contactor closes, IMPORTANT
there should be very little surge as the truck goes out of The ESM brakes are not self adjusting, but need to be
SCR RANGE and into 1A. All speed changes should be periodically inspected and adjusted accordingly. If
smooth while increasing and decreasing speed. Listen adjustments are not made as required, the slave
for any unusual drive train noises or actions of the cylinder can run out of stroke, and the springs will
controls and drive train components. not apply the brakes. This condition will not be a
sudden event, but will result in a gradual loss of
Stop truck with the service brakes by releasing the brake braking capability. If the brakes begin to get “soft”,
pedal. Note any unusual reactions in driving or braking this is an indication that the slave cylinder may be
performance, and need for adjustment. “bottoming out” and the brakes have not been ad-
justed as needed. Checking the brake adjustment
2. PLUGGING is an SCR control function which provides setting in addition to the driving test must be part of
for reversing the direction of travel under controlled the Planned Maintenance program. When the covers
conditions. A correctly-adjusted plugging control should are removed for air cleaning the travel controls, the
result in a smooth deceleration and stop from any speed brake arm positioning and lining wear must be in
in one direction, and acceleration in the opposite direc-
tion. Plugging speed and distance are determined by
The ANSI standard requirement for these brakes is that they
control handle travel position.
hold the truck and a rated load on a 15% grade. If such a grade
is available, after adjustment, the brakes can be tested by
Check PLUGGING function first at a slow speed. If plug-
slowly and carefully driving the truck with a rated capacity
ging operates correctly, then test at full speed. First, drive load straight up a known 15% grade, with the load upgrade
truck in the FORWARD direction. Accelerate to the desired and bringing the truck to a stop with the brakes applied. If the
travel speed. Then, rotate the control handle to the same speed brakes hold the loaded truck stationary on the grade the
in REVERSE travel position. The truck should slow to a brakes are satisfactorily set. Even if this test shows satifactory
smooth, controlled stop and then accelerate in the opposite performance, the adjustment check on PM-10 m still be
direction. Repeat test by turning control handle back to done. After observing the performance of the brakes slowly
FORWARD position. drive the truck straight back down the grade. Do not try to
perform any maneuvers on the grade. While this is a test
SM 556, Jan ‘96 Copyrighted Material PM-7

Planned Maintenance
method, the ESM is m intended for use on 15% grades, FORWARD, then back to NEUTRAL. Next, test shift from
except as encountered for short distances such as dock plates. NEUTRAL to REVERSE, then back to NEUTRAL. Check
If no grade is available, the brakes can be approximately for positive control action when changing directions.
tested by measuring the stopping distance as follows. Test
only with an unloaded truck in a pedestrian and traffic free Listen for clunking, squealing, grinding, scraping or other
aisle. An empty parking lot with a smooth, level surface is unusual noises. Check for vibration. Listen for wheel bearing
alsoagoodoperatinglocation.Markalineonthefloorornote or other specific running noise.
a floor joint as a measurement line. Starting at a point
approximately 150 to 200 feet in front of the line, drive the Lift Mechanism and Controls
truck in a straight line at full speed towards the line. As the NOTE: It is recommended that these tests be conducted with
front wheels roll over the line apply the brakes by raising the a rated capacity load, if possible.
brake pedal. When the truck has come to a complete stop,
safely park the truck at this same spot and measure the Test the operation of the hydraulic system and upright.
distance from the front wheels to the measurement line. This
is your stopping distance. Compare to the table below for the A ! CAUTION
model you are working with. If the measured distance is less Be sure there is adequate overhead clearance
thanthetablevaluethenthebmkesaresatisfactorilyset(The before raising the upright.
approximate rule of thumb is that the stopping distance for an
ESM without a load shall be between l-1/4 (one and one
quarter)and 1-1/2(one and one half) times the length of the
truck with no forks.)
Modei Distance inches
ESMl2 100
ESM15S 100
ESM15 97
ESM17 94
ESM20 92
ESM22 90
ESM25 90
Cycle (raise to full height and then lower) the upright at both
Do not operate lift truck if the brakes are not slow and fast speed, with the upright tilted slightly back-
operating properly. wards. Watch the upright assembly as it rises. All move-
ments of the upright, fork carriage, and lift chains must be
Check steering control operation. First, drive the truck in a even and smooth, without binding or jerking motions. Watch
straight line. The truck must drive in a straight line without for chain wobble or looseness; the chains should have equal
drifting toward either side. Then, drive slowly (creep speed) tension and move smoothly without noticeable wobble.
through a series of full right and left turns. Check steering
response and smoothness of operation. Turning effort must Check function of the control handle and main hydraulic
be the same in either direction. If there is a steering problem, valve. Listen for abnormal noises in the hydraulic valve, main
have it repaired. Also refer to Group 17, Drive Motor Cut-Out hydraulic pump, and system components.
check and adjustment.
If the maximum fork height is not reached, there is low oil
level in the hydraulic sump tank, or severe binding within the
upright.
Do not operate lift truck if steering system is not
operating properly.
A WARNING
FALLING FORKS
IMPORTANT
It is recommended that the following tests also be Do not walk or stand under raised forks. The
conducted with a rated capacity load, if available. forks can fall and cause injury or death.
Test for general drive train operation. Drive the truck at Check the upright rails, rollers, carriage, lift chains and
various speeds and operating conditions, in both FORWARD cylinders as they move. Watch for binding or excessive
and REVERSE directions. Test shifting from NEUTRAL to freeplay (looseness) between the carriage and the upright
PM-8
Copyrighted Material SM 556, Jan’96
Planned Maintenance
rails and rollers. Listen for abnormal noises. If there is

excessive clearance between the rails and channels, the need
for upright roller adjustment is indicated. If the rails or
carriage bind or hesitate when lowering, the rollers are either
damaged or roller adjustment is incorrect.
Check the upright for excessive downdrift. Stop the fork

carriage in an intermediate position. Check that it holds its
position and raises or lowers smoothly from any height
position. If the fork carriage does not hold its position when
stopped, the lift cylinder seals may be worn. Conduct an
upright cylinder downdrift test, with rated load, as needed.
Test the tilt function. Check for excessive tilt cylinder drift.
Stop the upright at a position near vertical. Check that the
upright holds its position without moving forward. If you Standard Shutdown Procedures:
observe forward movement (drift), or have a report of a tilt l Always come to a complete stop.
drift problem, the tilt cylinder seals may be worn. l Park only in authorized locations.
l Lower the forks to the floor and tilt them forward.
Test for correct tilt cylinder rod adjustment. Raise the car- l Allow travel control to return to neutral.
riage to an intermediate position. Tilt the upright fully l Turn the key switch off.
FORWARD, without a load on the forks. Check for upright l Step from the truck; the brake will set itself.
racking (twisting) as the tilt cylinders reach the end of their
stroke. Be sure to make a record of all maintenance and operating
problems you find.
Tilt the upright fully BACK. The upright should not rack
(twist) when the tilt cylinders reach the end of their travel. If Battery Compartment Inspection
upright racking is found, adjustment of the tilt cylinder rod Turn key switch OFF. Disconnect battery from truck recep-
ends (yokes) is required. tacle.
Inspect condition of the battery connector and truck battery
Check fork height adjustment and carriage chain adjustment. receptacle. Check the spring-loaded terminals, connectors,
Tilt the upright to the vertical position and fully lower the and retaining tabs. Look for poor connections due to burning,
carriage. The forks should stop and be held approximately bad crimps, or broken or loose retainers. Check the molded
0.50 inch [13 mm] above the floor. If the forks hit the floor, body for damage from overheating, burning and chips or
the carriage lift chains should be adjusted. cracks. Clean all corrosion from contacts, as necessary.
Inspect condition of the battery and cables. Check the battery

Auxiliary Function Control cables for wear or other damage. Also check for signs of
interference or rubbing with other components. Be sure that
the cable terminals are tight and clean. Clean off minor
deposits of corrosion that you find on the battery.
Never wash the battery when it is in the truck.
Check battery post terminals for corrosion and damage.

Clean all corrosion from cable end and battery post. Check
Single Auxiliary Double Auxiliary tightness of cable and post terminals.
Function Function
If necessary, check the state-of-charge condition of the bat-
If truck is equipped with an attachment, check the control for
tery. Take a specific gravity test of the electrolyte with a
correct function by briefly operating the attachment.
hydrometer. Be sure to check a minimum of six battery cells.
IMPORTANT
Checktheelectrolytelevelof thebattery. Adddistilledwater,
When you have completed the operational tests,
as required, to fill each cell to the correct level. Check to be
park and leave truck according to standard shut-
sure the vent hole in all battery cell caps is open. If cap vents
down procedures.
are plugged with corrosion, remove the caps and wash in a
Copyrighted Material PM-9

SM 556, Jan ‘96
Planned Maintenance
solution of baking soda and water. etc.) in the air or on the floor, will require more frequent
cleaning. If air pressure does not remove heavy deposits of
Refer to Group 12, Battery Maintenance, for additional grease, oil, etc., it may be necessary to use steam or liquid
information. spray cleaner. Do not clean electrical components with steam.
Motor SCR Controls Inspection IMPORTANT

Lift trucks should be cleaned at every PM inter-
IMPORTANT val, and otherwise as often as required.
Do not clean electrical components with steam.
Only approved solvents should be used to clean Air cleaning should be done using an air hose with special
controls and SCR components. Use Clark adapter or extension having a control valve and nozzle to direct
#1801146 Degreaser (or the equivalent to MS- the air properly. Use clean dry, low-pressure compressed air;
180 Freon TF Degreaser and Cleaner). restrict air pressure to 30 psi [207 kPa] , maximum. Wear
suitable eye protection and protective ciothing.
Turn key switch OFF. Disconnect battery from truck recep- Air clean the following: Upright assembly; drive axle;
tacle. Remove control and hydraulic compartment cover battery, cables, switches and wiring harness; SCR controls
from truck. and wiring; drive, lift, and steer motors; steer axle, steer
cylinder.
Discharge the capacitor. Use an insulated tool, such as a
screwdriver with plastic or wood handle, to short between the Brake Adjustment
terminals. In addition to the functional brake checks previously per-
formed it is very important that the brake arm and spring
Inspect the SCR controls for clean condition. Check for oily settings be checked. When the covers are removed for the air
dirt buildup on contactors, SCR control card, capacitor, etc. cleaning this check must be made.
Inspect all controls wiring and terminals for any obvious
damage. Look for cracks or worn areas in the wiring insula- IMPORTANT
tion. Check for loose connections at the control terminals. The ESM brakes are not self adjusting, but need to be
Air clean, as necessary. periodically inspected and adjusted accordingly. If
adjustments are not made as required, the slave
cylinder can run out of stroke, and the springs will
Control and Hydraulic Compartment Inspection not apply the brakes. Thii condition will not be a
Check the condition of all hydraulic system components, sudden event, but will result in a gradual loss of
hoses, piping and connections. Check for wear, leakage, and braking capability. If the brakes begin to get “soft”,
damage. this is an indication that the slave cylinder may be
“bottoming out” and the brakes have not been ad-
Inspect all control levers, and linkages. justed as needed. Checking the brake adjustment
setting in addition to the driving test must be part of
Inspect the drive motor, lift pump motor and steer pump the Planned Maintenance program. When the covers
motor power cables. Check drive motor mounting fasteners. are removed for air cleaning the travel controls, the
brake arm positioning and lining wear must be iu-
Check steer and lift pump mountings.
AIR CLEANING
Always maintain a lift truck in a clean condition. Do not
A WARNING
Failure to perform these procedures will cause a
allow dirt, dust, lint, or other contaminants to accumulate on
loss of brakes and may cause property damage
the truck. Keep the truck free from leaking oil and grease.
au/or severe or fatal bodily injury.
Wipe up all oil spills.
Keeptbecontmlsandfloorboardcleananddry. Acleantruck
With the brakesreleasedrotate thebrake drum by hand so that
makes it easier to see leaks, loose, missing or damaged parts,
the shoe pivot pins are visible. Let the foot pedal return to its
and will help prevent fires. A clean truck will mn cooler.
full up position. Measure the angle of the brake arm to a
suaightlinethroughthepivotpins.Seesection23-4-02. If the
The environment in which a lift truck operates will determine
angle is more than 12’ the brakes need adjusting. Also inspect
how often and to what extent cleaning is necessary. For
the shoe lining condition. If the lining appears to be less than
example, trucks operating in manufacturing plants which
3/32” further checking by disassembly is needed. Record on
have a high level of dirt or lint (e.g., cotton fibers, paper dust,
the PM report form and, if you are not the maintenance
Copyrighted Material SM 556, Jai’ 96

PM-10
Planned Maintenance
mechanic, notify the maintenance department. Do not use the Hydraulic Oil Filter
truck until these conditions are corrected. Repeat these checks Remove and replace the hydraulic system fluid filter per
on both left and right-hand side brakes. recommended PM schedule, or as required by truck operating
conditions and usage. Install a new oil filter. Be sure to
Critical Fastener Torque Checks follow the installation instructions printedon thefilter. Check
Fasteners in highly loaded (critical) components can quickly for leaks after installation of the filter. Also, check that the
fail if they loosen. Loose fasteners can cause damage or hydraulic line connections at the filter adapter are tightened
component failure. For safety, it is important that the correct correctly.
torque be maintained on all fasteners of components which Always use genuine CLARK parts.
directly support, handle or control the load, or protect the
operator. Sump Tank Breather Maintenance
Remove the sump tank fill cap/breather and inspect for
excessive contamination and damage. Clean or replace the
Check torque of critical items, including:
fill cap/breather, per recommended PM schedule or as re-
Overhead guard; drive axle mounting; drive and steer wheel
quired by operating conditions.
mounting; counterweight mounting; load backrest exten-
sion; tilt cylinder mounting and yokes; upright mounting &
components. Access to the Drive Axle
The best method to use for reaching the drive axle check
points (oil level/fdlerplug and drain plugs) is dependent upon
LUBRICATION, FLUIDS AND FILTERS
the style of upright, carriage and attachments on your truck.
Hydraulic Sump
One method is to raise the upright carriage to provide easy
Check the hydraulic sump tank fluid level. Correct fluid level
access to the drive axle from the front.
is important forproper hydraulic system operation. Low fluid
level can cause pump damage. Overfilling can cause loss of
RefertoMachineJackingandBlockingsectionforadditional
fluid or lift system malfunction.
information on supporting the upright.
Hydraulic fluid expands as its temperature rises. Therefore,
it is preferable to check the fluid level at operating tempera-
ture, after approximately 30 minutes of truck operation.
Tocheckthefluidlevel,firstparkthetruckonalevelsurface. Block the wheels. Be sure to put blocking under
Put the upright in a vertical position and lower the fork the carriage and upright rails.
carriage fully down. Pull the dipstick out, wipe it with a clean
wiper and reinsert it fully into the dipstick tube. Remove the
dipstick and check the oil level. Keep the oil level above the
A WARNING
AN UPR%HT OR CARRIAGE CAN
LOW mark on the dipstick by adding recommended hydrau- MOVE UNEXPECTEDLY.
lic fluid only, as required. DO NOT OVERFILL. Chain or block the carriage and rails. Failure to
follow this warning can result in serious injury.
Check the condition of the hydraulic fluid for color, clarity,
and contamination. Change (replace) the oil as necessary. Drive Axle Fluid
The drive axle inspection and service plug openings are
Hydraulic Fluid and Filter Change shown by the following illustration.
Drain and replace the hydraulic sump fluid every 2000
operating hours, or sooner, as required. Replace the hydrau-
lic oil filter at every oil change. Replace the sump tank
breather/fill cap every 1000 operating hours.
There is no drain plug in the hydraulic sump tank. The

hydraulic fluid can be changed by one of the following
methods:
a. Removal of the hydraulic sump tank cover assembly and
pumping the fluid out by suction using a separate pump
and hose.
b. Pumping the fluid out by using the truck hydraulic
system. This method may be used most easily and
satisfactorily for routine changes of the fluid.
SM 556, Jan ‘96 Copyrighted Material PM-1 1

Planned Maintenance
1. Fill/oil level dipstick plug. Also acts as the breather cap. Upright and Tilt Cylinder Lubrication
2. Drain plug. Clean the fittings and lubricate the tilt cylinder rod end
bushings, front end only.
Check the drive axle fluid level with the truck on a level
surface and oil at operating temperature. Clean the fittings and lubricate the upright trunnion bushings
(one fitting on top of trunnion, each side).
Remove the flmd level inspection plug located in the front
surface of the drive axle center housing. Wipe dipstick clean Lift Chains
and reinstall. Remove dipstick and examine. Oil level should Lubricate the entire length of the rail lift and carriage chains
be between the two marks on the dipstick. If oil level is low, with Clark Chain and Cable Lube.
add enough oil to bring oil level up to full mark on dipstick.
DO NOT OVERFILL. NOTE: Do not lubricate the carriage roller rails.
Add recommended fluid only, as required. Refer to Specifi-
cations for drive axle recommended oil specification.
Inspect the fill plug for damage. Replace as needed. Install

and tighten the plug.
IMPORTANT
Check the PM interval (operating hours), or the
condition of tbe oil to determine if the drive axle
fluid needs to be changed.
Drive Axle Fluid Change

Drain and replace the drive axle fluid every 1000 operating
hours. The oil should be drained when it is at operating
temperature. Put the truck in a level position. Block the
wheels to prevent truck from moving.
Inspect and clean the drive axle breather (air vent).
Truck Chassis Inspection and Lubrication

Lubrication aud inspection of truck chassis components,
including steer wheels and wheel bearings will be easier if the
rear of the truck is raised and blocked up under the frame.
RefertoMachineJackingandBlockingsectionforadditional
information.
A DANGER
Do not raise truck by lifting under the counter-
weight. Be sure to put blocking under the frame
to keep the truck safe.
Be sure to clean the grease fittings before lubricating and

remove the excess grease from all points after lubricating.

GROUP 12 SECTION 01 A! WARNING
BAlTERY REMOVAL& Electric truck batteries are heavy and
awkward to handle. They are filled with a
MAINTENANCE
very hazardous chemical solution. On
charge, they give off hydrogen and
CONTENTS NO.
oxygen which, in certain concentrations,
are explosive. Elect& truck batteries are
Battery Removal and Handling 12-01-01
also costly, so before you remove,
Battery Maintenance 12-01-02
service, or install a truck battery, consult
the BATTERY MANUFACTURER,
SUPPLIER or your SERVICE MANUAL
12-01-01 BATTERY REMOVAL AND for more recommendations and instruc-
HANDLING tions on handling and charging batteries.
Carefully read and follow recommenda-
tions and instructions.
n! WARNING
SULFRIC ACID Change or service batteries only in an area desig-
THE BATTERY CONTAINS CORROSIVE nated for this purpose.
ACID WHICH CAN CAUSE INJURY. IF
ACID CONTACTS YOUR EYES OR
SKIN, FLUSH IMMEDIATELY WITH
WATER AND GET MEDICAL ASSIS-
TANCE.
Position the truck in the designated area, turn off key

switch and disconnect the battery. The battery can
be removed from either side of the truck.
Be sure this area has provisions, to flush

and neutraliie spillage, to ventilate fumes from gas-
sing batteries and provisions for fire protection.
Before attempting to change or charge a battery, the

truck shall be positioned in the designated battery
service area. Be sure the truck cannot move.
Be sure the area is equipped with material handling

equipment designedforthe purposeof removing and
,. :Xreplacing batteriessuch asa conveyer or overhead
hoist equipped with safety hooks.
When using an overhead hoist, be sure

A recommended method of handling the battery is to an insulated spreader bar or similar
use a platform equipped with rollers. Similar to the lifting device is.used so the lifting force
one shown. If the battery to be handled is uncovered, is vertical.
cover the battery with a nonconducting material,
such as plywood. To avoid side forces from damaging the
battery, the distance between the lifting
hooks must be the same as the distance between the
battery lifting eyes. Make sure the lifting hooks are
the correct size to fii the lifting eyes of the battery.
If the battery does not have a cover of its own, cover
SM556 12 - 01 - 1
Non-Conductive Cover, 12-01-02 BATTERY MAINTENANCE
When charging batteries, the vent caps must be kept

in place to avoid electrolyte spray. Care must be
taken to assure that vent caps are functioning. The
it with a non-conductive material such as plywood

prior to attaching a battery lifting device.
When using a power hoist, be

surethe hoist is equipped with a
chain container to accumulate
the excess chain. If this is not
possible, be sure the battery is vent cap holes must be open to allow the battery to
covered. breathe. Thebattery, orbatterycompartmentcover(s)
must be open to dissipate heat.
Keep all tools and other metal
objects away from the n ! CAUTION
terminals. DO NOT ADD ELECTROLYTE OR
ATTEMPT TO SERVICE THE BATTERY.
A! WARNING
BATTERY SERVICE
BATTERY SERVICE MUST BE DONE
BY TRAINED PERSONNEL. BATTERY ’
ACID CAN CAUSE SEVERE BURNS
AND INJURY.
Persons maintaining storage batteries must wear Once the battery is out of the truck,
protective clothing such as face shield, long sleeves a lifting device equipped with an
and gauntlet gloves. insulated spreader bar and safety
hooks can be used to transport
this style of battery.
Battery Cleaning
A DANGER
Hydrogen emissions from charging batter-
ies are flammable. No smoking shall be
allowed in the charging area. Do not
check the electrolyte level with an‘ open
flame. Do not allow open flame, sparks
or electric arcs in the battery charging
area. The easiest and most satisfactory method of clean-
ing a battery is to wash it occasionally with a low
SM556 12 - 01 - 2
pressure cold water spray. The top can also be
washed off with a baking soda solution (add a box of
baking soda to a pail of water and stir untildissolved)
and rinsed with clear water. It is wise to have this
solution around a battery room at all times. Be sure
all vent caps are tightly in place during cleaning
operation.
Battery Maintenance, Records and Life
BATTERY MAINTENANCE:
Refer to the battery vendor for their recommended
procedures.
KEEPING BAT-l-TERY RECORDS:.

Some type of records should be kept to get the best
service out of your battery and truck. Select a pilot
cell, take readings of specific gravity and tempera-
ture before and after charging, and record with the
date. .It is best to change the pilot cell occasionally to
distribute and electrolyte loss over the battery in
taking the readings. Every two to three months, take
complete battery readings. Check specific gravity,
temperature and voltage. Record these readings.
HOW TO GET MAXIMUM LIFE FROM THE

BATTERY:
l DO NOT ADD ACID TO A.BATTERY. Only a quali-
fied battery representative should determine if this is
necessary.
l Lift only with a carefully constructed lifting device
which will not put pressure on the battery tray.
l Battery shall be checked before each charge for
electrolyte level. Add water beforecharge, but do not
overfill. Overfilling causes loss of electrolyte. The
levelshould beslightfybelowthelower lipofthefilling
vent hole.
l Keep battery clean and dry. Wash down as needed.
l Do not over charge.
l Keep battery records as indicated above.
l Keep metal objects and tools away from top of
battery to prevent explosions.
SM55612-01 -3
GROUP 13 SECTION 01 All contactors are controlled by drivers in the oscilla-
tor card to energize at proper time.
ACCELERATORAND
DIRECTIONAL CONTROL The plugging function of oscillatorcard senses change
SYSTEM in direction of motor rotation. Plugging uses reverse
motor torque to smoothly slow down and then re-
verse travel direction of the truck. Thevoltage at TBl
will determine rate of plugging.
CONTENTS NO.
Control Description 13-01-01

Master Switch Troubleshooting 13-01-02 13-01-02 MASTER SWITCH TROUBLE-
Control Handle Removal 13-01-03 SHOOTING
Master Switch Disassembly 13-01-04
Master Switch Assembly 13-01-05 1. HANDLE IS FREE AND DOES NOT RETURN TO
Control Handle Assembly 13-01-06 CENTER (NEUTRAL).
a) Probably due to broken return spring.
Replace module.
13-01-01ACCELERATOR AND DIREC- 2. MASTER SWITCH OPERATES OFF CENTER

TIONAL CONTROL DESCRIPTION AND DOES NOT HAVE EQUAL TRAVEL ON EI-
THER SIDE OF NEUTRAL.
a) Stop cam assembled incorrectly.
The accelerator and directional control consists of a
Remove control module and reassemble,
control handle in the operator’s compartment linked
making sure space is equalon either side of
to a master switch assembly. The master switch
center.
controls a voltage source applied to pin TBl. This
voltage source, when compared to negative, enables
3. MASTER SWITCH BINDS WHEN OPERATED IN
the oscillator card to regulate truck speed.
FORWARD OR REVERSE DIRECTION.
a) Assembly screws too tight.
At start, the master switch is stroked by rotation of the
Loosen two assembly screws one half turn
control handle to either forward or reverse direction.
This energizes the oscillator card by applying posi- and check for binding. Repeat if necessary.
tive voltage and completes forward or reverse con-
4. LACK OF SPEED CONTROL.
tactor circuits, allowing them to close.
a) Full OFFvoltage-measured between S
and N terminals of transducer, voltage is to
Wiih the master switch in the creep position, the
voltage on pin TBl is about 3.8 volts. Rotating the be approximately 3.5 VDC when control
control handle further reduces the voltage until it shaft is rotated to position where F or R
reaches a value of approximately 0.5 volts or less. switch contacts just close (approximately
10” from neutral position). A voltage in
As the voltage changes, the oscillator card changes _ . : excess of 4.-&V&G is undesirable.
If voltages are incorrect, check for loose
on time and frequency from about 50 Hz at low creep
speed to 300 Hz maximum frequency, then back connections. Then check SCR control for
down to 50 Hz at full speed. problem.
., b) Full On voltage - measured as
The card constantly monitors the voltage at TBl . A aboveshould be not more than 0.4 VDC
voltage of less than 0.5 volts signals the oscillator when control shaft is rotated to maximum
card to start time delay and the 1A contactor is position. A voltage as low as 0 VDC is
energized. acceptable.
Replace module if correct voltage can not
An internal spring in master switch returns accelera- be obtained.
tor control to neutral position.
SM556 13 - 01 - 1
5. SWITCH CONTACTS DO NOT MAKE OR BREAK 3. Identify and disconnect control handle wire
CURRENT PROPERLY. terminals.
a) Contacts may be worn or welded.
Replace contact module. 4. Loosen clamping screw (items 06.094 & 06.186)
b) Cam may be deformed. and remove lever and ball-joint assembly. Disas-
Replace cam(s). semble lever and ball-joint assembly only if it requires
service.
13-01-03 CONTROL HANDLE Master Switch Removal

REMOVAL
5. Identify and disconnect wire terminals at master
1. Turn key switch OFF and disconnect battery. switch.
2. Remove two front covers and top compartment 6. Remove master switch mounting screws (item
cover. 13.448) and remove master switch (item 13.400).
NOTE l- REMOVE THE EXISTING SCREWS AND PLATE FROM

MASTER SWITCH AND USE SCREWS SHOWN
06.1
06.05
30.086 -&
Apply Locktite” 242 to all threads before
SPEED, DIRECTIONAL SELECTOR & VALVE LINKAGE
SM556 13-01-2
Copyrighted Material Rev. Jan’96
7. Withdraw control handle lever (item 06.101) from 13-01-04 MASTER SWITCH
bellcrank (item 06.143). Do not disassemble control DISASSEMBLY
handle further unless washer and snap ring (items
06.182 & 65.576) or pushbutton switch replacement NOTE
is required. Disassemble only as far as necessary to
replace suspected component.
PushbuttonSwitch Replacement
1. Use a felt pen to scribe a line across the major
To replacea switch, remove allen screws and switch assembly which will serve to help assemble parts in
cover plate in end of control handle. Push switch up correct order. When viewed from square shaft end,
out of control handle with a screwdriver.Cut switch exposed resistors are on RH side of switch along with
wires and solder wires to new switch. Push new contact markings of ‘F’ and ‘2’. Markings ‘R’ and ‘3’
switch down into control handle. Install switch cover are on LH side. Also, RH side has two cam operated
plate and allen screws. switches, and LH side has one plus spacer.
2. RemoveTWO (2) frame mounting screws. Remove

8. Disconnect bellcrank to valve link (items 30.085 8 housing exposing return spring assembly. Note that
30.732) by removing spring clips (items 30.088 & boss inside housing fits between legs of spring.
90.387), washers (items 90.797 & 30.644), and pins
(items,30.067.& 36...091).. NOTE
Pof normal’rep&r procedure, it is not nec-
9. Remove snap ring (item 30.086) and slide bellcrank essary to remove snap ring from shaft for
(item 06.143) off pivot shaft. disassembly of switch.
10. Inspect nylon bushings (items 06.053 & 30.151) 3. Grasp assembly across ends to keep assembly
for wear or damage. Replace if required. fromseparating and pulloutward on square shaft and
spring assembly. Shaft will pull out of square bore in
PoTENTIC++ERASSEMBLY cam.
PLASTIC SWITCH HOUSING
/RESISTOR SiOE
R SIDE)
LEFT
SM556 13 - 01 - 3
4. Remove thin plastic cover. Note that square 7. Install fasteners and tighten to a torque of
screw hole bosses are on exterior of cover and [1,4-2,7 N-m] 6-12 Ibf in.
match slots in metal outside cover.
8. Install mounting bracket on face of master switch
5. Plastic cam is exposed and can be pulled off and tighten screws.
potentiometer shaft. Use pliers to pull cam off po-
tentiometer. 9. Adjust potentiometer shading disk to intersect
LED. Remove square shaft corner, insert screw
6. Remove three (3) switches from plastic shell driver down square shaft and into potentiometer
housing. Note that switches are Identical and two shaft slot. Viewing from potentiometer end, align
are on RH side. Remove spacer. to potentiometer shading disk (flat side marked top)
vertical to resistor side of housing-This will assure
7. Remove plastic housing from potentiometer that switch travel is equal in each direction. Insert
assembly. square are shaft cover.
8. Do not remove any other parts. Potentiometer

assembly is serviced as a unit. Do not remove two 13-01-06 CONTROL HANDLE
(2) plastic fiber spacers on side of housing. ASSEMBLY
1. Slide bellcrank (item 06.143) onto pivot shaft and

13-01-05 MASTER SWITCH ASSEMBLY install snap ring (item 30.086).
1. Install plastic switch housing to potentiometer 2. Install bellcrank to valve link (items 30.085 &
assembly, aligning screw slots. Potentiometer shad- 30.732) with pins (items 30.087 8 30.091), wash-
ing ing disk must be positioned with flat facing to- ers (items 90.797 8 30.644), and clips (items 30.088
wards right side (resistor side). Line must be cen- 8 90.387).
tered inside of LED. Install cam on potentiometer
shaft with long arc pointing towards bottom of plastic 3. Carefully insert control lever (item 06.101) and
cover and square bore of cam square with plastic wires through bellcrank (item 06.143).
switch cover. Do not push cam fully on shaft; stop
about [l mm] or l/32 inch short to prevent shaft Master Switch Installation
from binding on housing.
4. Mount master switch (item 13.400) to bellcrank
2. Install switches in slots in housing. F side (RH with screws (item 13.448).
side) has two switches, R side has spacer and
switch. Switches have three (3) push-on spade 5. Connect master switch wires to proper termi-
connection posts, the middle post being off center. nals. Cover terminals with Clark 3799761 shrink
Position switches so that off center is toward top, tubing.
making center post closer to top terminal post.
6. Set center line to center line length of ball-joint
3. Install thin plastic cover, making sure square assembly to 2 l/4”. Make sure both locknuts, (item
bosses are to outside surface of this cover (these 05.524), are tightened against the ball-joints.
bosses mate into slots on adjoining cover).
7. Install lever and ball-joint assembly. Torque
4. Insert shaft and spring assembly into square bore clamping screw (item 06.186) to 23-31 Ibf-ft [2,5-
in cam. Note that legs of spring are on same side 3,5 Nm]. Hold control lever horizontal and torque
of assembly as external resistors. clamping screw (item 06.094) to 15-20 Ibf-ft [1,6-
2,3 Nm).
5. Install shaft assembly (with springs in place) and
thin plastic cover onto assembly. 8. Connect control handle wires to proper termi-
nals. Cover terminals with Clark 3799761 shrink
6. Put housing in place over spring assembly. Be tubing.
sure that boss on inner surface goes between
spring legs 9. Install top compartment cover and two front
covers.
10. Connect battery and test truck.

SM556 13-01-4 Rev. Jan ‘96
GROUP 13 SECTION 02
MAIN PUMP MOTOR SWITCH
CHECK AND ADJUSTMENT
CONTENTS NO.
PUMP MOTOR SWITCH CHECK 13-02-01
PUMP MOTOR SWITCH ADJUSTMENT 13-02-02
13-02-01 MAIN PUMP MOTOR

SWITCH CHECK
Test function of main pump motor switch on

control handle in LIFT position. Turn key switch
4. Loosen lift switch mounting screws (item
ON. Slowly pull the control handle back into the
13.115) and lower switch mounting screws (item
LIFT position. The main pump motor should start
13.117).
to mn as the lever moves from the neutral position
and upright should rise. Return the control handle
to the neutral position. Pump motor should stop.
Push control handle forward into the LOWER
position until upright starts to lower.
If control handle movement is excessive before

the pump motor starts, or if pump motor does not
stop running when control handle returns to
neutral, the switch needs adjustment or
replacement.
LIFT LOWER
13-02-02 MAIN PUMP MOTOR 5. Adjust lift switch (item 13.114)) so that switch
SWITCH ADJUSTMENT roller is.in corner of the detent of the valve spool
link (item 30.085) as shown. Tighten switch
1. Turn key switch OFF. mounting screws. Adjust lower switch (item
13.116) in same manner.
2. Remove two front and top compartment covers.
6. Turn key switch ON and test main pump
3. Make sure control handle is in the neutral switches for correct operation.
position.
7. If the switches are correctly adjusted, but the
pump motor does not start running when the
control handle is moved to the lift or lower position,
a switch or the wiring is defective. Replace the
switch or repair wiring as required.
8. Turn key switch OFF.
9. Install top and two front compartment covers.
SM556 13 - 02 - 1
GROUP 14 SECTION 01
ELECTRICAL SYSTEM AND
COMPONENTS
CONTENTS NO.
BRAKE INTERLOCK SWITCH 14-01-l
ELECTRICAL ASSEMBLIES MOUNTING 14-01-2
CONTROL WIRING 14-01-3
POWER WIRING 14-01-4
..y;
.;..+
,. /
,
BRAKE INTERLOCK SWITCH
13.142 SWITCH, BRAKE INTERLOCK
13.143 BRACKET, BRAKE INTERLOCK SWlTCH MOUNTlNG
13.145 FASTENER, BRAKE INTERLOCK SWITCH MOUNTING
39.303 SHIELD, BRAKE INTERLOCK SWITCH
SM556 14 - 01 - 1
13.023
PART OF 13.023
‘.
ELECTRICAL ASSEMBLIES MOUNTING
13.003 HORN 60.184 NUT, BATI. DISCUARGE INDICATOR CONTROL FAS.

13.004 FASTENER, HORN MOUNTING 60.314 SWITCE, TILT SOLENOID VALVE ACTUATING
13.023 METER.HOUR 65.489 RELAY, CIRCUIT LOCKING SWITCH
13.047 SWITCH, CIRCUIT LOCKING 65.751 RELAY, CONTROL SELECTOR SOLENOID - "Rl"
13.114 SWITCH, UPRIGHT CONTROL (LIFT) 65.752 RELAY, CONTROL SELECTOR SOLENOID - "R3"
13.115 FASTEEER, UPRIGHT CONTROL LIFT SWITCE I'-"i ;;.;:: "'~~""RELAY,,"CONTROL'SnECTOR

SOLENOID - "R4"
13.116 SUITCH, VPRIGHT CONTROL (LOWER) . FILTER, AUX. SOLENOID VALVE COIL
13.117 FASTENER, UPRIGUT CONTROL LOWER SWITCE 65.915 RELAY, CONTROL SELECTOR SOLENOID - "R2"
13.132 INDICATOR, BATTERY DISCHARGE 65.916 FILTER, TILT SOLENOID VALVE COIL
13.574 SWITCU,DEV. SELECIORVALVEACTUATING 65.917 FILTER, CONTROL SELECTOR RELAY - "R2"
13.781 FILTER, PRESSURE SOLENOID VALVE COIL 65.918 FILTER, CONTROL SELECTOR RELAY - "Rl"
13.783 FILTER, CONTROL SELECTOR RELAY - "R4" 65.919 FILTER, CONTROL SELECTOR RELAY - "R3"
13.853 FILTER, LIFT/LOWER SOLENOID VALVE COIL 90.641 WASHER, CONTROL SELECTOR RELAY FASTENER
13.973 SPACER, HORN MOUNTING 90.757 WASHER, HORN MOUNTING FASTENER
30.902 COVER, DEVICE SELECTOR VALVE SWITCH 92.558 NUT, UPRIGHT CONTROL LIFT SWITCH FASTENER
33.442 LOCRWASHER, CONTROL SELECTOR RELAY FASTENER 95.082 FASTENER, CONTROL SELECTOR REIAY
33.443 NUT, CONTROL SELECTOR RELAY FASTENER 95.820 NUT, UPRIGHT CONTROL LOWER SWITCH FASTENER
60.095 SWITCH, HORN
60.180 CONTROL, BATTERY DISCBARGE INDICATOR
60.181 FASTENER, BATTERY DISCHARGE INDICATOR CONTROL
SM556 14-01-2
CONTROL WIRING
14.005 HARNESS, INSTRUMENT PANEL WIRING
14.050 ?IARNRSS,CONTROL LEVER WIRING
14.114 HARNRSS, TRUCK WIRING - MAIN
14.352 ~FUSE,XONTROL CLRCUIT
14.486 FUSE. KEY SWITCH Fmxl
14.688 RARNRSS, RELAY WIRING
14.722 -SS, SRLECTOR SOLENOID VALVE WIRING
15.342 RARNESS, STEERING INTRRLOCR WIRING
15.438 RARNIBS, RATTRRY DISC'SARGRREGULATOR WIRING
18.027 STRAP, WIRING IURNESS
SM556 14-01-3
Al
POWER WIRING
14.039 RECEPTACLE6 CABLE,BATTERY
14.040 RECEPTACLE,BATTERY
14.087 CONDUCTOR,DRIVE XOTOR (RA-2)
14.088 CONDUCTOR,DRIVEMOTOR (RS-2)
14.089 CONDUCTOR,DRIVEMOTOR (RS-1)
14.091 CONDUCTOR,RYD..PUMPMOTOR.(PM-A)
14.347 CONDUCTOR,STERRPUMP MTOR @S-A)
14.348 CONDUCTOR,STRRR PUNT MOTOR (PS-S)
14.509 CONDUCTOR.RYD. PUMP MOTOR (PM-S)
14.522 CONDUCTOR,DRIVEEZDMR @A-l)
14.606 CONDUCTOR,DRIVRMOTOR (U-l)
14.607 CONDUCTOR, DRIVEMOTOR (LA-2)
14.608 CONDUCTQR.DRIVRMOTOR (LS-2)
14.609 CONDUCTOR, DRIVEKtTOR (LS-1)
18.089 STRAP, CABLE
SM556 14-01-4
GROUP 16 SECTION 01 The presence of any oil on or near motor could
indicate either bad bearings or leaking hydraulic
ELECTRIC MOTOR system. Determine cause and repair problem
GENERAL MAINTENANCE before extensive motor damage occurs.
MOTOR INSULATION
If a change (reduction) in truck (motor)

performance has been noted, it may be due to
breakdown in motor insulation causing internal
grounding or a short circuit.
Failures of motor insulation are due to: (1)

contamination, (2) mechanical factors, and (3) high
ELECTRIC MOTOR MAINTENANCE temperatures.
GENERAL PROCEDURES
Contamination includes_dirt, moisture, oily vapors,
A planned maintenance program of regular, metal chips, carbon dust from brushes, etc.
routine inspections is important for long life and Mechanical factors include shock, vibration,
trouble-free operation of electric motors. Make overspeed, etc.
and keep records of your inspections. Use these
records to help establish correct P. M. intervals and Operation at prolonged or excessively high
to indicate maintenance required to prevent major temperature will cause insulation to become brittle
problems from occurring during operation. and crack leading to premature failure. The
insulation condition can be judged both visually
INSPECTION PROCEDURES and by test measurement. Regular, periodic
measurements of insulation resistance can give a
To perform these service procedures, it is useful indication of the rate of insulation
recommended that you first: deterioration.
Park truck safely. . A sudden drop or consistent trend toward low

values of insulation resistance give evidence that
Fully lower upright. insulation is deteriorating and that failure may be
imminent.
Turn key switch OFF.
TEST FOR MOTOR INSULATION
Disconnect battery from truck receptacle. RESISTANCE TO GROUND
(USING A 500 VOLT MEGGER)
Discharge capacitor on control panel.
1. Disconnect battery from truck receptacle.
MOTOR CLEANLINESS
2. Disconnect power cables from all motor
Electric motors should be kept clean at all times, to terminals..
prevent shorting, minimize wear, and for best
cooling. . ,,.3.Xonnect~one dead.of,a 500~volt megger to any
motor terminal. NOTE: Test ALL terminals
Wipe off all dust, dirt, oil, water, etc., from outer individually or by interconnecting with jumper
surface of motor. wires. Connect other lead to motor frame. Apply
voltage.
Remove any debris from cooling air vents and
around motor frame to prevent overheating. 4. Resistance should measure at least l,OOO,OOO
ohms (1 megohm). If less than this, motor should
Air clean (blow out) open motors using clean, dry be air-cleaned or dried to attempt to increase
(moisture-free) compressed air at [207 kPa] 30 psi insulation resistance.
maximum air pressure. Air clean all inner areas
around commutator and brushes, including 5. If reading is less than 1 megohm after cleaning,
cooling air vents and fan. motor should be removed from truck for inspection
and repair.
SM556 16 - 01 - 1
6. Brushes must be replaced when worn to
TEST FOR MOTOR INSULATION approximately half of original length.
RESISTANCE TO GROUND
(USING A VOLT - OHM METER) IMPORTANT
NEW BRUSHES MUST BE OF SAME
Use a Simpson 260-6~ or equivalent VOM, SIZE AND GRADE (MATERIAL
calibrated on the Rx1 0,000 scale. SPECIFICATION) AS REPLACED
BRUSHES.
1. Disconnect battery from truck receptacle.
Observe how- brushes are assembled in brush
2. Disconnect power cables from all motor holders, and position of brush lead (brush shunt).
terminals. New brushes must be installed in same manner.
3. Connect the positive lead of the VOM to all 7. Check brush shunt for good contact with brush
terminal studs of test motor. Use jumper wires to holder. Be sure shunt is not damaged or burned
connect between motor terminals. Connect VOM since this may cause brush spring to carry current
negative lead to motor frame. and lose tension.
NOTE: Test all terminals individually, or 8. If brushes do not need to be replaced, and
joined together, as noted. commutator is in good condition, install brushes
and brush springs into brush holders.
VOM must show l,OOO,OOOohms (1 megohm)
resistance or higher for a good motor insulation. IMPORTANT
ALWAYS REPLACE BOTH BRUSHES
5. If less than 1 megohm is measured, air clean AND SPRINGS. DO NOT REUSE OLD
motor and repeat test of motor resistance. If air SPRINGS.
cleaning does not make an improvement, motor
will have to be removed from truck for closer Be sure brush spring is correctly placed on brush
inspection and repair if needed. holder and that brush is free to slide in brush box.
BRUSH AND COMMUTATOR INSPECTION 9. Clean and check brush box and connector
screws. Tighten if loose. Be sure brush box shunt
1. Remove brush cover(s) and remove brushes connection is tight. Install brush cover on motor
from brush holders. Clean brushes and holders. case.
Check brush holders for damage.
10. Check and tighten all motor bolts. Check
2. Inspect condition of brushes. Remove each lower nut on each terminal post. It should be
brush from brush holder and inspect brushes and installed finger-tight, then tightened another l/4
commutator for worn condition and uneven wear. turn with a wrench.
3. Clean commutator surface. Wipe commutator

with a dry, lint-free cloth.
DO NOT USE LUBRICANT OR SOLVENT

ON COMMUTATOR.
4. Check appearance of commutator surface

where brushes ride. Inspect commutator bars for
burned, damaged or raised areas. The best signs
of good commutation are a dark brown highly-
polished commutator and uniform glossy brush-
wearing surfaces.
5. Measure and make a record of brush length at

each inspection. The record will verify amount of
brush wear and indicate if there is enough brush
length remaining until next scheduled inspection.
SM55616-01-2
GEA-7053
SATISFACTORY COMMUTATOR SURFACES
LIGHT TAN FILM over entire commutator MOTTLED SURFACE with random film pot- SLOT BAR-MARKING, o slightly darker HEAVY FILM con appear over entire
surface is one of many normal conditions tern is probably most frequently observed film, appears on bars in a definite panem area of efficient and normal commuta-
often seen on a well-functioning machine. condition ol commutators in industry. related to number of conductors per slot. tor and, if uniform, is quite acceptable.
WATCH FOR THESE DANGER SIGNS
STREAKING on the commutator surface signals the THREADING of commutator with fine lines results GROOVING is a mechanical condition caused
beginning of serious metal transfer to the corbon when excessive metal transfer occurs. It usually leads by abrasive moteriol in the brush or atmos-
brush. Check the chart below for possible cwses. to resurfacing of comnw+a+or and rapid brush weor. phere. If grooves form, start corrective action.
COPPER DRAG, an abnormal build-up of commutator PITCH BAR-MARKING produces low or burned spots HEAVY SLOT BAR-MARKING can involve
material, forms most ohen at trailing edge of bar. Con- on the commutator surface. The number of these mark- etching of trailing edge of commutator bar. Pat-
dition is rare but con cause flashover if not checked. ings equals half or oil the number of poles on the motor. tern is related to number of conductors per slot.
Carbon Products
General Electric Company
East Stroudsburg,Intended
Pa. 18301
for CLARK dealers only
4. Identify and disconnect motor leads. Replace the
GROUP 16 SECTION 02
motor terminal nuts to avoid loss.
DRIVE MOTOR
5. Disconnect hydraulic brake line to brake slave
cylinder on drive motor.
CONTENTS NO.
6. Remove motor mounting capscrews and washers
Motor Description 16-02-01 (items 16.001 & 93.363).
Motor Maintenance 16-02-02
Motor Removal 16-02-03 7. Use chain hoist and strap to remove drive motor
Motor Disassembly 16-23-04 from drive axle. Lower motor to floor or dolly.
Motor Inspection 16-23-07
Motor Assembly 16-23-09 n ! WARNING
Motor Installation 16-02-04 USE ONLY APPROVED HOIST,
CHAINS, AND STRAPS TO LIFT DRIVE
MOTOR. Be sure hoist and accessories
have correct capacity to safely support
16-02-01 MOTOR DESCRIPTION th8 load.
The drive motor is a series wound type with Class H 8. Remove and discard O-ring (item 20.275) from
insulation and integral cooling fan. The exterior drive motor flange pilot.
connections are easily accessible from side of motor
wheretheyareprotectedfromextemaldamage. The 9. Remove service brake. Refer to service brake
brushes are accessible and can easily be changed. group for details.
The motor has no armature shaft bearing on the drive
end; armature shaft is supported in drive axle pinion For Driv8 Motor Overhaul information, refer to
pilot. Group 16, Section 23.
16-02-02 DRIVE MOTOR

MAINTENANCE
Refer to GROUP 16, SECTION 01 for electric motor

general maintenance procedures.
16-02-03 DRlVE MOTOR REMOVAL
I. Turn key switch off, disconnect battery and

block the wheels.
2. Remove top cover and two front covers.
3. Raise carriage and block. Refer to Machine

Jacking and Blocking section for additional informa-
tion.
n ! WARNING
AN UPRIGHT OR CARRIAGE CAN
MOVE UNEXPECTEDLY.
Chain or block the carriage and rails.
Failure to follow this warning can result in
serious injury.
SM55616-02-I
16-02-04 DRIVE MOTOR
INSTALLATION
1. Install senrice brake if removed.

Refer to service brake group for details.
2. Install new O-ring (item 20.275) on drive motor

flange pilot.
3. Use chain hoist and strap to lift drive motor from

floor or dolly. Lower motor and carefully insert motor
shaft into splined pilot of drive axle pinion.
4. Install motor mounting capscrews and washers

(items 16.001 & 93.383). Torque capscrews to
[70 - 80 Nom] 52 - 59 Ibfeft.
5. Connect hydraulic brake line to slave cylinder on

drive motor brake and bleed brake lines. Refer to the
hydraulic brake system group for details.
6. Connect power cables to correct drive motor

terminals. Replace motor terminal nuts and tighten.
7. Replace top compartment and two front covers.
8. Connect battery and test truck operation.
SM556 16 - 02 - 2
GROUP 16 SECTION 03 n
! WARNING
USE ONLY APPROVED HOIST, CHAINS,
MAIN PUMP MOTOR AND STRAPS TO LIFT PUMP MOTOR. BE
SURE HOIST AND ACCESSORIES HAVE
CORRECT CAPACITY TO SAFELY
CONTENTS NO. SUPPORT THE LOAD
PUMP MOTOR DESCRIPTION 16-03-01

PUMP MOTOR MAINTENANCE 16-03-02 7. Remove motor mounting fasteners (items
PUMP MOTOR REMOVAL 16-03-03 92.591,92.598, & 16.706).
PUMP MOTOR DISASSEMBLY 16-03-04
PUMP MOTOR INSPECTION 16-03-05 8. Remove capscrews (item 29.106) attaching
PUMP MOTOR ASSEMBLY 16-03-06 pump to motor. Lift off pump motor with chain
PUMP MOTOR INSTALLATION 16-03-07 hoist. Lower pump motor to floor or dolly.

16-03-01 MAIN PUMP MOTOR DISASSEMBLY
DESCRIPTION
The main pump motor is a series wound type with NOTICE

Class H insulation and integral cooling fan. The If brushes have not been removed before
exterior connections are easily accessible from disassembling motor, brushes must be
side of motor where they are protected from lifted off commutator and held in raised
external damage. The brushes are accessible and position. This is done by lifting brush
can easily be changed. spring clip off end of brush and moving
spring clip to one side of brush which traps
or “locks” brush in place.
‘MAINTENANCE
Refer to GROUP 16, SECTION 01 for electric

motor general maintenance procedures.

REMOVAL
1. Lower carriage to floor.
2. Turn key switch OFF and disconnect battery. ,+:yPut-match mark oneach end frame of motor and
extend mark onto body. This will assure exact
3. Remove battery. alignment of frames for assembly of motor.
4. Remove two front and top compartment covers. 2. Remove plastic brush covers.
5. Identify and remove motor leads. Replace motor 3. Remove brushes if they are to be replaced. If
terminal nuts to avoid loss. brushes are not to be replaced, all brushes should
be raised and locked in manner described above.
6. Put lifting strap on pump motor and raise hoist
chain until slack is taken up.
SM556 16 - 03 - 1
PUMP MOTOR MOUNTING
16.500 lmmRAssn4RLY,RYDRADLxcPDMP
16.704 DAXPRNRR.PDl@ lQT0R VIBRATION
16.706 FAST-, PUHP MOYORMODNTYNG
29.100 Put@ ASSRUBLY.EYDRAln1c
29.106 FAsTmRR,EYDuDLfCPDxeAssRuBLY
92.591 NUT,PUHPB3?0RIWJNTINGPASlZNRR
92398 WASERR,PQIP PymlB HOlmTING FASTRNER
SM55616-03- 2
4. Use an impact tool to loosen mounting screws If a press is not available, it can be removed by
in drive end frame. careful use of a puller.
If this is method used, use care not to apply

excessive or concentrated loads to aluminum end
frame.
NOTE
The, ventilation fan is not normally
removed. If it is to be removed, it can be
removed by using heat very carefully to
expand the fan hub and allow it to be
pulled off without damage.
9. To remove fan, use a puller over fan and against

end of armature shaft. Exert a small pressure
against fan. Use a propane torch to heat hub of fan
5. Use same procedure to remove screws in brush around shaft.
end frame.
When fan becomes loose (will be indicated by
becoming loose on puller) it should be removed as
quickly as possible.
After removal, clean shaft surface of armature.
10. Install new fan on shaft making sure it is a tight

fit. Use Loctite” Retaining Compound 40 or
equivalent applied to inside of fan hub.

INSPECTlON ~
After motor has been disassembled, all

components should be cleaned and inspected for
6. Remove brush end frame. wear and damage.
Before brush end frame can be removed, two Thoroughly clean all components, except bearings
wires from internal circuit of field coils must be and armature with a good grade petroleum-base
disconnected from brush holder assembly. Be cleaning solvent and then dry using compressed
careful to note location of these connections. It air.
might be helpful to make a sketch of location to
assist at assembly of motor. The armature should be blown off with
_-compressed-air to remove brush dust and dirt from
7. Remove drive end frame and armature‘ around commutator and windings. Bearings
assembly from body. should be wiped with a clean cloth.
NOTE. ’ After cleaning and drying, inspect all components
Drive end frame and armature assembly for problem areas that will require reconditioning.
can be removed first (for inspection of
commutator and bearings) 1. COMMUTATOR END FRAME. Check brush
holder insulation and wiring for cracks or any signs
8. If necessary, remove (separate) drive end frame of burning. Check brush holders for wear, and
and bearing assembly from armature. check bearing recess for signs of wear.
This is usually done by using a hydraulic press to
force armature out of drive end bearing.
SM556,16-03-3
2. DRIVE END FRAME. Check for cracks or other The bearing is retained with a snap ring. Remove
damage. Check bearing recess and snap ring internal snap ring from groove in frame at end of
groove for any signs of wear. bearing, then press bearing out of groove.
3. BEARINGS. Check bearings by turning them

with fingers. If bearing has binding, gritty effects,
excessive looseness, wobble, or turns very freely,
it should be replaced.
4. ARMATURE. Check windings, commutator

connections and commutator bars for any signs of
burning or looseness. Check commutator for worn
condition, excessive carbon build-up in undercuts
between bars, and excessive runout. Refinish
commutator surface if pitted or excessively worn.
Check shaft bearing journals and internal spline for
wear.
Install new bearing by pressing on outer race of
5. MOTOR BODY (Frame and Field Assembly). bearin,g to force it into bore until it is firmly seated
Inspect all insulation for burned, blackened or against shoulder.
charred areas. Check coil connections and
terminal studs. ,. ,. Install snap ring to retain it.
6. COOLING FAN. Inspect for broken or loose

sections.
MOTOR RECONDITIONING
1. COMMUTATOR REPAIR. Check commutator

condition for carbon build-up in undercuts
between commutator bars and for excessive wear
and runout before proceeding further with
disassembly. If necessary, commutator should be _-
removed, turned and re-undercut.
NOTE - Do not reuse bearings but replace

with new. +
3. If necessary, remove bearing from commutator

end of armature shaft by using a bearing puller.
Protect end of armature shaft with a nut or thick flat

washer.
2. BEARING REPLACEMENT. Remove bearing

from drive end frame.
’ SM55616-03- 4
Be careful not to damage commutator bars. Align match marks on end frame and motor body.
4. Install new bearing on armature shaft by 3. Install drive end frame mounting screws and
pressing inner race of bearing firmly against tighten lightly to temporarily hold assembly.
shoulder on shaft. Tighten alternately to assure good mechanical
alignment.
5. BEARING LUBRICATION. Replacement
bearings are packed with lubricant and need no 4. Put commutator end frame on work bench with
further lubrication. brush ring assembly facing upward.
5. Install bearing spring (end thrust) washer into

16-03-06 MAIN PUMP MOTOR bearing bore in commutator end frame. Use thin
ASSEMBLY film of grease to hold spring washer in place.
1. Press drive end frame assembly onto armature

NOTE -.If brushes are installed, raise all
shaft until bearing inner race is firmly seated
against shoulder on shaft. brushes to locked position. .
6. Assemble commutator end frame over bearings

on armature until it joins motor body.
Be sure bearing spring washer has remained in

place.
Make sure match marks are aligned.
7. Install commutator end cover mounting screws

and tighten lightly to hold assembly temporarily.
-
Tighten fasteners alternately to assure good
mechanical alignment.
Section showing shaft in place against bearing. 6. Connect two internal circuit field coil wires to
correct terminals.
NOTE - Install bearing on shaft by pressing 9. Fully tighten drive end frame mounting screws
on bearing inner race. using impact tool set.
DO NOT PRESS OR USE FORCE
AGAINST DRIVE END FRAME.
2. Install armature and drive end frame assembly

into motor body.
SM556 16 - 03 - 5
10. Use same tool set and procedure to tighten 2. Mate main pump to motor and fasten with pump
mounting screws in commutator end frame. mounting capscrews (item 29.106). Torque
capscrews to [65 - 73 Nom] 48 - 54 Ibfeft.
,:Y
,...*.’
16.500 7+&cc:+fl’
11. If brushes were not removed (replaced), set

brushes to final (lowered) position, by moving
brush springs to top of each brush.
12. If brushes were removed, install new brushes

and brush springs by:
a) Inserting brushes in holder with lead wire in * Apply LocktiteTM242 before assembly
same position as when removed and make
sure brush is free in holder.
3. Install pump motor fasteners (items 16.706,
92.598, & 92.591). Torque nuts to (20 - 25
W Connect brush leads to correct terminals. N*m]l77 - 221 Ibf*in. Remove lifting strap.
cl Install new brush spring clip on top of each 4. Connect motor power cables to correct
brush.
terminals.
6. Install and connect battery. Test pump motor

operation.
13. Install plastic brush covers.

INSTALLATION
1. Put lifting strap on pump motor and hook strap

to chain hoist. Raise motor and carefully lower
into position on truck.
SM55616-03- 6
IMPORTANT
GROUP 16 SECTION 04 PERMANENT - MAGNET MOTORS
STEER PUMP MOTOR SHOULD BE DtSAS-SEMBLED
ONLY IN AREA FREE OF
FERROUS METAL CHIPS
CONTENTS NO.
MOTOR DESCRIPTION 16-04-01

MOTOR MAINTENANCE 16-04-02
MOTOR REMOVAL 16-04-03
MOTOR DISASSEMBLY 16-04-04
MOTOR INSPECTION 16-04-05
MOTOR ASSEMBLY 16-04-06
MOTOR INSTALLATION 16-04-07
16-04-01 STEER PUMP MOTOR A ’

DESCRIPTION
The steer pump motor is a permanent magnet

type with Class H insulation. The exterior ITEM DESCRIPTION
connections are easily accessible from side of
motor where they are protected from external 1 Armature assembly
damage. 2 Stator assembly
3 Drive end cover
4 Hole plug
16-04-02 STEER PUMP MOTOR 5 Brush inspection cover
MAINTENANCE Bearing spring washer
$ Bearing-Commutator end
Refer to GROUP 16, SECTION 01 for ELECTRIC 6 Bearing-Drive end
MOTOR GENERAL MAINTENANCE procedure. Commutator cover
l!O Brush ring assembly
1. The permanent magnet motor differs from 11 Brush
coventional D.C. motors in that field winding has 12 Terminal bott and lead assembly
been replaced with ceramic magnet pole pieces.
MOTOR TROUBLESHOOTING
IMPORTANT 1. Try to turn shaft by hand.

DO NOT STRIKE MOTOR HOUSING OR
COMPONENTS WITH HAMMER, O.ROP If motor leads have not been removed, keep them
MOTOR, OR SQUEEZE MOTOR IN A separated while doing this.
VISE. THESE ACTIONS CAN CAUSE
DAMAGE TO CERAMIC POLE PIECES lf shaft won’t turn, proceed to item 2.
AND WILL AFFECT MOTOR WARRANTY.
2. Care must be taken when permanent magnet

motor is disassembled, since magnet pole pieces
will attract ferrous metals (iron and steel).
SM55616-04-1
29
STEER PUMP & MOTOR
16,200 kfOYoaAssEwBLY,SYEEx
Puw .
16,225 FAsFENEB,szEEBPuHPmu
16.226 DMPEXER, STEEX PUHP mR VIBUYION
16.227 CODPLING,SYEERPDKPDRIVE
16.535 SP~,PDMPkWI'ORHWNITNG
29.200 p(R8 AS-Y, SYEER (INCLUDES16.227AND i9.27Oj

29.269 msrENEIL.sYEexPlmPmDNYInG
29.270 GsKR.sYEERPDmmJNYRx
90.887 uAsIlER,sYEERPmxuYORnOmxNG
90.889 NDY,!nEEuPlmPlIoloBHDuNYINcF~
90.891 LocKuAsHER.~PtlmPIou)(TIIw;F~
93.280 ltmumt, STEER Pwm mmu MmmNG NLsrENq
95.784 IuSaER, STEER HMP WTOR VIBUAYIONDAWENER
SM55616-04-2
If shaft turns freely, go to item 3. 3. If motor turned freely, connect an ammeter in
circuit as shown.
With rated voltage applied and shaft running free,

ammeter should read less than 20% of name plate
2. The shaft could be tight for several reasons. full load current.
This check is to determine if tightness is of a A higher current reading indicates a faulty

temporary, nature only. armature.
Step 1: You will need a power source equal to If motor meets above conditions, the problem is
name plate voltage (36 volt). Use truck not in the motor.
battery with cable adapter.
BRUSH REMOVAL AND INSPECTION
=5.
36~
1. Loosen and remove clamping screw in brush
cover band.
Step 2: Provide power cable leads between

motor and power source.
DO NOT MAKE A PERMANENT

CONNECTION.
Step 3: First, touch motor leads quickly to power

supply just long enough to observe if shaft
turns.
If it does turn, hold motor leads on power supply

for a longer time.
If motor sounds normal, go to item 3. If motor

sounds noisy, it should be disassembled (refer to
motor disassembly group)
SM556 16-04-3
2. Remove brush cover band segments by prying Remove each brush from brush holder and inspect
cover pins out of engagement in motor housing. brushes and commutator for worn condition and
uneven wear, arcing, etc.
7. When reassembling motor, replace brushes

and brush springs (complete set), as needed, by
reversal of above procedure
NOTE: -If brushes have not been

removed before disassembling motor,
brushes must be raised off commutator
and held in “locked position.” This is done
by moving brush spring clip from top of
brush and placing it against side of brush
to hold (lock) brushes in a raised position
in brush holders.
3. Air clean inside of motor around brushes and

commutator, using dry (moisture-free) compressed 16-04-03 STEER PUMP MOTOR
air. REMOVAL
NOTE: Observe how brushes are 1. Lower carnage to floor.
assembled in brush holders and position
of brush lead (shunt). New brushes must 2. Turn key switch OFF and disconnect battery.
be installed in same manner.
3. Remove battery.
4. Brushes should be removed as follows:
a) Remove brush spring clip from its mounting
on top of brush assembly. .Use a brush hook 5. Identify and disconnect motor leads and move
to reach into motor and lift brush springs. them out of way.
b) Disconnect brush assembly lead. 6. Remove hydraulic lines to pump and cap ends.
c) Lift brush assembly from brush holder. 7. Put a lifting strap on motor . Raise hoist chain
until slack is taken up.
5. Remove any carbon dust or dirt from brush ring
assembly.
A
! WARNING
AND STRAPS TO LIFT STEER MOTOR
AND PUMP. BE SURE HOIST AND
.ACCESSORIES.. ..HAVE ..CORRECT
CAPACITY TO SAFELY SUPPORT THE
LOAD
8. Remove pump motor mounting fasteners

(items 90.889, 90.887, 95.784, & 16.225).
9. Remove pump and motor from truck with chain

hoist and lower to a clean work surface, free of any
iron or steel chips.
10. Put match marks on pump and motor, to

ensure correct alignment at reassembly.
6. Inspect condition of brushes.
SM55616-04-4
11. Separate pump from motor by removing pump NOTE: Be sure parts have match marks
fasteners (items 29.269 & 90.891). before disassembly.
8. Remove commutator end cover for inspection

16-04-04 STEER PUMP MOTOR of commutator and commutator end bearing.
DISASSEMBLY
Remove and save bearing spring washer from
cover bore.
IMPORTANT
9. Carefully inspect commutator end bearing and
Do not place stator ring (motor housing) in
a vise or any mechanical holding device commutator surface for wear, burning, or other
damage that will require repair or replacement of
during disassembly or assembly operation.
parts.
Permanent distortion or other damage will
result. Hold motor by clamping on
mounting bracket.
With motor disassembled, care must also be
taken not to drop stator ring assembly, since it
can be distorted.
NOTE: Before disassembling
motor, note if there are match marks on
stator assembly housing and commutator
cover. lf marks are not visible, use a scribe
tool to make match marks. These marks
will be used at assembly.
IMPORTANT
PERMANENT MAGNET MOTORS
SHOULD BE DISASSEMBLED ONLY IN A
CLEAN AREA FREE OF FERROUS NOTE: It may not be necessary to remove
METAL CHIPS (IRON ORSTEEL). armature, unless. other inspection and
tests show requirement for repair or
1. Remove brush cover band. servicing of stator assembly, armature or
bearings. If armature removal is required,
2. Remove brushes and brush springs. refer to procedure listed below.
IMPORTANT
ARMATURE REMOVAL - RECOMMENDED
If brushes are left installed, raise all
brushes to locked position. PROCEDURE
To avoid damage to either armature or permanent

3. Remove pump drive coupling segment from magnets, it is recommended that armature be
motor shaft end. removed only with motor housing and armature
-’ -shaft positioned vertically.
4. Loosen motor assembly thru-bolts at
commutator end cover.
5. Remove thru bolts from assembly.
6. Scribe a match mark on cover and housing,

then remove drive end (pump mounting) cover.
Carefully pry on cover to loosen. Tap lightly on pry

bar, if necessary.
7. The drive end bearing may now be inspected.
SM556 16 - 04 - 5
1. Reassemble either commutator end cover or
drive end cover to armature shaft and stator (C) Stator. Check magnets to be sure they are
housing. securely mounted.
2. Support and hold stator housing firmly on end (D) Inspect wire harness and all connections
cover. A helper will be required. on brush ring assembly for signs of damage
due to overheating.
3. Pull armature out of assembly in one quick
motion. (E) Brushes. Remove any carbon dust or dirt
from brush ring assembly. Check brushes for
wear and to make sure they are free in brush
NOTE: holders.
IT IS IMPORTANT THAT PULLING
MOTION ON THE ARMATURE BE
CONTINUOUS. DO NOT PULL
PART WAY OUT AND RELEASE. ARMATURE AND BEARING REPAIR
If pulling motion is not continuous, the magnets will 1. Check commutator condition for carbon build-
pull armature back into stator and cause severe up in undercuts between bars and excessive wear
damage. and runout, prior to reassembly. If necessary,
commutator should be turned and re-undercut.
4. Remove end cover from stator housing.
. 2. Remove bearings with a standard ball bearing
puller. Use extreme care not to damage armature
with bearing puller.
NOTE: Do not reuse bearings which have
been removed from armature shaft.
(Commutator-end cover with brushes in

“locked” position shown).
16-04-05 STEER PUMP MOTOR

INSPECTION
Typical view of bearing puller shown.
With motor disassembled, go through following
checklist to locate problem: 2. Install new bearings on armature shaft. New
bearings should be installed by pressing inner race
(A) Bearings - Should spin smoothly and of bearing into correct position against shoulder on
easily, have ample lubrication and be free of armature shaft.
corrosion. Replace bearings if they are worn
out, damaged, or have been removed from
armature shaft.
(B) Armature. Check for grounds and shorted

turns. Check commutator for worn condition,
excessive carbon build-up in undercuts
between bars, and excessive tunout. Refinish
commutator surface if pitted or excessively
worn.
SM55616-04-6
3. Take a complete armature assembly, with
BEARING LUBRICATION bearings installed, and insert comutator end
bearing into bearing bore of cover.
Replacement bearings are packed with lubricant
during manufacture and require no further
lubrication during life of bearing.

