SM-555 - TM 12-25

Main Table of Contents
SM=555
TM 12/25 36Volt
EV-100 Supplement
SM555
CONTENTS
..
III INTRODUCTION
iv HOW TO USE THIS MANUAL
V SUBJECT / PICTORIAL INDEX
vi SAFETY INFORMATION
Driver’s Daily Checklist
PM Report Form
1.1 PM - PLANNED MAINTENANCE PROGRAM
1.2 1 Visual Inspection
2.1 2 Operational Checks / Test Drive
3.1 3 Air Cleaning
4.1 4 Critical Fastener Torque Checks
5.1 5 Chassis Components Maintenance / Inspection
6.1 6 Lubrication, Filters & Fluid Level Checks
7.1 7 Electrical Tests
GROUP Section PROCEDURE
01 1 PLANNED MAINTENANCE SCHEDULE

01 2 PLANNED MAINTENANCE AND LUBRICATION CHARTS
12 1 BATTERY REMOVAL
12 2 BATTERY MAINTENANCE
13 1 LIFT PUMP MOTOR MICROSWITCH ADJUSTMENT

13 2 SERVICE BRAKE MICROSWITCH ADJUSTMENT
13 3 PARKING BRAKE MICROSWITCH ADJUSTMENT
13 6 ACCELERATOR CONTROL
14 1 ELECTRICAL SYSTEM
16 1 ELECTRICAL MOTOR MAINTENANCE
16 2 DRIVE MOTOR BRUSH REPLACEMENT

16 4 STEER MOTOR BRUSH REPLACENT
16 22R/22 STEER PUMP MOTOR
16 23 R/23 DRIVE MOTOR
16 24RI24 LIFT PUMP MOTOR
16 27 GENERAL MOTOR MAINTENANCE
17 4 STEER AXLE TRUNNION MICROSWITCH ADJUSTMENT
19 1 SCR CONTROL PANEL
19 2 SCR CONTROL OPRERATION AND TROUBLESHOOTING
20 1 DRIVE AXLE MAINTENANCE

20 lOR/lO DRIVE AXLE
22 PNUEMATIC TIRE AND WHEEL MAINTENANCE
23 : BRAKE BLEEDING PROCEDURE
23 4 PARKING BRAKE ADJUSTMENT
23 17R/17 BRAKE CALIPER ASSEMBLY
23 18R/18 BRAKE MASTER CYLINDER
25 5 PYLON RELEASE ADJUSTMENT
SM555 i
25 1 OR/l 0 STEERING GEAR CONTROL

26 1 STEER AXLE TRUNNION BEARINGS ADJUSTMENT
26 2 STEER WHEEL BEARING MAINTENANCE
26 3 POWER STEERING RELIEF PRESSURE CHECK
26 STEER CYLINDER LINKAGE CHECK & ADJUSTMENT
26 ;: STEER AXLE, STEERING LINKAGE, STEERING TRUNNION
26 9R/9 STEERING CYLINDER
26 14w14 STEER PUMP
29 1 HYDRAULIC SUMP FLUID AND FILTER CHANGE
29 1 OR/l 0 LIFT PUMP
30 HYDRAULIC SYSTEM RELIEF PRESSURE CHECK AND ADJUSTMENT

30 lR19 HYDRAULIC VALVE (MAIN HYDRAULIC VALVE)
31 1 HYDRAULIC SYSTEM SCHEMATIC DIAGRAM
32 1 TILT CYLINDER ADJUSTMENT
32 11 TILT CYLINDER
32 2 TILT CYLINDER DRIFT TEST
34 1 LIFT CHAIN CHECK AND ADJUSTMENT
34 3 UPRIGHT DOWNDRIFT TEST
4 FORK MAINTENANCE
;:: 7 LIFT CHAIN MAINTENANCE
34 9R UPRIGHT REMOVAL
1 COUNTERWEIGHT REMOVAL
:: 2 FRONT BATTERY PLATE ADJUSTMENT
3 MACHINE JACKING AND BLOCKING
z: 1 OVERHEAD GUARD REMOVAL
39 2 HOOD REMOVAL
40 1 TRUCK DATA PLATES AND DECALS

40 SUGGESTED EQUIPMENT FOR ELECTRIC TRUCK PM
40 3” FIRE EXTINGUISHER RECOMMENDATIONS
40 4 LUBRICANT SPECIFICATIONS AND RECOMMENDATIONS
40 5 TRUCK SPECIFICATIONS
40 17 MEASURING VOLTAGES WITH THE V - 0 - M
40 18 MEASURING RESISTANCE WITH THE V - 0 - M
NOTE: “R” denotes Removal Procedure for components
SM555 ii
INTRODUCTION
Clark Equipment Company welcomes you to the growing group of professional

people who own, operate, and maintain Clark lift trucks. We take great pride in
the long tradition of quality products and superior value that the Clark name
represents. This manual has been written to help you maintain your Clark lift
truck in an efficient and safe operating condition.
Regular maintenance and care of your lift truck is not only important for
economy and utililization reasons, it is essential for your safety. A faulty lift
truck is a potential source of danger to the operator, and to other personnel
working near it. Approved methods of service and correct procedures of
repair are important for the safety of personnel and the safe operation of a
lift truck.
Genuine Clark parts should always be used when replacements are needed.
Substitute parts from other sources may not be designed like original parts and
may not meet OSHA or other safety requirements.
The mechanic is cautioned and expected to always work in a safe manner by

using the correct procedure. If a mechanic does not understand a safety
procedure when performing maintenance on a truck, the maintenance
supervisor should be consulted for assistance. Do not take chances which may
result in injuries.
Operator Inspection
Lift trucks should be inspected daily by the operator, or at the start of each
shift and the Operator’s Daily Checklist carefully completed. Be sure that all
safety items are checked and in good condition. Use the daily inspection sheet
as a check list and a record for your findings. This form is illustrated in this
manual. Also, please refer to the Operator’s Manual located on the truck.
Planned Maintenance Program
In addition to the daily operator inspection, Clark recommends that a planned

maintenance and safety inspection program be performed on a regular basis.
The program will provide an opportunity to make a thorough inspection of the
safety and operating condition of your lift truck. Necessary adjustments and
repairs can be done during the PM which will increase the life of components
and reduce unscheduled downtime. The PM can be scheduled to meet your
particular application and lift truck usage.
This manual includes repair procedures as well as instructions for a periodic

planned maintenance program which covers inspections, operational checks,
cleaning, lubrication and minor adjustments. A table of recommended planned
maintenance items and typical schedule is included. Also shown is the PM
report form which can be obtained from your local Clark dealer. He is
prepared to help you with a Planned Maintenance Program with trained
service personnel who know your lift truck and can keep it operating safely
and efficiently.
SM555 iii
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 components.
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 special instructions, before
doing any work.
Specifications 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 effect at the time of printing.
Clark Equipment Company reserves the right to make improvements and changes in specifications or design,
without notice and without incurring obligation. Please check with your authorized CLARK dealer for
information on possible updates or revisions.
0 Clark Equipment Company 1989
SM555 iv
OH
CLqRK
PICTORIAL INDEX TYPICAL FORK TRUCK

BASIC GROUP NUMBERS
L 26
23
12 BATTERY
13 ACCELERATOR CONTROL ASSEKBLY
14 WIRING
16 MOTORS
17 DRIVE MOTOR CUT-OUT, DIRECTIONALCOMROLS
19 CONTACTORS, CONTROLS
20 DRIVE AXLE
22 BRAKES
23 BRAKES, WHEELS/TIRES
25 STEERING COLUHN, LINKAGE
26 STEER AXLE, CYLINDER, PUMF, LINES
29 BYDRAULIC PUMP 6 FILTER
30 HYDRAULIC VALVE 6 LINKAGE
32 TILT CYLINDER
34 UPRIGHT 6 LIFT CYLINDER
38 FRAME 6 COUNTERWEIGHT
39 SHEET METAL, SEAT 6 OVERHEAD GUARD
SM555 v
SAFETY SIGNS AND SAFETY USER SAFE INSPECTION

MESSAGES PRACTICES
Improper or careless techniques cause accidents. The following instructions have been prepared
Don’t take chances with incorrect or damaged from current industry and government safety
equipment READ and UNDERSTAND the proce- standards applicable to industrial truck operations
dures for safe driving and maintenance outlined in and maintenance. They are listed here for the
this manual. reference and safety of all workers during
inspection / maintenance operations. When in
STAY ALERT ! Follow safety rules, regulations doubt of any inspection / maintenance procedures,
and procedures. Accidents can be avoided by please contact your local CLARK dealer.
recognizing dangerous procedures or situations
before they occur. 1 .Powered industrial trucks can become
hazardous if maintenance is neglected. Therefore,
DRIVE AND WORK SAFELY and follow the safety suitable maintenance facilities, trained personnel
signs and their messages displayed on the truck and procedures shall be provided.
and in this manual.
2. Maintenance and inspection of all powered
SAFETY SIGNS and MESSAGES are placed in industrial trucks shall be done in conformance with
this manual and also on the lift truck to provide in- the manufacturer’s recommendations.
structions and to identify specific areas where
potential hazards exist and special precautions 3. A scheduled planned maintenance, lubrication
should be taken. Be sure you know and under- and inspection system shall be followed.
stand the meaning of these instructions, signs and
messages. Damage to the truck or death or 4. Only trained and authorized personnel shall be
serious injury to you or other persons may result if permitted to maintain, repair, adjust and inspect
these messages not being followed. industrial trucks and in accordance with the
manufacturer’s specifications.
NOTICE
This message is used when special information is 5. Properly ventilate work area, vent exhaust
required to clarify procedures or identify compo- fumes, keep shop clean and floor dry.
nents pertaining to the truck.
6. Avoid fire hazards and have fire protection
equipment present in the work area. Do not use
IMPORTANT
an open flame to check electrolyte level. Do not
This message is used when additional attention is
use open pans of fuel or flammable cleaning fluids
required for proper operation or maintenance of
for cleaning parts.
the truck.
7.Before Starting To Work On Truck:
fi ! CAUTION a) Raise drive wheel free of floor or disconnect
This message is used as a reminder of safety power source and use blocks or other positive
practices which can result in personal injury if truck positioning devices.
proper precautions are not taken. b) Put blocks under the load-engaging means,
innermast( or chassis before working on them.
iz!! WARNING c) Disconnect battery before working on the
This message is used when a hazard exists which electrical system.
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
A DANGER area.
This message is used when an extreme hazard
exists which will result in death or serious injury if
proper precautions are not taken.
SM555 vi
9. Before Starting to Drive the Truck: 16. Batteries, motors, controllers. limit
a) Be in operating position. switches, protective device, electrical conductors
b) Turn on power. and connections must be inspected and
c) Check functioning of lift and tilt systems. maintained in conformance with good practices.
d) Check directional and speed controls. Special attention must be paid to the condition of
e) Check steering. electrical insulation.
f) Check brakes.
g) Check warning devices. 17. To avoid injury to personnel or damage to the
h) Check any load handling attachments. equipment, consult the manufacturer’s procedures
ii) Release parking brake. in replacing contacts on any battery.
10. Before Leaving the Truck: 18. Industrial trucks must be kept in a clean
a) Stop truck. condition to minimize fire hazards and help in the
b) Fully lower forks or attachment device. detection of loose or defective parts.
c) Put directional control in neutral.
d) Apply the parking brake. 19. Modifications and additions that affect capacity
e) Turn off the power switch. and safe truck operation must not be done without
ff) 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 manufacturer’s 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
fi ! 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.
SM555 vii
INDUSTRIAL TRUCK DMSION
DRIVER’S DAlFY CHECKLIST

CldRK Check Before Start Of Each Shift
CJATE
CHECK ONE: 0 GAS, LPG OR DIESEL TRUCK 0 ELECTRIC TRUCK
TRUCK NO. OPERATOR: S”PERYISOR’SOK
START OF DAY ENDOFDAY HRS. FOR DAY

HOUR METER READING:
J Boxes Accordingly
q OK
cl
Needs Attention or Repair
VISUAL CHECKS OPERATIONAL CHECKS
I, I OTHER GAUGES AND INSTRUMENTS II I I HYDRAULIC CONTROLS
1 1 OBVIOUSDAMAGEANDLEAKS SEAT BRAKE

I I I
ENGINE OIL LEVEL BA7TERY LOAD TEST
FORM NO. 597704937 HO” 80

See your Clark dealer
for copies of this form.
1321-z JUN 84
ELECTRIC TRUCK
PLANNED MAINTENANCE REPORT
e. Plugging & Directional Control i...

.,..,
....
f. Return to Neulral i...
.i...
....
g. Hydraulic System Operation ..::
....
.:.:,
h. Pedal Pads & Linkages
j. Seat Brake Operation I I 1&::::

...L b.
..““I Cu
1 c. Control Acceleralic
01 ClEANING & LUBRICAli~___ d. 1A Contactor Drop
d. Inspect Fan&Control ECAlEPA 1 f 1.x.:.:.:

:;:$$.
1 h. 1A Time Delay (SEC)
,
13 ~UGES.LlGHTS-INDICATDRS c. Security of Mounting
a. Hour Meter Oprahon ..:.:.
I I F:::::,
PM - PLANNED MAINTENANCE PROGRAM
As an aid in performing and documenting the PM inspections, Clark has prepared

an "ELECTRIC TRUCK PLANNED MAINTENANCE REPORT" form. See opposite paqe.
Copies of this form may be obtained from your authorized Clark dealer: We
recommend that you use this form as a checklist and to make a record of your
inspection and truck condition.
This manual is intended to be used in conjunction with the PM Report Form.

It is arranged by groupings of items of work that are done in a logical and
efficient sequence.
PM Report Form
A check mark or entry is made on the

PM Report Form when the PM is performed.
Please note the special coding system
for indicating the importance of needed
repairs and/or adjustments.
When you have finished the PM inspections,

be sure to give a copy of the report to
the designated authority or the person
responsible for lift truck maintenance.
Do not make repairs or adjustments

unless authorized to do so.
For safety, it is good practice to:

DISCONNECT THE BATTERY AND RE-
MOVE ALL JEWELRY BEFORE WORK-
Remove all jewelry (watch, rings,
ING ON ANY ELECTRICAL SYSTEM.
bracelets, etc.) before working
SEVERE BURNS CAN RESULT FROM
on the truck.
CONTACT WITH ELECTRICAL SYSTEMS
Disconnect battery from truck receptacle
before working on electrical components.
Always wear safety glasses. Wear a

safety (hard) hat in industrial plants
and in special work areas where protec-
tion is necessary or required.
K MAINTENANCE
DO NOT WORK ON THIS TRUCK

UNLESS YOU ARE TRAINED AND
AUTHORIZED AND KNOW THE
SHOES AND CORRECT FITTING
CLOTHING WHEN WORKING ON CORRECT MAINTENANCE PROCE-
LIFT TRUCKS. INJURY CAN
RESULT IF YOU 00 NOT WEAR DURES.
Code: PM-540, NOV 85 Page 1.1

PM CLqRK
1 Visual Inspection
85M549
The objective of the visual inspection is to be sure

that all components of the lift truck are:
1) in place
2) attached securely
3) in a safe and efficient operating condition
Be sure to make a thorough inspection of the critical

components that handle or carry the load.
Page 1.2 Code: PM-540, NOV 85

Cl!!!!RH PM
1 First, perform a visual inspection

of the truck and its components.
o Walk around the truck and take note

of any obvious damage.
a Check for loose fasteners
and fittings.
o Check for leaks.
When you find oil leaks due

simply to a loose fitting,
tighten the fitting. 85M501
Report other leakages as major ,.,_
repairs on the PM Report form.
2 Inspect the overhead guard for damage.

Be sure that it is properly positioned
and all mounting fasteners are in place
and tight.
85M473
3 Inspect the load back rest extension

for damage. Be sure that the mounting
fasteners are all in place and tight.
4 Inspect the fork carriage for damage,

cracks, wear, and high stress areas.
5 Inspect the complete upright assembly; rails,

rollers, lift chains, and lift cylinders.
Look for any loose parts or fittings. Be sure
that a17 safety guards and chain retainers are
in place and not damaged.
Inspect the carriage stops and cylinder
retainer bolts.
Check all welded connections.
6 Check the lift cylinder piston rods for wear

marks, grooves and scratches. Check the
cylinder seals for leaks.
85M502
rnr(a* PM-540. NOV 85 Page 1.3

7 Check the upright 1ift chains for equal

tension.
8 Inspect the condition of the carriage and

rail lift chains. Look for wear, rust and
corrosion, cracked plates, tight joints or
other damaged parts.
If the chains show slack due to an

increase in length they should be 85M538
measured for wear. When chains have
stretched by wear more than 3% of
their original length they are not
safe and must be replaced.
Please refer to GROUP 34, Section 7,

Lift Chain Maintenance.
On Triple Stage uprights, carefully

inspect both sets of chains and fittings.
85M769
9 Inspect lift chain anchors at both ends

of chain. Inspect each lift chain attachment
point, clevis end and retainer. Be sure
both nuts for each chain anchor are in place.
Be sure there is a retaining pin (cotter pin)
in the end of each anchor.
NOTICE - Style and location of lift chain

anchor fittings varies between upright
models.
10 Inspect the condition of the carriage and

upright rollers. Check for correct roller
clearance.
11 Inspect the rails for roller wear and correct

roller pattern. Look for deep grooves,
scratches, rust, grease and contamination.
Inspect the tie bars.
85M770

Cl!!RK PM
12 Check carriage chain adjustment.
If you are unfamiliar with this procedure,

please refer to GROUP 34, Section 1,
Upright Lift Chain Check and Adjustment
Procedure.
Also see operational tests for correct

fork height check.
17643
13 Inspect all lift line hydraulic hoses and

connections for damage and leaks.
DO NOT USE YOUR HANDS TO CHECK

FOR HYDRAULIC LEAKAGE. FLUID
UNDER PRESSURE CAN PENETRATE
YOUR SKIN ANU CAUSE SERIOUS
85M632
NOTICE
If necessary, raise the carriage for access
to upright components, hoses, fittings, etc.
l APPLY THE PARKING BRAKE AND BLOCK
THE WHEELS.
l BE SURE TO PUT BLOCKING UNDER THE
CARRIAGE AND UPRIGHT RAILS FOR SAFETY.
Refer to:
GROUP 38, Section 3, FALLING FORKS
Machine Jacking and Blocking. 00 NOT liALK OR STAND UNDER
RAISED FORKS. THE FORKS CAN 85M626
FALL AND CAUSE INJURY OR
DEATH.
NOTE - When carriage is raised and blocked,

the oil level in drive axle may also be
checked. Refer to section "6 Lubrication,
Filters and Fluid Level Checks”.
Also, check upright cylinder mounting bolt

torque while the upright is raised.
Refer to section "4 Critical Fastener
Torque Checks".

PM Cl!!‘lRIK
14 Inspect all lift cylinder mounting

retaining bolts to be sure they are
in place and tight. (NOTE - Style and
location varies with upright model.)
Refer to GROUP 40, Section 5 for torque

specification.
85M632
15 Check tilt cylinder rods for any damage

and scratches which may cause cylinder
seals to leak.
85M539
16 If carriage was blocked up for previous

inspections, raise carriage slightly and
remove the blocking. Lower the carriage.
,“_% d
85M627
85M630

PM
Cl!!!!RK
IMPORTANT
FORKS ARE A CRITICAL SAFETY ELEMENT OF

THE LIFT TRUCK. THEY MUST BE CAREFULLY Please refer to:
INSPECTED AT EACH PM INTERVAL AND ALWAYS GROUP 34, Section 4
MAINTAINED IN A SAFE CONDITION. Fork Maintenance.
FORKS THAT ARE BENT OR TWISTED WILL CAUSE

THE LOAD TO SHIFT OR SLIDE OFF AND BE DROPPED.
FORKS THAT ARE CRACKED OR WORN EXCESSIVELY
CAN BREAK SUDDENLY AND CAUSE SEVERE INJURY
OR DEATH.
17 Inspect the lift forks for:

l Cracks l Breaks l Bending l Wear
Move the fork blades together (side-by-
side). Check the fork blades for bent
or twisted condition, with respect to
each other and also to the fork shank.
Check for cracks and wear all around
the fork heel area.
18046
Inspect the fork blades carefully for

twists and bends.
The fork surfaces should be level and

even with each other. The height differ-
ence between both fork tips should be
no more than [6mm] 0.25 inch maximum.
25455
Check the forks to be sure they are not

bent or twisted at the heel. Put a
steel bar on the fork blade and use a
carpenter's square to check for 90' angle
Carpenter square
between blade and shank. Angle at fork
blade and shank must not be more than
dimension specified in chart shown in
GROUP 34, Section 4, Fork Maintenance.
25456

PM Cl!lRn;
Check the amount of wear at the heel

of the forks. If the fork blade at
the heel of the fork is worn down by
more than 10 percent, the load capacity
of the forks is reduced and they must
be replaced. Please refer to GROUP 34,
Section 4, Fork Maintenance. 10% of “A” max. wear
18 Inspect the fork latches. Be sure

they are not damaged or broken.
84M252
The fork latches are spring loaded.

Test them to be sure that they operate
freely and lock correctly. Inspect
for broken or damaged springs.
2498;
19 If your upright has a carriage with fork

stop pins, inspect the stop pins for secure
condition. Be sure that none are broken
or missing, on top and bottom (if so
equipped) of the carriage fork bar.

CLSRK PM
20 Check the condition of the drive and steer

wheels and tires. Remove objects that are
embedded in the tread.
Inspect cushion tires for excessive wear

and breaks or "chunking out", and bond
failure between tire and rim.
Inspect pneumatic tires and wheels

carefully for:
Damaged tire.
Damaged wheels or loosening of the PERSONNEL WORKING ON WHEELS

locking rings on multi-piece rims. AND TIRES MUST BE QUALIFIED
AND TRAINED TO DO WHEEL AND
Loosening of the clamping bolts and TIRE MAINTENANCE.
nuts on two-piece, split-rim wheels.
Low inflation pressure.
Please refer to section "6 Lubrication,

Filters and Fluid Level Checks" for tire
inflation pressure check.. Also, refer to
GROUP 40, Section 5, Truck Specifications.
24308
If pneumatic tire pressure is low, do not

add air. The tire may need to be removed
and repaired.
REMOVE THE AIR FROM TIRES
Move the truck to a maintenance area and BEFORE DOING ANY WORK ON
perform, or schedule, a careful and complete TIRES
RIMS
OR RIMS.
CAN
MULTI-PIECE
SEPARATE WITH
inspection of the tire and rim installation. ENOUGH FORCE TO CAUSE
INJURY OR DEATH.
Refer to GROUP 22, Section 1, Pneumatic

Tire and Wheel Maintenance.
24988

PM CMRK
21 Inspect the brake pedal for loose mounting.

Check for free movement and correct, full
travel of the pedal. Inspect the pedal
pad for wear and secure attachment.
Push down on the pedal and release to

check the return-spring action.
** See note below.
85M513
22 Inspect the accelerator pedal for correct

mounting to the floorboard and travel
movement.
** NOTE - Refer to section "5 Inner Chassis

Components Inspection", Page 5.6, for
additional inspection recommendations
with floorboard removed.
85M514
23 Inspect the directional control lever.

Be sure that it is mounted securely
and operates freely. Inspect the lever
knob for damaged condition. Be sure the
knob is attached securely and the screw
is tightened correctly. Refer to
GROUP 40, Section 5, for torque speci-
fication.
85M497
24 Check the hydraulic control levers for free-

dom of operation and security of mounting.
Inspec t the valve lever knobs for damaged
condit ion. Be sure that they are attached
secure ly to the lever and the screws are
tight.
Refer to GROUP 40, Section 5, for torque

specification.
85M491

CLIRK PM
25 Inspect the hood (seat deck/battery

compartment cover) sheetmetal for
damage and correct fitup.
Refer to section 5, Page 5.2, "Battery

Compartment Maintenance/Inspection", for
additional checks when compartment
cover is raised (open).
85M515
26 Check the driver's seat slide

mechanism for damage and security
of mounting.
Inspect the driver's seat cushion and

backrest for damaged condition.
85M856
27 Inspect the safety seat belt.
Be sure the seat belt and buckle are

in good (safe) condition. Replace the
seat belt if it is damaged, worn or
frayed.
85M855
28 FOR TRUCKS EQUIPPED WITH SPARK-ENCLOSED

CONSTRUCTION (EE), OR WITH POLYURETHANE
TIRES:
Check GROUND STRAP for security of

attachment and wear damage.
NOTE - Ground strap is attached at

center of crossmember at bottom of
frame.

29 Inspect the "Truck Data and Capacity Plate"

for condition, legibility and correct
information.
NOTICE - Be sure that a new (correct)

capacity plate has been installed, if
truck has been modified or attachments
added which affect the truck capacity
rating.
85M518
30 Inspect the "Operator's Safety Warning

Decal" and all safety decals.
Be sure none are missing and all

are clearly visible and legible.
85M525
Please refer to the Operator's Manual

for description and locations of the
data plate and safety decals. Also,
see GROUP 40, Section 1, Truck Data NAMEPLATES & DECALS
Plates and Decals.
DO NOT OPERATE A LIFT TRUCK
WITH DAMAGED OR LOST DECALS
AND NAMEPLATES. REPLACE THEM
IMMEDIATELY. THEY CONTAIN
IMPORTANT INFORMATION.
31 Be sure that an Operator's Manual is in

the holder or manual box on the truck
and attached securely.
85M492

CMRK PM
2 Operational Checks/Test Drive
85M639
YOU MUST BE TRAINED AND AUTHORIZED TO OPERATE A LIFT TRUCK
Be sure that all components, controls, systems

and safety equipment are functioning correctly
and in safe operating condition.
If you are unfamiliar with the function of each control

or system, please refer to the "Know Your Truck"
section. Also, refer to the "How Your Lift Truck
Operates" section in the Operator's Manual.
IMPORTANT
BATTERY MUST BE FULLY CHARGED BEFORE

YOU DO THE OPERATIONAL CHECKS

PM CMRK
FUNCTIONAL TESTS
1 Sit in the driver's seat and check the seat

adjustor slide mechanism for correct
operation. Test the latch and spring for
correct operation and locking engagement.
Adjust the seat to a comfortable position

which will allow easy reach to all controls.
Release the seat lever. Be sure that the
seat locking mechanism is engaged.
85M485
2 Press the horn button to check horn function.

If the horn does not operate, report the
failure and have it repaired before the
truck is put into operation.
85M484
3 Test the function and free movement of the

parking brake lever mechanism. Release,
then apply the parking brake with the lever.
The lever locks by an over-center action in
the applied (vertical) position. If the
lever binds or does not operate freely,
apply lubricant to the linkage at pivot
and sliding points.
Refer to GROUP 23, Section 4, for parking

brake adjustment procedures.
4 Check steering column (pylon) release lever.

(Parking brake shown released for clarity.)
Pylon must move up freely and also pull back
and latch into the driving position without
restrictions. Lubricate the lever pivot and
pylon hinge points as necessary.
Refer to GROUP 25, Section 5, for pylon

release lever adjustment.
1 CAUTION
NEVER DRIVE TRUCK WITH PYLON IN
THE FORWARD (UNLATCHED) POSITION.

CLRRK PM
5 Test the service brake system. Push down

on the brake pedal and hold. Check for a
feeling of solid resistance when the pedal
stops. The pedal must feel firm and not
move down farther after it stops. If the
pedal continues to move downwards, report
the failure immediately. DO NOT OPERATE
THE TRUCK UNTIL THE BRAKES ARE REPAIRED.
Refer to: .GROUP 20, Section 1, Drive Axle

Maintenance.
*GROUP 23, Section 3, Brake Bleeding 85M480
Procedure.
6 Fully depress the accelerator pedal and

release to check for free movement.
85M479
7 Test the directional control switch lever

for correct function. Check that the lever
operates freely and "holds" securely
in each position, "FORWARD", "NEUTRAL",
and "REVERSE".
Report any malfunction. Do not attempt to

operate the truck until repair has been
made.
85M498
8 Be sure the hydraulic control levers all

move freely and return to the center
or neutral position when released.
85M490

PM ELFIRK
9 Before starting a lift truck, be sure to

start from a safe condition. Check to
see that:
l Parking brake is applied.

b Forks are fully lowered to the floor.
l You are familiar with how all the
controls function.
l All controls are in neutral or other
correct position.
85M512
10 Turn key switch to the "ON" position.
11 Check hourmeter operation.

With key switch "ON", release parking brake
Move direction control lever to "FWD" or
"REV" position. The steer pump and hour-
meter should begin operating. Watch for
movement of the indicator in the right-
hand dial opening.
NOTE - Hourmeter operates only when steer
pump and/or 1ift pump is operating.
85M511
12 Return control to "NEUTRAL" and apply
parking brake
13 Check battery charge indicator.

The indicator should register in the green
area when key switch is "ON". Also, check
function of battery charge indicator when
making battery load test, below.
85M469
Battery Load Test
1 Check the battery condition by holding the
tilt lever in full-back position allowing
main pump to run against loading of bypass
relief pressure for a few seconds. Watch
the battery charge indicator. The needle
should stay in the green area. If needle
falls into the red area of gauge, the
battery is low and must be charged before
completing the other electrical tests and
performance parts of the P.M.
Refer to GROUP 12, Section 2, Battery

Maintenance.

CMRK PM
BEFORE DRIVING THE TRUCK, DO THESE TESTS:
1 Test for correct function of lift pump

motor switch on LIFT control lever.
Turn key switch to "ON" position.

Slowly pull back on the lift control lever
towards the "raise" position. The pump motor
should start to run as the lever moves from
the neutral position. Push lever forward
until upright starts to lower. Pump will
stop running. Pump motor will not operate
when lever is moved to "lower" position.
If lever movement is excessive before the

pump starts, or if pump does not stop
running when lever returns to neutral,
the microswitch needs adjustment.
Refer to GROUP 13, Section 1, Lift Pump

Motor Microswitch Adjustment.
2 Check for correct function of lift pump

motor switches on TILT and AUX levers.
Slowly move the tilt control lever forward

and then backwards, each a small distance
from the neutral position. The pump motor
stiould start up and run as the lever moves
from the neutral position, in each direction.
Refer to discussion above if lever movement

or switch action is not correct. See GROUP
13, Section 1, for adjustment procedure.
3 Repeat above test for tilt control lever

with each AUX control lever, if installed.
The pump motor should start and run as

the control lever moves from the neutral
position, in each direction.

4 Check function of parking brake microswitch.

With key switch "ON" and parking brake ap-
plied, move the direction control lever to
the "FORWARD" position. Push slowly on the
accelerator pedal. The drive motors should
not operate. If they do, the microswitch
on the parking brake linkage is not adjusted
correctly. Also, check "REVERSE" position.
Refer to GROUP 13, Section 3, Parking
Brake Microswitch Adjustment.
85M495
5 Check the parking brake.
Release the parking brake with the lever.

Push on accelerator pedal to move the
truck slowly forward. Then, apply the
parking brake. The parking brake should
turn the drive motors off and stop and
hold the truck from further movement.
85M481
6 Test for correct function of the power
steering pump SW itch and system.
Turn the key swi tch "ON", and release the

parking brake. Move the directional control
lever from neutral to either "FORWARD" or
"REVERSE" position. The steer pump should
begin operating.
85M497
With the truck not moving, rotate the steer-
ing handwheel to a full right turn, and then
a full left turn. Listen for the steering
pressure-relief valve to by-pass when the
steer wheel hits the stops on the steer axle.
The steer pump and motor should not stall
or exhibit excessive loading. If it does,
the power steering system pressure relief
valve may be malfunctioning.
Refer to GROUP 26, Section 3, Power Steering

System Relief Pressure Check.
85M507
7 Move direction control lever to "NEUTRAL".
8 Apply parking brake.

ElfIRK PM
TEST DRIVE THE TRUCK
NOTICE - It is recommended that these

(driving) tests be conducted with a
rated capacity load, if available.
BUCKLE UP. Be sure that you put on the seat

belt. Connect and adjust the seat belt to a
snug, comfortable position. ALWAYS WEAR
YOUR SEAT BELT WHEN OPERATING A LIFT TRUCK.
85M854
1 Check all around to be sure that your intended

path of travel and area of operation is clear
of obstructions and pedestrians.
85M522
2 Practice safe operation every time you drive

a lift truck. During your driving, observe
all functions of the truck. This will allow
you to immediately recognize a problem or
irregularity that could affect the safe
operation of the truck. DO NOT CONTINUE TO
OPERATE A TRUCK THAT HAS A MALFUNCTION.
STOP AND HAVE IT FIXED.
85M523
85M853

3 Test for correct function of the traction control ..
Check CREEP SPEED, 1A RANGE and PLUGGING.
1. CREEP SPEED should be obtained at the beginnina of SCR RANGE after

pushing lightly on the accelerator pedal and closing 1MS switch.
2. 1A RANGE. When the accelerator control is pushed farther and/or fully

down, the truck should accelerate in SCR RANGE and make a smooth transi-
tion into 1A RANGE for maximum travel speed. As the 1A contactor closes
(providing direct battery current to the drive motor), there should be
very litt1e surge as the truck goes out of SCR RANGE and into 1A.
3. PLUGGING. Plugging is an SCR control function which provides for revers-

ing the direction of travel under controlled conditions. A correctly-
adjusted plugging control should result in a smooth deceleration, or
gradual stop of travel from any speed in one direction, and accelera-
tion in the opposite direction. Plugging speed and distance is deter-
mined by accelerator control pedal position.
Refer to following comments for further details of these tests.
NOTICE - .If you observe (or have a report of a problem) that creep
speed, maximum travel speed, or plugging is not functioning correctly,
please refer to GROUP 19, Section 2, Traction Control Troubleshooting.
Check CREEP SPEED and 1A RANGE while driving the truck in a straight line
in both FORWARD and REVERSE directions. All speed changes should be
smooth while increasing and decreasing speed. Listen for any unusual
drive train noises or actions of the controls and drive train components.
Stop truck with the service brakes.