ASSEMBLY
1. Place commutator cover on a work bench with

brush ring assembly facing upward.
NOTE: If brushes are installed, raise all

brushes to locked position.
Keep armature assembly in a vertical position.
4. Put complete stator assembly over vertical

armature and into position on commutator cover.
2. Place bearing spring washer into bearing bore

in commutator cover.
CAUTION
Care must be exercised at this point.
There is a strong magnetic attraction
between stator assembly and armature.
This magnetic attraction tends to pull
stator assembly rapidly downward. It is
important to have a firm grasp on stator
assembly and be sure fingers are free from
space between stator assembly and
commutator cover.
5. The stator assembly must be placed in a definite

relationship with commutator cover in order to
obtain a neutral brush setting.
SM556 16-04-7
10. Install pump drive coupling segment.
11. Spin shaft by hand to make sure it is free.
Be sure motor leads (if attached) are not touching

each other.
c
If leads are touching, a generator action will give
effect of friction in motor.
12. A no-load test can be performed.
There should be match-marks on both items.
6. Assemble drive end cover in correct

relationship.
Install mounting thru bolts and tighten alternately

to ensure a good mechanical alignment.
Do not use hammer or excessive force.
7. If brushes were not removed (replaced), set

brushes to final (lowered) position, by moving At rated voltage, observe no-load current. It
brush springs to top of each brush. should be less than 20% of name plate full-load
current.
If brushes were removed, refer to step 8, below.
A higher reading indicates:
1. Brushes are not on neutral setting (check

match-marks for exact alignment).
2. Fautty armature.

INSTALLATION
1. Use match marks to properly align pump and

motor. Mount pump to motor with fasteners (items
29.269 & 90.891). Torque capscrews to [19.3 -
21.5 Nem] 170 - 191 IbfGn.
8. Install new brushes by reversing removal
procedure: 2. Lower pump and motor assembly into position
on truckWith’lifting strap and chain hoist.
a) Install brush with lead wires positioned
they were in before removal.
b) Install brush assembly into brush

holder. Be sure all brushes are free in
holder.
c) Connect brush lead assembly.
d) Install brush spring clip on top of brush.
9. Install brush cover.
SM55616-04-8
@A!3270
* Apply Lo&b Ty 242 before assembly

I o 16.227
i@-
3. Install pump and motor assembly with motor

mounting fasteners (items 16.225, 95.764,
90.887, & 90.889). Torque nuts to [8 .- 10 Nom] 71
- 88 Ibfain.
4. Connect hydraulic lines to pump.
5. Connect motor leads to correct terminals.
6. Install two front and top compartment covers.
7. Install battery and reconnect.
8. Test truck steerfng operation.
SM556 16-04-g
Cl!!mK GROUP
16
GROUP
16
SECTION
23
DRIVE MOTOR OVERHAUL
Code: OH-540, MAR 86 Do not sell or distribute GROUP 16, Section 23, Page 1
GROUP ECSRK
16
16.034
I
ASSEMBLY
COYRLYE
I-
16.000
NON YEvKEAME
IYEMS MABKED ‘k”
r16.017
DRIVE MOTOR 16069-l

.
16.000 UOTOR ASSEMBLY. DRIVE

16.002 BEARING, DRIVE MOTOR COHMUTATOR END
16.004 RETAINER, DRIVE MOTOR COMMUTATOR END BEARING
16.006 BRUSH HOLDER KIT. DRIVE MOTOR
16.011 ARl4ATURE.DRIVE HOTOR
16.014 .COIL SET, DRIVE MOTOR FILED

16.017 CAPSCREh'.DRIVE MOTOR POLE SHOE
16.018 BRUSH KIT. DRIVE MOTOR
16.029 SEAL, DRIVE MOTOR ARMATURE SHAFT DRIVE END
16.034 TERMINAL KIT. DRIVE MOTOR \
16.036 FAN. DRIVE HOTOR AiWATlJRE

16.078 FRAME ASSEK5LY. DRIVE MOTOR DRIVE RND
16.079 FRME ASSEMBLY. DRIVE MOTOR COMIJTATOR END
16.081 COVER, DRIVE I'IOTOR
COMMUTATOR END BEARING
1SN ROUSING, DRIVE MTOR USE 16.000
GROUP 16, Section 23, Page 2 Intended for CLARK dealers only Code: OH-540, MAR 86
GROUP
Cl!mK
16
/ -’ ..
‘\,
.’ BRUSH REMOVAL AND INSPECTION
1 Remove the plastic brush covers by

squeezing or prying the locking tabs
from the slots in the sides of opening
in end cover. Air clean
the inside of the motor
around the commutator
and brushes, using dry
(moisture-free) air.
85M717
NOT1 CE - Observe how brushes are assem-

bled in brush holders and position of
brush lead (shunt). New brushes must
be installed in same manner.
2 Remove screw and disconnect each brush

lead assembly from its terminal.
3 Remove brush spring clip from its

mounted position on top of brush
and move to the side. Use a brush
hook to reach into the motor and 85M719
,,i
lift the brus.h springs.
!. _:
4 Lift each brush assembly from brush holder.
5 Clean any carbon dust or dirt from

brush holder assemblies.
85M718
6 Inspect the condition,of the brushes.
Remove each brush from the brush holder
and inspect brushes and commutator for
worn condition and uneven wear, arcing,
burning, overheating, etc. Refer to
GROUP 16, Section 27, for more infor-
mation on motor maintenance and brush
inspection.
7 When reassembling the motor, replace the

brushes (complete set), as needed, by re-
versal qf removal procedure. Also, see 85M715
Page 10.
Code: OH-540, MAR 86 GROUP 16, Section 23, Page 3
GROUP
16
MOTORDISASSEMBLY
NOT1CE - If brushes have not been removed before disassembling

motor, the brushes must be raised off the commutator and held in
the "locked position". This is done by moving the brush spring
clip from the top of brush and placing it against the side of
the brush to hold (lock) brushes in a raised position in the
brush ho1 ders.
NOTE - Before disassembling motor, use a scribe tool to make

match marks on both end frames and motor body for correct
matching of parts and alignment at assembly.
26621
Remove plastic brush covers, if in-

stalled. Refer to Page 3.
Remove the brushes, if they are to be

replaced. Refer to Page 3.
IMPORTANT- If brushes
__ _ are left in-
stalled, raise all of the brushes to
the locked pos ition (Figure 26568).
26568
:
GROUP
CMRK
16
3 Use an impact tool set to loosen, and

to torque, the mounting screws in the
end frames.
4 Loosen the drive-end frame.mounting

screws, using the impact tool set.
5 Using the same procedure, also loosen

the mounting screws in the commutator-
end frame.
86M013
6 Remove the mounting screws, then remove

commutator-end head, or frame.
86M014
7 In general, motors have a slip-fit bear-

ing-at the-commutator end, and the end
head (frame) can be removed with very
little difficulty. If necessary, remove
the small end-frame bearing cover, and
use a puller to pull the commutator end
frame and bearing assembly off the arma-
ture shaft. Be careful not to damage
the aluminum frame.
Code: OH-540, MAR 86 Do not sell or distribute GROUP 16, Section 23, Page 5
GROUP
16
8 Remove the mounting screws from drive-

end frame. Then, the drive-end frame
and seal assembly can be removed from
the motor body and armature shaft.
_,_ .“’ ‘.
86M016
NOTE - This motor does not have an

armature bearing at the drive end.
The drive end of the motor armature
is supported by the internal spline
in the drive ,unit...This .design pro-
vides for less friction and power
loss during operation.
26612
9 Remove the armature assembly from the I

motor body (frame and field-assembly).
NOTE - There will be occasions when it

will be necessary to remove the venti-
lating (cooling) fan from the armature.
The ventilating fan may be cast iron or
aluminum, or pressed steel. Once these
fans have been pressed onto the armature
they must be heated to remove without
damage. J
26613
10 To remove the fan, install a puller over

the fan and against the end of armature
shaft. Exert a slight pressure against
the fan. Use a small propane torch to
heat the area of the fan around the shaft.
When the fan becomes loose, as evidenced
by the puller becoming loose, it should
be removed as quickly as possible.
Once the fan is removed, clean the
shaft thoroughly. Install new fan.
26614
11 When the fan is reassembled on the shaft, make sure it is a tight fit.
Use "Loctite Retaining Compound 40" or equivalent on the inside of the
fan hub when reassembling fan.
GROUP 16, Section 23, Page 6 Code: OH-540. MAR 86
CLflRls GROUP
i(
16
COMPONENT
CLEANINGAND INSPECTION
After the motor has been disassembled, the components should be cleaned and
inspected for wear and damage.
Thoroughly clean all components, except bearings and armature, with a good
grade petroleum-base cleaning solvent and dry with compressed air. The
armature should be blown off with compressed air to remove the brush dust
and dirt from around the commutator and windings. Bearings should be wiped
clean with a cloth. After cleaning and drying, inspect the components for
problem areas that will require reconditioning:
A. Commutator End Head - Check.brush holderinsulation and wiring for

cracks or any signs of burning. Check brush holders and springs for
wear, and bearing recess for any signs of wear.
B. Drive End Head - Check for cracks or other damage. Check seal recess
for any signs of wear.
C. Oil Seal - If the field coils or commutator are oily, a faulty oil seal
is indicated. Check oil seal seat on the armature shaft for rough spots,
grooves, or scars.
D. Bearing - Check bearing by turning with your fingers. If bearing has
binding, gritty effects, excessive looseness, wobble, or turns very
freely, it should be replaced.
E. Armature - Check windings, commutator connections and commutator bars
for any signs of burning or looseness. Check commutator for worn con-
dition, excessive carbon build-up in undercuts between bars, and exces-
sive runout. Refinish commutator surface if pitted or excessively worn.
Check the shaft bearing and seal journals and spline for wear.
F. Motor Body (Frame and Field Assembly) - Inspect all insulation for
burned, blackened or charred areas.
G. Cooling Fan - Inspect for broken'or loose sections.
Refer to GROUP 16, Section '27, General Motor Maintenance,

for additional information.
DRIVE MOTORSPECIFICATIONS (Reference GROUP 40, Section 5)

I
I Weight: [24.5 kg] 54 lb
Brush Dimensions: Length

Brushes/Holder: 1
[35 mm] 1.38 in

Brushes/Motor: 4
Width [32 mm] 1.26 in

Thickness [if;655 ;n3 .498 in
Replace @ Worn Length , .57 in on longest side
,_". Brush Spring Tension (force per brush) NEW: [935-1077 g] 33-38 oz
-_
i WORN: [453 g] 16 oz
_..
Code: OH-540, MAR 86 Intended for CLARK dealers only
GROUP 16, Section 23, Page 7
GROUP
* 16
MOTORRECONDITIONING
1 Check commutator condition for carbon

build-up in undercuts between bars and
excessive wear and, runout. If necessary,
commutator should be refinished (turned
and re-undercut).
26615
Bearing Replacement
With commutator-end frame removed from

armature shaft (Page 5):
To remove bearing from end frame, first

remove internal snap ring-from groove
in frame at end of bearing.
Remove the bearing by pulling from the

end-frame bore.
2661‘6
Install new bearing by pressing or

driving the bearing into bearing bore
until it is firmly seated against
shoulder in end frame. Then,
install snap ring.
Bearing Lubrication
Replacement bearings are packed with lubri-
cant and require no further lubrication.
26617
Seal Replacement
1 To replace oil seal in drive-end

frame, pull or drive old seal from
frame. Install new seal by pressing
or carefully driving the seal into
bore in frame until seated firmly
against the shoulder in bore.
26614
CLSRK GROUP
16
MOTOR REASSEMBLY
1 Assemble commutator-end frame and bear-

ing assembly to motor body. Align
match marks.
2 Install commutator-end cover mounting

screws and tighten lightly to hold
assembly temporarily. Tighten alter-
nately to ensure good mechanical
alignment.
26619
NOTE - If brushes are installed, raise

all brushes to the locked position.
3 Install armature assembly into motor

body. Be sure armature end is started
correctly into bearing in commutator-
end frame.
26613
4 Press armature into bearing inner race

until armature is seated firmly against
bearing shoulder.
26620
5 Install drive-end frame and seal assembly

over armature end and to motor body.
Align match marks.
6 Install drive-end frame mounting screws

and tighten lightly to temporarily hold
assembly.
;j
86M016
Code: OH-540, MAR 86
GROUP 16, Section 23, Page 9
GROUP CL~WKI
16
Then, fully tighten the drive-end frame

mounting screws, using the impact tool
set.
Using the same procedure, also final-

tighten the mounting screws in the
commutator-end frame.
86M013
If brushes were not removed (replaced),

set the brushes to final (lowered)
position, by moving the brush springs
to the top of each brush.
If brushes were removed; refer to

Step 10, below.
26643
IO Install new brushes by reversing the

removal procedure:
a. Install brushes with the lead wires

positioned as when removed.
b. Install brush assemblies into brush
holder. Be sure all brushes are
free in the holder.
c. Connect brush lead assemblies.
d. Install brush spring clip on top
of each brush.
86M015
11 Install the plastic brush covers.
85M717 ..
_.
GRiilJP 17 SECTION 01
DRIVE MOTOR CUT-OUT
SWITCH CHECK AND
ADJUSTMENT
CONTENTS NO.
CUT-OUT SWITCH CHECK 17-01-01

CUT-OUT SWITCH ADJUSTMENT 17-01-02
17-01-01 DRIVE MOTOR CUT-OUT

\,,Z?*..:....y
SWITCH CHECK
Ll! CAUTION
A!!
;
J.
._.:r
.
;
I
.._.r
17-01-02 DRIVE MOTOR CUT-OUT

To perform this service procedure, it is necessary
for you to first: SWITCH ADJUSTMENT
Park truck on a solid, level surface. Be sure that truck is parked and blocked up
correctly to raise the drive and steer wheels off the
Lower forks to floor. floor. See CAUTION under 17-01-01 procedure.
Turn steering tiller so that steer wheels are in a 1. Turn key switch ON.
straight ahead travel position..
2. Turn tiller arm so that steer wheels are in a
Turn key switch OFF. straight ahead travel position. Note position of cut-
out cam (item 25.443). .
Jack and block the truck up to raise the steer and
drive wheels off the floor. Refer to Machine 3. Identify RH & LH cut-out switches (item 13.682)
Jacking and Blocking Group for details. by wires.
1. Remove two front and top compartment covers. RH Switch: Wire #51 (brown w/ green stripe)
2. Turn key switch ON. LH Switch: Wire#52 (Red w/green stripe)
3. Rotate control handle slowly to forward travel 4. Slowly turn tiller arm for a RH turn until cam
position. Both drive wheels will begin turning. rotates 41.5” from center position. Loosen
fasteners (item 13.683) for right hand switch and
4. Slowly turn the tiller arm to make a right turn. adjust switch position on mounting plate (item
The right drive wheel should stop turning when 13.684) until switch just closes, Repeat
., ,,I
.,adjustmentprocedure for a.LH turn.

the steering axle trunnion is turned at an angle of
41.5 o from the center (straight ahead travel)
position. 5. Check cut-out switch adjustment for RH & LH
turns.
5. Repeat test for left turn. Check the left drive
wheel, as in Step 4. 6. Turn key switch OFF.
6. If the respective drive motor does not cut-out 7. If, after adjustment, drive motors do not cut-out
correctly or the drive wheel stops turning at an properly, check switch continuity with a Volt - Ohm
steering axle trunnion angle other than that Meter. Replace switches as required and re-adjust.
specified, the cut-out switches require adjustment
or replacement. 8. Lower truck to floor.
9. Install top compartment and two front covers.
SM556 17 - 01 -1
GROUP 19 SECTION 01 The control circuit is energized by closing key
switch and foot brake switches and moving control
CONTROL PANEL handle to desired forward or reverse position.
Rotating control handle closes thelMS switch;
further rotation gives desired speed. This applies
CONTENTS NO. power to control card, which will close selected
directional contactor and complete circuits to drive
CONTROL PANEL DESCRIPTION 19-01-01 motor.
CONTROL PANEL MAINTENANCE 19-01-02
CONTROL TROUBLE-SHOOTING 19-01-03 The control card then supplies a gate pulse to #2
CONTROL PANEL REMOVAL 19-01-04 REC, turning it on to a conducting state. This
CONTACTOR INSPECTION 19-01-05 allows current to flow from battery through lC, 1X,
CONTROL PANEL INSTALLATION 19-01-06 ##2REC, motor field, motor armature, sensor, and
back to battery.
After 1C charges, #2 REC turns off, due to lack of

19-01-01 CONTROL PANEi holding current. The control card checks that 1C is
DESCRIPTION charged and unlocks gate to #1 REC and #5 REC.
The EVlOOM CONTROL is an electronic device The control card then supplies a gate pulse to #l
that controls electrical power supplied to the REC, turning it on to a conducting state. This
vehicle drive motor to provide smooth power to allows current to flow from battery through #1
move the truck and to minimize power drain from REC, motor field, motor armature, sensor, and
battery. back to battery.
The control consists of a SCR unit and a contactor #5 REC turns on and allows current to flow
assembly unit. The SCR unit monitors power through T4-T3,1C, #l REC, #5 REC and to T4-T3.
demand of the truck and then responds by
controlling the power applied .to drive This current charges bottom of 1C positive with
components. The contactor panel contains respect to battery positive bus.’ This charging
switching devices to direct heavy power loads to cycle occurs in less than one millisecond [O.OOl
the drive motor and its components. second] and #5 REC shuts off. This charge is now
stored on capacitor until it is’time to turn off #l
REC. ’
SM556 19 - 01 - 1
Current continues to flow in #l REC until control
card fires #2 REC. When #2 REC conducts, FIG. 2. Motor current illustration. The dotted line
capacitor 1C discharges around circuit composed shows average motor current.
of lC, #2 REC, 1X, and #l REC.
FIG. 2 shows nature of motor current which is
This discharge current opposes battery current composed of both battery current and inductive (or
through #l REC so that resultant current is zero. flyback) current.
Due to lack of holding current, #l REC is turned
off. It should be noted that measured average motor
current will be greater than average battery current.
Current continues to flow in #I2 REC, lC, motor
and battery loop until capacitor (card terminal 14) is The SCR control converts battery current at battery
fully charged negative. volts into a higher motor current but at a lower
motor voltage.
This charge exceeds battery voltage by an amount
which is a function of peak motor current, and #2 The time for next ON / OFF cycle to start is
REC turns off. determined by time that control card takes to
oscillate. This frequency of oscillation is controlled
FIG. 1 illustrates pulsing current from battery. by position of variable inductor in accelerator and
oscillator control circuitry in card.
PEAK
CURRENT Siow speed is obtained by having maximum input
volts from accelerator. As input volts decrease,
speed of motor increases. The SCR circuit is
capable of delivering approximately 95% of
AVERAGE maximum speed. For full speed operation, 1A
CURRENT contactor is closed to apply full battery voltage
across motor.
CONTROL FEATURES
OSCILLATOR. The oscillator section of card has

FF two adjustable features and one fixed feature.
With accelerator output voltage at maximum volts,
creep speed can be adjusted by CREEP trimpot
on card.
FIG. 1. Battery current illustration.
Top speed is fixed by card design and is obtained
During off time, energy stored in motor, by virtue of
with accelerator output voltage at minimum.
motor’s inductance, will cause current to circulate
through motor around loop formed by ##3 REC.
The % ON-TIME. has a range of approximately 5-
This current is called FLYBACK CURRENT.
95%.
The center ( or mid) operating condition of

100 % AVERAGE oscillator is at 50% ON-TIME with a nominal 1.8
CURRENT. _
tiiilliseC&ids”ON-TIME and’ 1.8 milliseconds OFF-
5!
TIME. This corresponds to a maximum operating
g frequency of about 300 Hertz.
3
0
&O%
e
s
ON
oNOi=F~ OFF
TIME
SM556 19 - 01 - 2
If the truck is moving and the directional lever is
300 moved from that direction selection to opposite
direction selection, the motor field is reversed.
250
200 The plug signal is initiated by the fact that the
directional switch has been shifted from one
150 direction to the opposite direction.
100
The motor armature, driven by the inertia of
50 vehicle, acts as a generator. This generated
1
current passes through the #4 REC and the
Ics
5 50
SCR RANGE TS
sensor. The oscillator circuit regulates at a plug
current limit level as set by the PLUG trimpot on
control card.
% ON TIME
This controls pulse rate of the #l REC to regulate
generated motor current and bring the truck to a
FIG. 3. Oscillator frequency curve.
smooth controlled stop and then reversal.
At CREEP, ON-TIME will decrease to
The accelerator input witI modulate plugging
approximately 0.8 milliseconds while OFF-TIME will
current. With the accelerator at maximum
rise to about 20 milliseconds. At full SCR
depression, the plugging trimpot will enable
operation; this condition will be reversed -(short
adjustment of plugging current limit from maximum
OFF-TIME and long ON-TIME).
to minimum current limit level. With the accelerator
at minimum depression, plugging current limit will
This variation of ON/OFF TIME of oscillator
be reduced to minimum.
produces optimum frequencies through SCR
range. The frequency curve of oscillator is shown
RAMP START. This feature provides full SCR
in Fig. 3.
torque to restart a vehicle on an incline. The
The rate at which oscillator may increase its percent memory for this function is the directional control
switch. When stopping on an incline, the
ON-TIME is limited by. “CONTROLLED
directional. switch must be left in its ORIGINAL a
ACCELERATION”. The minimum time required to
position to allow the control to assure full power
go from creep speed to 80-85 % ON-TIME point
may be varfed by trimpot (C / A) on card. This is when restarted. The accelerator will modulate
adjustable from approximately 0.5 seconds to 3.5 ramp start current.
4.5 seconds.
FULL POWER TRANSITION. This built-in feature
CURRENT LIMIT. This circuit monitors motor provides smooth transition from SCR to 1A
current by utilizing a sensor in series with armature. bypass. This is accomplished by the SCR
The information detected across sensor is fed continuing to pulse until 1A contactor power tips
back to card so current may be limited to a preset close.
value.
1A CONTROL. The contactor has two modes
If heavy load currents are detected, this circuit of control:
over-rides oscillator and limits average current to ‘a
value set by C / L adjustment pot. The C/L setting 1). TIMED PICKUP. This feature works with
is based on maximum thermal rating of #l REC and the accelerator. When the accelerator is
peak voltage on capacitor. activated so that the accelerator voltage is
reduced to 0.4 volts or less, then 1A time
Because of flyback current through #I3 REC, motor is enabled. The time delay pickup of 1A
current usually runs 2 to 3 times that of battery is provided by a circuit in card. This allows
current. The current limit is set with C / L trimpot on the truck to accelerate through SCR
card. range until 1A picks up, even if the
accelerator is actuated immediately.
PLUGGING, or slowing down of the truck is
accomplished when reversing by providing a small This time delay is adjustable by means of a
amount of retarding torque for deceleration. !A TIME trimpot on card.
SM558 19 - 01 - 3
2). If motor current is reduced during thermal
cutback to a point where 1A pickup would For these reasons, normal maintenance should
cause a severe torque increase, 1A timed guard against any action which will expose
pickup function will be disabled. components to excessive heat, (such as steam
cleaning).
STATIC RETURN TO OFF. This built-in feature of
control requires the operator to return directional The following DO’S and DONT’S should be
selection lever to neutral position whenever he observed:
leaves truck and then returns.
Any controls that will be used in ambients of
If brake switch or key switch is opened, the control [SO” C] 120” F or over should be brought to
will shut off and cannot be restarted until the attention of Clark Material Systems
directional lever is. returned to neutral position. A Technology Co.
time delay of 1.0 sec. is built into the control for
allowing momentary opening of brake switch, if a All external components having inductive
bump is encountered. coils must be filtered
THERMAL PROTECTOR (TP). This temperature The control should not be steam cleaned. In
sensitive device is mounted on 1 REC. lf the 1REC dusty areas, use low-pressure air to blow off
temperature begins to exceed design limits, the control. In oily or greasy areas, a mild solution
thermal protector will lower maximum current limit of detergent or denatured alcohol can be
and not allow the 1REC to exceed its temperature used to wash off control. Then use low
limits;. . . - ,_ pressure air to blow unit completely dry. The
control can also be cleaned with a Freon TF
Even at reduced current limit, the truck will normally degreaser.
be able to reach sufficient speed for full ,1A
operation, thereby allowing panel to cool. Terminal boards and other exposed SCR
control parts should be kept free from dirt and
As the panel cools, the thermal protector will paint that might change effective resistance
automatically return the control to full power status. between points.
1A THERMAL HOLD-OFF. This feature prevents

the 1A contactor from closing when the truck is in THE TRUCK SHOULD NOT ‘BE
severe thermal cutback to avoid torque “jumps”. PLUGGED WHEN THE TRUCK IS
When the control goes into severe cutback, JACKED UP AND THE DRIVE
“MUST PULSE TO TIME” will disable 1A timer. WHEELS ARE IN A FREE-
WHEELING POSITION. THE
MUST PULSE TO TIME. This feature prevents the HIGH MOTOR SPEEDS CAN
1A timer from timing if oscillation pulse rate has not CREATE EXCESSIVE
reached a particular level of operation. VOLTAGES THAT CAN BE
HARMFUL TO THE CONTROL.
LOW VOLTAGE. Batteries under load, particularly
if undersized or more than 80 percent discharged,
will produce low voltages at the SCR control Do not HIPOT (or MEGGER) control. Unless
terminals. terminals of each semiconductor and card
are connected together, the control may be
Low battery volts may cause the control not to damaged. Refer to control manufacturer
operate correctly but PMT should open F or R before hlpottlng.
contactor in event of a commutation failure.
Use a lead-acid battery with voltage and
ampere hour rating as specified for the
19-01-02 CONTROL PANEL vehicle. Follow normal battery maintenance
MAINTENANCE procedures, recharging before 80 percent
discharged and with periodic equalizing
The SCR control, like all electrical apparatus, does charges.
have thermal losses. The semiconductor junctions
have finite temperature limits, above which these
devices may be damaged.
SM556 19-01-4
19-01-03 CONTROL PANEL
TROUBLESHOOTING l * DIRECTIONAL CIRCUITS which
control forward and reverse contactors.
When diagnosing and correcting cause of trouble
with a SCR control, do not begin by l * ACCESSORY CIRCUITS which
disassembling components. control components, including horn,
battery indicator and hourmeter.
Start by analyzing complaint of symptoms. Make a
preliminary investigation of trouble. Then
systematically determine probable cause. ALL TESTING SHOULD BE
DONE WITH DRIVE WHEELS
The following points are fundamental to trouble- RAISED OFF THE FLOOR.
shooting a SCR system.
Never start your troubleshooting until you get TROUBLE-SHOOTING NOTES

facts. Talk with truck operator and review work
order. Trouble-shooting is based on using a digital
voltmeter to determine if correct voltages are
Operate truck to observe fault and then available to permit control to operate correctly.
determine what corrective action should be.
Determine where to start. The pulsing of main SCR is too fast for
conventional instruments to measure. When
Perform basic checks. Check battery and test control is functioning properly, a low hum can be
for grounds and shorts. Do not take short cuts heard.
by assuming these checks do not have to be
made. Before proceeding with any testing, visually
check for loose wiring, signs of overheating of
Useless work can be avoided by diagnosing components, condition of battery and battery
trouble accurately on basis of preliminary receptacle, etc.
investigation and correct use of information in
the trouble-shooting guide. Take necessary Discharge capacitor by using an insulated
time for sufficient preliminary investigation. screwdriver or similar device that is insulated to
short across terminals of capacitor.
Use symptoms indicated by the trouble to
locate the proper diagnosis chart in trouble- Check resistance(s) from frame to SCR power and
shooting section. You may also want to use control terminals. A resistance of less than
sequence of operation manual as a diagnostic 20,000 ohms can cause misleading symptoms. If
tool. less than 20,000 ohms resisitance is measured,
conduct further tests to eliminate short circuit /
l Proceed to find problem by the using flow ground fault conditions.
chart in the trouble-shooting guide which
defines symptom and its possible cause(s) and An index of most common symptoms for EV-1 OOM
solution. Locate trouble by a process of SCR control troubles is:
elimination. The cause is usually simple, rather
than mysterious and complicated. 1. Directional contactors will not close.
l MOST IMPORTANT, USE THE ELECTRICAL 2. Directional contactors close. No power. No

SCHEMATIC DIAGRAM FOR THE TRUCK audible SCR hum. Truck inoperative with
YOU ARE WORKING ON. YOU MUST BE accelerator in SCR range.
ABLE TO TRACE THE:
3. Directional contactors close. No power.
l * POWER ClRCUiTS which consist of Audible SCR hum. Truck inoperative with
heavy cables and main power accelerator in SCR range.
components of truck.
4. Directional contactors close once or twice
l * CONTROL CIRCUITS which control and then remain open. PMT trips.
speed, time delay, and controlled
plugging.
SM556 19 - 01 - 5
NOTE: A digital VOM (such as Simpson
Digital Multi-meter Model 461, or
equivalent) is recommended for all electrical
and control testing.

REMOVAL
WARNING
ELECTRICAL SHOCK
DISCONNECT THE BATTERY AND
DISCHARGE THE CAPACITOR(S)
BEFORE HANDLING THE CONTROL
PANEL
BREAKING THIS RULE CAN

CAUSE SERIOUS INJURY TO
9. Remove the control panel assembly. The SCR
panel and contactor panel are considered an
1. Make sure truck has been parked in .a safe
assembly and are removed as a unit.
position with upright fully lowered. Block drive
wheels.
3. Disconnect battery (if not already removed from

truck).
5. Discharge capacitor by using an insulated

screwdriver or similar device to short across
terminals of capacitor.
6. Remove power cables from control assembly.

Make sure terminals of all cables have identification
labels to assure correct assembly.
7. Separate wire harness sections by

disconnecting the wiring couplers. Press in prongs
on each side of coupler to release and then pull
apart.
8. Remove fasteners (items 17.094 & 90.177)

attaching control panel to mounting plate.
SM556 19 - 01 - 6
CON TACTOR PANEL 19608-l
17.000 PANELhSSPIBLY,CONTAeraR
17.007 lAcoNTACTQRASSEmLY
17.015 TomcARm6~'REvmSE CourAmoRASspIBLY
17.023 P(A(pCmTACToRAsSEplBLY
17.033 PQWERSTEERINGCO2?TACmRASSE!BLY
17.750 SCR CONTROL PANEL AsSmmLY

17.596 smPREs.soR, Pvle ComAcToR
19.000 PLOCGMG, COW?ACTOR MS~LY
19.859 0RMET. PLUGGING CONTACTORmU!ITING
65.373 BRAa=?, POWER sTzERxx CowrACToR ?loumING
65.472 +4 REC, CotmDL PANEL

65.473 aUT SINK. CONTROL PAmI, 94 REC *
65.474 IN-TO& 94 REC SEAT SINK F-
63.475 m-T’% #I REC SEAT SINK
94.196 FASTENER. 94 REC SEAT SINK
94.197 a=, +I REC HUT SINK FASTENER

94.198 -HER, 94 SC BEAT SINK FASTENER
SM556 19-01-7
17.021 J T L 19.576
CONTACTOR PANEL
17.000 COmACTOR PANEL ASEMBLY coNTINuED)

17.010 CoNDuCmR. lA.CONTACTOR FEED
17.018 COEIDDCTOR, -ACTOR -AL
17.021 coIIDocKIR. 1A CONTACTOR FEP,
17.029 CONDDCTOR, =RWARD 4 REVERSE CONTAC’IDR FEED
17.069 WlRING RARBESS. CWACTOR PANEL

17.221 WNDUWR, PPIP COWMCl’OR m
17.334 CONDUC?OR, CONTACTOR PANEL WF,GkTNE
17.532 CORDKTOR. FoRlRRD 6 RFJUSE CORTXTOR FEED
17.889 CONDUCTOR, EVRMARD C REVERSE CONTACTOR FFXD
19.271 CDNDUCTOR. PIDGGING CWTACTOR FEED

19.322 CONDUCTOR, 1A CONTACTORFEED
19.573 CONDUffOR, COWTACTORFEED
19.576 CONDOCTOR, IA CONTACTOR EZED
19.598 CONDU~OR, PLUGGING CONTACTOR FEED
19.708 CONDUCTOR. SCR CONTROL FEE0

19.862 CONDUCTOR, CONTACTORFEED
SM556 19-01-8
90.323
93.810
ASSEMILY COMPLETE
SCR PANEL ” 19463-l
17.750 SCR PANEL ASSEMBLY 90.197 LOCKWASHER. TERMINAL BLOCK CONDUCTOR FASTENER
14.056 FASTENER, TERMINAL BLOCK CONDUCTOR 90.198 WASHER. TERMINAL BLOCK CONDUCTOR FASTENER
15.129 CONDUCTOR, 65 RECTIFIER 90.323 LOCKWASHER, SCR PANEL TRANSFORMER FASTENER
17.057 FASTENER, CONTROL PANEL CONDUCTOR TERMINAL . ..91.089 LOCKWASHER.,CONTRGL PANEL CONDUCTOR FASTENER
.- -_.
17.751 TRANSFORMER, SCR PANEL 91.091 WASHER, CONTROL PANEL CONDUCTOR FASTENER
17.753 FASTENER, SCR PANEL TRANSFORMER 91.132 WASHER, SCR PANEL TRANSFORMER TERMINAL FASTENER
17.756 FASTENER, SCR PANEL TRANSFORMER TERMINAL 91.604 LOCKWASHER, SCR PANEL TRANSFORMER TERMINAL FAST
17.757 #4 REC. SCR PANEL 92.768 WASHER, SCR CONTROL PANEL MOUNTING HEAT SINK FAS
17.759 13 REC. SCR PANEL 92.769 LOCKWASHER. SCR PANEL MOUNTING HEAT SINK FAST
17.775 #2 REC. SCR PANEL 93.195 FASTENER, SCR PANEL 14 REC HEAT SINK
17.780 t5 REC. SCR PANEL 93.196 WASHER, SCR PANEL #4 REC HEAT SINK FASTENER
17.850 SHUNT, CURRENT LIMITING 93.205 WASHER, CURRENT LIMITING SHUNT FASTENER
65.280 HEAT SINK, SCR PANEL #4 REC 93.346 FASTENER, HEAT SINK
65.283 CONDUCTOR, SCR CONTROL PANEL 93.352 LOCKWASHER, CURRENT LIMITING SHUNT FASTENER
65.284 CONDUCTOR, SCR PANEL 93.587 WASHER, CURRENT LIMITING SHUNT FASTENER
65.285 CONDUCTOR, SCR PANEL 93.810 WASHER, SCR CONTROL PANEL TRANSFORMER FASTENER
65.309 FASTENER. SCR PANEL REC 94.197 LOCKWASHER. CONTROL PANEL REC HEAT SINK FASTENER
65.310 LOCKWASHER, SCR PANEL MAIN POWER VALVE SW FAST 94.225 FASTENER, CURRENT LIMITING SHUNT
65.366 INSULATOR. SCR PANEL 14 REC HEAT SINK 94.759 LOCKWASHER, CURRENT LIMITING SHUNT FASTENER
65.537 INSULATOR, SCR PANEL #4 REC HEAT SINK FASTENER 94.760 FASTENER, CURRENT LIMITING SHUNT
65.544 HEAT SINK, SCR PANEL VOLTAGE SENSOR
SM556 19 - 01 - 9
COLOR CODE
@-BLUE
-WHITE
:-GREEN
@-BROWN
764
V -VIOLET
FNK
@-GRAY
o- SIRICED
u\ 17.763
\-f&347
; PANEL 19464-l
17.750 scR PANEL ASSEMBLY (CONTINUED) 65.542 INSULATOR, SCR PANEL REC
14.054 BLOCK, TERMINAL 65.623 FILTER, PUMP SCR PANEL 63 REC
17.763 CAPACITOR, SCR PANEL COMMUTATING 65.630 FILTER. PUMP SCR PANEL t5 REC
17.764 BRACKET, SCR PANEL COMMUTATING CAPACITOR MOUNTING 65.631 .FILTER,..PUMP..SCR
PANEL 62 REC
17.765 FASTENER, COMMUTATING CAPACITOR MOUNTING BRACKET 90.195 LOCKWASHER, TERMINAL BLOCK FASTENER
17.776 #l REC, SCR PANEL 90.196 WASHER, TERMINAL BLOCK FASTENER

17.788 FILTER, SCR PANEL 14 90.343 LOCKWASHER, SCR PANEL CAPACITOR CONDUCTOR FAST
19.046 FASTENER, SCR PANEL COMMUTATING CAPACITOR COND 90.344 WASHER, SCR PANEL COMMUTATING CAPACITOR COND FAS
19.072 THERM0 CUT-OUT, SCR PANEL I1 P.EC 90.345 LOCKWASHER, CAPACITOR MOUNTING BRACKET FASTENER
19.079 WIRING HARNESS, SCR PANEL 93.155 FASTENER. OSCILLATOR SPEED CONTROL UNIT
65.062 SCREW, MAIN POWER VALVE THERMAL CUT-OUT 93.156 LOCKWASHER, OSCILLATOR SPEED CONTROL UNIT FAST
65.063 LOCKWASHER, MAIN POWER VALVE THERMAL CUT-OUT FAST 93.661 FASTENER, TERMINAL BLOCK
65.197 FASTENER, SCR PANEL I1 REC 93.870 WASHER, SCR PANEL TERMINAL BLOCK FASTENER
65.198 LOCKWASHER, SCR PANEL 11 REC FASTENER 94.476 FASTENER, SCR PANEL FILTER
65.311 WASHER, SCR PANEL I:1REC FASTENER 94.514 LOCKWASHER, SCR PANEL FILTER FASTENER
65.347 CONTROL UNIT. OSCILLATOR SPEED 1N BASE, SCR PANEL
SM556 19-01-10
17,007 CONTAmoR ASSPIBLY. IA
17.101 COIL. 1A coNTAcToR
l?.lOS SPRING, 1A CONTACTOR ARMATURE RETURN
17,106 SEAT. 1A CONTACTOR ARUAlURz RzTtm SPRING
17.112 COUUCTOR SET, 1A CONTACTOR
17.11s SPRIRC, u cO?mxTOR mVAm.l? CONTACT

17.116 StAT, LA CORWXO~ K)VABLE COUUCT SPRmc
17.120 SUPPORT. 1A CONTACTOR STAIOHART CONTACT
17.533 RETAIIIUL IA CONTUTOR con
17.972 UXK. IA cawmcIoR mvABLz CORE
17.97s
65.237
17.977
17.979
65.23% 19.L9L
19,516
65.237
65.238
91.us
91.546
17.112
19.516
SM556 19 - 01 - 11
1A CONTACTOR 19606-1
17.023 CONTAcToR AsSImLY. PUKP
17.161 COIL. Puwp CONTACTOR
17.165 SPRING, PUMP CONTACTORCONTACT RETURN
17.169 CONTACT SET. PVW CONTACTOR
17.172 SPRING. Pum CONTACTOR MOVABLE CONTACT
17.173 SEAT, PUMP CONTACTOR 110VULE CaRuC-X SPRING

17.174 SEAT, P'J?@CONTACTOR MOVABLE CONIACT SPRING
17.182 SUP?‘ORT, PUkfP CONTACTOR SIAIONARY CONTACT
17.530 RRAxmR, PulQ CoRTAm COIL
17.891 LocK,PmtPfzomcrm mvABL2 COPE
r7.a93 INSUIATOI, PUIC m IWADLE TIP

17.(196 GUIDE. ?mYP collllrcm 9DVABL2 ColtTAm
17.099
17. a99 P~,PCMPcoAllcToI CONTACT SUPPOBT
19.495 BASL. Km CanAcmR
92.542 19.637 ABMUUU ASSQQL’I. ?UlQ -ACIDR
19.8Ll nmnAmR* PRlp Coamcrm CONTACT SUPPORT

91,550 LocLyIsBB. POW CWTACIDR MOVABLE CORE PASImR
Pl.Sfl WAS=. ?tR@ CONTACI’OR KIVAM.2 CORE FAsl’Ett~
92.542 Lm. POW COtmACTUR CONTACT SUPPORT PASTDER
19.637
9.&*
- 17.534
SM556 19-01-12
PUMP CSMACTOR 19607-l
17.033 CONTACTOR ASSEMBLY, POWER STEERING
17.230 COIL, POWER STEERING CONTACTOR
17.240 CONTACT SET, POWER STEERING CONTACTOR
17.243 SRAT, POWER STEERINGMOVABLE CONTACT SPRING

93.146-
17.244 SPRING, POWER STEERINGCONTACTOR k4OVARLE CONT
c
go, 080 -_(
19.899 ARMATURE,POUER STEERING CONTACTOR
65.052 INSULATOR, P/S CONTACTOR STAT CONTACT SUPPORT
90.080 LOCRWASHER, POWER STEERINGCONTACTORFASTEN-RR
91.539 LOCKWASEER, PWR STRG CONTACTOR CONDUCTORFAST
91.581 SCREW, POWER STRG STAT CONTACT SUPP INSULATOR
93.145 NUT, POWER STEERINGCONTACTORCONDUCTOR

-17.244
93.146 NUT, POWER STEERING PUMP CONTACTOR
17.240 I
-17.243
8 (
-& i_
17’240 lg.899
19168-l
SM556 19-01 - 13
POWER STEERING PUMP CONTACTOR
19.600 CONTACTORASSENSLY.
PLUGGING
19.602 COIL, PLUCCIRGCURTACTOR
19.615 CORTACT SEr. PLUGGINGCUNTACToR
19.621 FASTERRR,PLUGGIRG coRTAcTouSTAT CoRDUCToR
lg.621 19.623 SCREU, PLUGGINGCURT STAT CORT SUPP xtKiULATox

-t
92.396 - 19.849 AmATURRAssR5LY.PLUGGIRGCoRTACToR
65.275 SUT'. PLUGGINGCURT MOVABLS CONT ARUTUIIE SPRG
.279 65.276 SPRINC,PLUGGINGCONTXOVABLR CONTACT ABXATURE
65.279 PLUGGING COKI STAT CONTACT SUPPORT

IN!5UIATOR,
92.393 LOCRU~RRR, PLUGGINGCONTSTATC~CONUFAST
92.396 LOCKUASBRR.PLUGGINGCURT STAT CURT SUPP FAST
93.115 NUT,PLUGGING CUNTAtXORCONDUCPORFASTENER

:
19.602
r -19.615 lg.600
1
SM556 19-01-14
PLUGGING CONTACTOR w67-’
17.015 CONTACTOR ASSEMBLY, FORWARD 8 REVERSE
17.070 SUPPORT, FWD & REV STATIONARY CONTACT
17.072 SPRING. FORWARD & REVERSE CONTACTOR COIL
17.073 COIL, FORWARD a REVERSE CONTACTOR
17.077 SPRING. FWD h REV CONTACT TIP RETURN
17.084 CONTACT SET. FORWARD 8 REVERSE CONTACTOR
17.369 INSULATOR, F 8 R CONT STATIONARY CONTACT TIP
17.997 INSULATOR. FW~ a REV CONTACTOR MOVABLE CORE
19.021 CORE.FORWARD 6 REVERSE CONTACTOR MOVABLE
19.496 BASE. FORWARD a REVERSE CONTACTOR ASSEMBLY
65.469 CONDUCTOR. FWD 8 REV CONT STATIONARY CONTACT
65.815 COVER, FWD & REV CONTACTOR MOVABLE CONTACT
65.816 INSULATOR,FWD a REV CONT MOVABLE CONTACT N/O
65.817 INSULATOR.FWO 8 REV CONT MOVABLE CONTACT N/C
65.818 SEAT,F&R CONT CONTACTTIP REPJRN SPRING
95.441 FASTENER, FWD & REV CONTACTOR CLAMPING
95.442 LOCKWASHERfWD CLREV CONTACTOR CLAMPiNG FAST
95.443 FASTENERJWD & REV CONT STATIONARY CONTACT
95.444 WASHER. F & R CONT STATIONARY CONTACT FAST
95.445 LOCKWASHER. F&R CONT STATlONARY CONTACT FAST
95.446 FASTENER, FWD a REV CONT MOVABLE CONTACT
95.447 LOCKWASHER. F a R CONT MOVABLE CONTACT FAST
NON SERVICEARLE
ITEMS MARKED 'h"
lg.496
19603-l SM556 19-01 -15

FORWARD AND REVERSE CONTACTOR
19-01-05 CONTACTOR 8. Check armature and movable contact set for
INSPECTION free movement.
1A and MAIN PUMP CONTACTORS

POWER STEER PUMP CONTACTOR
1. Check armature and movable contacts for PLUGGING CONTACTOR
freedom of movement by depressing movable arm FORWARD / REVERSE CONTACTOR
with a screwdriver or small rod.
1. Check contactor for correct operation in same
Check for any restrictions to movement and for manner described for 1A and pump contactors.
return of parts by action of spring.
2. To replace tips on F/R contactor assembly,
2. Inspect contact tips. Look for any worn or disassemble both sections (F and R) of assembly.
eroded surfaces. Look for evidence of tip welding.
Inspect for evidence of any contaminants on tips Before attempting to disassemble unit, carefully
(paint, dirt, paper or cloth material, etc.) which observe location of each part and orientation of
would impair operation. part.
Do not use sandpaper or file tips. Any damage Loosen and remove four cover mounting screws
must be corrected by tip replacement. from coil frame.
Tips must be replaced before they wear through Remove cover. Be sure to note small return spring
and damage copper base. mounted under cover.
To remove and replace contact tips, use following Remove lock nut and washer from each contact
procedure: stud. Remove the fixed contact studs from top
cover.
1. Loosen and remove retaining lock nut,
lockwasher flat washer, spring seat,and spring Put new contact studs into top cover. Install
from armature bolt of center movable contact fasteners and tighten lock nut firmly on each stud.
tip set.
To replace moving contacts, lift moving contact
2.’ Remove movable contact tip set. assembly off body. Be careful to observe return
spring and washer locations on both sides of the
3. Loosen four long bolts holding fixed contact moving contact assemblies.
and insulators to assembly. Observe position
of short and long contact tip bus bar terminals. Hold stem of moving contact stud and remove lock
nut, lockwasher, return spring, insulator retaining
4. Remove bolts, lockwashers, insulators and washer and moving contact assembly.
two contact tips.
NOTE: Use care not to lose any of small
5. Install new contact tips by reversing above parts from assembly.
procedure. Check for correct positioning of
long and short fixed contact bus bars. Put new moving contact set on armature shaft and
install insulator retaining washer, return spring
6. Tighten four long bolts of fixed contact set’ Q.-(insulator-washer, lockwasher and locknut. Tighten
gradually and by even torque increments until locknut firmly.
firmly seated. (Tighten each fastener in a
sequential manner and use torque Remove lower fixed contacts from insulator cover %
increments to avoid overstressing and on coil. Replace with new contact tip assembly.
damaging insulator bars. DO NOT OVER Observe position of long and short contact tip bus
TORQUE! bars and connecting terminals.
7. Tighten armature and movable contact Assemble contactor by putting moving contact
assembly retaining nut. Tighten firmly but assembly armature shaft into coil plunger with
DO NOT OVERTORQUE. return spring on top of armature shaft.
SM556 19-01 -16
Put top cover over spring and install cover
mounting screws. OSCILLATOR CARD REMOVAL
Be sure return spring is fitted correctly on top of

moving contact assembly and that it fits into recess
in top cover.
NOTICE
When assembling top covers to bases,
make sure they are installed with positive
sign (+) markings facing inward, i.e., FARA
(+) towards FB/RB (+), and that contact tip
bus bars are placed correctly.
Use a bar or rod to move contacts. Be sure

movement is free of binding and that tips are in
correct orientation and tips contact correct mating
parts.
3. To replace tips on power steer and plugging

contactors, loosen and remove two cover
mounting screws attaching it to coil frame.
(Observe position of .positive (+) .marking ‘on
cover). Be careful not to lose return spring fitted Remove six-conductor plug connector from left
under cover. hand side of card (marked “B”).
Remove locknut and lockwasher from contact IMPORTANT

studs and remove contact studs from top cover TO PREVENT DAMAGE TO THE
and replace them with new studs. HARNESS BLOCKS AND TO THE OSC
CARD, ALWAYS REMOVE THE
Lift moving contact assembly off base. Remove CONNECTOR BY PRESSING DOWN ON
lock ring from armature shaft and remove moving CENTER TAB OF CONNECTOR WITH A
contact tips. Be careful not to disassemble or lose WIDE BLADE SCREWDRIVER, THEN
other parts under contact tips on armature ROTATE SCREWDRIVER 90” (WHILE
assembly. CONTlNUlNG TO PRESS DOWN) TO PRY
THE CONNECTOR OUT OF ITS SOCKET.
Replace moving contacts with new and assemble
onto armature shaft. Make sure lockring is fully WHEN INSTALLING CONNECTORS, BE
seated. SURE THEY ARE PRESSED FULLY INTO
SOCKET AND LOCKING TAB IS FULLY
Assemble contactor by putting moving contact ENGAGED.
assembly armature shaft into coil plunger with
return spring on top of armature shaft. Put top Remove fourteen-conductor plug connector from
cover over spring and install cover mounting right hand side of card in a similar manner (marked
screws. Be sure return spring is in recess in top “z”).
cover.
Remove seven control wires from six screw
NOTICE terminals on top surface of card.
When assembling top cover to base, make

sure it is installed with positive sign (+) OSCILLATOR CARD INSTALLATION
markings located correctly.
Install card on SCR panel base plate and tighten
Use a bar or rod to move contacts. Be sure fasteners.
movement is free of binding and that tips are in
correct orientation and tips contact correct mating Install seven control wires on six screw terrminals
parts. on top surface of card.
SM556 19-01 -17
Connect fourteen-conductor plug to top RH side
of card.
Connect six-conductor plug to top LH side of card.

INSTALLATION
1. Before attempting to install control in truck,
make sure truck is correctly blocked and battery is
disconnected.
2. Clean area where control panel will contact

mounting plate. Make sure surface is free from dirt,
dust, rust, etc, which would not permit panel base
to make good contact with mounting surface.
3. Install control panel on mounting plate and

tighten fasteners (items 17.094 & 90.177) to a
torque of [19.3 - 21.5 N*m] 170 - 191 Ibfain.
4. Connect wiring harness sections by joining

wiring couplers.
5. Connect power cables to correct terminals on

control panel. Make sure all connections are
tightened firmly.
6. Install top compartment and two front covers.
7. Remove blocks from drive wheels.
8. Connect battery and test control panel

operation.
SM556 19-01 - 18
ESM 12-25
GROUP 19
EV-1 OOM
SEQUENCE OF OPERATiON
AND
TROUBLESHOOTING
OPERATION SEQUENCE PAGE TEST PAGE

DRIVE CONTROL
1. GROUND FAULT CONDITION. ....I”....._._.. 19.~4-01
2. POWER STEER IDLE CURRENT. .._._.._.a...19.04-02
3. SCR CURRENT LIMIT ..............._...I........... 11404-02
4. 1A FREE-WHEELING CURRENT_...._._._. . ..19.04-02
5. 1A TIME DELAY..........“” ............“” ............. 19-o4-a3
6. CREEP SPEED MOTOR VOLTS._........._.....loo4M
7. PLUGGING FUNC~ON ...._.” ...............-.l acl4M
SYMPTOM CtiRT PAGE

3T CLOSE......... ....14050l
: NO POWER,
wmfE IN
...“.... ...... ........ ....lso5.u?
%3CLOSE. NO POWER,
g:uCK INOPERATIVE IN
PAGE .“..I .. ......I ......._.................19.05.lJ3
HYDRAULIC CONTROL CIRCUIT ;tCZC;S CLOSE BUT POP OPEN,
..“...” ............ ......._.. ..._.........lS.O5-C4
14 UPRIGHT LIFT FUNCTION_........_...:....._.lw2-29 ACTOR CLOSES, OTHER
15 UPRIGHT LOWER FUNCTION....I. . ..-._...19.@&30 .=“?..:.............-.__...-d~5-c6
16 TILT BACK FUNCTION_....._..__....__.. -. 1802-32 ._.
17 TILT FORWARD FINCTION....I... _._...... 19-02-34 lLE... .. ..... ....3905-05
19 AUX 1 BACK FUNCTION._...._ .......” ..........19-az-36 .L NOT CLOSE....--.140506
19 AUX 1 FORWARD FUNCTION..- ..._I”..... 19.02-39
20 AUX 2 BACK FUNCTiON..__.....____..... ....19-02-40 ’ %%%Z ...._......_....so507
21 AUX 2 FORWARD FUNCT0N ....._.“........” 19~2-42 \ DOES NOT
19.0507
CHECKING COMPONENTS PAGE
SPECIFIC GRAVITY TEST.” .....-..................... 19.#01 .. . . . ,.,
CHECK H. 2.5 RECS ....” .. .............. ............. 19.m.02
CHECK CAPACITOR (1C)............ ......_ ....._.“..lBw-oB
CHECK #22.23,24.25 FILTER BLOCKS._.._.. 190307
CHECK x3.4 RECS ............................... .. ........19.m-m
CHECK FILTER MOUNITNG BLOCK................ 1403-09
CHECK SENSOR...._...........................” .._...... 19a-10
CHECK THERMAL PROTECTOR........_I._. . ....1803-l l
CHECK REACTOR/CHOKE MODULE......._.I... 190312
CARD ADJUSTMENTS............._.I ........“” ..^... 19.&13
CARD VOLTAGE CHECKS.....“...“_..._... ..... ....19.03-14
CONNECTOR PLUGS A 8.2 .........” ........... .. 19-m-15
Sh4656 19-02-01
OPERATION SEQUENCE 1
DRIVE CONTROL
Drive control.
Standard schematic is shown with all switches and

contacts in normal off position. No circuits are
operating. Four basic areas of circuity are identified.
Power
Directional
SM556 19-02-02
.4& Gi
I
sM556 19-02-03
DRIVE CONTROL
Connect the battery.
A. Battery positive will be applied to the terminal 7 of the

card from the #l fuse by the white control wire.
B. The negative circuit will be completed from terminal 2 of the

card through the brown wire to the SCR panel negative cable
terminal.
C. The horn is operated by pushing the horn button which will supply
battery voltage to the horn through wire #25, and to negative
through wire #13.
Voltages Present:
A. Battery positive
8. Battery negative
C. Battery positive (wire.#25)
NOTE: The Vat&or (w ) does away with voltage spikes generated

by the horn as rt operates.
SM556 19-02-04
i
ri
OPERATIONS SEQUENCE 3
DRIVE CONTROL
Key Switch
A. Turn key switch on.
B. Battery voltage is supplied to the Card at TB-4 through wire #l 0 and

at TB-3 through wire #7.
C. Battery voltage is also supplied to the accelerator module through

wire #l 0 and to battery negative through wire #I 3.
..
D. The‘key switch relay coil is energized. Wire #l 0 connects it to battery
positive and wire #13 to battery negative.
E. The key switch relay coil closes the relay contacts, suppling battery
positive to the hydraulic function switchs through the #3 FU fuse and
wire #32.
Voltages present:
Battery positive at all points, A through E.
34556 19-02-06
--_-.,,- ___---
DRIVE CONTROL
Hour meter and power steering operation, and S. R. 0.
After the key switch has been turned on, and with the brake switch still released,
A. Moving the directional switch to forward will close the forward switch.
B. Closure of the forward switch signals the oscillator card to supply a voltage
through terminal PA1 to the power steering contactor coil Negitive.
C. The power steering contactor coil is now energized, closing the power
steering contact tips.
D. The power steering motor now operates because current flows from
5 battery posit@ethrough 1FU, to the steer motor and to battery
negative. (Note permanent magnet motor).
E. The hour meter will now operate because battery voltage is

supplied thru wire #71, blocking diode D9, and wire #72 to the hour
meter positive {SEE NOTE).
SRO (Static Return to Off) explanation;
1. The card monitors the sequence of voltage applied to terminals TB-4,

TB-3, TB-2, and TB-5 or TB-6.
2. Directional contactots will not be allowed to close if the directional

switch is dosed before the key switch is dosed.
3. This is done by the card sending voltage from terminal TB-2 to the
directional switch and sensing when the voltage returns to terminal
TB-5 (forward) or to terminal TB-6 (reverse).
4. The card also monitors the accelerator output voltage at terminal TBl .
The card will not allow the directfonai contactors to close if the
accelerator output voltage is below 2.5 volts.
NOTE: The hour meter operates when either the power steering contactor
is closed (which only operates when in either forward or reverse)
or by the hydraulic control circuit.
St4556 19-02-08
i
E
:
:
:
:
I
:
:
I
7,
DRIVE CONTROL
Energizing the D.irectional Contactors
A. The brake pedal (FBS) must be depressed to close the brake switch points.
The brake switch is provided to prevent operating the motor with the brakes
applied, since this wastes energy and may overheat components.
B. Rotating the directional lever forward slightly will close the forward directional
switch.
C. With all switches in the forward directional control circuits closed, battery posi-
.* tive will be applied to terminals .TB-2 and TB-5 of the card. This voltage,
coupled with the voltage from the key switch on terminals TB-3 and TB-4
causes the card to complete the circuit from terminals PB-1 and PB-2 to the
forward contactor coils’ negative.
D. The forward contactor coils are energized.
E. If #l REC is shorted, or the 1A tips are stuck closed, the blue wire to the card
plug pin 9 will be greater than 85% battery volts and the card will hold the
contacts open. (See note).
F. If the #/3 Ret or the #23 Ret is shorted, the blue wire to the card plug pin 9 will
be less than 25% battery volts and the card will hold the contactots open.
G. If the accelerator output voltage at terminal TBl , wire #29, is below 2.5 volts be-
fore directional switch is closed, the card will hold the contactors open.
Voltages present:
A. Battery volts.
B. Battery volts.
C. Battery volts on terminals TB-2 and TB-5.
D. 1O-l 3 volts acrosseach of the F coils.
G. Approximately 3.5 volts
NOTE 1: wires are twisted in pairs to aid in suppressing voltage spikes

generated by all coil type components in the control system.
NOTE 2: Closure of either of the turn cut-off switches disables the

corresponding directional contactor operations.
.%I556 19-02-10
BA-llERY
~111-111111-11111--- ~~~~T~__________________~
I POWER STEER MOTOR
7, ............ ... ........ ......... .. .. ........ .. ... ....... ...... .. .. ... . ..... ...... ...
i
:
i
I
i2
I
---I
RI-1ODM
OSCCARO CONNECTOR
rn
I--I
ACCELERATOR
“e PS3
* P84 ‘$f
* PS5 %
.. .,
A 13
Y KEYRS&;CH l3
%I!556 19-02-11
SAllERY
1 RBHTFIELD) i R
-- CAROZ
-..NECTOR
I\
El
DRIVE CONTROL
Contactor Closing and Capacitor Precharge
When the forward contactor coils are energized:
A. The coils’ magnetic fields pull the N. 0. power contacts closed, and
open the N. C. power contacts.
B. The card turns on the #2 REC by applying voltage to the white/red gate
lead. The #2 REC red lead provides gate lead filtering and is gate
current return path.
C. Positive potential on the ##2REC anode side of the capacitor now conducts
to negative as shown by the arrows. This leaves the capacitor 1C charged
to battery volts.
D. The card monitors the capacitor precharge. If card plug 14 (orange wire)
does not drop to battery negative, the card will not turn on #I REC. This
would occur if the capacitor were open or shorted, or if #I2 REC will not
gate on or is open.
Voltages present:
A. Not Applicable C. Battery volts across capacitor.
B. Not Applicable D. Battery negative.
SM!556 19-02-12
BAl-fERY
3
FU
DRIVE CONTROL
Turning ON #l and #5 RECS
A. A signal from the accelerator module starts the time delay which controls
the oscillator in the card.
_,: (. ,.
B. The card applies a gate voltage to the #l REC through the white/blue
wire and the REC turns ON.
C. The interaction of magnetic energy between the motor fields and arma-
ture causes the motor armature to rotate.
D. The card now applies a gate voltage to the #5 REC through the
white/voilet wire and the REC turns ON.
E. Positive voltage at T2 forces current through the #5 REC and reactor

to negative in the capacitor. This current builds a magnetic field in the
reactor.
SM656 19-02-13
BAllERY
l----l-
2 2
I
5
flFU
s
I __
23REC
. .
22 12 ~
i 13
I2 i 13
13
4%
KEY
RELAYi
r’ I
* .lO
a
c
DRIVE CONTROL
1C Capicitor Charging and Reactor Operation
A. In preparation for turning OFF the #l REC and #5 REC, the card removes
the gate voltages.
B. Current continues to flow from T2 (+) to the capacitor through #5 REC and
T4-T3 reactor until both sides of capacitor are equal to battery positive.
C. Battery potential on both sides of the capacitor stops current flow. This
causes the reactor field to collapse, which results in an increased voltage
at T3.
D. This higher than battery positive voltage is stored into the capacitor, making
the battery (+) side appear to be (-) as compared to the T3 voltage.
E. #5 REC is turned OFF, trapping the voltage in the capacitor.
Voltages -- Not measurable.
StvI6!56
19-02-14
BAllERY
CONNECTOR
DRIVE CONTROL
##2REC Turn On and #l REC Turn OFF
A. Positive poterntial at terminal 14 (orange wire) will cause the card

to turn on the #2 REC.
B. When voltage is applied to the gate of the #2 REC, it turns ON.
C. The 1C capicitor senses the #/2 REC turning ON and discharges

a positive potential against the #1 REC through the 1X choke and the
##2REC to the negative potential on the opposite pole of the capacitor.
D. The #l REC. se.nsesthe reve.rsscurrent~3flow

andturns OFF.
E. Current from the capacitor continues to flow through the choke and
the #2 REC to battery negative until the capacitor reaches a potential
of battery volts. The choke works to limit the surge of current through
the ##2REC to a safe value.
Voltage Sequence:
Too quick to measure. Also, voltages vary with speed setting.
Sbt556 19-02-15
DRIVE CONTROL
Flyback:
A. Current stops flowing through the #2 REC circuit when the capacitor
has reached battery voltage.
B. Because the battery no longer has a circuit through the motor, battery
current stops and the magnetic energy of the drive motor field is allowed
to collapse.
C. This collapsing magnetic field induces a voltage across the fields that is
opposite battery voltage.
- D. This voltage forces current through the armature and sensor and the #3
REC. This current (called “flyback” current) continues to drive the armature
during the #l REC OFF time.
Voltage Sequence:
Too quick to measure.
NOTE: Average armature current flow, when compared to battery current,

will be about two to three times as great when operating in SCR range.
.%I556 19-02-16
BATTERY
@-3fI~ 36 VOLTS POWER STEER MOTOR

n .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A
3
Fu
DRIVE MOTOR
22 12
i3
OSC CARD
CONNEdTOR II
T4
4,
6.
OSCCARD CONNECTOR
._
I --.-..-._.........__ ~._:
10 +-aTB4 i
.....
...” . . . . . . . . . . . . . . . “.. ,........ . . . . . “.” . . . . . . . . . . . . . . . . . . . ..-_. . . . . . ““... . . . . __ . . . . . I..* JB3
t
LET;,UJ$FF
L1o-----%~SWITCH l3
RELAY
SM556 19-02-17
DRIVE CONTROL
Accelerator module, thermal protector and PMT
Turning the #l REC ON and OFF produces a switching technique that controls
the power and speed of the truck. More (or longer) pulses produce more power.
A. The number and length of pulses is governed by the accelerator module

and the sensor. Rotating the multi-function handle changes the accelerator
output and the control works faster. The sensor monitors motor current and
signals the card to shorten pulses during high motor currents.
B. tf the control is ove,rworked,the #l REC and TP will get hot. Resistance in

the TP wilt increase and reduce control power regardless of accelerator position.
C. When the #l REC is turned ON, the #3 REC stops conducting.
D. The blue wire to the card plug ##9allows the card to sense pulsing. If the
#l REC fails to turn off, the card takes voltage away from PBl , PB2 or
PB3, PB4 so the directional coils de-energize, dropping out the contact tips.
E. The card will quickly re-close the contacts in a “look again” mode and drop out
the contacts if the problems still exist. Turn OFF the key to reset the PMT.
(See note).
Voltage present:
A. 3.5 to 4.0 volts at creep speed. 0.2 volts or less at top speed.
B. Less than 0.5 volts across TP is no cutback; greater than 3.4 volts across TP
is severe cutback.
NOTE: If PMT (pulse monitor trip) is tripped, power steer motor willcontinue to
to run regardless of directional lever position.
SM!556 19-02-18
BAll-ERY
befI[ POWER STEER MOTOR

.....VOLTS
71 . ..... .. ......I .. .......... .. ... ........ ........ ..35 .. .. ......... .. .. .... ........
3 2 In
Fu FU
Q
12
12
iK
!zY
BAY
T T4
i
12 10
1x
1
RI-1OOM 0% CARD’
OSCCARO CONNECTOR
12
10-----_96~--28 52 -....&.\13 -
10 p1 34 51 . ..LL13 -
>v 1A
RIGM&JJi$FF
. .._ (_. ., x._ ,_ .i .. .- .-_
LlO rt
kYgz:cH l3 13
St4556 19-02-19
DRIVE CONTROL
1A Contactor Operation
Rotating the multi-function handle will gradually reduce the voltage output from the
accelerator control module which allows more frequent pulsing of the control
resulting in smooth speed and power control up to 85 to 90 percent of available
motor voltage.
. ._ A. Rotating the multi:function handle fully,clockwise or counter-clockwise,

signals the card to start the 1A time delay.
B. After a short time delay, the card completes the circuit from PB5 through wire
#34, to the 1A contactor coil negative. This energizes the 1A coil.
C. The IA contactor power points close completing the control bypass circuit.
D. The card also monitors motor voltage and current flow through the sensor and
will energize the 1A coil, closing the 1A contacts anytime motor voltage is at 85
to 90 percent battery voltage (this is called a demand pickup).
E. The card has a built in thermal 1A hold-off. 1A will not dose if the control is in
severe thermal cut-back
Voltages present:
A. When accelerator voltage drops to 0.4 volts or less, the 1A timer will be
activated.
B. 1O-l 3 volts across the 1A contactor coil.
NOTE: Closure of either turn cut-off switch, disables the 1A contactor operation.
SM656 19-02-20
BATTERY
~----------------,-- +)+I~ __________ ““___l
I POWER STEER MOTOR

7, ....” .. ......... ..... ........ ......” ... ... ....” .... ...VOLTS
36
.... ... ......... ....-.......
FL Sl
3
FU
EV-1OOM
OSC CARD CONNECTOR
10
i
10 *la4
6 ...........................“‘7 ....... ... ..‘ .. ..... .......... ...........-...... 7 ........- .. ...... .. ... ..* TS3
LElX&JzFF
PM
PS4 &. ._......... !52--$++.-13-
28
pm P&____J, _&“db.,3 _
75 RIGHTC~T$JFF
-- 62. _ ._... A : . j
A
13
Y KMRES;CH l3
SM666 19-02-21
OPERATING SEQUENCE 13
DRIVE CONTROL
Plugging
Controlled plugging (using the reverse power of the motor as a brake) is attained
when changing direction from forward to reverse (or reverse to forward).
A. The multi-function control handle is moved from forward, opening the forward
switch.
‘B.+While the switch is in the neutral position, all directional coil circuits will
be open.
C. The card will stop functioning because voltage is removed from terminal TB5.
D. The card supplies voltage from PA1 keeping the power steering energized
up to 24 seconds.
E. Forward and 1A contactots will return to their normal position, opening the
drive motor circuit, because the contactor coils are de-energized.
NOTE: The truck will be coasting forward.
SM556 19-02-22
BATTERY
__.-_.-
3
n
2 2
FUG?
ae
2? 12
13
12- 13
13
4AU I I
A-J
T T4
1c 1x j
13
osc CARD2
-I CONNECTOR
__
Ib
,_+~-Jl3
L “1
a
I--d
ACCELERATOR
LEFWU;zFF
-524ll3- dl
-51 -\13 7
SM556 19-02-23
DRIVE CONTROL
Plugging (continued)
A. The operator rotates the control handle through neutral to reverse, closing
the reverse directional switch.
B. Voltage is applied to the card, through the directional switch to terminal

TB6 on the card.. The card senses that the truck has been moving and that
the control lever went through neutral. This causes the plugging logic in
the card to takeover. .
C. The card now completes the circuit from PB3 and PB4 (through wires #26
and ##27)to the reverse contactor coils’ negative. This energizes the
reverse coils.
D. The reverse directional contactors energize closing the motor circuits in

reverse direction.
E. The card turns on the #2 REC and prech,argesthe capacitor.
F. The card turns on the #l REC.
SM556 19 - 02 - 24
BAllERY
POWER STEER MOTOR

71 ...... .......... ......” ...... .......... .......... ... ...... ... ......... ....... .. ......
22 12
--i
I
%
K
RLY :w
4REc
; i
32 10
Ev-100M OSC CARDL

OSCCARD CONNECTOR
:‘........_........_____:
t-------lo
# ..... . . ...... ..”....... “..7..“.“.“..“..
10
... ..._...” . ..... .....“..“.“.7 .. ......” .. ... .. .... ... ;..*

:4TM
TS3
j
i
32
SM556 19-02-25
DRIVE CONTROL
Plugging (Continued)
As the #I REC is turned ON, the truck is continuing to travel in the forward direction.
Because the drive motor fields have been reversed, the motor armature now
becomes a generator because it is driven against the magnetic effect of the field by
the trucks inertia.
A. The voltage polarity reverses across the armature of each motor. This changes
the voltage of Al to negative and that of A2 to positive. This voltage also causes
the #4 RECs to conduct and thus provides a path for the generated currents.
B. These generated currents flow through the sensor, which over-rides the main
oscillator section of-the card allowing only predetermined slow pulsing of the
control, as adjusted by the plugging trim pot in the card and the control handle
position. The card is locked into the plugging oscillator mode.
C. This also causes the card to complete the circuit from terminal PB6 through
wire #75 to the DC contactor coil negative. This energizes the DC contactor
coil and closes the DC contactor power tips. The DC contactor ensures that
the generated currents flow equally in the two motor armatures.
D. The card also over-rides the 1A timer section of the card and will not allow the
1A coil to energize during the controlled plugging operation.
E. This slow pulsing will bring the truck to a smooth stop. The voltage polarity
at the armatures will return to normal and the truck will start to accelerate
normally in the opposite direction of travel and the DC contactor will be
de-energized.
Voltage present:
A,B,C = Description only
NOTE 1: The truck will always have torque to restart on a ramp (incline) unless
the operator moves the directional switch into the opposite direction,
which will result in plugging torque only. This is called “ramp start”.
NOTE 2: If either turn cut-off switch is closed, the DC contactor operation is

disabled.
SM556 19-02-26
BATEFlY
3
FU
11
12
12
1 sle
Ev-1WM OSC CARD’
T3
-i OSCCARD CONNECTOR
12
. . .. . 10 .. . . . . . . .. .
LEFT CUT-OFF
SWITCH
...A%?“...-.&~13 -
13
l3 13
RELAY
SM556 19-02-27
OPERATlON SEQUENCE 14
HYDRAULIC CONTROL CIRCUIT
Upright Lift Function
After the key switch has been turned on, which energizes the key switch relay,
A. Pulling back on the multi-function handle closes the ‘UP’ switch.
B. Current now flows through the #I3 FU, wire #22, key switch relay contacts,
wire #32, UP switch, wire #5, Dl blocking diode, wire #28, through the pump
coil and wire #13 to battery negative.
C. The pump contactor coil is now energized, closing the pump contact tips.
D. The pump motor now operates because current flows from

battery positive through 1FU to the pump motor and to battery
negative.
E. Voltage is supplied to the Rl relay through the #5 wire, #l Res dropping