Note any unusual reactions in driving
or braking performance, and need for
adjustment.
Check PLUGGING function first at a slow speed If operating correctly,

then test at full speed.
First, drive truck in the FORWARD direction. Push the accelerator pedal
and allow the truck to accelerate to the des red travel speed. Then, move
the direction control to REVERSE position while your foot is still depress-
ing the accelerator pedal. The truck should slow to a smooth, controlled
stop and accelerate in the opposite direction.
Repeat test by moving direction control

back to FORWARD position.

CMRK PM
4 Check the accelerator control while con-

ducting the speed range tests. It must
move easily and smoothly throughout the
acceleration stroke, and return without
binding. There should be no restriction
to movement on either acceleration or
deceleration.
85M479
5 Test the service brake (drive motor shut-off)

switch.
Drive the truck FORWARD (or in REVERSE) at

creep speed. While holding the accelerator
pedal steady in creep-speed position, push
on the brake pedal with left foot. The
braking action should interrupt power to the
drive motors and stop the truck. Release
the brake pedal. The drive motors should
sta rt again moving the truck.
6 Test service brake operation.
APP y and release the brakes several times

whi e driving the truck.
1) Check for firm pedal pressure, quick

pedal return, full stopping without pull-
ing to one side, and for brake fading
('. must use more pedal effort each
t:rnE'io stop the truck).
2) Check for changes in pedal pressure.

85M480
3) Listen for brake squeal and other
abnormal noise.
If you find a problem in the service brakes, report the failure immediately.
DO NOT OPERATE THE TRUCK UNTIL THE BRAKES ARE REPAIRED.
Refer to: e GROUP 20, Section 1, Drive Axle Maintenance.

l GROUP 23, Section 3, Brake Bleeding Procedure.
o OH-540, GROUP 23, Section 17, Brake Assembly Overhaul.

PM EMRK
7 Test steering operation.
First, drive the truck in a straight line.

Then, drive slowly (creep speed) through
a series of full right and left turns.
1) The truck must drive in a straight line

without drifting toward either side.
85M654
2) Check steering response and smoothness

of operation. Turning effort must be
the same in either direction.
Refer to GROUP 26, Section 3, for Power

Steering Relief Pressure Check, if you
find problems with the steering response.
85M507
8 Check steering/drive motor cut-off switches.
During full steering, as the steer wheel

turns to an angle of 58-62 degrees from
center, the drive motor on the inside of
the turn must stop running. The truck is
then driven by the outer motor only. If
inner motor does not stop running, refer
to GROUP 13, Section 4, Steer Axle
Trunnion Microswitch Adjustment.
NOTICE - It is recommended that the follow-

ing tests also be conducted with a rated
capacity load, if available.

CMRK
9 Test for general drive train operation

and noises.
Drive the truck at various speed and oper-

ating conditions, in both FORWARD and
REVERSE directions.
1) Listen for clunking, squealing, grind-

ing, scraping or other unusual noise.
3) Check for vibration.
2) Listen for wheel bearing or other

specific running noise.
4) Test shifting from "NEUTRAL" to

"FORWARD, then back to "N". Next
test shift from "N" to "REVERSE",
then back to 'IN".
**NOTE - Do these tests with no load,

and then with rated capacity load.
10 Test the operation of the hydraulic system

and upright.**
BE SURE THERE IS
Cycle (raise to full height and lower fully) ADEQUATE OVERHEAD CLEARANCE
the upright at both fast and slow speed, with BEFORE RAISING THE UPRIGHT.
the rails tilted slightly back of vertical.
l Check for correct function of the lift

control lever and main hydraulic valve.
l Listen for abnormal noise in the valve,

pump, and system components.
l Watch for correct staging.
85M638

PM CLiRIK
NOTE - If the maximum fork height is not

attained, this indicates there is an in-
adequate (low) oil level in the hydrau- FALLING FORKS
lic sump tank, low pressure-relief set-
ting, or severe binding within the DO NOT WALK OR STAND UNDER
upright assembly. RAISED FORKS. THE FORKS CAN
DEATH.
Observe the upright assembly and components:

rails, rollers, carriage, lift chains and
cylinders as they move. Look for binding or
excessive free play (looseness) between the
carriage and the upright rails and rollers.
Listen for abnormal noises. All movements
of the upright and carriage must be smooth
and free without binding or jerking motion.
85M628
NOTICE
If there is excessive clearance between If the operational tests
the rails and channels, the need for roller indicate excessive upright
adjustment is indicated. If the rails or looseness or free play,
carriage bind or hesitate when lowering the roller shim adjustment
this indicates either damaged rollers or should be checked for the
incorrect roller adjustment. top and bottom rollers in
all lift positions.
11 Check that chain and hose sheaves turn

freely with upright operation, and that
chain and hose guards are functioning
correctly.
85M769

CL9RK PM
12 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.
85M527
NOTICE
If you observe (or have a report of a problem)
that the fork carriage does,not hold its Refer to:
position when stopped in a raised condition GROUP 34, Section 3,
the upright may have too much downdrift due Upright Cylinder
to wear of the cylinder seals. Test the Downdrift Test
upright for downdrift.
13 Check for excessive tilt drift.**
Stop the upright at a position with the

rails slightly back of vertical. Check
that the upright holds its position
without moving forward.
NOT1CE
If you observe forward movement (drift) of
the upright (or have a report of a tilt drift Refer to:
problem), check the tilt cylinders for too GROUP 32, Section 2,
much drift. Tilt Cylinder Drift
Test.
14 Remove the test load.

PM CMRH
15 Test the tilt control system.
Raise the fork carriage to an intermediate

position and cycle the tilt control to tilt
the upright fully forward and backward
85M488
16 Test for correct tilt cylinder rod

adjustment (upright racking).
Raise the carriage to an intermediate

position. Tilt the upright fully FORWARD.
Check for upright racking (twisting)
as the tilt cylinders reach the end
of their stroke.
85M529
Tilt the upright fully BACKWARD. The up-

right should not rack (twist) when the tilt
cylinders reach the end of their travel. If
upright racking is found, adjustment of the
tilt cylinder rod ends (yokes) is required.
Refer to GROUP 32, Section 1, Tilt

Cylinder Adjustment.
85M530
17 Check for correct fork height adjustment

(also carriage chain adjustment).
Tilt the upright to the vertical position

and fully lower the carriage. The forks
should stop and be held approximately
[13 mm] 0.50 inch above the floor. If
the forks hit the floor, please refer to
GROUP 34, Section 1, Lift Chain Check
and Adjustment Procedure.
85M531

CLSRH PM
3 Air Cleaning
85M532
Always maintain a lift truck in a clean condition.

Do not allow dirt, dust, lint or other contaminants
to accumulate on the truck. Keep the truck free of
leaking oil and grease. Wipe up all oil spills.
Keep the controls and floorboards clean, dry and safe.
A clean truck makes it easier to see leakage, loose,
missing or damaged parts, and will help prevent fires.
A clean truck will run cooler.
The environment in which a lift truck operates will deter-

mine how often and to what extent cleaning is necessary.
For example, trucks operating in manufacturing plants
which have a high level of dirt or lint (e.g., cotton
fibers, paper dust, etc.) in the air or on the floor,
will require more frequent cleaning. If compressed-air
pressure does not remove heavy deposits of grease, oil, etc.,
it may be necessary to use steam or liquid spray cleaner.

PM
1 Use an extension on the air hose similar to

that shown. Use clean, dry air and
restrict air pressure to [207 kPa] 30 psi.
Wear suitable eye protection (e.g., safety
glasses) and protective clothing.
2 Air clean the upper portion of the

upright assembly.
* Chains
0 Inner rails
l Sheaves
l Cylinders
* Cylinder gland, rod wipers
and seals
85M535
3 Air clean the lower portion of the upright.
o Tilt cylinder ends

o Upright mounting pins
l Rollers
a Cylinder(s)
o Chains
o Rails
l Fork slide area
85M536
4 Air clean the top and front

of the drive axle.
85M537

PM
5 Remove the floorboard. Pry one edge up,

then lift at the rear, tilt forward to
disengage tabs at the front edge, and
remove from the truck. You may need a
screwdriver to pry one edge up first.
85M506
6 Remove cover enclosing the main valve.

Loosen and remove the two bolts at the
top of cover. Rotate cover to disengage
from control lever lock handle, then
lift cover from truck.
85M534
7 Open the hood (seat deck/battery

compartment cover).
85M616
8 Air clean the top of the battery and cables.
9 Air clean the traction controls.
85M532

10 Air clean the area under the floorboard.
a Drive motors
I,Main hydraulic pump and motor
o Steer pump and motor
e Drive axle and breather
1, Accelerator control
l Brake pedal, master cylinder and linkages
l Wiring harnesses
85M533
NOTE - Blow dust and dirt from vented NOTICE

motors. If the brush covers are
ON ENCLOSED MOTORS, REMOVE THE
excessively dirty, remove and clean
NON-VENTED BANDS EVERY THIRD
them before cleaning the motor.
P.M. AND AIR CLEAN THE MOTORS.
11 Air clean the:
l Hydraulic control valve

l Switches
l Wiring
l Linkage
l Hoses and fittings
85M652
12 Air clean the steer axle, steer cylinder

and linkage.
NOTE - Air cleaning of the steer axle is

easier when the rear of the truck is raised
and blocked up. Please refer to section
"Outer Truck Chassis Inspection and
Lubrication", Page 6.9.
85M773
Paqe 3.4 Code: PM-540, NOV 85

CMRK PM
4 Critical FastenerTorque Checks
14844
All components of the lift truck which are assembled with

threaded fasteners are designed to be held in place with
a torque that is correct for the application and size of
the fastener.
Fasteners in highly-loaded (critical) components can

quickly fail if they become loosened; also, loose
fasteners can cause damage or failure of the component.
For safety, it is important that the correct torque be

maintained on all critical fasteners of components which
directly support, handle or control the load, and protect
the operator.

Refer to:
l GROUP 40, Section 2, for suggested

torque wrenches.
l GROUP 40, Section 5, for torque
specifications.
14844
1 Check drive axle mounting bolts for

correct torque. Tighten each bolt to
correct torque specification.
85M873
2 Inspect and tighten drive wheel bolts

to correct specification.
85M614
3 Inspect and tighten steer wheel bolts

to correct specification.
85M615
Paoe 4.2 Code: PM-540, NOV 85

PM
4 Inspect and tighten the load backrest

mounting bolts to correct specification.
85M613
5 Inspect and tighten tilt cylinder yoke

clamp bolts to correct torque specifi-
cation.
85M612
6 Tighten outside counterweight mounting

bolt to correct specification.
83~649
7 Inspect and tighten inside counterweight

bolts when battery is removed. Refer to
GROUP 12, Section 1.
85M650

PM Cl!!!RK
8 Tighten front overhead guard leg

mounting bolts to correct torque
specification.
85M618
9 Tighten rear overhead guard leg

mounting bolts to correct torque
specification.
85M790
10 Inspect and tighten the driver's seat

mounting bolts.
85M787
11 Tighten all upright cylinder mounting

and retaining bolts to correct torque
specification.
NOTE - Each model of upright varies

in the style and location of the lift
cylinder mountings.

CLrlRK PM
5 Inner Chassis ComponentsMaintenance/Inspection
85M862
The following pages outline general procedures and recommendations

for inspection and maintenance of truck battery, brakes, motors
and motor controls. For more detailed information on maintenance
procedures for these components, please refer to the GROUP and
Section references when noted in the respective areas of the text.
Also, please refer to:
o GROUP 01, Section 1, Recommended Planned Maintenance Schedule
o GROUP 12, Section 2, Electric Truck Battery Maintenance
a GROUP 16, Section 1, Electric Motor Maintenance
l GROUP 40, Section 2, Suggested Equipment for Electric Truck PM
a GROUP 40, Section 5, Truck Specifications

PM Cl!!,9RU
BATTERY COMPARTMENT MAINTENANCE/INSPECTION
1 For convenience, release the pylon latch and

move the steering column to the raised
(forward) position.
85M546
2 Unlatch and open the hood (seat deck/

battery compartment cover). Check that
the gas springs correctly assist (help)
in raising the cover. Be sure that it
is held securely in the open position
by the supports (gas springs).
85M476
3 Inspect the hood latch and hinge brackets

for any damage. Also check them for free
operation, secure mounting and correct
alignment.
Make a report of damage and failure of the

latch, hinge or supports to operate or
hold securely.
Battery Removal
When it is required to remove the battery

from the truck, please refer to
GROUP 12, Section 1, Battery Removal.
NOTICE - A feature of the TM15-20 36-volt lift

trucks is a hinged front battery plate for im-
proved service accessibility to the chassis and
drive line components located beneath the floor-
board. Utilization of this feature requires
removal of the battery. See Page 5.8 for
information on how to adjust the front battery
plate when servicing chassis components.

CWRK PM
PM With Battery Installed In Truck
1 Turn key switch to "OFF" position.
'2Disconnect battery from truck receptacle.
3 Inspect condition of the battery connector.

Check the spring-loaded terminal and
retaining tab for poor connection due
to burning, bad crimp, or loose or
broken retainer.
Check the molded body for damage from
overheating, burning and chips or
cracks. Clean all corrrosion from
contacts, as nqcessary.
85M6il
4 Inspect the spring-loaded connectors in

the truck battery receptacle. Look for
looseness, burned parts and other dam-
aged areas due to excessive heat.
Refer to checks noted above. If any

of the above conditions are evident,
replace the connectors.
5 Inspect condition of the battery and cables.

Check the battery cables for wear or other
damage, and routing clear of interference
(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.
IMPORTANT- NEVER WASH THE BATTERY WHEN

IT IS IN THE TRUCK.

Maintenance.

PM
6 Check battery post terminals for corrosion

and damage. Clean all corrosion from cable
end and battery post. Check tightness of
cable and post terminals.
FLAMES OR SPARKS IN BATTERY

CHARGING AREAS OR NEAR BAT-
TERIES.AN EXPLOSION CAN RESULT
19563
7 If necessary, check the state-of-charge

condition of the battery.
To check the charge condition of the battery,
take a specific gravity test of the elect-
trolyte, using a hydrometer. Be sure to
check a minimum of six battery cells.
Maintenance.
19565
8 Check the electrolyte level of the battery.
Add distilled water, as required, to

fill each cell to the correct level.
(Typical view shown).
9 Check to be sure that the vent hole in all

battery cell caps is open.
If cap vents are plugged with corrosion,

remove them and wash in a solution of
baking soda and water.

CMRK PM
MOTOR SCR CONTROLS MAINTENANCE/INSPECTION
IMPORTANT
CLEANING AND INSPECTION OF ELECTRICAL COMPONENTS
DO NOT CLEAN ELECTRICAL COMPONENTS WITH STEAM. ONLY APPROVED SOLVENTS
SHOULD BE USED TO CLEAN CONTROLS AND SCR COMPONENTS. USE CLARK #1801146
DEGREASER (OR THE EQUIVALENT TO MS-180 FREON TF DEGREASER AND CLEANER).
1 Turn key switch to the "OFF" position.

2 Open hood (battery compartment cover).
3 Disconnect battery from truck receptacle.
4 Discharge the capacitor.

Use an insulated tool,
such as a screwdriver with DISCONNECT THE BATTERY AND
DISCHARGE THE CAPACITOR BEFORE
plastic or wood handle, to HANDLING SOLID STATE COMPO-
INJURY CAN RESULT FROM
short between the terminals.
85M543
5 Inspect the SCR controls for clean condition.

Check for oily dirt buildup on contactors,
SCR control card, capacitor, etc.
6 Inspect all controls wiring and terminals

for any obvious damage. Look for cracks
or worn areas in the wiring insulation.
85M545
7 Check for loose connections at the controls

terminals.
Refer to GROUP 19, Section 1, Traction

Control Troubleshooting, for additional
information.
85M544

UNDER FLOORBOARD AREA MAINTENANCE/INSPECTION
NOTE - For better clearance and convenience,

raise pylon to the forward position.
1 Lift up the back edge of floorboard and

remove it from the truck. You may need
a screwdriver to pry up the rear edge
first.
85M506
2 Inspect roller on accelerator control plunger

for excessive wear and to be sure it turns
freely. Check plunger for free movement
within the control. Check plunger seal
wiper for damage and plunger shaft for any
nicks or scratches that would cause wiper
damage. Check that the accelerator con-
trol mounting bolts are all in place
and tightened correctly.
85M623
3 Push the brake pedal with your hand to check

"free play", and to feel if there is any
binding or restriction to movement. If pedal
does not move freely, lubricate pedal pivot
pin, push ("work") the pedal several times
and check movement again. Adjust pedal stop
screw, as necessary, to provide "free play"
of [l,O-3,0 mm] .040-.118 in (clearance
measured at the stop screw). Inspect
master cylinder and fittings for leaks.
85M621
4 Inspect the tilt cylinder base mounting

pins. They should move freely and not show
excessive wear. Be sure that two undamaged
spring-pin retainers are correctly
installed in each mounting pin.
85M622

CMRK PM
5 Check that hydraulic line connections

at each tilt cylinder are tightened
correctly.
85M653
NOTICE - Inspection of the chassis components, hydraulic lines, pumps and

motors in the underfloorboard area may be more easily done when the
battery is removed and front battery plate loosened and pivoted
backwards (lowered) into the battery compartment.
See Page 5.8.
6 Remove cover enclosing the main valve, if

not previously done. (See page 3.3)
7 Inspect the condition of the hydraulic

system components, piping and fittings.
Check for leakage of connections at:

l sump tank 0 pump 0 tilt cylinders
0 filter l main hydraulic valve
DO NOT USE YOUR HANDS TO CHECK

FOR HYDRAULIC LEAKAGE. FLUID
UNDER PRESSURE CAN PENETRATE 85M656
8 Check the condition of all hydraulic hoses,

fittings and clamps. Check for wear,
blisters, routing and interferences.
Be sure to check hydraulic pump suction

(intake) and high-pressure (output) lines
for signs of leaking, wear and obstruction
from sharp bending or kinking.
85M667

PM CLRIRR
FRONT BATTERY PLATE ADJUSTMENT FOR MAINTENANCE ACCESS
The front battery plate is hinged at the bottom and adjustable for main-
tenance access to drive motors, brakes, hydraulic pumps, motors and
piping components installed in the compartment under the floorboard. When
this plate is loosened and pivoted towards the rear of truck, added clear-
ance between components is provided and the main hydraulic pump and motor,
and hydraulic oil filter are rotated to a position where they may be more
easily serviced. If you are unfamiliar with this procedure, please refer to
GROUP 38, Section '2,for additional information on battery plate adjustment.
Truck battery must first be removed, to

provide access to the battery plate
mounting bolts and to allow movement of
the plate into the battery compartment.

Removal.
Remove floorboard.
Remove valve cover, to avoid damage to
bottom flange of cover.
85M651
From the battery compartment side, loosen

and remove the four (4) bolts which mount
the battery plate at its sides to the frame.
Bolt torque: [40-45 N.m] 30-35 lbf.ft.
85M665
The battery plate may now be adjusted to

the maintenance position by moving the top
of the plate towards the rear of truck.
IMPORTANT - The plate may require blocking

to limit its travel. Put a block of wood
behind the plate and against the front edge
of the counterweight or frame to support
it. Refer to GROUP 38, Section 2 for addi-
tional information.
Install the battery plate in operating

position by reversing the above procedure.

SERVICE BRAKEMAINTENANCE/INSPECTION
1 Inspect the service and parking brake

discs and caliper assembly.
Inspect the surfaces of the brake

discs for wear damage, scratches
and grooves. Check the brake pads
for wear and need for replacement.
Check for brake fluid leakage at
the brake cylinders and fittings.
85M672
2 If the brake parts show excessive wear

damage, the brakes should be scheduled
for overhaul.
Refer to Overhaul Manual OH-540,

GROUP 23, Section 17, Brake Overhaul.
3 Inspect the brake assembly mounting bolts

and fittings. Check that the mounting
bolts are tightened correctly.
85M705

PM EMRK
DRIVE MOTORSMAINTENANCE/INSPECTION
NOT1CE - Inspection and maintenance of drive motor brushes is easier when

the motors are removed from the drive axle, or completely from the truck.
Refer to GROUP 16, Section 2, Drive Motor Brush Replacement.
AIR PRESSURE
1 Remove the battery from truck (See GROUP 12, Section 1).
2 Loosen the front battery plate to adjust for access to motors.
Refer to GROUP 38, Sectjon 2. -
3 Inspection of the general condition of the

brushes may be made by removing a brush cover
from the top side of the motor without remov-
ing the motor. Remove the plastic brush
covers by squeezing or prying the locking
tabs from the slots in the sides of the open-
ing. Air clean the inside of the motor
around the commutator and brushes, using
dry (moisture-free) air.
85M690
4 If the sample inspection indicates that the

brushes must be replaced, the motor must be
removed from the drive axle for access to
all brushes.
Refer to GROUP 16, Section 1, for more

information on motor maintenance and
brush inspection.
85M691
5 Loosen and remove the drive motor mounting

bolts from drive unit mounting flange.
6 Remove power cables from motor terminals.
NOTE - Attach lable tags to the cables

for easy indentification at assembly.
85M674

ClRRl4 PM
7 The bottom motor mounting bolt may be

more easily reached with better leverage
by using a socket wrench with a long
extension from the battery compartment.
85M763
8 Move each motor from the axle towards the

rear of truck until brush openings are
accessible within the battery compartment.
Motor may be carefully rotated for access
to all brushes.

detailed information on complete removal
of motors from truck and brush replacement.
85M680
9 Inspect the drive motor power cables.
Check the power cables for wear and damage

to the insulation and wire. Check the crimp
area of all cable ends. There must not be
any looseness or corrosion at this point.
If damaged, remove the damaged area and in-
stall a new terminal end. Replace each
cable, as necessary. Be sure all cable
connections are tightened correctly.
85M675
10 Inspect each drive motor housing and

mounting flange for cracks or damage
that could cause failure.
11 Install drive motors to drive axle, if

removed for brush inspection.
Check that the motor mounting bolts are

tightened correctly. Correct tightening
torque is [70-80 N.m] 52-59 lbf.ft.

PM CLRRK
LIFT PUMPMOTORMAINTENANCE/INSPECTION
NOT1CE - Inspection of the pump motors is easier k,hen the front battery
plate is adjusted (lowered) to the maintenance position. Also, if the
hydraulic lines are not removed, the lift pump must be disconnected from
the motor to permit rotation of the motor body for access to brushes on
lower side of motor.
1 Adjust the front battery plate for maintenance access.

(see page 5.8)
2 Disconnect lift pump from motor.
Clean the pump flange area and disconnect

the lift pump by removing the two mount-
ing bolts from the motor. Pump shaft may
remain engaged in motor spline.
85M902
3 Detach the lift motor from its installed

position.
Loosen and remove the bolt from the motor

mounting strap. The motor may now be ro-
tated within the mounting band for access
to all brushes. If necessary, also discon-
nect the power cables from motor to allow
motor to rotate fully.
85M686
4 Inspect the condition of the pump motor

b#rushes and commutator.
Remove the plastic brush covers by flexing

them or prying to disengage the locking tabs
from the slots in the opening. Air clean
the inside of the motor around the brushes
and commutator, using dry (moisture-free)
compressed air.
85M709

CLRRK PM
5 Remove each brush from the brush holder

and inspect the brushes and commutator
for wear, electrical arcing, etc.

information on motor maintenance and
brush inspection.
85M710
6 Replace the brushes (complete set), as needed.

Refer to Overhaul Manual OH-540, GROUP 16,
Section 24, for additional information.
7 When brush inspection or replacement is

completed, install the brush covers on
motor. Be sure the covers are fitted
correctly into the retaining slots.
85M708
8 Inspect the pump motor power cables.

to the insulation and wire. Check the
crimp area of all cable ends. There must
not be any looseness or corrosion at this
point. If damaged, remove the damaged
area and install a new terminal end. Re-
place each cable, as necessary. Install
cables (if removed) and be sure all cable
connections are tightened correctly.
85M903
9 Inspect pump motor housing and pump mount-

ing flange for cracks or damage that could
cause failure.
85M712

PM ClRRl4
10 Install the pump motor into its operating

position, by reversing the procedure of
disassembly. Also, see pump install below.
85M684
11 Adjust (rotate) the motor position for

correct routing of power cables to motor
and hydraulic lines to pump. Be sure
pump suction line is positioned to avoid
kinking or interference with other piping.
Install and tighten the bolt in mounting
strap. Be sure to include hose clip
when bolt is installed.
85M683
12 Install the lift pump.
Be sure all surfaces are clean when mount-

ing the pump to motor. Check that the
pump mounting bolts are tightened correctly.
Correct tightening torque is [40-45 N.m]
29-33 lbf.ft.
85M902
13 Check that the hydraulic line connections

to the pump are tightened correctly.
85M714

PM
STEER PUMP MOTOR MAINTENANCE/INSPECTION
NOTICE - Inspection of the steer pump motor brushes requires removal of

the sump filter mounting bracket, disconnection of the hydraulic lines from
pump, and removal of the motor and pump assembly from its mounting on the
front battery plate.
Refer to GROUP 16, Section 4, Steer Motor Brush Replacement, for removal
of steer motor and brush replacement procedure.
Refer to Overhaul Manual OH-540, GROUP 16, Section 2'2,for information on

steer motor troubleshooting.
1 Adjust front battery plate for maintenance access (see Page 5.8).
2 If brushes are to be inspected, remove steer motor and pump assembly from
the truck. Refer to GROUP 16, Section 4, noted above.
3 Inspect the condition of the steer motor

brushes. Remove each brush from the brush
holder and inspect the brushes and commutator
for worn condition and even wear, electrical
arcing, etc. Refer to GROUP 16, Section 1,
for more information on motor maintenance
and brush inspection.

Refer to GROUP 16, Section 4, Steer Motor
Brush Replacement, for more information.
5 Inspect the steer motor power cables.

to the insulation and wire. Check the
cable terminals for looseness and corro-
sion. If damaged, remove the damaged
area and install a new terminal end.
Replace each cable, as needed. Be sure
all cable connections are tightened
correctly.

PM CMRYC
6 Inspect steer motor housing and pump mount-

ing flange for cracks or damage that could
cause failure.
NOTE - If motor is removed from truck,

the above two items should be done when
motor is removed.
85M711

CLqRK
6 Lubrication, Filters & Fluid Level Checks
The following pages outline general procedures and recommenda-

tions for checking all fluids, fluid levels and filters, includ-
ing lubrication of truck chassis and upright components. For
more detailed information on maintenance procedures, please refer
to the GROUP and Section references when noted in each respective
area of the text.
Also, please refer to:
l GROUP 01, Section 1, Recommended Planned Maintenance Schedule
l GROUP 01, Section 2, PM and Lubrication Charts
o GROUP 40, Section 2, Suggested Equipment for Electric Truck PM
l GROUP 40, Section 4, Lubricant Specifications and Recommendations
l GROUP 40, Section 5, Truck Specifications

PM Cl!!~RK
STEERING COLUMN (PYLON) MAINTENANCE/INSPECTION
Remove access cover from the front of the

pylon. Use a screwdriver to rotate the
l/4-turn fastener.
Release the latch lever and move the pylon

to the forward (near-vertical) position.
85M510
Check service brake system reservoir for

correct amount of hydraulic brake fluid.
The "FULL" level is at the top ring on
reservoir. Clean dirt from reservoir
and cap, as needed.
The reservoir may be temporarily removed
from its retaining clip and held vertically
to facilitate checking fluid level position.
Refer to GROUP 40, Section 5 (also see
Section 4), for fluid specification.
85M645
Inspect all wiring connections for correct

routing and positioning. Check all termi-
nals for tight connections, and inspect all
wires for breaks or cracks in the insula-
tion and other damage.
NOTE - The 3FU 15-amp control fuse is

located in the pylon.
85M646
Inspect all steering hydraulic lines for

damage, cuts, breaks and leaks. Be sure
all fittings are tightened correctly.
When inspection is completed, install access

cover back on pylon. Be sure to fit the
indexing notches at the bottom of the cover
over the matching tabs on pylon base. Then,
move cover into the closed position and lock
85M647

CMRK PM
HYDRAULIC SUMP TANK FLUID CHECK
1 Check the hydraulic sump tank oil level with:

l Truck on a level surface.
l Upright in the vertical position.
o Fork carriage fully down.
0 Oil at operating temperature.
2 Pull the dipstick out, wipe it with a clean
wiper, and push it hack into the dipstick
tube. Remove the dipstick again and check
the oil level indication. 85M504
3 Check the condition of the hydraulic fluid

(age, color or clarity, contamination), to
determine if it should be replaced.
Refer to PM records for operating time

since last oil change.
Refer to next page (Page 6.4) if fluid

needs to be changed.
85M619
4 The hydraulic system oil level should be

between the oil level markings on dipstick.
NOTE - Approximately [2.8 L] 0.75 gallon

of hydraulic oil is required to fill the
hydraulic tank from the "L" (LOW) mark to
the "F" (FULL) mark. DO NOT OVERFILL.
See GROUP 40, Sections 4 & 5, for

hydraulic oil specifications.
IMPORTANT
5 Add recommended fluid only, as required.
NOTICE - Remove or pull dipstick part way

out to vent air from tank while filling.
When adding fluid, check the fluid level again with the dipstick
after operation of the truck including operation of the upright
through several lift cycles.

PM CLRRK
HYDRAULIC FLUID AND FILTER CHANGE
It is recommended to:
Refer to:
@ Drain and replace the hydraulic system fluid GROUP 29, Section 1,
every 2000 operating hours, or once a year. Hydraulic System Fluid
o Replace the hydraulic oil filter at every and Filter Change.
oil change.
l Replace the sump tank breather every
1000 operating hours.
NOTE - It is suggested that these procedures be scheduled with other

routine maintenance when the: 1) battery is removed, and 2) front
battery plate is adjusted for service access (page 5.8).
Refer to: GROUP 12, Section 1, Battery Removal

GROUP 38, Section 2, Battery Plate Adjustment for Maintenance
IMPORTANT
USE RECOMMENDED FLUID ONLY.
ALWAYS USE GENUINE CLARK PARTS.
Oil Filter Change
1 Remove and replace the hydraulic system

fluid filter per recommended planned
maintenance schedule, or as may be
required by truck operating conditions
and usage. (Replacement of the filter
may be more easily done when the front
battery plate is adjusted for mainte-
nance access, noted above.)
85M641
2 Install a new oil filter.

Be sure to follow the installation
instructions printed on the filter.
3 Check for leaks after installation of

the filter. Also, check that the hy-
draulic line connections at the filter
adapter are tightened correctly.
85M642

Cl!!!!RW PM
NOTE - In the event of failure of a major component,

e.g., main pump, in the hydraulic system, or the
possibility of severe contamination of the fluid,
samples of hydraulic oil may be submitted to an
independent commercial laboratory for analysis of
the contaminant level.
SUMP TANK BREATHER MAINTENANCE/INSPECTION
1 Remove floorboard first, if not removed

previously.
2 Then, remove the cover enclosing the main

hydraulic valve.
85M617
3 Remove the hydraulic sump tank fill cap/

breather and inspect for contamination
and damage.
85M509
4 Clean or replace the fill cap/breather,

per recommended planned maintanance
schedule, or as required by operating
conditions.
85M508

PM CMRK
DRIVE AXLE MAINTENANCE/INSPECTION
Access To The Drive Axle

Refer to
The best method for reaching the drive axle GROUP 38, Section 3,
check point (oil level/filler plug) may be Machine Jacking and
dependent upon the style of upright, Blocking.
carriage and attachments on your truck.
1 One method is to raise and block the

upright carriage to provide easier
access to the drive axle.
o APPLY THE PARKING BRAKE

AND BLOCK THE WHEELS.
85M626
l BE SURE TO PUT BLOCKING

UNDER THE CARRIAGE AND
UPRIGHT RAILS.
See reference at right above.
DO NOT WALK OR STAND UNDER

RAISED FORKS. THE FORKS CAN
85M630
85M627

ELFIRK PM
ORIVE AXLE FLUID LEVEL CHECK
Check the drive axle fluid level with: NOTICE
l Truck on a level surface. Check the planned maintenance

0 Oil at operating temperature. interval (operating hours),
or the condition of the oil
to determine if the drive axle
fluid needs to be changed.
Remove the fluid level inspection/fill

plug located in the front surface of each
drive unit housing (2 places).
The oil level is correct (FULL) when the

oil reaches to the lower edge of the
inspection plug opening.
85M877
IMPORTANT
Add recommended fluid only, as required.
Refer to GROUP 40, Sections 4 & 5, for

drive axle recommended oil specifications
After adding oil to the drive axle, wait

several minutes until the oil has
distributed evenly throughout the unit,
and check for correct oil level. DO NOT
OVERFILL.
85M874
Inspect each fill plug for damage.