resistor and wire #l 1. Battery negative is connected through wire #13.
F. The Rl relay is now energized, closing the Rl A contacts.
G. Voltage is supplied to the R2 relay through wire #28, blocking diode D3,
wire #35, through dropping resistor 2 RES and wire #21. Battery negative
is connected through wire #13.
H. The R2 relay is now energized, opening the normally closed R2A contacts
removing voltage from the tilt and aux switchs.
J. The R2C contacts close when the R2 relay is energized but, because the R3C
contacts are open, there is no voltage to these contacts.
K. Current now flows to the hour meter from wire #35, blocking diode D8, wire
#72 to wire #13, negative.
NOTE: The movement of the hydraulic valve spool now controls the lifting of
the upright
or by the hydrauliccontrol circuit.
NOTE: The Filters (&,.J ) do away with voltage spikes generated by the
relays when they are de-energized.
SM556 19-02-28
Upright Lower Function
A. Pushing forward on the multi-function handle closes the ‘DOWN’ switch.
B. Current now flows through the #3 FU, wire #22, key switch relay contacts,
wire #32, through the DOWN switch, wire #35, through the ##2RES dropping
resistor, wire #21 to the R2 relay and wire #13 to battery negative.
C. The R2 relay is now energized, opening the normally closed R2A contacts
removing voltage to the tilt or aux switchs.
;, j .
D. The R2C contacts also close when the R2 relay is energized but, because the
R3C contacts are open, there is no voltage to these contacts.
E. Current now flows to the hour meter from wire #35, blocking diode D8, wire
#72 to wire #13, negative.
NOTE: The movement of the hydraulic valve spool now controlls the lowering of
the upright
NOTE: The Filters (k,ws ) do away with voltage spikes generated by the
relays when they are de-energized.
SM556 19-02-30
Batt. Poe. Ban. Neg.
1
I !
d 1FJL i3
i
!I 1RES
5 . . . . . . . . . . . . . . . . . . . . . . . . . <. . . . . . . . . . . . . . 1, .................
+
~~~~~“-i-‘~~~__-,: i
--_-_-_q
!t 25 !
3
!
3FIL
!
3 RES
32 ......... ... r”7 ........ ..31 ......... .. .. 13
-74
3%
1OFIL
i
I 1lFlL
I
84
l3 i
I
........ .. ... .... ....7, ..I ......#...,-------------------.72 .--I- HM ---FTLFEr---_,3
u
DQ HOUR METER
“!_
12 aa------= 13
HORN
B%&
St4656 19-02-31
Tilt Back Function
A. Pushing the tilt button on the multi-function control handle closes the ‘TILT
switch.
B. Voltage is now supplied through the normally closed R2A contacts, through
the ‘TILT switch, #I3 Res dropping resistor, to the R3 relay and wire #13
connects the relay to battery negative.
.C. The R3 rel.ay,cot!,is now_energized closing the normally open R3A, R3B,
and R3C contacts.
D. Pulling back on the multi-function handle closes the ‘UP’ switch.
E. Voltage is now supplied to the R3 relay through the Dl and D4 diodes,

through the R3B contacts and the 3RES resistor. The TILT switch can now
be released without interrupting current to the R3 relay.
F. Voltage is also supplied to the Rl relay through the 1RES dropping resistor,
the PUMP contactor coil through the Dl blocking diode, and the R2 relay
through the Dl and D3 blocking diodes.
G. The Rl and R2 relays are now energized, closing the Rl A and the R2C
contacts and opening the normally closed R2A contacts breaking the circuit
to the function switchs.
H. Current now has a path to the HS-1 A, HS-1B, HS-2 and the HS3A
solenoids energizing them and directing the oil path to the tilt cylinders.
J. Current now flows to the hour meter from wire #35, blocking diode 08, wire
#72 and wire #13, negative.
K. The pump contactor has also been energized, closing the power tips and
the pump motor will now run.
NOTE: The movement of the hydraulic valve spool now controls the tilting
back of the upright.
SM556 19-02-32
Batt. PO..
Ban. ueg.
A
l-3
-13 __I_ t
-13 ----4
I
-13 ----•
3RES -
-cz]__-31’__ _“,3 -1-1
4FlL
t=
t
i
a4
-74 13
1_,,.~ -0*q
I
LLI
...._..............7, ..........))...+-------------------.72 .---- HM ---F~L~Ey--13
u
DQ
HOURMETER
_i_
Sh4556 19-02-33
Tilt Forward Function
A. Pushing the tilt button on the multi-function control handle closes the ‘TILT’
switch. -
9. Voltage is now supplied through the normally closed R2A contacts, through
the ‘TILT switch, #3 Res dropping resistor, to the R3 relay and wire #I3
connects the relay to battery negative.
, C. The R3 relay coil is now energized closing the normally open R3A, R39, and
R3C contacts.
D. Pushing forward on the multi-function handle closes the ‘DOWN’ switch.
E. Voltage is now supplied to the R3 relay through the D2 and D4 diodes,

through the R3B contacts and the 3RES resistor. The TILT switch can now be
released without interrupting current to the R3 relay.
F. Voltage is also supplied to the PUMP contactor coil through the D2 blocking
diode, and to the R2 relay through the D2 and D3 blocking diodes.
G. The R2 relav is now energized, closing the R2C contacts and opening the
normally closed R2A confacts breaking the circuit to the function switchs.
H. Current now has a path to the HS-1A, HS-1 9, and the HS-3A solenoids,
energizing them and directing the oil path to the tilt cylinders.
J. Current now flows to the hour meter from wire #35, blocking diode D8, wire
K. The pump contactor has also been energized, closing the power tips and the
pump motor will now run.
NOTE: The movement of the hydraulic valve spool now controls the tilting
forward of the upright.
SM556 19-02-34
wt. Neg.
A
1 FIL
I-3
_. _r_..- - .-v
_!h. DOWN
.__-d &45---+ +L-C-s2--+----92~~4t-
AUXl i
-13
i
10FlL
I 11FIL
I
I
i
*4----c&3 -1
f
n---m35 -- El
;;
!
. . . . . . . . . . . . . . . . . . . . . 7, . . . . . . ..I #..+-------------------q.---- HM --‘I~~L~~~---,~ -I--
u
DO HOUR MEJER
J_
12 *ab-----25 13 -_“.._I
HORN
SM656 19-02-36
AUX 1 Back Function
A. Pushing the AUX 1 button on the multi-function control handle closes the
‘AUX 1’ switch.
the ‘AUX 1’ switch and the #4 RES dropping resistor to the R4 relay and
through the D5 diode and #3 RES dropping resistor to the R3 relay. Wire
#13 connects the relays to battery negative.
,I C. The R3 and R4 relay coils are now energized dosing the normally open
R3A, R3B, R3C and R4A contacts and shifting the R4C contacts.
D. Pulling back on the multi-function handle closes the ‘UP’ switch.
E. Voltage is now supplied to the R3 and R4 relays through the Dl and D4 diodes,
through the R3B contacts and the 3RES resistor to the R3 relay and the R4A
and 4RES to the R4 relay. The AUX 1 switch can now be released without
interrupting current to the R3 or R4 relays.
G. The Rl and R2 relays are now energized, closing the RlA and the R2C
H. Current now has a path to the HS-1 A, HS-1B, HS-2 and the HS-3B
solenoids energizing them and directing the oil path to the attachment.
NOTE: The movement of the hydraulic valve spool now controls the aux 1
back function of the attachment.
or by the hydrauliccontrol circuit.
St4656 19-02-36
:...... *.................... 7, .... ...“. ...~~-~~~~~~~~~~~~~~~~~~.~~-- ---11----13
FILTER
D9 HOUR METER
J_
I-._..- 12 13
HORN
WITCH
SM556 19-02-37
Aux 1 Forward Function
A. Pushino the AUX 1 button on the multi-function control handle closes the
‘AUX 1’ &itch.
the ‘AUX 1’ switch and the #4 RES dropping resistor to the R4 relay and
,
C. The R3 relay coil is now energized closing the normally open R3A, R3B, and
R3C contacts and the R4 relay coil is energized closing the R4A contacts
and shifting the R4C contacts.
E. Voltage is now supplied to the R3 and R4 relays through the D2 and 04

diodes, through the R3B and R4A contacts and the 3RES and #4 RES
dropping resistors. The AUX 1 switch can now be released
without interrupting current to the R3 or R4 relays.
diode, and to the R2 relay through the D2 and 03 blocking diodes.
G. The R2 relay is now energized, closing the R2C contacts and opening the
normally closed R2A contacts breaking the circuit to the function switchs.
H, Current now has a path to the HS-1 A, HS-1B, and the HS-38 solenoids,
energizing them and directing the oil path to the attachment.
NOTE: The movement of the hydraulic valve spool now controls the AUX 1
forward function of the attachment.
SM556 19-02-38
Ban. PO..
Ban. tdeg.
; A
I l-3
12 d 1 FIL
I
i
! 1lFIL
i 84 f<), ,3
!
I
1-m--~ II
&; Ia
... ... ...... ... ... .. . ....*..... p- -1--_---_______1 ___.n.____~___~~A___,3
HOUR METER
j_
12 5-25 13
HORN
.si%z4
%I556 19-02-39
AUX 2 Back Function
‘AUX 2’ switch.
the ‘AUX 2’ switch and the #5 RES dropping resistor to the R5 relay,
through the D6 diode and #4 RES dropping resistor to the R4 relay and
C. The R3, R4 and R5 relay coils are now energized closing the normally open
R3A, R3B, R3C, R4A, R5A and R5C contacts, opening the R5B contacts and
shifting the R4C contacts.
D Pulling back on the multi-function handle closes the ‘UP’ switch.
E. Voltage is now supplied to the R3, R4 and R5 relays through the Dl and D4
diodes, through the R3B contacts and the 3RES resistor to the R3 relay, the
R4A and 4RES to the R4 relay, and the R5A, D7 diode and 5RES to the R5
relay. The AUX 2 switch can now be released without interrupting current to
the R3, R4 or R5 relays.
G. The Rl and R2 relays are now energized, closing the Rl A and the R2C
H. Current now has a path to the HS-1 A, HS-1B, HS-2 and the HS-1
solenoids energizing them and directing the oil path to the attachment.
‘:‘.‘i’
J. Current now flows to the hour meter from wire #35, blocking diode D8,
wire #72 and wire #13, negative.
back function of the attachment.
St465619-02-40
Batt. Pea.
S&t. Neg.
i
14
-774
10FIL
i3 -4
i
i
I”__~ II El
. .._................. 7, .. ... ... ..#...e ~11111~1_1~~111~_~_. n .-1-- 1-111--w-13 _I__
D9 FILTER
J_ HOUR MEER
12 13
HORN
SWITCH
St&!56 19-02-41
Aux 2 Forward Function
‘AUX 2’ switch.
the ‘AUX 2’ switch and the #5 RES dropping resistor to the R5 relay,
through the D6 diode and #@IRES dropping resistor to the R4 relay and
C. The R3, R4 and R5 relay coils are now energized closing the normally open
R3A, R3B, R3C, R4A, R5A and R5C contacts, opening the R5B contacts and
shifting the R4C contacts.
E. Voltage is now supplied to the R3, R4 and R5 relays through the D2 and D4
diodes, through the R3B, R4A and R5A contacts and the 3RES, 4RES and
5 RES dropping resistors. The AUX 2 switch can now be released without
interrupting current to the R3, R4 or R5 relays.
diode, and to the R2 relay through the D2 and D3 blocking diodes.
G. The R2 relay is now energized, closing the R2C contacts and opening the
normally closed R2A contacts breaking the circuit to the function switchs.
H. Current now has a path to the HS-1A, HS-1B, and the HS-1 solenoids,
energizing them and directing the oil path to the attachment.
J. Currentnow.flows to the.bour.meter~from.vi.re.#35,blocking~diode D8, wire

forward function of the attachment.
is dosed (which only operates when in either forward or reverse)
SM556 19-02-42
Batt. PO&
Batt. Neg.
1 FIL
i
!
13 ------f
i
04 I
-74 13 -.--i
i
.
i
I_,,,~ __&
.............................+p-
:
*a-----e 13------I
HORN
.G%
SM!556 19-02-43
CHECKING COMPONENTS
I SPECIFIC GRAVITY TEST 1
SPFCIFIC GRAVITY STATF OF CHARGE
1.260-l .300 100% CHARGED
1.230-l .250 75% CHARGED
1.200-l .220 50 % CHARGED
1.170-1.190 25 % CHARGED
1.140-1.160 VERY WEAK
1.110-1.130 ~ DISCHARGED
‘BY USIN% A HYtiFiOivlETEh, THE SPECIFIC GRAVlTY OF THE ELECTROLYTE SOLUTION IN A

BATTERY CAN BE DETERMINED. THE BATTERY SPECIFIC GRAVITY IS AN INDICATION OF
THE BAlTERY’S STATE OF CHARGE. IF THE STATE OF CHARGE IS LOW, THE HYDROMETER
WILL READ LOW. IFTHE STATE OF CHARGE IS HIGH, THE HYDROMETER WILLL READ HIGH.
PS AN FXA!d?f I= A RFADlNG FROM;

1.260 TO 1.300 INDICATES A FULLY-CHARGED BATTERY.
1.200-l .220 INDICATES A BAlTERY IS IN A DISCHARGED
CONDITION AND CANNOT GIVE SATISFACTORY SERVICE.
USE BOTH TESTS DESCRIBED HERE.

Hydrometer test -- Test at least six cells across battery with a temperature corrected
hydrometer, see chart above. Battery should be recharged if specific gravity is below
1.120 to 1.140 range. Battery is fully charged if the reading falls in the 1.280 to 1.300
range. If the difference between cells is more than .015, battery needs maintenance.
24 volt battery Load-Test ~7,put .thelmainhydraulicsystem > 36 volt battery

19.2 volts into by-pass while reading battery volts with 28.8 volts
a voltmeter.
48 volt battery 72 volt battery
Battery needs recharge or repair if voltage
38.4 volts drops below 80 % of the rated voltage of 57.6 volts
the battery.
SM556-19-03-01
CHECKING #l ,2. 5 REC’S CSCR’S\
(Use this 4 step procedure to check any SCR using a VOM)
STEP 1: Set meter to R X 10,000 and calibrate. Connect positive meter lead to
anode of SCR. Connect negative meter lead to cathode of SCR. Results
should be above 100,000 ohms.
STEP 2: With meter set as in Step 1, connect the meter positive to the cathode of
SCR. Connect the meter negative to the anode of the SCR. Again, the
Iresultsshould be above 100,000 ohms.
STEP 3: Set the meter to R X 1 and calibrate. Connect positive meter lead to the
gate terminal. Connect the negative meter lead to the cathode. Results
should be from 10 to 200 ohms.
STEP 4: With the meter set as in Step 3, connect the meter positive to the cathode
of the SCR. Connect the negative lead to the gate terminal. Results
should be from 5 ohms to infinity.
NOTE
ON EV-100 PANELS, THE #2 AND #5 RECTIFIERS
(PRESS PACK DESIGN) USE A PACKAGING ENCLOSURE
THAT HAS THE POLARITY SYMBOLS MISMARKED.
ON THE SIDE OF THE PACKAGE, YOU WILL SEE THE
SCHEMATIC SYMBOL. USE THE SCHEMATIC SYMBOL AND
NOT THE POLARITY SYMBOLS TO DETERMINE POLARITY!!
SM556-19-03-02
STEP 1 R X 10,000 SCALE 100,000 OHMS OR MORE
CHECKING SCR’S
RECTIFIERS
STEP 2 R X 10,000 SCALE 100,000 OHMS OR MORE
CHECKING SCR’S
RECTIFIERS
1
SM656 1g-03-03
STEP 3 R X 1 SCALE 10 TO 250 OHMS
CHECKING SCR’S
RECTIFIERS
STEP 4 R X 1 SCALE 5 OHMS TO INFINITY ACCEPTABLE
CHECKING SCR’S
RECTIFIERS
SM556 19-03-04
#2 AND #5 PRESS PACK RECTIFIERS
GATE CATHODE
I
v
+
I
3
0
C0
ANODE
SM55619-03-05
TO CHECK CAPACITOR (IC)
STEP 1 R X 10,000 SETTING

STEP 1
TO MAKE SURE THAT

CAPACITORS WILL RECEIVE
AND STORE A CHARGE,
AlTACH THE OHMETER
LEADS TO THE CAPACITOR
TERMINALS WITH ONE
TERMINAL DISCONNECTED.
AS THE CAPACITOR CHARGES

RESISTANCE BUILDS UP
FROM 0 TO BEYOND 10,000
OHMS.
GO TO STEP 2.
CHECKING CAPACITOR
STEP 2
REVERSE METER LEADS.

THE OHMETER NEEDLE
SHOULD GO TOWARD ZERO
AND THEN RISE AGAIN TO
BEYOND 100,000 OHMS.
IF YOU READ ZERO RESIS-

TANCE, INFINITY OR A
1. :-FIXED. RESISTANCE, THE
CAPACITOR IS BAD AND A
F;.‘ONE MUST BE INSTAL-
CHECKING CAPACITOR
SM556 1Q-03-06
CHECKING COMPONENT WITH VOM (ONLY)
STEP 1
DISCONNECT BATTERY.
y$C;;F&GE CAPACITOR
,
DISCONNECT ALL WIRES
FROM THE FILTER BLOCK.
CHARGE THE FILTER AS

INSTRUCTED HERE, AND
THEN GO TO STEP 2.
CHARGE THE FILTER, TOUCH

METER LEADS TO FILTER
TERMINALS’FOR A FEW SEONDS.
CHECKING #22,23,24,25 FILTER BLOCKS
STEP 2 R X 10,000 SE-T-I-ING
STEP 2
AFTER A FEW SECONDS

REVERSE THE METER
LEADS. WHEN YOU TOUCH
THE LEADS TO THE TERMI-
NALS OF THE FILTER
BLOCK, THE VOM NEEDLE
.,. : -: JvlUST DEFLECT AND RETURN
TO INFINITY. IF THIS DOES
NOT HAPPEN. THE FILTER
BLOCK IS BAd AND A NEW
ONE MUST BE INSTALLED.

THE DEEDLE OF THE METER
SHOULD DEFLECT AND RE-
TURN TO INFINITY. IF IT
DOES NOT, INSTALL A NEW
FILTER BLOCK.
CHECKING #22,23,24,25 FILTER BLOCKS
SM556 19-03-07
CHECKING COMPONENT WITH VOM
STEP 1 R X 10,000 SETTING 50,000 OHMS OR HIGHER STEP 1
OPERATION - NUMBER
3 AND 4 RECTIFIERS
~O;;~fTRIl-Y IS IN-
OHMMETER TEST:
MEASURE RESISTANCE
FROM CATHODE TO THE
ANODE.
A READING OF 50,000
OHMS INDICATES THE
RECTIFIER IS GOOD.
GO TO STEP 2.
IF METER REGISTERS
BELOW 50,000 OHMS, A
NEW RECTIFIER SHOULD
BE INSTALLED.
TESTING #3 AND #4 RECTIFIERS
STEP 2 R X 1 SE-I-I-ING 7 TO 12 OHMS
STEP 2

MEASURE RESISTANCE
FROM ANODE TO CATHODE.
A READING OF 7 TO 12 OHMS
CA-FDE . .,.._ INDICATES THE RECTIFIER
IS GOOD.
IF METER DOES NOT REGIS-

TER 7T0 12 OHMS, THE
RECTIFIER IS BAD AND A NEW
ONE SHOULD BE INSTALLED.
TESTING #3 AND #4 RECTIFIERS
SM556 1g-03-08
b
C
STEP 4
CHECKING COMPONENT
Disconnect battery and discharge capacitor. Remove filters from mounting

block. Note positions and hardware location. Mark wires for proper rein-
stallation. Disconnect mounting block from #I Rectifier. Use VOM ( R x 1
scale) to measure resistance in steps 1 through 4 (all measurements must
be “0” ohms). Other terminals are for mounting purposes only. Replace
mounting block if readings other than “0” ohms. When reassembling, be
sure to use original hardware in proper locations. Also, make sure all wires
are connected correctly.
SM556 19-03-09
CHECKING COMPONENT WITH VOM (ONLY)
CHECKING SENSOR
CALIBRATE METER ON R X 1 SCALE
1. CONNECT ONE METER LEAD TO THE GREEN

SENSOR WIRE, CONNECT THE OTHER METER
LEAD TO THE YELLOW SENSOR WIRE.
2. METER SHOULD READ “0” OHMS. REPLACE

SENSOR IF READING IS NOT “0” OHMS. IF YELLOW
OR GREEN WIRE HAS BEEN BROKEN OFF THE
SENSOR DO NOT SOLDER BACK ON BUT REPLACE
SENSOR
St4556 19-03-l 0
[11ClOClO
TPLUG -
BLACK
NOTE: ‘2” PLUG VIEWED FROM CARD END.
CHECKING COMPONENT
THERMAL PROTECTOR
Disconnect battery and discharge the capacitor.
Do not remove the Thermal protector from the #l rectifier heatsink. Remove the
“2” plug from the card. Using a VOM (R X 100 scale) measure the resistance between
the black and gray wires With the #l Rectifier heatsink at room temperature (24°C or
75°F) the meter should read 50 to 200 ohms. Replace thermal protector if readings
are other than this range.
If the readings are to specifications, set VOM ‘to R x 1‘0,‘OOO

scale and measure
resistance from each wire end (at “Z” plug) to #l Rectifier heatsink. Readings should
be infinity.
Sh4556 19-03-l 1
T-5 T-4
T-3
A-l
COMPONENT CHECKING
REACTOR/CHOKE MODULE
Disconnect battery and discharge capacitor.

Remove wires and bus bars from connection points.
Be sure to mark leads for proper reinstallation.
STEPl: Use a VOM (R X 1 scale) to measure resistance

from T-3 to T-4 (Reactor).
STEP 2: Use a VOM (R X 1 scale) to measure resistance

from T-3 to T-5 (Choke).
Both measurements must be “0” ohms.

Replace reactor/choke module if readings are
other than “0” ohms.
Terminal A-l is a binding post only. It has no

electrical connections to any other terminal.
NOTE: Zero meter before checking.
SM55619-OS-12
CARD ADJUSTMENTS
EVIOOM ONLY
CREEP C/A
I I
CREEP 4.5
C/A 6.5
,
C/L 9
1A TIME 1.5 SEC.
PLUG 8
MOUN-I‘ING SCREW A AND B PLUGS TERMINALS l-6 z PLUG MOUNTING SCREW
SM556 19-03-13
CARD VOLTAGE CHECKS
TB-1 Key on and accelerator released.. ................. 3-4 v.

Key on and accelerator fully rotated .............. .0.2 v. or less
TB-2 Key off ........................................................ 0 v.

Key on ......................................................... About l/2 battery volts
Accelerator rotated ....................................... B+ v.
TB-3 Key off ........................................................ 0 v.

Key on ......................................................... B+ v.
iB-4 K& bfi .......................................................... 0 v.

Key on ......................................................... B+ v.
TB-5 Key off .. ... . .. . ..... .... . .. .. . . ... .. ... .. .... .. .. .. .. . .. .. . .. . ov

Key on, accelerator rotated to forward,
brake pedal depressed . .....*.....*..................... B+ v.
TB-6 Key off .... . ... . .... .. ... .. . .. ... .. ... .. .. . .. ... .. ... .. .. .. . .. . 0 v.
Key on, accelerator rotated to reverse,
brake pedal depressed .. ..... ..... .. .... .... ....... . ....B+ v.
ShA55619-03-14
CONNECTOR PLUG
EVI OOM ONLY
I 1
NOT
#62
NOT USED
NOTE: VIEWED FROM CARD END
CONNECTOR PLUG “B”

EVI OOM ONLY
.-
#27
#24
#26
#34
“Z” PLUG
WHITE NOTUSED GRAY GREEN YELLOW BROWN BLACK
ORANGE VIOLET WHITE RED WHITE BLUE WHITE

VIOLET TRACER RED TRACER BLUE TRACER
St4556 19-03-l 5
RECOMMENDED TEST, TEST sheet. Open circuit battery voltage is
EQUIPMENT AND measured as follows:
PROCEDURES STEP #l: Turn Digital Multi-meter ON
Select 200 volts, DC scale.
I. RECOMMENDED TESTS: STEP #2: Connect RED lead to

POSITIVE (+) terminal on battery.
1. Ground Fault Condition. Connect BLACK lead to NEGATIVE (-)
2. Power Steer Idle Current. terminal on battery.
3. SCR Current Limit
4. 1A Free-Wheeling Current. STEP #3: Read and record voltage
5. 1A Time Delay. reading displayed. This is OPEN
6. Creep Speed Motor Volts. CIRCUIT BATTERY VOLTAGE.
7. Plugging Function.
6. Always have key switch turned OFF and
II. TEST EQUIPMENT: parking brake SET before connecting
battery to truck .
1. Current Monitoring Shunt, 500 Amps,
50 mV. 7. The test for parameter #3 (SCR Current
2. Digital Mu&Meter- Recommend “Simpson Limit) requires truck’s components (e.g.,
D.M.M. Model #461” or equivalent. cables, controls, axles, brakes, etc.) be in
cold condition, i.e., components are at
approximately same temperature as
Ill TEST PROCEDURES: normal, not to be operated / driven for any
significant period of time (more than 10
A. PRELIMINARY PRECAUTIONS: The minutes) before conducting test. If
following precautions must be adhered to while required, provide sufficient cool down
preparing for and / or conducting above tests: period for truck.
1. Tests #1 through #6 require drive wheels 8. Before connecting battery to truck, visually
be raised off floor. inspect to be sure contactor tips are not
welded.
2. Always inspect condition of battery cables
and connector of battery being used for 9. The preferred method of disabling any
test. If battery cables are worn out, cable function / component (e.g., preventing 1A
ends at terminations cracked, or cable contactor from closing) is to disconnect
insulation broken / cracked, battery should appropriate control wire, in order to break
not be used for test but should be sent for electrical circuit. Use of cardboard and / or
repair or maintenance. any other mechanical device is not
advised. These methods should only be
3. No extension cables should be used to used if breaking electrical connections is
connect battery to truck for test. It is not practical. SUCH METHODS SHOULD
recommended to install battery in truck for BE USED WITH CAUTION!
test whenever possible. When such
installation is not practical, battery should B. PROCEDURES:
be set on floor close to truck battery
receptacle, to eliminate need for 1. GROUND FAULT CONDITION:
extension cable.
STEP #l: Disconnect battery from truck
4. Always inspect condition of battery cells receptacle and turn key switch OFF.
for proper water level.
STEP ti: Turn ON Digital Multi-meter;
5. Before conducttng any test, measure select resistance measurement
open circuit voltage of battery. Record function, 200,000 Ohm scale.
measured value, nominal rating of battery
volts, and battery type number on test
SM556 19 - 04 - 01
STEP #3: Connect Red lead of Multi-meter 3. SCR CURRENT LIMIT:
to POSITIVE (+) terminal of truck
receptacle and connect BLACK lead of STEP #l : Raise drive wheels off floor. Make
Multi-meter to an unpainted surface sure truck is in cold condition.
(e.g., bolt, etc.) of truck frame. Record
resistance. STEP #2: Connect shunt to measure
battery current (i.e. connect in series
STEP #4: Connect RED lead of Multi-meter with positive or negative cable).
to negative (-) lead of truck receptacle
and leave BLACK lead of Multi-meter STEP #/3: Install jumper wire on foot brake
connected as in Step #3. Record switch to defeat its operation.
resistance.
STEP #4: Disconnect control wire #34 from
STEP #5: Compare values obtained in 1A contactor coil negative terminal and
Steps #3 and #4 against specification to tape up.
determine PRESENCE / ABSENCE of
GROUND FAULT. STEP #5: Connect battery to truck
receptacle, turn key switch ON.
NOTE: It is recommended that if ground
fault is detected on truck, tests for other STEP #6: To obtain a HARD STALL
parameters should be conducted ONLY condition of the motor, do not depress
, AFTER.ELIMINATING CAUSE OF AND foot brake pedal, gradually rotate the
THEREBY GROUND FAULT. multi-function control handle to the
FULLY FORWARD position. Measure
2. POWER STEER IDLE CURRENT: and record highest current reading
(voltage across shunt) obtained.
STEP #l : Raise drive wheels off floor.
STEP #7: Subtract power steer idle current
STEP #2: Connect current monitoring from reading obtained in Step #6 to
shunt to measure battery current. Shunt obtain SCR CURRENT LIMIT FOR
sensor wires are connected to Digital DRIVE SYSTEM.
Multi-meter. The voltage reading across
these two sensor wires gives Direct STEP #8: Repeat Steps #6 and #7. Take
Current reading. Turn ON the Digital average of two (2) readings and compare
Multi-meter: select DC VOLTS. average value to specifications.
STEP #3: Connect battery to truck NOTES:

receptacle. Turn key switch ON, push
hand brake down, select a direction of 1. Precautions should be taken not to stall
travel. The power steer motor noise traction motors more than 20 seconds
should be heard. during Step #6.
STEP #4: Measure and record voltage 2. There should be wait (idle) period
across shunt sensor wires (or terminals). minimum of two (2) minutes between
! Steps #6 and #8.
STEP #5: The voltage reading obtained in
Step #4 is a direct reading of POWER 3. Drive wheels should be allowed to turn
STEER IDLE CURRENT using between Step #6 and #8.
conversion of 1 mV equal 10 Amps for
500 Amp, 50 mV shunt. (i.e. 1.0 mV 4. 1A FREE WHEELING CURRENT:
equals 10 Amps)
NOTE: Precaution should be taken not to
touch steering handwheel while taking STEP #/2: Install jumper wire on foot brake
measurements / readings in Step #4. switch to defeat its operation.
STEP #3: Connect control wire ##34to 1A

contactor coil negative terminal.
SM556 19-04-02
STEP #7: Stop Watch reading is 1A TIME
STEP #4: Connect shunt to measure DELAY. Repeat Steps #5 through #7 at
battery current. least four (4) times. Take average of all
readings as 1A TIME DELAY to compare
STEP #5: Connect battery to truck against specifications.
receptacle, turn key switch ON.
6. CREEP SPEED MOTOR VOLTS:
STEP #6: Depress the foot brake pedal,
rotate the multi-function control handle STEP #l : Raise drive wheels off floor.
to the FULLY FORWARD position.
STEP ##2: Connect RED lead of Multi-meter
STEP #7: Gradually release the brake pedal to pig-tail of commutating diode (#3
until the battery current reading is REC) and BLACK lead of Multi-meter to
between 100-200 Amps. Hold brake negative (-) terminal on control panel.
and control handle in these positions for
a minimum of ten (10) minutes. STEP #3: Turn Digital Multi-meter ON;
select DC Volt measurement function,
STEP #6: After ten (10) minutes, depress 20 Volt scale.
the brake pedal completely while still
holding the control handle fully rotated. STEP #4: Install jumper wire on foot brake
After current reading has stabilized, switch to defeat its operation.
measure and record it.
STEP #5: Connect battery to truck
STEP #9: Release the control handle receptacle, turn key switch ON.
completely. After current reading has
stabilized, measure and record it as STEP #6: With the foot brake pedal in the
POWER STEER IDLE CURRENT. UP position, gradually rotate the control
handle until1 the FORWARD switch
STEP #lo: The difference of current closes. Record voltage reading of meter.
readings obtained in Steps #6 and #9 is
1A FREE-WHEELING CURRENT and STEP #7:Repeat step #6. Average of two
must be used to compare against reading is CREEP SPEED MOTOR
specifications. VOLTS and should be compared
against specifications.
5. 1A TIME DELAY:
7. PLUGGING:
STEP #l :Lower drive wheels to floor,
STEP #2: Install jumper wire on foot brake remove jumper wire from foot brake
switch to defeat its operation. switch.
STEP #3: Connect battery to truck STEP #2: Connect battery to truck
receptacle, turn key switch ON. receptacle, turn key switch ON, drive
truck to open space or aisle where at
STEP #4: To obtain a HARD STALL ‘least [76.m] 250 feet of running space is
condition of the motor, do not depress available.
foot brake pedal.
STEP #3: Drive in the FORWARD direction
STEP #5: Rotate the multi-function control at top speed. After the 1A contactor has
handle to the FULLY FORWARD picked up (closed) and truck has
position as fast as possible and start traveled in top speed mode at least 123
Digital Stop Watch the moment control m] 75 feet, change direction of travel to
handle stops. FULL REVERSE.
STEP #6: Stop the stop watch the moment

any motion or movement of 1A (bypass)
contactor tip is detected.
SM556 19-04-03
STEP #4: If truck continues to travel forward
with continuously decreasing speed
until truck stops and smoothly
accelerates in reverse direction,
PLUGGING function is correct.
STEP #5: Repeat Steps ##3and #4 starting

out with reverse travel, then changing to
forward travel. The PLUGGING function
should operate same way.
STEP #6: Measure distance from point on

travel path where direction change was
initiated to point where truck actually
started moving in reverse direction. This
measurement is PLUGGING DISTANCE.
NOTE:
Measurements made in Step #6 should

only be compared to specifications, if
test was conducted after truck was
operated for a minimum of 50 hours.
The plugging distance is adjustable by

means of a trim pot on the oscillator card
and may be adjusted to suit the
customer’s needs.
SM556 19-04-04
SYMPTOM 1
MFlEcTloNALccNTAclc%ls
wlLLNoTcLosE.
4
aixxccM7wLFusE2Fu.
1
c+lEcKAnJLsTMENT
YES
OF MRECTiCML
CU4lXlLASSENLLY
MASIJFE’AXTAGEON
TERM. TS5 (FWD) & TS6
(REbJOFOSC.C.MO.
cHECxFOR.9iCRTFRm
NO WIRE X15 TO WIRES X6 6
x8 &OPERATION OF FWD /
REVSWITCHES. REPAIR/
CHECK IF MRECTIONAL
CONTACTORTIPS ARE
C.+ECKFoRSHoRT
FROM WIRE Xl 5 TO
No WIRES x6 8 X8 &
UNPLUG MTIERY. CHECK IF CC CONDCTOR IS OPERATION OF FWD I
CHECKFcmSwRT REV SWTTCHES.
FRoMBATrERY REPAIR /REPLACE.
msm~ TO 72. I
J
TERMS. lWlRES#lOl OF
WIRES X10 TO COILS ON

PANEL REPAIR / REPLACE.
MEASURE VDLTAGE ACRCSS

WIRES iI & 10
BOTHCUli?.FCRSAME
ANC OPERATION OF
MRECTKlN.SELE~DlRECTDN
KEY SWTTCH. REPAIR/
6OFlZRATETRUCKREAC
METER FOR FIRSTO. SEC AND
NO
+YES
CeGcAm ~‘C+i5xCcuTACTCRSFORBNLnNG
OR OPEN CC4L REPAIR I REPLACE
c+lEcKrxLwmNum
OFSFlAKESWlTCH NO
AND WIRE 115.
REPAIR I REPLACE.
NOTE: ALL TESTING SHOULD BE DONE WITH

DRIVE WHEELS RAISED OFF FLOOR.
BAlTERYSHOULDBElJNPLUGGED
FOR CONNECTING OR DISCONNECTING
ANY WIRES AND/OR COMPONENTS.
SM556 19 - 05 - 01
SYMPTOM 2
DlRECllONALCONlACTORS
u_a~.mpMRm
AUOISLESCRHUYTRUCK
irnwww wrnwxx~
INSCRRANOE
OIECKTHERW
pRoTEcroRFoRlilGN
RESlSTANCE OR LOOSEI
&u)CONNECllONSTO
cARDTPL!JG
WITHSRAKEPEDAL
-AmcoNFRoL
l-!ANDCEHFWDORREV 4 YES
MEASUREVOLTAGEUJ72
2.1 TOSPIAl TOAZON
OiSCONNEcTwlRE
x28 FROM TERM. TBl 1 FORLOWRESISTANCE. 1
OFOSCCARD.
-voLTAoE
ON WIRE x29 AS
CONTRawNu_EIs
IROTKlEDTOUCSE
FWDsWrrC+i. I
cHEcKcumNurrYoF
co~Acr0Rnpsm
LrxJirEopENONBoTH
NOTE:
ML TESTING SHOULD SE DONE WITH
SATTEFiYSHOULDSEUNPLUGGED
RECCNNECTWl##220N
ORANGEWIRON-
AS ACCELEMTOR IS
ROTATED IN SCR RANGE
ri -1
CHKXGITENANDYELLOW
NO WlFlESCW cuwENTsENscR
FCR CONllNUilY, BROKEN
INSULATION AND LOOSE I
DEFECTIVE (Iz REC. SADCONNECllONTOCARD
REpvIcE TPLUG.
SM556 19-05-02
SYMPTOM 3
C4C6ENOPOWEP_AUMSJ_E
SCRHUMTRUCK
INOPERATlM Wml ACCEL
INSCRRANGE.
I ,
lJNPLlmsmrERY.
ol-GEM. 1c. m
cnscawEcTaREc. .
c+!EcuQREcFcR
CeEN
I
~PROTK;TORFCMFENORIF
lHELEADSAFlE SHomEDTon REC
UlliCcE I
Dlscct.lNEcTY2REc.
CHECK ri, REC SHORT.
DEFECTNE x2 REC.
NOTE:
ALL TESTING SHOULD SE DONE WITH
BATTERY SHOULD BE UNPLUGGED ) NO
FOR CONNECTING OR DISCONNECTING ID~CONNECT~.S~~~ I
SM556 19-05-03
+
C+iECK IF 1A CONTACTCR
TIPS ARE WELCEO.
CHECK CCNllNUiTY AND/OR

Xl REC. TURN KEY SWTCH ‘CM.
PRwERCuwEcrmNSCF
MEASURE WLTAGE ON I-Z
MEENANOMLU)WWRES
( I1 REC CAlHCOE ).
CNANOFRCMSENSCRTC
CARD PLUG T PIN UANO
PIN x3 RESPECTIVELY.
NOTE:
AU TESTING SHOULD BE DONE WITH
DRNE WHEELS RAISED OFF FLOOR.
BATTERY SHOULD BE UNPLUGGED
SM556 19-05-04
SYMPTOM 5 SYMPTOM 6
m STIFF PLUG AND/ ORPLUGGING

MSTANCE WILL NOT ADJUST.
FlUXHE HlERY. CLOSE K!3_

AND FOOT MAKE SwrcHEs.
HASUFUivoLTAGEoNlERM.lBS AWUSTPLUG POT.
6TERYmffOSc.cARD. TO DESIRED SmNG
HIIFfSFmM-sENsoFl
ARE CONNECTEDTO PIN #4AND
PIN x3 RESPECnVELY OF T
PLUGONCSC.CX3O.NoTETlMT
YELLcwWlRESHDULDBEC
WA!TDNESECUUD,THENCUSE TO SKITERY NEGATIVE AND NOT
MRECTlONAL SwlTCJi OF
COhTACTORSTMTWlLLNOT
C4.OSE-WXTh3EON
OTHERDlFlmONALIwurTERM REPAIR I REPLACE.
(TS5ORTSS)OFOSC.CAFlD.
IWIRS FWM CURIENT

SEMORFOR~EN I
M3SUREVUTAGEoNNoN-
CLOSlNGMRECTK)(JALINPUT
TSRM.(TS6ORTSS)ANDCOlLS
POSITIVE WIRES 1110.
IDISCONNECT BOTH 14 REC’S.
CHECK#4RJKZS FCRCPEN. I
J
CHECXCXXullNUlTYANDK#l 1
PRWER-ON
WIRES X10 AND x23.24 OR
x26.27 S OPERATION OF
DIRECTIONAL SWITCH ( FWD I
REV). REPAIR/REPLACE.
-voLTAGE-EACt
COILOF CONMCTORS lHATWlLl
N0Ta.0s5Sum~n~
omEcTiuNMRQTATECONTROL NOTE: ALL TESTING SHOULD SE DONE WITH
l-wxxEmcREEP-.READ
M3ERFORRRSTO.SSEC.AND
AmER 1 SEC.
BATTERY SHOULD SE UNPLUGGED
cztiEcKmAcToRsm
MEu-lANlcfu SINOI~ OPEN
COILS AND REVERSERS FOR NO
INTERMmENTNoRMALLY
CLOSED POWER TIPS. REPAIR
REPuaz.
1NO
SM55619-05-05
SYMPTOM 7
1ACONTACTCflWlLLNOTCLOSE 1
4
UNPLUG MllERY. CHECK 1A
INSTAUAJUMF%RFROMWlRE
X7 TO WlRE X15 ON FOOTSRAKE
SWITCH. PLUG BATTERY. WrrH
MAKE PEWREUZASED, ROTATE
C4BlROLHANCLETOTOPSPEED.
MEASUREVUTSONGFUYLEM
FROMTHERMLPROiECTORAT
0% CAFiD‘Z PLUQ PIN 15.
CONTRU_ IN THERMAL-
ALLcwTRUcKTOcooLFEamx
1ACUNTACTOROPEK4TlON.
MEASURE VOLTAGE ACROSS 1A
&
NO CO!LCLOSEKEYANDFS
ShlTCHES ROTA-l.5 COML
HAWXE FaRToP SPEED.
MEASURE VOLTS FOR FIRST 0.5
SEC. AND AFIER 1 SEC.
,*,
0Sc.CARD2PLUG.cHEcKTHERMK
PRO~ANowRESFcflOPEN. I
NO DEFECnVE 1A
CCNTACTORCOlL
MPOTFUUY
I
REPAIR REPLACE.
#h-rAcrOR
1 DEFEcmEOSc.cARD.REPlAcE
TRIM - POT PER SPEC.
WIRE #2S FROM TERM. TSl OF

0% CMD. PLUG IN SAllERY
ANDaOSEKEYsWmH.
h+EASURE VOLTAGE ON WIRE x29
AS CONTROL HANUJZ IS ROTATEt
KYITOPSPEED

r+.:.DRIVE WHEELS RAISED OFF FLOOR.
SWlTCtl DFF. FemNEcTwlREI
BAllERY SHOULD BE UNPLUGGED
129 TO TERM. lB1 OF 0%. CARD.
~wci wnERY. aosE KEY FOR CONNECTlNG OR DISCONNECTING
SWlTCHANOROTATECONYFDL ANY WIRES AND/OR COMPONENTS.
MNCi.5FoRTOPSPEED.
MEASURE VOLTAGE ON TERM. TSl
OFcec.cARD.
SM556 19 - 05 - 06
SYMPTOM 8
NO
PMTTRIPS awrfnb4iz HYCRAUJC
.swlTaesAR-OAOPENEO.
WIRES x6 AND 18 TO CARD
CMCKFORTHEVOLTAGESPIKES
ON FOSmM AND NEGATlVE
WIRES TO HYDRAULIC ClRCUT
MS. F!+JOSCURCEAND
ELIMINATETHE SPIKES.
WLTAGE ON P. s.
CONTACTORTERMlNALTO
WHlc+lBAllERYmm?vE
CAmEcONNBza
CLOSEKEYANDFCXXBRAKE
SWITCHES. h!EMURE VCLTAGE
ON TERMINALS TS4, T&3 AND
TEaOFOSc.mRO.
ME4SuREvOL-rAGEA##5s
PScQlL SELECTA
c%REclloN. READ wlER
FOR FIRST 0.5 SEC AN0

CARD.REFlACE SATI-ERY SHOULD SE UNPLUGGED
SM556 19-05-07
GROUP19 SUPPLEMENT
EVIOO LXT CONTROL PANEL
GENERAL the plug location “Y * on thecontrol card. After installing

The Handset is a multi-functional tool to be used with the handset tool, plug in the battery and turn on the key
the EV100/200 LXand LXTSCR controls. The Handset switch. The following is the start-up display sequence
consist of a Light Emitting Diode (LED) display and a that will occur:
keyboard for data entry.
START-UP DISPLAY SEQUENCE
PURPOSE:
The purpose of the Handset is to allow authorized
personntito perform-the-faltowingltmcti6ns: Key Switch on
- Monitorexistingsystemfauftcodes forbothtraction
and pump SCR systems Verify Display Segments for
* Monitor intermittent random status code one second
* Monitor battery state of charge on IX systems
- I
- Monitor hourmeter reading on traction and pump
SCR systems I
- Monitor or adjust the following control functions: BDf Display

. Creep speed
. Controlled Acceleration and 1A time B fa&&lay
. Current Limit No BDI used )
. Steer pump time delay and define signal input
( seat switch or directional switch ) I -- J
. Plugging distance (Current) Run Mode
. Pedal positiin plug range or disable
. 1A drop out current or disable
I
I
1
. field Weakening drop out BDI Display
. Field Weakening piti up or
. Regen braking current limit Blank Diipiay
. Regen braking drop out :NoBDIused)
. Speed timit points ( SLl .SL2. and SL3)
Tnrck Management fauft speed limit
. Internal resistance compensation for battery
state of charge indication
. Battery voltage ( 36!48 volts is auto ranging )
- Selectionof card operation type:
- Standard traction card selection:
- Standard traction with. Field Weakening
- Standard traction with speed liiits
* Standard traction with Regen/Fiefd Weaken-
ing Display pump
- High or low current limit for al! of the above. hourmeter for
four seconds
OPERATION: or
WarIIing : Before Wnn8Cting or disconnecting th8
handset tool, jack up the drive wheels of the ve- (if no Pu!$%R used)
hicle, turn off the key switch, unplug the battery
and discharge the capacitors. NOTE: The vehicle Can be operated with the handset
connected, however, the adjustment knob must
At the SCR control traction card; unplug the. Y plug l b8 set fur& CkEkwfS8 t0 illsul.8 the Control
if th8 dash display is in use and pfug in the handset to op8rates at top speed.
SM548
Copyrighted 19-14-1
Material
FUNCTION SET-UP PROCEDURES: DESCRIPllON AND LOCATION
Warning: Before making any adjustments to the

control you must consult the operating and maln- z PLUG
Y PLUG I
tenance instructions supplied by the vehkle
manufacturer. Failure to follow proper set up in- A PI
structions could result in mlsopemtion or damage
to the control system.
With the Handset connected, hold down the CONT key

and turn on the key switch. This will place you in the set
up mode, ready to monitor or adjust control function set-
tings.
NOTE: The term push, means to depress key for

approximately one second.
Action Display shows Remarks
Hold down CONT, [%6-i Segment check

turn on key displayed
Push function I[ Selected

function number Evloo WLXT
number
is displayed
After one second /-zq Stored value for

time delay the function is
displayed
Push CONT Displayed value

will blink
Value changes
while blii
Push STORE Newvafue

1
storedand
bfink@@ops CEV
Push ESC Segment 6heck

1
displayed
At this point another function can be monitored/

changed by pushing another function number, or the
vehicle can be placed in the run mcde by holdingthe
ESC key down for one second or longer. The display
will return to either the diagnostics mode or the SOI
display or a blank display ( if 801 is not used and HANDSET
there are no fault codes). The vehicle can now be
operated with the handset connected or the handset
can be diiconnected before operation.
NOTE: You can return to the segment check mode

at any time, by hofdii down the ESC key until 8888
appears in the display.
SM548 19-14-2
DESCRIPTION OF FUNCllON NUMBERS FOR:
tc3645EvLxcmTT Example: 0 = min. current, 255 - max. current
IC364SEVLXCDlTX
iC3645EVUCDiTK
FUNCTlON 5 PLUGGING DISTANCE (CURRENT)
FUhCTlON 1 STOm FAULT CODE (PushS)
( Push 1)
This function allows for the adjustment of the plugging
This function register contains the last fault that shut distance of the vehicle. The larger the current setting,
down vehicle operation ( PMT type fautt that is reset by the shorter the stopping distance.
cycling the key switch ) . This fautt code will be over
written each time a new fault occurs and can be cleared Range 200 to 1000 amps (EVl 00)
from memory by adjusting the value to zero. 300 to 1500 amps (EV200)
Set oto2Ss
FUNCTION 2 CREEP SPEED Resotuttion 3.14 ampsper set unit (EVlOO)
(Push2) 4.7 amps per set unit (EV200)
EXampie: Setting of 20 - 263 amps (EVIOO)
This function allows for the adjustment of the creep
speedofthevehicle.Aconstantcre8psp88dfmquency Wamlng: Ptug88tttngsmurt b8 In accordancewith
will be maintained when an acoel8rator input voltage control op8rating Instfuctions. An exceaaively
between 3.7 and 3.5 volts or an accelerator ohmii input hlgh~tngcouldcsu~damagetocont~lsyaem
between 6K and 4.7K ohms is provided. or traction motor.
Range S%tolS%ontime FUNCTION 6 1A DROP OUT CURRENT

Set oto2Ss (Purh6)
Resolution 03% per set unit
Thisfu~aUowskrtheadjustmentofthelAcontac-
Example: Setting of 20 - 5.6% on time tordropoutwrrent.ThelAcontactocwillbedropped
out and the vehii motor torque will be limited to SCR
FUNCTION 3 CONTROLLED ACCELERATION current limit when the set drop out current is reached.
AND 1A TIME
(Push3) FQw3 450 to 1260 amps (Wl 00)
675 to 1690 amps (EV200)
This function allows for the adjjstm8nt of the rate of set Ob2SO
time it takes for the control to accelerate to 960/oapplied R8&Utii 3.24 amps per set
unit (EVl 00)
battery vottage to the motor on hard aooe&ation. The 4.66 amps per set
unit (EV200)
1A contactor will automatically cloa8.2 seconds after
the controlled acceleration atopa and the accelerator S8&gs above250 set b&k willdisable 1A drop out
input is less than .S volts of less thah SO ohma. function ( 1A will not drop out).
Range .l to 22.0 seconds -we Settingof 20 = 515 amps (EVIOO)

Set oto2Ss
Resolution 034s8oohdap8ra8tunif FUNCTtON7 FIELD WEAKENINGPtCK UP
Wah7)
Example: S8ttiiof20=18a8con&C/A
and 2.0 1A time. This function allows th8 adjustment of field weakening
contac@ picic up ourrent. This setting allows the Fw
FUNCTION 4 CURRENT LIMIT cohtactortopi&upwh8hth8v8hidehasretumedto
(P-t4) about 150% of ita full bad level funning currentafter
Thii function albws for the adjjstment of the current

limit of the control. The rating of the control will deter- RanOe S2W66ampa(EVlOO)
mine the range of adjustment for thii function. Please 78 to 699 ampa(n/200)
refer to the op8rating instructions for th8 control used in Set oto265
your vehicle. Resolution 1.6ampspers8tunit
24ampspefsetunit
f-‘W seecontrot
c/L cunm l-mple S8ttingof20=64amps
Set oto255
19-14-3
FUNCTlON 8 FIELD WEAKENING DROP OUT SettingofOsetunitswilldisablespeedlimftfunctionand
(Push8) allow top speed with no lift switch connected.
Thisfunctionallowsfortheadjustmentofthefieldweak-
ening contactordropoutcurrent.Thii setting allowsthe
FW contactor to drop out when the vehicle requires FUNCTION 12 SPEED UMIT 2 (SL2)
greater than 300% of the full load level runhing current (Pueh12)
for greater torque.
Same as Function 11 except using SL2 limit switch for
Range 85 to 895 amps (EVl 00) input.
98 to 1343 amps (EVZOO) -
Set Oto285 FUNCTION 13 SPEED UMfT 3 (SL3)
Resolution 3.28 amps per set unit (EVlOO) (Push13)
4.88 amps per set unit (EV200)
Example . Setting of 20 = 130 amps Same as Function 11 except using SE3 limit switch for
input.
FUNCTION 9 REGEN BRAlkiNG k/L’
u-w TheSL3setspeediimitisalsoadivatedbytheTnrdc
Management Module fault codes 90 and 93. See in-
This function allows for the adjjstment of the Regen structions for IC3848TMMlA Truck Management
brakingcurrent limit.The higherthe current the shorter Module for detaii.
the stopping distance.
FUNClYON 14 INTERNAL RESISTANCE .
Range 75to83oamps COMPENBATION
Set oto255 (P-h14)
Resolution 22ampspersetunit
This functfon ls used when the Battery Discharge
Example: Settingof20=119amps lndiir is present Adjustment of this function will
improvethe accuracy of the BDI. In order to made this
FUNCTION 10 REGEN START setting the voltage drop of the battery under bad must
(PushlO) first be determined by folbwing the steps listed bekw.
Thishrnctionallowsfortheadjuamentofthepercenton 1.Loadthetractionmotorto1OOanpsin1Aand
time at which the control will start to regen. Adjustment record the voltage (Vo) at the SCR positiie and
of this function allows the OEM to set the regen start negativepowerterminal.
speed of the vehicle to eliminate regen attemptswhen 2Loadthetrac&ionmotorto2OOampsinlAand
motor regen current is low. recordthevoftage(V~) at the SCR positive and
negative powertenninal.
Range Oto95%ontime 3. Calculate voltage drop o/p) as follows:
Set 0 to 258 v0-vo-vL
Resolution .3796per set unit 4. Use the tabie befowto determine the setting using
the cafcufatedVDas a reference.
Example: Settfngof29= 7.4%ontfme
FUNCllON 11 f?P’EED~lfT 1 (SLl)
Thiifunctionalbwsfortheadjjofthespeedlimit
( maximumbattery volts to the motor ) when the SLl
limit switch input signal is received by the controf card.
SLl limit switch is a normaltyclosed switch connected
to battery negative,the switch opening enables speed
limit.
Range 98% to 0% battery volts

Set oto180
SM548
FUNCTlON15 BATIERY VOLTS
(Pushl5) RI100 standard
Function wfth FW Limit RegenFW
Thi: functionallowsfor the adjustmentof vottagerange
for controlsequippedwith the BatteryDischargeIndica- STD C/L 0 to 4 2Oto24 40 to44
tion function. In order for the BDI to operate properfy, High C/L 5to9 25 to 29 45to49
the setting as shown in the table must be entered . STD C/L
(Auto plug) 1oto14 3oto34 50 to54
Battery volts Set unlts High C/L
(Auto plug) 15to19 55to59
24 volts Between 0 and31
36 votts Between32and44 Ev200 Standard
48 volts Between45 and 69 Functbn wlth FW RegerWV
72 volts Between 70 and 80
84votts Between81 and 153 SlyI c/L 64 to 68 84to88 104to108
36M8 votts Between184and250 STD C/L
No BDI Between251 and 255 (Auto plug) 74 to 78 94to98 114to118
4 Settingsfor these function should be made in between

L shown.
the valuf3s
Warning: These settings must be changed by au-

thorized personnel only, following Instructions
suppliedby the manufacturer. Cardtype selectbn
FUNCTION 16 PEDAL POSMON PLUG must be made wlthln the capablllties of the SCR
(PushCONTandl) control panel used and the supportingelectro-ma
char&al devlcea. Failureto to complywith proper
This functionwill afbw the adjustment of the pedal applicatbnstandarda could result in mkoperation
position plug range. Pedal position wffl reduce the or damage to the control and/or motors.
pluggingcurrentto the currentvalue set by this function
as the accelerator is returned to the creep speed FUNC’RON18 STEER PUMP TlME DELAY
position. Maximum ptug current is obtained with the (Pueh CONTand3)
acceleratorin the top speed position.
Thii function allows for the selection of steer pump
Range looto930amps(N1OO) contactorpickup input, either seat switchor directional
150 to 1425 amps (01200) switch cbsing and adjustment of the time delay for the
Set Oto255 anltactordmpol&
Resolution 3.2 amps per set unit @WOO)
5.0 amps per set unit (Ev2gO) Pfck up on w switch&sure and time delay drop
Example Settfngof20=164amps out on wet ewftch opening.
To d&able the pedal positbn p&g functfon, adjj the Range 1.5to65seconds
current value to the same cunent value as the ptug Setting BetweenOand128
distance cutrent. Resobtii .5secondspersetunit
Example: If plug cfimnce wrrent Function 5 is set at Example: SettingofU)-10.5seconds

500amps,thensqwdalpbgcurrentat500amps.
with this setting pedal position will have no effect on Pick up on dkectbnal swttchclosure and drop out
pluggingdii. time delay on dlractbnal switch openlng.
FUNCTION17 CARD TYPE SELECIlON Range .5to53seconda

(PushCONTand2) 12910255
.5secondspersetunit
Thii functionallowsfor the selectionof the card type
used for your vehicle’s appliiion. The table below Example: setting of 149 - 10.5 seconds
shows the setting to select card appGcattontype de-
pending on which ccnhcf card is used. DroQoutwiUbel.5secondsaftertheseatswitchopens.
Intended for CLARK
SM548 dealers only
19-14-5
DESCRlP’TlON WFUl’Tlu~l~~MBERS FOR:
ntrol Cg& Example: 0 - min. current, 255 - max. current
rcss45EvU(cmMx
IC364!XVU(CDlMK
FUNCTION 5 PLUGGING DISTANCE (CURRENT)
FUNCTION 1 STORED FAULT CODE (Push5)
( Push 1)
This function allows for the adjustment of the plugging
This function register contains the last fault that shut distance of the vehicle. The larger the current setting,
down vehicle operation ( PMT type fault that is reset by the shorter the stopping distance.
cycling the key switch ) . This fault code will be over
written each time a new fault occurs and can be cleared Range 200 to 1000 amps (n/l 00)
from memory by adjusting the value to zero. 300 to 1500 amps (EV200)
Set oto255
FUNCTION 2 CREEP SPEED Resolution 3.14 amps per set unit(EVI 00)
(Push2) 4.7 amps per set unit (EV200)
.., ,. )_ ._ ExamPleZ-- -SettingofQg~~253 amps (EVIOO)
This function allows for the adjustment of the creep
speedofthevehicle.Aconstantcreepspeedfrequency Warning: Plug setting8 must be in accordancewith
will be maintained when an accelerator input voltage contml operating Instruc!lons. An excessively
between3.7 and 3.5 volts or an accelerator ohmic input high~lngcouM~damegetocontrolcrystem
between 6K and 4.7K ohms is provided. or tmctlon motor.
Range 5%tol5%ontime FUNCllON 6 IA DROP OUT CURRENT .

set oto255 (Push6)
Resolutbn .03% per set unit
ThiifunctbnaibwsfortheadjWnentofthelAcontac-
Example: Setting of 20 = 5.6% on time tordropoutcurrent.ThelAcontactorwiUbedropped
out and thevehicle motortorque will be lied to SCR
FUNCTtON 3 CONTROLLED ACCELERATION currentlimitwhenthesetdropoutcurrentisreached.
AND IA TIME
(Push3) RaW 450 to 1250 amps (EVIOO)
575 to 1890 amps (Ev200)
This function allows for the adjustment of the rate of Set Oto250
timeittakesforthecontroltoaccelerateto96?6applii Resolution 3.24 amps per set unit (EVI 00)
battery voltage to the motor on hard acceleration. The 4.35 amps per set unit(EWOO)
1A contactor will automatbaUy cbse .2 seconds after
the controlled acceleration stops and the accelerator Settings above 250 set units will disable IA drop out
input is less than 5 volts or less than 50 ohms. functbn( 1AwiUnotdropout).
Range .l to22.oseconds &ample Setting of 20 - 515 amps (EVIOO)

Set 0 to 255
Resolution .034secohdspersetuhit FUNC’TlON 7 PA4 INPUT SWITCH FUNCTlON
SELECllON
Example: Settingof2O=l&econdsC/A (_I)
and201Atime.
ThiifunctbnelbwsiorthesekctbnofPA4input
FUNCTION 4 CURRENT LIMIT fun&n. The PA4 ir+ can be adjjsted to operate in
(P-l4) eitherofthekaowingmodesz
This function allows for the adjustment of the current 1) To activate a speed limit if a normally cbsed switch
limit of the control. The rating of the control will deter- is opened between PA4 and negitiie.
mine the range of adjustment for this function. Please
referto the operating instructionaforthe C0fltfOi Used in 2) To reverse the dire&on of the in-board motor and
yourvehicle. activateaweedlimitifanofmaUvopenswitchis
cbwd behkn PA4 and negitik.
Range seecontmi
CR cunms
Set OtO255 Set 128orgreatertoselectopitbnl above.
Set dealers
Intended for CLARK O-127toseiectoptbn2above.
only
Do
SM546not sell or distribute
19-l 4-6
EVl69 EV296 EVlW EV2m
FUNCTION11 SPEED LlMD=1 (PA6 OR PA6) 7 11.44
VD 07.63
VD Se$tg 01.34
VD 00.89
VD
(Pushll)
3 07.60 06.07 18 01.27 00.85
4 06.72 03.81 19 01.20 al.80
This functionallows forthe adjustmentof the speed limit
( maximumbattery volts to the motor ) when the Ll or f 04.67
03.81 03.06
0264 20 01.14
01.09 00.78
00.73
Rl limit switch input signal is received by the control 7 @.27 02.18 ii 01.04 00.69
card. Ll or Rl limit switch is a normallyclosed switch 8 02% 01.91 23 00.99 00.66
connected to battery negative, the switch opening 9 02.64 01.69 24 00.95 00.63
10 02.28 01.62 26 00.91 00.61
enables speed limit.
11 0208 01.39 26 00.66 00.69
12 01.90 01.27 27 00.86 00.67
Range 96% to 0% battery vofts
13 01.76 01.17 28 00.82 00.66
Set Oto180 14 01.63 01.08 29 00.79 00.63
15 01.62 01.01 30 00.76 00.51
Settingof 0 set unitswilldisablespeedlimitfunctionand __ '16 .01.43 00.85 31 00.74 00.49
allow top speed with no limit switch connected.
FUNCTION 15 BATTERY VOLTS
(Push15)
FUNCTION12 SPEED LIMIT 2 (PA4) Thii function allowsforthe adjustmentof voltagerange

(Push12) forwnttolsequippedwiththeBattery Dischargelndica-
tion function. In order for the BDI to operate property,
Sameas Function11 except using I2 or R2 limit switch the setting as shown in the table must be entered.
for input. See function 7 for switch operation.
Battwyvotts set units
FUNCTION13 SPEED LlMfT 3
(Push13) 24 volts Between 0and31
36 volts Between32 and 44
This speed limit is activatedby the Truck Management 48 volts Between45 and 69
Module fault codes 90 and 93. See instructions for 72 volts Between 70 and 80
IC3646TMMlA Truck ManagementModulefor details. 84 volts Between 81 and 183
38/48 volts Between184and250
FUNCTION14 INTERNAL RESISTANCE No BDI Between 251 and 285
COMPENSATION
(Push14)
This function is used when the Battery Discharge

lndiitor is present. Adjustment of this function will
improvethe accuracy of the BDI. In order to made thii
setting the voltage drop of the battery under bad must
first be determined by fofbwing the steps Wed beiow. FUNGTlON 16 PEDAL POSITION PLUG
(PushCONTandl)
1.Loadthetractionmotorto100anpsin1Aand
record the voftage (Vo) at the SCR positiie and Thii function wilf albw the adjustment of the pedal
negative power terminal. position plug range. Pedal position will reduce the
Z.Loadthetraction~~to200ampsinlAand pluggingarrrent~oecurrentvakresetbythisfunction
record the vottage (VL) at the SCR positive and as the accelerator is returned to the creep speed
negative powerterminal. position. Maximum plug current is obtained with the
3. Calculate voltage drop (Vo) as follows: accelerator in the top speed position.
vo=vo-VL
4. Use the table bebw to determinethe setting using 100 to 930 amps (R/l 00)
Range
the calculated VOas a reference. 150 to 1426 amps (EV200)
Set Oto265
ReWMbIl 3.2 amps per set unit (EVIOO)
5.0 amps per set unit (EV2clO)
fianpfe Settingof20-164amps
IntendedSM848
19-14-7
To disable the pedal position plug function, adjust the Pick up on seat swftchcbsun and time delay drop
current value to the same current value as the plug out on seat switch opening.
distance current.
Range 1.5 to 65 seconds
Example: If plug distance current Function 5 is set at Setting Between 0 and 128
500 amps, then set pedal plug current at 500 amps. Resolution 5 seconds per set unit
With this setting pedal position will have no effect on
pluggingdistance. Example: Setting of 20 - 10.5 seconds
FUNCTION 17 CARD TYPE SELECTlON Pick up on directional switch closure and drop out
( Push CONT and 2 ) time delay on directional switch opening.
This function allows for the selection of the card type Range .5 to 63 seconds
used for your vehicle’s application. The table below Setting 129to255
shows the setting_to.select .card appkation type de_ . ResoWon-.. .5secondsper3et .unit
pending on which control card is used.
Example: Setting of 149 - 10.5 seconds
Evloo Standard
Function with PW ~Dropoutwiilbe 1.5 secondsafterthe seat switch opens.
STD CR 0 to 4
Hiih CR 5to9
STD C/L
(Auto plug) 1oto14
High C/t
Wo plug) 15to19
Ev200 Standard
Function with FW
STD C/L 20 to 24
STD C/L
Muto plug) 30 to 34
Settings for these function should be made in between

the values shown.
Warning: These settings must bs changed by au-

thorksd personnel only, folbwing instructlons
suppliedby the ma-. cardtypsaebctbn
must be made wfthbr the capabllftiss oi the SCR
control panel ussd and the supporting elect~b
ChanicaldeviceaF~totocomplywnhptoper
applicationstandards could result In mlsoperatlon
or damage to the control and/or motors.
FUNCTION 18 STEER PUMP TIME DELAY

(PurhCOMand3)
This function allows for the selection of steer pump

contactor pick up input, either seat switchor directional
switch closing and adjjstment of the timedelayforthe
contactordropout.
SM548
Intended 19-14-8
DESCRIPTIONOF FUNCTION NUMBERS FOR:
Control Card IC3645EVLXCDlPX FUNCTION11 SPEED UMIT 1 (SLl)
(Pushll)
FUNCTION 1 STORED FAULT CODE
( Push 1) This functionallowsforthe adjustmentof the speed limit
( maximumbattery votts to the motor ) when the SLl
Thisfunction registercontains the last status code that limit switch input signal is receivedby the control card.
shut down vehicle operation ( PMT type fault that is SLl limit switch is a normallyopen switchconnectedto
reset by cycling the key switch ) . This statuscode will batterynegative,the switchclosingenablesspeedlimit.
be over writteneach time a new fault occurs and can be
cleared from memoryby adjusting the value to zero. Range 0% to 100% battery volts
Set 0 to 255
FUNCTtON2 INTERNAL RESISTANCE ResoWon .375 volts per set unit
COMPENSATIONSTART Example Setting of 50-l 6.75 vofts
(Push2)
This function allows for the adjustment of the current FUNCTION 12 SPEED UMIT 2 (SL2)
level at which the internal resistance compensation (Push12)
feature (Function 16) will take effect.
Same as Function 11 except using St.2 limit switch for
Range 0 to 1325 amps input.
Set 52 to 255
Resolution 6.5 ampsper set unit FUNCTION13 SPEED LIMIT3 (SL3) .
(Push13)
Example: Setting of 72 - 130 ampa
Same as Function 11 except using SL3 limit switch for
FUNCTtON3 CONTROLLED ACCELERATlON input.
AND 1A TIME
(Push3) FUNCTtON14 SPEED LIMIT 4 (SL4)
(Push14)
This function allows for the adjustment of the rate of
time it takes forthe controlto accelerateto 96% applied Same as Function11 except using SL4 limit switch for
battery voltage to the motor on hard acceleration.The input.
1A contactor will automaticallyclose .2 seconds after
the controlled acceleration stops and the accelerator
input is less than .5 volts or less than 56 ohms.
Range .l to 5.5 seconds

Set oto255
Resolution .021seconds per set unit
FUNCTION16 INTERNAL RESISTANCE
Example: Settttof2fI-.52aecondaC/A COMPENSATION
and 72 seconds 1Atime. (PushCONTand1)
FUNCTION4 CURRENT LIMIT Thisfunctionis usedto stab&e pump speed at heavy

(-4) loads. This functton is set using information obtained
from the speed torque curve of the motor used. See
This function allows for the ad@hnent of the current OEM service manual for your vehicle for this setting.
limit of the contrd. The rating of the contrd wifl deter-
mine the range of adjustmentfor thii function. Please INTERNAL RESISTANCE COMPENSATION
referto theoperating instructionsforthe control used in TABLE
your vehicle.
VfWPW VOW. Dmp
Range see control CR curves “2”o
3
11.44
07.60
01.34
01.27
Set oto255
4 05.72 01.20
5 04.67 01.14
Example: 0 - min. current, 255 = max. current 03.31 01.03
s 03.27 01.04
Copyrighted Material3 0236 00.98
Intended for CLARK
SK48 dealers only
19-14-9
-m VN Dlop VN Drop
0 00.96
10 it: E 00.91
11
12
13
02.08
01.30
01.73
z
2s
00.33
00.35
00.32
14 01.63 29 00.79
15 01.52 30 00.73
16 01.43 31 00.74
FUNCTION 17 CARD TYPE SELECTlON

(PushCONTand2)
This function allows for the selection of the card type

used for your vehicle’s appliiion. The
. .
table below
shows the .setting tmel tJfpade.-.
pending on which control card is used.
With Pump Wtthout Pump

Function Ctr/PMT Ctr/PMT
STD C/L 0 to 8 38to44

High C/L 91017 45to53
STD C/L
BDI (Lockout) 18to28 54to82
Hiih C/L
BDI (Lockout) 27 to 35 83 to 71
BDILockoutmeansthattheBDIsignalfromthetraction
control must be present inorderforthe pumpcontrolto
operate. This control will stop operation when the
battery state of charge reaches 10%.
Settingsforthese functionsshould be made inbetween

.the values shown.
wmnlng:TheseBettlng~bedmgalby~
personnelonly, following ln8tructionsauppkd by
the manufacturer. Card type 8ebcUon mu8t be
made within the capabllltlw of tha SCR control
panel used and the auppottlngmkal
de&es. Failure to comply with proper appllcatlon
standards could rwult &I mlsopemtkn or damage
to the control and/or matan.
Copyrighted
SM548 Material
19-14-l 0
EVIOO LXT CONTROL PANEL
GROUP 19
STATUS CODE ’ DESCRPTION MEMORY No
RECALL
BLANK NodisplaymDashDisp~ycirHmdsa
DISPLAY
--lFrG--
SYMITOM
Disp$y screen on dash display OTbat&et is blank
POSSIBLE CAUSE
,i.
78
Positive ot negative conml volt5 missing.
lw
- rnsutcthatwith key switch0%voltage is pmetlt be
twmn Pi7 and PZ3 (NEG). and voltage is p==t
bsvozn TB4 and PZ3 (NEG).
3pcn ckuit bctwcul logic cad plug “y” and Dash Display or
krandscr
- alcckfumpcncimlitorlcQsccoancctionsbaween
each wire going be- logic card plug “Y” ami Da&
, Disphy/~Hanctsct FigurcL
3&ctivcDailDisplay/Handsct
- RcplaceDashDisplay/Handsu STATUS INDICATION CRITERIA
STATUS CODE 1 DESCRIPTION MEMORY No

Noscatswitchiqu~ REXALL
-Of I Imm I Tradcm
SYMPTOM
FOlWXdOfrevast amtactcuwinnazpickup.
POSSIBLE CAUSE
Mis-adjusedadcfaxivc fQt rwirriL
* c&dLsatswitchmilnmplcipudo8ut8.
Still548
Intended 19-15-2
STATUS CODE DESCRIPnON MEMORY No
Forwarddimiodswirchisclosedoninitialpowaup. REXXLL
-02 CIRCUIT TlWtioll
SYMPTOM
Fomard contactor will not pick up static return to off (SRO) lock
SWITCH
mu. ACCEi
IF
START
USED
h 4 SWlTCif
POSSIBLE CAUSE TB4
b 2
TB3
Forward directional switch closed on initial power up (closure of i
battery plug, key switch or scat switch).
. Return dircaional switch lever to neutral and then select
a direction.
FvfD
Fmvard directional switch is welded closed or m&adjusted to he
held clod
TBS
* Rcpiacemadjustdin!Yxionals~tchtoins~~ic. .-
opens when dkdonal switch is mumal to ncutml.
Figure L
Short circuit hecwecn TB2 and TBS.
. DlsumWxwiIcfmmTB5andc~forshm~
*
hctwcenTB2aridwhc. !3TATUS INDICATION CRITERIA
ThiSSQKUSCOdCWillkdiSphpdWhUlTB5isgreaerthan
kfective cd 6o%hataryvoltsatinitialpowaup.
* DisamncctwircatTBs;~voltagcatTB5,
shouldtJclcssthan60960fhatruyvolts.
STATUS CODE DESCRIPTION

Rcwmcdilwiodswitchisclased MEMORY
RECALL
No
I
03 CmCm Traction
SYMPTOM
Revnrccoriaccwillnotpickupspric-moff(SRO)lock SWITCH
3x.
l
TB4
TB2
lB6
Do not sell or19-15-3
SM548 distribute
DESCRIPTION MEMORY ym
STATUS CODE RECALL
Swswitchiqmbwafmini6dswq
-04 Traction
SmfPTOM
Folwardorlwer!Ruxlw willnot pick-up. --J-zE-G\ ACCEiFRATCfl
START
POSSIBLE CAUSE SWITCH
Folwardorrcvcrscktionalswitchcl&ontiti s*lrtq.
* Depress accclcralDrtoclose start switch. SmlS de
~chqp~~if~vcrscdinxtionalswitchorto(nif
forward directional switch is closed. If eitherof these
~sappear,~&&nalswitchtonedand
rhenscleathcctcsid~tion.
Exassive lenkagc koal TB2 to barnay ne&= r+-

- che&v01mgca,tTB2withkeyandscatstitchesclosed
&~.~.~~V&qpsgorddbe .’ .. -
graltertllan6o%ofbatreyvoltage. FigureL
- Iflcsstim6o%bmuyvoltagc.Removewireand
m~rnt~vd~~wiretoSCRXlCgative.VdUC STATUSINDICATION CRITERIA
ShOUldbelUSthll22kohms. ThismulsccdcisdisplayaiwhulTB2volragcislessthrn
f5o%oftmtexyvoltsatini~sciTt-q(seatstiticlosurt).
DESCRIPTION MEMORY No.

STATUS CODE
SesrtSWitCh~bIbSWiWhEdhtDclosa
RECALL
-05 -CUtT Tmcbn
SM548 19-15-4
STATUS CODE
Afai&mrdepressaiwit!lmdirtcrian~&clu
DE!3CRKPTION MEMORY
RECALL
No
-06 CIRCUIT TEifXiCil
SYMPTOM
6 MRECTKWL
FonvatdorrWcIsccontactorwill not pickup. FCII REV SWlTaiES
b ?
l
POSSIBLE CAUSE m
Accehator pedal is depressed before closing forwardor IVJ~ 0
Tm
dimxional switch.
. Statuscc& will disappearwhendkcciionalswitchis
closedof whenacceleratorpedalis dead.
Defectivedimxionalswitch
* checkfmWudormene switchto insureclo~ure
whendirectionis sclccted.
@en circuitbctraendire&o& swi~h(s)xnd battuypositiveos- HEG

bctwcend&c&d switch(s)andTBSm TB6. lW=L
* cheGkallconuoiwksand amnccria shown ill
FiguTe1.
STATUS INDICATION CRITERIA
ThisstmscodewillbcdisplaycdwbcnTB5andTB6arclcss
than~d~bamery~lts,cvdTBlLlessthan25volu.
STATUS CODE
-inplltvolmgctoohigh.
DESCRIPTION MEMORY
RECALL
No
-07 CIttm Traction
SYMPTOM TBI
bwardor rcvcr3ccontactcxpicksupbutamtrolwillnatopenoe
whenatxeiuatapablisdqawsdasmttucodeMisdisplayai
hendisappmwhcnrhcvchidesrpato-
POSIBLE CAUSE
4cceluataiqmt&djnseda&fadvs
* r4nxtvolmgcuTB1simldbolcuthm3.7vola.
Adjusta@ rcalamrlmittoiasmcthsthb
voltaspuTBlwiuv8rykfll35vobtohrthM5
voltswlwltbpaWicckprud
$ICllcirccritbCtWCUl~~VCdTBlinrcelentrrinpm NEG
5rcuiL
- ~fabmkaiwimaalooaeammdonsaapcn FiopeL
potmimem/voltagcsppplyinthc~shownin
Figm 1.
STATUS INDICATION -
%artcimitfKmlbamrypoaitivetowiIingin-inppt
- niasmtMal&winbedisp&dwbmtboaadlamriItpat
volmgcuTB1ishighathm3.7voluaxirdimiod
. *
Dlsamzm wimfmmTBldm-volrageuwirc axmcmispichdup.
tomgahvcSlmuldbczfovdufapaantianwtypc
andlusthau3.7voltafll!rsdidstalctypc~
inI=
SW48 distribute
STATUS CODE
Accehaxinpmvoitagemolowollpowcrupa
DESCRIPTION MEMORY
RECALL No
-08 switchdome. ,
CIRCUIT Traceou
SYMPTOM
Forwad mrcvcrsc contwor doa not pick up.
POSSIBLE CAUSE
Aaxiaator input mis-adjusted (T defective. ACCELERATOR
- Input voltage at TBl should be mote than 3.0 volts.
Adjust or replace acx&ramunitttliIlsurcthatthc
voltage at TB 1 is mQe than 3.0 volts before dqessing 1
K-l
Shcrtcimitbctwcenbatmync~vcandTBlinaccd~input 4
cimlit. NEG
. -
DUcomwtwirefromTsT;checkfarshon~6iom
witeoobattctyncgativcRc&anccshouldkgrerm nrprcI.
than 4.7K ohms.
DcfaxivccaId STATUSINDICATION CRITERIA
. DucoMectWkhXflTB1.MeasllrtVOl~fromTBl
* nisstamscodcwinbcdispl8yaiwhen thealxehax~
toIlcgativc.v01tagcshouldbcgxeamrthan43volft voltageatTB1islustllaa3.0volt%adany0fthcfolloeg
ifnosn@acccaxd anlnwhsrreapeaodaadclocdbumyplllgorsertswitdl
aakCySWitCh.
STATUS CODE
BothfMmdandrcversc-~hedrrrsclossdutb
DESCRIPTION MEMORY
RECALL
No
-09 sunctime.
SM546
Do not sell19-16-6
or distribute
STATUS CODE DESCRIPTION MEMORY No
RECALL
-15
Baany volts too low.
CIRCulT TraEtian
BATT
7 SYMPTOM CONN
+rward orrwcr3c mntactur will not pick up.
+
POSSIBLE CAUSE _t pq
Dischargedbattery BATTERY +
. Check battery fur proper open circuit voltage a~ outlined NOMINAL MINIMUM
infigml andchargebamyifrequircd BATTERY LlMiT VOLTS
VOLTS Q 1.95
Defective battery T-
BATT 24 23.4
. Checkeach baamy all for proper voltage (gnam than
CONN 36 35.1
1.95 volt? at cdl). Replace or repair barmy.
48 46.8
72 70.2
bcomct wmrol card adjustment
t 84 81.9
. Checkfunction 15 fur pmpcr adjustment for battcty
being used. See handset inmmion sheet for derails. Figurel.
Adjust u) proper settings.

Thisstatnscadcis&playedwhcnthebaUuyvolt3azeless
than1.%voltipcrcellatinitialmrtup.(scctablcin
figrrrt 1).
STATUS CODE
Balmyvolatootigll. DESCRIPTION MEMORY
RECALL
No
-16 TraEeioo
SYMPTOM .
Forwardandrevcrscc~ willnacpickq.
gjjy
PO!#IBLE CAUSE
W
IIlc0XIWtcOllUOlC3ldadjpstmmt +
* chcckfurrriar1sfcrpropcrldjllsmpemforbatiuy
Do not sell or
SM548 5-7
distribute
19-l
STAWS CODE DESCRIPTION MEMORY No
IavaAidcxrdtypeselectioa, RECALL
-17 CIRCurr TIXtiQl

.
SYMPTOM
Forwaid
orrevuscontactma
willnotchc.
POSSIBLE CAUSE
InvaMcardtypereleclioIL
* Rwiew flmction 17 in the Handset Insuuction sheets.
Adjustandsctcardtypcvai~~insaucoedbyOEM
service mamud
STATUSINDICATIONCRITERU
TlliSspmsCOdCiSdiSph)dWllCZlthCCXdtypeSCldUl
valneissertoaninvdidnumbcr.
Fcmvardarcvase-
coilcmcntlow.
STATUS CODE DESCRIPTION MEMORY
‘No
RECALL
I
23 CIRm Trmioll
!WMPTOM
FarwaniOrnvaSe caneEonWilIIlOtpiCkRpSpmrCOdC~
lltlslatcbctwecnaxle23and&24.~cbeckfaaYcb +
23,ifthcproblemisnotfolI&pcrfamc&ckfaaldo24.
- Remowp~B.Cbsekabmicvdmha1PB4oopod
tivesi&ofFcoiI.VduodmaHbal(F14dims.MJs
samcchkfaRalil.