Replace as necessary.
3 Install and tighten the plugs.
85M875

El!!RR
DRIVE AXLE FLUID CHANGE

NOTICE
It is recommended to:
Frequent changes of lubricant
eDrain and replace the drive axle is an inexpensive way to pro-
fluid every 1000 operating hours. tect and prolong the safe oper-
ating life of an essential and
relatively costly major compo-
nent such as the drive axle.
Extending the recommended in-

tervals at which drive axle
fluid is changed should be con-
sidered only after careful
evaluation of your operating
conditions and/or analysis of
the condition of the oil.
To change oil in the drive axle:
The oil should be drained when it Refer to

is warmed to operating temperature. GROUP 20, Section 1,
Drive Axle Maintenance,
Put the truck in a level position. for information on
draining and replacing
Apply the parking brake and block drive axle fluid.
the wheels to prevent the truck
from moving.
NOTE - When suitable equipment is

available, the truck may be raised Refer to
or hoisted up and placed in a level GROUP 38, Section 3,
position on wheel cradles to allow Machine Jacking and
access under the axle. Otherwise, Blocking.
raise the fork carriage only high
enough to provide access clearance
to the axle. Please refer to pro-
cedure described above in "Access
To The Drive Axle".

PM
Cl!!RK
OUTER TRUCK CHASSIS INSPECTION AND LUBRICATION
Refer to: GROUP 01, Section 2, Planned Maintenance and Lubrication Charts
GROUP 40, Section 4, Lubricant Specifications and Recommendations
GROUP 40, Section 5, Truck Specifications
NOTICE - Lubrication and inspection of truck chassis components, including

steer wheel, steer axle linkage, steering cylinder and wheel bearings will be
easier if the truck ,is raised and blocked up under the frame.
Refer to GROUP 38, Section 3, Machine

Jacking and Blocking
! WARNING
o DO NOT RAISE TRUCK BY LIFTING
UNDER THE COUNTERWEIGHT. I
a BE SURE TO PUT BLOCKING

UNDER THE FRAME TO KEEP
THE TRUCK SECURE.
85M776
Steer Axle
1 Inspect the steer axle and trunnion for

damage and wear.
Check steering trunnion bearing free-

play when checking wheel bearings,
noted below. If excessive trunnion
bearing free-play is found, refer to
GROUP 26, Section 1, Steering
Trunnion Bearing Adjustment.
85M765
2 Check the steer wheel and trunnion bearings

for excessive free-play or looseness. Hold
the wheel with both hands and try to move
it by a rocking motion from side to side,
and pull it in-and-out along the wheel
spindle. There should be a small amount of
free movement. Also, watch all linkage for
signs of loose joints. If the wheel has
excessive end play, the bearings require
service.
Refer to GROUP 26, Section 2, Steer Wheel 85M747

Bearing Maintenance,

PM CLRRK
3 Test the steer wheel (bearings) for

free rotation.
Check the planned maintenance interval

(operating hours) to determine if wheel
bearings should be lubricated.
Refer to GROUP 26, Section 2, for

Steer Wheel Bearing Maintenance.
85M748
4 Inspect the steer linkage for correct

mounting and operating condition.
Check for damaged components. Look for
bent links or unusual wear. Check the
condition of all linkage pivot pins for
binding or-excessive wear. Be sure the
pivot pins and nuts are tightened
correctly.
Refer to GROUP 26, Section 4, for in-

spection and adjustment procedures.
85M802
5 Inspect steer cylinder for damage to the

cylinder barrel, rod ends and mounting
studs. Check for excessive wear or
looseness at the ball joints. Be sure
the rod end ball joint studs and nuts
are installed and tightened correctly.
(Views shown with counterweight

removed for clarity.)
85M808
6 Inspect the steering cylinder piston rod

for damage: bending, wear marks, grooves
nicks and scratches. Check the piston
rod seal wiper for damage or leaking
condition.
NOTICE - Move steer wheel from full

right to full left turn for a complete
inspection.
85M798

ElfIRK PM
Inspect the steering hydraulic hoses and

fittings for damage, cuts, breaks and
leaks. Be sure that the hoses have the
correct routing and fittings are
tightened correctly.
85M800
Lubricate the steer axle linkage: rod ends

and linkage pivot points. Be sure to clean
the grease fittings before lubricating and
remove the excess grease from all points
after lubricating.
NOTE - These fittings are designed to

face downwards and/or to the rear for
access from rear of truck.
4 fittings.
Miscellaneous Linkage
1 Lubricate miscellaneous linkage, as needed.

PM Cl!!R#
Drive Wheels
With truck or drive wheels raised off the

floor:
1 Check for free rotation of the drive wheels.
'85M745
2 Check for looseness of the wheel bearings.
Hold the drive wheel and try to move it by
rocking from side to side and by pulling
or pushing in and out along the spindle
centerline. Check for a maximum of
[0,08 mm] 0.003 inch of end play. If bear-
ings are loose, the truck should be
scheduled for further service.
Refer to Overhaul Manual OH-540,

GROUP 20, Section 10, Drive Unit
Overhaul.
85M746
3 Raise the truck and remove blockins.

Lower the truck or drive wheels to-the
floor, and remove remaining blocking
from under the frame or upright, as
applicable.
85M741

Cl!!3Rl4 PM
Tire Pressure Check
1 Check for the correct air pressure on trucks

with pneumatic tires.
Refer to GROUP 40, Section 5 for tire

pressure specifications.
_, /,I
85M859
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 the tires are low, don't add air.

Have the tire and wheel inspected by
a person trained and authorized to do
tire and wheel maintenance. The tire
may require removal and repair.
Incorrect (low) tire pressure can
reduce the stability of your lift
truck and cause it to tip over.

UPRIGHT AND TILT CYLINDER LUBRICATION
1 Clean the fittings and lubricate the tilt

cylinder, rod end bushings (forward endj
at the upright).
2 fittings.
85M624
2 Clean the fittings and lubricate the tilt

cylinder base rod end bushings ( at the
anchor end, under floorboard).
2 fittings.
85M657
3 Clean the fittings and lubricate the

upright trunnion (mounting pin)
bushings (on top of mounting pin).
2 fittings.
85M637
4 Lubricate the upright rail l'ift and carriage

chains with Clark Chain and Cable Lube.
85M769

PM
Cl!!RK
5 Lubricate the free-lift guides by wiping

with multipurpose grease, Grade 2.
NOTE - Do not lubricate the carriage

roller rails.
6 When the P.M. has been completed, make a

record on the Planned Maintenance Report
form of all the operating and truck
problems that you find. Review the
checklist to be sure it has been com-
pleted. Give the report to the person
responsib'Iefor lift truck maintenance.
85M548

PM
7 Electrical Tests
When electrical tests are required, Refer to GROUP 40, Section 5,

Truck Specifications. Refer to GROUP 40, Sections 17 and 18 for
information and tips on using a volt-ohmmeter for measuring
voltages and resistance.
Refer to GROUP 17, Sections 1 and 2 for information on contac-

tors. Refer to GROUP 19, Sections 1, 3, 5, and 6 for trouble-
shooting and adjustment of EV-100 SCR and accelerator controls.
IMPORTANT
THE BATTERY MUST BE FULLY CHARGED

BEFORE DOING ELECTRICAL TESTS.
~1
DISCHARGE THE CAPACITOR BEFORE

SEVERE BURN-SCAN RESULT FROM
CONTACT WITH ELECTRICAL SYSTEMS
12704
1 Use a volt-ohmmeter and a shunt-type

ammeter for electrical tests. Be sure
the V-O-M is recalibrated when choosing
different range setting.
NOTE - Recommended for all electrical

tests and controls testing: Digital
Multi-Meter, Simpson D.M.M. Model 461
or equivalent (not shown).
12703

PM CMRn;
To perform this service procedure, it is

recommended that you:
l Park the truck on a level surface and

fully lower the upright.
l Put blocks under the upright rails and
l Raise the drive wheels off the floor.
l Return all controls to neutral, and
apply the parking brake.
85M743
Jacking and Blocking.
1 Turn key switch to the "OFF" position.
2 Open the battery compartment cover.
85M540
85M541
4 Discharge the capacitor.
Use an insulated tool, e.g., a screwdriver

with a plastic or wood handle, to short
between the terminals.
85M620
'Page 7.2 Code: PM-540, NOV 85

Cl!lRK PM
Test For Ground Fault Condition GROUND TEST
1 Make a record of the resistance measured

on the P.M. check sheet.
NOTICE - Truck resistance varies widely de-

pending on condition, age, and cleanliness.
Values shown are typical. However, values
ranging down to 20,000 ohms may be found on
some trucks, without a problem. Values
below 20,000 ohms must be further investi-
gated and corrected. See below.
2 Set volt-ohmmeter on Rx10,OOO scale and

calibrate the meter.
Turn key switch to "OFF" position and

check for ground fault condition, as
follows:
3 Connect RED lead to POSITIVE (t) of truck

receptacle. Connect BLACK (-) lead to
the truck frame. Make a record of the
resistance measurement.
IMPORTANT
IF LESS THAN 20,000 OHMS RESISTANCE
IS MEASURED, CONDUCT FURTHER TESTS
TO ELIMINATE SHORT CIRCUIT/ GROUND
FAULT CONDITION.
14860
4 Connect RED lead to NEGATIVE(-) of truck

receptacle and leave BLACK lead connected
to truck frame. Make a record of the
resistance.
IMPORTANT
IF LESS THAN 20,000 OHMS RESISTANCE
IS MEASURED, CONDUCT FURTHER TESTS
TO ELIMINATE SHORT CIRCUIT/ GROUND
FAULT CONDITION.
14861

Test For Short Circuit
85M541
3 Set volt-ohmmeter on Rx1 scale and calibrate

the meter.
Check for short circuit condition, as

follows:
4 Connect RED (+) lead of meter to the

POSITIVE (+) side of truck receptacle.
Connect BLACK (-) lead of meter to the
NEGATIVE (-) side of truck receptacle.
Make a record of the resistance

measurement.
25461
5 If the resistance value measured is

less than 30 ohms, this indicates there
is a short circuit in the system. You
must conduct further tests to locate and
eliminate the short circuit condition
before the battery is connected.

PM CMRK
OWNER SAFE MAINTENANCE PRACTICES
Powered industrial. trucks may become haz- 5. Before Leavina The Truck:
ardous if adequate maintenance is not
done. Therefore, suitable maintenance 1) Stop truck.
facilities, personnel, and procedures must
be provided. 2) Fully lower the load engaging
means.
Maintenance and inspection of all powered
industrial trucks should be done in 3) Put directional control in neutral.
agreement with the recommendations in
this manual and the following practices: 4) Apply the parking brake.
1. A scheduled preventive maintenance, 5) Stop the engine or turn off power.

lubrication, and inspection program must be
followed. 6) Lock the control or ignition circuit.
2. Only qualified and authorized 7) Put blocks at the wheels if truck is on

personnel should be permitted to maintain, a ramp, or being worked on.
repair, adjust, and inspect industrial trucks.
6. Before Workina On Truck:
3. Operation to check performance of the
truck or attachments must be done in an 1) Raise wheels free of floor or
authorized, safe, clear area. disconnect power source.
4. Before Startina To Drive The Truck: 2) Use blocks or other positive truck
positioning devices.
1) Be in operating position.
3) Put blocks under the load engaging
2) Push clutch (or brake pedal on means, innermast( or chassis
automatic transmission and before working under them.
electric trucks).
7. Before working on engine fuel system of
3) Put directional control in neutral. gasoline powered trucks with gravity-feed
fuel systems, be sure fuel shutoff valve is
4) Start engine or turn on power. closed.
5) Before operating truck, check 6. Before working on engine fuel system of

functioning of lift and tilt systems, LP-gas powered trucks, close LP-gas
directional and speed controls, cylinder valve and run engine until there is
steering, warning devices, no more fuel in the system and engine
brakes, and any attachments. stops running.
6) Release parking brake.
1023-2.1 REV OCT 86

ELqRU PM
OWNER SAFE MAINTENANCE PRACTICES
9. Avoid fire hazards and have fire protec- 16. All hydraulic sytems must be regularly
tion equipment available. Do not use an inspected and maintained in conformance
open flame to check level or for leakage of with good practice. Tilt cylinders, valves,
fuel, electrolyte or coolant. Do not use open and other like parts must be checked to
pans of fuel or flammable cleaning fluids for make sure that “drift” has not developed to
cleaning parts. the extent that it would create a hazard.
10. Provide ventilation to the work area, 17. Capacity, operation and maintenance
vent exhaust fumes, and keep shop clean instruction plates, tags, or decals must be
and floor dry. maintained in legible condition.
11. Handle LP-gas cylinders with care. 18. Batteries, motors, controllers, limit
Do not drop, dent, or damage in any way. switches, protective devices, electrical
conductors and connections must be
12. Brakes, steering mechanisms, control inspected and maintained in conformance
mechanisms, warning devices, lights, with good practice. Special attention must
governors, lift overload devices, guards and be paid to the condition of electrical
safety devices must be inspected regularly insulation.
and maintained in a safe operating
condition. 19. Industrial trucks must be kept in a
clean condition to minimize fire hazards
13. All parts of lift and tilt mechanisms and and help in the detection of loose or
frame members must be carefully and regu- defective parts.
larly inspected and maintained in a safe
operating condition. 20. Modifications and additions which
affect capacity and safe truck operation
14. Special trucks or devices designed must not be done by the customer or user
and approved for hazardous area operation without the manufacturer’s prior written
must receive special attention to make sure approval. Capacity, operation and
that maintenance keeps the original, maintenance instruction plates, tags or
approved safe operating features. decals must be changed accordingly.
15. Fuel systems must be checked for 21. Care must be taken to make sure that
leaks and condition of parts. Extra special all replacement parts are interchangeable
consideration must be given in the case of a with the original parts and of a quality equal
leak in the fuel system. Action must be to that provided in the original equipment.
taken to prevent the use of the truck until the
leak has been corrected.
1023-2.2 REV OCT 86

INDUSTRIAL TRUCK DIVISION
SAFETY SIGNS AND SAFETY MESSAGES
STAY ALERT! Follow safety rules, regulations and procedures. Accidents can
be avoided by recognizing dangerous procedures or situations before they occur.
Improper or careless techniques will cause accidents. Don't take chances with
incorrect or damaged tools and equipment. WORK SAFELY and follow the safety
signs and their messages.
READ and understand the procedures for safe lubrication, adjustments and
maintenance outlined in this manual.
Safety signs and messages are also put on the forklift truck to provide
instructions and to identify specific areas where potential hazards exist.
Study and follow the instructions, signs and messages. Serious injury or
death to you or other persons may result if these messages are not followed.
IMPORTANT -- This message is used when special precautions should be

taken when dis-assembling or assembling components to
avoid damage or malfunction.
NOTICE ----- This message is used when special instructions or

identification is required relating to tools, pressure
readings, capacities and other special data.
CAUTION ---- This message is used as a reminder of safety practices

which can result in personal injury if proper precautions
are not taken.
WARNING ---- This message is used when a hazard exists which can result
in injury or death, if proper precautions are not taken.
DANGER ----- This message is used when an extreme hazard exists which
will result in death or serious injury if proper precautions
are not taken.
1322-Z JUN 84
CMRl4 GROUP
01
GROUP
01
SECTION
1
RECOMMENDED PLANNED MAINTENANCE SCHEDULE
Code: PMA-540, NOV 85 GROUP 01, Section 1, Page 1

GROUP CLSRK
01
For: TM
PM Interval Code: 8 = 8-10 hours

50 - 250 = 50-250 hours or each PM
500 = 500 hours
1 = 1000 hours or every 6 months
A/R = As required
Nominal
Maintenance Interval
8 50-250 500 1 2
PM PROGRAM
Visual Check 0
Functional Performance Checks - Test Drive 0
Air Clean The Truck
n
Chassis Components Maintenance/Inspection

Electrical Tests
,12 BATTERY AND CABLES

1 Battery electrolyte level - check/add water 0
2 Battery condition - performance load test
n
3 Batterv terminals/cables - clean/tishten
13 GAUGES, LIGHTS, INDICATORS. WIRING

1 Hourmeter - check
A n
2 Battery discharqe indicator - check
3 Wirinq harnesses - inspect
.16 MOTORS
1 Drive motor brushes - inspect/replace
2 Lift motor brushes - inspect/replace 0
3 Steer motor brushes - /\
. inspect/replace
,19 ELECTRICAL TESTS

1 Ground tests 0
20 DRIVE AXLE
_ 1 Fluid level/condition - check
2 Fluid change - drain/fill
3 Breather air vent - clean
4 Axle mounting bolts - inspect/tighten 0 1
GROUP 01, Section 1, Page 2 Code: PMA-540, NOV 85

ELqRK GROUP
01

Nominal
Maintenance Interval

CLRRK GROUP
01
GROUP
01
SECTION
2
PLANNED MAINTENANCE AND LUBRICATION CHART
AIR CLEAN THE TRUCK PRIOR TO PERFORMING

THE CHECKS AND LUBRICATION INSTRUCTIONS
WIPE GREASE FITTINGS CLEAN

BEFORE APPLYING A GREASE GUN
REFER TO GROUP 40, SECTIONS 4 & 5

FOR LUBRICANT SECIFICATIONS
UNLESS OTHERWISE NOTED

GROUP
01
PLANNED MAINTENANCE AND LUBRICATION CHART
For: TH
PM Interval Code: 8= 8-10 hours

50 - 250 = 50-250 hours or each PM
500 = 500 hours
A/R = As required
Nominal
Chart Maintenance Interval
Lubricate trunnil
,Z!Z!HYDRAULIC SUMP Ch
AND FILTER Chanqe fluid
Replace fluid filter 16 1 O/
Replace sump breather/fill ca
n 17 I I I

GRiXJP‘
CMRK
01
LEGEND Planned Maintenance and Lubrication Char?

EO Engine Oil
TF Transmissionfluid TM 15-17-20 36-Volt
IF Hydraulicbrake fluid
HO Hydraulicoil
CL Chain lubricant
DL Dry-film lubricant
HP1 Multipurposegrease NLGI 1
HP2 tlulticwroose
grease NLGI 2
,@ MP2
Code: PMA-540, NOV 85 GROUP 01, Section 2, Page 3 ”

GROUP Cl!!lRH
01
LUBRICANTSPECIFICATIONS
Engine crankcase oil

Upright latch, Control rods, API "CC", M IL-L-2 104B,
Miscellaneous linkage MIL-L-46152
Transmission fluid
Drive axle DEXRON II ATF
Automatic Transm ssion Fluid
Hydraulic fluid
Hydraulic sump Clark Specificat on
Normal temp application MS-68 Hydraulic oil
Cold storage Clark Specification

MS-226 Hydraulic oil
Multi-purpose grease
Axle ends, NLGI Grade No. 1
Wheel bearings Lithium soap base grease,
Clark Spec MS-9B and
MS-107&, or equivalent.
Steering linkage, NLGI Grade No. 2
Upright mast & carriage Lithium soap base grease,
rollers, Trunnion bushings, Clark Spec MS-9B and
Tilt cylinder rod ends, MS-107C, or equivalent.
Brake pedal shaft
Chain lube
Upright lift chains Clark #886399 Chain and
Cable Lube, or equivalent
Dry-film lubricant
Side shifter, Attachments, Dow Corning Molykote 321 Bonded
Clamp slides Lubricant, Graph-0-Kote #220,
Molub-Alloy #369 Dry Lube,
or equivalent
Low temperature grease
Co1 d storage general Low temperature grease,
purpose grease MIL-G-23827A, or equivalent
Protective spray coating

Wiring, terminals, switches Clark #886784 Spray Coating
after assembly
Moistureproofing spray coating

Contactor panels, SCR cards Clark #1801145 Spray Coating
Battery Distilled water
NOTICE - Refer to GROUP 40, Section 4, Lubricant Specifications and

Recommendations for further information.

CLqRl4 GROUP
01
COLD STORAGE APPLICATIONS NOTE
High moisture-exposure operation in Encapsulated cards or potted

such as freezers or caustic atmosphere cards are no longer available
can cause premature failure of SCR for use in problem areas and
control cards. CONQUER Spray Coating must be
used.
CLEAN THE SCR CONTROL.
If the SCR control is oily or greasy,

use "Freon TF Degreaser", CLARK Part IMPORTANT
No. 1801146.
The instructions written on the
To protect the cards, spray them all spray can of CONQUER suggests
over with CONQUER Spray Coating, that parts be cleaned with an
CLARK Part No. 1801145. agent called "SYNCRONATE." We
do not recommend the use of this
cleaning agent as it may damage
CONQUER is an electrical moisture- the card. Any cleaning of
proofing spray coating for contactors, controls should be with a mild
SCR panels, solid state control cards, detergent solution. Then blown
#l timer and oscillator cards. dry with clean, moisture-free
compressed air at low pressure.
CONQUER spray should be applied in

accordance with the following
recommendations:
NOTE
TRUCK EXPOSURE RE-APPLICATION CYCLE
ELECTRICAL SWITCHES, WIRING &
Indoors Every 12 Months TERMINALS should be sprayed
Outdoors Every 4 Months with SPRAY COATING, CLARK Part
Freezer or Every 4 Months No. 886784.
Cold Storage
SPRAY COATING is a clear acrylic
plastic protective coating which acts
as an insulator and a corrosion
Also each time the control is cleaned preventative.
during a normal planned maintenance,
the card should be re-sprayed.

CL(IRK GROUP
12
GROUP
12
SECTION
BATTERY REMOVAL
Refer to GROUP 40, Section 5, Specifications,

for battery weights

recommended that you first:
Park the truck on a level surface and

Return all controls to neutral and turn
key switch to the "OFF" position.
Apply the parking brake.
Block the drive wheels.
85M512
IMPORTANT
Before you remove, service or install
a truck battery, carefully read the
recommendations and instructions in
BATTERY SERVICE MUST 8E DONE
GROUP 12, Section 2, 8Y TRAINED PERSONNEL. BATTERY
Electric Truck Battery Maintenance. ACID CAN CAUSE SEVERE BURNS
AND INJURY.

GROUP CLARK
12
BATTERY REMOVAL
1 Push the control valve levers forward (all

together) and pull up on the lock lever
handle to lock the control levers in the
forward position.
85M521
2 Release the pylon latch and move the

steering column to the raised (forward)
position.
85M660
3 Unlatch and open the hood (seat deck/

battery compartment cover).
85M616
4 Disconnect battery at truck receptacle.
85M541

clcilln GROUP
12
5 NOTICE- If the battery to be handled is

uncovered, and has exposed terminals and
cell connectors, cover the battery with a
non-conducting (insulating) material, e.g.,
plywood or heavy cardboard, before attach-
ing the lifting device, to prevent short-
ing across the battery terminals while
handling.
85M753
6 The overhead hoist shou Id be equipped with

a safety hook. Be sure the hoist, chains,
and spreader bar are in good condition
and have correct capaci ty to safely lift
and carry the battery.
834758
7 Use an insulated spreader bar to lift and

remove the battery. Adjust the hooks of
the spreader bar so that the lifting force
is directly vertical to avoid side forces
from damaging the battery or case.
85M757
8 Raise the battery carefully. Check that

all cables are out of the way, and the
steering pylon and control levers are
locked in the forward position.
85M752

GROUP CWRK
12
9 When the battery is raised above the

frame side, move the battery away from
truck.
85M754
10 Store the battery in a safe position on

a pallet or in the battery service area.
ACID WHICH CAN CAUSE INJURY.

IF ACID CONTACTS YOUR EYES OR
SKIN, FLUSH IMMEDIATELYWITH
WATER AND GET MEDICAL ASSIS-
85M756
IMPORTANT
o USE ONLY A LEAD-ACID BATTERY WITH THE VOLTAGE AND

AMPERE-HOUR RATING SPECIFIED FOR YOUR TRUCK.
l FOLLOW NORMAL BATTERY MAINTENANCE PROCEDURES,

RECHARGING BEFORE 80-PERCENT DISCHARGED AND
WITH PERIODIC EQUALIZING CHARGES.

CLSRK GROUP
12
BATTERY INSTALLATION
1 Refer to removal and equipment recommendations noted previously

for lifting and handling the battery.
2 Be sure that front battery plate bolts are tightened correctly.
3 Be sure no tools or other materials are left in the battery compartment.
4 Be sure steering pylon and control levers are locked in the forward position.
5 Lift and move battery slowly to the truck.

Do not bump battery on frame side while
installing. Be careful not to strike the
control levers, or hood stop brackets at
the rear of compartment.
85M754
6 Lower the battery into battery compartment.
85M751
7 Remove the lifting hooks and spreader bar.
8 Remove the temporary insulating cover from

top of battery, if it was required.
85M759

GROUP CMRK
12
8 Connect battery at truck receptacle.
85M541
9 Close the battery compartment cover.
85M476
10 Release the valve control levers from

the locked position.
11 Move and lock the steering column pylon

into the rear or down position.
85M660
12 Check battery charge condition:
Turn key switch to "ON" position.
Check battery charge indicator.
Do a battery load test.
Turn key switch to "OFF" position.
85M511

CLflRH GROUP
12
GROUP
12
SECTION
ELECTRIC TRUCK BATTERY MAINTENANCE
Changeorservice batteries
only in an areadesignatedfor
thispurpose

GROUP Ck!lRK
12
IMPORTANT
Electric truck batteries are heavy P
and awkward to handle. They are
filled with a very hazardous chemi-
cal solution. And they are costly.
SAFETY
HOOK-
li
Before you remove, service or in-
stall a truck battery, carefully
read the following recommendations
and instructions.
BATTERY HANDLING
LIFTING
1. Change (remove) or service storage
batteries only in an area desig-
nated for this purpose.
2. Be sure this area has provisions:
l to flush and neutralize spillage

l to ventilate fumes from gassing
batteries
0 for fire protection.
3. Be sure the area is equipped with 2545

material-handling equipment desig-
nated for the purpose of removing
and replacing batteries, such as
a conveyor or overhead hoist
equipped w ith hooks having safety
latches. 5. If the battery does not have a cover
of its own or has exposed terminals
4. When using an overhead hoist, always and connectors, cover the top with a
use a spec ial lifting device such as non-conductive (insulating) material,
an insulated spreader bar to attach e.g., a sheet of plywood or heavy
the hoist to the battery. The width cardboard, prior to attaching the
of the spreader bar hooks must be the lifting device.
same as the lifting eyes of the bat-
tery, so that the lift is directly
upward. If the spreader bar hooks NON-CONDUCTIVE
are movable, carefully adjust the posi MATERIAL I
tion (width) of the hooks so that the
pull is directly upward (vertical) and
no side load or force (pressure) is
\r,
exerted on the battery case. Also,
be sure the lifting hooks are the
correct size to fit the lifting eyes
of the battery.
25460

CILSRN GROUP
12
6. When using a power battery hoist,

be sure the hoist is equipped with
a chain container to accumulate the
excess lifting chain.
CHAINCONTAINER
25461
7. Keep all tools and other metallic

objects away from the terminals.
25462
8. Personnel maintaining storage
batteries must wear protective
clothing, such as face shield,
long sleeves and gauntlet gloves.
BATTERY SERVICE MUST BE DONE

BY TRAINEO PERSONNEL. BATTERY
AC10 CAN CAUSE SEVER' BURNS
25463
9. Hydrogen emissions from charging

batteries are flammable. No smok-
ing shall be allowed in the charg-
ing area. Do not check the electro-
lyte level with an open flame. Do EXPLOSIVE GASES
not allow open flame, sparks or DO NOT SMOKE OR HAVE OPEN
electric arcs in the battery charg- FLAMES OR SPARKS IN BATTERY
CHARGING AREAS OR NEAR BAT-
ing area. TERIES.AN EXPLOSION CAN RESULT
AND CAUSE INJURY OR DEATH.

GROUP ELqRU
12
10. When handling electrolyte, a carboy If the battery is to be serviced, be

tilter or siphon must be provided. sure there are provisions to flush
and neutralize spillage to disperse
11. When mixing or using electrolyte: (ventilate) fumes from gassing bat-
teries on charge. And be sure there
l Always pour acid into water.
are provisions for handling elec-
l Never pour water into acid.
trolyte.
Pouring water into acid will cause
a dangerous (explosive) chemical 2. Before attempting to remove or
action. charge a storage battery, the truck
should be positioned in the desig-
nated battery service area and the
brake applied so the truck cannot move.
3. If the battery to be handled is not

SULFURIC ACID equipped with a cover, cover the bat-
THE BATTERY CONTAINS CORROSIVE tery when handling with a non-conduc-
ACID WHICH CAN CAUSE INJURY. tive (insulating) material (e.g.,
IF ACID CONTACTS YOUR EYES OR
SKIN, FLUSH PlMEDIATRY WITH
plywood or heavy cardboard) before
WATER AND-GET MEDICAL ASSIS- I attaching the lifting device. Also
see "Battery Handling", Item 5.
4. Use an approved lifting device with

an insulated spreader bar, to remove
and transport a truck battery. Be
12. When charging batteries, the cell sure the hoist and chains are equipped
caps must be kept in place to with safety hooks.
avoid electrolyte spray. Care
must be taken to assure that 5. Remove the battery and move it to a
cap vents are ope'n (clean) and safe storage position. Store batteries
functioning. The vent holes must either on an approved battery rack or
be open to allow the battery to on a wooden pallet.
breathe. The battery,
or battery compartment cover(s),
must be open to dissipate heat.
BATTERY REMOVAL FROM TRUCK
Also refer to GROUP 12, Section 1,

Battery Removal.
1. Check the designated service and

charging area for fire protection,
and be sure all sources of ignition
are cleared from the area. DO NOT
SMOKE. Be sure all previous noted
equipment is in the area, in good 25464
repair and working properly.

GROUP
Cl!!RK 12
BATTERY CLEANING BATTERY SERVICE RECORDS
NEVER WASH THE BATTERY WHEN A record of battery service and main-
IT IS IN THE TRUCK. tenance should be kept to obtain the best
service life from your battery and truck.
The easiest (and satisfactory) method of Select a pilot cell, take readings of
cleaning a battery is to wash it occa- specific gravity and temperature before
sionally with a low-pressure cold-water and after charging, and make a record of
spray. The top can also be washed off readings with the date. It is best to
with a solution of baking soda and change the location of the pilot cell
water (add a box of baking soda to a occasionally to distribute any electro-
pail of water and stir until dissolved) lyte loss over the battery when taking
and rinsed with clear water. It is good readings. Every 2 to 3 months, take
practice to have this solution available complete battery readings (specific
around a battery room at all times. gravity, temperature and voltage) and
make a record of them.
IMPORTANT - During cleaning, THE
BATTERY CELL CAPS MUST BE TIGHTLY IN
PLACE! HOW TO GET MAXIMUM LIFE FROM BATTERY
1. Follow normal battery maintenance

BATTERY CARE AND MAINTENANCE procedures, re-charging before 80%
discharged and with periodic
Refer to the BATTERY MANUFACTURER or equalizing charges.
SUPPLIER for their recommended proce-
dures. 2. Don't add acid to a battery. Only a
person trained and qualified to do
BATTERY SAVER and CLEANER, Clark Part battery maintenance should determine
No. 886398, may be used to clean and if this is necessary.
protect the truck battery.
3. Lift battery only with a correctly-
New Truck Batteries: constructed lifting device which will
not put pressure on the battery case.
Spray a light coat of BATTERY SAVER
and CLEANER over the entire surface 4. Keep open flames, tools and metal
of the battery. Do not wipe off. objects away from top of battery to
prevent short circuits and explosions.
Old Truck Batteries:
5. Check the battery electrolyte level
Apply a coat of BATTERY SAVER and before each charging. The correct
CLEANER to entire surface of battery. electrolyte level should be just
Allow to set for approximately 30 seconds, below the lower edge of the filler
then wipe thoroughly with a wiping cloth cap opening. Add water, if needed,
or rag. Chemical action will dissolve before charging. DO NOT OVERFILL!
corrosion and rust. After cleaning,
apply a second coating for protection. 6. Do not overcharge.
This will prevent the start and growth
of corrosion on battery terminals and 7. KEEP BATTERY CLEAN AND DRY. Wash
cable connections. down as needed.
8. Keep battery service records.
Code:'PMA-540, NOV 85 GROUP 12, Section 2, Page 5

CLqRK
GRYp
BATTERYINSTALLATION
1. Use only a lead-acid battery with the voltage and

ampere-hour rating specified for the truck.
2. Handle battery only with appproved lifting device

as previously described.
3. Install the battery correctly in the truck and secure

it in position.
NOT1CE - Some trucks are equipped with battery stops or blocks.

Others do not require them. If the truck being serviced has battery
stops or blocks, be sure none are missing or damaged. Replace them,
as necessary. If they are an adjustable type, be sure they are correctly
adjusted and tightened.
IMPORTANT
If batteries discharge rapidly during

normal operation or do not charge to
the correct specifications, contact a
qualified battery service technician to
check the battery for you. DO NOT ADD
ELECTROLYTE OR ATTEMPT TO SERVICE THE
BATTERY.

CLSRK GROUP
13
GROUP
13
SECTION
LIFT PUMP MOTOR
MICROSWITCH CHECK AND ADJUSTMENT
(LIFT, TILT, AUX CONTROL LEVERS)

GROUP CMRK
13
LIFT LEVER SWITCH CHECK
1 Check lift lever switch adjustment.
Turn key switch "ON".

Slowly pull back on the lift control lever.
The pump motor should start to run as the
lever moves from the neutral position.
Push lever forward. Pump should stop
running. Pump motor does not operate
when lever is moved to "lower" position.
85M490
Normal lever movement is approximately

[25,4 mm] 1.0 inch at the lever knob,
before pump starts. If lever movement
is excessive before pump starts, or if
pump does not stop running when lever
returns to neutral, the microswitch needs
adjustment.
Refer to the following adjustment

procedure. Also, see illustration,
page 6.
85M487
LIFT LEVER SWITCH ADJUSTMENT
Step 1: Turn key switch "OFF".
85M506 85M534
Step 2: Remove floorboard. Step 3: Remove cover from main

hydraulic valve.

CLflRK GROUP
13
a
Step 4: Loosen and remove the nuts from
the two mounting bolts at underside of plate
and remove valve lever top plate from the
main valve.
85M817
Step 5: Loosen the mounting bolts that

hold the microswitch in position.
85M872
Step 6: Adjust the microswitch body so

that the switch roller is at the bottom of
the "ramp" on lever, when lever is in the
neutral position.
Step 7: Tighten the switch mounting screw

when the switch is in the correct position.
85M869
Turn key switch "ON" and check for correct

operation of the switch with movement of
the lift lever. The pump motor switch
should actuate when the switch roller is
3/4 of the distance up the "ramp" on lever,
or before reaching the tip of the cam.
Repeat adjustment, as necessary.
Before assembling valve lever top plate,

refer to Page 4 for tilt and aux lever switch
check.
85M870
PMA-540, NOV 85 GROUP 13, Section 1, Page 3

GROUP CMRK
13
TILT AND AUX LEVER SWITCH CHECK
1 Check tilt lever switch adjustment.
Turn key switch "ON".

Slowly pull back on TILT control lever.
As the lever moves from neutral, the pump
motor switch must actuate and pump start
to run. Return lever to neutral. Pump
should stop running.
Slowly push the control lever forward.

The pump motor switch must actuate and
pump start running as the lever moves
from neutral.
If your truck has an auxiliary valve, repeat

the above test with AUX lever(s).
Normal lever movement is approximately

[25,4 mm] 1.0 inch at the lever knob,
before switch actuates and pump starts.
If lever movement is excessive before the
pump starts, or if pump does not stop
running when lever returns to neutral, the
micraswitch needs adjustment.
Refer to the following adjustment procedure.

Cl!lRH GROUP
if
TILT AND AUX LEVER SWITCH ADJUSTMENT
Step 1.: Be sure key switch is turned

to "OFF" position.
Step 2: Remove floorboard and cover

from hydraulic valve, if not removed
for previous tests. See page 2.
85M482
Step 3: Remove vaive lever top plate

from main valve, for access to switches.
See page 3.
85M817
Step 4: Loosen the switch mounting screws.
85M820
Step 5: Adjust the microswitch body so the

switch roller is in the bottom of the groove
of the lever (arrow), when lever is in the
neutral position.
Step 6: Tighten the switch mounting screws

when switch is in the correct position.
85M818

GROUP
13
Step 6: Turn key switch "ON" and test

for correct operation of the switch with
movement of the tilt lever in both direc-
tions. The pump motor switch must actuate
when the roller is approaching the top of
the groove, as the lever moves from
neutral.
Turn key switch "OFF".
85M819
Step 7: When adjustment is completed,

install the valve lever top cover plate,
valve cover over main valve, and floorboard.
85M617
13.114 SWITCH, LIFT VALVE PUMP OPERATING

13.115 FASTENER, LIFT VALVE PUMP OPERATING SWITCH
13.150 SWITCH, TILT VALVE ?UMF OPERATING
13.152 FASTENER, TILT VALVE PUMP OPERATING SWITCH
30.000 VALVE ASSEHBLY, HYDRAULIC
30.087 PIN, VALVE CONTROL LEVER PIVOT
30.088 RETAINER, VALVE CONTROL LEVER PIVOT PIN
30.090 LEVER. TILT CONTROL
30.091 PIN. VALVE CONTROL LEVER TO SPOOL
30.102 BRACKET, PUMP OPERATING SWITCH MOUNTING
30.146 BRACKET, VALVE CONTROL LEVER MOUNTING

30.148 FASTENER, VALVE CONTROL LEVER MOUNTING BRACKET
30.945 LOCKOUT, VALvZ LEVER
30.949 PIVOT, VALVE LEVER LOCKOUT
37.114 FASTENER, VALVE LINKAGE ACCESS COVER

39.556 COVER, VALVE LINKAGE ACCESS
91’.983 NUT, TILT VALVE PUMF OPERATING SWITCH FASTENER
92.558 NUT, LIFT VALVE PUMP OPERATING SWITCH FASTENER

92.781 NUT, VALVE LINKAGE ACCESS COVER FASTENER
93.391 FASTENER. VALVE CONTROL LEVER KNOB
93.393 FASTENER, HYDRAULIC VALVE SWITCH BRACKET
93.610 RETAINER, VALVE LEVER LOCKOUT PIVOT

95.171 NUT. RYDRAULIC VALVE SWITCH BRACKET FASTENER
95.172 RETAINER, vux LINKAGE ACCESS cove FASTENER
VALVE CONTROL LINKAGE 30-559

CMRK GROUP
13
GROUP
13
SECTION
2
SERVICE BRAKE
(DRIVE MOTOR CUT-OFF)


Put blocks under the upright rails, and
Raise the drive wheels off the floor.
Return all controls to neutral, apply
the parking brake, and turn key switch
to the "OFF" position.

85M743

GROUP EUlRl4
13
SERVICE BRAKE SWITCH CHECK
BE SURE DRIVE WHEELS ARE

RAISED OFF THE FLOOR.
1 Turn key switch "ON". Release parking brake.
85M519
2 Put direction lever in "FORWARD" and push

on accelerator pedal to slow-speed
position.
85M479
3 Hold the accelerator pedal steady in the

slow-speed position. Push on the brake
pedal with the other foot. Power to the
drive motors should be interrupted and
wheels should stop turning.
4 Release the brake pedal. The drive motors

should again start turning the drive
wheels.
85M643
5 Put direction control lever in "NEUTRAL"

and turn key switch "OFF“.
If the service brake microswitch does

not operate correctly, refer to the
following adjustment procedures.
85M496

el!!Rw GROUP
13
SERVICE BRAKE SWITCH ADJUSTMENT
Step 1: Remove the floorboard.
NOTE - The microswitch is located on the

left-hand side of the brake pedal mount-
ing bracket. The switch should be
actuated at the end of pedal free travel.
Be sure parking brake is released.
85M477
Step 2: Slowly push the brake pedal by hand,

and listen for the switch to actuate (open)
when the pedal reaches the end of free travel.
85M621
Step 3: Slowly release the brake pedal, and

listen for the switch to actuate (close).
Step 4: If adjustment is necessary, loosen

the switch mounting screws, adjust the switch
to the correct position, and tighten the
mounting screws.
Switch is mounted in a hinged bracket,

with adjustment screw in bracket.
85M706
Step 5: Test for correct operation of the

switch. Readjust as necessary.
Step 6: Insta 11 the f loorboard.
Step 7: Apply parking brake, lower the drive

wheels to the f loor and remove the b lock inq.
85M621

CMRK GROUP
13
GROUP
13
SECTION
3
PARKING BRAKE
(DRIVE MOTOR CUT-OFF)


l Put blocks under the upright rails, and
l Raise the drive wheels off the floor.
0 Return all controls to neutral, apply
the parking brake, and turn key switch
to the "OFF" position.


GROUP
13
PARKING BRAKE SWITCH CHECK
1 Turn key switch "ON". Release parking brake.
BE SURE DRIVE WHEELS ARE

RAISED OFF THE FLOOR.
85M5l.9
2 Put direction lever in "FORWARD" and push

on accelerator pedal to slow-speed position.
85M479
3 Slowly pull up on parking brake hand lever.

As you reach the one-third point (approxi-
mately) of lever travel, the microswitch
must actuate (open) to stop (cutoff) the
drive motors.
4 Pull brake lever fully to applied position.
5 Slowly release the parking brake. As the

lever reaches the two-thirds point of travel
from the applied position, the microswitch
must actuate (close) and the drive motors
start to run.
85M520

GROUP
Cl!!lRK
13
6 If the parking brake microswitch does not

operate correctly, refer to the following
adjustment procedures.
PARKING BRAKE SWITCH ADJUSTMENT
Step 1: Turn key switch "OFF".
Step 2: Remove the pylon access cover.
85M510
Step 3: Loosen and remove the hand brake

bracket mounting bolt nuts and move hand
lever away from pylon for access to switch
mounting screws.
85M815
Step 4: Loosen the microswitch mounting

s.crews.
Step 5/ Move and hold the hand brake lever

at a point one-third of the way through its
travel from the released position. Move
the microswitch until the switch lever makes
contact with the actuating stud on hand lever.
Then, tighten the switch mounting screws.
See NOTICE, Page 4.

85M816

GROUP
13
Step 6: Install and tighten the brake

lever bracket mounting bolts and nuts.
85M815
Step 7: Fully release the parking brake
hand lever and check for correct adjustment of
the microswitch (see Page 2). Repeat the
adjustment procedure, if necessary.
NOT ICE - The switch body allows only

limited movement for adjustment. If
additional adjustment is needed, care-
fully bend the switch lever to contact
the stud on hand lever at the correct
Pasition.
_.-.
85M51g
Step 8:
20283
Step 9: Apply the parking brake, tilt the

upright fully back to lower drive wheels to
the floor, and remove the blocking under the
upright.
85M741

CMRK GROUP
13
GROUP
13
SECTION
6
ACCELERATOR CONTROL MAINTENANCE
AND
TROUBLESHOOTING
EV-100 SCR CONTROL

SOLID-STATE
ACCELERATOR SWITCH ASSEMBLY
BEFORE ANY ADJUSTMENTS, SERVICING, PARTS

REPLACEMENT OR ANY ACT IS PERFORMED REQUIRING
PHYSICAL CONTACT WITH WORKING COMPONENTS
OR WIRING OF THIS COMPONENT: ELECTRICAL BURNS
DISCONNECT THE BATTERY AND RE-
l RAISE DRIVE WHEELS OFF THE FLOOR, MOVE ALL JEUELRY BEFORE WORK-
SEVERE BURNS CAN RESULT FROM
l DISCONNECT THE BATTERY, AND CONTACT WITH ELECTRICAL SYSTEMS
a DISCHARGE THE CAPACITOR 1C.
Code: SM555, IvIAR 89 ........ .............. ..... ................... .......... ... .GROUP 13, Section 6, Page 1
GROUP
13
CLflRK
EV-100 SCR CONTROL

SOLID-STATE
ACCELERATOR CONTROL (SWITCH) ASSEMBLY
“OTC: INTERNAL COMPONENTS ARE
WOT SERVICEABLE. OPENING OF
THIS “NlT WLLL “OlD WARRANTY
Iwm
ACCELERATING CONTROL ASSEMBLY
The accelerator control assembly contains:
1. a switch (1 MS start switch) which closes at the beginning of shaft travel to

energize the control circuit.
2. a solid-state inductor circuit which varies the speed of the truck while in
SCR control.
This accelerator control assembly contains no serviceable

components. Opening this unit will void the warranty.
GROUP 13, Section 6, Page 2 Code: SM555, MAR 89

GROUP
14
GROUP
14
SECTION
ELECTRICAL SYSTEM
Code: SM555, MAR 89 GROUP 14, Section 1, Page 1

REVERSE SWITCH-,
FORWARD SW ITCH
CONTROL
CONTROL WIRING
13.003 HORn
14.005 HARNESS. DASH END WIRING
14.114 WIRINGHARNESS, PUCRINE
14.146 RARNESS,VALVE SWITCHWIRING
14.486 FUSE,KEY SUITCHFEED
14.864 GROMKET,PUKING SAFETY-

I~CK SWITCHCONDUCTOR

CONTROL
RECEPTACLE
ASS.% BLV
DRIVE
>R LLI
-14.o89
POWER WIRING
14.039 RECEPTACLE AND CABLE, BATTERY

14 .olro RECEPTACLE. BATTERY
14.087 CONDUCTOR, DRIVE MOTOR (RA-2)
14.088 CONDUCTOR, DRIVE MOTOR @A-2)
14.089 CONDUCTOR, DRIVE MOTOR (RS-1)
14.091 CONDUCTOR, HYDRAULIC PUMP MOTOR (PM-A)

14.347 CONDUCTOR, STEER PUMP MOTOR (PM-A)
14.348 CONDUCTOR, STEER PUMP MOTOR (PS-S)
14.509 CONDUCTOR, HYDRAULIC PUMP MOTOR (PM-S)
14.522 CONDUCTOR, DRIVE MOTOR (Al)
14.606 CONDUCTOR, DRIVE MOTOR (LA-11

14.607 CONDUCTOR, DRIVE MOTOR (LA-21
14.608 CONDUCTOR, DRIVE MOTOR (LS-2)
14.609 CONDUCTOR, DRIVE MOTOR (LS-1)
93.651 NUT, BATTERY RECEPTACLE MOUNTING FASTENER
94.069 FASTENER, BATTERY RECEPTACLE

CLRRK GROUP
16
GROUP
16
SECTION
1
ELECTRIC MOTOR MAINTENANCE
GENERAL PROCEDURES
NOTICE
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 temperatures. Contamination includes dirt, moisture,
oily vapors, metal chips, carbon dust from the brushes, etc. Mechanical
factors include shock, vibration, overspeed, etc. Operation at prolonged
or excessively high temperature will cause the insulation to become
brittle and crack leading to premature failure. The insulation condition
can be judged both by visual inspection and by test measurements.
Regular, periodic measurements of insulation resistance can give a useful
indication of the rate of insulation deterioration. A sudden drop or
consistent trend toward low values of insulation resistance give evidence
that the insulation is deteriorating and that failure may be imminent.

GROUP CLclRK
16
ELECTRIC MOTOR MAINTENANCE
A planned maintenance program of regular, routine inspections is important

for long life and trouble-free operation of electric motors. Make and keep
records of your inspections. Use these records to help establish the correct
P.M. intervals and to indicate maintenance required to prevent major problems
from occurring during operation.
TYPICAL OPERATING CONDITIONS
NORMAL SERVICE - Basically an 8-hour day of mostly indoor or outdoor

material handling operation.
SEVERE SERVICE - Extended operating hours, or constant usage.
EXTREME SERVICE - l Dusty or sandy locations, e.g., cement plant, lumber

or flour mills, coal dust, or stone-crushing areas.
l High temperature areas, e.g., steel mills, foundries, etc.
l Sudden temperature changes (continuous indoor-outdoor
movement), e.g., refrigeration plant, etc.
NOTE - Since the operating environment of lift truck motors varies widely,
the above descriptions should be applied as actual conditions dictate.
MOTOR MAINTENANCE/INSPECTION SCHEDULE
SERVICE INSPECTION FREQUENCY RECOMMENDED MOTOR POSITION

CONDITIONS (OPERATING TIME) INSPECTION
-_______-----___--^--~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~_~~~~~~~~~~~~~~~~
NORMAL 1000 Hours Routine *Motor installed
As required Periodic Motor removed

by inspection
_____________^^_____~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~___~~~~~~~~~~~~~~_~____
SEVERE 500 Hours Routine *Motor installed

by inspection
______---_________________l_l___________~~~~~~~~~~~---____~~~~~~~~-_-_________
EXTREME 250 Hours Routine *Motor installed

by inspection
____________________--~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
*As truck design dictates.

CL!!fWlH GROUP
16
General Motor Maintenance/Inspection Procedures
To perform these service procedures, it is

ANDLING SOLID STAT
Park truck safely and fully lower the
upright. AN ELECTRICAL SHOCK.
Turn key switch "OFF".
Disconnect battery from truck receptacle.
Discharge the capacitor.
Remove the battery, as necessary, for

access to motors. (GROUP 12, Section 1)
Adjust the front battery plate, for

access to motors. (GROUP 38, Section 2)
85M862
Motor Cleanliness
Electric motors should be kept clean at all

times, to prevent shorting, minimize wear,
and for best cooling.
Wipe off all dust, dirt, oil, water, etc.,

from the outer surface of the motor.
Remove any debris from cooling air vents

and around motor frame to prevent
overheating.
85M672
Air clean (blow out) open motors using
clean, dry (moisture-free) compressed air
at [207 kPa] 30 psi maximum pressure. Air
clean all inner areas around the commutator
and brushes, including the cooling air
vents and fan.
The presence of any oil on or near the motor

could indicate either bad bearings or a
leaking hydraulic system. Determine the
cause and repair the problem before exten-
sive damage to the motor occurs.
85M708

GROUP
16
Test For Motor Insulation Resistance To Ground

Using a 500-volt megger IMPORTANT
1 Disconnect the battery. BE SURE ALL OTHER ELECTRICAL

COMPONENTS THAT MIGHT BE
2 Disconnect the power cables from all ~ DAMAGED BY THE HIGH VOLTAGE
external motor terminals. ARE DISCONNECTED AND NOT IN
, THE CIRCUIT.
3 Connect one lead of a 500-volt megger to
any motor terminal. NOTE- Test all termi-
nals individually or by interconnecting
with jumper wires. Connect the other lead
to the motor frame. Apply the voltage.
4 The resistance should measure at least

l,OOO,OOO ohms (1 megohm). If less than this,
the motor should be air cleaned or dried to
attempt to increase the insulation resistance.
5 If, after cleaning, the reading is less than

1 megohm, the motor should be removed from the
truck for inspection and repair, as needed.
26548
Test For Motor Insulation Resistance To Ground
Using a volt-ohmmeter
Use a Simpson 260-6P or equivalent V-O-M,

calibrated on the Rx10,OOO scale.
Disconnect the battery.
Disconnect the power cables from all

external motor terminals.
Connect the positive lead of the V-O-M

to all the motor terminal studs, using
jumper wires to connect between the
motor terminals. Connect the V-O-M
negative lead to the motor frame.
(NOTE - Test all terminals individually,
or joined together, as noted.)
The V-O-M must show 1,000,000 ohms (1 megohm)

resistance or higher for a good motor insulation.
If less than 1 megohm is measured, air clean the motor and repeat
the test of motor resistance. If air cleaning does not make an
improvement the motor will have to be removed from the truck for
closer inspection and repair, as needed.

GROUP
EMRK 16
Brush and Comutator Inspection
Remove brush cover(s) and remove the 7 Check the tension on the brush
brushes from the brush holders. Clean springs. Spring pressure (load) on
the brushes and holders. Check the all brushes must be equal. Refer to
brush holders for damage. brush spring tension check below.
Inspect the condition of the brushes. a Check brush shunt for good contact
Remove each brush from the brush holder with brush holder. Be sure shunt is
and inspect the brushes and commutator not damaged or burned, since this may
for worn condition and uneven wear, cause brush spring to carry current
burning, electrical arcing, etc. The and lose tension.
brushes should be worn evenly. Refer
to brush inspection chart, page 6. 9 If brushes do not need to be
replaced, and commutator is in good
Clean the commutator surface. condition, install the brushes and
Wipe the commutator with a dry, lint- brush springs into brush holders. Be
free cloth. DO NOT USE LUBRICANT sure brush spring is correctly in
OR SOLVENT ON THE COMMUTATOR. place on the brush and that brush
slides freely in brush box.
Check appearance of commutator surface
where the brushes ride. Inspect the 10 Clean and check brush box and
commutator bars for burned, damaged, connector screws, as applicable.
or raised areas. The best signs of Tighten if loose. Be sure the
good commutation are a dark brown- brush shunt connection is tight.
colored, highly-polished commutator and Install brush cover on motor case.
uniform glossy brush-wearing surfaces.
11 Check and tighten all motor bolts.
Refer to the COMMUTATOR CHECK CHART at
Check the lower nut on each terminal
the end of this section.
post. It should be installed finger-
tight, then tighten another l/4-turn
Measure and make a record of brush
with a wrench.
length at each inspection. The record
will verify the amount of brush wear
Measuring Brush Spring Tension
and indicate if there is enough brush
length remaining until the next Put a piece of paper between the
scheduled inspection. brush and commutator.
Use a spring scale with its hook or
Brushes must be replaced when worn to
an adapter fitted around the spring
approximately half their original
between the brush and spring, at the
length.
point where the spring presses on
BRUSHES MUST BE REPLACED WHEN WORN TO the brush.
DIMENSION NOTED IN TRUCK SPECIFICA-
Pull the scale to lift the brush
TION. REFER TO GROUP 40, SECTION 5.
spring until the paper under the
brush can be moved freely in the
IMPORTANT
direction of rotation of the
NEW BRUSHES MUST BE THE SAME SIZE motor. Measure the tension.
AND GRADE (MATERIAL SPECIFICATION)
Replace the spring if the tension
AS THE OLD BRUSHES.
is too weak (does not meet the
Observe how brushes are assembled in spring tension specification).
the brush holders, and position of Refer to GROUP 40, Section 5.
brush lead (brush shunt). New brushes
must be installed in same manner.
Code: PMA-540, NOV a5 GROUP 16, Section 1, Page 5

GROUP CL!RK
16
BRUSH INSPECTION
IF SPRING TENSION IS NOT THE SAME

REPLACE BRUSH IF OIL SOAKED
FOR EACH BRUSH, REPLACE SPRINGS. I I
I 1
IF BRUSH PIGTAIL
IS LOOSE AT THE
IN THE BRUSH. BRUSH I-QLDER -
TIGHTEN SCREW.
I-
* REPLACE BRUSHES -
;Vt.&N WORN TO
.
4
NEW BRUSHES
*Refer to motor brush specifications.

Measurement should be taken to the
longest side on commutator contour.
Continued use of worn-out brushes will result in damage

to commutator and impaired performance. Always replace
brushes with original equipment parts.

GEA-7053
c s
SATISFACTORY COMMUTATOR SURFACES
LIGHT TAN FILM over en+ire commu,qtor MOTTLED SURFACE with random film pat- SLOT BAR-MARKING, a slightly darker
surface is one of many normal conditions tern is probably most frequently observed film, appears on bars in a definite po++ern
ohen seen on o well-functioning machine. condition 01 tommutator~ in industry. related to number of conductors per slot. +or and, if uniform, is quite atceptable.
WATCH FOR THESE DANGER SIGNS
STREAKING on the commutator surface signals the THREADING of commutator with fine lines results GROOVING is CI mechanical condition caused
beginning of serious metal transfer to the carbon when excessive metol transfer QCCUR. I+ usually leads by obmsive material in the brush or otmos-
brush. Check the chart below for possible causer. to resurfacing of ~omnwt~ltor and rapid brush wear. phere. If grooves form, s+ort corrective action.
COPPER DRAG, cm abnormal build-up of commutator PITCH BAR-MARKING produces low or burned spots HEAVY SLOT BAR-MARKING <on involve
material, forms mos+ ohen ot trailing edge of bar. Con- on the commutator surface. The number of there mork- etching of trailing edge of commutator bar. Pat-
dition is rare but can cause flashover if no+ checked. ingr equals half or all the number of poles on the motor. +ern is related to number of conductors per slot.
How to Get the Most Value from This Chart
Carbon Products
General Electric Company
East Stroudsburg, Pa. 18301
GROUP
GL4RU 16
GROUP
16
SECTION
DRIVE MOTOR BRUSH REPLACEMENT
GROUP 16, Section 2, Page 1

Code: PMA-540, NOV 85
GROUP
16
16.034
ASSEMBLY
COMPLETE -
16.000
16.034-
I/BRUSH AND SPRING

KIT
INCLUDESITEMS
MARKED “K”
-16.018
\.
x
r
16.017
OA
+- I”
DRIVE MOTOR 16-069
16.000 MOTOR ASSEMBLY, DRIVE

16.002 BEARING, DRIVE MOTOR COMMUTATOR END
16.004 RETAINER, DRIVE MOTOR COMMUTATOR END BEARING
16.006 BRUSH HOLDER KIT, DRIVE MOTOR
16.011 ARMATURE, DRIVE MOTOR
16.014 COIL SET, DRIVE MOTOR FILED

16.017 CAPSCREW, 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 MOTOR ARMATURE

16.078 FRAMF.ASSEMBLY, DRIVE MOTOR DRIVE END
16.079 FRAME ASSEMBLY, DRIVE MOTOR COMMUTATOR END
16.084 COVER, DRIVE MOTOR COMMUTATOR END BEARING
15N HOUSING, DRIVE MOTOR USE 16.000

GROUP
CLRRW;
16
DRIVE MOTOR REMOVAL FROM TRUCK
Remove the battery from truck

(See GROUP 12, Section 1).
Adjust the front battery plate for mainte-
nance access. Refer to GROUP 38, Section 2.
Loosen and remove the drive motor mounting

85M674
The bottom motor mounting bolt may be

85M763
NOTE - Attach label tags to the cables

Replace the nuts on motor terminals to
avoid losing them.
85M675

rear of truck and into battery compartment.
Motor can be temporarily rested on frame
crossmember. NOTE - At this point the
brush openings are accessible from the
battery compartment and brushes may be
inspected or replaced without further
removal of the motors. However, the motors
may be fully removed from truck, as noted
below, for better access to brushes.
85M677

GROUP CUIRK
16
NOTE - Motor can be removed either from

the battery compartment or up through
the center of truck, as shown here.
7 Each drive motor can now be removed from

the truck by lifting up through the center
of truck.
Drive motor weight: [ZO kg] 44 lbs.
85M676
Refer to PM Section, and GROUP 16, Section 1,
for inspection of drive motor brushes.
DRIVE MOTOR BRUSH REPLACEMENT
1 Remove the plastic brush covers by squeezing

or prying the locking tabs from the slots
in the sides of opening. Air clean the
inside of the motor around the commutator
and brushes, using dry (moisture-free) air.
85M717
Brush Removal
NOTICE - Observe how brushes are assembled

in brush holders and position of brush lead.
New brushes must be installed in same manner.
a. Move brush spring clip from its

mounting on brush assembly.
b. Disconnect brush assembly lead.

85M719
c. Lift brush assembly from brush holder.
Remove any carbon dust or dirt from brush

holder assembly.
85M715

GROUP
CMRK 16
Brush Replacement
1 New brush assemblies to be installed by

reversing above removal procedure.
a. Install brush with the lead wires

positioned as when removed.
b. Install brush assembly into brush

holder.
85M718
c. Connect brush lead assembly.
d. Install brush spring.
85M719
Repeat brush installation for all brushes.
Be sure that all brushes are free (move

easily) in the holder.
When brush installation is completed, install

the brush covers on motor.
85M717
Drive Motor Instal1ation
1 Install drive mo tors in truck by reversing

the procedure of removal. Be sure motor
shaft spline and mounting flange is clean
and O-ring seal installed correctly on
pilot flange of motor before installation.
Motor mounting bolt torque:

[70-80 N.m] 52-59 lbf.ft.
85M688

CMRlilC GROUP
16
GROUP
16
SECTION
STEER MOTOR BRUSH REPLACEMENT

GROUP
16
___ .
INCLUDES ITEMS
MARKED “I” 16.209, -
16.208, I
/
L16.258
16.212
--A_ /
STEER PUMP MOTOR

16-300
16.200 MOTOR ASSEMBLY, STEER PUMF

16.208 BEARING, STEER PUMP MOTOR DRIVE END
16.209 ARMATURE, STEER PUMF MOTOR
16.211 BEARING, STEER PUMP MOTOR COMMUTATOR END
16.212 SPRING WASHER, STEER PUMP MOTOR COMMUTATOR END BEARING
16.218 BRUSH KIT, STEER PUMP MOTOR

lb.223 COVER, STEER PUMP MOTOR BRUSH HOLE
16.231 CONDUCTOR, STEER PUMP MOTOR CROSS
16.232 COVER, STEER PLRQ MOTOR BRUSH HOLE
16.233 FASTENER, STEER PUMP MOTOR BRUSH HOLE COVER
16.234 TERMINAL KIT, STEER PUMP MOTOR

16.238 BRUSH HOLDER KIT, STEER PUMP MOTOR
16.239 FASTENER, BRUSH HOLDER MOUNTING RING
16.251 FASTENER, STEER PUMP MOTOR COMMUTATOR END FRAME
16.258 FRAME, STEER PUMP MOTOR DRIVE END
16.259 FRAME, STEER PUMP MOTOR COMMUTATOR END

92.550 NUT, STEER PUMP MOTOR BRUSH HOLE COVER FASTENER
18N BODY, STEER PUMP MOTOR USE 16.200

GROUP
C14RK 16
STEER PUMP AND MOTOR REMOVAL FROM TRUCK
NOTICE - Inspection of the steer pump motor

requires removal of the sump filter mounting
bracket, disconnection of the hydraulic lines
from pump, and removal of the motor from its
mounting on the front battery plate.
1 Adjust front battery plate for maintenance

access. (Refer to GROUP 38, Section 2.)
85M861
2 Loosen and remove the nuts from the mounting

bolts, then remove hydraulic oil filter
mounting bracket from the battery plate.
8514707
3 Put the bracket, with hydraulic lines and

filter attached, aside out of the way.
85M682
4 Loosen the clamp and remove intake hose

from pump.
85M695

GROUP CMRK
16
5 Disconnect the high pressure hydraulic

line from pump.
Put caps on all fittings for their

protection.
85M696
6 Be careful to avoid losing or damaging

the O-ring seal in the tube fitting.
85M697
7 Disconnect the power cables from motor

terminals. Attach label tags to the
cables for easy identification at
assembly.
85M880
8 Loosen and remove motor mounting nuts (four)
from bolts, at front side of battery plate.
NOTE - Wrench clearance is limited at the

outer (L.H.) side by the frame. Wrench must
be turned and re-positioned frequently while
removing and installing the nuts. DO NOT
LOOSEN OR ATTEMPT TO REMOVE THE SOCKET-HEAD
BOLTS FROM THE BATTERY COMPARTMENT SIDE.
They are fastened in place with locknuts
(spacers) at front side of battery plate
under the motor mounting plate flange.
25465
GROUP 16, Section 4, Page 4 Code: PM-540, NOV 85

CMRK GROUP
16
9 Steer motor may now be removed. Raise

motor and pump assembly up and out of
truck.
85M698
STEER MOTOR BRUSH INSPECTION/REPLACEMENT
Brush Removal

in brush holders and position of brush lead.
New brushes must be installed in same manner.
85M701
1 Remove the brush cover band by removing the

clamping screw and prying the cover pins out
of engagement in the motor housing.
Also, see Figure 85M699, Page 7.
Air clean the inside of motor around the

brushes and commutator, using dry
(moisture-free) compressed air.
85M700
2 Brushes should be removed, as follows:
a. Move brush spring clip from its

mounting on brush assembly.
85M702

GROUP CMRK
16
3 Remove any carbon dust or dirt from brush

ring assembly.
85M703
4 Inspect the condition of the b,rushes.
Remove each brush from the brush holder and

inspect the brushes and commutator for worn
condition and uneven wear, electrical arcing,
etc. Refer to GROUP 16, Section 1, for more
information on motor maintenance and brush
inspection.
Brush Replacement
1 New brush assemblies to be installed by

reversing above removal procedure.


holder.
85M703
85M702

Cl!!!!Rl4 GROUP
16
2 Repeat brush installation for all brushes.
3 Be sure that all brushes are free (move

easily) in the holder.
4 When brush installation is completed, install

the brush covers on motor.
' i^'(
,_,,
85M699
STEER MOTOR INSTALLATION
1 Install steer motor to the battery plate,

by reversing the procedure for removal.
Be sure motor mounting nuts are tightened
completely and correct1Y.
25465
2 Connect hydraulic lines to pump.

Check that both hose and tube connections
to the pump are tightened correctly.
Check that the pump mounting bolts are

tightened correctly. Corrrect tightening
torque is [40-45 N.m] 29-33 lbf.ft. for
pump bolts.
894696
3 Connect the power cables to steer motor.
85M880

GROUP Cl!!RN
16
4 Install the hydraulic oil filter mounting

bracket to the battery plate.
Check that the hydraulic line connec-

tions to the filter are all tightened
correctly.
85M642

GROUP
EDIRK 16
GROUP
16
SECTION
22R
STEER PUMP AND MOTOR ASSEMBLY REMOVAL

Park truck on a level surface and

0 Return all controls to neutral and turn
0 Apply the parking brake.
l Block the wheels.
85M626
Truck Preparation
?emove floorboard.
?emove cover from main valve.
3pen hood.
disconnect battery from truck receptacle.
Remove battery from truck.
Adjust front battery plate for
naintenance access.
See Page 2 for additional information.
Code: OH-540, MAR 86 GROUP 16, Section 22R, Page 1

GROUP CMRK
16
85M482
1 Turn key switch "OFF". 5 Remove battery from truck. Refer

to GROUP 12, Section 1.
85M506 85M762
2 Remove floorboard and cover from 6 Adjust front battery plate to

main valve. maintenance position. Refer
85M541 85M850
3 Open hood. 7 Put a drain pan under truck at

4 Disconnect battery from truck steer motor position.
receptacle.
GROUP 16, Section ZZR, Page 2 Code: OH-540, MAR 86

CL!!RH GROUP
16
STEER PUMP AND MOTOR 26-420
16.200 MOTOR ASSEMBLY, STEER PUMF
16.243 FASTENER, STEER PUMP MOTOR MOUNTING BRACKET
16.535 SPACER, PUMP MOTOR MOUNTING
29.200 PUMP ASSEMBLY, STEER
29.269 FASTENER, STEER PLJMP
90.887 WASHER, STEER PLlMPMOTOR FASTENER
90.889 NUT, STEER PUHP MOTOR MOUNTING FASTENER
90.891 LOCKWASHER, STEER PUMP FASTENER
93.280 RETAINER, STEER PUMP MOTOR MOUNTING BRACKET FASTENER

GROUP
16
STEER PUMP AND MOTOR ASSEMBLY REMOVAL
1 Remove plastic strip (floorboard support).