FilarrL
IDcfcfkvc IA, RB, SP,aFWamtxxrad.
- RcmuveplngB.t3eckobmicvdnehnnpo&ivoside
OfdlCOiltOiIS~phlgcomrscdoaV~ STATUSINDICATION CRlTERu
shoddbc1614ohu. l%iSspmrCOdBiSdiSp&?dWhUlthBClSZUttQlWinthO
famda-amamx coir&l+tirkS8dU100~
-. for CLARK dealers only
Intended
SM548 19-158
DESCRIPTION
STATUS CODE
‘I-2
voltage
too
high.
(circacr
than 12% of batmryvolts).
MEMORY
RECALL
No
-24 mCul”l- Traction
SYMPTOM n
SCR cona-oidoes not operate.Statuscode may alterrue between
code 23 andcode 24. Completechecksfor 24, if theproblemis not F R
found,pcrfotmcode 23 check. 51 fZ t t
mul i
0 l
POSSIBLE CAUSE 6 Ic i
*1 I R
DefectiveF or R contactor. W4
l
I* .
. ForRpowcrtipsfailtoclosebecause: _W l
1) w&lai normallyclosedpowertips. *t .
wz
2) Bindingconmctortip assembly. F~ R fgiii!d~
3)DefcctivcForRctorcoiL 42 : ’
(s&staaucode23)
*
Dcmve Rwzoa~ --
* chcckRBcontactorpowertipsforclosureandprupcr F%glUtL
pick up.
* chcckforopcncircuitcrloosecomlcctionsbctwcul
positiveside of RB con- coil andPB2. STATUS INDICATION CRITERIA
ThisstatuscodcisdisplayedwhcnT2voltsisgnucrtban
Openmotorcircuit 12%ofbateryvoltsandthcFandRd1iverisencqizd.
- Checkforopencircuitorloosccomzctiuninmoar
cinxit&omthcAl comWdontotbeA2coMec&non
theSCR connol panel.
DefectivelW,SP or Fw ConW
f Pufomcimksas-illsmpr23.
DESCRIPTION MEMORY y#
STATUS CODE
1AamtacmrQesnotdropoutardropaocUskly. RECALL
-25 ClRCurr Traction
P
SYMPTOM
ih~tiplifeonFandRorlAcontlrtn.Stamscode46displayed
mdno faultfound
POSSIBLE CAUSE
Yoe:Thisstatluc&canallybcfoundbyusingtheh8ndW=d -I--
1A
ookingatfuncdonl.T&issmuucodcisfoatWcdaaatnm-
kshoolingaidfarsmmscodc46
Muxive lA- T2
* CbccklArrrmym forbindingaslowaperrrdoawhcn
droppias-
T
nsm,L

Tbissmmscodek~wbu11Aatamctudmpouttime
exceds.msecondr
SM548
distribute
STATUS CODE DESCRIPTION MEMORY yes
shmalcoildIivuforRB,sPmlWamacm. RECALL
-26 mm Trwtim
SYMPTOM
RB,
SP ,,r nv contactm picas up immay when J=Ywi=h is I ’ ’
:loscd.
POSSIBLE CAUSE
Defective coil driver imcmal to logic card.
* Replace logic cad.
PB6 l
PB2 l
STATUS INDICATION CRlTERIA

TitisstamscodcisdisplayedwhcntbercisashcmdRB,SP
oaFwcoildrivcr.
opcnthcmld~arcutuoiovera
DESCRIPTION MEMORY No
STATUS CODE
RECALL
-41
Deflxtivethum8lpmmalx.
. DlSCQUWWifUfbllFZ1rrdpzs.A!IUXlempar
*
tmc(29Ca7YF)mmm8rui8mmbawaabtck
andgnywirt.RcpkeTPifotlmkvdIJaisgleatcxthim
3ooohu.
SM548
Do not sell 19-15-10
or distribute
No
SCRmooxcum5ntscnsoritqmtmissing. RECALL
-42 CIRCUlT Traction
SYMPTOM
Nopowcrtoaa&nmotorinSCFtrangc.
POSSIBLE CAUSE
opsensorwin:circlittoFz4. I
. check for lcesc collncction or broken wire (green wilt) l ?Z4
from culTem sensor to PZA on the logic cad.
1
NEG

This sraau code is displayedwhen voltage bcnvan PY7
and negative is greater than 1.6 volts with no cumnt flow:
ing in the moux cizcuir.

SCRmotcccmxcntsenairpttmhing. RECALL
1
-43 am Traction
SYMPTOM
StdlcurrcnuiaScRrangehighL7thannanulawlwlcontrollabla
withCn adjustment A2
POSSIBLE CAUSE 0 -
DpcnsensorwitecitaittopP. SCR
CURRENT 0 - PZ3
- chcckfalooec- abmkenw%eQellow
Will2)hllCUUUltsaWtOpPaOiOgiCd
NEG
STATUSINDICATION -
l%ssatllscod8isdisphycdwknvolmgcbawaxlPY7
aldncg8tiveisleuthut.84voltswi$lnoclmtatflowing
inmaaacircttk
DESCRIPIlON MEMORY y_
STATUS CODE
IREC did not mm off propdy. RECALL
r
=44 mm Tractioa
SYMPTOM
Fonvxdarrcnnecon-opcaandd-v~-o~Y~
closedby openingaad closingthe key switch.
POSSIBLE CAUSE
Dcfaxive 5 REC circuit.
* Chcckforshorled5REc.
- check for shoted 5 REC snubber(25 RX).
DcfaMJe2REcckcuiL
- Checkforshoncd2REc.
* chcckf4xshgaed2REG~~~’
fiw=L
Openchoke(lx).
. ChcckftxopcncitcuitbctwccaT5 andT3.Ohmmetcr
shouldredzaoolmw. STATUSINDICATION tDWI’ERIA
1 REC d&ctivc.
. Turnofftimcfa1RECoutofspa%nthNofidd nissmtuSco&isdiSplaycdwhctLdmingsCRopcmt+
tcstispossiblc.Rcphcc1RECafm-checks,rhow 1REcfdstomtnofE
noprobiemfouod
STATUS CODE DESCRIPTION MEMORY y#

1REcdifiaamnlarpKl@y. RECALL
r
-45 mm Tracrion
P
SYMPTOM
Forwardarlwene contacttxwill~aadcloa,thcaapmd
thencaaodybeclosalbycqeahgdcloeiIlgtbulay~
POS!SlBLE CAUSE
D&cfivc2REccircuiL
- chskfarshaed2RBC
* checkfa&lxmd2RECinmbba(22REC).
DCfUSiWlRECciIUtiL
- CllefAfccfJpmc.itcdar~colmscrionrbctwcuI1
REc8adpza(vvbiwbh~)
2ZREC
- CkkfaopcnL5Imlitarlotl6e-bewen1*
piopI1.
REc(3REcsmlbber)mdPz9.(bltlewire)
DZfWliVClREC!. STATUSINJXCATIONCIWERIA
Iw *. taapm1RECgmeAeJdtutm8yamay ThirSmmscadeiSd&&ycdlhen1RECfd8togaleoo.
aotshuwdcfaxRqhce1REcrfmabovecbeck&
showaoproblemfaund.
Stvl548
Do 19-1112
not sell or distribute
Loolr~oestfar’Izvoltt.(Gream~85%ofbarmyvolo) RECALL
-46 a- Traction
!3YMPTOM .
ForwardCnICVCXSCconlactcu will not pick up.
4)
POSSIBLE CAUSE
DcfBxive1 REC.
. Check for shorted 1 REX.
1A -=
0 c
. check for dcfaxivc 1 REC insulator (co-therm) that
may short 1 REC heat sink to base plate. 0 c
Defective IA contacto~ 7’2

* (Ihedcfor~weMed~1A~~~
Ql-1.
STATUS INDICATION CRITEFUA

ThisstamcodeisdisplaycdwhulthevolragcarT2ir
greamrthan85%ofbattuyvohs.

2REcdclcsmtDnnalpqJdy. RECALL
I
47 CIRCUIT TlXtiOll
aIs4
SYMPTOM
Fulwardor
ICWSCCUiltXXIXWiUOpCIlddo&,tkSlOpClld @au@*- @
(0866 0 ‘mc
fhencanonlykckxcdbyopelitlgaadcloringthckeyswitch
U-
7 ZIG
9!!i!q- 6 ]
P0SSIBI.S CAUSE Pm
Dcfa3ivc2REcciImit
- Chccktimt2REcwillgamaL
* Checkforupca~aloorsrmnrr?rinnbctwcea2 1
REcgam8edPzlo.(whiw&dwire)
* Chcckfuopalcimlitalawecaarr;ctiao1REc8nd m
ICthmlghthe2REcc
F@=L
ForRcontactccqowutipsbomcingapca.
- C&cktfutpo~~tipa~PaadRcooac~~ ’
QrlotbOwseopndmingapartom(&mZ STATUS INDICATION CRITERU
speedbmnpr-daw-). nlissamsccdcisdisplapdwhm~2REcfailamtmn
on.
SM548 19-15-13
DESCRIPTION MEMORY
STATUS CODE No
RECALL
Lookakadtcstfolrzvoiu(lesstban12%t0nuyvolts).
m
48 CIRCUIT T&On
SYMPTOM
Forward
orrcvcrsc
contactor
willnot pick Up.
POSSIBLE CAUSE
Dcfcctive folward or rcvcrsc c0Iltactor.
. Check for welded forward or ~crse COUtaCtOrpOWa
tips.
* check for sluggish opcrafioIlof forward or rcvcrsc

comacwr.
Defective 3 REC circuit. .

. chazkforshcctd3REc.
Figure 1.
- Checkfor shti 3 REC snubber (23 REQ.
STATUSINDICATIONCRITERIA
Thisstamsaldeisdispla~when~volrageat12isless
than 12% of battuy vola
DESCRIPTION MEMORY yes

STATUS CODE
5REcdocsDottumalpropcdy.
RJXXLL
-49 CIRCUIT Tnxtion
PO!WBLE CAUSE
Dcfectivc 5 REC ckcuit
* Checkfarshcmd5REC.
* clla&forqKatzhcuizcrloosscaurocrion-5
REC gale ami Fz12 (whiwkiolct wire).
m=t
Shurtcd2RECcircd
* Ch&2REcand2FtECsmb&r(22RE~forshcxt
cimd SIATUS INDICATION CYWERIA
Thisst8mcaleisdia@ycdwbeatbe5mC6Icrlit~.m
Dcfet.ivclzsqmci~cbcuiT. mnm.
* chcckforopulcaprcioca.
SM548 19-15-14
capcim
volt3
low. DESCRIPTION MEMORY
I
STATUS CODE NO
I50
RECALL
CIRCUIT TXtiOtl
UsA
SYMPTOM
Fonvarcimnversc coIltacmpicksup. Gxltrol does not operate. @@w9*- 69
@Q6Q 0 lREc
WSB- RD*rt
POSSIBLE CAUSE
Defective 2 REC circuit URE
,. q Q 2-c
,
open circuit or loose colltlcclion between spider
PZIC
assembly and 5 REC (BUS A).
opcllcircuitar1ooscconnectionbcnvccn5RECand
2 REC. I
open&zircuitor1oosecoMeclionbaween2REcaad ,C
I-
PZ11(raiwire)andbetween2REC~andPZlO 1 .2&c
(whit4red wile).
ml-1.
Chak2RECtoinsurethatitwillgatcon.

nisstatuscodcisdisplayedwberr2REc~failto
mrnonatinitialsmrtup.

RECALL4
51
EXCCSSiVCCi3pCitIXVOlt8gCWbCllmotracmrenti.lhi~
.
I
CIRCulT Tlaceal
SYMPTOM
Fowatdorrcvcrsccontacwapenandclosc,tbcncauonlybc
closcdbyopulingandclosingthekeyswioch.
PO!B’XBLE CAUSE
Excusivcsourceinrlwrrr
+ Taglimwihmt~~beingwd.
* Bauuycabiarrslmlal~
Higbpc&cmcntinlwtlr.
- checkflxskclcdfiold~
* chcckfilrsholtcd8Tmuln8~
m-r.
SIATUS INDICATION CWIERIA

mstmucdoisdi@~whmllzqmlcb~ucoDd
23volprndmoaralzcca!L~lhtn3oormpr.
sM54a 19-l 5-i 5
EXCC3SiVC~VOl~WhUIUlOtaClXUCUtiSiOW.
RECALL
-52 I
SYMPTOM
5nwaxdormmsccon~openaadclose,ti~~~ybe
:losai by opening and dosing the key switch.
POSSIBLE CAUSE
tiassive sour inductana.
. TaglineswithoutfiltPsarcbcingusai
- Baauy cables arc too long.
rkfcctive 4 REC CinxliL

* chcckforshoraed4REc.
- checkforopencimtitcrloc6eco, zlnmionill4REc
circuit.
kfcctive 3 REC circpit

* ch~fooopalcitcnitorloosecanntctianin3REc STATUSINDICATION CRITEIUA
circuit. Iisstamsankisdisplaycdwhalczapdmrvoltacxca!d
2svoltsandmottx-tislusthanmam~

RECALL
lREcfailstoarmoffdnchgplt@tgcyclt.
-53 CIitm Tractian
Intended for CLARK
SM546 dealers only
19-15-16
ShadF.~a1Actnmcaxcoildrivcr. RECALL
-54 CIRCUIT -haxioa
SYMPTOM
zmurcd
willnotoperate.
POSSIBLE CAUSE
Defectivelogic card.
F&placelogic cad

lIissatuscodeisdisplayedwhcneithcrthcfonvant
xevaseor1Acontnnorcoildrivuisshonedintanaltothc
logiccard.
DESCRIPTION MEMORY y#
STATUS CODE
clarcntsulsoroutpmvolagc~~c L
RJXALL
-57 CIRCUlT TEilXiOIl
STATUS INDICATION CRITERW

nisstm8cdokdi@aycdwhahtbvolqpiIlpcmPZ4
audPz3isthewralgp&dly.
SM548
Do not sell19-15-17
or distribute
STATUS CODE
RCgUlCUUClXSUlSXiIlpUtm RECALL
I
70 CIRCUIT Trdat
SYMlpM
culuolQesnot.operaa~ POS SENSOR 2
POSSIBLE CAUSE
Ddectivcregal sensorinput citcuit.
* chc&yellowscnsrawirefcRopcncircuitorloose
connncction between scmur (welded coMcction~ ad 7 REC
PA4
STATUS DlDICATION CRITERIA

Thisstamcodcisdisphycdwkt1inputsignalatPA4is
missing.

RqcnclmntscnxYinpttt~(grtenwht). RFdCALL
I
71 CIRCUIT Tractiat
POS SENSOR 2
It ?I
YEL GRN
PA& bP*5
v
STATUS INDICATION C
TItiSspnuCOdCiSdiSphyl!4-lWhCttillpUtSigUdUPASi3
txlisshg
..__-.-
SM548
distribute
STATUS CODE
Regulcontacalrdasnotpickup. REXALL
-72 CIRCUIT TtXtioll
SYMPTOM +
Regen
conaddoesnotopemc.
POSSIBLE CAUSE
h
@Cn COMCCtiOn PA6 C&lit.
in thC
DRIVE
MOTOR F82 PA6
. c&?ck for open circuit or loose COnneCtiOn between PA6
9
and the A2 connection of the RB contactor. A2
17
. chcCkfOrOpen&Cllit~hJSCCOMCCtiOnbCtween~ 0 A
REcandthcA2conncctionofthcRBcotltacaa. - 13%
C0&4CTOR
A2
FisrvcL
STATUS INDICATION CRITEiUA

Thisstaaucodeisdisplayedwhenlogiccardisinrunmade
and2.5volfsargttatcrisprucntatPA6.
_. - - -
DESCRIPTION MEMORY
STATUS CODE
RegCtlWHJICtordOMnotdlUpO RECALL
Yes
-73 CIRCUIT Traction
SYMPTOM
Forward~rCnnecOntWtXopmsandcloses,thUlapauandCm
onlycloscbyopcningandclosittgrbckeyswish.
DRIVE
POSSIBLE CAUSE MOTOR PA6
Defecti~ RB camcta.
A2
. check- amactccfa-dopartiolland l7
exasaivewematmovillgpatu. *
4c
tlucrmittwlt PA6 ingla ” ?!i%KTOR

- cIlcckforlotMe-inPA6cirmaitfromPA6ttl
RBcontEuxAZc A2
B
W-1.
STATUS INDICATION CIWXRIA

Tbissmmslzo&isdisplayedwbenthcRBcammaccpower
tipSfhltOOpCttdtl!Z100tIhUWX&8ftCCpowair~
movcdfromtiBRBamrroacoit
DESCRIPTION ’ MlBfORY yes
STATUS CODE
Rcgcncon~pi~upmslow. RECALL
II
74 -CUI’I Tracrion
SYMF’TOM +
ForWdCatWCtSC contm%x opens anti closa thal opens and call &.
oaly close by o@llg and closing the key switch.
DRIVE &
POSSIBLECAUSE MOT6R PB2 PA6
Defective RB comactor.
* chcckRBclmacmforsm00rhn~0foperationand A2
17
excessive war on moving part%
4c A
Intcn.TJi~t PA6 inplx - RB C$.4;4CTOR

* Chazkforlooscconwxds inPA6circuitfromPA6m
RBCOll~A2COlUWth A2
Defeceve RR-amtactor coili- +

* ChazkRBcomactordfbrpropaohmicvalue.It
W-1.
should be 10-14 ohms.
- clleckcail- &omPB2toRBcoil(-jforloosc STATUS INDICATION CRITERIA

ccnuladons. ThiSStltllSCO&iSdiSphJ%dWhCIithCRBCUl~powa
tipsdonotclOscwitbia1oomiuiwodaftcrpowcris
* ckckcoi.l- hbanaypositivemRBd epplied~~~~&_
(+) for loose conwans.
DESCRIPTION MEMORY yes

STATUS CODE
1REcfaiL3totumoffdntiaglcgca.
RECALL4
L
175 am Traction
WS SENSOR 2
!SYMPTOM
blwaxdor meneam~opauaadclorer,tbenopcluaudCan
mlycloscbyopeningaadclaingtbckyswiacb
POSSIBLE CAUSE
lREcmtnofffailuIenotrttosdto~
* sallvchicleillbath-Ildmculystrmrcodw
displ8yaltbatm8ymoR8clcmlydeenstbshilmemode.
TtDUb&S&OtprnSrSt8tMCOdR
LRECtUUlOffrckosdtOrsgse 0
* ckkfabors- akdlrgmpmlm~ -RB cgml
halbawypodivomRB-Azcooasrioa.
* c!kkfaloo88~gntbe~~inpn M
cixcuiu. +
~Ydlowwirefmnseasa2toPA4
.ckenwilekanscnsa2tQPA5. PiolrrrL
~wii17eunRBcaomcuxtDPA6.
mAm INDICATION tXW%RlA
DefectivcmuKrdrcoit Tbi#Smxuc&iSdi@yedwllalalyf8ihm3af1REcto
. Checkmoaxciadtftrapmalawamsuias
=~dpriruwcyck
- chccklnotfx~far~serring.
ForRammcaxpowexbounciqopa~
- InsurctbatFatdR conmcbxcbesnotbormcs~
dnrhlgld?iclc~(ii~ovsrspsod
bmnprrrddOCk~~-
DoSW548
19-15-20
capaEirorovavoltagcdlningrcgcn.
DESCRIPTION MEMORY’ yes
STATUS CODE
RECALL
I
76 CIRCUIT TlXCtiOLI
SYMITOM
Forward or ICVCISC contactor opens and closes, then opens and can
only close by opening and closing the key switch /I *
FUSE LINE
BAT-r fl CTFI
CONN CAPACITOR
POSSIBLE CAUSE
l
Intmminenr connection in battery power circuit 1 F T
. Check bamy power circuit, both positive and negative e aurw

-
for loose conections.
8.4R
CQNN
. Check power fuse, battery connaxors, line contacxrs, I
and etc. for possible opening during rcgen cycle.

TN,,
Excessive source indwtance.

. chcckforlmfiltzledtaglincs.
. Check for long battery cables. HgurcL

Thisstallscodeis displayed whencxpacitrx
voltage is
grcatuthan22svolndlIxingthcngencyclc.
STATUS CODE
uscrddinaistaalscode-seeoEM RECALL
-90 CIRCUIT TMMl
!WMPTOM
staalsccdeflashcsonandoff.vchiclcspeedmayarmaynotbe
pz%iFJ
1
BATTERY _I
NEGATIVE
- DcfcctivuMn4lcard
FtprcL
NoTE:WbenSCRpump~isusaiwithinmnrlT~~l
fllDClkiDpUtt+Z&WdiSPA3OnprnnplOgiCcard STATUS INDICATION CRITERIA
ThiS~CCJ&kdiSp@3dWhL%t&~8ttUkMl1
dTMMliS8t?XOvalrr.
SM!548 19-15-21
USQd&ixdscamscocle-sccO
RECALL
91
L
I TMMl
SYMPTOM
StfltUSCO&flashesOllandOff.
POS!DLE CAUSE ‘- ;;
f&r defined
satuscodeisdisplayed
byswitch closure to negative. 3
. See OEM insuuction manual for c0mctiVe action
requind
SW3
orhcrcauses:
. Tenninal3shatedtonc@vc.
BATTERY T
. Dcfkctivc iuput swiazh(she). NEGATIVE
. Defoctire:~&s~
Figurel.
NoTE:WhcnSCRpumpcoadisdwithintcd~~
fuucti0ns~inputccImiMlisPA6onthcpumplogiccald
STATUSINDICATION CRITERIA
Thissmalscodcisdisplayalwhentllevollageatlrdd3
OfTMMlisat~VOlU.
UscrddildstamsCOdt-WOEM
RECALL
-92 TMlUl
SYMPTOM
St%llSCOdCfhShSOlldC&
&v
POSSIBLE CAUSE
USad&IlCdSCWCUkisdiSpiryed~SWitChcbrratOI&@iVC 4
* scc0EMiasulmhdbrr cmuxivertiao
lsqpirsd
SW4
otbrcausuz
- Tcnnid4shamdtnmgmiva
BATTERY _I
NEGATIVE
-inpotrwioch(rborsd).
N~WhcnSCRpampcaaadisrwdwithintanalTMMl RonrL
functi~,inppt-isPB6oathc~ca1d.
SIATUS INDICATIONCRITERIA
nissaal8aYdlDisdiqkycdwbmtbvollageummiml4
ofTMMlisatosn,vola
Do!3&48
19-15-22
STATUS CODE
uscrdalalstaalscak-scfoEMills RECALL
-93
SYMPTOM
Stamscode flashes on and off. Vehicle speed may or may not be
POSSIBLE CAUSE
Userdefinedstatuscodeis displayedby switch closure or motor
brush sensor closurt to negadve.
. SeeOEM’ueanmion manual for concctive action
required
3thcrcausex
* Tuminal5ur6shortcdtonc8ativc.
. Defective input switch (shored).

FigurcL
- DcfcctivcTMMlcaxd.
wYIE:when SCR pump control is used with interal TMMl func- STATUS INDICATION CRITERIA
ions,inputtumiaalisPA1andPA2onthepumplogiccard. ThisstatuscodeisdisplaycdwhetIthevokagcat-5
a6ofTMI4llisatzcrovoIa.
STATUS CODE
uscrd&IlaismnlsaYde-seeoEM RECALL
-94 CIRCUXT TMMl
SYMPTOM
statusccldeflashesoaand&
POSSIRLE CAUSE
Usad&ncdstatuscodcisdisplaycdbyswkhclosutcamoax
bmshscnstxclosuretotlcgative.
- sccoEM-maml8lfor camdvedal
reqpirrd
otk(Taulcs
- TenlliMl8ar1oskrEdtotBgntiv8.
* DcfadvcTMMlcatd.
FioaL
NUIE:Wha~SCRpumpaxwlku&withimunaITMMl
funcdw,inputte&ulisPA4aadPASontbcpumplogicatd STATUS INDICATION m
Tl1iss~mr~icdispl@wbattbevoimgcatmminll8
trlOdTM4llLaoaovolQ
Do not sell or
SM548 distribute
19-15-23
uJerdcfinaisQuu¶codt-scc
RECALL
-95 CIRCUIT lMA41
SYMPTOM
StupsCOCkfhk3OlliUldOfE
POSSIBLE CAUSE
u~a defined SEUUScode is displayed by switchclosureor motur
brushsensorciosuIeto negalive.
* sccoEh4 -on manualfor clxraxive a&m
SW12
nq-
otbcrcauses:
. Tumid11or12shortcdtoncgatin.
* Dcfcctivcillputstitch(shorted~.
. .._ .-.
- DdkctivcTMh41cad
W-L
NOTEzWhcnSCRpumpcontrolisuscdwitbintcd~l
lillbau,inputtcHniMlisPB1andPB2ondlcpumplogiccard. STATUS INDICATION CRITERW
TbissmmsaYdeisdisplayaiwhe.nthcvol.lagcat-
11cc12dTMMlisatzaovolu.
STATUS CODE
halidcardtypescibiaa
DESCRIPTION MEMORY
RECALL
No
m
117 CIRCUrr Pump
SYMPTOM
3nttol will not opera@.
POSSIBLE CAUSE
iwalidcaldtypesekcIiaA
* Revicwtilucwl17inthe~Inmpctionskcu
AdjustudxtcktdypevalmuinsaaadbyOEM
xkalumunl
-1.
STATUSINDICATION m
Tbisstanscaleisdirplrysdwhen~cadLypo#Lcrioll
vabai8aetmmilmlidMmlbm.
Intended for CLARK
SM548 dealers
19-l 5-24 only
STATUS CODE DESCRIPTION MEIVORY No
Pump contactor coil cmrult low. RECALL
-123 CIRcUrr Pmnp
SYMFTOM
?ump amtactor will not pick up. Status code may alternate between r
t
:odc 23 and code 24. Complete check for code 23, if the problem is
lot foul& perform check for ccdc 24.
+
POSSIBLE CAUSE 1-t

Icfuxive pump contactor coil circuiL ?A
Q
- Check for open circuit or bow CoMUXiotl between PB4 l
PB4 and positive side of pump comactor coil.
PM l
- Remove plug B. Check ohmic value f%xn PB4 to posi

rive side of pump coiL value should be lo-14 ohms.
Figurct
STATUSINDICATIONCRITERIA
Thisstatusco&isdisplayedwhenthecurrcntdrawinthc
pumpcQntactor~circuitislcssfhan1ooma . .
STATUS CODE
12 DESC~ON MEMORY
RECALL
No
-124
voltage too high. (Greater than 12% d battery volts).
CIRCUIT Pump
T2
SYMPTOM
iCRcontroldounotaperate.S~WdC~yalta7WEktween
~123andcode124.compleoecbccbta1~,iftheproblemis P P
lot folK&pufcamcode 123chaTk.
POSSIBLE CAUSE F +
Dcfaxivcpumpalamazx. R +
* PlmlppOWtip6failtocloeblWLW * m4*
m l
uweldsdoamrlrycbadpawerdps. *Ry;lWE m6. +

2)Bindingcott~cx tip aaaanbly. u s
3)D&&vepnlltpaxlmcmrcoiL 1 m
“iPe2 ‘I.;;
ml
(ssssmmaldel23)
PBl
A2
nolrc1.
Opcnmoax&xiit
* aKckforapaltzimitarloose-in-
citcuit&xnt&Al amaecoimm~A2rmnrrirrral STATUSINDICATIONCRITEXIA
thCSCRCUtUCdpUlI& lItiSsatluCOhiSdiSp&dWhT2VdC3iSgresmlhtl
1246ofhaacryvQIuandtIlopumpdIivcrk~
Dcfazdvc 1A contxtu
- PufatnchazksasomlinsdinsmtiL9123.
Do not sell19-15-25
SM548 or distribute
1Aconmcux&ullotriropoutordFopsoatdowly. RECALL
I
125
POSSIBLE CAUSE
Nooe:Thisstanwcodecanonlybefouadbyufiagthehandsetand 1A
lootigatfumion1.Thisstatusaxieis~asam-
bkshooting aid far statuscode 46.
Defective 1A amtsxce T2
a CkcklAcootacou forbindingarslowopcmionperationwhen
,drapping-
T--f-
Figurel.
STATUS INDICATION CRiTERIA

l%isstauucodcisdispiaycdwhcp1Acontac~dropou!timc
cxce&.060-
STATUS CODE
open~~ar’amcrdoverpempr
DESCRIPTION -OR’
RECALL
No
I
141 I CIRCUIT Fkup
SM648
Do not sell 19 5-26
or distribute
STATUS CODE
scxulotcralucn~scnsorinp
DESCRIPTION MEMORY
RECALL
No
.
I)
142 CIRCUIT Pump
VOM
NopowcrmpumpmotorinSCRrange
POSSIBLE CAUSE
Dpalsensorwirt~tsoPZ4.
. Checkfor loose cmnection or b~~kcnwtt @en wire) SCR * PZ4
fromcurrcntscxwxt0pz4onthclogiccard. CURRENT l
*
NEG.

Thisstatucodeisdisplayed
whenvoltage hctwan PYl
aadnqativcisgea~~thau1.6volcwithnocunat flow-
ingintkmoarchuk

SCRmotacuxcntsauorinputmissiag. RECALL
I
143 CIRCUIT Pump
CAUSE +-
POSSIBLE 0 *
opulsaufxwirccircpitmm. SCR
.PZ3
- amck6ahFmnerrirra 4cbm&awixuo_tlbw CURRENT 0
Wh)hlIlcmrsntsQ#lOpL3OnlOgiCd
NEG
STATUS INDICATION CRTTERIA

lllisanl8co&irdhplayaiwbcavohgektar&n~
8ldncgaaiwLlestthrn.84vdowidlllo-flowing
inmoaxcircnk
stma
Do not sell19-i
or distribute
5-27
RECALL4
1144
lRECdidnotumloffpropdy.
CIRCUIT Pump
*
SYMPTOM
Pumpconnrctonapenardclose,thtncanonlybedosedbyapen-
illgaxldclasingdlckcytitch.
POSSlBLE CAUSE
Defective 5 REC circuk
- alcckforshort#15REc.
- Checkfor shomd 5 FUX snubber (25 REQ.
XaAve 2 REC &cuiL

- Chcckforshalcd2REc.
. check-2 ~.&@&~_---- “.
FigurrL
3pcn ChokB(lx).
- CbaAforopcacitcuitbetweenT5andT3.Olmmctcr
shouldrwdoeroohtm. STATUS INDICATION CRITERIA
I RECdefective.
+ TumofftimcfcrlRECoutofspaSMmNoiicld ThisstamscodctidisplayaiwhcsdmiagsCRopention,
tcstispossibkRcplacc1REcaffrraboveckckshow l~Cfails~~o&
llOpblUllfOUd
DESCRIFI’ION MEMORY yes

STATUS CODE
RECALL
=145
1REcdidaotalnlonpropdy.
CIRCurr Pllmp
SYMPTOM
Rmlpamortorwillopalaudclmc,~opalrmd~caadybc
ascdbyopmitlgadfuiagthekcyswitdL
POSSIBLE CAUSE
D&ctivc2REccitcd
* amckfmdnxd2REc
MCCtiV81RECchcpit
* Ckcktrropea~arbas--1
Rxalldzz3.(wbiwblmwim)
2aEc
* c2Eck~opcacimitarlooso-bawren1‘
RahL
REc(3REcsnubller)andm9.(bhlewite)
lMkctile1REc STATUSINDICATION CRITERU

. IIlmamtaropm1REC(paaMdtestm8yarmay nisstms4xdcfirdirpLgsdwhca1REchtitto~aa
notdlowd&cLRepka1REc&mbovechcc4
slKnvnopmblamfamtL
Do not sell19-15-28
SM548 or distribute
STATUS CODE DESCRJPTION MEMORY No
RECALL
-146
IJJakabmdwtfarnvoia.(Grwiuth8n85%afbannyvala)
ICIRCUIT I
Pump
POSSIBLE CAUSE
3efccTivc 1 REC.
- chcckforshoncd 1 REC.
- checkfordcfcclivc1REcinsula.tcR(c&thum)ti
mayshcnt1REchcatsinktobasephte.
STATUS CODE 1 DESClUPTION MEMORY yes

RECALL
-147 1
2REcdocsnottlmlonpzupcrly.
CIRCUIT Pump
4
SYMPTOM
Ehlmpccmzmorwillopulanddoae,rbenopalaudthulcanonlybc
clc4aibyopulhgandclosingthclRyswitch.
POSSIBLE CAUSE
De~vc2REccircpa
* c!lecktha2REc!willgmaa.
- (=heckfaopencilcuitalam-between2
RJx@mmdPzlO.(~wirt)
STAmS INDICATION CRlTHUA

nli3smmscodmisdisplayaiwhalthe2REcfhilstDuml
XL
St&j48 19-15-29
RECALL
-148
~Pbedtutfor~vdu(lurdwt12%ktpayvolts).
i
CIRCUIT Pump
POSSIBLE CAUSE
kfuxiw fcmvatdar IcverscCuIl-.
* ckckforwcl&dfawdarlEvctsc contxuxpowu
tips.
* cIleckforsluggishopmtionoffaw8tda-
QIIMQ.
hfdve3REcl5xcniL
. c&&far-j&& .’ %‘.
* Cbcckfcfsbatcd3RECsaIlbkr(23REC).
!8IdtypciaaxKcL STATUS INDICATION CRITERIA

- xfplmlpamlTolosedwithoutpumpcalmalx.c&must %iSSI8tlUCUki.ldiSph$dWklltbCVOlugeiU’IziSlCSS
bcs8tcaxeuly.sccflmction17far-~ tm 12’Adbacryvaltr
STATUS CODE
ICIRculT I
Pump
I I A
STAmS INDICATION CRITERU

[hirnmplCUbiSdiSpl8JTdWbXltk5RECtiiIlktfEllSlD
lnnaa.
Do not sell or19-l
distribute
5-30
SM548
No
RECALL
150
CapnciDxVolLs
low.
I
CIRCUIT Pump
as.
SYMPTOM
bmp contacmrpicksup.Control does not OPcIatc. 6aOQ*- Q
aaaa 0 IRc
WS8- mm
POSSIBLE CAUSE Y-
kfective 2 REC cinxit. d 2=
q i
Open circuit or loose connectiOn bctwaa spider
PZIO
assembly and 5 REC (BUS A).
t
Open circnit or loose connection between 5 REC and w/AEp

ZREC. 1
15
Openchuitorlooscconnectionbetween 2REC <c
gateand FzlO (white/red wire). 1 SEC
chadc2REca,insurefhatitwiugflreon. Figurel.
STATUS INDICATION CWIERL4

Thissnl!ucodeisdiqlaycdwhul2REcciIc&faitsto
tnrncma!initialscutLp.
Exccssivccapacitor~whenm DESCRIPTION
STATUS CODE MEMORY yes
RECALL
-151 MP
SYMPTOM
mmpconlactorupcnaudclose,thulcanonlybcclwedbyopening
andclosiagthckcyswirch.
Highpeaklzuncntinmour.
- ckkftxshatcdfiddwindirlg.
STATUS INDICATION CWIXRIA

Tbissmmscodoiadisplayedwknc4rpa&ryolod
225vdtsa&nacrcprrmtisgrumth8nMormpr
Do not sell19-l
SM548 or distribute
5-31
STATUS CODE
Excessive
capaciufrvoltage
when DESCRIPTION MEMORY yes
-152
momrcmxemis low. RECALL
CIRCUIT pump
SYMPTOM
Fumpconracm open and close, then can only be ~bscd by opening
and closing the key switch.
POSSIBLE CAUSE
Excessive source inductance.
* un-filteredtaglines arcbeingusal.
. Baauy cables arc too long.
Dcfaxivc4REccircuik
* chcckforsholTcd4REc.
- checkfoLclpeaL~-C~~ rg;
cYircuit.
QiP=1.
kfcctivc 3 REC circuil.
* chcckforqmlcircuitorloosc coMcclioniJl3REc STATUS INDICATION CRITERIA
CirclliL TllissmmsaxkisdispIa~whcnc8pacit4xvoltscxca?d
22!5voltYandmotxxclxmzntisle3sthanu)oalnp&

RECALL
-154
Sharadpumpa1Aammcnxcoildriver.
. CIRCUIT Pmnp
SYMPTOM
Conaol will not F.
POSSIBLE CAUSE
DefectivclogiccaIli
. Replacelogicard.
SM548
Do not sell or19-l 5-32
distribute
STATUS CODE DESCRPI’XON MEMORY j yes
cumnt)Qw oqmt voltqppoinityc&CL RECALL
-157 ClRCurr Pump
SYMPTOM
Pump conmcwr open and clwe. rhen can only be closed by opening
and closing the key switch.
POSSIBLE CAUSE
Rverxd yellow and green current scnors wires
. Inslmrllafthe:-grceawimconnect,mPz4withnO
open circuiu.
-yellow wire comam to PZ3 with no
open circuiu or loose cotuleaions.
Rcvenedpowacablc~
. rnsumtbatthebalmyncgilivccablecaMecatoscR
NEGandthemotaA2cablecotmaxsmSCRti
L
STATUS INDICATION CRITERU
Thissranucodcisdisplaycdwhal~volagciaputtopz4
aadPz3istkwnlagpolmi~.
Copyrighted
SMs48 19-15-33
Material
CHECKINGCOMPONENTS
Main Logic Card
Ail trouble-shooting is written to check all outside devices and eliminate them as the source of the
symptoms. The conclusion being then that the card is faulty.
Remove control wires on the screw termit& 1 through 6 as required
Unplug A, B, and 2 plugs by pressing down on tab with wide blade screwdriver
and rotating 90 degrees.
Removethe two mounting screws and lift cti box fret.

NOTE:Donotattcmpttoovecircuitbroad&omcardbox.
Reverseproceduns to install new control carrd.
Mounting AandBPlugs TcrIealal-6 Y Plug z Plug

screw
Capacitor 1C
Disconnect the battery and discharge the capacitor. Measure ohms through the capacitor using the R
x 10,000 scale. Meter should read zero and then swing slowly to above 100,000 ohms. Replace the
capacitor if above reading is not obtained.
Contactors F, R, lA,SP,FW,D,REGEN and P
150 ampere contactors instruction sheets.

300 ampere contactors instruction sheets.
NOTE: . ..
Control is arranged so that the F and R contactors do not break currenL Check to see that
the 1A contactor drops out before the F or R contactor.
Most contactor coils are polarity sensitive. The left-hand termir& must be connected to
positive.
Potentiometer in Accelerator
To check operation of the potentiometer, discoxmectthe battery and disconnect the wire
at control card TBl. Connect a VOM to the wire that was removed from TBl and to
negative. Place the VOM on the R x 100 scale. With the accelerator in the creep speed
position, the ohms reading should be 4800 to 6000 ohms. With the accelerator in the top
speed position, the ohm nading should be 50 ohms or less. With the wire disconnected as
above, check for resistance of 1 megohm or higher fi-ompot wire to the truck frame.
SCR’s (IREC, 2RECJREC)
These arc silicon controBcd r&.&rs. Before checking, disconuect the battery and
discharge Ci3&&~ lc Disconnect gate leads Of Sa’S at the sa tCKflid
To check an SCR, it is necessary to have a 6 volt battery and 2 A-14 diodes.
Coxwct the positive lead to the anode, co~cct the negative lead to the cathode as shown
m 0 0
SM548 19-16-2
NOTE
control card. Read the resistance between these two wires with the VOM set on the R x
900 scale. VOM should read 100 to 200 ohms if the 1REC heatsink is at room tempera-
ture (25C or 7%). Set the VOM to the highest ohm scale and read Tom each wire end to
the 1REC heatsink Reading should be infinity.
Filter Block(23FLetc.)
To check, disconnect all wires f?om the filter block on removal f?om panel. With VOM on
the R x 10,000, touch the leads to the filter terminals to charge the filter. After a few
seconds, reverse the meter leads and touch the filter terminah The VOM needle will
deflect and return to infinity. If this capacitor action is not observ& replace the filter
block.
Filter block test 4K is only to detect an open or shorted filter. If the control has sympo-
tams as in lE, inter-change22REC and 25REC and tq again. If the problem is corrected,
the old 25REC is marginal and should be replaced If the problem is not corrected replace
both filters.
1X Choke and Reactor T3-T4
Refm to panel wiring diagram to locate windings. With VOM on R x 1 scale, measure
choke or reactor winding. Reading should be less than 1 ohm.
REPLACEMENTOF EV-100 COMPONENTS
When replacing stud semiconductors such as 3REC and 4REC, it is not necessary to torque these
devices to a specific value.
The use of a heat-transfer grease (such as GE Versilube G-350-M or equivalent) is recom-

mended.
When replacing module semiconductorssuch as lREC, 2REC or XX!
Remove all module connections. (ASrequired)
Remove module by backing out the two screws at the &vice sides.
Clean the insulator surface with a clean rag and isopropyl alcohoL
Inspect the insulator surface for tears or cracks. If defective, replace. Wipe a light layer.
of machine oil on the base and smooth the insulator into position.
NOTE: Insulator not required for 2REC and SREC.
Coat insulator with a light coat of heat-transfer grease similar to GE-350.
Set new module on insulator and start screws back into base. Be sure to use the original
screws and washers. Run screws in to base “finger tight”.
Check that the bottom of the module is flat against the insulator or base.
Alternately tighten the two screws by l/4 turn until firm.
Replace all connections removed in step 1.
Capacitor
Remove nuts from capacitor connections and remove wires.
Remove hold down brackets and lift out.
Reverseproc&mtoreplacecapacit(=
22REC, 23REC and 25REC
Remove mounting screws and lift out
NOTE: When replacing these devices, use the original hardware in the same holes, as the
inserts are used for electrical connections.
Intended for CLARK
SM548 dealers only
19-18-8
EVl 00-LXT
CARD
FUNCllON
SET-UP
E235 TRUCKS ONLY

Traction Control
OCT91
19-l 6-6
EVl 00-LXT
CARD
FUNCTION
SET-UP
ECS Std TRUCKS ONLY

PUMP Control
FAULT CODE
NOTE: SETTING BASED ON FLOW CARTRIDGE USED

\
FLOW CARTRIDGE SE-I-IING MIN MOTOR VOLTS
1.5 GPM 057 - 059 21.5 VOLTS
2.5 GPM 061 - 063 23.0 VOLTS
4.0 GPM 068 - 070 25.5 VOLTS
5.5 GPM 075 - 077 28.0 VOLTS
7.0 GPM 081 - 083 30.5 VOLTS
10.0 GPM 250 - 255 BAlTERY VOLTS
\
OCT 91 19-16-7 SM548
EVI 00-LXT
CARD
FUNCTION
SET-UP
ECS Std TRUCKS ONLY

Traction Control
I
FUNCTION SETTING DESCRIPTION

CODE ___. ”
. .. ,, .
. _
1 001 FAULT CODE

2 018 i 022 CREEP .
3 004 - 006 C/A & IA TIME

4 250 - 255 C/L
5 148 - 152 PLUGGING
I 6 250 - 255 I 1ADO .
I 8 I 001 NA .
9 001 NA
10 001 NA
I 11 I 001 NA
I 001 NA
13 001 NA
.
14 15 IR COMP
I .
15 184-250 BATT VOLTS .
16 38 - 42 PEDAL PLUG
17 000 - 004 CARD lYPE .
18 175 - 177 S/P TIMER
OCT91 SM548
19-16-8
EVl 00-LXT
CARD
FUNCTION
SET-UP
ESM TRUCKS ONLY
kIJNCTlON SElllNGSEXCEPT SElTINGSFOR DESCRIPTION I

CODE,. . . ESMi 7J2!5_.o_
WIE d ESM.1 X!LW/EE I _.I
I.
1 001 FAULT CODE

I.
2 018 - 022 CREEP

.I
3 004 - 006 C/A & 1A TIME

I.
4 . .
250 - 255 C/L
I.
0
I.
250 - 255 106 - 110 1ADO
7 001 - 003 TURN SWITCH SPEED LIMIT
.
.
8 001 I I NA
I.
I
9 001 NA
I.
10 001 NA
I.
11
I.
052 - 055 TURN SWITCH SPEED LIMIT
12 001 I I NA
I.
1
13 001 NA j
I.
14 14 IR COMP
I.
15 I.
032 - 044 BATT VOLTS
16 038 - 042 PEDAL PLUG
I.
17 I.
000 - 004 CARD TYPE
18 175 - 177 S/P TIMER
I.
I.
I.
I.
OCT 91
19-16-9
EVl 00-LXT
CARD
FUNCTION
SET-UP
TM TRUCKS ONLY
FUNCTIONSElllNGS
CODE I TM22l25 W/EE I
EXCEIT SElllNGS FOR
TM22/25 WIEE I DESCRIPTION
I FAULT CODE
2 018 - 022 CREEP
3 004 - 006 C/A & 1A TIME
4 250 - 255 C/L
6 250 - 255 106 - 110 1ADO
I 8
9
! 001 1 I NA
r 001 NA
10 001 NA
12 001 NA
I NA
I 14 I 14 I I IR COMP
15 032 - 044 BATT VOLTS
16 038 - 042 PEDAL PLUG
17 000 - 004 CARD TYPE
18 175 - 177 S/P TIMER
OCT 91 SM548
19-16-10
T
OP15B ONLY,
FUNCTION
SETTING DESCRIPTION
CODE
1 001 FAULT CODE

2 200 ’ CREEP
3 015 C/A & 1A TIME
4.. .I 095. C/L
5 080 PLUGGING
6 130 1ADO
7 010 F/W PU
8 010 F/W DO
9 010 NA
10 010 NA
1 1’ 114 SPEED LIMIT 1 (2.5 MPH)
12’ 137 SPEED LIMIT 2 (1 .O MPH)
13’ 177 SPEED LIMIT 3 (0 MPH)
14 010 IR COMP
15 024 BATT VOLTS
16 040 PEDAL PLUG
17 20-24 CARD TYPE
18 018 S/P TIMER
*These functions control the speed of the vehicle when mast is raised.t never
be bvoassed or set above the soecifications described above.
The function should be adjusted to the prescribed setting and then the speed of the vehicle
should be checked and the function readjusted, if necessary.
Function 11 controls the speed of the truck at lift heights between 24” & 150”.
Top speed of the truck must be 2.5 MPH.
Function 12 controls the speed at lift heights above 150: when traveling
in a straiaht line.
Top speed of the truck must be 1.O MPH.
Function 13 controls the speed of the vehicle af lift heights above 150” when
the truck is steered beyond 10 degrees off center and when above 226”.
The truck must not travel though the contactors will close.
The travel speed is determined by timing the vehicle through a 50-foot run.
At 2.5 PMH, the vehicle will take 14 seconds to travel 50 feet.
At 1.0 MPH, the vehicle will take 34 seconds to travel 50 feet.
OCT 91 19-16-11 SM548
1I
EVl 00-LXT
CARD
FUNCTION
SET-UP
NPI 5/l 5D/20/22 ONLY

FUNCTION SE-I-IING DESCRIPTION
CODE
1 001 FAULT CODE

2 200 CREEP
3= a1 2 C/A, &, 1A TIME
4 095 C/L
5 080 PLUGGING
6 130 1ADO
7 . 010 F/W PU
8 I 010 ! F/W DO
9 010 NA
10 010 NA
11’ 114 SPEED LIMIT 1 (2.5 MPH)
12* 001 SPEED LIMIT 2 (1 .O MPH)
13’ 001 SPEED LIMIT 3 (0 MPH)
14 010 IR COMP
15 024 BATT VOLTS
16 040 PEDAL PLUG
17 022 CARD TYPE,
18 018 S/P TIMER
*These functions control the speed of the vehicle when mast is raised.
The function should be adjusted to the prescribed setting and then the speed of the vehicle
should be checked and the function readjusted, if necessary.
Function 11 controls the speed of the truck at lift heights above free lift.
Top speed of the truck with a MPH above 240 inches must be 1 MPH above free lift.
Top speed of the truck with a MFH below 240 inches must be 3 MPH above free lift.
The travel speed is most easily determined by timing the vehicle through
a 50-foot run.
At 3.0 MPH the truck will take 11 seconds to travel 50-feet.
At 1.0 MPH the truck will take 34 seconds to travel 50-feet.
The speed limiting function is vital to the safety of the truck and must
never be bypassed or set above the specifications described above.
OCT 91 19-16-12
GROUP 20 SECTION 01 Check fluid level by removing dipstick on the right
hand axle end. Wipe dipstick clean and reinstall.
DRIVE AXLE Remove dipstick and examine. Fluid level should
be between the two marks on dipstick. If fluid level
is low, add enough fluid to bring level up to full
mark on dipstick. DO NOT OVERFILL.
Refer to Specifications group, for recommended

CONTENT NO. transmission fluid specification.
GENERAL DESCRlPTlON 20-01-01

SERVlCE NOTES 20-01-02 FLUID CHANGE PROCEDURE
DRIVE AXLE MAINTENANCE 20-01-03
DRIVE AXLE REMOVAL 20-01-04 IMPORTANT
DRIVE AXLE DISASSEMBLY 20-01-05 DRAIN DRIVE AXLE WHEN FLUID IS AT
DRIVE AXLE ASSEMBLY 20-01-06 OPERATlNG TEMPERATURE
DRIVE AXLE INSTALLATION 20-01-07
Raise upright caniage only to height that will permit
access to plugs on axle. Block carriage.
20-01 :Ol GENERAL fi ! WARNING

DESCRIPTION MAKE SURE BLOCKS ARE SECURELY
INSTALLED UNDER CARRIAGE SO THAT
CARRIAGE CAN NOT FALL.
Thedrive axle consists of right hand and left hand
axle end assmblies. The two axle ends are
Turn key switch OFF. Disconnect battery.
fastened together to form the drive axle assembly.
Each axle end half contains a ring gear and pinion
Place a low flat drain pan under drive axle. Pan
and final drive gearing. The drive motors are
should have a capacity of more than [6,5L] 6.8
mounted directly to the axle ends.
quarts .
20-01-02 SERVICE NOTES
The drive axle contains metric fasteners . Use only

metric tools to setvice unit.
Service instructions refer to one axle end, unless
othewise noted.
FILLER PLUG 8 DIPSTICK
20-01-03 DRIVE AXLE DRAIN PLUGS

MAINTENANCE
When troubleshooting a drive axle problem, it
should be kept in mind that the drive axle is only a
central unit in a group of related powertrain Remove dipstick cap. Remove drain plug from
components. each axle end and allow fluid to drain. While fluid is
draining, check condition of vent in dipstick cap.
Proper operation of drive axle depends on Replace dipstick cap if vent is damaged or
condition and correct function of other plugged.
components of group. It is necessary to consider
transmission fluid, drive motors and connections Reinstall drain plugs.
to properly diagnose and repair a problem.
Fill drive axle to proper level with specified fluid
through dipstick hole. DO NOT OVERFILL.
FLUID LEVEL CHECK
Reconnect battery, remove blocking and lower
Check fluid level. It must be at correct level. carriage.
SM556 20 - 01 - 1
DRIVE MOTORS Y&i!
* Apply LocktitefM242 before assembly
_
20-01-04 DRIVE AXLE REMOVAL 9. Remove drive wheels.
10. Put a drip pan under drive axle to catch any

1. Park truck on hard, level surface..
fluid.
2. Lower upright.
11. Disconnect and cap hydraulic lift cylinder line.
3. Remove forks.
12. Disconnect tilt cylinders at upright. Refer to tilt
cylinder group for details.
4. Turn key switch OFF and disconnect battery.
13. Remove upright. Refer to upright group for
5. Remove battery.
details.
6. Put blocks on each side of steer wheels.
14. Disconnect hydraulic brake lines.
7. Lift truck with a jack and put blocks under each
15. Identify and disconnect motor power cables.
side of frame just behind drive wheels. Refer to
Tie cables out of way to avoid damage.
truck jacking group for details.
MAKE
n!
SURE
WARNING
BLOCKS ARE n ! WARNING
SECURE AND PLACED SO THAT USE ONLY APPROVED HOIST, CHAINS,
CLEARANCE TO AND STRAPS TO LIFT THE DRIVE AXLE
THERE IS
AXLE WITHOUT AND MOTORS. BE SURE HOIST AND
REMOVE
INTERFERING WITH BLOCKING ACCESSORIES HAVE CORRECT
OR TRUCK.
LOAD
8. Remove two front and top compartment

16. Put lift straps on drive motors and hook straps
covers.
to chain hoist. Remove slack from hoist chain to
stablize drive axle assembly.
SM556 20 -01-2
IMPORTANT
TO AVOID INJURY, REMOVE AXLE
MOUNTING FASTENERS IN THE
FOLLOWING ORDER
20,239 - g
17. Remove axle rear mounting fasteners (items
90.358, 94.085, & 20.377) from each side of
frame.
Remove axle front mounting fasteners

Elms 90.358, 94.085, & 20.377) from each side
of frame.
19. Lower axle to floor and remove it from under

truck. Store axle in a safe manner.
9. Use 2 mounting flange capscrews (item
20. If drive motors are to be removed, refer to 20.239) to remove motor mounting flange from
drive motor group for details. axle housing. Thread capscrews into tapped holes
“A” in motor mounting flange. Turn capscrews
alternately into tapped holes until mounting flange
20-01-05 DRIVE AXLE is extracted from axle housing.
DISASS,EMBLY ., 10. With special tool, remove pinion retaining nut
(item 20.819). Note: In order to remove item
Disassemble drive axle only on a clean floor or on a 20.819, it will be necessary to fabricate a tool to
work table strong enough to support the weight of keep the output shaft (item 20.586) from turning.
the axle. Drain drive axle fluid, if has not been
done previously. 11. Use a soft hammer to drive the pinion from
the motor mounting flange. The upper bearing
1. Block axle to stablilize it on the work surface. cone (item 20.230) will come off the pinion shaft in
the process. Clean and inspect bearing for wear or
2. Remove drive motors, if they have not been
damage. Replace as required. Bearing cone and
removed previously. Refer to drive motor group
cup should be replaced as a set.
for details.
12. Remove backing washers (items 20.238 &
3. Clean exterior of axle before beginning
20.240) and adjusting sleeve (item 20.288). Press
disassembly. lower pinion bearing cone (item 20.252) from
pinion (item 20.248).
4. Examine entire assembly for damage. Note if
there is any evidence of cracks or broken parts.
13. Draw pinion bearing cups (items 20.316 &
20.649) from the motor mounting flange.
5. Remove housing flange capscrews (items
20.227 & 20.228).
14. Loosen bevel gear nut (item 20.835) using
fabricated tool to keep output shaft (item 20.586)
6. With a drift pin and hammer, drive out housing
from turning.
flange roll pins (item 90.663).
15. Remove locking capscrew (item 95.782).
7. Separate the two axle end assemblies. Note:
Sealant was applied to the axle end housing 16. With special tool, remove output shaft nut
flanges at assembly. Force may be required to
(item 20.565). Use fabricated tool to keep output
separate the two housings.
shaft (item 20.586) from turning.
8. Remove motor mounting flange capscrews
17. Remove housing cover capscrews (item
(item 20.239).
20.546).
SM556 20 - 01 - 3
PINION SET
20.337 RH /
ASSEMBLY
CoMPLErE
20.376 1
DRIVE AXLE - RH
20.376 AXLE ASSEHSLY, DRIVE RH 20.542 BEARING, DRIVE AXLE SHAFT OUTER
20.201 SRM, DIFFERENTIAL PINION BEARING CARRIER 20.544 SEAL, DRIVE AXLE SHAFT
20.212 SEAL, DIFFERENTIAL PINION BEARING CARRIER 20.546 FASTWER, DRIVE AXLE END HOUSING
20.227 FASTENER, THICK FLANGE TO AELE HOUSING 20.553 CONE, DRIVE AXLE SHAFT INBOARD BEARING
20.228 FASTENER, THIN FLANGE TO AXLE HOUSING 20.565 RETAINER, DRIVE.AXLE SHAFT BEARING
20.230 CONE, DIFFERENTIAL PINION BEARING 20.579 CUP, DRIVE AXLE.SRAFT INBOARD BEARING
..- SHAFT; DRIVEAXLE
20.236 CARRIER, DIFFERENTIAL PINION BEARING 20.586’
20.238 SHIM KIT, DIFFRRENTIAL PINION BEARING CAGE 20.636 SRAFT, DRIVE AXLE RING GEAR
20.239 FASTENER, DIFFERENTIAL PINION BEARING CARRIER 20.638 CONE, RING GEAR SHAFT OUTBOARD BEARING
20.240 SPACER, DIFFERENTIAL PINION BEARING 20.646 CUP,RINGGEAR SHAFT INBOARD BEARING
20.248 RING 6 PINION SET, DIFFERENTIAL 20.647 LOCATOR, DRIVE AXLE SRAFT INBOARD BEARING
20.252 CONE, DIFFERENTIAL PINION INNFR BEARING 20.649 CUP, DIFFERENTIAL PINION INBOARD BEARING
20.288 SPACER, PINION BEARING CONE 20.666 SPACER, DRIVE AXLE RING GEAR SHAFT INBOARD BRG
20.316 CUP, DIFFERRNTIAL PINION OUTBOARD BEARING 20.667 SPACER. DRIVE AXLE RING GEAR SHAFT
20.387 HOUSING, DRIVE AXLE RH 20.668 SPACER, DRIVE AXLE SHAFT INBOARD BEARING
20.427 PLUG, DRIVE AXLE DRAIN 20.819 NUT, DRIVE AELEPINION SRAFT LOCK
20.520 RETAINER. DRIVE AXLE SHAFT GEAR 20 e 835 RETAINER, DRIVEAELERINGGEAR
20.522 GEAR, DRIVE AELE SHAFT 20.837 CUP. RINGGEAR SHAFT OUTBOARD BEARING
20.524 BEARING, DRIVE AXLE RING GEAR SHAFT 90.663 DCWEL RING, AXLE HOUSING FASTENER
20.539 HOUSING, DRIVE AXLE END RH 95.782 FASTENER. DRIVE AXLE SHAFT BEARING RETAINER
SM556 20 - 01 * 4
26. From inside the axle end housing, use a soft
hammer to drive the output gear pinion (item
20.636) out of the housing (item 20.388).
Remove loose inner bearing cone (item 20.524)
from housing. Clean and inspect bearing for wear
or damage. Replace as required. Bearing cone and
cup should be replaced as a set. Remove spring
bushing (item 20.667) from output gear pinion.
27. Press outer bearing cone (item 20.524) off

output gear pinion (item 20.636). Clean and
inspect bearing for wear or damage. Replace as
required. Bearing cone and cup should be
replaced as a set.
28. Remove the pinion bearing cups (item 20.646

& 20.837) from the axle end housing (item
20.388).
18. Use 2 housing cover capscrews (item
20.548) to remove housing cover from axle
housing. Install capscrews into tapped holes “B” in 20-01-06 DRIVE AXLE
housing cover. Turn capscrews alternately into ASSEMBLY
tapped holes until housing cover is extracted from
axle housing. After the housing cover assembly is ASSEMBLY NOTES
off, reach into the axle end housing and remove
loose inner bearing cone (item 20.553) 1. Clean all parts with a good grade of solvent and
dry thoroughly. Do not let bearings spin dry if
19. With special tool, remove output shaft nut drying parts with air pressure.
(item 20.520). Use fabricated tool to keep output
shaft from turning. Slide output gear (iem 20.522) 2. Remove all Permatexm and Lo&item residue
off shaft (item 20.588). from threads and machined surfaces.
20. Remove the output shaft (item 20.588) from 3. Inspect all components for wear or damage.
housing cover. Replace as required.
21. Press outer bearing cone (item 20.542) off 4. Replace all oil seals and O-rings.
output shaft (item 20.586). Clean and inspect
bearing for wear or damage. Replace as required. 5. Use Permatex”and Loctitem only where
Bearing cone and cup should be replaced as a set. specified.
22. Remove oil seal (item 20.544) and outer 6. All lead-in chamfers for oil seals and O-rings
bearing cup (item 20.542) from housing cover must be smooth and free from burrs. Inspect at
(item 20.539). assembly. Correct as necessary.
23. Remove snap ring and back-up ring (items 7. Coat all bearings with transmission fluid before
20.647 & 20.668) from housing cover (item installing.
20.539).
24. Draw inner bearing cup (item 20.579) out of ASSEMBLY

axle end housing (item 20.388).
1. Install pinion bearing cups (items 20.837 &
25. Remove and discard bevel gear nut (item 20.646) into axle end housing (item 20.388).
20.835). Remove bevel gear and spacer (items
20.248 & 20.666) from output gear pinion (item 2. Press outer bearing cone (item 20.638) onto
20.636). output gear pinion (item 20.636).
SM556 20 - 01 - 5
3. Slide spring bushing (item 20.667) onto output install flange & pinion assemby. Torque capscrews
gear pinion (item 20.636). install pinion into axle to [67 Nmm]49.5 Ibfeft.
end housing (item 20.388).
15. Lock the bevel gear nut (item 20.835) by
4. Install inner bearing cone (item 20.524) onto crimping the nut into the groove in the end of
pinion (item 20.636). Install spacer (item 20.666), pinion shaft (item 20.636).
bevel gear (item 20.248), Apply Locktitem No.92
to a new bevel gear nut (item 20.835) and install. Install inner bearing cup (item 20.579),
Tighten bevel gear nut to give a running torque of &&ig ring (20.668) and snap ring (item 20.647)
[0.7 Nom] 6.2 Ibfain on the pinion bearing. into axle end housing (item 20.388).
5. Install pinion bearing cups (items 20.316 & 17. Install outer bearing cup & cone (item 20.542)
20.649) into motor mounting flange (item 20.236). into output shaft housing (item 20.539). Apply a
thin coating of grease between the lips of oil seal
6. Press inner bearing cone (item 20.252) onto (item 20.544). Apply a thin layer of Permetexm #2
pinion (item 20.248) and insert pinion into motor to the outside diameter of oil seal and install.
mounting flange (item 20.236).
18. Insert output shaft (item 20.586) through
7. Slide backing washer (item 20.240), spring housing (item 20.359). Do not damage oil
bushing (item 20.288), backing washer (item seal (item 20.544) with spllnes of output
20.238), and outer bearing cone (item 20.230) shaft. Slide output gear (item 20.522) onto shaft.
onto pinion (item 20.248). Apply Locktite TMNo.92 to nut (item 20.520) and
install. Torque nut with special tool to j200 Ngm]
8. Apply Locktitem No.92 to slotted nut (item 147.5 Ibfeft . Use fabricated tool to keep output
20.819) and install on pinion. Tighten nut to give a shaft from turning.
running torque of [0.5 Nom] 4.4 Ibfain on the
pinion bearing. Use special tool to torque nut. 19. Apply a thin layer of Permetexm #2 to
machined surface of housing cover (item 20.359).
9. Check motor pinion and bevel gear mesh Apply Lo&item No.92 to capscrews (item 20.546)
adjustment. Note: Mesh adjustment is made with and install housing cover to axle end housing
motor mounting flange shims (item 20.201) and (item 20.388). Torque capscrews to 167 Nom] 49.5
bevel gear spacer (item 20.666). Mark teeth of Ibfaft .
motor pinion and bevel gear with gear checking
compound. 20. Slide bearing cone (item 20.553) onto output
gear shaft. Apply Locktitem No.92 to nut (item
10. Install flange & pinion assembly into axle end 20.565). Install nut and torque to [68 N*m] 50.2
housing (item 20.388), using shim (item 20.201) to Ibfeft with special tool. Apply Locktite” No. 92 to
align assembly with housing. Install and tighten locking screw (item 95.782). Lock nut (item
only 2 flange capscrews (item 20.239). Note: Do 20.565) with screw. Torque screw to [13 Nom] 9.6
not install O-ring (item 20.212 at this time). Ibf*ft.
11. Rotate the pinion several times in a clockwise 21. Apply a thin layer of Permetex” #2 to
or counterclockwise direction and check against machined surface of axle end housing flanges.
the tooth bearing contact chart on pages 8 & 9. Mate the two axle end housings together and drive
Pinion gear backlash should be 0.0078 - 0.0040 in roll pins (item 90.663). Apply Locktitem No. 92
inch. ..I .; to capscrews(item 20;227. & .20.228) and fasten
axle end housings together. Torque capscrews to
12. Adjust pinion by changing the number of [67 N*m] 49.5 Ibfmft.
flange shims (item 20.201). The bevel gear is
adjusted by grinding the gear spacer (item
20.666) to the thickness required. Use a surface 20-01-07 DRIVE AXLE
grinder to remove material from the gear spacer. INSTALLATION
13. When gear mesh adjustment is correct, 1. Make sure truck is blocked in a secure manner
remove (2) capscrews and flange & pinion and that there is clearance to move axle in place
assembly. Coat O-ring (item 20.212) with from underside of truck without disturbing
transmission fluid and install. Apply Locktitem blocking.
No.92 to all flange capscrews (item 20.239 and re-
SM556 20 - 01 - 6
2. install drive motors to d&e axle assembly. Refer 16. Connect battery and test drive axle operation.
to drive motor installation group for details.
fi ! WARNING
AND STRAPS TO LIFT THE DRIVE AXLE
AND MOTORS. BE SURE HOIST AND
ACCESSORIES HAVE CORRECT
LOAD
3. Put hoist straps on drive motors and hook

straps to chain hoist.
4. Position axle under truck with chain hoist.
IMPORTANT
TO AVOID INJURY, INSTALL AXLE
MOUNTING FASTENERS IN THE
FOLLOWING ORDER
5. Mount axle assembly to frame by installing

front fasteners (items 20.377, 94.085 & 90.358)
on each side of frame.
5. Install rear mounting fasteners (items 20.377,

94.085 & 90.358) on each side of frame. Torque
nuts to (408 - 469 Nem) 301 - 339 Ibfmft.
6. Connect drive motor power cables. Make sure

cable ends are connected to correct motor
terminals.
7. Connect hydraulic brake lines and bleed

brakes. Refer to hydraulic brake system group for
details.
8. Install upright. Refer to upright group for details.
9. Attach tilt cylinders at upright. Refer to tilt

cylinder group for details.
10. Connect hydraulic lift cylinder line.
11. Install drive wheels. Torque wheel mounting

bolts to [225 - 275 Nem] 188 - 203 Ibfaft.
12. Install two front and top compartment covers.
13. Remove blocks and lower truck to floor. Refer

to truck jacking group for details.
14. Install battery.
15. Install forks.
SM556 20 - 01 - 7
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
GEAR IN THIS DIRECTION

I
PROFILS
AU CONTACT BEARINGS SHOWN BELOW ARE ON LEFT HAND SPIRAL

RING GEAR - THE DRlVE IS ON THE CONVEX SIDE OF THE TOOTH.
FIG. 1
TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH

WHILE UNDER A LIGHT LOAD
1
w
FIG. 2 \%+ .
TOE BEARING ON BOTH SIDES OF TOOTH - GEAR SET NOISY. TO MOVE -: _ ‘I,
BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOV- ‘1 \
.h
ING GEAR AWAY FROM PINION.
FIG. 3
HEEL BEARING ON BOTH SIDES OF TOOTH - GEARSET NOISY AND

COULD RESULT IN EARLY GEAR FAILURE. TO MOVE BEARING TOWARD
TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD
PINION.
FIG. 4
LOW BEARING ON GEAR AND HIGH BEARING ON PINION. CORRECT

BY PULLING PINION AWAY FROM GEAR (INCREASE MOUNTING DIS-
TANCE.
FIG. 5
HIGH BEARING ON GEAR AND LOW BEARING ON PINION. CORRECT

BY MOVING PINION IN TOWARD GEAR (DECREASE MOUNTING DIS-
TANCE.
BACKLASH
BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICU-
LAR TO THE TOOTH SURFACE AT THE EXTREME HEEL.
SM556 20 - 01 - 6
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
MOVE PINION TOWARD

GEAR !N THIS DIRECTION
MOVE PINION AWAY FROM

GEAR IN THIS DIRECTION
MOVE GEAR AWAY FROM MOVE GEAR TOWARD

V PINION tN THIS DIRECTION PINION IN THIS DIRECTION A
LARGE END ALL CONTACT BEARINGS SHOWN BELOW ARE ON RIGHT HAND SPIRAL
RING GEAR - THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH.
FIG. 1
TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH
WHILE UNDER A LIGHT LOAD
FIG. 2
TOE BEARING ON BOTH SIDES OF TOOTH - GEAR SET NOISY. TO MOVE
BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOV-
ING GEAR AWAY FROM PINION.
FIG. 3
HEEL BEARING ON BOTH SIDES OF TOOTH - GEARSET NOISY AND
COULD RESULT IN EARLY GEAR FAILURE. TO MOVE BEARING TOWARD
TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD
PINION.
FIG. 4
LOW BEARING ON GEAR AND HIGH BEARING ON PINION. CORRECT
BY PULLING PINION AWAY FROM GEAR (INCREASE MOUNTING DIS-
TANCE.
FIG. 5
HIGH BEARING ON GEAR AND LOW BEARING ON PINION. CORRECT
BY MOVING PINION IN TOWARD GEAR (DECREASE MOUNTING DIS-
TANCE.
BACKLASH
BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICU-
LAR TO THE TOOTH SURFACE AT THE EXTREME HEEL.
SM556 20 - 01 - 9
GROUP 22 SECTION 01 22-01-02 CUSHION DRIVE TIRE
REMOVAL
CUSHION WHEELS AND
TIRES
SAFETY NOTE
To perform this service procedure,
CONTENTS NO. it is recommended that you first:
DRIVE & STEER TIRE SPECS 22-01-01 Park truck on a level surface.Put
DRIVE WHEEL REMOVAL 22-01-02 the upright in a vertical position and
DRIVE TIRE INSPECTION 22-o l-03 lower the carriage fully down.
DRIVE TIRE REPLACEMENT 22-o l-04 Turn key switch OFF.
DRIVE WHEEL INSTALLATION 22-01-05
STEER WHEEL REMOVAL 22-01-06
STEER TIRE INSPECTION 22-01-07 Use a portable jack of correct capacity placed
STEER TIRE REPLACEMENT 22-O l-06 under the frame of the truck to raise the drive
STEER WHEEL INSTALLATION 22-03-09 wheel off the ground. Refer to Machine Jacking
and Blocking Group for details.
Remove the drive wheel mounting bolts.
22-01-01 CUSHION DRIVE &

STEER TIRE SPECIFICATIONS
NOTICE
The cushion drive and steer tires specified
for the ESM 12 - 25 Series fork lift trucks
were chosen after extensive testing as the
best combination of tread and shape
design and material compounding,
including hardness, to provide the
required wear and handling characteristics.
Standard Cushion Drive Tire Size:
ESM 12,158,15 18x7x12.1 2 Remove the tire and wheel assembly from the
ESM 17,20 18X8X1 2.12 drive axle hub.
ESM 22,25 18x9x1 2.12
Steer Tire Size: All models 9x5 22-01-03 CUSHION DRIVE TIRE
.INSPECTION
IMPORTANT Remove objects (nails, metal fragments, etc.)
The user Is advised that embedded in the tread of the tire. Be careful not
replacement of the original to further damage the tire when removing these
equipment tires with tires other objects.
than those recommended by
CLARK may result in decreased
operating performance and
stability.
SM556 22 - 01 - 1
Position tire on a hydraulic press. Be sure there is
Check the tire for separation from the base band. If adequate clearance for the tire to be pressed off
a thin steelrule or similar tool can be inserted more wheel assembly.
than [I2 mm] 0.5 inch into the separation area from
the side of the tire, the tire should be replaced. Be sure to take note of the mounting distance that
the original tire is offset on the wheel (distance
from edge of tire base band to edge of wheel).
Check the tire tread. If the tread is worn down to [6
mm] 0.25 in. or less in height, the tire should be Use suitable tooling with the hydraulic press to
replaced. correctly contact the base band of tire to press it off
the wheel.
Check the tire for damage from chunking or heat
damage. This is a judgment requirement for
replacement. In general, if the damage is greater
than [12 mm] 0.5 in. deep and involves more than
[650 mm21 4 in2 , it will usually affect the tire
performance and the tire should be replaced.
Look for bulges or other evidence of internal

damage. Replace all tires that show evidence of
internal damage.
22-01-04 CUSHION DRIVE TIRE

REMOVAL AND REPLACEMENT
The correct procedure for tire removal and

replacement requires a suitable press for pressing
tire off wheel and for pressing new tire onto wheel.
Install new tire. Be sure to press the tire on the
wheel with the same offset as measured above
when originally installed.
22-01-04 CUSHION DRIVE

WHEEL INSTALLATION
Be sure the truck is safely positioned on a level

floor and upright fully lowered.
SM556 22 01-2
Use a portable jack of correct capacity placed
under truck frame to raise truck off the floor and
permit drive tire and wheel assembly to be
positioned on truck drive axle hub.
Install drive wheel mounting bolts and tighten to a

torque of [225 - 275 Nom] 188 - 203 Ibfaft.
Lower truck to floor and remove jack.
22-01-06 STEER WHEEL

REMOVAL
SAFETY NOTE
To perform this service procedure,
it is recommended that you first:
Check the tire for separation from the base band. If
Park truck on a level surface.Put
a thin steel rule or similar tool can be inserted more
the upright in a vertical position and
than [12 mm] 0.5 inch into the separation area from
lower the carriage fully down.
the side of the tire, the tire should be replaced.
Check the tire for damage from chunking or heat

1. Turn steer axle trunnion to expose axle shaft
damage. This is a judgment requirement for
fastener (item 26.223).
replacement. In general, if the damage is greater
than [12 mm] 0.5 in. deep and involves more than
[650 mm21 4 in2 , it will usually affect the tire
performance and the tire should be replaced.
3. Use a portable jack of correct capacity placed
under the frame of the truck to raise the steer
Look for bulges or other evidence of internal
wheel off the floor. Be sure that truck is correctly
damage. Replace all tires that show evidence of
and safely blocked up. Refer to Machine Jacking
internal damage.
and Blocking Group for details.
4. Remove axle shaft fastener (item 26.223).

22-01-08 STEER TIRE REMOVAL
5. Remove axle shaft (item 26.222) and steer AND REPLACEMENT
wheels.
The correct procedure for tire removal and
6. Remove wheel bearings (items 26.139 & replacement requires a suitable press for pressing
26.134) from steer wheels. Clean bearings and tire off wheel and for pressing new tire onto wheel.
thrust washer (item 26.140) and inspect for wear
or damage. Replace as required.
22-01-07 STEER TIRE

INSPECTION
Remove objects (nails, metal fragments, etc.)

embedded in the tread of the tire. Be careful not
to further damage the tire when removing these
objects.
SM556 22 - 01 - 3
I
</\;F&.,
0-c-__
/ ---_ -’
\ --__
r
26.352
26.353 -/ ‘,U _/ -\ .
‘\-’ --+a,
26.139 \
.134 ‘, ‘h%
STEER WHEEL & TIRE

23.006 TIRE, STEERWHEEL
23.031 UB~ELANDTIREASSEK~LY,STEB
26.134 BEAlUNG,STEBVIEL~I-
26.139 BEUING,ST'EER~~~
26.140 T~~Tw~~sTEEX~EELHW-B~~#G
26.222 AxLESEAFT,STEERwHm
26.223 FASTENER.sfeERwlIEEL~s~
26.352 FTlmNG-LUB, sTEERVBELmSEAFr
26.353 SPACER, STEXUHEELHUB OUTER BEARING
SM55622-01 -4
Position tire on a hydraulic press. Be sure there is
adequate clearance for the tire to be pressed off
wheel assembly.
Use suitable tooling with the hydraulic press to

correctly contact the base band of tire to press it off
the wheel.
Install new tire.
22-01-09 STEER WHEEL

INSTALLATION
Make sure the truck is safely positioned on a level

floor and upright fully lowered. Use a portable jack
of correct capacity placed under truck frame to
raise truck off the floor and permit tire and wheel
assembly to be installed on truck.
1. Pack wheel bearings with grease. Refer to

Specifications Group for proper grease. Install
wheel bearings in wheel.
2. Position wheels, thrust washer (item 26.140)

and wheel spacers (item 26.353) in steer axle
trunnion. Slide axle shaft (item 26.222) through
axle trunnion and wheels.
3. Install axle shaft fastener (item 26.223). Torque

axle shaft fastener to[40 - 45 Nem] 30 - 33 Ibfmft.
4. Lower truck to floor and remove jack.
SM556 22 - 01 - 5
GROUP 22 SECTION 02
PNEUMATIC DRIVE TIRE AND WHEEL MAINTENANCE
A! WARNING!
FOR YOUR SAFETY AND THE SAFETY OF OTHERS!
BEFORE YOU DO TIRE OR RIM MAINTENANCE:

READ THE OSHA RULES REGARDING OWNER
RESPONSIBILITY. DO NOT WORK ON TIRES OR RIMS
UNLESS YOU HAVE BEEN TRAINED IN THE CORRECT
PROCEDURES. READ AND UNDERSTAND ALL
MAINTENANCE AND REPAIR PROCEDURES ON TIRES
AND RIMS. SERIOUS INJURY OR DEATH CAN RESULT
IF THE SAFETY MESSAGES ARE IGNORED.
.
The Occupational Safety and Health Act (OSHA) specifies required

procedures for servicing multi-piece rim wheels in 29 CFR Section 1910.177.
It is the owners responsibility to comply with OSHA.
In accordance with OSHA, the owner must provide a training program to train
and instruct all employees who service multi-piece rim wheels in the hazards
involved and the safety procedures to be followed. Do not let anyone mount,
demount or service multi-piece rim wheels without correct training.
The owner should obtain and maintain in the service area current copies of
the United States Department of Transportation, National Highway Traffic
Safety Administration publications entitled “Safety Precautions for Mounting
and Demounting Tube-Type Truck/Bus Tires” and “Multi-Piece Rim/Wheel
Matching Chart” or other similar publications applicable to the types of multi-
piece rim wheels being serviced.
The following instructions supplement the OSHA requirements. In the event

of any conflict or inconsistency between these instructions and the OSHA
requirements, the OSHA requirements shall be controlling.
SM556 22 - 02 - 1
GROUP 22 SECTION 02
PNEUMATIC WHEELS AND
TIRES
CONTENTS NO.
PNEUMATICTIRE SPECIFICATIONS 22-02-01
PNEUMATICTIRE MAINTENANCE 22-02-02
DRIVEWHEELAND TIRE REMOVALAND

DISASSEMBLY 22-02-03
DRIVETlRE REPLACEMENT 22-02-04
DRIVEWHEELAND TIRE INSTALLATION 22-02-05
SAFETY PROCEDURES 22-02-06
22-02-01 PNEUMATIC DRIVE A! CAUTION

TIRE SPECiFlCATlONS Check tire pressure from a position
facing the tread of the tire, not the side.
Use a long-handled gauge to keep your
NOTICE body away from the side. If tires are low,
The pneumatic drive tires specified for the don’t add air. Have the tire and wheel
ESM 12 - 20 series fork lift trucks were inspected by a person trained and
chosen after extensive testing as the best authorized to do tire and wheel
combination of tread and shape design maintenance. The tire may require
and material compounding to provide the removal and repair. Incorrect (low) tire
required wear and handling characteristics. pressure can reduce the stability of your
lift truck and cause it to tip over.
Standard pneumatic drive tire size:
ESM 12,15S,15 18x7~8 16PR

ESM 17,20 18x9x8 16PR
22-02-02 PNEUMATIC TIRE

MAINTENANCE
/\ ! WARNING
Remove the air from the tires
before you remove wheels from
the truck.
Check for the correct tire air pressure.
Refer to Specifications Group for tire pressure IMPORTANT

specifications. Check wheels and tires for damage
every time you check tire pressure.
Make repairs when needed. Dirt can
get into cuts and cause damage to the
tire cord and tread. Remove debris
from all cuts.
SM556 22-02-2
Check the condition of pneumatic drive wheels
and tires. Remove objects that are imbedded in TIRES INSTALLED ON LOCK-RING TYPE
the tread. Inspect the tires for excessive wear, WHEELS
cuts and breaks.
Check all wheel mounting bolts to be sure none

are loose or missing. Have missing bolts replaced
and loose bolts tightened to the correct torque
A!WARNING
Before youloosen the wheel
before operating the truck. mounting bolts, remove the air
from the tire. Failure to remove
the air from the tire can result in
CHECKING, MINOR REPAIR & CLEAN-UP Injury.
Inspect pneumatic tires and wheels carefully for:
1. Low inflation pressure.

2. Damaged tire. Check tires for cuts and breaks.
3. Damaged wheels or loosening of the locking
rings on multi-piece rims.
4. Check for loose nuts or bolts not in position.
5. Check the bolts for damage.
6. Check the surface of the’ wheels for bent
flanges.
7. Check all parts for rust or corrosion.
8. Mark the damaged areas with chalk so that the
parts can be removed from operation.
9. Remove all parts that have damage and install
new parts in the same position. Remove valve core from the valve stem.
10. Replace parts with the correct sizes and types.
See your parts manual. Remove all air from the tire, then loosen and
11. Include your truck serial number when ordering remove the wheel mounting bolts. Remove the
replacement parts. wheel.
22-02-03 PNEUMATIC DRIVE

WHEEL AND TIRE REMOVAL AND
DISASSEMBLY
A! CAUTION
To perform these service procedures, it is
recommended that you first:
Park truck on a hard, level and solid surface.

Put upright in vertical position and fully lower
the forks or attachment.
Block the wheels.
Remove lock ring.
Refer to Machine Jacking and Blocking Group for
additional information.
SM556 22 - 02 - 3
Check for cracks in the wheel.
CRACKS IN THE WHEEL ARE CAUSED BY:

Remove wheel wedge. 1. Deep rim tool marks.
2. Too much load on wheels.
3. Too much air pressure in the tires.
/
4. Using the wrong size tires.
Remove tire from wheel.
0/
,Check ,.fordracks -W.,the lock ring.
CRACKSIN THE LOCK RING ARE CAUSED BY:

1. Deep rim tool marks.
2. Too much load on whels.
3. Too much air pressure in the tires.
4. Using the wrong size tires.
Remove the rubber tube protector

tire and/or tube.
SM556 22 - 02 - 4
Clean the wheels. Remove rust and dirt.
Check for cracks between the stud holes

in the wheel.
CRACKS ARE CAUSED BY:

1. Loose wheel mounting bolts.
2. The wheel was not installed correctly.
3. The wrong size or type of parts was used.
4. Too much torque on the wheel fasteners. If the

wheel mounting bolts are too tight, the bolts can
break, causing cracks in the wheel between the
stud holes.
5. Too little torque on the wheel mounting bolts. If

the wheel mounting bolts are loose, damage to
parts and tire wear will result.
Clean the tire bead seat area. Remove all
rust and rubber.
Check wedge ring for wear or damage.
CORROSION BUILDUP WILL CAUSE WEAR AND

DAMAGE TO THE WHEEL WEDGE RING.
Clean wedge and lock rings. Make sure
the seating surface and bead seat areas
are clean.
SM556 22 - 02 - 5
22-02-04 PNEUMATIC DRIVE TIRE
REPLACEMENT
Put the tube into the tire. NOTE - Install washer

22.095 on tube over valve stem before flap is
Apply paint to the tire rim with a brush, or use an installed, if specified.
aerosol can of metal primer.
The parts must’be clean and dry-before you apply

the paint. Make sure to apply paint to the outside WHEEL WASHER
I
or tire side of the rim. This is important because air
is on the metal surface of the tire side of the rim.
_L_-A J- * Ml7
x3, - &II
InEEL
4v.s IbJSTILL WASnER
VALVE
22 09s wlwEEt4
STEM OPEwPui *No nJ9E.
Put the rubber tube protector (flap) over the tube.
Apply lubricant on the tire side of the rim base. Do

not use a lubricant that has water or solvent which
will cause damage to the rubber. CLARK Install the tire onto the wheel rim, against the bead
DEALERS CAN SUPPLY THE CORRECT seat area.
LUBRICANT WHICH CONTAINS A RUST
INHIBITOR.
SM556 22 - 02 - 6
Connect air chuck and put [21 kPa] 3 psi of air into
the tire.
Put the wheel wedge over the rim.
Turn wheel to the other side. Check to make sure

lock ring is in correct location.
Install the wheel wedge.
Use a mallet and hit the ring to make sure the ring is
Put the side ring over the rim and install the lock fully installed. Disconnect the air chuck.
ring as shown.
SM556 22 - 02 - 7
FILLING TIRES WITH AIR
All wheel and tire assemblies must be

filled In a safety cage. The air hose and
components should be arranged as shown on
page 9. The hose must have an adapter that can
be connected to the valve stem.
1. Attach an air hose to valve stem.
2. Open the control valve which will let

compressed air into the tire.
3. At intervals, close the control valve and check

the pressure in the tire by reading the gauge. Do
not overinflate the tire.
4. Continue to inflate the tire to the correct air

pressure reading.
IMPORTANT