This part is held in place by fitting
over tabs projecting from the front
battery compartment plate.
85M671
2 Loosen and remove the nuts from the
mounting bolts, then remove hydraulic
oil filter mounting bracket from the
battery plate.
85M707

85M685

from pump.
85M695
GROUP 16, Section ZR, Page 4 Code: OH-540, MAR 86

CMRK GROUP
16

line from pump.

protection.
85M696

85M697
7 Disconnect the power cables from motor

terminals. Attach label tags to the
cables for easy identification at
assembly.
85M880
8 Loosen and remove motor mounting nuts from
bolts, at front side of battery plate.
NOTE - Wrench clearance is limited at the

outer (L.H.) side by the frame. Wrench must
be turned and re-positioned frequently whiie
removing and installing the nuts. DO NOT
LOOSEN OR ATTEMPT TO REMOVE THE SOCKET-HEAD
BOLTS FROM THE BATTERY COMPARTMENT SIDE.
They are fastened in place with locknuts
(spacers) at front side of battery plate
under the motor mounting plate flange.
25465

GROUP CMRK
16
9 Steer motor may now be removed. Raise

motor and pump assembly up and out of
truck.
Motor and pump assembly weight is

approximately [9.5 kg] 21 lbs.
85M698
STEER PUMP REMOVAL FROM MOTOR
1 Remove the four pump mounting bolts.
Pump mounting bolt torque:

[40-45 N.m] 29-33 lbf.ft.
85M721
2 Remove the pump from motor.
85M720
3 Inspect pump shaft coupling for wear

and damage.
Put the pump in a safe location to

protect from damage until required
for reassembly.
85M722
GROUP 16, Section ZZR, Page 6 Code: OH-540, MAR 86

GROUP
WIRW; 16
STEER PUMP AND MOTOR INSTALLATI0N
Install steer pump to motor. Pump mounting

bolt torque is [40-45 N.m] 29-33 lbf.ft.
85M721
Install steer motor to the battery plate,

by reversing the procedure for removal.
Be sure motor mounting nuts are tightened
completely and correctly. Refer to NOTE,
Page 5.
Mounting nut tightening torque is

[ZO-25 N.m] 177-221 lbf.in.
25465
Connect hydraulic lines to pump. Be sure

that O-ring seal is installed correctly in
tube fitting. Check that both hose and
tube connections to the pump are tightened
correctly.
85M696
4 Connect the power cables to steer motor.
85M879

GROUP CMRH
16
5 Install the hydraulic oil filter mounting

bracket to the front battery plate.
Mounting bolt and nut tightening

torque is [140-154 N,m] 103-114 lbf.ft.
85M707
6 Check that the hydraulic line connections

to the filter are all tightened correctly.
85M642
GROUP 16, Section 22R, Page 8 Code: OH-540, MAR 86

GROUP
16
GROUP
16
SECTION
22
STEER PUMP MOTOR OVERHAUL
[ D.C. PERMANENT-MAGNET MOTOR]
NOTICE
1 The permanent magnet motor differs from conventional

D.C. motors in that the field winding has been replaced
with ceramic magnet pole pieces.
IMPORTANT - DO NOT IMPACT MOTOR HOUSING OR COMPONENTS

(STRIKE WITH HAMMER, ETC.), DROP, OR SQUEEZE THE MOTORS
AS THIS CAN CAUSE DAMAGE TO THE CERAMIC POLE PIECES AND
WILL AFFECT WARRANTY CONSIDERATIONS.
2 Care must be taken when the permanent magnet motor is

disassembled, since the magnet pole pieces will attract
ferrous metals (iron and steel).
IMPORTANT - PERMANENT-MAGNET MOTORS SHOULD BE

DISASSEMBLED ONLY IN AN AREA FREE OF FERROUS METAL CHIPS.
Code: OH-540, MAR 86 GROUP 16, Section 22, Page 1

GROUP CMRK
16
STEER PUMP MOTOR FEATURES
Item Description
1 Armature assembly
2 Stator assembly
3 Drive end cover
4 Hole plug
5 Brush inspection cover
6 Bearing spring washer
7 Bearing-Commutator end
Bearing-Drive end
; Commutator cover
10 Brush ring assembly
11 Brush
12 Terminal bolt and lead assembly
View A-A
GROUP 16, Section 22, Page 2 Code: OH-540, MAR 86

GROUP
16
- 16.238
.-__ . .._ 16.211, \\ Y-r/\\
16.208 -, B
/
16.2j,_/+\‘$.
16.212
STEER PUMP MOTOR 16-300
16.200 MOTOR ASSEMBLY, STEER PUMP

16.208 BEARING, STEER PUMP MOTOR DRIVE END
16.209 ARMATURE, STEER PUMP MOTOR
16.211 BEARING, STEER PUMP MOTOR COMMUTATOR END
16.212 SPRING WASHER, STEER PUMP MOTOR COMMUTATOR END BEARING
16.218 BRUSH KIT, STEER PUMP MOTOR

16.223 COVER, STEER PUMP MOTOR BRUSH HOLE
16.231 CONDUCTOR, STEER PUMP MOTOR CROSS
16.232 COVER, STEER PUMF MOTOR BRUSH HOLE
16.233 FASTENER, STEER PUMP MOTOR BRUSH HOLE COVER
16.234 TERMINAL KIT, STEER PUMP MOTOR

16.238 BRUSH HOLDER KIT, STEER PUMP MOTOR
16.239 FASTENER, BRUSH HOLDER MOUNTING RING
16.251 FASTENER, STEER PUMP MOTOR COMMUTATOR END FRAME
16.258 FRAME, STEER PUMP MOTOR DRIVE END
16.259 FRAME, STEER PUMP MOTOR COMXUTATOR END

92.550 NUT, STEER PUMP MOTOR BRUSH HOLE COVER FASTENER
18N BODY, STEER PUMP MOTOR USE 16.200

GROUP CMRK
16
MOTOR TROUBLESHOOTING
1 Try to turn the shaft by hand. Keep motor

leads, if attached, separated while doing this.
If the shaft won't turn, proceed to item-Z.
If the shaft turns freely, go to item 3.
85M724
2 The shaft could be tight for several reasons.

This check is to determine if the tightness
is of a temporary nature only.
Step 1: You will need a power source equal

to the nameplate voltage (36 volt), e.g., 0
use the truck battery with a cable adapter. 36~
Step 2: Provide power cable leads between

motor and power source. DO NOT MAKE A
PERMANENT CONNECTION.
26558
Step 3: First, touch the motor leads

quickly to the power supply just long
enough to observe if the shaft turns.
If it does turn, then hold the motor leads I I I i
0
on the power supply for a longer time.
If the motor sounds normal, go to item 3.
If the motor sounds noisy, it should be O------l
I bC
A
K
disassembled (described later). 36v -
26566
3 If the motor turned freely, connect an

ammeter in the circuit as shown in Figure
26559. With rated voltage applied and
the shaft running free, the ammeter should
read less than 20% of the nameplate full
load current. If the motor meets the
above conditions then it can be assumed
the original problem is external to
the motor. A higher current reading
indicates a faulty armature.
26559

GROUP
CMRW 16
BRUSH REMOVAL AND INSPECTION
1 Loosen and remove the clamping screw in

the brush cover band.
85M699
2 Remove the brush cover band segments by

prying the cover pins out of engagement
in the motor housing.
3 Air clean the inside of

motor around the brushes
and commutator, using dry
(moisture-free)
compressed air.
85M700

in brush holders and position of brush lead
(shunt). New brushes must be installed in
same manner.
4 Brushes should be removed, as follows:
a. Remove brush spring clip from its

mounting on top of brush assembly.
Use a brush hook to reach into the
motor and lift the brush springs.
85M702

GROUP CLrlRK
16
85M703
5 Remove any carbon dust or dirt from

brush ring assembly.
6 Inspect the condition of the brushes.
Remove each brush from the brush holder

and inspect the brushes and commutator
for worn condition and uneven wear,
arcing, etc. Refer to GROUP 16,
Section 27, for more information on
motor maintenance and brush inspection.
85M701
7 When reassembling the motor, replace the

brushes (complete set), as needed, by
reversal of above procedure. See Page 13.
NOTICE
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 holders.
86MO24
Also see Figure 86M001, above.

GROUP
CL!RK 16
MOTOR DISASSEMBLY
IMPORTANT - Do not place the stator ring (motor housing) in any

mechanical holding device (e.g., vise) during the disassembly or
assembly operation. Permanent distortion or other damage will
result. With the motor disassembled, care must also be taken not
to drop the stator ring assembly, since it can be distorted.
Motor may be held by clamping on the mounting bracket.
NOTE - Before disassembling motor, note that there are match

marks on the stator assembly housing and the commutator cover.
If marks are not visible, use a scribe tool to make match marks.
These marks will be used at assembly (page 13).
IMPORTANT
Remove brush cover band, if installed.
Refer to Page 5. PERMANENT-MAGNET MOTORS SHOULD BE
DISASSEMBLED ONLY IN A CLEAN AREA
Remove the brushes. Refer to Page 5. FREE OF FERROUS (IRON, STEEL)
METAL CHIPS.
IMPORTANT - If brushes are left in-

stalled, raise all of the brushes to the
locked position, noted on page 6.
Remove pump drive coupling segment from

motor shaft end.
Refer to GROUP 26, Section 14, for

information on pump drive coupling.
86M002
4 Loosen motor assembly thru-bolts

at commutator-end cover.
Wrench size: 3/8" hex.
86M003

GROUP CWRK
16
5 Remove the thru bolts from assembly.
86M004
6 Scribe a match mark on cover and housing,

then remove the drive end (pump mounting)
cover. Carefully pry on cover to loosen.
Tap lightly on the pry bar, if necessary.
7 The drive end bearing may now be

inspected.
NOTE - Be sure that parts have match marks

before disassembly.
8 Then, the commutator end cover may be re-

moved for inspection of the commutator and
the commutator-end bearing. Remove and
save the bearing spring washer from the
cover bore.

GROUP
16
9 Carefully inspect the commutator-end bearing

and commutator surface for wear, burning, or
other damage that will require repair or re-
placement of parts.
NOTE - It may not be necessary to remove

the armature, unless other inspection and
tests show requirement for repair or serv-
icing of the stator assembly, armature or
bearings. See discussion of procedure
below.
86M009
Armature Removal - Recommended Procedure
To avoid damage to either the armature or

permanent magnets, it is recommended that
the armature be removed only with the
motor housing and armature shaft position-
ed vertically.
Reassemble either the commutator-end cover

or the drive end cover to the armature
shaft and stator housing.
Support and hold the stator housing firm 1Y

on the end cover (a second person is sug
gested).
Pull the armature out of the assembly in

one quick motion. IT IS IMPORTANT THA T
THE PULLING MOTION ON THE ARMATURE BE
CONTINUOUS. 00 NOT PULL PART WAY dUT
AND RELEASE. If this is done, the
magnets will pull the armature back into
“I
the stator and cause severe damage.
26604
4 Remove the end cover from the stator

housing.
(Commutator-end cover with brushes

in the "locked" position shown.)
86MOO5

GROUP
16
COMPONENT TROUBLESHOOTING
With the motor disassembled, go through the following checklist

to locate the problem:
A. Bearings - Should spin smoothly and easily, have ample

lubrication and be free of 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 runout. Refinish
commutator surface if pitted or excessively worn.
C. Stator - Check magnets to be sure they are securely mounted.
D. Inspect wire harness and all connections on brush ring

assembly for signs of damage due to overheating.
E. Brushes - Remove any carbon dust or dirt from brush ring

assembly. Check brushes for wear and that they are free
in the brush holders.
STEER PUMP MOTOR SPECIFICATIONS (Reference GROUP 40, Section 5)
Weight: [19.3 kg] 43 lb
Brush Grade: Clark No. per Holder: 1 No. per Motor: 4
Brush Dimensions: Length [28,7 mm] 1.13 in

Width I;";; ;;j $I; 1;
Thickness
Replace @ Worn Length [lo:65 mm] .420 in on longest side
Brush Spring Tension (force per brush) NEW: [782-870 g] 27.6-30.7 oz

WORN: [326-357 g] 11.5-12.6 oz

Cl!FlRICl GROUP
16
MOTORRECONDITIONING
1 Check commutator condition for carbon

build-up in undercuts between bars and
excessive wear and runout, prior to
reassembly. If necessary, commutator
should be turned and re-undercut.
18415
Refer to GROUP 16, Section 27, General

Motor Maintenance, for additional infor-
mation.
Bearing Replacement
NOTE - Do not reuse bearings which

have been removed from armature shaft.
1 Remove bearings with a standard ball

bearing puller. Use extreme care not to
damage armature with bearing puller.
(Typical view of bearing puller shown)
84M520
2 Install new bearings on armature shaft.

New bearings should be installed by
pressing inner race of bearing into
correct position against shoulder on
the armature shaft.
Bearing Lubrication
Replacement bearings are packed with lubri-

cant during manufacture and require no
further lubrication during the life of 26641
the bearing.

GROUP CMRK
16
MOTOR REASSEMBLY - Reconmended Procedure
1 Place commutator cover on a work bench

with brush ring assembly facing upward.
NOTE - If brushes are installed, raise

all brushes to the locked position.
86M005
2 Place the bearing spring washer into

bearing bore in commutator cover.
26640
3 Take a complete armature assembly, with

bearings installed, and insert commutator
end bearing into the bearing bore of cover.
Keep armature assembly in a vertical
position.
4 The next step is to place the complete

stator assembly down over the vertical
armature, and into position on the
commutator cover.
CAUTION - Care must be exercised at this

point. There is a strong magnetic attrac-
tion between the stator assembly and the
armature, which tends to pull the stator
assembly rapidly downward. It is important
to have a firm grasp on the stator assembly
and be sure fingers are free from the space 26606
between stator assembly and commutator
cover.

GROUP
16
5 The stator assembly must be placed in a

definite relationship with the commutator
cover in order to obtain a neutral brush
setting. There should be match-marks on
both items. These two marks must line up
exactly. Rotate stator or cover until
they do.
(Typical view shown)
18410
6 Assemble the drive end cover in the

correct relationship. Install mounting
thru bolts and tighten alternately to
ensure a good mechanical alignment. Do
not use a hammer or excessive force.
86M004
7 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 8, below.
26643
8 Install new brushes by reversing the

removal procedure:

holder. Be sure all brushes are
free in the holder.
d. Install brush spring clip on top
of brush.
85M703

GROUP Cl!!!!RIC
16
9 Install brush cover.
10 Install pump drive coupling segment.
85M699
11 Spin the shaft by hand to check if it is

free. Be sure motor leads (if attached)
are not touching together. If the leads
are touching, a generator action will
give the effect of friction in the motor.
85M724
12 A no-load test can now be performed.

Refer to "Motor Troubleshooting",
Page 4, Item 3.
26559
At rated voltage, observe the no-load

current. It should be less than 20% of
the nameplate full-load current.
A higher reading indicates:
1) Brushes are not on neutral setting

(check match-marks for exact align-
ment).
2) Faulty armature.

CVBRK GROUP
16
SECTION
23R
DRIVEMOTOR REMOVAL


Block the wheels.
NOTE - It is optional to raise and block up

entire truck. Refer to GROUP 38, Section 3,
Machine Jacking and Blocking.
Truck Preparation
Remove floorboard.
Remove main valve cover.
Open hood.
Adjust front battery plate for access.

GROUP CLRRU
16
85M482 85M750
1 Turn key switch "OFF". 6 Remove battery from truck.

Refer to GROUP 12, Section 1.
85M617 85M667
2 Remove floorboard. 7 Adjust front battery plate to

3 Remove cover from main valve. maintenance position. Refer
85M616 85M850
4 Open hood. 8 Put a drain pan under truck at

5 Disconnect battery from truck the drive motor flange positions
receptacle. to catch drive axle fluid.

CMRK GROUP
16
LDRIVE MOTOR
DRIVE MOTOR INSTALLATION

26569

GROUP CMRIS
16
DRIVE MOTOR REMOVAL FROM TRUCK
Loosen and remove the drive motor mounting

NOTE - Be sure drip pan is located

under the drive unit flange to
catch any drive axle fluid which
may drain from drive unit.
85M674
The bottom motor mounting bolt may be

85M763
NOTE - Attach label tags to the cables

avoid losing them.
85M675

rear of truck and into battery compartment.
Motor can be temporarily rested on frame
crossmember.
85M677

GROUP
ELfIRK 16
5 The drive motor can now be removed

from the truck.
NOTE - Motor can be removed either from

the battery compartment or by lifting up
through the center of truck, as shown here.
Drive motor weight: [ZO kg] 44 lb., approx.
85M676
DRIVE MOTOR INSTALLATION
1 Be sure motor shaft spline and mounting

flange is clean and O-ring seal installed
correctly on pilot flange of motor before
installation.
85M704
2 Install drive motors in truck by reversing

the procedure of removal.
Motor mounting bolt torque:

[70-80 N.m] 52-59 lbf.ft.
85M688
3 Connect power cables to motor terminals.
Refer to GROUP 14, Section 1, Page 3,

for information on power wiring.
85M705

GROUP
16
GROUP
16
SECTION
23
DRIVE MOTOR OVERHAUL

Code: OH-540, MAR 86
GROUP
16
Gl!!!!RK
16.034
ASSEMILY
16.000
COMPLETE -
I I
16.034
INCLUDES ITEMS
\ 16.014
’
NON SERVICRM!LE
ITEMS MARUED’k”
DRIVE MOTOR 16069-l
16.000 MOTOR ASSEMBLY, DRIVE

16.002 BEARING, DRIVE MOTOR COMMUTATOR END
16.004 RETAINER, DRIVE MOTOR COMMJTATOR END BEARING
16.006 BRUSH HOLDER KIT, DRIVE MOTOR
16.011 ARMATURE, DRIVE HOTOR
16.014 COIL SET, DRIVE HMOR FILED

16.017 CAPSCREW, DRIVE MOTOR POLE SHOE
16.018 BRUSH KIT, DRIVE MOTOR
16.029 SEAL, DRIVE MOTOR ARMATURE SHAFT DRIVE END
16.034 TERHINAI.KIT, DRIVE MOTOR
16.036 FAN, DRIVE MOTOR ARMATURE

16.078 FRAME ASSEKBLY, DRIVE MOTOR DRIVE END
16.079 FRAHE ASSEHBLY, DRIVE MOTOR COMMUTATOR END
16.084 COVER, DRIVZ:MOTOR COK?lUTATOREND BEARING
15N EOUSING, DRIVE MOTOR USE 16.000

CLRRK GROUP
16
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
TIVE CLOTHING WHEN CLEANING
(moisture-free) air. OR DRYING WITH AIR PRESSURE.
REDUCE PRESSURE 10,[207 kPa]
85M717
NOTICE - 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
lift the brush springs.
4 Lift each brush assembly from brush holder.
5 Clean any carbon dust or dirt from

brush holder assemblies.
85M718

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.

brushes (complete set), as needed, by re-
versal of removal procedure. Also, see 85M715
Page 10.

GROUP ClrlRK
16
MOTORDISASSEMBLY
NOTICE - 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 holders.
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.
1 Remove plastic brush covers, if in-

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

replaced. Refer to Page 3.

stalled, raise all of the brushes to
the locked position (Figure 26568).
26568

CMRK GROUP
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.

GROUP CLRRK
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.
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.
9 Remove the armature assembly from the

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.
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.

Cl!!lRK GROUP
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 holder insulation 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)
Weight: [24.5 kg] 54 lb Brushes/Holder: 1 Brushes/Motor: 4
Brush Dimensions: Length [35 mm] 1.38 in

Width [32 mm] 1.26 in
Thickness [tfi6; rnrrmj.498 in
Replace @ Worn Length , m .57 in on longest side
Brush Spring Tension (force per brush) NEW: [935-1077 g] 33-38 oz

WORN: [453 g] 16 oz

GROUP Cl!!RK
16
MOTORRECONDITIONING

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):
1 To remove bearing from end frame, first

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

end-frame bore.
26616
3 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.
26618

CMRI4 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

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.

GROUP CLRRR
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),


Step 10, below.
26643

removal procedure:
a. Install brushes with the lead wires

b. Install brush assemblies into brush
free in the holder.
c. Connect brush lead assemblies.
of each brush.
86M015
11 Install the plastic brush covers.
85M717

ClRRllC GROUP
16
GROUP
16
SECTION
24R
LIFT PUMP AND MOTOR ASSEMBLY REMOVAL
TO perform this service procedure, it is

ret:ommended that you first:
0 Park truck on a level surface and

l Apply the parking brake.
l Block the wheels.
85M626
Truck Preparation
Open hood.
Remove floorboard.
Remove cover from main valve.
maintenance access.

GROUP
16
85M482 85M847
1 Turn key switch "OFF". 5 Remove floorboard.

6 Remove cover from main valve.
85M541 85M862
2 Open hood. 7 Adjust front battery plate to

3 Disconnect battery from truck maintenance position. Refer
receptacle. to GROUP 38, Section 2.
85M751 85M850
4 Remove battery from truck. 8 Put a drain pan under truck

Refer to GROUP 12, Section 1. at lift motor location.

CLSRK GROUP
16
LIFT PUMP & MOTOR INSTALLATION
26570

GROUP CL!lRK
16
LIFT PUMP AND MOTOR ASSEMBLY REMOVAL
1 Clean the fittings and disconnect the

hydraulic lines from the lift pump.
Put caps on all fittings to protect
from dirt and damage.
85M714

from front battery plate.
3 Loosen and remove the bolt from the

motor mounting strap.
85M686

Replace the nuts on motor terminals
to avoid losing them.
NOTE - Put tags on the cable terminals
5 Spread the ends of the mounting strap

sufficient to remove the lift motor
from the truck.
85M684

16
LIFT PUMP REMOVAL FROM MOTOR
1 Loosen and remove the two pump mounting

bolts from motor flange, using an
internal hex wrench.
Pump Mounting Bolt Tightening

Torque: [65-73 N.m] 48-54 lbf.ft.
26629;
26628
2 Pull the pump away from the motor flange

until pump drive shaft is disengaged
from spline in motor shaft.

Main Table of Contents GROUP
16
GROUP
16
SECTION
24
LIFT PUMP MOTOR OVERHAUL

GROUP
16
16.,,?--E
r16.505
II MARKED
"I("
RRUSH HOLDER AND

161515 - RRUSH KIT
INCLUDES ITEMS
MARKED “It’ ,
16.533 -, /
ASSEMRLY
PUMP MOTOR
16-162
16.500 MOTOR ASSEMBLY, HYDRAULIC PUMP

16.502 BEARING. HYDRAULIC PUMP MOTOR DRIVE END
16.503 ARMATURE, RYDRAULIC PUMP MOTOR
16.504 WASliER,PUMF MOTOR COMHUTATOR END THRUST
16.505 COIL SET, i'UKPMOTOR FIELD
16.506 TERHINAL KIT, HYDRAULIC PUMP MOTOR

16.507 FASTENER, PUMF MOTOR FIELD COIL SET
16.508 COVER, PUMP MOTOR BRUSB ACCESS
16.511 FRAME, PUMP MOTOR COMMUTATOR END
16.513 BRUSR KIT, RYDRAULIC PUMP MOTOR
16.515 HOLDER KIT, RYDRAULIC PUMP MOTOR BRUSH

16.519 BEARING, PUMP MOTOR COtQ4UTATOREND
16.533 FRAME, HYDRAULIC PUHP MOTOR DRIVE END
16.536 FAN, HYDRAULIC PUMP MOTOR ARMATURE
16.555 RETAINER, PUMP MOTOR DRIVE END BEARING
16N BODY, RYDRAULIC PUKP MOTOR USE 16.500

GROUP
16
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 TIVE CLOTHING UHEN CLEANING
(moisture-free) air. OR OWING WITH AIR PRESSURE.
REDUCE PRESSURE TO [207 kPa]
(Shown in truck)
85M709
NOTICE - 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
lift the brush springs.
4 Lift each brush assembly from brush holder.
5 Clean any carbon dust or dirt from

brush holder assemblies.
86M017
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.

brushes (complete set), as needed, by re-
versal of removal procedure. Also, see
Page 10.

GROW’
16
MOTOR DISASSEMBLY
NOTICE - 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 holders.
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.
26622
1 Remove plastic brush covers, if in-

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

replaced. Refer to Page 3.

stalled, raise all of the brushes to
the locked position (Figure 26568).
26568

CUMW GROUP
16
3 Use an impact tool set to loosen, and

to torque, the mounting screws in the
end frames.
(Typical view of tools shown)
86M012
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.
(Typical view showing use of tools)
86M013
6 Remove the mounting screws, then remove

commutator-end frame. See NOTE, Item 7
below.
NOTICE - Two interconnecting wires from

the internal electrical circuit to field
coils must first be disconnected from
brush holder assembly before end can be
removed. Tag, or make note of where
these wires attach at assembly.
26607
Remove and set aside the bearing

spring (end thrust) washer from
the end-frame bore.

GROUP Cl!!Rl4
16
7 Remove the mounting screws from drive-

end frame. Then, the drive-end frame
and armature assembly can be removed
from the motor body.
NOTE - The drive-end frame and armature

assembly may be removed first (before
Step 6 above) for inspection of commu-
tator and bearings. Remove commutator-
end frame when necessary for further
inspection and parts replacement.
86M019
8 If necessary, remove (separate) the

drive-end frame and bearing assembly
from the armature. This operation is
usually done by pressing the armature
out of the drive-end bearing. If a
press is not convenient, the end head
and bearing will have to be removed
with a puller. Be careful not to
apply excessive force on the alumi-
num frame.
26608
NOTE - There will be occasions when it will

be necessary to remove the ventilating fan
from the armature. Once these fans have
been pressed onto the armature they must
be heated to remove without damage.
9 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 26609
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. When
the fan is removed, clean the shaft
thoroughly. Install new fan.
10 When new fan is reassembled on the shaft,

be sure it is a tight fit. Use "Loctite
Retaining Compound 40" or equivalent on
the inside of the fan hub when install- 26623
ing fan.

Cl!!!!RK GROUP
16
COMPONENT CLEANING AND 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 holder insulation 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 bearing recess
and snap ring groove for any signs of wear,
C. Bearings - Check bearings by turning them with your fingers. If a bear-

ing has binding, gritty effects, excessive looseness, wobble, or turns
very freely, it should be replaced.
D. 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 journals and internal spline for wear.
E. Motor Body (Frame and Field Assembly) - Inspect all insulation for
burned, blackened or charred areas. Check coil connections and termi-
nal studs.
F. Cooling Fan - Inspect for broken or loose sections
Refer to GROUP 16, Section 27, General Motor Maintenance,

for additional information.
LIFT PUMPMOTORSPECIFICATIONS (Reference GROUP 40, Section 5)
Weight: [42.2 kg] 93 lb Brushes/Holder: 2 Brushes/Motor: 8

I Brush Dimensions: Length [35 mm] 1.38 in
Width
I:;>", 1;; :;;; ;;
Thickness
Replace @ Worn Length [14:5 mm] .57 in on longest side
Brush Spring Tension (force per brush) NEW: [935-1077 g] 33-38 oz

WORN: [453 g] 16 oz

GROUP
16
MOTORRECONDITIONING

excessive wear and runout, prior to
further disassembly. If necessary,
commutator should be removed, turned
and re-undercut.
86M022
Bearing Replacement
With drive-end frame removed from

armature shaft (Page 6):
Remove the bearing from the drive end

frame. The bearing is retained with a
snap ring. Remove the internal snap
ring from groove in frame at end of
bearing. Then press the bearing out
of the end frame.
Install new bearing by pressing (on) the

outer race of bearing into bearing bore
until it is firmly seated against shoulder.
Then, install snap ring.
26642
NOTE - Do not reuse bearings which
have been removed from armature shaft.
4 When necessary, remove bearing from

commutator end of armature shaft by
using a bearing puller. Protect the
end of the armature shaft with a nut
or thick flat washer. Also, be careful
not to damage end of commutator bars.
(Typical view showing use of bearing

puller only)
84M520

Cl!lRU GROUP
16
5 Install new bearing on the armature shaft

by pressing inner race of bearing firmly
against shoulder on shaft.
Also see Figure 26622, Page 4.
Bearing Lubrication
Replacement bearings are packed with lubricant

and require no further lubrication.
26624
MOTOR REASSEMBLY
Press drive end frame and bearing assembly

onto armature shaft until bearing inner race
is firmly seated against shoulder on shaft.
NOTE - Install bearing on shaft by

pressing on bearing inner race. DO
NOT PRESS OR DRIVE ON DRIVE-END FRAME.
26625
Install armature and drive-end frame

assembly into motor body. Align the
match marks on end frame and motor
body.
Install drive-end frame mounting screws

and tighten lightly to temporarily hold
assembly. Tighten alternately to
ensure good mechanical alignment.
I I
26626
Put comutator-end frame on a work bench

with brush ring assembly facing upward.
Install the bearing spring (end thrust)

washer into bearing bore in commutator-
end frame. Use a thin film of grease
to hold in place.


GROUP Cl!!R#
16
6 Assemble commutator-end frame over bear-

ing on armature and to motor body. Be
sure bearing spring washer is correctly
in place. Align match marks.
7 Install commutator-end cover mounting

screws and tighten lightly to hold
assembly temporarily. Tighten alter-
nately to ensure good mechanical
alignment. Reconnect the two
internal electrical circuit wires.
8 Then, fully tighten the drive-end frame

mounting screws, using the impact tool
set.
9 Using the same procedure, also tighten

the mount ing screws in the commutator-
end frame
(Typica1 view showing use of tools)
86M013
10 If brushes were not removed (replaced),


Step 11, below.
26643

removal procedure:
a. Install brushes with the lead wires

b. Install brush assemblies into brush
free in the holder.
c. Connect brush lead assemblies.
of each brush.
86M017
12 [nstall the plastic brush covers.
GROUP .6, Section 24, Page 10 Code: OH-540, MAR 86

CMRW GROUP
17
GROUP
17
SECTION
4
STEER AXLE TRUNNION
MICROSWITCH CHECK AND ADJUST?dENT
(DRIVE MOTOR CUT-OUT)


Return all controls to neutral, and turn
Lift and block the truck up to raise the
steer and drive wheels off the floor.

85M777

GROUP CL9Rlt
17
15.342
TO TRACTION
CONTROL PANEL
60.018
90.746
13.684
95.603
-93.4aa
-25.443
DRIVE MOTOR CUT-OUT
13.682 SWITCH, DRIVE MOTOR STEERING INTERLOCK

13.683 FASTENER, DRIVE MOTOR STEERING INTERLOCK SWITCH
13.680 BRACKET, STEERING INTERLOCK SWITCH
15.342 URNESS, DRIVE IrOTORSTEERING INTERLOCK SWITCR
25.443 CAM, DRIVE MOTOR STEERING INTERLOCK SWITCH
60.016 FASTENER, DRIVE E!OTOR STEERING INTERLOCK SWITCH BRACKET

90.7L6 LOCKWASHER, DRIVE ?lOTORSTEERING INTERLOCK SWITCH BRACKET FAST
93.412 NUT, STEERING INTERLOCK SWITCH MOUNTING FASTENER
93.488 LOCATOR, DRIVE MOTOR STEERING INTERLOCK Sh'ITCHCAN
95.603 FASTENER, STEERING INTERLOCK SWITCH CAM

WIRK GROUP
17
Steer Axle Trunnion Switch Check
Be sure that truck is parked and blocked up

correctly to raise the steer and drive wheels
off the floor. See CAUTION, Page 1.
Turn key switch "ON". Release parking brake.

Put direction lever in "FORWARD" and push
on accelerator pedal. Both drive wheels must
now be turning.
85M479
Slowly turn the steering handwheel to make a

right turn. Each drive wheel must stop rota-
ting (cut off) when the steering trunnion
(steer 'axlewheel) is turned at an angle of
41.5 degrees from center (straight-ahead).
Check the right-hand drive wheel to know when
it stops. Check the steering trunnion or
steer axle wheel to determine the angle of turn
from center when drive wheel stops rotating.
85M507
Repeat test for left turn. Check left-hand

drive wheel and steer axle wheel, as above.
85M524
6 If the respective (right and left) drive
motor does not cut off (stop) correctly,
or if the turning angle of the steer axle
wheel differs from that specified, the
steering trunnion microswitches require
repair or adjustment.
Refer to the following adjustment procedure.
NOTICE - The steering trunnion microswitches

are located at the top of the steer axle trunnion
in the SCR controls compartment.

CROUP
17
Steer Axle Trunnion Switch Adjustment
Step 1: Open the battery compartment cover.
NOTICE - Access to the switches will

be made much easier when the battery is
removed from truck.
85M616
Step 2: Turn the steer axle wheel to the

straight-ahead position.
(Shown in partially-turned position.)
85M774
Step 3: Identify the RH & LH cut-out
TO TRACTION
switches by the wires. CONTROL PANEL
RH Switch: Wire #51 (brown w/green

stripe)
LH Switch: Wire #52 (Red w/green stripe)

GIST-OUT SWITCH
.....--.--’ MOUNTING PLATE
Step 4: Slowly turn steering wheel for a
RH turn until cam rotates 41.5” from center
position. Loosen switch mounting screws
for RH switch and adjust switch position on
mounting plate until switch just closes.
Repeat adjustment procedure for a LH turn.
Step 5: Check RH & LH cut-out switch

operation.
Step.6: If, after adjustment, drive motors do

not cut-out properly, check switch
continuity with a Volt-Ohm Meter. Replace
switches as required and re-adjust.

GROUP 19 SECTION 01 The control circuit is energized by closing key

switch, parking brake/seat switch and moving
CONTROL PANEL forward/reverse hand selection lever to desired
forward or reverse position. Depressing foot-
controlled accelerator closes the 1MS switch;
CONTENTS NO. further depression gives desired speed. This
applies power to control card, which will close
CONTROL PANEL DESCRIPTION 19-01-01 selected directional contactor and complete
CONTROL PANEL MAINTENANCE 19-01-02 circuits to drive motor.
CONTROL TROUBLE-SHOOTING 19-01-03
CONTROL PANEL REMOVAL 19-01-04 The control card then supplies a gate pulse to #2
CONTACTOR INSPECTION 19-01-05 REC, turning it on to a conducting state. This
CONTROL PANEL INSTALLATION 19-01-06 allows current to flow from battery through lC, 1X,
#2 REC, motor field, motor armature, sensor, and
back to battery.
19-01-01 CONTROi PANEL After 1C charges, #2 REC turns off, due to lack of
DESCRIPTION holding current. The control card checks that 1 C is
charged and unlocks gate to #l REC and #5 REC.
The EVlOOM CONTROL is an electronic device
that controls electrical power supplied to the The control card then supplies a gate pulse to #l
vehicle drive motor to provide smooth power to REC, turning it on to a conducting state. This
move the truck and to minimize power drain from allows current to flow from battery through #I
battery. REC, motor field, motor armature, sensor, and
back to battery.
The control consists of a SCR unit and a contactor
assembly unit. The SCR unit monitors power #5 REC turns on and allows current to flow
demand of the truck and then responds by through T4-T3,1C, #l REC, #5 REC and to T4-T3.
controlling the power applied to drive
components. The contactor panel contains This current charges bottom of 1C positive with
switching devices to direct heavy power loads to respect to battery positive bus. This charging
the drive motor and its components. cycle occurs in less than one millisecond [O.OOl
second] and #5 REC shuts off. This charge is now
stored on capacitor until it is time to turn off #1
REC.
SM555 19-01 -1
Current continues to flow in #l REC until control 100 % AVERAGE

card fires #2 REC. When #2 REC conducts, CURRENT
capacitor 1C discharges around circuit composed !TZ
of 1C, #2 REC, 1X, and #l REC. I?
This discharge current opposes battery current !Z
through #l REC so that resultant current is zero. 0
E 50%
Due to lack of holding current, #l REC is turned
off. e
Current continues to flow in #2 REC, lC, motor 8

and battery loop until capacitor (card terminal 14) is
ON
fully charged negative. ONoFFoN
OFF
office
This charge exceeds battery voltage by an amount
which is a function of peak motor current, and #2
FIG. 2. Motor current illustration. The dotted line
REC turns off.
shows average motor current.
FIG. 1 illustrates pulsing current from battery.
FIG. 2 shows nature of motor current which is
composed of both battery current and inductive (or
100 %
flyback) current.
Z
It should be noted that measured average motor
current will be greater than average battery current.
The SCR control converts battery current at battery

volts into a higher motor current but at a lower
motor voltage.
The time for next ON / OFF cycle to start is

determined by time that control card takes to
oscillate. This frequency of oscillation is controlled
by position of variable inductor in accelerator and
oscillator control circuitry in card.
FIG. 1. Battery current illustration. Slow speed is obtained by having maximum input
volts from accelerator. As input volts decrease,
During off time, energy stored in motor, by virtue of speed of motor increases. The SCR circuit is
motor’s inductance, will cause current to circulate capable of delivering approximately 95% of
through motor around loop formed by #3 REC. maximum speed. For full speed operation, 1A
This current is called FLYBACK CURRENT. contactor is closed to apply full battery voltage
across motor.
CONTROL FEATURES
OSCILLATOR. The oscillator section of card has

two adjustable features and one fixed feature.
With accelerator output voltage at maximum volts,
creep speed can be adjusted by CREEP trimpot
on card.
Top speed is fixed by card design and is obtained

with accelerator output voltage at minimum.
The % ON-TIME. has a range of approximately 5-

95%.
SM555 19-01 -2
The center ( or mid) operating condition of Because of flyback current through #3 REC, motor
oscillator is at 50% ON-TIME with a nominal 1.8 current usually runs 2 to 3 times that of battery
milliseconds ON-TIME and 1.8 milliseconds OFF- current. The current limit is set with C / L trimpot on
TIME. This corresponds to a maximum operating card.
frequency of about 300 Hertz.
PLUGGING, or slowing down of the truck is
accomplished when reversing by providing a small
300 amount of retarding torque for deceleration.
2 250
If the truck is moving and the directional lever is
moved from that direction selection to opposite
direction selection, the motor field is reversed.
The plug signal is initiated by the fact that the

directional switch has been shifted from one
direction to the opposite direction.
The motor armature, driven by the inertia of

vehicle, acts as a generator. This generated
cs SCR RANGE TS
current passes through the #4 REC and the
% ON TIME sensor. The oscillator circuit regulates at a plug
current limit level as set by the PLUG trimpot on
control card.
FIG. 3. Oscillator frequency curve.
This controls pulse rate of the #I REC to regulate
At CREEP, ON-TIME will decrease to
generated motor current and bring the truck to a
approximately 0.8 milliseconds while OFF-TIME will
smooth controlled stop and then reversal.
rise to about 20 milliseconds. At full SCR
operation, this condition will be reversed (short
The accelerator input will modulate plugging
OFF-TIME and long ON-TIME).
current. With the accelerator at maximum
depression, the plugging trimpot will enable
This variation of ON/OFF TIME of oscillator
adjustment of plugging current limit from maximum
produces optimum frequencies through SCR
to minimum current limit level. With the accelerator
range. The frequency curve of oscillator is shown
at minimum depression, plugging current limit will
in Fig. 3.
be reduced to minimum.
The rate at which oscillator may increase its percent
RAMP START. This feature provides full SCR
ON-TIME is limited by “CONTROLLED
torque to restart a vehicle on an incline. The
ACCELERATION”. The minimum time required to
memory for this function is the directional control
go from creep speed to 80-85 % ON-TIME point
switch. When stopping on an incline, the
may be varied by trimpot (C / A) on card. This is
directional lever must be left in its ORIGINAL
adjustable from approximately 0.5 seconds to 3.5
position to allow the control to assure full power
4.5 seconds.
when restarted. The accelerator will modulate
ramp start current.
CURRENT LIMIT. This circuit monitors motor
current by utilizing a sensor in series with armature.
FULL POWER TRANSITION. This built-in feature
The information detected across sensor is fed
provides smooth transition from SCR to 1A
back to card so current may be limited to a preset
bypass. This is accomplished by the SCR
value.
continuing to pulse until 1A contactor power tips
close.
If heavy load currents are detected, this circuit
over-rides oscillator and limits average current to a
1A CONTROL. The contactor has two modes
value set by C / L adjustment pot. The C/L setting
of control:
is based on maximum thermal rating of #1 REC and
peak voltage on capacitor.
1). TIMED PICKUP. This feature works with
the accelerator. When the accelerator is
activated so that the accelerator voltage is
reduced to 0.4 volts or less, then 1A time
SM555 19 - 01 - 3
is enabled. The time delay pickup of 1A

is provided by a circuit in card. This allows
the truck to accelerate through SCR 19-01-02 CONTROL PANEL
range until 1A picks up, even if the MAlNTENANCE
accelerator is actuated immediately.
The SCR control, like all electrical apparatus, does
This time delay is adjustable by means of a have thermal losses. The semiconductor junctions
1A TIME trimpot on card. have finite temperature limits, above which these
devices may be damaged.
2). If motor current is reduced during thermal
cutback to a point where IA 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 R’ETURN 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 parking brake/seat switch or key switch is [50” C] 120” F or over should be brought to
opened, the control will shut off and cannot be attention of Clark Material Systems
restarted until the directional lever is returned to Technology Co.
neutral position. A time delay of 1.0 sec. is built
into the control for allowing momentary opening of * All external components having inductive
brake switch, if a 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. If the 1 REC 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 1 REC 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 POSITEON. 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 controt 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 hipotting.
contactor in event of a commutation failure.
SM555 19-01 -4
l Use a lead-acid battery with voltage and

ampere hour rating as specified for the l * POWER CIRCUITS which consist of
vehicle. Follow normal battery maintenance heavy cables and main power
procedures, recharging before 80 percent components of truck.
discharged and with periodic equalizing
charges. l * CONTROL CIRCUITS which control
speed, time delay, and controlled
plugging.
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 /
* 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:
SM555 19-01 -5
3. Directional contactors close. No power. 1. Make sure truck has been parked in a safe
Audible SCR hum. Truck inoperative with position with upright fully lowered. Return all
accelerator in SCR range. controls to neutral and turn key switch OFF
4. Directional contactors close once or twice 2. Apply parking brake and block drfve wheels.
and then remain open. PMT trips.
3. Remove battery from truck. Refer to Battery
5. One directional contactor closewith normal removal group for details.
operation but other contactor will not close.
4. Discharge capacitor by using an insulated
6. 1A contactor will not close. screwdriver or similar device to short across
terminals of capacitor.
7. 1A contactor will not close when in SCR stall
or going up a ramp. 5. Remove power cables from control assembly.
Make sure terminals of all cables have identification
8. Stiff plug and/or plugging distance will not labels to assure correct assembly.
adjust.
6. Separate wire harness sections by
9. PMT trips everytime hydraulic switches are disconnecting the wiring couplers. Press in prongs
closed or opened. on each side of coupler to release and then pull
apart.
10. Power steer function does not operate.
7. Remove control panel fasteners (items 17.094
Refer to Systems Diagnostic area for detailed & 90.177).
information on sequence of operation and trouble-
shooting of control.
Tools and test equipment required are:
l 6 volt lamp
l 6 volt battery
lTwo Al4 diodes (1 amp 400 v)
,177
l Clip leads
* Volt-ohm meter (VOM) * (20,000 ohms)
* General hand tools
NOTE: A digital VOM (such as Simpson

Digital Multi-meter Modef 461, or
equivalent) is recommended for all electrical
and control testing.

REMOVAL
WARNING
ELECTRICAL SMOCK
DISCONNECT THE BATTERY AND
DISCHARGE THE CAPACITOR(S)
BEFORE HANDLING THE CONTROL
PANEL
BREAKING THIS RULE CAN CAUSE 8. Remove the control panel assembly. The SCR
SERIOUS iNJURY TO YOURSELF panel and contactor panel are considered an
assembly and are removed as a unit.
SM555 19 - 01 - 6
ASSEMBLY
COMPLETE
17.0237
CONTACTOR PANEL 19608-l
17.000 PANEL ASSEMBLY. CONTACTQR

17.007 1A CONTACTOR ASSEMBLY
17.015 FORWARD 6 REVERSE CONTACTOR ASSEMBLY
17.023 PUMP CONTACTOR ASSEMBLY
17.033 POWER STEERING CONTACTOR ASSEMBLY
17.750 SCR CONTROL PANEL ASSEMBLY

17.596 SUPPRESSOR, PUMP CONTACTQR
19.000 PLUGGING, CONTACTOR ASSEMBLY
19.859 BRACKET, PLUGGING CONTACTOR MOUNTING
65.373 BRACKET, POWER STEERING CONTACTQR MOUNTING
65.472 C4 REC, CONTROL PANEL

65.473 =T SINK, CONTROL PANEL R4 REX?
65.474 INSULATOR, t4 REX! HEAT SINK FASTENER
65.475 INSULATOR, t4 REC BEAT STNK
94.196 FASTENER, #4 REC HEAT SINK
94.197 iLOCXWASBER,#4RECHEATSINKFASTENER
94.198 WASHER, t4 RJX HEAT SINKFASTENER
SM555 19-01 -7
17.221
L17.069
CONTACTOR PANEL 19609-l
17.000 CONTACTOR PANEL ASSEMBLY (CONTINUED)

17.010 CONDUCTOR, 1A CONTACTOR FEED
17.018 CONDUCTOR, CONTACTOR TFBMINIAL
17.029 CONDUCTOR, FORWARD & REVERSE CONTACTOR FEED
17.069 WIRING HARNESS, CONTACTOR PANEL

17.221 CONDUCTOR, PUMP CONTACTOR FEED
17.334 CONDUCTOR, CONTACTOR PANEL NEGATIVE
17.532 CONDUCTOR, FORWARD h RXVEPSE CONTACTOR PEED
17.889 CONDUCTOR, FORWARD h REVERSE CONTACTOR FEED
19.271 CONDUCTOR, PLUGGING CONTACTOR FEED

19.573 CONDUCTOR, CONTACTOR FEED
19.576 CONDUCTOR, 1~ CONTACTOR FEED
19.598 CONDUCTOR, PLUGGING CONTACTOR FEED
19.708 CONDUCTOR, sex CONTROL FEED

19.862 CONDUCTOR, CONTACTOR FEED
SM555 19 - 01 - 8
@
94.760 ---‘g
SCR PANEL 19463-1
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, %5 RECTIFIER 90.323 LOCKWASHER, SCR PANEL TRANSFORMER FASTENER
17.057 FASTENER, CONTROL PANEL CONDUCTOR TERMINAL 91.089 LOCKWASHER, CONTROL 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 84 REC, SCR PANEL 92.768 WASHER, SCR CONTROL PANEL MOUNTING HEAT SINK FAS
17.759 t3 P.EC,SCR PANEL 92.769 LOCKWASHER, SCR PANEL MOUNTING HEAT SINK FAST
17.775 N2 REC, SCR PANEL 93.195 FASTENER, SCR PANEL 14 REC HEAT SINK
17.780 H5 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 (14REC 93.346 FASTENER, HEAT SINK
65.283 CONDUCTOR, SCR CONTROL PANEL 93.352 LOCK!dASHER.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
SM555 19 - 01 - 9
65.062
65.063
-19. 072
19.079 7
@ ( ,/ 165.347
SCR 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 113REC
17.763 CAPACITOR, SCR PANEL COMMUTATING 65.630 FILTER, PUMP SCR PANEL 15 REC
17.164 BRACKET, SCR PANEL COMMUTATING CAPACITOR MOUNTING 65.631 FILTER, PUMP SCR PANEL 12 REC
17.765 FASTENER, COMMUTATING CAPACITOR MOUNTING BRACKET 90.195 LOCKWASHER, TERMINAL BLOCK FASTENER
17.776 111REC, 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 lilRX 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 111REC 93.870 WASHER, SCR PANEL TERMINAL BLOCK FASTENER
65.198 LOCKWASHER, SCR PANEL f/lREC FASTENER 94.476 FASTENER, SCR PANEL FILTER
65.311 WASHER, SCR PANEL tl REC FASTENER 94.514 LOCKWASHER, SCR PANEL FILTER FASTENER
65.347 CONTROL UNIT, OSCILLATOR SPEED 1N BASE, SCR PANEL
SM555 19-01 -10

17.007 CONTACTOR ASSEMBLY, IA

17.101 COIL, 1A CONTACTOR
17‘105 SPRING, 1A CONTACTOR ARMATURE RETURN
17.106 SEAT, 1X CONTACTOR ARMATURE RETURN SPRING
17.112 CONTACTOR SET, 1A CONTACTOR
17.115 SPRING, IA CONTACTOR MOVABLE CONTACT

17.116 SEAT, IA CONTACTOR MOVABLE CONTACT SPRING
17.120 SUPPORT, 1A CONTACTOR STAIONARY CONTACT
17.533 RETAINER, 1A CONTACTOR COIL
17.972 LOCK, 1A CONTACTOR ?fOVABLECORE
17.975 INSULATOR, 1A CONTACTOR MOVABLE TIP

17.977 GUIDE, 1A CONTACTOR MOVABLE TIP
17.979 INSULATOR, 1A CONTACTOR STAIONARY CONTACT
19.494 BASE, 1A CONTACTOR
17.979 19,516 ARMATtiRE, IA CONTACTOR
65.237 FASTENER, 1A CONTACTOR CONTACT SUPPORT

65.238 LOCKWASHER. LA CONTACTOR CONTACT SUPPORT FASTENER
91.545 LOCKWASHER. IA CONTACTOR MOVABLE CORE FASTENER
91.546 WASHER, 1A CONTACTOR MOVABLE CORE FASTENER
17.112
17.120
r 17.112
I I 1A
U coN1AcloR 1 cs> 19.516
1A CONTACTOR SM555 19-01 -11

17.023 CONTACTOR ASSEMBLY, PUMP

17.161 COIL, PUMP CONTACTOR
17.023 17.165 SPRING, PUMP CONTACTOR CONTACT RETURN
17.169 CONTACT SET, PUMP CONTACTOR
17.172 SPRING, PUMP CONTACTOR MOVABLE CONTACT
17.173 SEAT, PUM.PCONTACTOR MOVABLE CONTACT SPRING

p&q 17.174 SEAT, PZTMPCONTACTOR MOVABLE CONTACT SPRING
17.182 SUPPORT, PUMP CONTACTOR STAIONARY CONTACT
17.534 RETAINER, PUMP CONTACTOR COIL
17.891 LOCK, PUMP CONTACTOR MOVABLE CORE
17.893 INSULATOR, PUMP CONTACTOR MOVABLE TIP

17.896 GUIDE, PLiMpCONTACTOR MOVABLE CONTACT
17.899
17.899 FASTENER, PUMP CONTACTOR CONTACT SUPPORT
19.495 BASE, PUMP CONTACTOR
19.841 92.542 19.637 ARMATURE ASSEMBLY. PUMP CONTACTOR
19.841 INSULATOR, PUMP CONTACTOR CONTACT SUPPORT

91,550 LOCKWASHER. PUMT'CONTACTOR MOVABLE CORE FASTENER
91.551 WASHER, PUMP CONTACTOR MOVABLE CORE FASTENER
92.542 LOCKWASHER, PUMP CONTACTOR CONTACT SUPPORT FASTENER
17.169
CONTACT
SET
I- 19.637
17.165
PUMP CONTACTOR SM555 19-01 -12

17.033 CONTACTOR ASSEMBLY, POWER STEERING
17.230 COIL, POWER STEERING CONTACTOR
17.240 CONTACT SET, POWER STEERING CONTACTOR
17.243 SEAT, POWER STEERING MOVABLE CONTACT SPRING

93.146- .581
go.o8@-,
4 17.244
19.899
65.052
SPRING, POWER STEERING CONTACTOR MOVABLE CONT
ARMATURE, POWER STEERING CONTACTOR
INSULATOR. P/S CONTACTOR STAT CONTACT SUPPORT

65.052
90.080 LOCKWASHER, POWER STEERING CONTACTOR FASTENER
91.539 LOCKWASHER. F-WRSTRG CONTACTOR CONDUCTOR FAST
91.581 SCREW, POWER STRG STAT CONTACT SUPP INSULATOR
93.145 NUT, POWER STEERING CONTACTOR CONDUCTOR
93.146 NUT, POWER STEERING PUMP CONTACTOR
899
'.230
17.240 17.033
I- 1
POWER STEERING PUMP CONTACTOR SM55.5 19 - 01 - 13

19.600 CONTACTOR ASSEMBLY, PLUGGING
19.602 COIL, PLUGGING CONTACTOR
19.615 CONTACT SET, PLUGGING CONTACTOR
19.621 FASTENER, PLUGGING CONTACTOR STAT CONDUCTOR
9.623 19.623 SCREW, PLUGGING CONT STAT CONT SUPP INSULATOR
92.396 -___( 19.849 ARMATURE ASSEMBLY, PLUGGING CONTACTOR
65.275 SEAT, PLUGGING CONT MOVABLE CONT ARMATURE SPRG
-65. 279 65.276 SPRING, PLUGGING CONT MOVABLE CONTACT ARMATURE
65.279 INSULATOR, PLUGGING CONT STAT CONTACT SUPPORT
92.393 LOCKWASHER, PLUGGING CONT STAT CONT COND FAST
92.396 LOCKWASHER, PLUGGING CONT STAT CONT SUPP FAST
93.115 NUT. PLUGGING CONTACTOR CONDUCTOR FASTENER
lg.615
- 65.275
_ lg.849
lg.602
r 19.6’5
19.600
1
PLUGGING CONTACTOR SM555 19-01-14

17.015 CONTACTOR ASSEMBLY, FORWARD 8 REVERSE,
17.070 SUPPORT, FWD 8 REV STATIONARY CONTACT
17.072 SPRING, FORWARD 8 REVERSE CONTACTOR COIL
17.073 COIL, FORWARD & RNERSE CONTACTOR
17.077 SPRING, FWD k REV CONTACT np R~RN
17.084 CONTACT SET, FORWARD 8 REVERSE CONTACTOR
17.369 INSULATOR. F 8 R CONT STATIONARY CONTACT TIP
17.997 INSULATOR, MID & REV CONTACTOR MOVABLE CORE
19.021 CORE,FORWARD & REVERSE CONTACTOR MOVABLE
19.496 BASE, FORWARD 8 REVERSE CONTACTOR ASSEMBLY
66.469 CONDUCTOR, FWD 8 REV CONT STATIONARY CONTACT
66.815 COVER, FWD & REV CONTACTOR MOVABLE CONTACT
66.816 INSULATOR,FWD 8 REV CONT MOVABLE CONTACT N/O
66.817 INSULATOR,FvVD 8 REV CONT MOVABLE CONTACT N/C
65.818 swi,F&R cow CONTACT np RETURN SPRING
95.441 FASTENER. FWD & REV CONTACTOR CLAMPING
95.442 LCCKWASHERFWD % REV CONTACTOR CLAMPING FAST
95.443 FASTENER,FWD & REV CONT STATIONARY CONTACT
95.444 WASHER, F & R CONT STATIONARY CONTACT FAST
95.445 LOCKWASHER, F&R CONT STATIONARY CONTACT FAST
95.446 FASTENER, FWD & REV CONT MOVABLE CONTACT
95.447 LOCKWASHER, F 8 R CONT MOVABLE CONTACT FAST
.19.496
SM555 19-01-15
FORWARD AND REVERSE CONTACTOR
1 Q-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 e,vidence 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 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 OVER TORQUE. return spring on top of armature shaft.
SM555 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., FAIRA
(+) 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. CONTINUING 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.
SM555 19 01-17
Connect fourteen-conductor plug to top RH side 4. Connect wiring harness sections by joining
of card. wiring couplers.
Connect six-conductor plug to top LH side of card. 5. Connect power cables to correct terminals on
control panel. Make sure all connections are
tightened firmly.
INSTALLATION 6. Remove blocks from drive wheels.
1. Before attempting to install control in truck, 7. Connect battery and test control panel
make sure truck is correctly blocked and battery is operation.
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.
90.177
3. Install control panel in truck. Torque control

panel fasteners to [20 - 25 N-m] 177 - 221 Ibf-in.
SM555 19-01 -18

GROUP19
EV-1 OOM
SEQUENCE OF OPERATION
AND
TROUBLESHOOTING
PAGE TEST PAGE

OPERATION SEQUENCE
DRIVE CONTROL
1. GROUND FAULT CONDlTtON _..._....................19-04-01
DRIVE CONTROL _....._......._.............................19-02-02 2. POWER STEER IDLE CURRENT . . . . 19-04-02
BATTERY ._._.__................................................... 19-02-04 3. SCR CURRENT LIMIT ... ... .. .. .. . ... .. .. .. .. . . ... .... .. 19-04-02
BATTERY INDICATOR & PUMP MOTOR....19-02.06 4. 1A FREE-WHEELING CURRENT . . .. .. .... . .. .. .. .. 19-04-02
HOUR METER, STEERING 8 SRO . .. . .... . .. . 19-02-06 5. IA TIME DELAY .._.t.__...._..._................................. 1404-03
FWD/REV CONTACTORS ,............................ 19-02-l 0 6. CREEP SPEED MOTOR VOLTS ..__....__..__.,__.__ 19-04-03
CONTACTOR OPERATION & 7. PLUGGING FUNCTION __..._.._............................ 1 g-04-03
CAPACITOR RECHARGE ___..__.__.._..._...._..... 19-02-i 2
7 Xl REC ON, #5 REC ON ................................ 19-02-l 3
6 1C CAPACITOR CHARGING &
REACTOR CfERATlON.. ............................ 19-02-14 SYMPTOM CHART PAGE
9 12 REC ON. Xl REC OFF. .............................. 19-02-I 5
10 FLYBACK .......................................................... 19-02-l 6 1 CONTACTORS WILL NOT CLOSE .. . .. . .. ... . .. 19-05-o 1
11 ACCELERATOR MOWLE. 2 CONTACTORS CLOSE, NO POWER,
THERMAL PROTECTOR 8 PMT ................ 19-02-16 NO HUM. TRUCK INOPERATIVE IN
12 1A CONTACTOR OPERATKIN ..................... 19-02-20 SCR RANGE .. ...... ... .. ... .._...............................19-05-02
13 PLUGGING ....................................................... 19-02-22 3 CONTACTORS CLOSE, NO POWER,
SCR HUM, TRUCK INOPERATIVE IN
SCR RANGE ..,_...__._....___._..................,............ 19-05-03
CHECKING COMPONENTS PAGE
4 CONTACTORS CLOSE BUT POP OPEN,
PMT TRIPS . .._.................................................1 g-05-04
SPECIFIC GRAVIiY TEST . .. . . .. .. ... ... ... . . .. . .. . 1 g-03-01
CHECK ~1, 2. 5 REC’S ........................................... 19-03-02 5 ONE CONTACTOR CLOSES. OTHER
WILL NOT ... ........ . .._....__._..........._...................
19-05-05
CHECK CAPACITOR (1C). .................................... .19-03-06
6 STIFF PLUG AND/OR PLUGGING
CHECK tQ2.23.24.25 FILTER BLOCKS.. ........ .19-03-07
DISTANCE NOT ADJUSTABLE .._.__.,.._...__. 1g-05-05
CHECK 113,4 AEC’S ............................................... 19-03-06
7 1A CONTACTOR WILL NOT CLOSE .._.____ 19-05-06
CHECK FILTER MOUNITNG BLOCK ................. .19-03-09
6 PMTTRIPS WHEN HYDRAULIC
CHECK SENSOR .................................................... 19-03-l 0
CHECK THERMAL PROTECTOR .......................... 19-03-l 1 SWITCHES ARE ACTIVATED .. .. . .. . .... .. . . . 1 g-05-07
CHECK REACTOWCHOKE MODULE.. ............... 19-03-I 2 9 POWER STEER MOTOR DOES NOT
OPERATE . .._.__.._..._._._..................................... 1 g-05-07
CARD ADJUSTMENTS. .......................................... 19-03-l 3
10 LIFT/ TILT/ATTACHMENTS DO NOT
CARD VOLTAGE CHECKS .................................... 1g-03-14
OPERATE . ..._._..._..._._.__.,___..__..____.___..__.._..__......19-05-06
CONNECTOR PLUGS A, E. 2.. ............................ ..19-03 -1 5
SM555 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
Speed
Directional
Access0 ry
SM555 19-02-02
3 REC
1 -c
li
6iWITCH
I
12 IO
HAND
BRAKE
i
.. . . ‘ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . j... T&S
d
.. r--- 7
; SPEED
r--1
TBi :
. . . . . . . . . 29 &L->&,3 ..
I ACCELEiATOR
-m
Ian- ._ 23- PB21
‘FL
27 ,................................... . . . . . . . . . . . . . . .;... PB3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.a
SWITCH
62 d
‘O-----------dbjrs-
1; ACCESSORY
I
-*++?q____i:___
10
+_--_ ,o ___!%~~._.,~_+
AUX 2 .-#-.
L___._ ,o _____._~*__ 3, _~________ __________
3, . . . . . . . . ..i..~..l.... ,3__________________---________-----
SOLENOID
BATTERY
DISCHARGFJ1NDICATOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ pJ) 5.. . . . *.........,.... ;i..Kii ,....... ,3 . . . . . . . . . . . . . . . . . . . . . . . .
h;__,,i
l2d25 HORN
SWITCH
SM555 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
B. Battery negative
C. Battery positive (wire #25)
NOTE: The Zener Diode (* ) does away with voltage spikes generated
by the horn as it operates.
SM555 19-02-04
OPERATIONS SEQUENCE 3
DRIVE CONTROL
Battery Indicator and Pump Motor
A. Turn key switch on.
B. Battery voltage is supplied to the Card at TB-4 through wire #lO.
C. Battery indicator (BDI) will now operate. Wire #lO connects it to

positive and #13 to negative.
D. Operating the lift lever closes the lift switch.
E. Current now flows to the hour meter (HM) from wire #28, blocking
diode, wire #72 to wire #13, negative.
F. The pump contact coil now gets voltage from wire #28, through
the coil to wire #13, negative.
G. The pump coil closes the contacts. Current now flows thru #l fuse
to the pump motor, to battery negative.
H. The pump motor operates.
Voltages present:
Battery positive at all points, A through G.
NOTE: The blocking diode is used to prevent the hydraulic control

circuit from back feeding the power steering control circuit
and vice versa.
SM555 19-02-06
s PUMPMcmm _ . !
i
f
f
:
:
:
:
s
:
f
E
ACCELERATOR
:
:
m
-23: PB~ j
:
.. . . . . . . . . . . . . . . . . . 7 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i.4 pB3 j LEFT CUT-OFF
SWITCH
PA6 j
:
d 26 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i.* pm +------- 52.---&~l3.-.-
PA5j
#------lo------4,A
,o .. . . . . . . . . . . . . . . . . . “-
34 B
75 ,...........................................
PB5 +-..._” 51-...4~13_-.-
RGHTCUT-OFF :
ii-----
+------10~~62-
SWITCH
:
i3
e
‘I :
: :
:,
HOURIETER
El :
HORN
SWITCH
I I I POWER PATH
SM555 19-02-07
DRIVE CONTROL
Hour meter and power steering operation, and S. R. 0.
After the key switch has been turned on, and with the hand brake released,
A. The Hand Brake switch will close and,
B. Wire #7 applies voltage to the card at terminal TB-3
C. Moving the directional switch to forward will close the forward switch.
D. Closure of the forward switch signals the oscillator card to supply a voltage
through terminal PA1 to the power steering contactor coil Negitive.
E. The power steering contactor coil is now energized, closing the power
steering contact tips.
F. The power steering motor now operates because current flows from
battery positive through 1 FU to the steer motor and to battery
negative. (Note permanent magnet motor).
G. The hour meter will now operate. Because battery voltage is

supplied thru wire #71, blocking diode and wire #72 to the hour
meter positive. (See note).
H. 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 contactors will not be allowed to close if the directional

switch is closed before the key switch and/ or Hand Brake Switch.
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 TBI .
The card will not allow the directional 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.
SM555 19-02-08
i
:
:
71
i
t
I
z
rr 2FlJj+$
i:
e
3
I
12
:
e
-12---+
1;
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e
KN
SWITCH :
e
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e
z
:
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e
ia
T4
:
e
I
I EV-100 OSC CARD2 I:
e
!zz?E I
T3
OSC CARD CONNECTOR
e
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71
i
TB5
TSl
I”““’ ,.,........ 1 I:
I DIRECTIONAL ; 15 i
.... ..rS .....+~~+.3 .,... :
z
I
10 SWITCH [.sy ----j+ TS8
:.......... ....._.. :
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . f--24-j+ pB1 ACCELERATOR
e B PB2 :
e
.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ;..* PS3 LEFT CUT-OFF
SWITCH :
:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . j.* PS4 “2 -52~~13~
:
e k-_-l’
E---_-lo ,..................
%A
-75
34
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.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i._*
PS5 pg -.....51,..“.$~13
RK;HTCUT-OFF
-
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:
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SWITCH
E
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e i
: :
10
e 1 :
7; 12 1
:
AUX 1
j-_-_ ,o____________~..__.23 .A
AUX 2
i .. ,o . . .. .. v * 3,
3, ..+._________-_______-----_ . .. i::$ . . ,3 . . . . . . . .. . . . . . . .._......
SOLENOID
BATTERY
13
DISCHARGflDICATOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.3 ! . . . . . . . . . . . . . . . . . . . . ;.;.+.; . . . . . . . ,3 .. . . . . . . . . . . . . . . . . . . . . . . .
12------&NcII”III25
I - - I POWER PATH SWITCH
SM555 19-02-09
DRIVE CONTROL
Energizing the Directional Contactors
The directional control switch has been moved to a forward position in a previous
sequence, next,
A. The brake pedal (FBS) must be released 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. Depressing the accelerator pedal slightly will close the 1 MS switch points.
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 contactors 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.
H. The thermostat, mounted on the shield above the brake caliper, will open if the
brakes are overheated and cause the directional contactors to de-energize. Once
the thermostat has cooled, the contactors will operate normally.
Voltages present:
A. Battery volts.
B. Battery volts.
C. Battery volts on terminals TB-2 and TB-5.
D. 1O-l 3 volts across each 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.
SM555 19-02-10
j OSCCARD
1 CONNECTOR
iw
i..*7
:._. . . . . . .. ... . .. ... .
EV-100 OSC CAAOc

T3
CSC CARD CONNECTOR
:..... ._____..._.___._...~
---------------10-----------m* TB4 ;
in . . . . . . . . . . . . , IJ .. . . . . . . . . . . . . . . . . . 27 ,.................................................. I..* pB3 j LEFT CUT-OFF

%I SWITCH
* 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ;.* pB,$
PA%
b
f
j+-----10 52-...&~13.-..-
*FL
34- PAS!
-f-r PBS +-.-.- 51-+..4\13 -
.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RlUtT CUT.OFF
SWITCH
. . ..#__*
I_ .. .,,o 3, 3, . . . i..+...l.... ,3 . . . . . . . ,.................,,
SOLENOID
BATTERY
.,.. . . . . . . . . . . . . . . . *. . . . . . . . . . . ., 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN
SWITCH
. I I POWER PATH
SM555 19-02-11
WER STEER MOTOR I
1A
i DRIVE MOTOR
1111 POWERPATH
diii.-&
EV-100 OSC CARD’
@SC CARD CONNECTOR
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 #2 REC 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 #l REC. This
would occur if the capacitor were open or shorted, or if #2 REC will not
gate on or is open.
Voltages present:
A. Not Applicable C. Battery volts across capacitor.
B. Not Applicable D. Battery negative.