Put equal air pressure in both tires of a
dual assembly. Do not put air into a tire
that is flat without first inspecting it and the
wheel for damage.
Put the tire in an OSHA-approved safety cage.
FILLING TIRES WITH NITROGEN
Follow the procedures on the next two pages
when you put air into your tires.
HOW TO ADJUST THE REGULATOR ON
THE NITROGEN CYLINDER
A! WARNING
Make sure all items of equipment used
(nitrogen cylinder, regulator, gauges, hoses) Be sure cylinder valve is closed.
are UL approved and in good condition. Use
the correct regulator and hose for the
pressures that are necessary.
NOTE - If your air supply does not have enough

pressure to fill the tire, you can use a pressurized
cylinder of commercial nitrogen gas to get the
correct tire pressure. Connect the nitrogen
cylinder to the valve stem with the use of an air
chuck. BE SURE TIRE IS STILL IN SAFETY
CAGE! Refer to “How to adjust the regulator on
the nitrogen cylinder”.
/\ ! WARNING
Use nitrogen only. DO NOT use oxygen or Turn the regulator valve counterclockwise (CCW)
any other gas to fill your tires. until you can feel no resistance from the regulator.
This will adjust the regulator pressure to a low
pressure near zero.
SM556 22 - 02 - 8
SAFETY
CAGE
AIR
GAUGE /
SHUTOFF \\ I I
VALVE \ a
SOUR CE
OF A,IR
SUPP LY
Fig. 9702 Typical Tire Filling Procedure
Slowly turn the cylinder valve counterclockwise The tank gauge will now show tank pressure.
(CCW) to open position.
SM556 22 - 02 - 9
Turn the regulator valve clockwise (CW) until the
regulator gauge reads the correct tire pressure. Fill
the tire with nitrogen.
Turn the regulator valve counterclockwise (CCW)
to the off position.
Use a tire pressure gauge to check the tire

pressure. If necessary, put more air into the tire.
Do this as many times as necessary to reach the
correct tire pressure.
n ! CAUTION
Use a long-handled gauge so that
your hand does not go Inside the
cage, or in front of any component
of a multi-piece wheel.
Turn the tank valve clockwise (CW) and close
the valve.
PROCEDURES FOR ADDING AIR

PRESSURE TO MOUNTED TIRE
AND WHEEL ASSEMBLIES
Disconnect the air chuck from the valve stem.
SM556 22-02-10
Put a clip-on type air chuck on the nitrogen
cylinder hose and attach it to the valve stem. Refer
to “How to adjust the regulator on the nitrogen
cylinder” for details.
/\ ! WARNING
Use nitrogen only to fill your tires.
DO NOT use oxygen or any other
gas.
/\ ! WARNING
Before you add air pressure to the DIRECTIONAL-TREAD TIRES
tire, make sure the lock ring is
correctly positioned In the rlm and All directional- tread tires are to be mounted in the
side ring. The lock ring can
correct position with respect to the arrow cast on
separate from the rim with enough
the side of the tire as explained below.
force to cause injury or death.
INSIDE
FRONT OF TRUCK
1. Tire arrow to point in the direction of forward

rotation.
Attach a clip-on air chuck to valve stem. Stand by
the side of the wheel and put the correct air Rotate wheel to bring arrow on tire above the
pressure in the tire. wheel center. Arrow must point toward front of
truck.
If your air supply does not have enough pressure
to fill the tire, you can use a nitrogen cylinder to get
the correct pressure. 22-02-05 PNEUMATIC DRIVE
WHEEL AND TIRE INSTALLATION
Be sure the truck is safely positioned on a level

floor and upright fully lowered.
SM556 22-02-11
corrosion. The filter should be checked
Use a portable jack of correct capacity placed periodically to make sure it is working properly.
under truck frame to raise truck off the floor and
permit drive tire and wheel assembly to be 9. Make sure correct parts are being assembled.
positioned on truck drive axle hub. Ask your distributor or the manufacturer if you have
any doubts.
Install drive wheel mounting bolts and tighten to a
torque of [225 - 275 Nom] 188 - 203 Ibf*ft. 10. Do not be careless or take chances. If you are
not sure about the proper mating of rim and wheel
Lower truck to floor and remove jack. parts, consult a wheel and rim expert. This may be
the tire man who is servicing your fleet, the rim and
wheel distributor in your area, or the CLARK
22-02-06 SAFETY PROCEDURES dealer.
1. Do not fill a tire with air that has been run flat 11. Mixing parts of one manufacturer’s rims with
without first inspecting the tire, rim and wheel those of another is potentially dangerous. Always
assembly. Double check the lock ring for damage. ask manufacturer for approval.
Make sure that it is secure in the gutter before
filling the tire with air. 12. Do not use undersized rims. Use the right rims
for the job.
2. Never sit on or stand in front of a tire and rim
assembly that is being filled with air. Use a clip-on 13. Do not overload rims. Ask your rim
chudk and make sure hose is long enough to manufacturer if special operating conditions are
permit the person filling the tire with air to stand to required.
the side of the tire, not in front or in back of the tire
assembly. 14. Do not seat rings by hiiing with a hammer while
the tire is filled with air pressure. Do not hit a filled
3. Do not let anyone mount or demount tires or partially-filled tire/rim assembly with a hammer.
without proper training.
15. Double check to make sure all the components
4. Always remove all air from a tire and prior to are properly seated prior to filling tire with air.
removing any rim components.
16. Fill the tire with air in a safety cage.
Always remove the valve core to remove air from
tire. Be sure all air is removed from the tire. Check 17. When removing wheels, regardless of how
the valve stem by inserting a piece of wire through hard or firm the ground appears, put hardwood
the stem to make sure it is not plugged. blocks under the jack.
5. Check rim components periodically for fatigue 18. Block the tire and wheel on the other side of
cracks. Replace all cracked, badly worn, damaged the vehicle, before you place the jack in position.
and severely rusted components. Place blocks under the truck frame as near as
possible to the jack to prevent the truck from falling
6. Do not, under any circumstances, attempt to if the jack should fail.
rework, weld heat, or braze any rim components
that are cracked, broken or damaged. Replace 19. Remove the bead seat ‘band slowly to prevent
with new parts or parts that are not damaged, which it from dropping off and crushing your toes.
are of the same size, type and make. Support the band on your thigh and roll it slowly to
the ground. This will protect your back and feet.
7. Never attempt to weld on an inflated tire/rim
assembly. 20. Bead breakers and rams apply pressure to
bead flanges. Keep your fingers away from the
8. Clean rims and repaint to stop detrimental bead flanges. Slant bead breaker about 10” to
effects of corrosion. Be very careful to clean all dirt keep it firmly in place. If it slips off, it can fly with
and rust from the lock ring gutter. This is important enough force to kill. Always stand to one side
to secure the lock ring in its proper position. when you apply hydraulic pressure.
A filter on the air filling equipment to remove the 21. When using a cable or chain sling, stand away
moisture from the air line prevents a lot of (clear). It might break.
SM556 22-02-12
Group 23, Brakes
Group 23
Section 1
Brake System and Bleeding
Brake System Description ...................................................................... 2

Brake Bleeding Procedure ...................................................................... 3
SM 556, Jan ‘96 Copyrighted Material 23-l-l

Group 23, Brakes
Brake System Description IMPORTANT

The brake system consists of a brake assembly, equipped The brakes on this truck are snt self adjusting
with a slave cylinder, mounted on top of each drive motor. and must be periodically checked and adjusted
They are spring applied and hydraulically released by a brake as needed. If adjustments are not made as re-
pedal and a master cylinder. A plastic reservoir supplies fluid quired then the slave cylinder can run out of
to the master cylinder. When the brake pedal is depressed, a stroke and the springs will not apply the brakes.
mechanically operated switch activates the electrical circuit Thisconditionwillh&beasuddenevent,butwill
to the drive motors. The fast l/32 of an inch of movement result in a gradual loss of braking capability. If
closes the passage from the reservoir to the master cylinder. the brakes begin to get “soft? this is an indication
that the slave cylinder has possibly “bottomed
Force applied to the foot pedal, forces brake fluid from the
out” and the brakes have NOT been adjusted as
master cylinder through the brake lines to the slave cylinders.
needed. See 2342
The slave cylinders disengage the brakes by rotating the
brake arms against spring force. When force on the foot pedal
is removed, fluid is forced from the slave cylinders as the
brake arms return under spring force. The release of the brake
A WARNING
Failure to follow these procedures will cause a
fluid pressure allows the springs to engage the brakes. loss of brakes and may cause property damage
an/or severe or fatal bodily injury.
Reservoir
Bleeder Screw
Foot
23-1-2 Copyrighted Material SM 556, Jan ‘96

Group 23, Brakes
Brake Bleeding Procedure 7. Cheek level in brake fluid reservoir and refill as required.
1. Turn key switch OFF and disconnect battery. 8. While an assistant pumps the brake pedal, crack each
bleeder screw separately to expel air into fluid containers.
2. Remove two front and top compartment covers. Repeat this pumping procedure 5 or 6 times, or until all air
is removed from brake system. Frequently check the
brake fluid level in the reservoir and refill as required.
0
Reservoir
+E!s IMPORTANT
Be sure ends of bleed lines remain fully im-
mersed in fluid or air will be drawn back into
brake system.
9. When brake system bleeding is completed, remove bleeder

screw discharge lines and tighten bleeder screws. Check
the brake fluid level in the reservoir and refill as required.
11. &connect battery and test truck brake operation.
NOTE
A brake system pressure bleeder may also be
3. Clean all dirt and contamination from brake fluid reser- used. Follow direction furnished with unit.
voir and cap. Fill brake fluid reservoir to full mark.
NOTE
Use only SAE J1703b DOT 3 brake fluid.
4. Clean bleeder screws located on top of each slave cylin-

der. Install bleeder screw discharge lines from both bleed
screws. Fully immerse open end of each bleed line into a
container of clean brake fluid.
5. Crack (loosen slightly) bleeder screws.
Bleeder Hose
Il
Air Bubbles
Brake Fluid
6. Air bubbles will be seen in brake fluid containers as lines

and slave cylinders fill with fluid. Wait until air bubbles
stop, then close both bleeder screws.
SM 556, Jan ‘96 Copyrighted Material 23-1-3

Group 23, Brakes
Group 23
Section 2
Brake Master Cylinder
Master Cylinder Operation ..................................................................... .3

Master Cylinder Removal ....................................................................... 2
Master Cylinder Disassembly ................................................................. 3
Master Cylinder Inspection .................................................................... 4
Master Cylinder Assembly ..................................................................... 4
Master Cylinder Installation ................................................................... 4
SM 566, Jan ‘96 Copyrighted Material 23-2-l

Group 23, Brakes CIRRU
Brake Master Cylinder Operation Brake Master Cylinder Removal
When pressure is applied to the foot pedal, the push rod 1. Turn key switch OFF and disconnect battery.
contacts the plunger and pushes it down the bore of the 2. Identify and disconnect wire leads to drive motor cut-off
cylinder. During the first [0.08 mm] l/32 inch of movement, switch.
the spring washer fitted under the valve head resumes its 3. Disconnect line to brake slave cylinders.
natural “bowed” shape and closes the port to the fluid 4. Pinchoffanddisconnectfluidreservoirline(item23.794).
reservoir. As the plunger continues to move down the bore, 5. Remove master cylinder bracket fasteners (items 90.493
fluid is forced through the brake lines to the brake slave & 94.784). Remove master cylinder and bracket as an
cylinders. assembly.
6. Remove cotterpin and clevis pin (items 92.026 & 23.118)
When pressure on the foot pedal is released, the plunger from master cylinder push rod clevis. Remove master
moves back with the return of the brake fluid. The final cylinder mounting boltsand nuts (items 23.156 & 90.092)
movement of the plunger compresses the spring washer, and withdraw mastercylinder from bracket (item 23.434).
lifting the valve seal off its seat and opening the fluid
reservoir port Brake fluid then moves freely between the
master cylinder and the fluid reservoir.
90.493
94.784
L 23.434
Figure 1. Master Cylinder Removal/Installation

Group 23, Brakes
Brake Master Cylinder Disassembly

NOTE
1. Remove push rod clevis and jam nut (items 22.240 & If the seals are loose on the plunger and appear
22.027). See Figure I oversize, suspect contamination. Compare the old
seals with the new, but don’t let them touch. If the
2. Remove fluid reservoir line nipple (item 23.795) and seal old seals are significantly larger, contamination is
(item 22.342). See Figure I indicated. The brake system should be thoroughly
flushed and all hoses replaced.
3. Remove the rubber dust cover by carefully removing the
metal retaining band. See Figure 2 5. Lift the leaf of the spring retainer and remove the spring
assembly from the plunger. Compress the spring to free
4. Remove the plunger assembly by shaking the master the valve stem from the keyhole of the spring retainer,
cylinder. See Figure 2 thus releasing the spring tension. Remove the spring,
valve spacer and spring washer from the valve stem and
the valve seal from the valve head.
Plunger
Push Rod Assembly
Retaining
Washer
Circli
Dust-
Cover
Retainer
Figure 2. Master Cylinder Disassembly/Assembly

Group 23, Brakes
Master Cylinder Inspection

Clean the cylinder body and plunger in a commercial parts Master Cylinder Installation
cleaning fluid and then thoroughly rinse with a Stoddard-type 1. Install push rod clevis and jam nut (items 22.240 &
solvent or clean brake fluid. Clean rubber parts in Stoddard- 22.027). Tighten jam nut securely. See Figure 1
type solvent and rinse in clean brake fluid. Use only low-
pressure compressed air or a lint-free cloth to dry parts. Lay 2. Fit master cylinder into bracket (item 23.434) and install
the cleaned parts on a clean sheet of paper and protect from fasteners (items 23.156 & 90.092). Install master cylinder
contamination until re-assembly. clevis pin and cotter pin (items 23.118 & 92.026). See
Figure 1
Inspect the piston and cylinder bore for visible score marks,
ridges, and corrosion. Check that the cylinder bore is smooth 3. Install master cylinder and bracket assembly fasteners
to the touch. Replace the master cylinder if there is any doubt (items 90.493 & 94.784). See Figure 1
about its serviceability. Inspect all other components to make
sure they are in good condition. 4. Connect wire leads to drive motor cut-off switch.
5. Connect brake fluid reservoirline (item 23.794) to master

Master Cylinder Assembly cylinder and unpinch line. See Figure 1
Use all parts from the service kit.
1. Lubricate inner diameter of new plunger seal with clean 6. Connect line to brake slave cylinders.
brake fluid. Install the seal on the plunger.
7. Bleed brake system. Refer to hydraulic brake system
2. Install the valve seal, small diameter first, onto the valve group for details.
head. Position the spring washer on the valve stem so that
it “flares” away from the valve stem shoulder as shown. 8. Connect battery and test truck brake operation.
(Fig 2) Follow with the valve spacer, ‘legs’ first, and
spring.
3. Fit the spring retainer to the spring. Compress the spring

until the valve stem passes through the ‘keyhole’ in the
spring retainer and engages in the center. Slide the spring
sub-assembly onto the piston until the spring retainer leaf
locks the sub-assembly to the piston.
4. Coat the piston seal and cylinder bore with clean brake
fluid. Insert the piston assembly, valve end first, com-
pletely into the cylinder bore, easing the entrance of the
piston seal.
5. Position the push rod and retaining washer and install the
c&lip.
6. Smear the sealing areas of the dust cover with rubber

grease and insert the push rod. Pack the dust cover with
theremainder of the rubber grease. Position the dust cover
on the cylinder body and install the rubber band and metal
clip.
7. Install fluid reservoir line nipple (item 23.795) and seal

(item 23.342). Use new seal. See Figure 1
8. Cover the master cylinder ports to keep out foreign matter

until cylinder installation is complete.
Copyrighted Material SM 666, Jan ‘96

23-2-4
Group 23, Brakes
Group 23
Section 3
Brake Slave Cylinder
Slave Cylinder Operation ............................................................ 2

Slave Cylinder Removal .............................................................. 2
Slave Cylinder Disassembly ....................................................... 3
Slave Cylinder Inspection ........................................................... 3
Slave Cylinder Assembly ............................................................ 3
Slave Cylinder Installation ........................................................... 3

Group 23, Brakes CWIIW
Brake Slave Cylinder Operation Slave Cylinder Removal
When pressure is applied to the foot pedal, the master 1. Turn key switch OFF and disconnect battery.
cylinder forces fluid to the slave cylinders. The slave cylin- 2. Remove two front covers and top compartment cover.
ders in turn disengage the brakes by rotating the brake arms 3. Disconnect line to brake slave cylinder.
against spring pressure. When pressure on the foot pedal is 4. Release pushrod spring pressure by backing off locknut
released, fluid is forced from the slave cylinders as the brake and adjusting nut (item 23.859).
arms return under spring pressure. The release of brake fluid 5. Remove slave cylinder mounting fasteners (items 23.259
pressure allows the brakes to engage. & 95.794).
6. Remove slave cylinder assembly.
. .
o.~~.”:
:” .
-? ______..
... ,....,‘:
‘..
;\,
“,x.
$$ . . ..:,,- ..
_..’
“’ .h L /=FTHAND
.!!
ye....:*_ c..;.* +’ :
!
i MOTOR
RIGHTHAND
MOTOR
- FRONT
Figure 1. Brake Slave Cylinder Removal

CWRK Group 23, Brakes
Slave Cylinder Disassembly Slave Cylinder Assembly

Use all parts from the service kit.
1. Remove rubber boot (item 22.059R). 1. Fit spring seat and spring into cylinder bore.
2. Remove retaining ring and internal components. Remove
bleeder screw (item 23.223R) and plug (item 22.467R). 2. Lubricate new piston cup with clean brake fluid and
install. Install piston, retaining ring, and rubber boot.
3. Re-install bleeder screw (item 23.223R) and plug (item

22.467R).
Slave Cylinder Installation

1. Fit push rod (item 23.252) into seat of slave cylinder
piston. Mount slave cylinder to bracket (item 22.546,
R.H. or 22.547, L.H.) with fasteners (items 23.259 &
95.794). Torque fasteners to (9.4 - 10.6Nem) 83-94lbfG.n.
2. Connect line to brake slave cylinder.
3. Adjust brake. Refer to service brake group for details.
3. Bleed brake system. Refer to hydraulic brake system

group for details.

Figure 2. Slave Cylinder
5. Connect battery and test truck brake operation.
Slave Cylinder Inspection
Cleanthecylinderbodyandothermetalpartsinacommercial
parts cleaning fluid and thoroughly rinse with a Stoddard-
type solvent or clean brake fluid. Clean rubber parts in
Stoddard-type solvent and rinse in clean brake fluid. Use only
low-pressure compressed air or a lint-free cloth to dry parts.
Lay the cleaned paas on a clean sheet of paper and protect
from contamination until reassembly.
Inspect the piston and cylinder bore for visible score marks,
ridges, and corrosion. Check that the cylinder bore is smooth
to the touch. Replace the slave cylinder if there is any doubt
about its serviceability.

Group 23, Brakes
Group 23
Section 4
Knott Brake Assembly
Brake Operation ......................................................................... 2

Brake Inspection and Adjustment ............................................... 2
Brake Disassembly ..................................................................... 3
Brake Shoe Replacement ........................................................... 4
Brake Assembly ........................................................................... 4
NOTE: For Mercury Brake Assembly see 23-4A- 1

Group 23, Brakes
Brake Operation
The brakes are spring applied and hydraulically released. Removing allfoot force from the foot pedal will fully apply the brakes.
Raising the foot pedal releases the hydraulic pressure in the slave cylinder, allowing the spring forces t&rotate the brake arms
thus applying the brakes. Brake arm rotation rotates a cam inside the brake assembly that forces the brake shoes onto the brake
drum.
90.766 ~ _ 90.997
23.252
,,/ :.,
3. . .._. .._,b. .‘; LEFTHAND
:‘&.z.v.g.3,
.....n&:..@ ; MOTOR
<?............... y&
..&
.,+.::............... ..-;y<:.: ..,
‘, .... ::_...;:.::a.
-. ..........
. .
FRONT
Figure 1. Knott Service Brake
2”
Shoe Pivot Pins
Adjust cam arm within the range shown above.
Figure 2.

Group 23, Brakes
l$z!j- 90.997
I
90.996 @
22.408
22.404
e 22.407
Snap Ring-G 22.406

Backing Plate
Cam w/Splines
23.319
I
Figure 3. Knott Brake
Knott Brake Inspection and Adjustment
Note: Some ESM trucks have been fitted with adjustable 8. With the brakes applied that is, the foot pedal in the fully
length push rods. For all of the following procedures raised position, release andremove the nut (item90.997) and
this push rod should be set to 7.559” (192mm) long, washer (item 90.996) on the top of the brake drum.
over all length. 9. Depress the pedal to release the brakes and block the pedal
in the down position. Remove the drum (item 22.408) from
IMPORTANT the motor shaft, using a soft facedmallet as needed. Remove
Read the complete instructions before starting work. the key (item 16.041) from the keyway in the shaft.
10. Remove the shoes (item 22.404) from the brake assembly,
being careful to not lose the springs (item 22.407) on the
1. Safely park the truck on level surface.
shoes. Place shoes in a place that will not contaminate them
2. Lower forks to the ground.
with oil.
3. Tum off key switch 11. Inspect theconditionoftheshoeliningmaterial. Itshouldnot
4. Disconnect the battery. be glazed. There should be more than 3/X?’ of thickness of
5. Remove the front covers to gain access to the brake assem- material left on the shoe. If the lining material shows signs of
blies. heavy glazing, or heat distress such as cracking or discolora-
6. Depress the foot pedal to release the brake. Rotate the brake tion, then the shoes and linings MUST be replaced. Do not
drum by hand so that the brake shoe pivot pins can be seen proceed with this adjustment. See Brake Shoe Replacement
through the vent holes in the brake drum. instructions. Always replace shoes in sets, both left and right
7. Measure, from a straight line through the brake shoe pivot sides. DO NOT replace only one shoe, or only one side.
pins, the angle of the brake arm. If the angle is within the 0 12. Ifthebrakeshoesareinguudusableconditionandthearmneeds
to 12’ as shown in Fig. 2, then the brake arm is correctly adjustment,then continue with the following procedures.
adjusted. Inspect the amount of lining on the shoe through 13 Inspect the drum for scoring or any other abnormal wear.
the drum vent hole. If the lining appears to be less than 3/32 Service drum surface or replace drum as needed.
of an inch, the drum must be removed for a closer examina- 14. Remove the cotter andthe pin (item 90.765,95.745,90.766)
tion of the shoes and drum. Brakes with more than 3/32” of connecting the brake arm to the push rod.
lining material and the arm between 0” and 12” are fit for 15. Loosen and remove the four fasteners holding the brake
continued service. If the angle is greater than 12”the brakes backing plate to the drive motor.
must be adjusted. These checks must be performed for both 16. Remove the snap ring holding the brake arm (item 23.3 19)
the left and right hand side brake assemblies. and cam together.

Group 23, Brakes
17. Lift the backing plate just enough to allow removal of the The ANSI standard requirement for these brakes is that they
arm and cam from the backing plate. Be careful to not hold the truck and a rated load on a 15% grade. If such a grade
have the arm/cam assembly come apart. They are splined is available, after adjustment, the brakes can be tested by
together. slowly and carefully driving the truck with a rated capacity
lS.Carefully separate the cam from the arm, noting their load straight up a known 15% grade, with the load upgrade
relative positions, and, then reposition the cam in the arm and bringing the truck to a stop with the brakes applied. If the
by indexing one spline m from the slave cylinder. brakes hold the loaded truck stationary on the grade the
19. Replace the arm/cam assembly into the backing plate and brakes are satisfactorily set. After observing the performance
seat the snap ring back into its groove. Ensure the snap of the brakes slowly drive the truck straight back down the
ring is fully seated in the groove. grade. Do not try to perform any maneuvers on the grade.
20. Set the backing plate on the motor, insert and torque the While this is a test method, the ESM is m intended for use
fasteners, [20-22 N.m] 177-1941bf.in., holding the plate on 15% grades, except as encountered for short distances
to the motor. such as dock plates. If no grade is available, the brakes can be
21. Install the brake shoes and springs. approximately tested by measuring the stopping distance as
22. Pump the foot pedal to extend the push rod from the slave follows. Test only with an unloaded truck in a pedestrian and
cylinder. Connect the arm to the push rod with thepin and traffic free aisle. An empty parking lot with a smooth, level
cotter. Slip the drum on the motor shaft and release the surface is also a good operating location. Mark a line on the
footpedal.Measmetheangleofthearmagain.Iftheangle floor or note a floor joint as a measurement line. Starting at
is within the 0” to 12” as shown in Figure 2, the adjustment a point approximately 150 to 200 feet in front of the line, drive
is correct. If the angle is still not within this range then the buck in a straight line at full speed towards the line. As the
index the arm one more spline. front wheels roll over the line apply the brakes by raising the
23.When the setting is correct, depress the foot pedal and brake pedal. When the truck has come to a complete stop,
block in the down position. Remove the drum, insert the safely park the truck at this same spot and measure the
key in the keyway and replace the drum. Release the foot distance from the front wheels to the measurement line. This
pedal to its up position. is your stopping distance. Compare to the table below for the
model you are working with. If the measured distance is less
24.Replaceand torque, [95-108 N.m] 70-80lbf.ft. thewasher
than the table value then the brakes are satisfactorily set. (The
and nut on the motor shaft. Note thepedal should be in the
approximate rule of thumb is that the stopping distance for an
raised position to facilitate torquing the nut.
ESM without a load shall be between l-114 (one and one
25. Repeat for the other brake
quarter) and l-1/2 (one and one half) times the length of the
26.Check and, set as needed, the brake actuating spring on
truck with no forks.)
both brakes. With the brakes applied the spring length
should be 2”. Be sure when tightening the two nuts to use
Model Distance inches
TWO wrenches. If two wrenches are not used damage to
ESM12 100
the brake lever will result.
ESMlSS 100
27. Replace the front covers.
ESM15 97
28. Connect the battery. ESM17 94
29. Check the operation of the brakes. They should not pull ESM20 92
to either side. ESM22 90
IMPORTANT
ESM25 90
TheESM brakes are not self adjusting, but need to be
periodically inspected and adjusted accordingly. If
adjustments are not made as required, the slave Brake Disassembly
cylinder can run out of stroke, and the springs will IMPORTANT
not apply the brakes. This condition will not be a Read the complete instructions before starting work.
sudden event, but will result in a gradual loss of 1. Safely park the truck on level surface.
braking capability. If the brakes begin to get “soft”, 2. Lower forks to the ground.
this is an indication that the slave cylinder may be 3. Turn off key switch.
“bottoming out” and the brakes have not been ad- 4. Disconnect the battery.
justed as needed. Checking the brake adjustment 5. Remove the front covers to give access to the brake
setting in addition to the driving test must be part of assemblies.
the Planned Maintenance program. When the covers 6. With the brakes applied, that is, the foot pedal in the fully
are removed for air cleaning the travel controls, the raised position, release and remove the nut and washer on
brake arm positioning and lining wear must be in- the top of the brake drum.

Group 23, Brakes
7. Depress the pedal to release the brakes and block the pedal 12. If the setting is now correct, depress the foot pedal and
in the down position. Remove the drum (item 22.408) from block in the down position. Remove the drum (item
themotor shaft, using a soft facedmallet as need. Remove the 22.408), insert the key (item 16.041) in the keyway and
key (item 16.041) from the keyway in the shaft. replace the drum. Release the foot pedal to its up posi-
8. Remove the shoes (item 22.404) from the brake assembly, tion.
being careful to not lose the springs (item 22.407) on the 13. Replace and torque, [95-108 N.m] 70-80 lbfft. the
shoes. Place shoes in a place that will not contaminate washer (item 90.996) and nut (item 90.997) on the motor
them with oil. shaft. Note: The pedal should be in the raised position to
9. Remove the cotter and the pin (items 90.766 and 90.765) facilitate torquing the nut.
connecting the arm to the push rod. 14. Repeat for the other brake.
lOLoosen and remove the four fasteners holdingthe brake 15. Check and, set as needed, the brake actuating spring to
backing plate (item 22.406) to the motor. Lift the backing the correct length of 2”. Be sure when tightening the two
plate from the end of the motor. nuts to use TWO wrenches. If two wrenches are not used
11.Remove the snap ring holding the brake arm and cam damage to the brake lever will result.
.ogether and remove cam (item 23.319) and lever from 16. Replace the front covers.
>acking plate. 17. Connect the battery.
18. Check the operation of the brakes. They should not pull
Brake Shoe Replacement to either side.
IMPORTANT 19. Burnish the brakes. Load the truck with a rated load and
Always replace shoes in sets, that is, all four shoes fasten the load to the carriage with a chain. Operate
for both left and right hand-side brakes. Do not ONLY in a pedestrian and traffic free aisle. An empty
replace single shoes, or two shoes on only one side. parking lot with a smooth level surface is also a good
operating location. Run the truck close to maximum
speed and apply the brakes bringing the truck to a
1. Safely park the truck on level surface.
complete stop. Immediately operate in the opposite
direction and repeat the procedure. Continue for ap-
3. Turn off key switch. proximately 20 times. You should try to get the brakes
4. Disconnect the battery. hot but do not overheat them. When 20 repetitions have
5. Remove the front covers to gain access to the brake been completed, re-check the brake settings and readjust
assemblies. as needed.
6. With the brakes applied, that is, the foot pedal in the fully
raised position, release and remove the nut and washer
Brake Assembly
on the top of the brake drum.
1. Replace the arm/cam assembly into the backing plate
7. Depress the pedal to release the brakes and block the
(item 22.406) and seat the snap ring back into its groove.
pedal in the down position. Remove the drum (item
Ensure the snap ring is fully seated in the groove.
22.408) from the motor shaft, using a soft faced mallet as
2. Set the backing plate back on the motor, insert and
needed. Remove the key (item 16.04 1) from the keyway
torque, [20-22 N.m] 177-1941bf.m the fasteners (item
in the shaft.
90.998) holding the plate to the motor.
8. Remove the shoes (item 22.404) from the brake assem-
3. Install the brake shoes and springs (items 22.404 and
bly. Discard old shoes.
22.407).
9. Position replacement shoes on the anchor pins. The ends
4. Pump the foot pedal to extend the push rod. Reconnect
of the shoes must be firmly seated in the pin groove and
the arm to the push rod with the pin and cotter (items
on the cam.
90.765 and 90.766). Slip the drum on the motor shaft and
10. Install the two tension springs (item 22.407) on the
release the foot pedal. Measure the angle of the arm. If
shoes.
the angle is within the 0’ to 12”as shown in Figure 2, the
11. Pump thefootpedaltoextendthepushrodfrom theslave
adjustment is correct. If the angle is still not within this
cylinder. Reconnect the arm to the push rod with the pin
range then index the spline .as needed. See Section 23-04-
and cotter (items 90.765 and 90.766). Slip the drum on
02.
the motor shaft and release the foot pedal. Measure the
5. If the setting is now correct, depress the foot pedal and
angle of the arm again. If the angle is within the 0” to 12
block in the down position. Remove the drum, insert the
as shown in Figure 2 the adjustment is correct. If the
key (items 16.041) in the keyway and replace the drum.
angle is still not within this range then index the spline as
Release the foot pedal to its up position.
needed.
6. Replace and torque [95- 108 N.m] 70-80 lbf.ft. the washer
(items 90.996 and 90.997) and nut on the motor shaft.

Group 23, Brakes
Note the pedal should be in the raised position to

facilitate torquing the nut.
7. Repeat for the other brake
8. Check and, set as needed, the brake actuating spring to
the correct length of 2”. Be sure when tightening the two
nuts to use TWO wrenches. If two wrenches are not used
damage to the brake lever will result.
9. Replace the front covers.
10. Connect the battery.
to either side.
12. Check brake stopping ability per 23-4-3 Brake Inspec-
tion and Adjustment.
Note: If new shoes were installed they must be burnished.

See Brake Shoe Replacement.

ClRRK Group 23, Brakes
Group 23
Section 4A
Mercury Brake Assembly
Brake Operation.. ....................................................................... 2

Brake Inspection and Adjustment ............................................... 3
Brake Disassembly ..................................................................... 4
Brake Shoe Replacement ........................................................... 4
Brake Assembly . ...... .. .... ..... ............................. ... .................. ... .... 5
Note: For Knott brake assembly see 23-4- 1
SM 556, Jan ‘96 Copyrighted Material 23-4A-1

Group 23, Brakes CIIIRK
Brake Operation.
The brakes are spring applied and hydraulically released.Removing all foot force from the foot pedal will fully apply the brakes.
Raising the foot pedal releases the hydraulic pressure in the slave cylinder, allowing the spring forces to rotate the brake arms
thus applying the brakes. Brake arm rotation rotates a cam inside the brake assembly that forces the brake shoes onto the brake
drum.
90.766 _ _ 90.997
90.765 \
7.. 71
23.252
23.859
22546 ‘m, w \_ 22.547
0
0
0
0
0
Figure 1. Mercury Service Brake

Top View
Shoe Pivot Pins
Adjust cam arm within the range shown above.
Figure 2.
Copyrighted Material SM 556, Jan ‘96

23-4A-2
Group 23, Brakes
22.408
-
91.233
22.411
22.404 - I
SHOES
Q- 22.407
$
23.330 --_@ 23.336
91.231 -9 ; /
ACTUATOR ARMS
22.405
CAM ASSEMBLY -E
23.319 -I$?+
y 22.406
da
91.258 -
&a
23.349 - MOUNTING PLATE
Figure 3.
Mercury Brake Inspection and Adjustment

IMPORTANT
Read the complete instructions before starting work.
1. Safely park the truck on level surface. 8. With the brakes applied, that is, thefoot pedal in the fully
2. Lower forks to the ground. raised position, release and remove the nut and washer
3. Turn off key switch. on the top of the brake drum.
4. Disconnect the battery. 9. Depress the pedal to release the brakes and block the
5. Remove the front covers to give access to the brake pedal in the down position. Remove the drum from the
assemblies. motor shaft, using a soft faced mallet as needed Remove
6. Depress the foot pedal to release the brake. Rotate the the key from the keyway in the shaft.
brake drum by hand so that the brake shoe pivot pins can 10. Inspect the condition of the shoe lining material. It
be seem through the vent holes in the brake drum. should not be glazed. There should be more than 3/32”
7. Measure, from a straight line through the pivot pins, the of thickness of material left on the shoe. If the lining
angleof thebrakearm. Ifthebrakearm isnotstraight,but material shows signs of heavy glazing, or heat distress
is “bent” at the splined joint in its middle, then measure such as cracking or discoloration, then the shoes and
the angle as if the arm were a straight line between its two linings MUST be replaced. Do not proceed with this
end points. If the angle is within the 0” to 12’ as shown adjustment. See Brake Shoe Replacement instructions,
in Figure 2, then the brake arm is correctly adjusted. section 23-4A-04. Always replace shoes in sets, both left
Inspect the amount of lining on the shoe through the and right sides. DO NOT replace only one shoe, or only
drum vent hole. If the lining appears to be less than 3/32 one side.
of an inch, the drum must be removed for a closer 11. If thebrakes are in good usable condition and the arm needs
examination of the shoes and drum. Brakes with more
adjustment, then continue with the following procedures.
than 3/32” of lining material and the lever between 0”
12. Inspect the drum for scoring or any other abnormal wear.
and 12” are fit for continued service. If the angle is
greater than 12” the brakes must be adjusted. These Service drum surface or replace drum as needed.
checks must be performed for both the left and right 13. Remove the cotter and the pin connecting the brake arm
handside brake assemblies. to the push rod.

Group 23, Brakes
14. Remove nut and washer (item 91.258,23.349). Index follows. Test only with an unloaded truck in a pedestrian and
the outer half of the brake arm one notch on the spline traffic free aisle. An empty parking lot with a smooth, level
in the brake arm away from the slave cylinder. surface is also a good operating location. Mark a line on the
15. Slip the drum onto the motor shaft and release the foot floor or note a floor joint as a measurement line. Starting at
pedal. a point approximately 150 to 200 feet in front of the line, drive
16. Measure the angle of the arm as before. If the angle is the truck in a straight line at full speed towards the line. As the
not between 0’ and 12’ as shown in Figure 2 then front wheels roll over the line apply the brakes by raising the
remove the drum and index one more notch on the brake pedal. When the truck has come to a complete stop,
spline. When the correct setting is obtained then insert safely park the truck at this same spot and measure the
the key in the keyway. With the pedal depressed, in- distance from the front wheels to the measurement line. This
stall the drum. With the foot pedal released, that is, is your stopping distance. Compare to the table below for the
with brake applied, torque the drum retaining nut to model you are working with. If the measured distance is less
[95-108 N.m] 70-80 lbf.ft. than the table value then the brakes are satisfactorily set. (The
17. Repeat for the other brake. approximate ruleof thumb is that the stopping distance for an
18. Check and, set as needed, the brake actuating spring on ESM without a load shall be between l-114 (one and one
both brakes. With the brakes applied the spring length quarter) and l-112 (one and one half) times the length of the
shouldbe 2”. Be sure when tightening the two nuts to use truck with no forks.)
TWO wrenches. If two wrenches are not used damage to Model . Distance inches
the brake lever will result. ESM12 100
19. Replace the covers. ESMlSS 100
20. Connect the battery. ESM15 97
21. Check the operation of the brakes. They should not pull ESM17 94
to either side. ESM20 92
IMPORTANT ESM22 90
The ESM brakes are not self adjusting, but need to be ESM25 90
periodically inspected and adjusted accordingly. If
adjustments are not made as required, the slave
cylinder can run out of stroke, and the springs will Brake Disassembly
not apply the brakes. This condition will not be a IMPORTANT
sudden event, but will result in a gradual loss of Read the complete instructions before starting work.
braking capability. If the brakes begin to get “soft”, 1. Safely park the truck on level surface.
this is an indication that the slave cylinder may be
“bottoming out” and the brakes have not been ad-
3. Turn off key switch.
justed as needed. Checking the brake adjustment
4. Disconnect the battery.
setting in addition to the driving test must be part of
the Planned Maintenance program. When the covers 5. Remove the front covers to give access to the brake
assemblies.
are removed for air cleaning the travel controls, the
brake arm positioning and lining wear must be in- 6. With the brakes applied, that is, the foot pedal in the fully
spected, recorded and corrected as necessary. raised position, release and remove the nut and washer
on the top of the brake drum.
The ANSI standard requirement for these brakes is that they 7. Depress the pedal to release the brakes and block the
hold the truck and a rated load on a 15% grade. If such a grade pedal in the down position. Remove the drum from the
is available, after adjustment, the brakes can be tested by motor shaft, using a soft faced mallet as need. Remove
slowly and carefully driving the truck with a rated capacity the key from the keyway in the shaft.
load straight up a known 15% grade, with the load upgrade 8. Remove clip and washer (items 90.766 & 95.795).
and bringing the truck to a stop with the brakes applied. If the Remove brake arm pin (item 90.765). Release the foot
brakes hold the loaded truck stationary on the grade the pedal.
brakes are satisfactorily set. After observing the performance 9. Remove brake shoe retainers (items 91.233 & 22.411).
of the brakes slowly drive the truck straight back down the 10. Remove brake cam nut and washer (items 23.330 &
grade. Do not try to perform any maneuvers on the grade. 91.231)
While this is a test method, the ESM is m intended for use 11. Lift off brake shoe set. If brake shoes are to be replaced,
on 15% grades, except as encountered for short distances unhook return springs (item 12.407). Place shoes in a
such as dock plates. If no grade is available, the brakes can be place that will not contaminate them with oil.
approximately tested by measuring the stopping distance as 12. Remove actuator arm nut and washer (items 23.336 &
92.463). Remove actuator arm (item 23.75 1).
23-4A-4 Copyrighted Material SM 556, Jan ‘96

Group 23, Brakes
13. Remove brake drive blocks (item 22.405). shouldbe 2”. Be sure when tightening the two nuts to use
14. Remove brake cam (item 23.319). TWO wrenches. If two wrenches are not used damage to
15. Remove the brake mounting plate capscrews (item the brake lever will result.
90.998) and remove brake mounting plate (item 22.406). 19. Replace the covers.
16. If drive motor is to be serviced, remove the brake bracket 20. COMCYZt the battery.
fasteners (items 95.788, 95.791, 95.790 & 95.789). 21. Check the operation of the brakes. They should not pull
Remove brake bracket (item 22.546, R.H. or 22.547, to either side.
L.H.) from drive motor). 22. Burnish the brakes. Load the truck with a rated load and
fasten the load to the carriage with a chain. Operate
ONLY in a pedestrian and traffic free aisle. An empty
Brake Shoe Replacement
parking lot with a smooth level surface is also a good
IMPORTANT
operating location. Run the truck close to maximum
Always replace shoes in sets, that is, all four speed and apply the brakes bringing the truck to a
shoes for both left and right hand-side brakes. complete stop. Immediately operate in the opposite
Do not replace single shoes, or two shoes on only direction and repeat the procedure.
one side. Continue for approximately 20 times. You should try to
1. Safely park the truck on level surface. get the brakes hot but do not overheat them. When 20
2. Lower forks to the ground repetitions have been completed recheck the brake
3. Turn off key switch. settings and readjust as needed. Check brake stopping
4. Disconnect the battery. ability per 23-4A-3 Brake Inspection and Adjustment.
5. Remove the front covers to give access to the brake
assemblies. Brake Assembly
6. With the brakes applied, that is, the foot pedal in thefully 1. If removed to service the drive motors, instaIl brake
raised position, release and remove the nut and washer bracket (item 22.546, R.H. or22.547, L.H.) with bracket
on the top of the brake drum. fasteners (items 95.788, 95.791, 95.790 dz 95.789).
7. Depress the pedal to release the brakes and block the Torque fasteners to [9.4-10.6 N.m] 83-94 lbf.in.
pedal in the down position. Remove the drum from the 2. Install brake mounting plate ( item 22.406) with mount-
motor shaft, using a soft faced mallet as need. Remove ing plate fasteners (items 90.998). Torque fasteners to
the key from the keyway in the shaft. [20-22 N.m] 177-194 Ibf.in.
8. Inspect drum for scoring or other abnormal wear. Ser- 3. Apply Lubriplate #63OAA, or equivalent to the sides of
vice brake drum surface, or replace as required. four anchor posts on the brake mounting plate.
9. Remove clip and washer (items 90.766 & 95.795). 4. Install brake cam (item 23.3 19) on post nearest notches
Remove brake arm pin (item 90.765). Release the foot on the brake mounting plate.
pedal. 5. Install brake drive blocks (item 22.405) on mounting
10. Remove brake shoe retainers (items 9 1.233 & 22.411). plate. Note: Large end of brake drive blocks must face
11. Remove brake cam nut and washer (items 23.330 & center of brake.
91.231) 6. Install actuator arms (item 23.751) on brake mounting
12. Unhook return springs (item 13.407), and reuse on the plate. Align sides of actuator arms with shoulders of
new shoes. Lift off brake shoe set and discard brake cam. Install brake actuator arm fasteners (items
13. Apply Lubriplate #63OAA, or equivalent to the sides of 23.336 & 92.463). Torque fasteners to [3-5 N.m] 2644
four anchor posts on the brake mounting plate. lbf.in.
14. Position replacement shoes on anchor pins. Brake shoes 7. Assemble brake shoes (item 22.404) with return springs
must be level with actuator arms (item 23.751). Install (item 22.407). Install brake shoe set over drive blocks on
brake shoe retainers (items 91.233 & 22.411). Torque brake mounting plate. Be sure the brake shoes are level
retainers [3-5 N.m] 2644 lbf. in. with the actuator arms.
15. Align brake drum keyway with motor shaft key, (item 8. Install brake shoe retainers (items 91.233 & 22.411).
16.041) depress foot pedal and install brake drum. Tap Torque to [3-5 N-m] 2644 lbf.in.
on top surface of brake drum with a soft faced mallet to 9. Install brake cam fastener (item 22.330 & 91.231).
seat drum on motor shaft. Torque to [2-3N.m] 18-26 lbf.in.
16. Install drum washer and fastener (items90.996 &90.997). 10. Depress the foot pedal and block in the down position.
Release foot pedal. Torque fastener to [95-108 N.m] 70- Install brake arm pin, clip, and washer (items 90.765,
80 lbf.ft. 90.766,95.795). Note: Brake adjusting nut and lock nut
17. Adjust brake arm within 0” and 12” per Figure 2. (item 23.859 may be adjusted to ahow instaIIation of
18. Check and, set as needed, the brake actuating spring on brake arm pin. Two wrenches mbe usedon these nuts.

Group 23, Brakes
11. Align brake drum keyway with the motor shaft key (item
16.04 1 and install brake drum. Tap on the top of the drum
surface with a soft faced mallet to seat the drum on the
shaft.
12. Install brake drum fastener and washer (items 90.996 &
90.997). Torque nut to [95-108 N.m] 70-80 lbf.ft. Re-
lease the foot pedal.
13. Adjust brake arm within 0” and 12” per Figure 2.
14. Check and, set as needed, the brake actuating spring on
should be 2”. Be sure when tightening: the two nuts to use
TWO wrenches. If two wrenches are not used damage to
the brake lever will result.
15. Replace the covers.
16. Connect battery.
to either side.
NOTE
If new shoes were installed they must be bur-
nished. See brake shoe replacement (23-4A-4)
NOTE
Check brake stopping ability per (23-4A-3) Brake
Inspection and Adjustment.
23-4A-6 Copyrighted Material SM 666, Jan ‘96

GROUP 25 SECTION 01 25-01-01 STEERING GEAR
STEERING GEAR DESCRIPTION
The power steering gear is a remote-positioning

control valve that senses an input signal from
steering tiller arm, multiplies this signal to assist in
CONTENTS NO.
reducing steering effort, and turns steer wheels to
desired position by supplying hydraulic oil flow and
STEERING GEAR DESCRIPTION 25-01-01 pressure to steering actuator on steer axle.
STEERING GEAR TROUBLESHOOTING 25-Ol-02 When steering tiller arm is turned, it causes the
valve spool to shift from its closed neutral position
STEERING GEAR REMOVAL 25-01-03 to a “turn” position and allows oil under pressure to
flow to steering actuator. When steering tiller arm
STEERING GEAR DISASSEMBLY 25-o l-04 stops turning, centering springs in valve
automatically center spool, stopping flow of oil
STEERING GEAR PARTS INSPECTION 25-01-05 pressure to steering actuator.
STEERING GEAR ASSEMBLY 25-01-06
The low-pressure oil from steering actuator is
STEERING GEAR INSTALLATION 25-01-07 returned through the opposite port in valve. It is
controlled by the same spool as the high pressure
port.
1. Dust Seal 13. Quad Ring Seal 24. Control Sleeve

2. Retaining Ring ‘,‘*25.-Centering Springs
3. Seal Gland Bushing 15. Bearing Race 26. Pin
16. Needle Thrust- Bearing 27. Control Spool
17. Set Screw 28. Seal, 3” OD
18. Seal, 518” OD 29. Spacer Plate
19. Check Ball Seat 30. Drive
20. Seal, 7/16” OD 31. Meter (Gerotor)
21. Check Ball 32. Spacer(s)
22. Check Ball Retainer 33. End Cap
11. Seal, 2-l/B”00 23A. Standard Housing 34. Cap Screw
SM556 25 - 01 - 1
In event of power or pump failure, steering gear identified and can be installed in same location at
can develop sufficient hydraulic power for limited, assembly.
emergency steering only by manual movement of
steering tiller arm. An internal check valve closes 4. Disconnect hydraulic lines from steering gear
automatically to divert this generated oil flow to and cap open ends. Plug ports in steering gear.
selected port of steering actuator. However,
steering tiller arm turning effort is considerably 5. Remove steering gear capscrews and
higher than with power steering. This method of lo&washers (items 25.034 & 90.102).
steering should be limited to emergency use only
6. Remove steering gear assembly from truck.
25-01-03 STEERING GEAR

TROUBLESHOOTING
The following list of symptoms and possible
causes are most common steering problems
encountered.
25.00
1. High number of steering tiller arm turns: 25.00
Cylinder seal leakage
Steering gear wear
2. Steering tiller‘arm effort too high:

Relief valve setting too low
Axle load too heavy
3. Steering tiller arm spins freely:

Air in system (cavitation)
Low oil supply
Faulty steering gear 25-01-05 STEERING GEAR
DISASSEMBLY
4. Truck turns in wrong direction:
Hydraulic lines not installed correctly When working on steering gear, it is important to
keep internal parts free from dirt and other
5. Steering tiller arm kickback. contaminants. Thoroughly clean exterior of gear
Check valve faulty or not in system before disassembly. Disassemble steering gear in
a clean work area.
6. Slow steering response:
Oil viscosity too heavy 1. Remove steering gear column fasteners and
column.

REMOVAL
1. Turn key switch OFF and -disconnect. battery
from truck receptacle.
2. Remove top compartment cover.
3. Remove tiller arm cover (item 25.345) and nut

(item 25.003).
4. Remove tiller arm (item 25.004).
3. Remove dirt and contamination around steering

gear ports before disconnecting hydraulic steer 2. Clamp gear housing in a vise that has had jaws
lines. Make sure hydraulic steer lines are correctly protected with brass liners or equivalent material.
Do not overtighten jaws.
SM5.56 25-01-2
9. Remove spacer plate.
10. Remove seal from housing.
3. Remove 5/16-inch capscrews that retain end

cap to housing.

11. Remove housing from vise and place on a soft
clean surface. Use a thin-bladed screwdriver tip to
pry retaining ring from housing.
Seal
5. Remove meter (gerotor) assembly from housing 12. Rotate seal and sleeve until pin is horizontal.
(be careful not to drop star). Then, use fingers to push spool and sleeve
assembly forward until gland bushing clears
6. Remove seal from meter. housing. Remove bushing.
7. Remove drive spacers from housing.
Dust Seal A
6. Remove drive. 13. Remove quad ring seal from seal gland
bushing.
SM556 25 - 01 - 3
14. Use a thin-bladed screwdriver tip to pry dust 16. Push spool part of the way off control end of
seal from seal gland bushing. Be careful not to sleeve sufficient to expose six (6) centering
damage bushing. springs. Remove these springs carefully. Note
their position in unit before they are removed.
Needle Bearing
Thrust Race 19. Push spool opposite way after springs have
Bearing \ been removed. Separate spool from sleeve by
rotating slowly as sleeve is pushed off.
15. Remove two bearing races and needle thrust

bearing from spool and sleeve assembly.
Seat 7/16” Seal Ball Retainer
21. Remove set screw in end of housing.
Pin
22. Thread al/6 - 24 NC machine screw into end
of check ball seat. Then pull on screw using pliers
(or equivalent method) to pull seat out of housing.
23. Remove two (2) seals from check valve seat.
16. Remove spoof and sleeve assembly from cap 24. Remove check ball by tilting housing and
end of housing. NOTE: Be careful not to bind lightly tapping on side of housing if ball sticks.
spool and sleeve in housing. Rotating spool and
sleeve slowly while removing will help prevent 25. Remove steer gear check valve retainer.
binding.
17. Push pin from sleeve and spool assembly. 25-01-06 STEERING GEAR PARTS
INSPECTION
..I
--. : 1:~lnspecthoosing~fordamage;including cracks or
broken parts, damaged threads, corrosion or
erosion of surfaces, worn spots, burrs or scratches
on machined surfaces.
2. Examine meter assembly for evidence of

excessive wear, corroded or pitted surfaces, nicks
or scratches, or any other damage that might
hamper operation of assembly.
3. Check springs to be sure they are not bent,

worn, or twisted. Examine ends to be sure they
are not damaged and will seat properly.
4. Make sure sleeve assembly does not bind Install seat in housing using care not to damage
when it is rotated on spool. Inspect assembly for seals when installing seat. Insert open end of seat
any corrosion, nicks or scratches, or evidence of first.
damage.
4. Install set screw and tighten to a torque of [ll
5. Check bearings and races making sure they are N-ml 100 Ibf*in. Top of set screw should be slightly
not damaged and that they rotate without being below surface of . housing mounting surface to
noisy or have evidence of binding. prevent interference of parts.
6. Replace all seals with new ones.
7. Inspect steer gear pump drive shaft making sure

drive end and spline end are not damaged. Spring
Slot -
8. Check wear plate for corrosion or evidence of

abnormal wear.
9. Check steer gear cover to make sure machined

surface is not damaged and will seat properly on
housing.
5. Position sleeve on spool assembly, making
10. Make sure all parts are clean and free of dust. sure spring slots line up at same end. When
sliding sleeve on spool use a rotary motion as well
Before assembly, coat all internal parts with a layer as a sliding motion. If spool and sleeve have
of oil. If parts are left exposed, cover them with a identification marks, they should be aligned.
clean cover to prevent airborne dust from
collecting on them. After parts are in correct position, test for freedom
of rotation. Parts should slide and rotate on each
other with” finger force”.
ASSEMBLY 6. Stand sleeve and spool assembly on end after
making sure spring slots are aligned.
1. Use needle-nosed pliers to put steer gear
check valve retainer in steer gear valve housing. Install spring-installation tool through spring slots
Make sure retainer is seated in housing in correct of both parts. (Tool is available as Part No.
position to support ball and is not tilted on edge. 6000057). Position three (3) pairs of centering
springs (or 2 sets of 3 each) on bench so that
2. Insert check ball into housing. extended edge is down and arched center
sections are together. Insert one end of this
arrangement of springs into insertion tool.
o- Set Screw +
See Figure 12A 1
5/a**
Check 6all Seat
7116
- \
Retainer
3. Put new seals on check ball seat. Lubrfcate seal Compress free ends of centering springs together
with petroleum jelly before installing seat. as springs are inserted into spool and sleeve
assembly.
SM556 25 - 01 - 5
Center springs in assembly to ensure they push
evenly and are flush with outer surface of spool
and sleeve assembly. Needle
Pin
7. Install pin into sleeve and spool assembly until it 11. Install needle thrust bearing.
is flush with outer surfaces.
12. Install a new dust seal in dust seal bushing with
flat or smooth side of dust seal face down toward
bushing.
13. Install a new DRY quad ring seal in seal gland

bushing by smoothing seal in place with light finger
pressure. Seal should not “fall” into place but
should require light force to seat.
Reraining
Ring
Seal
Gland -
8. Insert sleeve and spool assembly into housing Bushing
(from end opposite check valve assembly). (wirh seals)
When inserting, use a light force plus a slow

rotation of parts. Do not force parts and use care
not to tilt assembly. The assembly should be
inserted until it is flush with face of housing. Check
installation for freedom of movement by turning
with light finger pressure.
14. Install seal gland bushing over spool assembly
NOTE - Do not insert assembly beyond end using a rotary motion as well as a sliding
flush position. This will prevent pin from motion.
dropping into discharge groove of
,... ,PaP;-bushing lin place-using a soft-faced hammer.
housing.
Make sure bushing is flush and against bearing
9. Install new seal in housing (from check valve race and that retaining ring groove is exposed.
end).
15. Insert retaining ring into housing. After
10. Install two bearing races. installing, use a soft-faced hammer and drift to tap
around circumference of ring to ensure it is seated
in groove.
18. Put housing in a vise with spool and sleeve

assembly upward. Use. light clamping force to
retain housing.
SM556 25-01-6
Make sure spool and sleeve are flush or slightly
below face of housing. Be sure surfaces are Meter (Gerotor) Star Valley ,A
clean.
Install a new seal in housing.
17. Install spacer plate. Be sure bolt holes in

spacer plate are aligned with threaded holes in
housing.
Pi, Port’ Face
20. Position meter on housing with seal side of

meter toward spacer plate.
Note position of meter on housing (note that there

are seven (7) holes to be aligned with threaded
bolt holes).
18. Rotate sleeve and spool assembly until pin is
parallel with port face. Make sure star has engaged spline and is in
position shown.
Before installing drive shaft, mark spline end of
drive shaft with a line that is parallel to slot in 21. Install new seal in end cap.
opposite end. This will assist in proper assembly of
unit.
Drive Spacerbl Seal End Cap Screw
0
Install drive shaft making sure slotted end engages
pin.
22. Install end cap on rotor.
19. Install new seal in meter. 23. Install seven (7) fasteners holding cap and
meter to housing and tighten to an initial torque of
117 Nmm]150 Ibf4n .
SM556 25 - 01 - 7
Retighten these fasteners to a torque of [31 Nem]
275 Ibfain in the sequence shown above.
Mount steering gear column with (2)

z$screws. Torque capscrews to [28,25 Nom] 250
Ibfein.
Inspect assembly to -be sure all *parts have been

installed and fasteners have been correctly
positioned and tightened.

INSTALLATION
1. Position steering gear assembly on truck.
2. Install steering gear mounting fasteners (items

90.102 & 25.034).
3. Connect hydraulic lines to steering gear. Be

sure of correct position of each line. Make sure O-
rings are in correct position on fittings and that port
seal surfaces and fittings are clean. Tighten all
fittings to a torque of [8-9 Nom] 70-80 Ibf*in.
4. Install tiller arm (item 25.004) on steering gear

shaft.
5. Install tiller arm retaining nut (item 25.003).

Torque nut to 147 - 54 Nom] 35 - 40 Ibfaft.
6. Install tiller arm cover.
7. Install top compartment cover.
8. Connect battery and test steen’ng operation of

truck.
SM556 25 - 01 - 8
GROUP 26 SECTION 01
STEERING AXLE A! WARNING
All lifting used in this
components
procedure must be in good
CONTENTS NO. condition, meet the lifting
requirements, and have OSHA
STEERING AXLE REMOVAL 26-01-01 approval labels when requlred.
STEERING AXLE INSTALLATION 26-01-02
26-01-01 STEERING AXLE 8. Remove the upper fork bearing retainer (item
26.238) and carefully lower and remove the steer
REMOVAL axle fork.from the truck.
/\ ! CAUTION 9. Remove, inspect, and replace fork bearings and

To perform this service procedure, it is other components as required. Inspect steer axle
recommended that you first: fork for wear or damage. Replace, if required.
Park truck on a solid, level surface. 10. Inspect steer axle fork lower housing (item
Lower forks to floor. 26.232) for wear or damage. Replace, if required.
i. Rembve~the battery.’ .‘. 26-01-02 STEERING AXLE

INSTALLATION
2. Put chocks at the drive wheels.
3. Remove forks. 1. Pack lower fork beating (item 26.228) with

grease. Refer to Specifications group for
recommended bearing grease.
4. Remove the steer torque generator. Refer to
steer torque generator group for details.
2. Assemble steer axle fork lower bearing cup,
5. Loosen, but do not remove,the steer axle cone and seal (items 26.227, 26.228, 26.229)on
upper fork bearing retainer (item 26.238). steer axle fork.
4. Install steer axle fork into truck.
5. Install upper bearing, retainer, thrust washer,

lockwasher and retainer (items 26.235, 26.237,
26.341, 95.785, 26.238).
6. Snug up bearing retainer (item 26.238). Check

to make sure steer axle rotates freely.
7. Lock bearing retainer in position by bending up

tab_of_lock.washer.(jtem 95.785).
8. Carefully lower rear of truck to floor.
9. Install steer torque generator. Refer to steer

torque generator group for details.
10. Install forks.
11. Remove drive wheel chocks and install

battery.
6. Use a chain hoist to carefully lift the rear of the
truck to allow removal of the steer axle fork. Refer
to machine lifting and blocking group for details.
SM556 26 -Ol- 1
;.:
/- 26.238
95.785
26.341
e26.237
@ - 26.235
1 \/ 26.232
STEERING AXLE
26.224 FORK, STEKP.AXLE

26.227 SEAL, STEER AXLE FORK HOUSING
26.228 CONE, STEER AXLE FORK LOWER
26.229 CUP, STEER AXLE FORK LOWER
26.232 HOUSING, STEER AXLE FORK LOWER
26.233, _~/.,FASTENER,.STEERAXLE.FO=HOUSING
26.235 BEARING, STEER AXLE FORK UPPER
26.237 RETAINER. STEER AKLE FORX BEARING
26.238 FASTENER, STEER AXLE FORK BEARING
26.341 THRUST WASHER, STEER AXLE FORK UPPER BEARING
26.354 SPACER, STEER AXLE FORK HOUSING FASTENER

95.785 LOCKWASHER. STEER AXLE FORK BEARING FASTENER
SM556 26 - Ol- 2
GROUP 26 SECTlON 02 b) Contaminated oil.
Drain oil, clean filter and fill.
POWER STEERING PUMP c) Cavitating pump.
See 1a, b, c, d
d) Drive shaft not aligned.
CONTENTS NO. Check mounting and alignment.
e) Axial loading on drive shaft.
GENERAL DESCRIPTION 26-02-01 Check shaft end clearance.
PUMP TROUBLESHOOTING 26-02-02 Check shaft alignment.
PUMP REMOVAL 26-02-03 Check for worn key or spline.
PUMP DISASSEMBLY 26-02-04 f) Relief valve usually in bypass.
PUMP PARTS INSPECTION 26-02-05 Check relief setting.
PUMP ASSEMBLY 26-02-06
PUMP INSTALLATION 26-02-07 4. Low Pump Output.
PUMP RELIEF VALVE ADJUSTMENT 26-02-08
a) Cavitating pump.
See la, b, c, d
b) Air in fluid.
26-02-01 STEERING PUMP See 2b.
DESCRIPTION c) Relief valve leakage or valve set too low.
Check relief valve.
The power steering pump is a fixed-displacement d) Overheated oil.
type gear pump. The steering system relief Check oil temperature.
pressure is controlled by a pressure relief valve in
the power steering pump. This valve is set at a 5. Shaft Seal Leakage.
fixed relief pressure value of [6895 kPa]lOOO psi .
a) Damaged or worn seal.
Replace seal.
b) Front cover bearing out of position.
26-02-02 STEERING PUMP
Replace front cover assembly.
TROUBLESHOOTING c) Scratches on shaft seal housing bore.
See 5b.
Before steer pump is removed and/or d) Improper fit of shaft.
disassembled, check following list of problems and See 5b.
solutions. It could save cost, time, and effort.
6. External Leakage.
1. Noisy Pump.
a) O-ring damaged.
a) Low supply of oil. Replace C-ring.
Fill reservoir. b) Damaged surfaces in O-ring groove.