SM555 19-02-12
PS
2FU
4
12
.12-
n
.
e
!zTCH
3
e
:
HAND EV- 100
CONNECTOR :
:
BRAKE OBC CARD
:
TB2
:
TB5
TB6
:
PBl
.a.........., 0 .. . ... . .. .. ... ... .. % ... .. . .. ... . .. .. .. .. .. .. .. . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..I
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 #1 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.
SM555 19-02-13
OSC CARD
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.
SM555 19-02-14
~“4&..dTS EV-100
OSC CARD
OSC CAAD-
CONNECTOR
10
I I I POWER PATH
DRIVE CONTROL
#2 REC Turn On and #I 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 #l REC through the 1X choke and the
#2 REC to the negative potential on the opposite pole of the capacitor.
D. The #l REC senses the reverse current flow and turns 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 #2 REC to a safe value.
Voltage Sequence:
Too quick to measure. Also, voltages vary with speed setting.
SM555 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.
SM555 19-02-16
ZFU;
NEG
.12-
KEY
SWITCH
DRIVE MOTOR
4 REC i
: a!! 1
I
;3
41
i-;-
EV- 100 OSC CARD-
HAND T3
OSC CARD CONNECTOR
BRAKE , . . . . . . . . . . . . . . . . . . . . . . . .,
.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*T&$ /
f- 7 3 TS3
SWITCH i .&%-&-6 ******) i

24-+e PBI
-p-24 . . . . :.::..: . . . . . . . . . . . . . . . . . . . . . . . . . I”” ; ACCELERATOR
$...m.-,,
m
+------lo 23~ PBZ j
---%L
PS3 LEFT CUT-OFF
* . . . . . . . . . . . . . 0 .. . . . . . . . . . . . . . . . . . RR 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ;..*
SWITCH
$-------lo------+ 52---dIJ$.13-
RL
&-----10 51~+13_.._.
---%i
+-...- ,O ,................,. “k,, RIGHTCUT-OFF
SWITCH
+-----lo-------h--62-
10
HOUR METER
13-
13-
:.. ‘#..,
3, I.......... :..+.L . . . . ,3 . . . . . . .... . .
SOLENOID
SAlTERY
I
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ‘ ..,, 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,3 ,........................
SWITCH
. I I POWER PATH
SM555 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. Depressing the accelerator pedal changes the inductance
and the control works faster. The sensor monitors motor current and signals
the card to shorten pulses during high motor currents.
B. If the control is overworked, the #l REC and TP will get hot. Resistance in
the TP will 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 #9 allows 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 will continue to
to run regardless of directional lever position.
SM555 19-02-18
-12----
KEY
SWITCH
12
1c
i T5
IX
T4
4
6
3
EV-100 OSC CARD=

T3
OSC CARD CONNECTOR
:......................_.,
u............ <. . . . . ..(I....................... . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . j..* m i
7 ;*TS3 j
*. ...........
10 ................... 27 ................................................... i .. LEFT CUT-OFF
%h i*
PA6 j
n<.,,.rmt I
Jllllcl”
$+----lo- 26 .................................................. (.a f’S4 +-----52.---i\l

RI .-
PAS i
&------lo...---+ 34F . PB5 ++-..-.51...-&~13--
1A
jb.--. 10 .. . . . . . . . . . . . . . . . . . .+DC RIGHT CUT-OFF
SWITCH
f----=-lo_62
f__. lo__.YE~__28 4
AUX 2
i .. ,O . . . . . . . . . . w *
3, .~__-__-______________-__
3, . -.-. .i::$::i . . . . 13 . . . . . . . . . . .._._......
SOLENOID
BATTERY
DISCHARGflDICATOR
I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p)J .. .. . .. . .. . . . .. . .. . . ,........................
HORN
SWITCH
%sew POWER PATH
SM555 19-02-19
DRIVE CONTROL
1A Contactor Operation
Depressing the accelerator 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. Depressing the accelerator fully 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 1A 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 close if the control isin
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.
SM555 19-02-20
BATTERY
- .
e
3 REC
i
, q CP \FL Sl F SOR I
----L-l
..; , :
LEF+Di 3
:
E
13
:
--N S-X
4 REC
ii
i 3
i T’..“_: _..__._......~..__...:1.~.:
i T4 3
1:
3
HAND ; EV-lco OSC CARD-
BRAKE 1 OSC CARD CONNECTOR :
:.. . . . . . . . . . . . . . . . . . . . . ..
. . . . . . . . . . . . p.* TB4 /
:
TB3 ;
:
TB2
:
TB5 ; ~. . . . . . . ..I........ I
:
ACCELERATOR
&-----10
-23 PB2 !
;. ........... , 0 . .. . . . .. .. . . .. . . ..
+ll 27 ,.................................................. i..# PB3
LEFT CUT-OFF
SWITCH
p&l PAGi
+10, 26 ..........................................
w,; &.-.-52--.i~13---.-
lfil4k
PA5!
Ir 111,0.11 ~~~~~~~34~~~~~~~~~~~ PBS * 51._...$~13”_._.
&-.__qJ.. ......... .v 75 ................................................... i .. RIGHT CUT-OFF

:*
: ....... SWITCH
62
*lop
:...&
3, :..+.. . . ,3 .... . . .. .. . . . .. .
SOLENOID
BATTERY
1:
I................................. o . .. ... ... . .. .. . .. . .. . .. . .. .. .. . . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. ... . . . .. . .. . .. . . .. . . .. . ,,,,.~.~pj~‘cAToR .. . .. . . . .. ... .. . . . . . . . .. . . .. .. . .. . .. ,

FkFR
3 . *. . . . . . . . . . . . . . . . . . . . . .
12va5 SWITCH
I I I POWER PATH
SM555 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) with the
accelerator depressed.
A. Directional switch lever 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 contactors 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.
SM555 19-02-22
WER STEER MOTOR
HAND EV-100 OSC CARD-

13
BRAKE 0% CARD CONNECTOR
:. . . . _. . . . . ..__... . . . . . ..
ACCELERATOR
23 PPB2 i
27 ,........................................,......... i..* PS3 LEFT CUT-OFF

SWITCH
PA61
26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.
: + PB4 +----52--+~l3.----
PASj
=:r PB5 +s--.-- 51..-.._&+13_
75 I.................................................. ;.* pB6 RffiHT CUT-OFF

SWITCH
62
f___ ,o_-!!!E~____26
AUX 2
i . ,O ..,......... -... 3, 3, ..(..... i::$:i . 13 . . . . . . . . . . . . . . . . . . . . . . . . . . .
SOLENOID
BAnERY
DlSCHARG$J$DlCATOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ,, . . . . . . . . ..I.............. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..-......................................... (BDI! . . . . . . . . . . . . . . . . . . . 3 .. . . . . . . . . . . . . . . . . . . . . . ..
HORN
SWITCH
.-I POWERPATH
SM555 19-02-23
DRIVE CONTROL
Plugging (continued)
A. The operator moves the directional lever through neutral to reverse, closing
the reverse directional switch.
B. With the 1 MS switch closed, 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 take over.
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 precharges the capacitor.
F. The card turns on the #l REC.
SM555 19-02-24
BAlTRY
*WGi 36 VOLTS
7, .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . .. . .. . .. .. . .. . .
POWER STEER MOTOR
0
0
u,
2 a
NSOR
2FlJi$
4
12 NEG
-
-12---
KEY
SWITCH
4
6
HAND EV-1M) 0
T3
BRAKE OSC CARD CONNECTOR
:. . . . . . . . . . . . . . . . . . . . . ..
............................................................ 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F* TB4 i
I--- ------+ TB3 i
ACCELERATOR
LEFT CUT-OFF
SWITCH
*\13-
-s.+%--13-
+,, ................... a 76 ................................................... i .., PB6 PA1 j RffiHT CUT-OFF
:....................... . SWITCH
f----Q-----~62 ..
HOURITER
BATTERY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ., 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN
SWITCH
.I- POWERPATH
SM555 19-02-25
DRIVE CONTROL
Plugging (Continued)
As the #l 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 accelerator
pedal 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, 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.
SM555 19-02-26
\L
......... ...
r
..I
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
..*. ‘ . . . . . . . . . . . . . . . . . . . ..*.*................ i..‘, TBQ
*
ACCELERATOR
LEFT CUT-OFF
........ , 0 .. . . . . . . . . . . . . . . . . . 27 ,....................................... a... . . . . . . . i..# pS3
.+fK”“- PA6 i
SWITCH
---10 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . f.* ps.4 &-----52--..-&\13-

?Fll
-10
-
-10
,0 . .. . .. . .. . . .
34
75 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
RIGHT CUTc)FF
SWITCH
i
13
HOUR METER
13------
+&.(
3, . . . . . . . . . . . . .$....? . . . ,3 . . . . . . . . . . . . . . . .. . .. . .. . .. .
SOLENOID
BATTERY
HORN
SVilTCH
. I I POWER PATH
CHECKING COMPONENTS
SPECIFIC GRAVITY TEST
l-
Ic: GRAVlN
1.260-l .300 100% CHARGED
1.230-l .250 75% CHARGED
1.200-l .220 50 % CHARGED
1.170-l .190 25 % CHARGED
1.140-1.160 VERY WEAK
1 .ll O-l .130 DISCHARGED

BY USING A HYDROMETER, THE SPECIFIC GRAVITY OF THE ELECTROLYTE SOLUTION IN A
BATTERY CAN BE DETERMINED. THE BATTERY SPECIFIC GRAVITY IS AN INDlCATlON OF
THE BATTERY’S STATE OF CHARGE. IF THE STATE OF CHARGE IS LOW, THE HYDROMETER
WILL READ LOW. IF THE STATE OF CHARGE IS HIGH, THE HYDROMETER WILLL READ HIGH.
AS AN FXAMPL F,. A READING FROM:
1.260 TO 1.300 INDICATES A FULLY-CHARGED BATTERY.
1.200-I .220 INDICATES A BATTERY IS IN A DISCHARGED
CONDITION AND CANNOT GIVE SATISFACTORY SERVICE.
BATTERYTESTS;
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 -- put the main hydraulic system

19.2 volts into by-pass while reading battery volts with
a voltmeter.
48 volt battery
38.4 volts Battery needs recharge or repair if voltage
drops below 80 %, of the rated voltage of
the battery.
SM555 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
results should 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!!
SM555 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 1000,000 OHMS OR MORE
CHECKING SCR’S
RECTIFIERS
SM555 19-03-03
STEP R X 1 SCALE IO TO 250 OHMS
CHECKING SCR’S
RECTIFIERS
STEP 4 R X 1 SCALE 5 OHMS TO INFINITY ACCEPTABLE
CHECKING SW’S
RECTIFIERS
SM555 19-03-04
#2 AND #5 PRESS PACK RECTIFIERS
GATE CATHODE
1 t
3
0
:,;“:-
ANODE
0
SM555 19-03-05
TO CHECK CAPACITOR (1C)
STEP 1 R X 10,000 SElTlNG

STEP 1
TO MAKE SURE THAT

CAPACITORS WILL RECEIVE
AND STORE A CHARGE,
AI-I-ACH 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 R X 10,000 SETTING
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
FIXED RESISTANCE, THE
CAPACITOR IS BAD AND A
NEW ONE MUST BE INSTAL-
LED.
CHECKING CAPACITOR
SM555 19-03-06
CHECKING COMPONENT WITH VOM (ONLY)
STEP 1 R X 10,000 SETTING
STEP 1
DISCONNECT BATTERY.
DISCHARGE CAPACITOR
1C, THEN
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-I’TING
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
MUST 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
SM555 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
IN G. E. SYSTEMS
ARE DIODES. THEY
WILL CONDUCT CURRENT
IF THE APPLIED VOLTAGE
POLARITY IS CORRECT
AND BLOCK CURRENT IF
THE POLARIlY IS IN-
CORRECT.
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
TESTING #3 AND #4 RECTIFIERS
BELOW 50,000 OHMS, A
NEW RECTIFIER SHOULD
BE INSTALLED.
STEP 2 R X 1 SETTING 7 TO 12 OHMS
STEP 2

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

TER 7 TO 12 OHMS, THE
RECTIFIER IS BAD AND A NEW
ONE SHOULD BE INSTALLED.
TESTING #3 AND #4 RECTIFIERS
SM555 19-03-08
CHECKING COMPONENT
FILTER MOUNTING TERMINAL BLOCK

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 #l 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.
SM555 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, CONNECTTHE 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.
SM555 19-03-10
TPLUG -
lllclllun
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
“Z” plug from the card. Using a VOM (R X 100 scale) measure the resistance between
the black and gray wires. With the #I Rectifier heatsink at room temperature (24OC 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 10,000 scale and measure
resistance from each wire end (at “z” plug) to #l Rectifier heatsink. Readings should
be infinity.
SM555 19-03-11
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.
STEP 1: 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.
SM555 19-03-12
CARD ADJUSTMENTS
EVlOOM ONLY
CREEP 4.5
C/A 6.5
C/L 9
1ATlME 1.5 SEC.
PLUG 8
MOUNTING SCREW A AND B PLUGS TERMINALS l-6 Z PLUG MOUNTING SCREW
SM555 19-03-13
CARD VOLTAGE CHECKS
TB-1 Key on and accelerator released.. ................. 3-4 v.

Key on and accelerator depressed .............. .0.2 v. or less
TB-2 Key off or hand brake on ................................ 0 v.

key on, hand brake off .................................... About l/2 battery volts
accelerator depressed.. ................................... B+ v.
TB-3 Key off or hand brake on ................................ 0 v.

Key on and hand brake off ............................ B+ v.
TB-4 Key off .............................................................. 0 v.

Key on .............................................................. B+ v.
TB-5 Key off ............................................................... 0 v.

Key on, hand brake off,
directional control to forward ........................ About l/2 battery volts
TB-6 Key off .............................................................. 0 v.

Key on, hand brake off,
direction control to reverse ............................ About l/2 battery volts
SM555 19-03-14
CONNECTOR PLUG “A”

EVlOOM ONLY
NOT I
#62
NOT USED
NOTE: VIEWED FROM CARD END
CONNECTOR PLUG “B”

EVIOOM ONLY
#27
“2” PLUG
ORANGE VIOLET WHITE RED WHITE BLUE WHITE

VIOLET TRACER RED TRACER BLUE TRACER
SM555 19-03-15
RECOMMENDED TEST, TEST sheet. Open circuit battery voltage is

measured as follows:
EQUIPMENT AND
PROCEDURES STEP #l: Turn Digital Multi-meter ON
Select 200 volts, DC scale.
STEP #2: Connect RED lead to

1. RECOMMENDED TESTS: POSITIVE (+) terminal on battery.
Connect BLACK lead to NEGATIVE (-)
1. Ground Fault Condition. terminal on battery.
2. Power Steer Idle Current.
3. SCR Current Limit STEP #3: Read and record voltage
4. 1A Free-Wheeling Current. reading displayed. This is OPEN
5. 1A Time Delay. CIRCUIT BATTERY VOLTAGE.
6. Creep Speed Motor Volts.
7. Plugging Function. 6. Always have key switch turned OFF and
parking brake SET before connecting
II. TEST EQUIPMENT: battery to truck .
1. Current Monitoring Shunt, 500 Amps, 7. The test for parameter #3 (SCR Current
50 mV. Limit) requires truck’s components (e.g.,
2. Digital Multi-Meter- Recommend “Simpson cables, controls, axles, brakes, etc.) be in
D.M.M. Model #461 wor equivalent. cold condition, i.e., components are at
approximately same temperature as
normal, not to be operated / driven for any
Ill TEST PROCEDURES: significant period of time (more than 10
minutes) before conducting test. If
A. PRELIMINARY PRECAUTIONS: The required, provide sufficient cool down
following precautions must be adhered to while period for truck.
preparing for and / or conducting above tests:
8. Before connecting battery to truck, visually
1. Tests #l through #6 require drive wheels inspect to be sure contactor tips are not
be raised off floor. welded.
2. Always inspect condition of battery cables 9. The preferred method of disabling any
and connector of battery being used for function / component (e.g., preventing 1A
test. If battery cables are worn out, cable contactor from closing) is to disconnect
ends at terminations cracked, or cable appropriate control wire, in order to break
insulation broken / cracked, battery should electrical circuit. Use of cardboard and / or
not be used for test but should be sent for any other mechanical device is not
repair or maintenance. advised. These methods should only be
used if breaking electrical connections is
3. No extension cables should be used to not practical. SUCH METHODS SHOULD
connect battery to truck for test. It is BE USED WITH CAUTION!
recommended to install battery in truck for
test whenever possible. When such B. PROCEDURES:
installation is not practical, battery should
be set on floor close to truck battery 1. GROUND FAULT CONDITION:
receptacle, to eliminate need for
extension cable. STEP #l: Disconnect battery from truck
receptacle and turn key switch OFF.
4. Always inspect condition of battery cells
for proper water level. STEP #2: Turn ON Digital Multi-meter;
select resistance measurement
5. Before conducting any test, measure function, 200,000 Ohm scale.
open circuit voltage of battery. Record
measured value, nominal rating of battery
volts, and battery type number on test
SM555 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, push hand brake lever
NOTE: It is recommended that if ground down, turn key switch ON.
fault is detected on truck, tests for other
parameters should be conducted ONLY STEP #6: Select FORWARD direction;
AFTER ELIMINATING CAUSE OF AND depress foot brake pedal down fully and
THEREBY GROUND FAULT. hold down to obtain HARD STALL
condition of motor. Depress accelerator
2. POWER STEER IDLE CURRENT: pedal gradually down to FULL DOWN
position. Measure and record highest
STEP #1 : Raise drive wheels off floor. current reading (voltage across shunt)
obtained.
STEP #2: Connect current monitoring
shunt to measure battery current. Shunt STEP #7: Subtract power steer idle current
sensor wires are connected to Digital from reading obtained in Step #6 to
Multi-meter. The voltage reading across obtain SCR CURRENT LIMIT FOR
these two sensor wires gives Direct DRIVE SYSTEM.
Current reading. Turn ON the Digital
Multi-meter; select DC VOLTS. STEP #8: Repeat Steps #6 and #7. Take
average of two (2) readings and compare
STEP #3: Connect battery to truck average value to specifications.
receptacle. Turn key switch ON, push
hand brake down, select a direction of NOTES:
travel. The power steer motor noise
should be heard. 1. Precautions should be taken not to stall
traction motor more than 20 seconds
STEP #4: Measure and record voltage during Step #6.
across shunt sensor wires (or terminals).
2. There should be wait (idle) period
STEP #5: The voltage reading obtained in minimum of two (2) minutes between
Step #4 is a direct reading of POWER Steps #6 and #8.
STEER IDLE CURRENT using
conversion of 1 mV equal 10 Amps for 3. Drive wheels should be allowed to turn
500 Amp, 50 mV shunt. (i.e. 1.0 mV between Step #6 and #8.
equals 10 Amps)
4. 1A FREE WHEELING CURRENT:
NOTE: Precaution should be taken not to
touch steering handwheel while taking STEP #l : Raise drive wheels off floor.
measurements / readings in Step #4.
STEP #2: Install jumper wire on foot brake
switch to defeat its operation.
SM555 1g-04-02
STEP #3: Connect control wire #34 to 1A STEP #6: Stop the stop watch the moment
contactor coil negative terminal. any motion or movement of 1A (bypass)
contactor tip is detected.
STEP #4: Connect shunt to measure
battery current. STEP #7: Stop Watch reading is 1A TIME
DELAY. Repeat Steps #5 through #7 at
STEP #5: Connect battery to truck least four (4) times. Take average of all
receptacle, push hand brake lever readings as 1A TIME DELAY to compare
down, turn key switch ON. against specifications.
STEP #6: Select FORWARD direction, 6. CREEP SPEED MOTOR VOLTS:

depress accelerator pedal fully down
and hold down. STEP #I : Raise drive wheels off floor.
STEP #7: Gradually depress brake pedal STEP #2: Connect RED lead of Multi-meter
until battery current reading is between to pig-tail of commutating diode (#3
100-200 Amps. Hold brake and REC) and BLACK lead of Multi-meter to
accelerator pedals in these positions for negative (-) terminal on control panel.
minimum of ten (10) minutes.
STEP #3: Turn Digital Multi-meter ON;
STEP #8: After ten (10) minutes, release select DC Volt measurement function,
brake pedal completely while still holding 20 Volt scale.
accelerator pedal fully depressed. After
current reading has stabilized, measure STEP #4: Install jumper wire on foot brake
and record it. switch to defeat its operation.
STEP #9: Release accelerator pedal STEP #5: Connect battery to truck
completely. After current reading has receptacle, push hand brake lever
stabilized, measure and record it as down, turn key switch ON, select
POWER STEER IDLE CURRENT. FORWARD direction.
STEP #lo: The difference of current STEP #6:Depress accelerator pedal until
readings obtained in Steps #8 and #9 is 1MS switch (Start) closes while foot
1A FREE-WHEELING CURRENT and brake is held down (fully depressed).
must be used to compare against Record voltage reading of meter.
specifications.
STEP #7:Repeat step #6. Average of two
5. 1A TIME DELAY: reading is CREEP SPEED MOTOR
VOLTS and should be compared
STEP #l : Raise drive wheels off floor. against specifications.
STEP #2: Install jumper wire on foot brake 7. PLUGGING:

switch to defeat its operation.
STEP #l:Lower drive wheels to floor,
STEP #3: Connect battery to truck remove jumper wire from foot brake
receptacle, push hand brake lever switch.
down, turn key switch ON.
STEP #2: Connect battery to truck
STEP #4: Select FORWARD direction; receptacle, push hand brake lever
depress brake pedal fully down and hold down, turn key switch ON, drive truck to
down to maintain HARD STALL open space or aisle where at least [76 m]
condition of traction motor. 250 feet of running space is available.
STEP #5: Depress accelerator to floor as

fast as possible and start Digital Stop
Watch the moment accelerator pedal is
touched.
SM555 19-04-03
STEP #3:Select FORWARD direction,

depress accelerator pedal to floor, and
hold down. After top speed contactor
has picked up (closed) and truck has
traveled in top speed mode at least [23
m] 75 feet, change direction of travel to
REVERSE while still holding accelerator
pedal completely down.
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 #3 and #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.
SM555 1g-04-04
YES
SYMPTOM 1 )r
t
l3AECTlONAL CoNTACTCftS CHECK 03iTlNUll-f OF
WILL NOTCLOSE. WIRES X15 & P38.
7
TAKE FOOT OFF ME ACCEL

PEDAL AND RETURN
DlRECTlONAL LEVER TO
Nf3JTRAL MEASURE VOLTAGE
ON TERM. TEsl OF 0.X. CARD.
DEFECTiVEACXZLERATCf3
LINKAGE. REPAIR I
h4EASURE MLTAGE ON
TERM. TE5 (FWD) h TE6
lREvI OF 0% CARD.
CtlECKFORSHoRT
FROM WlREP15TO
NO WIRES 116S eS B
OPERATIONOFFWD/
REV SWTCHES.
REPAIRIREPLACE.
MEASURE VOLTAGE ON POS.

TERMS. (WIRESIlO) OF
CiRECTK)NALCONTACTOR
CaLS.
NO CHECKCCNTINUTP(OF
WIRES Cl0 TO COILS ON
PANEL. REPAIR/REPLACE.
MEASURE VOLTAGE A-
BOTH CMLS FOR SAME
MRECTION. SELECT DlRECTlON
&OPERATE TRLiCK READ
METER FOR FIRST 0.5 SEC AND
AFTER 1 SEC.
SRAKEMERMOSTAT. DEFECl%E 0%
C4RD. REPLACE.
NO
BRAKESARE OVERHEATED.
ALLOW TO CCXX RfX+iECK CHECK CGf4lACTGRS FOA SINDING
OR OPEN COIL REPAIR I REPLACE.
ALL TESTING SHOULD BE DONE WITH

DRIVE WHEELS RAISED OFF FLOOR.
BATTERY SHOULD BE UNPLUGGED
FOR CONNECTING OR DISCONNECTING
ANY WIRES ANDIOR COMPONENTS.
SM55519-05-01
SYMPTOM 2
+
MEASURE VOLTAGE ON #i
REC (ANODE) POSITIVE.
SlTOS28AlTOA2ON
DEFECTIVE 0%. CARD.
BJTH DRIVE MOTORS.
REFIACE.
+YES
MSCONNECTWlRE
1123FROM TERM. TSI
OF 0%. CARD.
MUISURE VOLTAGE
ON WIRE X23 AS
CHECKCCNTlNUrrYOF
ACCELERATOR IS ALL TESTING SHOULD BE DONE WITH
$1, S2, Al, A2 AND BAT.
DEPRESSEDTO C4OSE DRIVE WHEELS RAISED OFF FLOOR.
1MS SWITCH.
CHECKCOM1NUllY FOR CONNECTING OR DlSCONNECTlNG
OF WIRES 113.15 6 ANY WIRES AND/OR COMPONENTS.
38 AND LOOSE/SAD
CONNC7KMSON
PL-5 AND SO-5
CHECKCCNT~NUITYOF
CONTACTOR TIPS TO
ON WIRE X29 AS
LCCATEOPENONKXH
ACCELERATOR IS
REVERSERS.
I DEFRESSEDFCRTOP
SPEED.
+ YES
RECONNECT WIRE x29 ON
TERM. TBl OF 0% CARD.
b
MEASU4E VOLTAGE ON
ORANGEWl~ONREAGTC&i
AS ACCELERATOR IS
DEPRESSED IN SCR M.
WlRESCfdCzlRREKTSENSCf4
FORCONTINUITY, BROKEN
INSULATION AND LOOSE /
DEFECTIVE 12 REC. BADCONNECTlONTOCARD
FbZPlAGE.
SM555 19-05-02
SYMPTOM 3
lIRECllCNALCONlACTCftONTACTORS
CLOSE. No POWER. AUMSLE
S’ZHLMTRJCX
INOPERATIVE WmC ACCEL
IN 3CR RANGE.
UNPLUG MTTERY.
CISCHARGE CAP. 1C.
CHECX #3 REC FOR

CFEN
DEFECTIVE t3
REC. REPLACE.
MSCONNECTTi-E
PIGTAILS OF BOTH
114RECS. CHECK 14
RECS FOR SHORT:
DEFECTIVE t4
RECS. REPLACE
iN0
1 DlSCOFNECTTMRh’ALPRR 1
DEFECTIVE MERMAL
DlSCONNECT M REC.
DEFECTIM #5 REC.
ALL TESTING SHOULD BE DONE WITH
BAlTERY SHOULD BE UNPLUGGED
FOR CONNECTING OR DISCONNECTING DISCONNECT P22 & 125
AECS. CHECK RECS Wrrli
ANY WIRES AND/OR COMPONENTS.
OHM. METER
DEFECTlVE 122 6
X25 REC. REPLACE.
REINSTALL 122 6
X25 RECS. CHECK IF NO
TRUCK OPERATES.
NO
c
SM555 19-05-03
SYMPTOM 4
DlRECTlONALCONTACTORS CLOSE
ONCE OR TWICE AND THEN REMAIN
OPEN. PMT. TRIPS.
4
CHECK IF IA CON-i-ACTOR
TIPS ARE WELDED.
REPAIi3REPLACE.
TURN KEY SWlTCM ‘OFF.

CiSCXJNMCT GATE LEAD FROM
#l REC. TURN KEY SWITCH ‘ON’.
PROPER CONNECTIONS OF
MEASURE VOLTAGE ON 72’
GREENANDYELLOWWIRES
( Xi REC CATHODE ),
ONANDFRCMSENSORTO
CARD PLUG ‘T PIN lt4 AND
PIN #S RESPECTIVELY.
CONNECT GATE LEAD ON H

REC. DISCCNNECT#S REC.
CHECKXSRECFOROPEN.
ALL TESTING SHOULD SE DONE WITH

DRIVE WHEELS OFF FLOOR.
RAISED
DlSCONNECT Q REC.
CHECK ik2 REC FOR SHORT.
INSTALL 12 REC.
REMOVE tQ2 REC.
CHECK XX? REC
DEFECTIVE 122
REC. REPLACE.
INSTALL X22 REC.

CHECK 1C CAP. FOR
CPENORLo3sE
CONJE-.
CHECKICCAP FOR
SnxT.
SM555 19-05-04
SYMPTOM 5 SYMPTOM 6
MVE MRECTlCNALCONTACTOR CLOSES STIFF PLUG AND/OR PLLkXlNG

V.lTH NORMALOPERAllON w OTHER CISTANCE WILLNOTAIUJST.
DlRECTlCNS COKTACTOR WILL NOT
CLDSE
CHECK PLLiGADJl!STMENT
SUllNG ON 0%. CARD.
ADJUST PLUG POT.

TO MSIRED SETTING.
CHECK IF GREEN AND YELLOW

WlRES FRX CURRENTSEM
ARE CONNECTED TO PIN aI4AND
PIN x3 RESPECTIVELY OF?
PLUG ON OS’2 CARD. NOTETHAT
YELLOwwIF(EslwJu38ECLOSER
TO &r\lTERY NEGATlVE AND NOT
MRECTIONAL SWITCH OF l33ERKD.
CONTACTORS THAT WILL NOT
CLOSE. MEASURE VOLTAGE ON
OTHER CiRECTlONAL INPUTTER!.,.
(TS5ORTB6)OFOSC.CARD.
SWITCH ( FWO OR REV ) OF C+EQ(GFIEENANDYELLOW

‘XXTACTORS MAT WlLL NOT WlFEs FR3M CuimENT
C4OSEICa-mEspoNDlNG SENKxIFoRwpL
WIRE ( x6 OR #S ) TO OTHER
DIRECTION INPUT TERM, (TS5
OR TSS ) ON OSC. CARD.
SENSOR. REPLACE
POSlTi’E WIRES #lb.

, 1 I
DEFECTIVE t4 RECF.
DEFECTlVE OSCUATOR
CARD. REPLACE.
.
1CONNECTKILTtKlERTO 1
MEASURE VOLTAGE ACROSS EACH
COIL OF CONTACTOl?S THAT WILL

BAl-l’EAY SHOULD BE UNPLUGGED
YES
1CHECKCCNTACTCfIS FOP, 1 i I
DEFECTIVE OSCXJATOR CARD.

lw+ACE
SM555 19-05-05
SYMPTOM 7
1A CONTACTOR WILLNUT CLOSE.