b) Oil too heavy. Replace damaged part.
Change to correct viscosity.
c) Inlet line has restriction. 7. Failure to Build Pressure.
Check for foreign material.
Clean filter or strainer. a) .Defective relief valve.
d) Air leak in inlet line. Repair and reset valve.
Check plumbing tightness. b) Low oil supply.
FiN reservoir.
2. Foaming Oil.
a) Cavitating pump.
See la,b,c, and d
REMOVAL
b) Wrong fluid.
Drain and fill with correct oil. 1. Remove pump and motor assembly from truck.
See steer pump motor group for details.
3. Heated Pump and/or Oil.
a) Thin oil
Drain and fill with correct oil.
SM556 26-02-l
POWER STEERING PUMP 26164-l
29.200 PlRfP4SLssMSLY.
STEER 29.284
16.227 COUPLING,STEERPDMPDBIVE 29.283
29.102 8EAL,STEERPm4PDRIVESmAm 29.286
29.190 PLIlIWER,8TEEEPlMPRELIEFVALVE 29.287
29.206 B~UI.RIMG,SIEPSPDHPS~ I. :!:,29:288
..
29.208 ?mmmcovltll 29.289 SEAL. STmR ARIP mLJ.E?vALVE PLUG

29.211 PLUG, STEmPvm BtLIEPV4LVz 29.323 stbG.sTEzztPtmPBoDY-AMSER
29.215 SiU?T,slEGllPUMP.DAUVE 29.323 SxAL,STEERPunPBoDT-GDLD
29.217 DOUZL.,SrUn PIMPCOVER ASSElQlLI 29.323 sEAL,STEFaPDMPBoDY-sILvEB
29.228 VALJE Su8-Assm8LY, STEmPaP RELIEF 231s COVER,STZERPUMPOUTLCT USE 29.200
29.229 sPxInG,sTEtRPlM?RELIEFvALV?i 24N COVElt.STXRPDl4PSEMTEMD USE 29.200

29.270 ChSRr,STEERPmPlio~
29.281 iUZMNE&mPDUPDBIVEa
29.282 KEYtEEERpulIpDEIVEGEAR
29.283 GEARSTEEKPWPDRIVE
SM556 26-02-2
DISASSEMBLY
1. Clean exterior of pump and motor assembly. Be __Q

sure to plug pump ports to avoid contaminating _@-=
internal parts.
2. Put an identification mark on pump and on

QGQ---
motor to assure that pump will be reinstalled in
same location on motor as when removed (ports
and terminals will be in proper position).
3. Remove capscrews and lockwashers (items 11. Disassemble idler shaft and gear assembly
29.269 & 90.891). only if necessary for replacement of these parts.
4. Carefully separate pump and motor. Put motor As these parts are removed from end cover,
in a safe place. carefully note position of each to be sure of correct
reassembly.
5. Use a sharp scribe or marker to scribe a line or
punch marks into body halves to assure correct
/
positioning of parts at assembly. i0
6. Loosen and remove bolt from end of shaft and

lift coupling from pump.
7. Clamp pump in a vise with shaft end pointing

down.
Use only a light clamping force by vise to avoid

damaging pump.
12. Remove shaft retainer snap rings, drive gear

and key from drive shaft.
8. Remove fasteners which hold pump assembly

together.
9. Carefully separate pump assembly by lifting

pump body off assembly.
13. Remove pump drive shaft from front end cover
It may be necessary to tap lightly on housing with by pulling it through the oil seal from the mounting
soft faced hammer to assist separation of parts. flange side.
Do not rotate parts in an attempt to separate them.

There is an alignment dowel in mating face.
10. Remove gasket, then idler shaft and gear

assembly from the end cover.
SM556 26-02-3
PARTS INSPECTION
1. Wash all parts in solvent and dry thoroughly.

Do not use material that leaves lint when drying
parts. If parts must be left for a long period of time
or overnight, cover them with a clean cover.
2. Inspect the bearing journals on both gear shafts

for wear. Replace if journals are scored or worn
over 0.001 inch.
3. Replace complete pump if bearing journals on

14. Remove needle bearings by pulling from pump shafts show signs of unusual wear.
body and end cover.
4. Check drive shaft for wear in the seal lip contact
area. If the shaft is grooved, pitted, or worn
undersize, the shaft must be replaced.
5. Inspect gear faces and sides (ends) for scoring

or galling. Smooth off sharp edges of otherwise
undamaged gear teeth with crocus cloth and
return to service.
If gears are pitted or eroded, they should be

replaced.
6. Check fit of drive gear key in shaft and in gear.

Replace key, shaft, and/or gear, if excessive wear
is found.
15. Turn pump end cover over and clamp in vise
with input drive shaft seal up. Remove shaft seal by 7. Check fit of idler gear on shaft and key. Remove
prying it out with a large screwdriver. idler gear if necessary. Remove idler gear retainer
snap ring with screwdriver and remove gear. If key
IMPORTANT (pin) is worn or pin hole is elongated in shaft,
replace as needed.
Be careful not to damage the shaft seal bore in end
cover. Nicks or scratches in the surface where seal 8. Check needle bearings. The needle rollers
is press fitted will result in leakage. should roll freely. If they bind, skew, or fall out,
replace the bearing. NOTE: If the bearings are
worn enough to require replacement, it is
recommended that the complete pump be
replaced.
-9; Inspect-gear bores in puwbody and gear side

face of end cover for scoring and galling (metal
pickup). Pump must be replaced if these surfaces
are scored or worn excessively. NOTE: A slight
lapped condition will neither harm performance nor
require replacement.
10. Inspect components of relief valve for wear or

damage. Replace as required.
16. Loosen and remove relief valve cap nut and
seal. Remove adjustor, pin, springs, and relief 11. Examine all port threads to be sure they have
valve. not been damaged and will form good seals.
SM556 26-02-4
ASSEMBLY
3. Apply LubricateTM grease or equivalent to outer

surface area of pump drive shaft. Install drive shaft
by inserting through the oil seal from the mounting
flange side. Move the shaft carefully through the
seal to avoid damage to lip of seal.
1. Put pump body on a flat surface with shaft seal
up.
---it-E
I
4. Install needle bearings in bearing bores. NOTE:

A shoulder is machined in bearing bore to ensure
correct depth of bearing seating. Press bearing
fully against this shoulder.
Install new seal by pressing inward on seal until it is
[2,794-3,048 mm] 0.1 lo-O.120 inch below inner Dimension I3
Shaft diameter A
face of pilot (Dimension E).
0.4387 in. 0.045 - 0.050 in.
Coat lips of seal with Lubriplatem, or equivalent 0.5000 in. 0.058 - 0.063 in.
lubricant.
4. Lubricate gears, shafts, bearings, and pump
housing and cover inner surfaces with hydraulic
fluid. Assemble and install gears and shafts into
end cover.
2. Install the pump relief valve components.
SM556 26-02-5
5. Install new gasket and assemble the pump body
onto end cover. Be sure the dowel pin is in place.
Install and tighten the assembly fastener bolts to
draw pump together. At this point, rotate the drive
shaft to be sure the pump turns freely. The pump
body and cover can be shifted slightly to allow the
gears to turn freely. Then torque assembly bolts to
[12,88 - 14,24 Nom] 9.5 - 10.5 Ibfeft. Check again
to verify that pump shaft still turns freely.
6. Install one half of drive coupling on pump. Put

elongated hole of on half of drive coupling over
matching shape on pump drive shaft, with flat side
towards pump. Install lo&washer and short bolt
furnished with the coupling. Torque bolt [9,6 N*m]
85 Ibfain. Check steering pump relief valve adjustment in
truck at the diagnostic check port fitting in steer
7. Install other half of coupling on motor shaft. Put pump outlet line. Remove dust-cap and connect
coupling half on motor shaft with flat side towards pressure gauge using quick disconnect adaptor
motor. Install square washer, lo&washer, and bolt fitting, Clark part number 3797029.
into motor shaft. Torque bolt to [9,6 Nmm]85 Ibfain.
NOTE: When installing pump to motor, install the For bench test, inlet and outlet lines to pump
rub ber coupling insert (cross) into. either the motor should be correctly installed and the specified
or pump half of coupling, with slots in the insert hydraulic fluid supplied. Connect a control valve to
over the tangs of coupling half. simulate steering cylinder in stopped (relief)
position.
IMPORTANT
a) Connect pressure test gauge in pump outlet
Do not lubricate coupling with grease or oil, which line.
will cause rubber insert to soften and be damaged.
b) Operate pump at 2500 rpm speed and allow
the test system to build up pressure.
INSTALLATION 1. Remove protective cap which covers relief valve
adjusting screw.
1. Install new pump mounting gasket. Use match
marks to properly align pump and motor. Align 2. Adjust relief valve pressure using a screwdriver
coupling tangs with remaining two holes in rubber to rotate adjusting screw to change setting.
insert. Mount pump to motor with capscrews and
lo&washers (items 29.269 & 90.891). Torque 3. Rotate CLOCKWISE to INCREASE pressure.
capscrews to [19,3 - 21,5 Nem] 170 - 191 Ibfein . Turn COUNTERCLOCKWISE to REDUCE
pressure.
2. Install pump and motor assembly into truck. See
steer pump motor group for details. 4. The relief valve setting is correct when pressure
is [6895 kPa] 1000 psi and relief valve is
operating.
26-02-08 STEERING PUMP RELIEF
5. Install protective plug and seal over screw and
VALVE ADJUSTMENT tighten.
After overhaul and reassembly, relief valve 6. Recheck pressure setting. Readjust, as
pressure setting may be checked and adjusted necessary. DO NOT EXCEED THE SPECIFIED
either when pump is installed in truck or with pump RELIEF PRESSURE SETTING. When correct,
mounted on a test stand. remove pressure gauge.
SM556 26-02-6
GROUP 26 SECTION 03 26-03-01 STEER TORQUE
STEER TORQUE GENERATOR GENERATOR DESCRIPTION
The unit generates torque to turn the steer axle.

CONTENTS NO. The steer torque generator responds to hydraulic
pressure signals from the steering gear to turn the
TORQUE GENERATOR DESCRIPTION 26-03-01 steer axle in the direction indicated by the steer
gear.
TORQUE GENERATOR REMOVAL 26-03-02
TORQUE GENERATOR DISASSEMBLY 26-03-03

26-03-02 STEER TORQUE
TORQUE GENERATOR PARTS INSPECTION GENERATOR REMOVAL
26-03-04
1. Turn key switch OFF and disconnect battery
TORQUE GENERATOR ASSEMBLY 26-03-05 from truck receptacle.
TORQUE GENERATOR INSTALLATION 26-03-06
2. Remove two front and top compartment
covers.
/- 95.603
3. Remove motor cut-out cam capscrew (item
95.603). Remove motor cut-out cam.
4. Remove (2) front torque generator fasteners

(items 26.270, 95.796, & 92.237).
3. Remove rear torque generator fastener (item

26.270, 95.796, & 92.237).
4. Lift off motor cut-out switch plate and bracket

and set aside.
5. identify hydraulic lines to torque generator and

disconnect. Cap hose ends.
6. Put hoist lift straps around torque generator as

shown. Note: position lift straps as close to center
of torque generator as possible.
SM556 26 - 03 - 1 Rev Jan 90
LOCKSCREW HOLE
26.36 1
26.356 UPPER
PINION SHAFTKEYWAY 26.357 LOWER
pi--b 26.250
I I
STEER TORQUE GENERATOR
26.250 TORQUE GENERATOR. STEERING

26.258 BODY, STEER TORQUE GENERATOR
26.263 SW, STEER TORQUE GENERATOR OUTPUT
26.356 RETAINER, STEER TORQUE GENERATOR OUTPUT SRAFT BUSHING
26.357 BUSHING, STEER TORQUE GENERATOR OUTPUT SRAFT
26.358 RACK,STEERTORQUE -TOR

26.359 PISTON, STEER TORQUE GENERATORCYLINDER
26.360 SEAL, STEER TORQUE GRRERATOR OUTPUT PISTON
26.361 CYLINDER. STEER TORQUE GENERATORRYDRAULIC
26.362 PELLET. STER TORQUE GEN. 'XL. RETAINING
95.819 FASTENER, STEER TORQUE GEN. RYD. CYLINDER
SM556 26 - 03 - 2
GROUP 26 SECTlON 03 26-03-01 STEER TORQUE
STEER TORQUE GENERATOR GENERATOR DESCRIPTION
The unit generates torque to turn the steer axle.

CONTENTS NO. The steer torque generator responds to hydraulic
pressure signals from the steering gear to turn the
TORQUEGENERATOROESCRlPTlON 26-03-01 steer axle in the direction indicated by the steer
gear.
TORQUEGENERATORREMOVAL 26-03-02
TORQUEGENERATORDISASSEMBLY 26-03-03 26-03-02 STEER TORQUE

TORQUEGENERATORPARTS INSPBCTION GENERATOR REMOVAL
26-03-04
1. Turn key switch OFF and disconnect battery
TORQUEGENERATORASSEMBLY 26-03-05 from truck receptacle.
TORQUEGENERATOR INSTALLATlON 26-03-06 2. Remove two front and top compartment
covers.
3. Remove motor cut-out cam capscrew (item

95.603). Remove motor cut-out cam.
4. Remove (2) front torque generator fasteners

PART OF MOTOR
(items 26.270, 95.796, & 92.237).
CUTOFF
3. Remove rear torque generator fastener (item
26.270, 95.796, & 92.237).
4. Lift off motor cut-out switch plate and bracket

and set aside.
5. Identify hydraulic lines to torque generator and

26.355 - GENERATOR disconnect. Cap hose ends.
92.237
6. Put hoist lift straps around torque generator as

shown. Note: position lift straps as close to center
of torque generator as possible.
SM556 26 - 03 - 1
26.361 \ /
.E -
26.359
26
26.258
26.356 UPPER
26.357 UPPER
PINION SHAFTKEYWAY 26.357 LOWER
STEER TORQUE GENERATOR
26.250 TORQUE GENERATOR,STRERINC

26.258 BODY, STRERTORQWGENRRATOR
26.263 SRAFT,STEER TORQUE GRNEBATOROUTPUT
26.356 RRTNNER, STEERTORQUE GRNERATOROUTPQT SIuFl BUSHING
26.357 BUSRING,STXRT'ORQURGRNRRATOROUTPUTSRAFf
26.358 BACK,STEERTORQUEGRNEBATox
26.359 PISTON,STRRR TORQUR GRNRRATORCYLINDER
26.360 SELU,STRRRTORQUEGENERATOBOUTPUTPISTON
26.361 CYLINDER,STFZR TORQUEGWERATOR RYDBAULIC
26.362 PELLRT,STERRTORQUE GEN. CYL. RRTAINING
95.819 FASTENER.STEBR TORQUEGEN. BYD. CYLINDRR
SM556 26 - 03 - 2
7. Hook lift straps to chain hoist and apply tension 26-03-04 STEER TORQUE
to torque generator with hoist. Carefully pry GENERATOR PARTS INSPECTION
torque generator loose from steer axle cone with a
screwdriver. 1. Clean all torque generator components and lay
on a clean sheet of paper. Protect pans from dirt
Note and comtamination before reassembly.
Be sure to retrieve and set aside locating key
(item 26.355) 2. Inspect all parts for wear or damage. Replace
parts as required.
GENERATOR DISASSEMBLY 26-03-05 STEER TORQUE
GENERATOR ASSEMBLY
Note
When working on steer torque generator, it is
1. Install upper retaining ring (item 26.356) and
important to keep internal parts free from dirt and
upper pinion bushing (item 26.357) in generator
other contaminants.Throroughly clean exterior of
housing.
torque generator before disassembly.
Disassemble torque generator in a clean work area.
2. Insert rack into generator housing. Position rack
to extend an equal distance from each side of
generator housing.
1.. Remove lock screws (item 95.819) and plastic
pellets (item 26.362). from generator housing
3. Insert pinion into generator housing, meshing
(item 26.258).
pinion teeth with teeth on rack. Be sure pinion
2. Remove cylinder tubes (item 26.361) from shaft keyway is In same location as at
generator housing by unscrewing with a spanner
disassembly.
wrench.
4. Pack pinion and rack teeth with general
3. Remove pistons (item 26.359) from cylinder puur&ose (No. 2) grease. Pill gear cavity with grease
.
tubes by pushing them out with a brass drift pin
inserted through the cylinder port. Note: Drift pin
5. Install lower bushing (item 26.357) and lower
maximum diameter is 0.5 inch.
retaining ring (item 26.356) over pinion and into
4. Remove piston seals (item 26.360) from generator housing.
pistons and discard.
6. Install new seals (item 26.360) on pistons (item
5. Position rack (item 26.358) at midpoint of travel. 26.359).
Rack should extend an equal distance from each
side of generator housing. Note and record 7. Lubricate pistons with hydraulic oil and install
into cylinder tubes (item 26.361). Be carefull not to
location of pinion shaft keyway. Keyway
locatlon will be needed to properly nick or damage the piston seals during installation.
assemble torque generator.
8. Screw cylinder tubes into generator housing
6. Remove lower retaining ring (item 26.356). Pull I .._
with spanner wrench. Torque cylinder tubes to
pinion (item 26.263) and lower bushing (item [40.7 N*‘m] 30 tbfaft .
26.357) from generator housing.
9. Install nylon pellets (item 26.362) and
7. Remove rack (item 26.358) from generator lockscrews (item 95.819). Tighten lockscrews
housing. firmly to retain cylinder tubes in generator housing.
8. Remove upper pinion bushing (item 26.357)

and upper retaining ring (item 26.356) from
generator housing.
SM556 26 - 03 - 3
GENERATOR INSTALLATION
MOTOR CUT-OUT CAM LOCATING PIN
,. .. .
GENERATOR .- ‘. ‘.
1. If installing replacement steer torque generator,

install motor cut-out cam locating pin as shown.
2. Position locating key (item 26.355) in generator

pinion keyway. Position torque generator on steer
axle cone, align generator pinion key with steer
axle and install. Seat torque generator by carefully
tapping on top surface of generator with a block of
wood and hammer.
2. Connect hydraulic lines to torque generator.

Make sure O-rings are in correct position on fittings
and that port seal surfaces and fittings are clean.
3. Install generator rear fastener (items 26.270,

95.796, & 92.237)
3. Position motor cut-out switch plate and bracket

and install (2) front generator fasteners (items
26.270, 95.796, & 92.237).
4. Position motor cut-out cam on torque generator

and install capscrew (item 95.603).
6. Connect battery and test steering operation of

truck.
SM556 26 - 03 - 4
GROUP 29 SECTION 01 c). Cavitating pump.
%e 1 [a, 1 .b, 1 .c, 1 .d
MAIN HYDRAULIC PUMP d). Drive shaft not aligned.
Check mounting and alignment.
e). Axial loading on drive shaft.
Check shaft end clearance.
CONTENTS NO. Check shaft alignment.
Check for worn key or spline.
PUMP DESCRIPTION 29-01-01 f). Relief valve usually in bypass.
PUMP TROUBLESHOOTING 29-01-02 Check relief setting.
PUMP REMOVAL 29-01-03
PUMP DISASSEMBLY 29-01-04 4. Low Pump Output.
PUMP PARTS INSPECTION 29-01-05
PUMP ASSEMBLY 29-01-06 a). Cavitating pump.
PUMP TEST PROCEDURE 29-01-06 See l.a, l.b, l.c, 1.d
PUMP INSTALLATtQN 29-o l-07 b). Air in fluid.
See 2.b.
c). Relief valve leakage or set too low.
Check relief valve.
29-01-01 PUMP DESCRIPTION d). Overheated oil.
Check oil temperature.
The main hydraulic pump is a fixed-displacement,
high-performance, pressure-compensated gear 5. Shaft Seal Leakage.
pump.
4. Damaged or worn seal.
Replace seal.
29-01-02 PUMP b Front cover bearing out of position.
Replace front cover assembly.
TROUBLESHOOTING
cl* Scratches on shaft seal housing bore.
See 5.b.
Before the main hydraulic pump is removed and/or
d). Improper fit of shaft.
disassembled, check the following list of problems
See 5.b.
and solutions. It could save cost, time and effort.
6. External Leakage.
1. Noisy Pump.
a). O-ring damaged.
a). Low supply of oil.
Replace O-ring.
Fill the reservoir.
b). Damaged surfaces in O-ring groove.
b). Oil too heavy.
Replace damaged part.
Change to correct viscosity.
c). Inlet line has restriction.
7. Failure to Build Pressure.
Check for foreign material.
Clean filter or strainer.
a). Defective relief valve.
d). Air leak in inlet line.
Repair and reset valve.
Check plumbing tightness.
_b).. Low oil supply.
“Fill reseivoir.
2. Foaming Oil.
a). Cavitating pump.

See l.a,l.b,l.c, and 1.d 29-01-03 MAIN HYDRAULIC
b). Wrong fluid. PUMP REMOVAL
Drain and fill with correct oil.
1. Lower carriage to floor.
3. Heated Pump and/or Oil.
a). Thin oil
Drain and fill with correct oil. 3. Remove two front and top compartment covers.
b). Contaminated oil.
Drain, clean filter and refill. 4. Remove hydraulic lines to pump and cap ends.
SM556 29-01 -1
2. Use a sharp scribe or marker to scribe a line or
put punch marks into body halves to assure correct
positioning of parts at assembly.
3. Carefully clamp the pump in a vise (with shaft

down) and remove the external fasteners.
MAIN HYDRAULIC PUMP -
r
2
5. Remove- pump’ mounting capscre& (item

29.106) and remove pump from truck.
4. Remove the pump from the vise and tap the
shaft with a wooden block or soft-faced hammer to
29-o-I -04 PUMP DISASSEMBLY separate the pump halves.
1. Before disassembling the pump, be sure the 5. Remove the rear cover. The dowel pins may
work area is clean. Overhaul pump only in a clean, remain with either section. Keep parts in order as
dust-free location, using clean tools and removed to assure correct positioning at assembly.
equipment. Dirt or grit will damage the highly-
machined surfaces and will result in leakage or
premature failure of the pump.
Clean the exterior of the pump using a wire brush

if necessary to remove accumulations. Be sure to
plug openings before brushing to avoid
contaminating the internal parts.
6. Remove the thrust plates.
SM556 29 - 01 - 2
ASSEMBLY - 29.100
COMPLETE
WEAR ?lAlE
29.117- AND SEAL KIT
29550-l
HYDRAULIC PUMP
29.100 PUMP ASSEmLY. RYDFMJLIC
29.117 WEARPLATE 6 SEAL KIT, HYDRAULICPUMP
29.123 DOWEL, HYDRAULICPUMP COVRR
29.129 PLUG, PUMP CONTROLVALVE
29.171 GEAR ASSEMBLY,HYDRAULICPUMP DRIVE
29.187 GEAR ASSFHBLY,HYDRAULfCPUMP IDLER
29.198 CAPSCRRW,RYDRAULICPUMP HOUSING
29.259 COVER ASSEMBLY,HYDRAULICPUMP OUTLET
29.260 COVER ASSEMBLY,HYDRAULICPUMP (SIiAmEND)
91.147 WASHER, HYDRAULICPUMP HOUSING FASTENER
SM556 29 - 01 - 3
screwdriver to pry it out. Be careful not to damage
the seal bore in the cover when prying seal out.
29-01-05 PUMP PARTS

INSPECTION
1. Wash all parts with clean solvent and dry
thoroughly. Do not use wiping cloth material that
leaves lint when drying parts. If parts must be left
for a long period or overnight, cover with a clean
cover.
2. Examine the wear and thrust plates. If any

7. Remove the gears. Note the location of the uneven or unusual wear is evident or if they are
match marks on the ends of the shafts and their scratched or eroded, they should be replaced.
location with respect to the pump cover.
8. Remove the wear plate. Remove the seal from

the wear plate and discard the seal.
3. A heavy wear pattern is normal for the low
9. Remove the gasket seal and lift out the thrust pressure (inlet) side of the wear plate. But there
plate from the rear cover. should be no heavy scoring visible.
4. Remove and discard the pressure loading seal

from the wear plate. Install a new seal in the groove
making sure the smooth surface is out. The seal
should extend a minimum of [O-12 mm] 0.005 in.
10. Invert the pump body so that the shaft seal is beyond surface of wear plate. Do not push the
up. Remove and discard the shaft seal using a seal below surface of wear plate at any point.
SM558 29 - 01 - 4
7. Inspect the body and cover for wear and
scoring. If the gear contact surface on the low
pressure (inlet) side exceeds [0.012 mm] 0.005 in.
wear depth, replace the body assembly. If the
body is usable, remove any burrs with a suitable
burring tool.
8. Examine the threads in all ports to be sure they

have not been damaged and will form good seals.
29-01-06 PUMP ASSEMBLY
5. Inspect the bushings in both body and cover.

Replace the assembly if bushings show any
evidence of damage.
1. Put the pump body on a flat surface with the

shaft seal up. Install the new seal by pressing
inward on seal until it is [6 mm] l/4 inch below the
6. Carefully inspect the gears and shafts (journals) face of the pilot. Pack the area between the
for damage. Worn or damaged teeth will greatly double lips of the seal with LubriplateTM, or
reduce the performance of the pump and should equivalent lubricant.
be replaced if any undue wear or damage is found.
The journals should be bright and free from any

scoring. If any bearing or journal surfaces have
eroded areas or deep scratches, they should be
replaced with new parts.
2. Turn the body over, putting pump gear bores

up-
SM556 29-01 -5
Matchmarks on the ends of the drive and driven
shafts must face the rear of the pump.
5. Lubricate the rear gear faces and journals with

SAE 10 oil and install the thrust plate in its original
position.
Put the wear plate in the bottom of the bores

making sure the pressure loading seal is
positioned properly in the seal grooves and
installed against the bottom of the bore surface.
NOTE - 180” rotation of the pressure plate

will change the pump rotation (CCW to
CW). Humps of the “w” should face the
outlet side of the pump. 8. Apply a small amount of grease to the rear cover
IF THE PRESSURE PLATE IS seal groove and install the new gasket seal into the
INSTALLED IMPROPERLY, IT WILL groove on the cover.
CAUSE THE SEAL TO BE BLOWN.
7. Lubricate the rear cover bushings with SAE 10
oil and install the rear cover. Make sure the match
3. Lubricate the bushings in the body and the face marks are in correct position.
of the wear plate with SAE 10 oil.
8. To assure assembly, it may be necessary to put
4. Apply Lubripiate or equivalent lubricant to the pump in an arbor press (shaft end down) and press
outer surface of the drive shaft installation sleeve. cover into position.
Insert the sleeve into the shaft seal from the front If press is not available, insert the fasteners and
of the pump until the sleeve contacts the drive tighten evenly to a torque of [38 - 43 Nom] 28 - 32
gear bushing. Ibf*ft.
Install the drive gear with the long journal toward 9. After tightening, make sure the drive shaft turns
the front of the pump. freely without binding or grabbing.
29-01-07 PUMP TEST

PROCEDURE
1. Install pump in test stand.
2. Run pump for 1 minute at minimum pressure

loading.
3. Raise output pressure to [3448 kPa] 500 psi for

5 seconds, then lower to minimum pressure for 5
seconds. Continue repeating this cycle for 1
minute.
SM556 29-01-6
4. Repeat this cycle (Step 3) for 3 minutes but
using one-half the input speed as above.
5. Repeat this cycle for 3 minutes using full speed.
6. Repeat Step 3, but increase pressure in [3448

kPa] 500 psi increments until maximum operating
pressure, or [20658 kPa] 3000 psi is obtained.
Check flow by best method available.
7. With pump running at idle speed

(approxiamately 500 rpm), check for leaks. No
shaft seal leakage sufficient to form a droplet of oil
is permissible. No external leakage is permissible.
29-01-08 PUMP INSTALLATION
1. Put the pump into position on the motor using a

new gasket. Make sure the coupling is in place.
,,2. I.nstall pump, mounti.ng capscrews @tern29.106).

Torque capscrews to [65 - 73 Nom] 48 - 54 Ibf=ft .
3. Install the hydraulic lines on the pump making

sure the O-ring seals are properly positioned.
4. Install and connect battery.
5. Start the truck and note if the pump is running

properly and is not making any unusual noise. Tilt
the upright fully forward and backward and again
listen for any unusual pump noise.
SM556 26-01 -7
GROUP 30 SECTION 01
MAIN HYDRAULIC VALVE
CONTENTS NO.
MAIF VALVE DESCRIPTION 30-01-01

MAIf VALVE RELIEF PRESSURE TEST PORT -
ECK 30-01-02
M.z VALVETROUBLESHOOTING 30-01-03
MAll VALVE REMOVAL 30-01-04
MAll VALVE DISASSEMBLY 30-01-05
MAlf VALVE INSPECTION 30-01-06
MAII VALVE ASSEMBLY 30-01-07
MAII VALVE INSTALLATlON 30-01-06
30-01-01 MAIN VALVE

, DESCRIPlYON
The main hydraulic valve is a manually operated

spring centered directional valve. It is a balanced
sliding spool type valve and has an open-center
valve circuitry, which allows free flow from inlet to
outlet in the neutral position. The valve
incorporates a fixed pressure relief valve and a
check valve.
30-01-02 MAIN VALVE RELIEF

PRESSURE CHECK
Remove snap-on cap and connect pressure
IMPORTANT gauge to diagnostic check port fitting on main
Do not exceed relief pressure setting hydraulic valve inlet line. NOTE: Use quick-
specified for truck model capacity rating. disconnect adapter fitting, Clark Part No. 3797029.
Changing pressure will not increase lifting
capacity or lifting speed. Turn key switch ON.
Refer to Specifications Group for main hydraulic Move control handle to full back-tilt relief position.
system relief pressure settings. Hold control handle in relief position until pressure
_. ,..Lzr.eadingis obtained,andthen release.
Hydraulic system relief pressure setting may be
checked with a pressure gauge of 0 to 124132 IMPORTANT - Do not operate system
kPa] 3500 psi capacity. over relief any longer than necessary to
read pressure gauge.
If relief pressure is not correct, clean or replace

relief pressure valve.
SM556 30 - 01 - 1
30-01-03 MAIN VALVE TROUBLESHOOTING
Problem Probable Cause Remedy
Oil leaks at either end of spool Defective O-rings in valve body Replace O-rings
Spool does not return to neutral Broken springs Replace springs
Foreign particles Clean system and valve
Binding of valve linkage Repair valve linkage
No motion; slow or jerky action Relief valve worn or stuck in base Repair or clean relief valve
Dirt or foreign particles lodged between Disassemble, clean, and

relief valve control poppet and seat reassemble relief valve
No relief valve action (high pressure) Small particle of dirt plugging orifice in Remove relief valve and
relief valve sub-assembly check orifice for blockage.
Clear orifice if blocked.
Upright or carriage will not hold Oil by-passing between spool and Replace valve
body
Oil by-passing piston in cylinder Repair or replace cylinder
Spool not centered See “Spool does not

return to neutral”
Upright or carriage mOves when Dirt or foreign particles lodged between Disassemble, clean, and
spool is moved from neutral to a check valve poppet and seat reassemble check valve
power position
Scored or sticking check valve poppet Replace poppet
SM556 30-01-2
30-01-04 MAIN VALVE REMOVAL 30-01-05 VALVE DISASSEMBLY
1. Turn keyswitch OFF and disconnect battery. IMPORTANT - Overhaul valve only in a
clean, dust-free location, using clean tools
2. Remove battery. and equipment. Dirt or grit will damage
highly-machined surfaces and will result in
3. Remove two front covers and top compartment leakage or premature failure of
cover. components. Cleanliness of hydraulic
circuit is extremely important to proper
4. Air clean main valve and fiiings. operation and maintenance of system.
5. Loosen and remove all hydraulic lines from Clean outside of valve with a good grade solvent
valve. Mark or tag each line as removed to ensure and dry thoroughly.
correct position of line at assembly. Cap ends of
lines to prevent contamination 1. Before starting disassembly, valve should be
carefully examined to determine if there is any
evidence of external damage.
2. Remove spool cover retainer and cover (items

30.040 & 30.039) and slide the spool out of its
bore from the cover end. Remove the spool bore
O-rings (item 30.031) from the valve body. Do not
remove the centering spring and retainer (items
30.006, 30.005, 8 30.101) from the spool, unless
it is necessary to replace them.
3. Remove the check valve plug (item 30.106) and

remove the O-ring from the plug. Remove the
check valve spring and poppet (items 30.105 &
30.104).
4. Remove relief valve plug (item 30.018) and

remove the O-ring from the plug. Remove the
6. Disconnect valve linkage at main valve by relief valve spring (item 30.020) and relief valve
removing spring clip (item 90.387), washer (item sub-assembly (item 30.022).
30.644), and link pin (item 30.091).
30-01-06 MAIN VALVE

INSPECTION
1. Discard all old O-rings.
2. Wash all parts carefully in clean mineral oil

solvent and place them on a clean surface for
inspection.
3. Inspect valve spool and bore for burrs,

scratches, paint, corrosion or erosion or scoring.
4. If any burrs are found, they should be removed

by light stoning or lapping. Be certain there is no
paint or burrs on mating portions of sliding or
rotating parts.
5. If any scoring is evident but is not deep enough

to cause objectionable leakage, the surfaces can
6. Remove main valve fasteners (items 30.195 &
be stoned or polished with crocus cloth. If scoring
91.788). Remove main valve.
is excessive, the valve body and spool must be
SM556 30 - 01 - 3
NOTE:
NON SERVICEABLE
ITEMS MARKED “N”
30.000
-*I .
HYDRAULIC VALVE 30463-l
30.000 vALVEASsmLY,RYD~ULIc 30.101 F.ETAINER.VALVESPOOLCENTERINGSPRING

30.005 GUIDE, VALVE SPOOL CENTKRINGSPRING 30.106 CONE, CHECK VALVB
30.006 SPRING,VALVE SPOOL CENTERING 30.105 SPRING, CHBCKVALVE
30.018 CAP,RELIEFVALVEASSEKBLY 30.106 PLUG*CiiECK.VALVB
30.020 SPRING, RELIEF VALVE ASSEXBLY 15N BODY, RYDUULIC VALVE USE 30.000
30.022 VALVE ASSEMBLY,RELIEF 16N SPOOL, EYDBAULICVALVE USE 30.000
30.031 sw,RYDRAULIcvALVF.sPooL
30.032 SW KIT, HYDRAULICVALVE
30.039 COVER, VALVE SPUO& CRNTFiRING
SPRING
30.060 FASTENER, VALVE SPOOL COVER
SM556 30-01-4
replaced. Check the valve spool for freedom of necessary. Refer to main pump motor switch group
movement in the bore. for details.
6. Check the relief valve for smooth movement in

its bore. The valve should move by its own weight.
7. Make sure all springs are free of corrosion and

not broken or bent.
NOTE - If parts must be left unasssembled for a

period of time, cover with clean lint- free material.
30-01-07 MAIN VALVE ASSEMBLY
1. Coat all parts with clean hydraulic oil to aid re-

assembly and provide initial lubrication.
2. Install new O-ring on relief valve plug (item

30.018). Place the relief vafve sub-assembly (item
30.022) in its bore. Install the relief valve spring
(item 30.020) and the plug. Tighten plug securely,
but do not overtighten.
3. Install new O-ring on check valve plug (item

30.106) with the O-ring toward the check valve
spring and poppet.
4. Place the check valve poppet and spring (items

30.104 8130.105) in the valve body and install the
Plug-
5. Install the centering spring and retainers (items

30.006,30.005, & 30.101) on the spool, if they
were previously removed.
6. Install new O-rings in O-ring grooves in valve

body. Install spool in bore from cover end. Install
spool cover and retainer (items 30.039 & 30.040).
30-01-08 MAIN VALVE

INSTALLATION
1. Position main valve in truck and mount with

valve fasteners (items 30.195 & 91.788).
2. Connect valve linkage at main valve by installing

link pin (item 30.091), washer (item 30.644) and
spring clip (item 90.387).
3. Connect hydraulic lines to main valve.
4. Install top cover and two front compartment

covers.
5. Connect battery and test main valve operation.

Check main pump motor switches and adjust as
SM556 30 - 01 - 5
GROUP 31 SECTION 01 provided through a spin-on, full-flow return-line
filter in the power steering circuit.
HYDRAULIC SYSTEM
CONTENTS NO. 31-01-02 HYDRAULIC FLUID AND
FILTER CHANGE
GENERAL DESCRlPTlON 31-01-01
HYDRAULIC FLUID & FILTER CHANGE 31-01-02 There is no drain plug in the hydraulic sump tank.
HYDRAULIC SUMP TANK 31-01-03 When the sump tank must be drained of all fluid;
MAIN HYDRAUUC AND LIFT LINES 31-01-04 the procedure is to remove the pump suction line
HYDRAULIC STEERING LINES 31-01-05 from the sump outlet fitting and allow the fluid to
HYDRAULIC TlLT LINES 31-01-06 drain into a suitable drain pan. Unless the sump
tank is to be removed for other repair or
maintenance, the hydraulic fluid can be changed
by one of the following methods:
31-01-01 GENERAL
DESCRI,PTION 1) Removal of the hydraulic sump fill cover
assembly (sump filler cap adapter) and pumping
The parts of the main hydraulic system are the Fn\fl&:;ut by suction using a separate pump
hydraulic sump tank, main hydraulic pump and .
motor, main hydraulic valve, selector solenoid
vafve; and associated hydraulic lines and hoses. 2) Pumping the fluid out by using the truck
hydraulic system. This method, described
The parts of the hydraulic steering system are the below, may be used most easily and
steer pump and motor, steer gear, and steer satisfactorily for routine changing of the fluid.
torque generator.
SAf ETY NOTE
BREATHER CAP To perform this service procedure, it is
-SUMP CAP ADAPTOR
Park truck on a level surface.
8 Put the upright in a vertical position and
g
lower the carriage fully down.
Return control handle to neutral and turn
key switch OFF.
4
Remove the two front compartment covers for
SCREEN access to the hydraulic oil filter.
The hydraulic sump is a separate, removable tank.
Oil from the hydraulic sump tank is fed by a gear

pump to the main hydraulic valve and the selector Remove the top compartment cover for access to
solenoid valve. From the selector solenoid valve the hydraulic system pressure diagnostic check
the oil is directed to the lift and tilt cylinders. port located on left-hand side of main hydraulic
Filtration of the main hydraulic system oil is valve.
SM556 31 - 01 - 1
Remove the snap-on cap and connect a suitable
drain hose line to the diagnostic check port fitting.
NOTE: Use quick-disconnect adapter fitting, Clark
Part No. 3797029.
You will need a drain pan of [13.5 L] 3.5 gallon

minimum capacity, or other method of disposal, for
collecting the used oil. Be sure the outlet end of
the drain line is directed into the drain pan and held
from moving when pressurized.
NOTICE - If battery is removed, use an

adapter cable connected between battery
and truck receptacle to power hydraulic
system.
Turn key switch ON.
Move control handle and push tilt button in the

back tilt position to start the main pump. Hold
control handle and push button in this position Remove and discard old oil filter. Install new oil
until sump tank is emptied. A steady stream of filter. Be sure to follow the installation
used oil should flow,from the drain line. instructions printed on the filter body. Also,
check that the hydraulic line connections at
Continue operation until the sump tank is emptied. the filter base are tightened correctly.
This point will be reached when the pump starts to
cavitate. When cavitation occurs the pump speed Remove the used sump breather. cap. (NOTE:
will increase. A change in pump speed pitch will be Remove sump filler cap adapter to clean sump pre-
heard. Also, watch the dram line. The oil flow will filter screen, if necessary.)
become erratic or will stop when the pump can no
longer pick up oil from the tank. Cover service brake and fill sump tank with new
fluid. Refer to Specifications group for
Pelea%? the control handI6 and pUsh recommended hydraulic fluid.
m when pump cavitation occurs.
IMPORTANT
IMPORTANT Afways use genuine CLARK parts.
Be careful when sump is nearly emptied. Use recommended fluid only.
Watch for signs of pump cavitation. Do not
operate pump after cavitation occurs. Install new sump breather cap.
Turn key switch OFF. Check truck operation. Turn key switch ON.
Operate the hydraulic system. Cycle the lift system
Disconnect drain line from the truck. Replace several times: raise the lift carnage to full height
cap on main valve check port fitting. and lower fully down. Check for leaks.
1.1.- ,‘SAFETY .I%
NOTE
NOTICE - If old oil is excessively dirty or
hydraulic system contaminated, it is Be sure there is adequate overhead
recommended that the sump tank be clearance before raising upright.
completely drained by removing the pump
suction line from the sump outlet, and Turn key switch OFF.
flushed with clean oil.
Check sump tank fluid level again. Add
recommended fluid as required. DO NOT
OVERFILL.
Install the top and two front compartment covers.
SM556 31 - 01 - 2
SUMP BREATHER CAP
PRE-FILTER SCREEN
31-01-03 HYDRAULIC SUMP TANK SUMP TANK INSTALLATION
SUMP TANK REMOVAL 1. Install sump tank in reverse order of removal.
1. Remove upright. Refer to upright group for

details.
2. Remove drive axle. Remove to drive axle group

for details.
3. Drain hydraulic oil from sump tank.
4 Position a drain pan under truck to hold hydraulic

fluid. Disconnect hydraulic lines at sump tank.
Loosen hose clamp (item 29.781) and release

sump tank filler line from mounting bracket (item
29.720).
8. Carefully cut sump tank mounting strap (item

29.702) and remove sump tank.
SM556 31 - 01 - 3
l-31.019 /- 31.388
30.952 STANu~D~V~ILO
31.480 ,y-31.393
28.752
p; TO UPRIGHT
L30.060
- :i
.; 31.387
-ai.wi
MAIN HYDRAUUC & LIFT LINES
23.832 FITTING, SELEtXORVb3+VR OUTLET 31.037 FITTING, VALVE DISCRARGE FORT
27.024 PLUG, DRV. SRL. SOL. VALVE OUTLET PORT 31.038 SEAL. VALVE DISCHARGE PORT FITTING
27.025 SEAL. DW. SEL. SOL.VALVE C5 PORT 31.109 LINE, MAIN VALVE DISCRARG&
27.028 FITPING, DEV. SEL. SOL. VUVE Cf PORT 31.191 LINE, VALVETO sum RETURN
28.158 SEAL, HIGR PRESSDRE CARRY OVERLINE 31.195 LINE, VALVEPO SUKP RE
28.291 FITTING, PUMP OUTLET 31.198 PITTING, LIFT CYL. RF.TURNSUKP INLET
28.649 FIlTINC,VALVR LIRPRRSSURRLXNE " ~rCLAHP~VALVR~~TO~SUXP~RETURN LINE
.‘-35.387-
28.752 SRAL. PRESS.GAlJGEPORTFIlTMC 31.388 LINE, VALVE SUMP RETDRN
28.802 SEAL,HYD. PuplpODTLEr LINE 31.393 CAP. VALVE TO SUMP RETURNLINE
30.059 SEAL, CARRYOVER FIT1?NGINNER 31.421 SRAL. PUKP OUTLET PORT FITTTNG
30.060 SEAL.CARRYOVERFIlTfNGOUTER 31.480 FIlTING. PRESSURE GAUGE PORT
30.061 FITTING,HIGR PRESSURE CARRY OVRR 31.537 FITTING, VALVE SECONDARY INLET PORT
30.431 FImINC, HIGH PRESSURE CARRY OVea 31.538 SEAL, VALVE SECONDARYINLET PORT FITTING
30.952 DUST CAP. PRESSURE GAUGE PORT FITTING 31.586 FITTING,LIFT CYL. VENT LINE
31.001 LINE, sum OUTLET 31.628 SEAL. V&Vi? INLfi PORT LINE
31.002 CLAk@.sDMPOUTLETLINE 31.919 SEAL, VALVE.SUMF RErURN LINE
31.003 LINE,PuKP INLET 31.950 LINE.RIGRPRRSSURECAF.RY0VER
31.004 CLAm.PmPINLETLINE 32.110 SEAL, MAIN VALVE OD'ILETLINE
31.006 LINE, PUMP INLET 32.112 SEAL.VALvE Sm RETURN LINE
31.007 CLAMP. PUMP INLET LINE 33.503 FITTING, SOLENOID VALVE INLET
31.008 FITTING, PUMP INLET 33.504 SEAL, SOLENOID VALVE INLET FIlTING
31.010 SEAL, ~IIfLETFITTING 33.513 SEAL. SRLECTORVALVEOUTLET FITTING
31.013 SEAL, Puw OUTLET FITTING 33.761 FITTING,DEV. SEL. SOL. VALVE C4 PORT
31.016 FI'ITING,PUMP ODTLeP 33.762 SEAL, DEV. SEL. SOL. VALVE CL PORT FITTISc.
31.018 LINE, PW OUTLET 34.ss7 STRAP, LIFT CYL. PRESSURE LINE
31.019 LINE. VALVE INLET 34.559 SEAL, VALVE TO LI= CYL. LINE
31.023 siaL,vAtvEmmFfm~~ 51.339 FITTING. SELECTOR VALVE Cl PORT
31.030 LINE, VALVE TO LIFT CYL. 51.340 SEAL, SRLECTOR VALVE Cl PORT FITTING
31.036 FIlTING, MAIN VALVE INLET PORT 66.149 SEAL, LIW CYL. LINE FITTING
SM556 31 -Do
01not
- 4 sell or distribute
26.265 SEAL, TORQUE GENERATOR PRESSURE PORT 31.098 CLAMP, STEER PUMP INLET HOSE
26.363 SEAL, TORQUE GENERATOR INLET FITTING 31.100 TUBE, STEER PUMP INLET
27.044 BRACKET, RELIEF VALVE MOUNTlNG 31.102 FIITING, STEER PUMP INLET
28.059 SEAL, STEER VALVE CONTROL PORT FllTlNG ‘R 31.104 Fll-l-ING, STEER PUMP PRESSURE PORT
28.060 FITTING STEER VALVE CONTROL PORT ‘R 31.115 LINE, STEER PUMP OUTLET
28.061 LINE, STEER VALVE CONTROL ‘R 31.120 LINE, STEERING SUMP RETURN
28.062 LINE, STEER VALVE CONTROL lL 31.122, FITTING, STEERING SUMP RETURN LINE
28.065 SEAL; STEERVALVE CONTROL PORT FITTING ‘L’ ’ .. ;;.;‘t$ - “’ ClAMP,STEER LINES
28.066 FIlTlNG, STEER VALVE CONTROL PORT ‘L- LINE, STEER PUMP INLET
28.133 FITTING, RELIEF VALVE INLET PORT 31:149 FIlTlNG, STEER LVALVE INLET PORT
28.134 SEAL, RELIEF VALVE INLET PORT 31.150 FllTlNG STEER VALVE DISCHARGE PORT
28.136 FIllING, RELIEF VlAVE OUTLET PORT 31.164 LINE, STEER VALVE DISCHARGE
28.246 SEAL, RELIEF VALVE INLET LINE FllTlNG 31.373 SEAL, STEER PUMP PRESS. PORT FIT-I-ING
28.247 SEAL, RELIEF VALVE OUTLET LINE FITTING 31.399 SEAL, STEER VALVE DISCHARGE PORT
28.262 LINE, TORQUE GENERATOR “Cl” 31.449 SEAL, STEER PUMP INLET PORT
28.352 CAP, POWER STEERING GAUGE PORT FITTING 31.462 SEAL, STEER VALVE OUTLET PORT ‘L
28.383 FI-ITING, POWER STEERING GAUGE PORT 31.465 SEAL, STEER VALVE OUTLET PORT ‘R”
28.674 SEAL, RELIEF VALVE INLET PORT FllTlNG 31.466 SEAL, STEER VALVE INLET PORT
28.675 SEAL, RELIEF VALVE OUTLET PORT FllTlNG 31.606 LINE, STEER PUMP INLET
28.751 SEAL, POWER STEERING GAUGE PORT Fill-ING 31.683 FITTING, TORQUE GENERATOR INLET ‘Cl”
28.760 SEAL, RELIEF VALVE OUTLET PORT 31.684 FIlTlNG, TORQUE GENERATOR INLET “C2”
28.799 SEAL, STEER VALVE OUTLET PORT FllTlNG 31.690 LINE, TORQUE GENERATOR ‘C2
28.801 SEAL, STEER PUMP OUTLET PORT FITTING 31.830 SEAL, FILTER INLET PORT FllTlNG
28.804 SEAL, STEER VALVE INLET PORT FllTlNG 31.974 FITTING, RELIEF VALVE OUTLET LINE
30.662 VALVE ASSEMBLY, RELIEF 33.056 FASTENER, RELIEF VALVE
31.043 FITTING, FILTER INLET PORT 95.874 FASTENER, RELIEF VALVE MTG. BRKT.
31.044 SEAL, FILTER INLET PORT 95.875 NUT, RELIEF VALVE FASTENER
31.047 SEAL, FITLER OUTLET PORT
31.050 FITTING, FILTER OUTLET PORT ,
SM556Do31
not- 01
sell- or
5 distribute
REV JAN 90
CLqRH N&erzrn:Handling
.31.077
31.364
31.072 ’ l- 26.833
HYDRAULIC TILT LINES
28.830 Seal, RH Tilt Cyl. Anchor Port Line Fitting 31.162 Fitting, RH Tilt Cyl. Anchor Port
28.831 Seal, LH Tilt Cyl. Rod Port Line Fitting 31.364 Seal, LH Tilt Cyl. Rod Port
28.832 Seal, RH Tilt Cyl Anchor Port Line Fitting 31.365 Seal, RH Tilt Cyl. Rod Pot-l
28.833 Seal, RH Tilt Cyl. Rod Port Line Fitting 31.366 Seal, LH Tilt Cyl. Anchor Port
28.834 Seal, LH Tilt Cyl. Anchor Port Line Fitting 31.367 Seal, RH Tilt Cyl. Anchor Port
28.835 Seal, LH Tilt Cyl. Rod Port Line Fitting 31.370 Fitting, Tilt Cyl. Rod Port Line
28.836 Seal, Tilt Cyl. Rod Port Line Fitting 31.372 Fitting, Tilt Cyl. Anchor Port Line
28.837 Seal, Tilt Cyl. Rod Port Line Fitting 31.600 Fitting, RH Tilt Cyl. Rod Port
30.563 Seal, Valve Port (C3) Ftiing
30.565 Seal, Valve Port (C2) Fitting
31.061 Fitting, Hyd. Valve Tilt Port (C3)

31.062 Fitting, Hyd. Valve Tilt Port (C2)
31.065 Seal, Hyd. Valve Tilt Port (C2)
31.072 Line, RH Tilt Cyl. Rod Port
31.073 Line, LH Tilt Cyl. Rod Port
31.077 Fitting, LH Tilt Cyl. Rod Port

31.083 Line, RH Tilt Cyl. Anchor Port
31.152 Seal, Hyd. Valve Tilt Cyl. Anchor Port
31.158 Line, LH Tilt Cyl. Anchor Port
31.160 Fitting, LH Tilt Cyl. Anchor Port
SM55631 -01 -6Do not
REVdAN
sell or distribute
GROUP 32 SECTION 01 2. Disconnect the hydraulic lines from the tilt
cylinders and cap the ends of the lines to prevent
TILT CYLINDER contamination of the lines. Note: Put a drain pan
under the truck at the tilt cylinder position when
CONTENTS NO. removing hydraulic lines.
TtLT CYLINDER REMOVAL 32-01-01 3. Remove the tilt cylinder rod end retainer
TILT CYLINDER DISASSEMBLY 32-01-02 capscrew and washer (items 34.091 & 34.090).
TlLT CYLlNDER INSPECTION 32-01-03
TlLT CYLINDER ASSEMBLY 32-01-04 4. Remove each tilt cylinder rod end (item 32.027)
TILT CYLINDER INSTALLATION 32-01-05 by pulling it off the upright attachment pin.
TILT CYLINDER ADJUSTMENT 32-01-06
5. At the anchor end of the tilt cylinder, remove
both spring clip retainers (item 32.034) from ends
of mounting pin (item 32.033).
32-01-01 TILT CYLINDER
REMOVAL 6. Drive the mounting pin (item 32.033) from tilt
cylinder anchor end and frame brackets.
1. Be sure all hydraulic attachments are in a 7. Remove the tilt cylinder from the truck.
position of rest and the upright and carriage are in a
fully lowered position. TILT CYLINDER ROD END REMOVAL
, _, ,... ~ .1 Ij , . _I., ,
9. Fully loosen the tilt cylinder rod end clamp bolt

WARNING
n! and nut (items 32.029 & 90.436).
If both tilt cylinders are to be removed,
the upright must be supported by use of Remove the rod end from the tilt cylinder rod.
an overhead chain hoist of adequate Note number of turns required for removal. This
capacity. will aid initial setting at installation. Keep the tilt
cylinder rod from turnina with a wrench on the flat
p&ion of the rod at the&d of the threads.
I) - 32.034
/-- 32CM & 32.033

n -0’
32.000
7
32.027
90.438
--l
34.091 J 32.053 1
34.090 --I
SM556 32 - 01 - 1
I ASSSMUY
COYfim
- 32.000 32.105-
__._____
32.002K -
\-32.002
32.0727 ?ACKlNO KIT

lNcLuoKs IlfYL
L 32.024
MUKID “K”
TILT CYLINDER
32.000 TILT CYLINDERASSMBLY
32.002 BARREL.TILT CYLINDER
32.005 SEAL. TILT CYLINDERPISTON
32.014 SPACER,TILT CYLINDERPISTON ROD
32.015 SEAL. TILT CYLINDERGLAND
32.017 GLAND. TILT CYLINDER
32.019 PACKING,TILT CYLINDER GLAND
32.023 WIPER. TILT CYLINDERPISTON ROD
32.024 NUT, TILT CYLINDERGLAND
32.036 ROD 6 PISTOti.

TILT CYLINDER
32.072 PACRINC KIT, TILT CYLINDER
32.105 PLUG, TILT CYLINDERPORT FITTING
32.106 SEAL, TILT CYLINDERPORT FITTING PLUG
SM556 32 -01 - 2
10. Remove shim(s) (item 32.102) and spacer Make sure the threads on the rod are free of
(item 32.014) (if used) from tilt cylinder rod. Note damage.
location and number of shims removed. This will
aid initial setting at installation. 3. Check the bore of the cylinder for any damage.
11. Inspect tilt cylinder anchor end beating (item Parts with deep gouges or pitted surfaces will
32.043). Replace if worn or damaged. require replacement.
Check the threaded section of the cylinder to be

32-01-02 TILT CYLINDER sure the threads have not been damaged.
DISASSEMBLY
Inspect the ports to be sure they are free of
1. Before disassembly, clean the exterior of the tilt contamination and that the threads are clean and
cylinder to remove all contamination. not damaged.
Be sure all hydraulic oil has been removed from the 4. Put a light coat of hydraulic fluid on all parts. If
cylinder. Stroking the piston rod will help force the parts are to be left out for a period of time or
oil out. overnight, they should be covered with a clean
cover.
When overhauling hydraulic components, it is
necessary to avoid any dirt particles from
contaminating the system.. ,cThesmallest particles 32-01-04 TILT CYLINDER
are capable of severely damaging the system. ASSEMBLY
2. Put the base end of the cylinder in a vise or use 1. Install a new packing (item 32.019) in the gland
an alternate method of preventing the cylinder assembly (item 32.017).
tube (item 32.002) from rotating.
2. install a new rod wiper (item 32.023) in the gland
3. Use a spanner wrench to loosen and remove assembly.
the end cap (item 32.024).
3. Install a new gland seal (item 32.015) on the
4. Carefully pull the piston rod assembly (item gland assembly.
32.036) and the gland assembly (item 32.017) out
of the cylinder bore. 4. Install a new piston seals and back-up rings
(item 32.005) on the piston.
5. Pull the gland assembly (item 32.017) off the
piston rod (item 32.036). 5. Coat the bore of the gland assembly and the
piston rod assembly with a light coat of hydraulic
6. Remove and discard the tilt cylinder gland seal oil.
(item 32.015) the gland packing (item 32.019) and
the wiper (item 32.023) from the gland assembly. 6. Slide the gland assembly onto the piston rod
assembly, being careful not to damage the gland
7. Remove and discard the piston seals and back- packing and rod wiper with the end of the piston
up rings (item 32.005) from the piston assembly. end.
7. Install piston into cylinder barrel, being careful

32-01-03 TILT CYLINDER not to damage the piston seals on the edge of the
INSPECTION cylinder barrel.
1. Carefully clean all parts in an approved solvent 6. Install the gland assembly into cylinder tube.
and position them on a clean surface.
9. Install the gland nut and torque to [67 - 81 Nom]
2. Check the piston rod for any damage. Look for 50 - 60 Ibfaft .
gouges, scratches, corrosion or evidence of
unusual wear. Minor surface damage can be 10. Check the assembly by making sure the piston
repaired by use of fine abrasion cloth or stoning. rod will slide in the cylinder tube.
Deeper damage will require replacement of piston
rod assembly.
SM556 32-Ol- 3
32-01-05 TILT CYLINDER To shorten, loosen the clamping fastener on the
INSTALL mATION rod end (item 32.027) and rotate the piston rod
CLOCKWISE into the rod end threads.
1. Install shim(s) (item 32.102) and spacer (item
32.014)(if used) on cylinder rod. When the racking effect has been corrected,
tighten the rod end fastener.
2. install rod end on cylinder rod. The number of 4. Slowly tilt upright fully backwards.
turns to install should be same as noted when rod
end was removed. If necessary, keep the tilt 5. Note if tilt cylinders “bottom out” (stop) at the
cylinder rod from turning with a wrench on the flat same time. If they don’t, tilt cylinder backward tilt
portion of the rod at the end of the threads. must be adjusted.
3. Install the rod end clamp bolt and nut (items 6. Slowly tilt the upright backward until one tilt
32.029 & 90.438). Torque the clamp bolt nut to cylinder “bottoms out” against its rod spacer (item
[20 - 25 N*m) 177 - 221 lbfmin. 32.014)or gland end cap (item 32.024).
4. Position the tilt cylinder in its location on the 7. Install rod shims (item 32.102) on rod to fill in
frame and install the hydraulic lines. space between rod end and spacer or gland end
cap.
5. Install the mounting pin (item 32.033) through
the tilt cylinder anchor end and frame brackets. 8. Test for proper forward and backward tilt
Install both mounting pin spring clip retainers, (item cylinder adjustment.
32.034).
6. Install tilt cylinder rod end (item 32.027)on the

upright attachment pin.
7. Install the tilt cylinder rod retainer fastener (items

34.091 & 34.090). Torque capscrew to [20 - 25
N-m]177 - 221 Ibf*in .
8. Remove the chain hoist and chain from the

upright.
32-01-06 TlLT CYLINDER

ADJUSTMENT
Note: Forward tilt cylinder adjustment

must be made before backward tilt
adjustment.
1. Use a capacity load centered on the forks.
2. Raise the upright only to the height that will

allow the fork tips to clear the floor by a small
amount when tilted fully forward.
3. Slowly tilt upright fully forward.
Note if upright “racks” or twists during its

movement by unequal stroke of tilt cylinders.
Correct this twisting effect by shortening the

cylinder that is the longest length.
SM556 32 - 01 - 4
GROUP 33 SECTION 01
SELECTOR SOLENOID
VALVE 33-01-02 SELECTOR SOLENOID
VALVE TROUBLESHOOTING
CONTENTS NO. A problem with the selector solenoid valve will be

either in the electrical or hydraulic circuits. Use the
SELECTOR VALVE DESCRIPTION 33-01-01 truck electrical and hydraulic schematics to
determine which selector solenoid valve cartridge
SELECTOR VALVE TROUBLESHOOTING 33-01-02
is faulty. Because the solenoid and relief valve
SELECTOR VALVE REMOVAL 33-01-03 cartridges can not be serviced internally, it will be
necessary to replace the defective cartridge to
SELECTOR VALVE REPAIR 33-01-04 repair the valve.
SELECTOR VALVE INSTALLATION 33-01-05

33-01-03 SELECTOR SOLENOID
DEVICE SELECTOR VALVE 33-Ol-06
VALVE REMOVAL

2. Remove battery.
VALVE DESCRIPTION
3. Remove two front covers and top compartment
The selector solenoid valve is an electrically cover.
operated hydraulic directional valve. The valve
incorporates hydraulic circuits to control lift, lower, 4. Air clean main valve and fittings.
tilt, and one auxiliary function. Note: A device
selector solenoid valve may be joined to this valve 5. Identify and disconnect wire leads at valve
to add another auxiliary function. cartridges.
6. Loosen and remove all hydraulic lines from

valve. Mark or tag each line as removed to ensure
correct position of line at assembly. Cap ends of
lines to prevent contamination.
SELECTORVALVE
27.031
30.572
27.033
33.523
SELECTOR SOLENOID VALVE

33.300 VALVE ASSEMBLY, SRLECTOR SOLENOID 33.236 SEAL KIT, LIFT SOLENOID VALVE COIL
27.031 VALVE ASSMBLY, SEX. SOL. VALVE COUNTER BAuNCE 33.264 COIL. TILT SOLENOID VALVE
27.032 PLATE, SRL. SOL. VALVE END 33.267 SEAL KIT, TILT SOLENOID VALVE COIL
27.033 SEAL, SEL. SOL. VALVE OPTIONi+ OUTLET PLUG 33.320 ROW CONTROL, TILT
27.034 SEAL, SKL. SOL. VALVE END PLATE (LARGE) 33.385 COIL, DEVICE SOLKNOID VALVE
27.035 SW, SEL. SOL.VALVKENDPLATE (SHALL) .33.387 .-:

:SEAL-'KIT,DEVICE SOLENOID VALVE COIL
27.038 SEAL KIT, SKL. SOL. VALVE RKLIEPVALVE 33.523 PLUG, S&L. SOL. VALVE OPT. OUTLET PORT
27.039 SEAL KIT. SEL. SOL. VALVR COUNTER BALL.VALVE 33.680 COIL, PRESSURE SOLENOID VALVE
27.040 SEAL KIT. TILT FLOW CONTROL VALVE 33.683 SF& KIT, PRESSURE SOLENOID VALVE COIL
27.043 SEAL KIT, LOWERING VALVE SOLENOID COIL 95.818 FASTKNER.SKLECTOR SOLENOID VALVE KND PLATE
30.572 COIL, LOWERING VALVE SOLENOID 25N MANIFOLD, SELECTOR SOL. VALVE USE 33.300
33.000 FLOW CONTROL, DEVICE
33.009 SF.ALKIT, DEVICE FLOW CONTROL
33.052 VALVE, SRLECTOR SOLENOID VALVE RELIEF
33.233 COIL, LIFI SOLENOID VALVE
SM556 33-01-2
7. Remove selector solenoid valve fasteners (item 33-01-06 DEVICE SELECTOR
30.307). Remove selector solenoid valve. SOLENOID VALVE
The device selector solenoid valve, if used,

33-01-04 SELECTOR SOLENOID controls a second hydraulic function.
VALVE REPAIR
The device selector solenoid valve is serviced like
~ the selector solenoid valve. Torque end cover
fasteners (item 33.381) to [6,8 - 95 Nam] 5 - 7
NOTE .
Ibf*ft.
Items illustrated are the only service parts
available for the selector solenoid valve.
Disassembling solenoid or relief valve cartridges
will void the warranty on the valve assembly.
IMPORTANT
Removevalve components only in a clean,
dust-free location, using clean tools and
equipment. Dirt or grit will result in leakage
“- or. premature failure of components.
Cleanliness of hydraulic circuit is extremely
important to proper operation and
maintenance of system.
1. Clean outside of valve with a good grade

solvent and dry thoroughly.
2. Remove and replace valve cartridges, cartridge

seals, and O-rings as required. Torque valve
cartridges to [47 - 54 Nom] 35 - 40 tbfgft. Torque
end cover fasteners (item 95.818) to [6,8 - 9,5
N*m] 5 - 7 Ibfeft. Torque valve body plugs to [20 -
27 Nam] 15 - 20 Ibfaft.

VALVE INSTALLATION
1. Position selector solenoid valve in truck and

mount with valve fasteners (item 30.307’).
2. Connect hydraulic lines to selector solenoid

valve.
3. Connect wire leads to valve cartridges.
4. Install top cover and two front compartment

covers.
5. Connect battery and test selector solenoid

valve operation.
SM56 33 - 01 * 3
ASSEMBLY COMPLETE
DOES NOT INCLUDE I- 33.360
’ t d ’ 27.027
@> 27.026
27.024
DEVICE SELECTOR SOLENOID VALVE
33.380 Valve Assembly, Device Selector Solenoid

27.024 Plug, Dev. Selector Sol. Valve Outlet Port
27.026 Seal, Dev. Selector Sol. Valve C6 Port
27.027 Seal, Dev. Selector Sol. Valve C7 Port
27.036 Seal, Dev. Selector Sol. Valve Section (Large)
27.037 Seal, Dev. Selector Sol. Valve Section (Small)

27.045 Plug, Selector Solenoid Valve
33.009 Seal Kii, Device Flow Control
33.030 Flow Control, Device
33.381 Fastener, Device Selector Solenoid Valve
33.385 Coil, Device Solenoid Valve

33.387 Seal Kit, Device Solenoid Valve Coil
12N Body, Device Selector Solenoid Valve Use 33.380
SM556 33 - 01 - 4 REV JAN 90
-.
‘. .
-.
.-\. ‘.
.’ ;,t::: ‘,._,_’ . ,
A’ :.
: x X\ -..
13.574 /,’ : ‘... ‘. ..
.‘-- ._
,.. -/;
\,/
I’
65.914
27.027
27.030
27.026 - CL
n 33.380
27.029 -
AUX. VALVE INSTALLATION
75.021 Kii, Aux. Vavle Installation (6Hose)
13.574 Switch, Dev. Selector Valve Actuating
13.960 Filter, Auxiliary Relay #l
I7.378 Relay., Auxiliary #l ., ,
27.029 Fiiing, Dev. Selector Solenoid Valve C6 Port
27.030 Fiiing, Dev. Selector Solenoid Valve C7 Port
33.380 Valve, Dev. Selector Solenoid
65.914 Filter, Dev. Selector Solenoid
SM55633-01-5 .‘JAN90
CI!!IIRH
65.914 J 14.722 -I
AUX. VALVE INSTALLATION
75.021 Kit, Aux. Valve installation (2 Hose & Cable)
13.574 Switch, Dev. Selector Valve Actuating
13.960 Filter, Auxiliary Relay #l
14.722 Harness, Solenoid Valve
17.378 Relay, Auxiliary #l
33.380 Valve, Dev. Selector Solenoid
65.914 Filter, Dev. Selector Solenoid
SM55S 33 - 01 - 6Do not
-.. sell
: JAN 90
or distribute
GROUP 34 UPRIGHT 34-01 UPRIGHT
MAINTENANCE
CONTENTS NO.
Shim inspection at least every 500 hrs of
Upright, Maintenance 34-o 1 operation.
Upright, Shim I,nspection, Triple Stage 34-02
Carriage, Shim Inspection, Triple Stage 34-03 Check mounting fasteners.
Carriage, Shim Installation, Triple Stage 34-04
Upright, Triple Stage, Shim Disassembly 34-05 Check for leaks at hydraulic connections.
Upright, Triple Stage, Reassembly 34-06
Upright, Cylinder, Troubleshooting 34-07 Check for interference of hosing, chains, etc.
Upright, Cylinder Repair, Triple Stage 34-08 during lift operations.
Upright, Lit Chain, Maintenance 34-09 Keep piston rods and tops of cylinders clean.
Upright, Shim Inspection, Standard 34-l 0
Carriage, Shim Inspection, Standard 34-11 Always keep piston rods in retracted position when
Carriage, Shim Installation, Standard 34-l 2 not in use.
Upright, Standard, Shim Disassembly 34-l 3
Upright, Standard, Reassembly 34-l 4 Lubricate lift chain. Refer to 34-09 for instruction.
Standard Type Cylinder Troubleshooting 34-15
Upright, Cylinder Repair, Standard 34-16 Check chain adjustment and chain anchor adjustor
jam nuts.
Refer to “Upright Reassembly” for chain

adjustment procedures.
A! WARNING 34-02 UPRIGHT SHIM

INSPECTION, TRIPLE STAGE
This Group 34 describes procedures which can
produce unexpected movement of the upright Position the truck where the overhead height will
rails and other parts. allow the upright/load back rest to be raised to
maximum height. Set the parking brake and block
Do not walk or stand under raised forks. the steer wheels. The directional lever should be
placed in neutral. Start the motor, set the tilt at
Do not reach through upright open areas. Use “0” degree vertical and raise the forks to maximum
only hardwood blocks which are free from cracks height then lower approximately two (2”) inches.
and other visual damage. These blocks must be Turn key off.
square on the ends and not tapered or rounded.
Use a “c” clamp to force the rollers to one side for
Tuck blocks into the channel under the rail where shim clearance, if any at the opposite side for
specified. measurement. Note: Use a shim block under the
“C” clamp on the inside of channel rail. Note:
Review all described procedures before starting .,. LTorque on’the”“C”.ctamp should not exceed 20
any maintenance or service function. Failure to Ibf .-ft.
follow this warning can result in serious injury.
For inspection use an approved safety
platform/step ladder.
Measure the rail to roller clearance using feeler

gauges (See figure “Al” for measuring points).
Determine acceptance/rejection for each rail to

roller point from the listing in chart “C”. If shimming
is required take the truck to a Clark dealer or a major
repair shop. This service requires trained and
qualified maintenance personnel and the use of an
overhead hoist chainfall.
SM556 34 - 01 - 1
Check shimming of center roller on six (6) roller
carriage by raising upright until carriage top rollers
Rail/Roller Acceptance/Rejection List come out of top of inner rails.
CHART “c” Measure the rail to roller clearance using feeler

gauges at points shown in figure “I31 . Refer to
Feeler Gauge will Shimmed chart “C” for shim tolerance.
Seq Gauge Pass/not pass Correctly Cty
Reinstallation of side thrust roller with lock patch
1 .020” Yes 0 requires torque of 55 - 59 Ibf.-ft.
020” Try .040
: :w Yes 0 34-04 CARRIAGE SHIM
Try.060” - INSTALLATION TRIPLE STAGE
3’ -g No 2
3 k!J60~ Try 960” Remove carriage as described under 34-05
4 .080” 3 Upright Triple Stage Shim Disassembly. Shim as
4 .w TryffOO” - needed.
Evaluation of shim requirements generally dictates
that a specific roller is acceptable until (.040) two
(2) shims are required. It is recommended that the
shims are split evenly within one shim from side to
side and that all the uneven quantity of shims are
on one side. ,
34-03 CARRIAGE SHIM

INSPECTION TRIPLE STAGE
Position carriage as shown in figure “61”. Use a

“C” clamp to force the rollers to one side for shim
clearance, if any at the opposite side for
measurement. Note: Before application of the “C
clamp to the carriage remove the fork bar thrust
roller opposite the intended “C” clamp position, if
applicable. Note: Use a shim block under the “C”
clamp on the inside of channel rail. Note: Torque
on the “c” clamp should not exceed 20 Ibf. ft.
SM547 34 - 01 - 2
UPRIGHT AND CARRIAGE SHIM
INSPECTION TRIPLE STAGE
RAIL SHlfvl lNSPECTlON CARRIAGE Sjil,M INSPECTICN
Fiq.ure A -I Figure B I
6auge
center roller
J of six roller
carriage
‘C”
Clamp-_) w
! ,:
6auge
%RQfX FCRK em S1’E

/ THVn ROLLER f3fZFCE
AFPUING “C ‘* CUM’ TO
OP?csITE SLDE.
gauge
gauge
6auge
/
/
/
6auge 6auge
SM547 34 - 01 - 3
34-05 TRIPLE STAGE SHIM Lower carriage and forks onto the pallet and
DISASSEMBLY continue to lower until the primary (center
mounted) cylinder piston rod is completely
Shimming of the upright should be performed by collapsed into the cylinder. It may be necessary to
maintenance personnel in a properly equipped have a helper hold the control handle in the
shop with overhead hoist chainfall. Think out each lowering position while you pull on the carriage
procedure. chains to fully collapse the primary (center
mounted) cylinder.
Refer to Charts “D”, “E” & “F” for tools and

supplies list at end of text.
Note: Reference to “Left” or “Right” is utilized

relative to position of truck operator in the seat.
Remove the (carriage) chain anchor pins and cotter

keys near the top rear of the primary cylinder and
lay the chains over the carriage.
Use a “C” clamp to clamp one fork to the pallet.

This will prevent the carriage from falling over after
it is removed from the inner rails.
After shimming requirements have been
established the first step is removal of the carriage.
Remove the hydraulic hose leading to the primary
(center mounted) cylinder, at the top of divertor
Start motor , set tilt to “0” degrees vertical and
valve block, located on the left side of the upright.
raise the forks a minimum of six (6”) inches and
place a good substantial pallet under the forks.
Plug hydraulic line with #12 plug and place a #12
Turn key off. Place directional lever in neutral.
cap on the divertor valve fitting and tighten. This
Apply parking brake and block steer wheels. will allow hydraulic raising of the upright without
extending the primary cylinder.
SM556 34 - 01 - 4
As applicable on some models remove upper NOTE: Check to assure that upright tilt is still “0”
primary hose retainment bracket located on left degree vertical.
underside of top tie bar.
Raise upright high enough to place a four (4’) foot

Remove steer wheel blocks. Start the motor and length 4x4 block vertically into the intermediate rail
raise the upright until the inner rail clears the rollers channel under the inner rail and on opposite side
on the carriage. Release the parking brake and place a two (2) foot length 4x4 block vertically into
sbwfy back the truck away from the carriage. the outer rail channel under the intermediate rail.
Remove fasteners on the primary lift cylinder hose

bracket which is located near the left chain anchor.
Place an oil pan under the primary (center

mounted) Iii cylinder.
Remove the bracket and primary lift cylinder hose

and tube assembly at the base of primary lift
cylinder. Use #I2 plug in tube and ~712cap on
cylinder fitting to prevent dirt contamination. This
will prevent hose and tube damage when the rails
are lowered at a later time.
Position drive wheels of truck on raised supports

to provide a minimum of 5-114 inches under
upright outer rail. Place directional control in
neutral. set parkina brake and block steer wheels.
SM556 34 - 01 - 5
The final lift cylinder is located on the right side of From the rear of the upright remove both lower
the upright, loosen but do not remove the lower chain anchor fasteners located on both inner rails.
support fastener(s). Note: on some models the left and right chain
anchor bolts are different lengths.
I.. ,,
Hydraulically raise the upright rails and remove From the left rear of the upright pull the Left chain
both blocks and the oil pan. anchor out and tie it to the top left outer tie bar
area.
Lower the upright rails completely.
Remove the final lift cylinder rod fastener, located
NOTE: Top of the rails should be flush on top of the intermediate rail top tie bar. Note:
Some models may have two fasteners in the top of
Wrap 3/6” chain/safety strap around the top tie bar final lift cylinder rod. In either case the lift chain
of the inner rails. With a hoist/chainfall raise the partially covers the cylinder rod fastener(s) and
inner rail high enough to insert a fourteen (14”) must be moved over to remove fastener(s).
inch block vertically under the primary lift cylinder
base. Lower the hoist/chainfall until the primary lift Remove the final lift cylinder lower support
cylinder base rests securely on the fourteen (14”) fastener(s) available from rear of upright.
inch block.
SM556 34 - 01 - 6
From the front of upright pry the lower part of final 6. or it may be removed from the upper end of
lift cylinder over towards the center of the upright cylinder and lay the hose over the cowl. Also in
and pull right lift chain anchor out from right rear of this case, new tie straps will be required upon
the upright. Tie the right chain anchor to upper replacement.
right side of chain anchor bar adjustment area.
Disconnect the final lift cylinder hose on the
bottom of the divertor block located on the left side
of upright. Plug the hose and cap the fittings
with#12 male and female fittings. Tighten both
fittings.
Remove the 3/8” chain/safety strap from the inner

rail tie bar and attach it to the-intermediate rail top
tie bar. Raise the hoist/chainfall until the
intermediate rail is high enough to place a twelve
(12”) inch 4x4 block vertically into the outer rail
channel under the intermediate rail. Then lower Remove 3/8” chain/safety strap from the
the intermediate rail onto the 12” block. The intermediate rail top tie bar
primary lift cylinder must remain on the 14”
Wrap the 3/8” chain/safety strap around the final lift
cylinder just below its top retaining bracket. Lower
the hoisffchainfall hook down in front of the upright
and attach hook onto the chain/strap which is
wrapped around the final lift cylinder.
Remove final lift cylinder return vent line:
A. This may be disconnected under the floor

board.
SM556 34 - 01 - 7
Raising the hoistichainfall detach the final lift 4) Also the outer rail upper rollers are now
cylinder upper mounting bracket from the tie bar exposed. Shim as needed.
hook and out the front of the upright. Lower the
cylinder onto a pallet or other adequate support.
, . - _ , ,. .. . , I
B. To expose inner rail and intermediate rail upper
rollers:
You Are Now Ready To Expose the Rail 1) With both rails resting on the floor wrap
Rollers For Shimming the 318” chain/safety strap around only the
intermediate rail top tie bar.
A. To expose the outer rail upper and intermediate
rail lower rollers: NOTE: Check to assure chain anchor mounts are
1) Wrap 3/8” chain/safety strap clear. Also assure the chain and anchors do not
around both the inner and intermediate rail top tie catch or jam when raising or lowering the rails.
bars and hook onto hoistlchainfall,
2) Raise the ,intermediate rail with
NOTE: Check to assure that lift chains and hoistlchainfall until a two (2’) foot 4x4 block can be
anchors will not catch or jam when raising and inserted horizontally, front to back across the tie
lowering the rails. bars and under the top of the intermediate rail tie
bar.
2) Raise both rails with hoist/ 3) Lower the intermediate rail until the tie
chainfall and remove the blocks from under the bar rests on the block.
primary cylinder and the intermediate rail. NOTE: Inner rail must remain on the floor during
3) Lower the rails to the floor which will this procedure.
expose the lower intermediate rail rollers. Shim as 4) Intermediate rail upper rollers are now
needed. exposed. Shim as needed.
NOTE: Both rails must be on the floor at this time.
SM556 34 - 01 - 8
5) inner rail lower rollers are now exposed. WOOD BLOCKS
Shim as needed. CHART “F”
1 -6”-4X4
1-12”-4x4
1-14”-4x4
1 -2ft.-4x4
1-4ft.-4x4
4-12”-2x6
34-06 UPRIGHT TRIPLE STAGE

REASSEMBLY
With the 3/8” chain/safety strap still around the

intermediate rail top tie bar, raise the intermediate
rail and remove the 4x4” block from under the top
tie bar. Lower the intermediate rail to the floor.
NOTE: Make sure upright is vertical. Check to
assure that intermediate rail lower tie bar clears the
chain anchor blocks.
TOOLS AND SUPPLIES NEEDED Wrap 3/8” chain/safety strap around both the inner
CHART “D” and intermediate rail top tie bars. Then hook on
hoist/chainfall. Raise rails high enough to insert
1 1Omm allen wrench the 14” length 4x4” block under the primary lift
1Omm open end wrench or socket cylinder and the 12” length 4x4” block under the
: 13mm open end wrench and socket intermediate rail.
1 18mm open end wrench
1 19mm open end wrench and socket Lower rails onto blocks.
2 22mm open end wrench (or 7/8ths)
1 24mm socket Install final lift cylinder. Wrap the 3/8” chain/safety
1 30mm socket strap around cylinder just below its top retaining
1 9/l 6” open end wrench bracket. Hoist the cylinder and maneuver into the
l-1/4” angle wrench front of the upright making sure the hydraulic hose
: pair side cutters connection is toward the left side of the upright.
hammer Position the cylinder upper mounting bracket on
: small pry bars (12”) the tie bar hook. Reconnect the final lift cylinder
1 screwdriver (standard) hydraulic hose to the bottom of the divertor block
bng pry bar (about 3 ft. or longer) located on left side of upright. Install the return
: 6” “c” clamps + l-1/4” spacers vent line.
8 feeler gauges .OlO ea. 3/4” wide 12” long
Use the truck hydraulic system lever to slowly
extend the final lift cylinder piston rod end without
SUPPLIES ._raising_rails off blockto align with the intermediate
CHART “E” rail top tie bar mounting holes. Then install
fastener(s) in top tie bar into the end of final
Safety platform or stepladder cylinder piston rod.
3 #12 JIC female caps
3 #12 JIC male plugs Hydraulically raise intermediate rails and remove
Drain pan the 12 inch 4x4 * block.
Quantity of roller shims PN2359551
Sand paper NOTE: Do not remove 14 inch block under
Approximately 6 ft. of 3/8” chain/equivalent primary lift cylinder.
strap with hooks
6 - plastic wire ties Fully lower the intermediate rail.
Cleaning rags
Install both lower lift chain anchors with fasteners
loose (finger tight). Install final lift cylinder lower
SM547 34 - 01 - 9
mounting fasteners from rear of upright. free lift range. Close the high pressure valve. Mark
Remember, do not reach through upright rails. the position of the forks. After five minutes
measure the drift of the forks if any.
Raise intermediate rails hydraulically to put tension
on chains and tighten lower chain anchors. If the drift exceeded 718 of an inch, the primary
Recommended torque is 50-55 Ibf.-ft. cylinder is in need of repair.
Raise rails high enough to remove 14 inch block To check the secondary cylinder open the high
from under primary cylinder and install 4 foot length pressurs valve and continue to raise the maximum
4x4” block vertically under inner rail with a 2 foot load above the free lift range until the secondary
length 4x4” placed vertically under the cylinder piston rod is extended approximately one
intermediate rail. foot or more. Close the high pressure valve. Mark
th8 position of the forks. After five minutes
Lower the rails down onto the blocks. measure the drift of the forks, if any.
Install th8 bracket, hose and tube assembly at the If the drift of the forks exceeded 7/8 of an inch,the
base of the primary lift cylinder. Raise rails secondary cylinder is in need of repair. Open the
hydraulically and remove both blocks. high pressure valve and lower the load to the floor.
Completely lower upright to adjust lift chains at the NOTE: The drift dimensions specified are based
right hand outer rail upper tie bar. Turn the on conducting the inspection with the hydraulic oil
adjusting nuts .on. both chain .anchors until both temperature at 80-l 00 degrees fahrenheit.
chains are slack. Tighten the forward chain anchor
nut until the inner rail just begins to raise. Tighten
the rear chain anchor nut until both chains have 34-08 HYDRAULIC CYLINDER
equal tension. Lock the jam nuts on both chain REPAIR TRIPLE STAGE
anchors. Recommended torque is 110-130 Ibf.-ft.
using two wrenches and a third hand to hold the
Remove cylinder from upright (se8 34-05
chain anchor from turning.
Disassembly). Position cylinder on a work bench
with adequate support for safe and convenient
Drive truck up to the carrfage making sure the inner
disassembly. Two sets of 4x4” “V” notched blocks
rails are aligned with the carriage rollers. Check to
are helpful. One set for cylinder barrel and a
assure that the upright is still “0” degrees tilt. Raise
second set for the piston rod to prevent nicks and
inner rail high 8nOUgh to clear carriage rollers,
scratches from being inflicted on the piston or rod.
slowly mov8 forward where the upright inner rails
will lower over the carnage rollers. Assure that the
Clean entire cylinder to prevent dirt and other
final cylinder is fully COllapS8d. Reinstall the
contamination from entry into the cylinder during
carriage chains. Install the primary cylinder
reassembly. Parts may be cleaned with solvent or
hydraulic hose at the top of divertor valve block
mineral spirits and dried completely. If petroleum
located on the left side of the upright. If applicable
solvent is not available use hydraulic fluid
install upper primary hose retainment bracket
compatible with that used in vehicle system.
located on left underside of top tie bar. Remove
“c” clamp from fork to pallet. Raise carriage and
RemOV8 cylinder gland cap with proper size
back away.
spanner wrench or equivalent tool. Pull the piston
rod out of the cylinder barrel and-place it on a set of
Check for leaks. Check hydraulic oil in sump tank
“V” notched blocks. Remove all packings and
for proper level. Load test.
seals from the piston and the cylinder cap.
34-07 TRIPLE STAGE CYLINDER NOTE: Use extreme care that your tools do not
TROUBLESHOOTING make nicks and burrs on the interior surface area of
the cap or the exterior surface area of the piston.
To determine cylinder drift it is necessary to install a
high pressure shut off valve between the cylinder The U-cup seals are the most difficult to remove,
and the control valve. particularly from the cylinder cap. An electric
soldering gun tip (Weller 250 or equal) will melt
Open the high pressure valve and raise the forks through the U-cup seals in one or two minutes.
to maximum lift height. Lower forks to the floor and The soldering tip may need to be bent
raise a maximum load above the floor within the
SM547 34 - 01 - 10
approximately 90 degrees to effectively penetrate Use new parts as necessary. Always use new
the U-cup seal inside the cylinder cap. “Packing Kit” listed in the parts manual which
includes all the seals, wiper rings, wear rings and
After disassembly and cleaning inspect cylinder “0” rings necessary for the particular cylinder.
barrel and bore for cracks, pitting, scoring or other
irregularities that may require replacement of
barrel. Likewise inspect the piston and rod for
nicks, scratches, scoring or other defects that may
demand new parts.
66.400- FImL LIIT cn SEDER
Minute imperfections inside the cylinder barrel, on 66.401- BARREL

the piston or rod may be improved for acceptable
66.402- PACKIaC KIT
use by careful honing.
66.403- PISTON ROD
NOTE: Removal of material that produces a notch, 66.404- GLAND CAP

groove or out-of-roundness may cause excessive
66.405 U-CUP
leakage upon beginning operation or at best a
shortened life. 66.406- BACK-UP RING
66.409- WIPER
66.410- U-CUP
66.413- SPACER
66.414- BEARING
.’ .:FINAL Ll!T CYL‘INDER
NOTE: Care should be utilized in the installation

CYLINDER
of these parts to assure that damage to any part
does not happen or go unnoticed. Dip all
packings, seals and rings in clean compatible
hydraulic oil prior to reassembly.
Installation of some parts require special attention/

tooling. “0” rings should be carefully installed to
eliminate cuts or twisting. U-cup seals should be
installed with tools depicted in the following pages.
SM547 34-01 - 11
Installation of U-cup seal onto the piston is
Installation of U-cup seal into the cylinder cap accomplished with the proper size piston cone and
requires the use of tool #2195AT. Collapse the seal driver tools equivalent to #2525AT drawings
rool handles to insert the U-cup seal with the U- on following pages.
side down. The tool has three pins. Place the tool
so two pins are on the inside of seal and one pin Place the seal on the cone end of the piston cone
on the outside of seal. tool with the U-side toward the point of the cone.
Now place the driver on the cone and tap the driver
until the seal is positioned on the wide end of the
cone tool. Position the wide end of the tool over
the bottom of the piston so the piston is all the way
into the countersink part of the tool. Continue to
drive the seal off the tool into the piston groove.
Pull the handles apart which will force the outside

pin to collapse the seal enough to place the tool
pins and seal down into the top of the cylinder cap.
Place the edge of the seal opposite the pins into

the interior groove of the cap. Release tension on
the handles then pull tool up which should let NOTE; The primary cylinder (ram type) flow control
remaining part of seal expand into the groove. valve assembly that mounts in the base of the
piston must be installed with the arrow toward the
NOTE: Check to be sure the seal is inserted with piston.
the U-side toward the cylinder barrel.
After all seals and packings are replaced,
reassemble the piston into cylinder barrel. Install
gland cap and torque to 50-60 Ibf.-ft.
Install cylinder in upright as described in upright

reassembly.
SM547 34-01 -12

SEAL INSTALLATION TOOL LIFT
CYLINDER
(16296 1.
DR&RM
b40
.375(9,525)0lA.
REF
HO ES
---_
\ 219%AT_
i
ASSEMBLED VIEW - I
03,te
3REV0
Oh X 2 b2 LG CWEC PIN
WELD IN RACE AFTER DE% I&Z ASH.
Procure or manufacture
all tools locally.
SM547 34-01 -13

2525AT INSTALLATION TOOL
U-CUP TO PISTON LIFT
CYLINDER
SM547 34-01 -14
U-CUPTO PISTON LIFT CYLINDER
$%l.C&pE FOR
. co.00
‘,I WON’&
4.50
1 /
SM547 34 - 01 - 15
34-09 UPRIGHT LIFT CHAIN During the inspection, check for the following
MAINTENANCE chain conditions:
Rust and corosion Cracked plates *Raised or

Lift chains are very important components of fork turned pins *Tight joints *Wear-worn pins or holes.
lift trucks. The chain system on your upright was
designed for safe, efficient, and reliable
transmission of lifting force from hydraulic cylinder
to the forks. Safe use of your truck with minimum
downtime depends on the correct care and
maintenance of the lift chains. Most complaints of
unacceptable chain performance are a result of
poor maintenance. Chains need periodic
maintenance to give maximum service life. ..
Lift Chain Lubrication
Lii chain lubrication is an important part of your

maintenance program. The lift chains operate
under heavy loadings and will function more safely
and have longer life if they are regularly and
correctly lubricated. Clark chain lubricant is
recommended: ‘it -is~ easily’sprayed on and
provides superior lubrication. Heavy motor oil may
also be used as a lubricant and corrosion inhibitor.
When the pins or holes become worn, the chain
Lift Chain Adjustment Check becomes longer. When a section of chain is 3%
longer than a section of new chain, the chain is
The lift chains are correctty adjusted if the lower worn and must be discarded.
fork carriage rollers reach their end (lowest)
position approximately (13 mm) 50 inch from the Chain wear can be measured by using a chain
lower edge of the inner rail. This also positions the scale or a steel tape measure. When checking
bottom of the forks the same (equal) distance chain wear, be sure to measure a segment of chain
above the floor. To check this dimension, raise the that moves over a sheave. Do not repair chains by
carriage to a height that exposes several inches of cutting out the worn section and joining in a new
the inner rail at the roller path. Apply a layer of piece. If part of a chain is worn, replace all the
grease to the roller path on the inner rail. Lower chains on a truck.
the carriage and pick up a rated capacity load, tilt
the upright back slightly and raise the load until the Important
carnage rollers have passed over the greased area.
Lower the load completely and remove the load DO NOT ATTEMPT TO REPAIR A WORN
from the forks. Raise the carriage again to expose CHAIN. REPLACE WORN OR DAMAGED
the inner rail. You can now check the roller path CHAIN.
pattern in the grease and determine the correct
adjustment of the chains. LIPT CHAIN INSPECTION AND WEAR
CRITERIA
The lift chains can be adjusted by loosening or
tightening of the chain anchor nuts. (1) NEW CHAIN LENGTH - The distance from the
first pin counted to the last pin counted in a span
NOTICE -- It is important to make the lift chain while the chains are lifting a small load.
adjustment check with a rated load to be sure that
the chains are stretched to their maximum length. (2) WORN CHAIN LENGTH - See (1) above.
Lift Chain Inspection and Measurement (3) SPAN - The number of pins in the length
(segment) of chain to be measured.
Inspect and lubricate the lift chains every truck PM
(50-250 hours). When operating in corrosive
environments, inspect the chains every 50 hours .
SM547 34 -01 - 16
(4) PITCH - The distance from the center of one 5. Replace anchor pins and worn or broken
pin to the center of the next pin. anchors when installing new chains.
6. Adjust tension on new chains.
7
1. New Chain Length
2. Worn Chain Length 7. Lubricate chains when they are installed on the
3. Spm
4. Pitch upright.
34-10 UPRIGHT SHIM

INSPECTION STANDARD
Refer to figure “A2” for upright shimming

inspection. Think out each procedure. Wear
safety glasses.
Position the truck where the overhead height will

allow the upright/load back rest to be raised to
maximum height. Set the parking brake and block
the steer wheels. The directional lever should be
placed in neutral. Start the motor, set the tilt at
.Table of Chain ,Dimensions “0” degree vertical and raise the forks to maximum
height then lower approximately two (2”) inches.
Turn key off.
Use a “c” clamp to force the rollers to one side for

shim clearance, if any at the opposite side for
measurement. Note: Use a shim block under the
“C” clamp on the inside of channel rail. Note:
Torque on the “C” clamp should not exceed 20
Ibf.-ft.
For inspection use an approved safety

platform/step ladder.

gauges (See figure “A2” for measuring points).
Determine acceptance/rejection for each rail to

roller point from the listing in Chart “c”. If shimming
is required take the truck to a Clark dealer or a major
repair shop. This service requires trained and
Lift Chain Replacement
qualified maintenance personnel plus the use of
anoverhead hoist chainfall.
1. All chains must be replaced if any strand has
wear of 3% or more, or if any of the chaindamage
conditions noted previously are found during
inspection.
2. Order replacement chains from your CLARK

dealer.
3. Replace ail chains as a set.
4. Do not remove factory lubrication or paint new

chains.
‘SM556 34 - 01 - 17
Rail/Roller Acceptance/Rejection List
CHART “c” gauges at points shown in figure “B2 . Refer to
Chart “C” for shim tolerance.
Feeler Gauge will Shimmed
Seq Gauge Pass/not pass Correctly Qty Reinstallation of side thrust roller with lock patch
requires torque of 55 - 59 Ibf.-ft.
.020” Yes 0
.020" Try.040” -
.040- Yes 0
Try.060” - 34-12 CARRIAGE SHIM
;gI No 2 INSTALLATION STANDARD
Try 680”
1% 3
Remove carriage as described undere “Shimming
.080” Try%lO” -
of Upright for Single Stage”. Shim as needed.
Evaluation of shim requirements generally dictates
that a specific roller is acceptable until (.040) two
(2) shims are required. It is recommended that the
shims are split evenly within one shim from side to
side and that all the uneven quantity of shims are
on one side.
34-l 1 CARRIAGE SHIM

INSPECTION STANDARD
Position carriage as shown in figure “B2”. Use a

“C” clamp to force the rollers to one side for shim
clearance, if any at the opposite side for
measurement. Note: Before application of the “C
clamp to the carriage remove the fork bar thrust
roller opposite the intended “C” clamp position, if
applicable. Note: Use a shim block under the “C”
clamp on the inside of channel rail. Note: Force
on the “c” clamp should not exceed 20 Ibf.-ft.
Check shimming of center roller on six (6) roller

carriage by raising upright until carriage top rollers
come out of top of inner rails.
SM547 34 - 01 - 18
UPRIGHT AND CARRIAGE SHIM
INSPECTION STANDARD
.RAIL SHIM INSPECTION CARRIAGE SHIM INSPECTION
Figure A2 F&e 82
gauge
/ center roller
of six roller
. C.
carriage
ClanQL- .e
: b
6auge ._
f *aRmE FCRK BAR SIDE

lRU5T’ ROCLER E3EKIFE
AF?WNC “C ’ CLAMP TO
l
OP?OSITE SIDE.
gauge
SM547 34 - 01 - 19
34-13 UPRIGHT STANDARD SHIM
DISASSEMBLY
Shimming of upright should only be performed by

maintenance personnel in a properly equipped
shop with overhead hoist chainfall. Think out each
procedure.
Refer to Charts “D”, “E” & “F” for tools and

supplies list at end of text.
NOTE: Reference to “Left” or “Right” is utilized

relative to the position of trucK operator in the
seat.
Hydraulically raise inner rail until the carriage upper

rollers are clear.
Remove steer wheel blocks release parking brake

and slowly back the truck away from the carriage.
_ o”,
After shim requirements have been established

the first step is removal of the carriage.
Block steer wheels and apply parking brake. Start

the motor, set tilt to “0” degree vertical and raise
the forks a minimum of six (6”) inches. Place a
good substantial pallet under the forks and lower
onto the pallet. Continue to lower until tension on
chain is released.
J i
*
. _.._.. 7 Position drive -wheeL-of truck on raised supports

Remove cotter pins and chain anchor pins from the to provide a minimum of 5-l/4 inches under
chain anchors located on lower rear side of fork upright outer rail. Place directional control in
bars. neutral, set parking brake and block steer wheels.
Use a “c’ clamp to clamp on fork to the pallet. This

will prevent the carriage from falling over after it is
removed from the inner rails.
SM556 34 - 01 - 20
NOTE: Check to assure that upright tilt is still “0” sling thru the lift eye of lower sling and around the
degree vertical. upper part of the cylinder and hook into
hoist/chainfall. Now take up the slack.
Remove fastener in the top end of the lift cylinder

piston rod located on top of the inner rail top tie
bar.
NOTE: Remove only the cylinder rod fastener to

the cylinder that has been restrained by the sling
strap to the hoist/chainfall.
.
Hydraulically raise inner rail and place 12” - 18”
length 4x4 block vertically into the outer rail onto
the block. Turn key off.
Place a pan under the lift cylinders and disconnect

the hose and tube assembly at the base of each lift
cylinder. Use #12 caps and plugs to avoid dirt Piston rod should be collapsed into cylinder for
contamination. protection of the rod. It may be necessary to
manually collapse the piston rod into the cylinder
prior to removal of lift cylinder.
Upon removal of piston rod from top tie bar, take

note of shim/washer(s) if any on the piston rod.
Check where the piston rod came from on
underside of tie bar for the possibility of
shim/washer(s) remaining in counter bore. These
shim/washer(s) must be replaced in exact quantity
and respective side of upright as removed.
_.- Make note of cylinder position relative to hose

connection for reassembly.
Remove lift chain anchor clamp straps from around

each lift cylinder.
Remove lift cylinder saddle block mounting

retainers located at the lower end of each lift
cylinder.
From the rear of upright manually raise one cylinder

barrel a few inches to wrap a sling around under
the cylinder mounting pins. Then use a second
SM556 34 - 01 - 21
Carefully raise the lift cylinder out and up from the 1 18mm open end wrench
rear of upright. Lower the cylinder onto a pallet or 1 19mm open end wrench and socket
other adequate support. 2 22mm open end wrench (or 7/8ths)
1 24mm socket
1 30mm socket
1 9/l 6” open end wrench
1 1-l/4” angle wrench
1 pair side cutters
hammer
: small pry bars (12”)
1 screwdriver (standard)
long pry bar (about 3 ft. or longer)
: 6” “C” clamps + 1-l/4” spacers
8 feeler gauges .OlO ea. 3/4” wide 12” long
SUPPLIES
CHART “E”
. .- Safety platform or stepladder

3 #12 JIC female caps
3 #12 JIC male plugs
Drain pan
Repeat preceding paragraphs for the opposite lift Quantity of roller shims PN2359551
cylinder. Sand paper
Approximately 6 ft. of 3/8” chain/equivalent
Wrap chain or safety strap around top tie bar of 6 - plastic wire ties
inner rails and raise a few inches to remove block Cleaning rags
from under the inner rails.
WOOD BLOCKS
Lower inner rails to floor so that top and bottom CHART “F”
rollers are exposed.
1-6”-4X4
1 - 12”-4X4
Shim as needed.
1 - 14”-4x4
a 1 -2ft.-4x4
1-4ft.-4x4
4-12”-2x6
TOOLS AND SUPPLIES NEEDED

CHART “D”
1 1Omm allen wrench

1 1Omm open end wrench or socket
1 13mm open end wrench and socket
SM556 34 - 01 - 22
34-l 4 UPRIGHT STANDARD Repeat preceding paragraphs for the opposite
REASSEMBLY cylinder.
With chain or safety strap around top tie bar of Replace lift chain anchor clamp straps on both
inner rails, raise the inner rails to insert 12” - 18” cylinders.
length 4x4 block vertically into the outer rail
channel and under the inner rail. Lower inner rail Connect hydraulic hose and tube connectors at
onto the block. base of both lift cylinders.
Start engine, hydraulically raise inner rails and

remove block from under the inner rails.
Check for hydraulic oil leaks.
Remove blocks from steer wheels and move truck

to the carriage for reassembly.
Position truck with inner rails raised to clear the top

rollers of the carriage. Check to assure that tilt is
still “0” degree vertical and rails are aligned with
carriage rollers.
Slowly lower the inner rails down onto the carriage

rollers. Be sure inner rails are completely collapsed
to provide chain slack for reassembly .
h
i
Replace the chain into the chain anchors and
secure with the anchor pins. Use new cotter pins
in the anchor pins.
Wrap two sling straps around one of the lift
If necessary, adjust chains. Turn chain anchor
cylinders, one strap around the lower part under
adjustments to remove slack and the heels of the
the mounting pins and the second strap wrapped
forks are l/2” off floor. Tighten jam nuts to 11 O-
thru eye of lower strap and around upper part of
130 Ibf.-ft. using two wrenches and a third hand to
cylinder.
hold the chain anchor from turning.
Replace shim/washer(s) on piston rod same as
Remove “C” clamp from the fork and pallet.
removed.
Lll carriage and back away.
Then raise the cylinder for positioning at the rear of
the upright.
Check hydraulic oil in sump tank for proper level.
Load test.
Bring the cylinder in under the top tie bar and
guide the cylinder rod up into the countersink hole
on under side of tie bar.. Replacsfastenerthru the 34-15 STANDARD TYPE
top of tie bar into the cylinder rod. Then allow slack ‘.--CYLlNDER”TROUBLESHOOTlNG
from hoist and manually guide the cylinder
mounting pins down into the saddle block The determining factors for cylinder repair are
mounting. variable depending on the environment of
operation relative to the amount of oil seepage that
NOTE: That the hydraulic hose connection in is acceptable.
bottom of cylinder is aligned for proper hose
connection as removed. After a reasonable break in period of a new cylinder
there should not be visual evidence of sagging oil
Reinstall the lift cylinder mounting retainer and on the piston rod.
torque to 50-55 Ibf.-ft. Remove both sling straps.
Tighten rod fastener in top of tie bar to 125-140 When oil accumulation is evident at the top of the
Ibf.-ft. torque. cylinder it is recommended that the cylinder be
repaired. Examine the piston rod for scratches or
SM547 34 01 - 23
other damage that will cause accelerated wear of includes all the seals, wiper rings, wear rings and
the seals. “0” rings necessary for the particular cylinder.
NOTE: Care should be utilized in the installation of

34-16 UPRIGHT CYLINDER these parts to assure that damage to any part does
REPAIR STANDARD not happen or go unnoticed. Dip all packings,
seals and rings in clean compatible hydraulic oil
prior to reassembly.
Remove cylinder from upright (see 34-13
Disassembly). Position cylinder on a work bench Installation of some parts require special
with adequate support for safe and convenient attention/tooling. “0” rings should be carefully
disassembly. Two sets of 4x4” “V” notched blocks installed to eliminate cuts or twisting. U-cup seals
are helpful. One set for cylinder barrel and a should be installed with tools depicted in following
second set for the piston rod to prevent nicks and pages.
scratches from being inflicted on the piston or rod.
Installation of U-cup seal into the cylinder cap
Clean entire cylinder to prevent dirt and other requires the use of tool #2195AT. Collapse the
contamination from entry into the cylinder during tool handles to insert the U-cup seal with the U-
reassembly. Parts may be cleaned with solvent or side down. The tool has three pins. Place the tool
mineral spirits and dried completely. If petroleum so two pins are on the inside of seal and one pin
solvent is not available use hydraulic fluid on the outside of seal.
compatible with that used in vehicle system.
Remove cylinder gland cap with proper size

spanner wrench or equivalent tool. Pull the piston
rod out of the cylinder barrel and place it on a set of
“V” notched blocks. Remove all packings and
seals from the piston and the cylinder cap.
NOTE: Use extreme care that your tools do not

make nicks and burrs on the interior surface area of
the cap or the exterior surface area of the piston.
The U-cup seals are the most difficult to remove,

particularly from the cylinder cap. An electric
soldering gun tip (Weller 250 or equal) will melt
through the U-cup seals in one or two minutes.
The soldering tip may need to be bent
approximately 90 degrees to effectively penetrate
the U-cup seal inside the cylinder cap.
Pull the handles apart which will force the outisde
pin to collapse the seal enough to place the tool
After disassembly and cleaning inspect cylinder
pins and seal down into the top of the cylinder cap.
barrel and bore for cracks, pitting, scoring or other
irregularities that may require replacement of
Place the edge of the seal opposite the pins into
barrel. Likewise inspect the piston and rod, for ‘_?
the-interior groove of the cap: Release tension on
nicks, scratches, scoring or other defects that may
the handles then pull tool up which should let
demand new parts.
remaining part of seal expand into the groove.
Minute imperfections inside the cylinder barrel, on
the piston or rod may be improved for acceptable
use by careful honing.
NOTE: Removal of material that produces a notch,

groove or out-of-roundness may cause excessive
leakage upon beginning operation or at best a
shortened life.
Use new parts as necessary. Always use new

“Packing Kit” listed in the parts manual which
SM547 34 - 01 - 24
NOTE: Check to be sure the seal is
inserted with the U-side toward the Install cylinder in upright as described in upright
cylinder barrel. reassembly.
Installation of U-cup seal onto the piston is

accomplished withe the proper size piston cone
and seal driver tools equivalent to #2525AT
drawings on fobwing pages.
Place the seal on the cone end of the piston cone

tool with the U-side toward the point of the cone.
Now place the driver on the cone and lap the driver
until the seal is positioned on the wide end of of
the cone tool. Position the wide end of the tool
over the bottom of the piston so the piston is all
the way into the countersink part of the tool.
Continue to drive the seal off the tool into the
piston groove.
i/.-’
LIFT CYLINDER
%.Lw
I..ML
34.Lot
,‘.‘LS
X.U6
- X.60
3‘..1,
,.A,,
l,.‘,S
I‘.‘79
After all seals and packings are replaced,

reassemble the piston into cylinder barrel. Install
gland cap and torque to 50-60 Ibf.-ft.
SM547 34 - 01 - 25
SEAL INSTALLATION TOOL LIFT
CYLINDER
T
1
(8599)
3.33 (73,i)
L88I
D 2-B
(162.6:
I DR&RM
J75C9.525) DIA.
, I HOLES
f
(E’
. r
. ,
pK-i--~
I I-l
-
*
-li
”1
-‘L
-.__
‘. .
.. (’
_ -
ASSEMBLED VIEW
0 3, 3
qe
REWO
01; X 2 b2 LG. WUEC PIN
WELD IN PLACE AFTER DE% I&Z ASSEH.
Procure or manufacture
all tools locally.
4
SM547 34-01 -26
2525AT 1NSTALLATlON TOOL
U-CUP TO PISTON LIFT
CYLINDER
SM547 34 - 01 - 27
U-CUPTO PISTON LIFT CYLINDER
- .-
---
cp.00
I
4.50
_ J-'-m
SM547 34-01 -28

-_
GROUP
CL9RK 34
GROlJP
34
SECTION
9R
UPRIGHT REMOVAL
.- .,
C’
..‘-“.
To perform this service procedure, it is
l Park truck on a level surface and

fully lower the upright.
l Return all controls to neutral and turn
key switch to the "OFF" position.
l Apply the parking brake.
l Block the steer wheel.
Truck Preparation
Remove the forks.

Raise the drive wheels off the floor
and block up the front of truck under
the frame. Refer to GROUP 38, Section 3,
Machine Jacking and Blocking, for sug-
gested procedures.
Remove the drive wheels for access to
upright mounting pins and lock fastener
bolt.
Code: OH-540, MAR 86 Do not sell or distribute GROUP 34, Section 9R, Page 1
UPRIGHT MOUNTING
34.093 SPACER, UPRIGHT MOUNTING

34.600 PIN, UPRJGHT SUPPORT
34.605 FASTENER, UPRIGHT SUPPORT PIN LOCK
34.607 FllllNG - LUB, UPRIGHT SUPPORT
95.166 WASHER, UPRIGHT SUPPORT PIN LOCK FASTENER
GROUP 34, Section 9R, Page 2 Code: SM556, MAR 89

CLqRK GROUP
34
UPRIGHT REMOVAL
Typical TM TSU upright assembly weight, USE APPROVED HOOKS, CHAINS AND
l;;; r;oks, is approximately [680 kg] CONNECTING LINKS WHEN REMOVING
. THE UPRIGHT. BE SURE THE HOIST
AND CHAIN HAVE CORRECT CAPACITY
TO SAFELY HANDLE THE LOAD.
1 Attach lifting chains and hoist to upright.
Be sure to secure and support the upright

from falling before removing the tilt
cylinders.
ATTACH. A CHAIN OR SLING-OF CORRECT

CAPACITY TO THE UPRIGHT AND A HOIST
AS SHOWN BEFORE REMOVING ANY TILT
CYLINDER ATTACHMENT PARTS.
85M893
,,’ _
.
._
‘. ;:
‘.., ’
2 Disconnect tilt cylinders:
1) Loosen and remove each tilt cylinder rod

end to upright retainer fastener bolt
and retainer washer.
85M624
Bolt tightening torque:

[ZO-25 N.m] 177-221 lbf.in.
26573
Code: OH-540, MAR 86 Do not sell or distribute GROUP 34, Section 9R, Page 3
GROUP CMRU
34
2) Remove each tilt cylinder rod end by pull-

ing it off the upright attachment pin.
17066
3 Disconnect the hydraulic lift line.
26574
4 Reraove upright mounting (pivot) pins: ’
1) Loosen and remove each mounting pin .

lock fastener bolt and washer.
Bolt tightening torque:

[ZO-25 N.m] 177-221 lbf.in.
2) Remove each upright mounting pin.
5 Remove upright from truck.
Move upright carefully away from truck

and to a safe storage position.
GROUP 34, Section 9R, Page 4 Code: SM556, MAR 89

GROUP 38 SECTION 01
Park truck on a solid, level surface.
COUNTERWElGHT Lower forks to floor.
1. Remove the battery.
2. Put chocks at the drive wheels.

CONTENTS NO.
3. Remove the overhead guard assembly. Refer
COUNTERWEIGHT MAINTENANCE 38-01-01 to overhead guard group for details.
COUNTERWElGHT REMOVAL 38-01-02
COUNTERWEIGHT INSTALLATION 38-01-03
A
! WARNING
All tools and lifting components
used In these procedures must be
38-01-01 COUNTERWEIGHT In good condition, meet the lifting
MAINTENANCE requirements, and have OSHA
approval labels when required.
The counterweights must be maintained in good
condition and securely attached to the lift truck.
Because of their heavy weight and bulky mass, the
counterweights must be carefully supported and
handled. Store at floor level in a stable position so
that they will not fall or tip and cause damage or
injury.
/\ ! WARNING
REMOVING COUNTERWEIGHTSCAN
CAUSE LIFT TRUCK TO BE IMPORTANT
UNSTABLE. Use lifting hooks with safety latches to
Do not operate a lift truck or prevent hook from slipping from the lifting
handle loads with any eye
counterweights removed. Failure
to follow this warning can result In
severe injury or death. MAIN COUNTERWEIGHT
REMOVAL
38-01-02 COUNTERWEIGHT 4. Install eyebolt in cored hole in top surface of

main counterweight (item 38.869).
REMOVAL
5. Attach hook of chain hoist to the eye of the
bolt.
/\ ! WARNING
6. Use an overhead chain hoist of correct capacity
IMPROPERLY SECURED to lift the counterweight out of the truck.
COUNTERWEIGHTSCAN MOVE OR
7. Lower the counterweight to floor level. Move
Before removing mounting bolts, secure counterweight carefully and store in a safe
counterweights for removal. Fallure to location.
follow the Instructions in this manual can
result In severe Injury or death.
/\ ! CAUTION
SM556 38 - 01 - 1
COUNTERWEIGHT
35.559 COUNTERWEIGHT, MAIN

55.975 FASTENER, COUNTERWEIGHT
95.551 COLJNTERWEIGHT, AUXILIARY
59.552 FASTENER. AUXtLlARY COUNTERWEIGHT
55.555 COUNTERWEIGHT, OPER. CWPT. R.H.
95.557 -. COUNlERWEIGHl, OPER. COMPT. L.H.
55.995 RETAINER. COUNTERWEIGHT
91.202 WASHER, COUNTERWEIGHT FASTENER
95.999 NUT. COUNTERWEIGHT RETAINER FASTENER
95.901 FASTENER, COUNTERWEIGHT RETAINER
SM556 38 - 01 - 2
AUXILIARY COUNTERWEIGHT 5. Attach hook of chain hoist to the eye of the
REMOVAL bolt.
Note: Main counterweight and steer axle housing 6. Raise the hoist to take all slack out of the chain.
must be removed before auxiliary counterweight
can be removed. Refer to steering axle group to 7. Remove counterweight fasteners (items
remove steer axle housing. 38.875 & 91.202).
1. install lifting straps through core holes of 8. Use an overhead chain hoist of correct capacity
auxiliary counterweight. to lift the counterweight out of the truck.
2. Attach hook of chain hoist to tiiing straps. 9. Lower the counterweight to floor level. Move
counterweight carefully and store in a safe
3. Raise the hoist to take all slack out of the chain. location.
4. Remove auxiliary counterweight fasteners and

retainer (items 95.901, 38.905, 95.900, & 38-01-03 COUNTERWEIGHT
38.882). INSTALLATION
to lift the counterweight out of the truck.
A
! WARNING
All tools and lifting components
7. Lower the counterweight to floor level. Move
used In these procedures must be
counterweight carefully and store in a safe
In good condition, meet the lifting
location.
requlrements, and have OSHA
approval labels when required.
REAR OPERATOR COMPARTMENT
COUNTERWEIGHT REMOVAL
1. Install eyebolt in cored hole in top surface of n! WARNING

FASTENERS WHICH ARE NOT CLARK
rear operator counterweight (item 38.887).
OEM PARTS MAY NOT HOLD
COUNTERWEIGHT SECURELY.
2. Attach hook of chain hoist to the eye of the Use only o;rl;;l equipment
bolt. fasteners installing
counterweights. Torque to
3. Raise the hoist to take all slack out of the chain. specifications shown in this
manual. Failure to follow these
4. Remove counterweight fasteners (items instructions may result In severe
38.875 & 91.202). Injury or death.
5. Use an overhead chain hoist of correct capacity IMPORTANT - Do not use
to lift the counterweight out of the truck. substitute, defective, or Incorrect
I-mcuntks.g.xbolts..a,”Be sure. that the
7. Lower the counteweight to floor level. Move mounting bolts are undamaged
counteweight carefully and store in a safe and have the correct material
location. hardness)
(strength and
specification. Replace worn or
defective bolts with genuine
FRONT OPERATOR COMPARTMENT CLARK parts.
COUNTERWEIGHT REMOVAL
1. Install eyebolt in cored hole in top surface of

front operator compartment counterweight (item
38.886).
SM556 38 - 01 - 3
to lift the counterweight and lower into the truck.
Do not remove chain hoist hook yet.
AUXILIARY COUNTERWEIGHT
INSTALLATION 4. Install counterweight fasteners (items 38.875 &
91.202). Torque nuts to [19 - 21,5 N*m] 170 - 191
1. Install lifting straps through core holes of Ibf*in.
auxiliary counterweight.
51 Remove chain hoist hook.
2. Attach hook of chain hoist to lifting straps.
6. Remove eyebolt.
to lift the countennreight and lower into the truck.
Do not remove chain hoist hook yet. FRONT OPERATOR COMPARTMENT
COUNTERWEIGHT INSTALLATION
4. Install auxiliary countenveight fasteners and
retainer (items 95.901, 38.905, 95.900, &
38.882). Torque bolts to [70 - 80 Nom] 52 - 59 1. 1. Install eyebott in cored hole in top surface of
Ibf+t. Torque nut to [40 - 45 Nom} 30 - 33 Ibfeft. countenveight (item 38.886).
7. Remove chain hoist hook from lifting straps. 2. Attach hook of chain hoist to the eye of the
“j ,., .,.
bolt.
8. Remove lifting straps.
all steer axle housing. Refer to steer axle group for to lift the counterweight and lower into the truck.
Do not remove chain hoist hook yet.
4. Install counterweight fasteners (items 38.875 &

MAIN COUNTERWEIGHT 91.202). Torque nuts to [19 - 215 N-m] 170 - 191
INSTALLATION Ibfmin.
Note: Auxiliary countemeight (item 38.881) and 5. Remove chain hoist hook.
steer fork must be installed first in truck.
6. Remove eyebolt.
main counterweight (item 38.869). 7. Install overhead guard assembly. Refer to
overhead guard group for details.
bolt. 8. Remove drive wheel chocks.
3. Use an overhead chain hoist of correct capacity 9. Install and connect battery.
to lift the counterweight and lower into the truck.
4. Remove chain hoist hook.
5. Remove eyebolt.
REAR OPERATOR COMPARTMENT

COUNTERWEIGHT INSTALLATION

counterweight (item 38.887).

bolt.
SM556 38 - 01 - 4
GROUP 38 SECTION 02
MACHINE JACKING AND
BLOCKING
CONTENTS NO.
RAISING DRIVE WHEELS 38-02-01

BLOCKING THE UPRIGHT 38-02-02
RAISING REAR OF TRUCK 38-02-03
RAISING ENTlRE TRUCK 38-02-04
RAISING TRUCK WITH A HOIST 38-02-05
CAUTION 3. Put a solid 4x4 inch [100x100 mm] hardwood

To perform these service procedures, it is block under the front section of each upright rail.
recommended that you first: Put a 0.125 - 0.250 inch [3.1 - 6.2 mm] thickness
steel plate on top of each block.
Park truck on a hard, level, and solid surface,
such as a concrete floor with no gaps or breaks. 4. Tilt the upright fully forward. This action
should raise the drive wheels off the floor.
Put upright in vertical position and fully lower Release the tilt control pushbutton.
the forks or attachment.
6. Check for safe clearance between drive wheels
and floor.
WARNING
DEFECTIVE EQUIPMENT CAN 7. Check the stability of the truck. Be sure that the
CAUSE ACCIDENTS blocks are located securely under the upright rails
All tools and lifting equipment must be in before operating the drive motor or working on
good condition, meet the load capacity truck.
requirements and have OSHA labels when
required. Tools with defects can have
failures causing severe injury or death. 8. Lower the drive wheels to the floor by reversing
the above procedure.
38-02-01 RAISING DRIVE _Tum.key switch CN.

WHEELS
Tilt upright fully back.
This procedure uses the upright as a lever to lift
the drive wheels off the floor and prevent Turn key switch OFF.
accidents due to inadvertent powering of the drive
wheels. 9. Remove the blocks and steel plates from under
the upright rails.
1. Park the truck safely.
2. Turn key switch ON. Tilt the upright fully

back.
SM556 38-02-l
38-02-02 BLOCKING THE 38-02-03 RAISING REAR OF
UPRIGHT IN RAISED POSITION TRUCK WITH A JACK
This procedure is used to safely provide clearance Refer to Specifications Group for truck weights.
for access from the front of truck to components
on or near the drive axle. The truck may be raised by jacking at the rear and
blocking under the sides near the rear section of
WARNING the frame.
DO NOT STAND UNDER THE FORKS
WHEN BLOCKS ARE PUT UNDER THE 1. Park the truck safely. Put chocks at front and
CARRIAGE AND RAILS. THE FORKS rear of drive wheels.
CAN FALL AND CAUSE INJURY OR
DEATH TO PERSONNEL. NOTE - When convenient, it is
recommended to remove the battery from
truck, to reduce weight for both safer and
1. Park the truck safely. easier jacking.
::
2 . Put chocks in front of and behind drive wheels.
3. Put wooden support blocks conveniently near

upright’ rails before raising the’opright: Use two
4x4 inch flOOx100 mm1 hardwood blocks of
approximate lengths. _
4. Turn key switch ON and raise the upright

c
carriage. ,
/’
.* A*
II I I I II I
2. Position a floor jack under the rear of truck frame

as shown.
NOTE - If there is insufficient clearance

under frame for your jack, the truck may
first be driven onto thin platforms, such as
l”x6”x12” pieces of board (shims), to
increase the truck frame underclearance.
3. Raise the truck only as high as necessary to

5. Hold the taller block against inner rail and lower perform the maintenance work.
the uptight until carriage rests on block.
4; Put b!ocks at both sides of the truck, fully under
6. Hold the shorter block against the outer rail and the frame main side structure. Put an equal amount
lower the upright until inner rail rests on the block. of blocks under each side of the truck to provide a
level working position. Individual pieces of
NOTE - For STANDARD UPRIGHT, block blocking with minimum length equal to the width of
may be needed to be cut to suit. the truck are recommended.
SM556 38 - 02 - 2
5. Lower the truck onto the blocks and remove the
jack. Check truck stability before performing any
. maintenance work.
6. When maintenance work is completed, lower

the rear of truck to the floor by reversing the above
procedure:
Put jack under frame and raise truck
Carefully remove blocks and lower truck
Remove jack
Remove chocks from drive wheels
3. Raise front of truck using two chains hooked

38-02-05 RAISING TRUCK WITH into the upright tie bar. Lift truck up and place
A HOIST wheel caradles under the drive wheels. Lower
drive wheels o’nto the cradles.
When suitable equipment is available, the truck
may be raised by means of a hoist and wheel LlFTlNG REAR OF TRUCK -
cradles placed under the wheels.
1. Remove battery.
IMPORTANT - Lift only the front or the
rear of the truck at one time. Watch truck 2. Put chock at drive wheels.’
for signs of lateral instability. It may tip
sideways. You may have to support or 3. Remove forks.
guide the side of the truck or overhead
guard to prevent tipping.
Refer to Specifications Group for truck weights.
LlmNG FRONT OF TRUCK -
1. Remove battery.
2. Chock steer wheels.

._....-..._._,__
4. Raise rear of truck using hoist and chain hooked

at the location shown above.
SM556 36-02-3
GROUP 39 SECTION 01 Park truck on a solid, level surface in
correct position to use an overhead hoist.
OVERHEAD GUARD
Lower forks to floor.
CONTENTS NO. Block the wheels.
OVERHEAD GUARD MAINTENANCE 39-01-01 1. Remove the battery.

OVERHEAD GUARD REMOVAL 39-01-02
OVERHEAD GUARD INSTALLATION 39-01-03 2. Use an approved sling of correct capacity to
attach an overhead hoist to the overhead guard.
Raise hoist to take slack out of sling.
39-01-01 OVERHEAD GUARD 3. Remove front mounting fasteners (items,

MAINTENANCE 39.933, 92.409 & 90.967).
4. Remove rear mounting fasteners (item 39.934

The overhead guard must be maintained in
LH,39.936, RH, 91.633, 90.129, LH & 91.632,
good condition and securely attached to the
RH).
lift truck.
5. Raise hoist and sling to lift overhead guard up
and away from truck.
6. Lower the overhead guard to floor and store in

a safe position until required for reassembly.
39-01-03 OVERHEAD GUARD

INSTALLATION
1. Install overhead guard in reverse order of

removal. Torque rear fastener nuts (item 91.632)
to [117 - 131 Nom] 86 - 97 Ibf*ft. Torque front
fastener nuts (item 90.967) to [40 - 45 Nom] 30 - 33
Ibf*ft.
39-01-02 OVERHEAD GUARD

REMOVAL
n ! CAUTION
SM556 39 - 01 - 1
95.899
Spray all fastener threads with PrimerFc 5

minutes before assembly; then apply
Locktltem242 to all threads and assemble.
OVERHEAD GUARD
39.933 FASTEN’& 0VEREiEA.D GUARD @Mxn L&IX)
39.934 FASPENER, OveruIuD GUti (REAR LEGS)
39.936 FAS’PENER, OVERHEAD GUARD REAR
SUPPORT
39.948 LRG.OYERHEADGUUZDFRONT
39.953 Fh=EN=.owcBEM GUARD TOP SECTION
39.956 LRG;OVRRUWGUllRDREARRII
39.957 LEG,OW%lluDGUARDREARLR
39.962 TOP SRGTION,OVERBEADGUARD
90.129 NvT,-GUARDRRARLEG FASTENER
90.963 NVT. OVRRElW CllARD TOP SEcnON FASTENRR
90.967 NUT, OveRBRAD GUARD FROM LRG FASTDRR

91.632 NUT, OvEBBEM GUARD RI&R SUPPOBf FASTRNRR
91.633 USlfRR, OtQRHRAD GUARD FASTRNER
92.609 LOCICUMER, OVEIUI~ GUARD FRONTLEG FASTFiNER
95.899 SPACRR, TOP ROOD MOUNTINGBRAGKRT
SM556 39 - 01 - 2
GROUP 39 SECTION 02
SHEET METAL AND TRIM
/- 39.532
-39.501 -93.671
SHEET METAL AND TRIM

12.075 RETAINER, BATTERY 39.594 HOOD, TOP
37.200 COVER, FRONT 39.595 FASTENER, TOP HOOD
37.268 NUT,TOP HOOD FASTENER 90.017 NUT, INSTRUMENT PANEL FASTENER
37.309 COVER, FRONT (UPPER) 90.653 FASTENER, DRIVERS COMPARTMENT PAD
37.374 COVER. HYDRAULIC VALVE 90.852 NUT, INSTRUMENT PANEL FASTENER
39.106 FASTENER, FRONT COVER 90.865 FASTENER, SIDE PAD

39.417 STRAP, GROUND (URE. 6 NON MARE TIRES) 91.269 NUT, TOP HOOD FASTENER
39.463 PAD, SIDE 92.410 NUT, FRONT COVER FASTENER
39.474 PAD. FLOOR PLATE 93.671 FASTENER, HYDRAULIC VALVE COVER
39.478 PLATE. FLOOR 93.672 NUT, HYDRAULIC VALVE COVER FASTENER
39.500 PANEL, INSTRUMENT 95.808 RETAINER, FRONT COVER FASTENER

39.501 FASTENER, INSTRUMENT PANEL 95.809 RETAINER, TOP HOOD FASTENER
39.502 PAD,DRIVERS COMPARTMENT 95.810 RETAINER, HYDRAULIC VALVE COVER FASTENER
39.532 GROMMET, STEERING COLUHN
39.535 BRACEET. TOP HOOD MOUNTING
SM556 39 - 02 - 1
GROUP 40 SECTION 01
TRUCK DATA PLATE AND DECALS
R
r 4o.m
1- 40.001
r
40.089
40.121
r!5
40.108
7
. 40.162 t
81
0
i
L 93.575
DATA PLATES AND DECALS
37.205 TRAY, LITERATURE 40.054 DECAL. CONTROLS INSTRUCTION
40.000 PLATE, CAPACITY 6 SERIAL NUMBER 40.089 DECAL, WARNING
40.001 FASTENER, CAPACITY h SER. NUMBER PLATE 40.108 DECAL, ELEC. CLEAN INSTR.
40.006 DECAL, UNIVERSAL PATENTS 40.121 DECAL, BATTERY SPEC d RESTRAINT
40.010 DECAL, CLARK LOGO - 1.5" WHITE 40.130 DECAL, FORK SAFEn
40.011 DECAL, CLARK LOGO - WHITE 40.131 DECAL, RANDSAFETY

40.012 DECAL, CURK LOGO - BLACK 40.139 DECAL, TRUCK MODEL SPEC.
40.014 DECAL, MODEL NAME 40.162 DECAL, BATTERY DISCONNECT
40.024 PLATE, UNDERWRITERS LABEL 93.575 FASTENER, LITERATURE TRAY
40.025 FASTENER. UNDERWRITERS LABEL PLATE
SM556 40 - Ol- 1
GROUP 40 SECTION 02
TRUCK DATA AND SPECIFICATIONS
Group
12 POWER SUPPLY - BATTERY Maximum Size and Rating
ESM12f15S 36V, 18 cell, 11 plate, 27.0 kWh, 775 amp-hr @ 6 Hour rating
ESM 15 36V, 18 ceil, 13 plate, 32.2 kWh, 930 amp-hr @ 6 Hour rating
ESM 17 36V, 18 cell, 15 plate, 37.6 kWh, 1085 amp-hr @ 6 Hour rating
ESM 20,22,25 36V, 18 cell, 17 plate, 43.0 kWh, 1240 amp-hr @ 6 Hour rating
Fully Charged: 1.275 specific gravity (1.3010 Exide Load Hog )

Discharged: 1 .120 specific gravity
Recommended Battery Fluid: Distilled water only
16 MOTORS
DRIVE i 36V, ‘6.64 in‘diameter, Series Wound.
Weight: 54 lb (24.5 kg)

Open Rating (60 Min.): 34.8V, 1600 rpm, 4.0 hp, 117 amps
Brushes: : 1.38 in. (35 mm), W 1.26 in (32 mm), T 0.498 in (12.65 mm)
No. per holder:
No. per motor: 4
Brush Grade: Morganite H803
Worn Length: 0.57 in (14.5 mm) on longest side.
Brush Spring Tension (force per brush) NEW: 33-38 oz (935-l 077 g)
WORN: 16 oz (453 g)
LIFT - 36V, 7.15 in. diameter, Series Wound.

Open Rating (15% Time): 33.18V, 1170 rpm, 11.8 hp, 360 amps
Brushes: L 1.38 in. (35 mm), W 0.997 in (25.3 mm), T 0.548 in (13.9 mm)
No. per holder: 2
No. per motor: 8
Brush Grade: Morganite Hl 00
Brush Spring Tension (force per brush) NEW: 33-38 oz (935-1077 g)
WORN: 16 oz (453 g)
STEER - 36V 6.5 in. diameter , Permanent Magnet.

Enclosed Rating (Continuous): 36.OV, 1220 rpm, 0.9 hp, 27 amps
Brushes: L 1.13 in. (28.7 mm), W 0.812 in (20.6 mm), T 0.368 in (9.35 mm)
No. per holder: 1
No. per motor: 4
Brush Grade: Stackpole 2192
Brush Spring Tension (force per brush) NEW: 27.6-30.7 oz (782-870 g)
WORN: 11.5-l 2.6 oz (326-357 g)
SM556 40-02-l
19 ELECTRICAL COMPONENT/ TEST SPECIFICATIONS
GROUND TEST: (Minimum Resistance)
Resistance values may range from 20,000 to 30,000 ohms, without problems.
When below 20,000 ohms, further testing must be conducted to repair problem.
CURRENT DRAW VALUES: (Warm Truck, 36 volt fully charged battery)
Drive Motor - 1A Freewheeling (less power steering motor idle current)

@ Battery: 26 amps each motor
Power Steer Motor - Idle current @ Battery: 5-8 amps
SCR CURRENT LIMIT: ( Cold Truck )
Drive Motor - 525-575 amps Motor Current (Both Motors)

(250-350 amps Battery Current)
CREEP SPEED: 1.6 volts to 3.6 volts @ motor
1A PICKUP TIME DELAY: 1.5 seconds
POWER STEERING TIME DELAY: 24 seconds
FUSES:
FUSE BAIIlcG FUNCJ-W

1FU 500 amp Drive, Pump
2FU 15 amp Control
3FU 15 amp Hydraulic Control
CONTACTORS:
FUNCTION RATING COIL RFSISTANE

1A 150 amps 19.55 ohms
Forward/Reverse 150 amps 19.55 ohms
Fewer Steering 100 amps 49

29 ohms
Pump 150 amps 20 ohms
20 DRIVE UNITS (TWO)
Recommended Oil Specifications: DEXTRON II ATF Automatic Transmission Fluid

Drive Unit Oil Capacity, Each: 6.6 qts. (6.5 L)
Overall Ratio: 22.85:1 Reduction
SM556 40-02-2
23 WHEELS AND TIRES
Drive Tire Size: Cushion - 18x7x12.12 (ESM 12,158,15)

18x8x12.12 (ESM 17,20)
18x9x12.12 (ESM 22,25)
Pneumatic - 18x7~8 18 ply (ESM 12,15S,15)
18x9x8 18 ply (ESM 17,20)
Tire Pressure: 140 psi (970 kPa)
Steer Tire Size: 9x5 Dual Poly
23 BRAKES
Brake System: Spring Applied, Hydraulic Released
Recommended Brake Fluid: Heavy-duty hydraulic brake fluid, SAE J1703b

specification, or Type DOT, Grade DOT3.
Master Cylinder: 0.75 in diameter
26 STEERING SYSTEM:
Power Steering System Relief Pressure Setting: 1000 psi (6894.8 kPa)
Recommended Power Steering Fluid: Uses main hydraulic sump oil supply
Steer Handwheel Turns, Lock to Lock: 4.75 turns
29130 HYDRAULIC SYSTEM
Recommended Hydraulic Ffuid:

Normal Temperature- Clark Specification MS-68 Hydra& Oil with anti-wear additives
Cold Storage- Clark Specification MS-228 Hydraulic Oil with anti-wear
additives
Sump Tank Capacity: 3.35 gal (12.68 L)
Lift Relief Pressure settings:

ESM12,15S,15,17: 2950-3050 psi (20340 kPa)
ESM 20,22,25: 3150-3250 psi (21719 - 22408 kPa)
Tift and Aux Relief Pressure settings:

ESM 12,158,15,17: 2000 psi (13790 kPa)
ESM 20,22,25: 2300 psi (15858 kPa)
SM556 40-02-3
32 TILT CYLINDERS
Tift Cylinder Diameter: 3.0 in (76.2 mm)
Tilt Speed, Nominal: Thru 151 in MFH - 3.2 to 3.9 degrees / second
Above 151 in MFH - 2.4 to 2.8 degrees / second
Standard Tilt Angle: HV Standard - 8 degrees back / 5 degrees forward

HV Tn’ple - 5 degrees back / 3 degrees forward
Tilt Drift (in 5 minutes, with rated load, new truck):

J&i&
80F (26.7C) 0.256 in (6.5 mm)
1OOF(37.8C) 0.433 in (11 mm)
120F (48.9C) 0.650 in (16.5 mm)
34 UPRIGHTS
Upright Speeds: Nominal performance for Uptight at cut-off MFH
HI-VIS STD ft/min HI-VIS TSU ft/min

‘FlB$Wl!J
ESM 12,158,15 Loaded: ???
Empty: 101 80 93 85
ESM 17 Loaded: 59 95 56 65
Empty: 101 80 93 85
ESM 20 Loaded: 55 95 52 65
Empty: 101 80 93 85
ESM 22 Loaded: N/A NJA 44 60

Empty: N/A N/A 70 65
ESM 25 Loaded: N/A NIA 42 63

Empty: N/A N/A 70 65
40 RATED LOAD CAPACITY - @ Load Center:
ESM 12 2500 Ibs @ 24 in (1134 kg @ 600mm)
ESM 15s 3000 Ibs @ 24 in (1360 kg @ 600 mm)
ESM 15 3000 Ibs @ 24 in (1360 kg @ 600 mm)
ESM 17 3500 Ibs @ 24 in (1590 kg @ 600 mm)
ESM 20 4000 Ibs @ 24 in (1815 kg @ 600 mm)
ESM 22 4500 Ibs @ 24 in (2041 kg @ 600mm)
ESM 25 5000 Ibs @ 24 in (2266 kg @ 600mm)
NOTE: Rated capacity applies when using uprights with maximum MFH up to
and including: HV STD 151 in (3835 mm) / HV TSU 152 in (3875 mm).
SM556 40-02-4
40 TRUCK WEIGHTS - Approximate, with typical upright:
ESM 12 15s 15 17 20 22 25
Service Weight
w/o load. Ibs 8425 8735 9055 9417 9752 10071 10686
Axle Loading:
w/o load, front, Ibs 4266 4404 4527 4659 4779 4814 5106
w/load, front, Ibs 4159 4331 4528 4758 4973 5257 5580
w/o bad, rear, Ibs 8911 9975 9987 10878 11731 12507 13673
w/ toad, rear, Ibs 2014 1757 2068 2040 2021 2064 2013
40 BATTERY COMPARTMENT SIZE
ESM 12115s 15 17 20. 22. 25

Length 13.88 in 15.88 in 18.38 in 20.75 in
Width 38.80 in 38.80 in 38.80 in 38.80 in
Height 31.50 in 31.50 in 31.50 in 31.50 in
40 WIRE COpES
Color Code
Black 0 Example:
Brown 1 wire no. 13 is a brown
Red 2 stripe on an orange wire.
Orange 3
Yellow 4 Wire no. 33 is a solid
Green 5 orange wire.
Blue
Violet ;
White
Gray :
SM556 40-02-S RevJan
40 TORQUE CHART
Critical Fastener Torque Specifications: Tightening Torque, Dry
W-inI lbf-ft
16 Steer Motor Mounting Nuts 71 - 88 Ibfein. (8 - 10)
19 Motor Cable Connections 90 - 100 Ibfain. (10 - 12)

Control Panel Cable Connections 100 - 120 Ibfein (11 - 14)
20 Drive Axle to Frame Mounting Bolts 301 - 339 Ibf*ft

Drive Motor Mounting Bolts 52 - 59 Ibf*ft
23 Drive Wheel Mounting Bolts 188 - 203 Ibf*ft
26 Steer Wheel Axle Shaft Bolt 30 - 33 Ibf*ft

Steering Tiller Arm Retaining Nut 35 - 40 Ibfeft
29 Main Hydraulic Valve Mounting Bolts 177 - 221 Ibf*in. (20 - 25)
32 Tilt Cylinder Yoke Clamp Bolts 125 - 140 Ibfaft. (170 - 190)
Tilt Cylinder Pin Retainer Bolts 177 - 221 Ibfmin. (20 - 25)
34 Upright Mounting Pivot Pin Bolts 177 - 221 Ibf=in. (20 - 25)
Upright Cylinder Retaining Bolts 50 - 55 Ibf*ft (68 - 75)
Load Backrest Extension Mounting Bolts 177 - 199 Ibfaft (240 - 270)
38 Counterweight Mounting Nut (left hand) 30 - 33 Ibfaft (40 - 45)

Counterweight Mounting Nuts (right hand) 170 - 191 Ibf*in. (19 - 21.5)
Counterweight Mounting Bolt 52 - 59 Ibfmft (70 - 80)
39 Overhead Guard Mounting Nut - Rear 86 - 97 Ibf*ft (117 - 131)

(0.5 inch diameter bolt)
Overhead Guard Mounting Nut - Front 30 - 33 Ibf=ft (40 - 45)
(10 mm diameter bolt)
NOTE: When checking tightness of major fasteners on new trucks, the values may be less
than the recommended specification due to metal deformation and fastener stretch.
This is a normal occurrence and does not indicate that the fasteners were not correctly
tightened during assembly. Tighten to recommended specifications.
SM 556 40 - 02 - 6 Rev Jan 90
40 LUBRICATION SPECIFICATIONS
Engine Crankcase Oil

Control rods, miscellaneous linkage API “CC”, MIL-L-2104B, MIL-L-46152
Transmission Fluid
Drive Axle DEXTRON II ATF
Automatic Transmission Fluid
Hydraulic Fluid
Hydraulic Sump -
Normal Temp. Application Clark Specification
MS-68 Hydraulic Oil
Cold Storage Application Clark Specification

MS-226 Hydraulic Oil
Multi-purpose Grease
Wheel Bearings NLGI Grade No. 1
Steer Axle Fork Bearing Lithium soap base grease,
Clark Spec MS-9B and
_ .. .
MS-1 078, or equivalent
Upright & Carriage Rollers, NLGI Grade No. 2

Upright Mounting Pins, Tilt Lithium soap base grease,
Cylinder Rod Ends Clark Spec MSSB and
MS-l 078, or equivalent
Chain Lube
Upright Lift Chains Clark #886399 Chain and
Cable Lube or equivalent
Dry-film Lubricant
Side Shifter, Attachments, Dow Coming Molykote 321 Bonded
Clamp Slides Lubricant, Graph-0-Kote ##220,
Molub-Alloy ##369Dry Lube,
or equivalent
Low Temperature Grease

Cold Storage General Low Temperature Grease,
Purpose Grease MIL-G-23827A, or equivalent
Protective Spray Coating

Wiring, Terminals, Switches .<Clark ##886784,Spray Coating
after assembly
Moisture-proofing Spray Coating

Contactor Panels, SCR Cards Clark #1801145 Spray Coating
Battery Distilled Water
SM556 40-02-7 RevJan
GROUP 40 SECTION 03
HYDRAULIC AND
ELECTRICAL DIAGRAMS
CONTENTS
HYDRAULIC DIAGRAM
ELECTRICAL SCHEMATIC
ELECTRICAL DIAGRAM
SM556 40 - 03 - 1
SEE NOTE I g
EE/ES--ESM 12/158/15
TRUCKS ONLY.
A
8FZAKE
Sk(ITCH
32 IO
1
27 *PEA
m “-I
IO I3 l3-
“;~W&UITCH
IFIL
32
0
-322.5
2FIL
1
32 85
3FIL
-32~45-++82 82-LE3l -m!@ l3-
AFIL
‘;A5-&92 92’&AI ,-mL 13-
I i
I I
: R5A
i
I’
32 45 f 06
95
I
I l
+ 07 SFI_L
I I 5RES ;-c-1 -;
I I !?5
~-.A5._~~;;i2__.42___*____42--_~______A2_-_--~~~~ r-.b, _.._+__.--- ____. ,3_------
bFIL
1 -32J A l3-
R3C’-T A
“LA--&IA A l3-
7FIL
l3-
8FIL
9FIL
iR5c
kc bA 13-
“HS-3A
I
I
I
I
I A W-36
l3-
iA
I IOFIL
I
I
I IFIL
I
;-m4-;
!.-________ ____ __84_-- ______ __-._4,~~~3i---- ___I 3___----
D8
- IOD IO0 IOD
r---2c 2A 11 11 11 -. ^^
B- a+
BATTERY
P
RECEPTACLE
,5 AMP
so-7:. -4 .I OPTIONS
I CONTROL
L. .^L
--I ---
__
500
3 r
ps__
---
IA g-
--J
I
r
71
I
Ir92 TrlT
45 25
- IOB-
552832458: 42
KEY
SWITCH
13c-4 3 -13
72-&d&-72
138 71
_ - -. ._
_ _ _ _
--_
---
w ,3E-,3A I? ::A ‘? 7’ 13A ______
SIN-221
L_____
E LEFT
%;%’
‘1 so-5
I234567
PD IN-22170.02
OP IN-22170.02A
I. WIRE X54A IS PLUGGED TO WIRE IIdA FOR
STANDARD TRUCK WITH NO AUX2 FUNCTION.
PL-4
SOLENOID BLOCKS
13E
HS IA
; -I-N<22Tfd
L________
1. DISCONNECT EXISTING HIRE #I3
SHOWN IN OOYYEO LINES At PUMP
CONtACtOA COIL NEGAtI"F
AND TAPE THE WIRE YERniNtJL
-
BATTERY
*I , I , -
----: I--- _-_
I-- I :
t 3; YOlYS
1
i____--,;,___2fi-- 9 __,-;
2
so-9 PL-8 SO-8

CURtIs OPTIONS ~l+~'~--~l~y-, i
LIFT
INTERRUPT
‘ -2 1
2
i
BRYYERY
--t 13
INOICRYOR
I
12
2
1 L_ 13
2
I CURTIS LIFT INTERRUPT
, .l
I I I I
I 8RttERt
KEY
SWITCH
I
:
8YRY l INOICRTOR I
?lEtER -
1 20 REYER
I l
13
I I LEO
LIFT +
LSFY -
8tRY -
I
I
I
20
,
13
1
1
,
LIFT I
SHITCH P 1
t -IO--- /T-~-28--_-.-~~-- __-13___~>_---____13_________!
--
AUXILIflRY FUNCTION ii/ RUXILIARY FUNCTION
HIvIS STF~N~~IR~ TILT CYLINDERS
LIFT CYLINDERS L-.8 ,477
I I
k
I
I
r-m-
l I:= j2
1
5--Y-
r-- I 1 NOTE:
1 ’
i--_-J
I
I
rt--J
I
I
I
,
;
PLUG PORTS C6 &
C7 FOR 2 HOSE &
CFIBLE FIDFIPTATION
FLOW CDNT'ROL II
II PLUG PORTS FI & B
LOAD LOWERING II
FOR 4 HOSE FIDFiP-
VALVE II
II TFITION
II
I I
I I PLUGS FlND 0 RINGS
OPTIONfiL INCLUDED WITH ALIX
Flux VFILVE C6 %7 VALVE PA(:KfIGE.
--I-l.
rA
r
1
--
I_ OUTLEt
6(N
Ir-
II
I -_-J
L
P
’
INLET
STEER
Y-l
I
PUMP
MFlNUFlLLY CONTROLLED;
, SPOOL VALVE ,
I
I
,
1B
LIFT
EC .91180
- HRNSELL 1 108FEB89
,w,
SUMP TRNK
I-
BATTERY
m
36 VOLTS
- 71
r
v
2 23 REC
T
ADD TWO 300 AMP FUSES

EE/ES--ESM 12/158/15
TRUCKS ONLY.
IO
EV- 100
I
,. osc CARD
IO
0%CAR0
cOhwc1oR
7
I
IO
7-/m
4 I5 702 I
I
BRAKE
SWIlCH ‘6
32 IS TSJ Kst*
Itlb
t- I _...._. _.I ACCELERATOR
IS m . 23 Pi31
t- -t
IS 2. --p2
LEFT CUl-
FF SWIWH
32 IO
I- PA60 -52-L 13-
lS~---f$-J-26 PBS
t- PAW -51 ---ii IJ-
-t
RIGHT CUT-
L- l.-pJ--27-+tl’ OFF SWITCH
lb
IO I 34 ---+PSS
32
-32--%----5
!-.45.-i--;___.42._
CFIL
13-
9FIL
IJ-
:I I IFIL
pn- *
.______________.S,.___________.__~,.~~~______. ,J_______.
08
35
09
71 u 72
6%:” FILIER
I2 I3
--.
_-.
v-v
_--
LEFT
CUT-OUT
SWITCH
. :so-5
. . .a
-12345678
PO IN-22268.02
OP IN-22248.02A

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SM-556

PM Planned Maintenance Program PM-1

SM556 i Rev Jan 90

0 Clark Equipment Company 1989

SAFETY AND OPERATIONAL CHECKS

Recommended Planned Maintenance Interval

Rev Jan ‘96 Copyrighted

15. The truck manufacturer’s capacity, operation

16. Batteries, motors, controllers. limit switches,

Visual Inspection .............................................................................. 2

SM 556, Jan ‘96

PM - PLANNED MAINTENANCE PROGRAM

The periodic maintenanceprocedures outlined in this manual are

IMPORTANT Inspect the truck for signs of external leakage of transmission

PM-2 Copyrighted Material SM 556, Jan’ 96

Check the amount of wear at the heel of the fork.

Copyrighted Material PM-3

them inspected by a trained maintenance person

PM-4 Copyrighted Material SM 556, Jan’ 96

Operate the control handle in the travel, lift, and lower

Check hourmeter operation. With key switch ON, rotate the

Return control handle to NEUTRAL.

Write the hourmeter reading on the PM report form.

SM 556, Jan ‘96 Copyrighted Material PM-5

If control handle movement is excessive before the pump

With the truck not moving, check the steering system by

Test function of mainpump motor switches on control handle

PM-6 Copyrighted Material SM 556, Jan’ 96

Test for correct function of the SCR control.

Check CREEP SPEED, 1A RANGE, and PLUGGING.

1. Check CREEP SPEED and 1A RANGE while driving

SM 556, Jan ‘96 Copyrighted Material PM-7

rails and rollers. Listen for abnormal noises. If there is

Check the upright for excessive downdrift. Stop the fork

Inspect condition of the battery and cables. Check the battery

Never wash the battery when it is in the truck.

Check battery post terminals for corrosion and damage.

Copyrighted Material PM-9

Motor SCR Controls Inspection IMPORTANT

Copyrighted Material SM 556, Jai’ 96

There is no drain plug in the hydraulic sump tank. The

SM 556, Jan ‘96 Copyrighted Material PM-1 1

Inspect the fill plug for damage. Replace as needed. Install

Drive Axle Fluid Change

Inspect and clean the drive axle breather (air vent).

Truck Chassis Inspection and Lubrication

Be sure to clean the grease fittings before lubricating and

PM-12 Copyrighted Material SM 666, Jan’ 96

Position the truck in the designated area, turn off key

Be sure this area has provisions, to flush

Before attempting to change or charge a battery, the

Be sure the area is equipped with material handling

When using an overhead hoist, be sure

When charging batteries, the vent caps must be kept

it with a non-conductive material such as plywood

When using a power hoist, be

Battery Maintenance, Records and Life

KEEPING BAT-l-TERY RECORDS:.

HOW TO GET MAXIMUM LIFE FROM THE

Control Description 13-01-01

13-01-01ACCELERATOR AND DIREC- 2. MASTER SWITCH OPERATES OFF CENTER

13-01-03 CONTROL HANDLE Master Switch Removal

NOTE l- REMOVE THE EXISTING SCREWS AND PLATE FROM