+
UNPLUG B4lTERY. CHECK 1A
COt4TACTOR FCR FREE h+XfEMZKT
TERMINAL ( WIREXIO ) OF 1A
CCNTACTORCML
CHECK CONllNUllY OF
INSTALL A JUMPER FROM WIRE WlREXlOTO1ACOlL NO
17 TO WIRE x38 ON FOOTSRAKE POSITIVE. REPAIR /
swlTcH. PLUG EmERY. CLcsE REPLACE.
AU NECESSARY SWlTCHES TO
oPEP.4TETRuu(~FooT CHECK CONTlNUrrY OF WIRE X34
SRAKEALLTHEWAYDOWNAND FROM PLUG’& PINXSON OSC.
DEPRESSACCaTOTOPSPEED. CARD TO NEGATIVE TERMINAL OF
MEASURE VOLTS ON YylAr LEAD 1A CONTACTOR COIL
FROM THERk4U F3OTEcToR AT
OSC. CARD ‘2’ PLUG, PIN X5.
REPAIR/REPLACE
T
>LTS
CCNNECTVaTMElERTO
> MEASURE VOLTAGE ACROSS IA
NO COIL CLOSE ALL NECESSAFIY
SVdTCtiES. DEPRESSAXE!_ F03
TOP SPEED. MASURE VOLTS FOR
FIRSTO. SEC. ANDAFtER 1 SEC.
NO
1
IMPOT FULLY 1oEFEctlvEosc. CARD. REPLACE. e_
cxxlTmOR
READJUST’IATIMF ALL TESTING SHOULD BE DONE WITH

TRIM- POTPERSPEC. DRIVE WHEELS RAISED OFF FLOOR.
BAlTERY SHOULD SE UNPLUGGED
UNPLUG EAllERY. DlSCONNECT
WIRE I23 FROMTERM. TSl OF
OSC. CARD. PLUG Ml-lERY AND
CLOSE ALL NECESSAF?’
SWlTCHES. MASURE VOLTAGE
ON WIRE X29 AS ACCEL IS
DEPRESSED FcF(TCi’ SPEED.
ACCEL UNKAGE.
REPAIR / REPLACE.
UNPLUG EATTERY. TURN KEY

SWiTC+i ‘OFF. RECONNECT V.lRE
X29 TO TERM. TBl OF 0% CARD.
PLUG BATTERY. CLOSE ALL
NECESSARY SWiTC+lES AND
DEPRESS ACCEL FOR Top SPEED.
MEASURE VCLTAGE ON TERM. TSl
C+=0%. CARD.
SM555 19-05-06
SYMPTOM 8
NO
PMTTRIPS EVERY TlME HYGRAulJc
SWlT’3-E.5 ARE CXOSED OF! OPENED.
a
SELECT A DIRECTION. CtiECX
VOLTAGE ON TERM. TB5 AN0 T86
t OFOSCCARD.
UNPLUG &tlTEFiY. CHECK Pub&-
CONTACTOR COILS FILTER AND,
OR SOLENOID FILTER FOR OPEN.
OF FWD I REV SWITCHES.

REPAIR I REPMCE.
CHECK FOR ME VOLTAGE SPIKES

ON POSlTlVE AND NEGAnVE
WIRES TO HYDRAULIC CIRCUIT
CJZVICES.FIND SOURCE AND
ELIMINATE ME SPIKES.
SYMPTOM 9 UNPLUG BATTERY. CHECK

COMlNUllY ff P.S. t.‘OTOR.
VOLTAGE ON P. S.
CONTACTORlERMlNALTO
WHICH SATT-ERY FOSlTlVE
CABLE CCNNEC’IS.
CEFECTlVE PS CCNTACTOR.
REPAIR / REPLACE.
FuJG MfrERY. MEASURE

VOLTAGE AT P. 5. COIL
1DIRECTION LEVER IN NEUTRAL. 1
WSrf?VE (WIRE X10 ).
CLOSE KEY, HANDSRAKE AND 1MS
SWlTC+iES. MEASURE VOLTAGE
ON TERMINALS TS4. T83AND CHECK CONTINUIT, OF
TEt2 OF 0%. CARD. WIREslOT P.S. COIL
REPAIR I REPLACE.
CHECK COMlNUllY OF WIRE t62

FROM OSC. CARD PLUG%‘. PINIt
TO COIL
MWFoFlsHofiTCN
WIRES X6 6 x6 TO
CM’INECTVOLTMTERTO
AND OFERAT0N Ci=
MEASURE VOLTAOE AtXtXS
FWD/REVSWIT%HES.
PS COIL SELECT A
REPAIR/REPLACE.
DIRECTION. READ kmR
FOR FIRST 0.5 SEC AND
MEASURE VOCTAGE ATTERMTSl AFTER 1 SEC.
OF 0%. CAFID.
1 ALL TESTING SHOULD BE DONE WITH

NO DEFECTWE @SC.
ACCEL LINKAGE. DRIVE WHEELS RAISED OFF FLOOR.
REPAIR I REPLACE. CARD. REFIACE. BATTERY SHOULD BE UNPLUGGED
SM555 19-05-07
SYMPTOM 10
LlFTmLTIA7TACHMENT.S
MMYrOFERAlE I
-7
PLUG BATI-EFIY. NRN KEY
SWITCH ‘ON’. CLOSE UFT /
TILT/ AUXi/ AUX2 SWITCH.
CHECKlFPUNpMlTCfl
OPERATES.
SWITCH. CHECK PUMP
SWlTCHs NORhMLLY OPENTO

PUMP CONtACtOR COlL POSITIVE
AND WIRE 113 FROM BATTERY
NEGtTlVE TO COIL NEGATIVE.

SA’ITERY SHOULD BE UNPLUGGED
ANY WIRES AND/OR COMPONENT’S
SM555 19-05-08
GROUP 19 SUPPLEMENT
EVlOO LXT CONTROL PANEL
GENERAL the plug location ” Y * on the control card. After installing

The Handset is a multi-functional tool to be used with the handset too!, plug in the battery and turn on the key
the EV100/200 LX and UCTSCRcontrols. The Handset switch. The following is the startup display sequence
consist of a tight Emitting Diode (LED) display and a that wifl occur:
keyboard for data entry.
1 START-UP DISPLAY SEQUENCE 1
PURPOSE:
The purpose of the Handset is to allow authorized
personnel to perform the following functions: 1 Key Switch on. 1
- Monitor existing system fault cedes for both traction

and pump SCR systems
- Monitor intenittent random status code
- Monitorbatterystate of charge on LXT’systems
- Monitor hourmeter reading on traction and pump
SCR systems
* Monitor or adjust the following control functions:
Creep speed
. ControlledAcceleration?nd 1A time
. Current Limit
. Steer pump time delay and define signal input
( seat switch or directional switch ) -- -J
. Plugging distance (Current) Run Mode ---_
. Pedal posaiin plug range or disable
. IA drop out current or disable
. Field Weakening drop out
. Field Weakening p*dc up
. Regen braking current limit
. Regen braking drop out
Speed limit points (,SLl .SlZ. and 5X.3)
. Truck Management fault speed limit
Internal resistance compensation for battery
state of charge indication
. Battery voltage ( 36/43 volts is auto ranging )
- Selection of card operationtype:
- Standard traction card selection:
- Standard traction with. Fiefd Weakening
- standard tr-ach with speed hits
- Standard traction with Regen/Field Weaken-
ins DOPEYpump
- High or low cunent limitfor all of the above. hourmeter for
-,., four seconds
OPERA&N: or
Warning : Before connecting or disconnecting the
handset tool, jack up the drive wheeis of the ve- ( lf no Pu&%R used )
hicle, turn off the key switch, unplug the battery J
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 ” be set fully ciockwise to insure the control
if the dash diiptay is in use and pfug in the handset to operatea at top speed.
SM548 19-14-l
._
FUNCTION SET-UP PROCEDURES:
Warning: Before making any adjustments to the

control you must consult the operating and main- z PLUG
YPLUG 1
tenance instructions supplied by the vehicle
manufacturer. Failure to follow proper set up In-
structions could result in mlsoperation or damage
to the control system.
Withthe Handset connected, hold down the CONTkey

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

approximately one second.
SET UP MODE
Action Display shows
Holddown CONT, 1 8888 1 Segment check

turn on key displayed
Push function 1 uoo5 1 SekXted

number function number
is displayed
After one second Stored value for

1
time delay the function is
displayed
Push CONT Displayed value

will blink
Value changes DISPLAY

while bliing
Push STORE New value

1 stomdand
Minkins~ops
Push ESC Segment &heck

1 .-_
displayed
:.
At this point another function can be monitored/
changed by pushing another function number, of the
vehicle can be placed in the run mode by hold@ the
ESC key down for one second or tonger. The diyJlay
will return to either the diagno&s mode or the BDI
diiplay or a blank display ( if BDI is not used and
there are no fault codes). The vehicle can now be
operated with the handset connected or the handset
can be diinnecled before operation.
NOTE: You can return to the segmeirt check mode

at any time, by holdii down the ESC key until 8888
appears in the display.
St64548 19-142
DESCf?lPTiON OF FUNCTION NUMBERS FOR:

@ntrol card* lc364!xvLxCMlT Example: 0 = min. current,255 = max.current
Ic364sEvLxCD1TX
IC3645EVLXCDlTK
FUNCTION 5 ~LM+&G~ DISTANCE (CURRENT)
FUh&fON 1 STOF@DFAULT CODE
( Push 1)
This functionallowsfor the adjustmentof the plugging
This functionregistercontainsthe last fault that shut distanceof the vehicle.The largerthe currentsetting,
down vehicleoperation( PMTtype faultthat is resetby the shorterthe stoppingdistance.
cycling the key switch ) . This fault code will be over
writteneachtimea newfaultoccursand can becleared Range 200 to 1000amps (E-VI00)
from memoryby adjustingthe valueto zero. 300 to 1500amps (EV200)
Set 0 to 255
FUNCTION 2 CREEP SPEED ReWllJtii 3.14 ampsper set unit (EVlOo)
(Push2) 4.7 ampsper set unit (EVZOO)
Example: Settingof 20 - 263 amps(EVlOO)
This function allows for the adjustmentof the creep
speedofthevehiie.Aconstantcreqspeedfrequency Warning: Plug settings must be ln accordance with
will be maintainedwhen ah acceferator*npn vottage control operating lnstnrctions. An excessively
between3.7and3.5voitsoran~ratordrmicinput hlOhssttingcouldceu~damagek,coM~lgraem
between6K and 4X ohms is provided. or tractbil motor.
Range 5%to15%ontime FUNCTION6 1A DROPOUT CURRENT

Set Oto255 (bh6)
Resolution 03% per set unit
ThisfundionaUowslortheadjusMlentofelAaontac-
Example: Settingof 20 - 5.6% on time tar drop cut current.The 1A contactorwill be dropped
out and the vehicfemotortoque will be liiited to SCR
FUNCTlON3 CONTROLLED ACCELERATION currentlimit whenthe set drop out currentis reached.
AND 1A TlME
(Push3) R=w 450 to 1260amps (R/l 00)
675 to 1890amps (EV200)
This function allows for the adjustmentof the rate of Set Oto250
timeittakesforthecontroltoacceleratetoW!!applied Resohltii 3.24 ampsper set unit (EVl 00)
batteryvoltageto the motoron hardacceferation.The 4.66 ampsper set unit (EV200)
1A contactorwill automat&allydose .2 seconds after
the controlledaccelerationstops and the acc&rator Settingsabove 250 set units wilf d&able 1A drop cut
inputislessthan.5voltsoriessthan50ohms. function( 1A will not drop out).
Range .l to 22.0 seconds Example Settingof 20 - 515 amps (EVl 00)

Set oto255
Resolution 064secondspersetunit FUNCTlON 7 FIELD WEAKENING PICK UP
(hsh7)
Example: Settingof20=1.6secohdsC/A
and20 1Atime. This funotion
allows the adjjstmsnt of field weakening
contactorpi&uparfrent.ThissattingalbwstheFW
FUNCTION 4 CURRENT UMlT cohtaUortopickupwhenthevehiclehasretumedt0
(l3Jsh4) about15O%ofitsfuHfoadievefruhningcunentafter
This function albws for the adjjstment of the current

limit of the control.The ratingof the control will deter- 52to466amps(Ev100)
minethe rangeof adjustmentfor thii function. Pleasa 76to699amps(EBoo)
refer to the operatinginstructionsforthe controlused in set OtO255
your vehiife. RW&iofl 1.6ampsperSetunit
24ampspersetunif
Range seewntrcl c/L cuwes mle Settiiof20-84amps
Set oto255
19-14-3
FUNCTION8 FIELD WEAKENINGDRCP OUT SettingofosetlJnitswilldisahbspaediiifunctbnand

(Puah8) allowtop speedwith no iii switchconnected.
Thisfunctbnalbwsfortheadjustmentofthefi~weak_
eningcontactordropoutcurrent.Thii settingallowsthe
FW contactor to drop cut when the vehicle requires FUNCTION12 SPEED LIMIT 2 (Sll2)
greaterthan 300% of the full bad levelrunningcurrent (Puahl2)
for greatertorque.
SameasFunctbn11 excaptusingSL2limitswitchfor
Range 85 to 899 amps (EVlOO) input.
98 to 1343 amps (EVZOO)
Set Oto255 FUNCTION13 ;PEEDyMT 3 (SL3)
Resolution 3.29 amps par set unit (EVlOO)
4.88 amps per set unit (EWOO)
Example Settingof 20 = 130 amps Sameas Fmction 11 excaptusing SL3 limitswitchfor
input
FUNCTION9 REGENBRAKINGC/L
(Flmh9) TheSL3setspeedBnitisalsoactivatsdhytheTruck
ManagementModule fautt cedes 90 and 93. see in-
Thii function aibws for the adjustmentof the Regen structions for IC3645FIMMlA Truck Management
brakingcurrentlimit.The higherthecurrent the shorter Modulefor details.
the stoppingdiiance.
FUNCTION14 MERNAL RESISTANCE
Range 75to83oamps CCMPENBATION
Set Oto285 (P-hl4)
Resolutbn 22amjWjlersetlmit
This function is used when the Battery Discharge
Example: Settingof20-119amps Indicator is present. Adjjstmant of thii function will
improvethe accuracyof the BDI. In order to madethii
FUNCTION10 REGENSTART settingthe voltagedrop of the hattery underbad must
(PushlO) first be determinedby folbwingthe steps listedWow.
This function
allowsforthe adjustmentofthepercenton lLoadthetractbnm6tortolOOampsinlAand
timeat whichthe controlwiflstartto regen. Adjwtment recordthe voftageC/O) at the SCR positiveand
of this function allowsthe OEM to set the regen start negativepowerterminal.
speedof the vehicleto eliminateregenattemptswhen 2Loadthetractbnmotorto2OOanpsin1Aand
motorregen currentis bw. recordthe Wage (VL)at the SCR positiveand
negatfvepowerterminai.
Range 0to95%ontime 3.Calculatevoltagedrop (VD)as folkws:
Set 010255 vo=vo-VL
Resolution .37% per set unit 4. Usethe table ttebw to detemtinethe settingusing
the cabufatedVDasa reference.
Egrnple: SettingQf20= 7.496ontime
Evlw Rlzoo Evloo Ev299
M VD M VD
FUNCTION11 BPEED LIMIT 1 (SLl)
(-11)
78 11.44
07.59
07.53
05.07
0l.a
01.27
00.39
00.95
4 06.72 a91 01.20 00.90
ThiifunctbnalbwsfortheadjbstmentofthespeedBnit 5 04.57 a.% 01.14 90.75
01.99 00.73
(maximumbatteryvokstothemotor )whentheSLl s ifs Ei 01.04 90.59
limitswitchinputsignal is receivedby thecontrolcard. 9 02.99 01.91 00.99 00.68
SLl limit switchis a ncrmallycbsed switchconnactad 9 02.54 Old9 OO.% ao.53
to&attery
.
negative,theswitchopeningenablesspeed IQ 5229 01.52 00.91 00.61
. 11 02.59 01.39 OO.% 00.59
12 01.90 01.27 OO.% 00.57
Range 88%~~0% batteryvofts 13 01.X 01.17 00.92 00.55
Set Oto180 14 01.53 Ol.% 00.79 00.53
lb 01.52 01.01 00.75 00.51
16 01.43 00.96 00.74 00.49
StVl548 19-14-4
FUNCTION15 BATTERYVOLTS
C-15)
withFW RegenFW
Thi~fClnctionallowsfortheadjustmentof~~~range
forcontrolsequippedwiththeBatteryDischsftgeIndica-STD C/L 0 to 4 4oto44
tion function.In order for the BDI to operateproperty, High C/L 5to9 45to49
the settingas shownin the table mustbe entered. STD C/L
k$$$;g) 1oto14 3oto34 56 to54
Battery volts Set units
(Autoplug) 15to19 35to39 55to59
24 volts Between Oand31
36 volts Between32and44 Evm
48 volts BeSween45and69 Function RegenIFW
72 vofts Between7Oand80
84 volts Between81 and 183 STD c/L 64 to 68 84to88 104to108
36/48 votts Between184and250 STD c/L
No BDI Between251 and 255 (Auto plug) 74 to 78 94to98 114to118
xsst$$ functionshouldbe madein between

.
Warning:these setting8must be changedby au-

thor&M personnel only, following InstructIons
suppliedbythemanufacturer.CaMypeselection
FUNCTION16 PEDAL PGSRIONPLUG must be made within the capabilMesof the BCR
(PuabGGMandl) controlpanelusedandthe supportingelectwns
chanlcaldevices Failuretotocomplywith proper
Thii function will allow the adjustmentof the pedal applk=ationstandards couldresultin mlsopemtlon
position plug range. Pedal position will reduce the or damageto the controland/or motors.
pluggingcunenttothecurreMvaluesettrythisfundion
as the accelerator is return& to the creep speed FUNCTION18 STEERPUMPTIME DELAY
position. Maximumplug current is obtained with the (PqshCOMandS)
acceleratorin the top speedposibon.
ThiskmctionaUowsfortheselectionofsteerpump
Range looto93Oamps(Ev1OO) contactorpick up input,eitherseatswitchordirectional
150 to 1425amps (Ev200) switchclosingand adjustmentof the time delayfor the
Set 0 to 255 contactordmpout
Resotutiin 3.2 ampsper set unit (MOO)
5.0 ampsper sat unit (Ev200) Pickupon~rmftchcksune~timedelaydrop
Example Sf3Mlgof20=164amps out on seat 5wBchopening.
To disablethe pedal posibonpfugfunction,adjustthe Range 1.5to65seconds

current vatue to the same current value as the plug Setting Betweenoand128
distancecurrent Resoiution Ssecondspersetunit
Example:Ifptug&stancecurrentkmction5issetat Exampks: Setfingof20=10.5seconds

500amps,thensatpedatplugcunentat500amp&
With this setting pedal poshionwitl have no effect on Pkk up on directbnal switchclown, anddropout
pluggingdii. time delay on dlrectbnal switchopening.
FUNCTION17 CARDTYPE SELECTION Range .5to53secMds

(PushCONTand2) 12910255
Resdution Sseccwdspersstunit
Thisfunctionalknivsfortheseiectionofthecardtype
used for your vehicle%appiii. The table below Ewmpks: Settingof 149 - 10.5 seconds
showsthe setting to select card appkatii type de-
pendingon whichcontrolcard is used. Dropoutwiflbel.SsecoKEsaftettheseatswitchopens.
SM648 19-14-5
DESCRlPTlON 0~~~u31NlllMBERS FOR:

ControlCardg Example: 0 = min. current, 255 - max. current
tws45Evurcmux
lc3wEvLxCmMK
FUNCTION5 PLUGGINGDISTANCE(CURRENT)
FUNCTION1 STOREDFAULT CODE (Push5)
( Push 1)
This functionallowsfor the adjustmentof the plugging
This function register contains the last fault that shut distanceof the vehicle. The largerthe current setting,
down vehicle operation ( PMT type fault that is resetby the shorterthe stoppingdistance.
cycling the key switch ) . This fault code will be over
writteneachtime a newfaultoccursand can becleared Range 200 to 1000 amps (Evl 00)
from memoryby adjustingthe value to zero. x3 go0 amps (EV200)
Set
FUNCTION2 CREEPSPEED Resotution 3.14 amps per set unit (EVlOO)
(P-b21 4.7 amps per set unit (EV200)
Example: Settingof 20 - 263 amps(EWOO)
This function allows for the adjustmentof the creep
speedofthevehicle.Aconstantcreepspeedfrequency Warning:Plugsettingsmustbe in accordancewith
will be maintainedwhen an acceleratorinput voltage contfd operating instructions. An excesshdy
between3.7and3.5voltsoranacceleratorohmicinput highsettlngcddcsusedwragetocontmlsystem
between6K and 4.7K ohms is provided. or tractionmotor.
Range 5%to15%ontime FUNCllON 8 1A DROPOUT CURRENT

Set Oto255 (Push51
Resolution .03% per set unit
ThiifunctionallowsforUteadjustmentofthe1Acontac-
Example: Settii0f20=58%0ntime tordroQoutarnenS.ThelAcontadorwiUbedropped
out andthevehide mctortoquewill be limitedtoSCR
FUNCTION3 CONTROUED ACCELERATION current Iii when the set drop out current is reached.
AND 1A TIME
(Push3) Range 450 to 1260 amps (R/100)
675 to II890 amps (EV200)
This function allows for the adjustmentof the rate of Set Oto250
timeittakesforthecontroftoacceleratetoW?!appfii Resolutiin 3.24 ampsper set unit(EVl00)
battery voltageto the motoron hard acceleration.The 4.88 amps per set unit (EV200)
1A contactorwill automaticallyclose .2 secondsafter
the controlled accelerationstops and the accelerator Settingsabove 250 set units wii diile 1A drop out
input is less than 5 volts or less than 50 ohms. function( 1AwiUnotdrPQout).
Range .l to 22.0 seconds &ample Settingof 20 - 515 amps (EVlOO)

Set 0 to 265
Resoiutiin .084secondspersetunit FUNCTlON7 PA4 INPUTSWITCHFlJNCTlON
SELECllON
Example: Settingof 20 = 1.8 seconds CIA (P--f 7)
and 2.0 1Atime.
ThisfunctbnaUowsforthewWionofPA4input
FUNCTION4 CURRENTUNUT function. ThePA4inputoanbeacljustedtooperatein
(-4) eitherofthefonowiqmcdee:
This function allows for the adjjstment of the current 1)ToactivateaspeediimitifanormaUycbsedswitch

limit of the control. The rating of the control will deter- is opened betweenPA4 and negitiie.
minethe range of adjustmentfor thii function. Please
referto the operatinginstructionsforthe amtroDusedin 2)ToreversethediredionoftheMoardmotorand
your vehicle. activateaspeedtimitif.anormaUyopenswitchis
closed betweenPA4 and negitive.
Range see conttol CR curves
Set oto255 Set 128orgreatertoselectopition 1 above.
Set O-127toseWoption2above.
SM54fi 19-l 4-6
EVm EV2w
FUNCTION 11 SPEED LIMIT 1 (PA6 OR PA6) Evloo Ev200
(Pushll)
VD VD -ng VD VD
? 11.44 07.63 17 01.34 00.6Q
3 07.60 05.07 16 01.27 00.85
Thisfunctional~wsfortheadjustmentofthespeed limit 4 05.72 03.61 01.20 00.60
04.67 03.05 ii 01.14 00.76
( maximum battery volts to the motor ) when the Ll or 0264 21 00.73
f 03.61 Ol.oQ
Rl limit switch input signal is received by the control a3.27 02.16 01.04 00.89
card. Ll or Rl limitswitchis a normallyclosed switch x 02.66 01.91 00.99 00.66
connected to battery negative, the switch opening 9 0254 01.69 24 00.85 00.63
enablesspeed limit. 10 02.26 01.62 00.91 00.61
11 02.08 01.39 ii co.66 00.98
12 Ol.QO 01.27 27 00.65 00.67
Range 96%to 0% batteryvolts
13 01.78 01.17 00.62 in66
Set Oto160
14 01.63 01.06 z 00.79 00.63
15 01.62 01.01 30 00.76 00.61
SettingofOsetunitswilldisablespeedlimitfunctfonand 00.48
16 01.43 OQ.Q6 31 00.74
allowtop speedwith no limit switchconnected.
FUNCTION15 BATTERYVOLTS
(Puahl6)
FUNCTION12 SPEEDLIMIT 2 (PA4) Thisfunctionallowsfortheadjustmentofvoltagerange
(Push12) fwcontrolsequ$pedwiththeBafteryDischargeIndica-
tion function. In order for the BDI to operateproperfy,
Sameas Function11 exceptusingL2 or R2 limitswitch the settingas shown in the table must be entered.
for input. See function7 for switchoperation.
Bat&y volts Set units
FUNCTION13 SPEED LIMIT 3
(Pushl3) 24 volts Between 0 and 31
36 volts Between32 and 44
This speedlimit is activatedbytheTruck Management 46 volts Between46 and 69
Module fauft codes 90 and 93. See instructionsfor 72 volts Between70arxt60
IC3645TMMlA TruckManagementModulefor details. 84vofts Between81 and 183
36/43 volts Between184 and 260
FUNCTION14 INTERNALRESISTANCE No BDI Between251 and 265
COMPENSATION
(Push14)
Thii function is used when the Battery Die

Indicator is present. Adjustmentof this function wifl
improvethe accuracyof the BDI. In o&r to madethii
settingthe voltagedropof the batteryunder toadmust
first be determined by fdbwing the steps Tied bebw. FUNCTIGN16 PEDAL POSITIONPLUG
(PushCONTandl)
l.LoadthetractionmotortolOOampsinlAand
rscordthe voltage(VO)at the SCR positiie and This funcUon wiilalbwthe adjjstment of the pedal
negative power terminal. position pfug range. Pedal position will reduca the
2.LoadthetractWmotorto2OOampsinlAartd plylsingcurrend~oecunentvaluesetbythisfunction
recordthevoltage(V~)attheSCRpositiveand astheaccekatorisretumedtothecreepspeed
negativepowerterminal. position. Maximumplug current is obtaiied with the
3. Cafcuiatevoltagedrop (VD)as foflows: acceieratorinthetopspeedpos&n.
Vo=Vo-VL
4. Usethe table bebw to determinethe settingusing lOOto93Oamps(EV1OO)
Range
the cakxllated VD as a reference. 160t01426amps(EV200)
Set Oto266
Resokttii 3.2 ampsper set unit (R/l 00)
5.0 ampsper set unit (EV200)
&ample Settingof20=164amps
SM548 19-l 4-7

To disable the pedal positionplug function,adjjst the Pick up on seat switch closure and time delay drop
current value to the same current value as the plug out on seat switch opening.
distancecurrent.
Range 1.5 to 95 seconds
Example:If plug distancecurrent Function5 is set at Setting BetweenOand128
500 amps,then set pedal plug current at 500 amps. Resolution 5 secondsper set unit
Wiih this setting pedal positionwill have no effecton
pluggingdistance. Example: Settingof 20 X:10.5 seconds
FUNCTION17 CARDTYPE SELECTtON Pick up on directional switch closure and drop out
(PushCONTand2) , time delay on directional switch opening.
Range
This function allowsfor the selectionof the card type .5 to 63 seconds
used for your vehicle’sappkation. The table below Setting 129 to 255
showsthe settingto select card appbation type de Resotutii 5 secondsper set unit
pendingon whichcontrolcard is used.
Example: Settingof 149 - 10.5 seconds
EVloO Standard
Function withFW Dtopoutwillbe1.5secondsafteftheseatmvitchopens.
STD C/L oto4

Hiih C/L 5to9
STD C/L
Mo plug) 1oto14
Hiih C/L
(Auto Pw 15to19
EVMO Standard
Function with FW
STD C/L 20 to 24
STD C/L
(Auto Plug) 30 to 34
Settingsfor these functionshouldbe madein between

the values shown.
Warning: Thsss ssttlngs must be changed by au-

thorized personnel only, following instwtions
supplied by ths maw&tuw. Cwwypese&ction
must be made within the capabilities of ths SCR
control panel used andths supporting skctfo4ns-
chanicaldwices.Pal&retotocomplywIthproper
application standardscou!d rssult in mlsopsration
or damage to ths control and/or motors.
FUNCTION 18 STEER PUMP TIME DELAY

(PushCONTand8)
This function allows for the selection of steer pump

contactorpickupinput,eitherseatswitchordirectional
switchclosingand adjustmentof the time delay forthe
contactordrop cut.
SM548 19-14-8
DESCRIPTION OF FUNCTION NUMBERS FOR:

ControlCard IC3645EVlJGDi PX FUNCTION 11 SPEED WIT 1 (SLl)
(Pushll)
FUNCTION 1 STORED FAULT CODE
(PlJWl) Thiifunctionalbwsfortheadjustmentofthespeedlimit
( maximumbattery volts to the motor ) when the SLl
This function register contains the last statuscodethat limitswitchinput signalis receivedby the controlcard.
shut down vehicle operation ( PMT type fault that is SLl limitswitchis a normallyopenswitchconnectedto
reset by cycling the key switch ) . This statuscodewill batterynegative,theswitchclosing enables speed limit.
be overwritteneachtimea newfault occursandcan be
clearedfrom memoryby adjustingthe value to zero, 0% to 100% battery volts
Set- oto255
FUNCllON 2 INTERNALRESISTANCE Resolution ,375 volts per set unit
COMPENSATION START Example setting of 50=18.75volts
(Push2)
This function allows for the adjjstment of the current FUNCTION 12

level at which the internal resistancecompensation
feature (Function16) will take effect.
Same as Function11 except using SUE limit switch for
Range oto1326amps input.
Set 52to255
Resolution 6.5 ampsper set unit FUNCTION 13 yP$lUMT 3 (SW)
Example: Settingof 72 = 130 amps

Same as Function 11 except using SW limit switdh for
FUNCTlON 3 CONTROLLED ACCELERATION input.
AND 1A TIME
(Push3) FUNCTION 14 SPEED UMIT 4 (SL4)
(Push14)
This function allows for the adjustmentof the rate of
timeittakesforthecontroltoaccelerateto%?%applied Same as Function 11 except using SL4 limit switch for
batteryvoltageto the motoron hard acceleration.The input.
1A contactorwill automaticallyclose .2 secondsafter
the controlledaccelerationstops and the accelerator
input is less than 5 volts or less than 56 ohms.
Range .l to 5.5 seconds

Set oto255
Resolution .021secondsper set unit
FUNCTION 16 INTERNAL RESISTANCE
Example: Settingof 20 - 52 secondsCIA COMPENSATION
and.72secundslAtime. (PushcONTandl)
FUNCTION 4 CURRENT LIMIT Thiifunction is used to stabiiiie pumpspwd at heavy

(h&4) loads. This funcWn is set using information obtained
from the speed torque curve of the motor used. See
Thii function allows for the adjustment of the current OEM service manual for your vehicle for this setting.
limit of the conttd. The rating of the control will deter-
minethe rangeof adjjstment for thii function.Please INTERNAL RESISTANCE COMPENSATION
refertotheoperatinginstructionsforthecontrolusedin TABLE
your vehicle.
Range see control c/L curves 7 “Yrir- 7 “z-

Set 07io 01n
Oto255 : OS.72 if 01.20
20 01.14
Example: 0 = min.current, 265 = max. current t ZT 21. Ol.oQ
7 22 01.04
8 gg 22 m.Qo
SM548 19-l 4-9
--II VOW. Dm (k#inq V-Drop

9 0254 24 00.95
10
11 ~~ ii 00.91
00.88
12 01.90 27 00.85
13 01.76 28 00.82
14 01.63 29 00.79
15 01.52 30 00.76
16 01.43 31 co.74
FUNCTION17 CARDTYPE SELECTlON

(PushCONTand2)
This function allowsfor the selectionof the card type

used for your vehicle’sapplication.The table below
shows the setting to select card appliiion type de
pendingon whichcontrolcard is used.
STD C/L 0 to 8 38to44

Hiih C/L 9to17 45to53
STD C/L
BDI (Lockout) 18to28 ‘St082
Hiih C/L
BDI (Lockout) 27 to 35 83to71
BDILockoutmeansthatthe BDIsignal from thetraction

controlmustbe presentin orderforthe pumpcontrolto
operate. This control will stop operation when the
batterystate of chargereaches10%.
Settingsforthesefunctionsshouidbemadeinbetween
the valuesshown.
wsmlng:Thss0settiHgmustbectrngedbyauthariaed
personnelonly,followingInstructionssuppliedby
the manufacturer. Card typs ssbction must ba
made within the capabiUWsof ths SCR conW
panelussdandthe supportlngBkal
devices.Failureto complywith propsrapplication
standardscouldresti&in mbperaWn or damage
to the control and/ormotor&
SMM8 19-14-10
GROUP 19 EVIOO LXT CONTROL PANEL
I
1
2 I
SM!S48 19-151
STATUS CODE DESCRIPTION MEMORY No
NodisplaymDashDisphyccfZanda RECALL
BLANK
DISPLAY mm Tmaionaud
hP
SYMPTOM
DispIaysacenondashdisptayarlmdsctisblanL
s
POSSIBLE CAUSE
7%
Positiveor negative conmi volts missing.
- rnsurcthatwithktyswition.voltagcisprcscntbc
twccn FZ7 and I’23 (NEG). and voltqc is ptcscm
tetwc0nTl34andPZ3(NEG).
++s~;w TB1
DpcllcimtitbctwccLt10giccardphlg-raadDashDisplayor
FImdscL
- chcckfor~nchctlitmlOOsecoM~~ .
cachwitegoingbmmttlogiccatxiplug~~Dash
Display/ Handset Fiil.
Mcctiver)ashDisplay~
- RcplaccDashDisplay/Haadsd STATUS INDICATION CRITERLA
ThiSi&CUCS~ladc.Of~v0ltagCtOthOlOgiCCUdaradl
CXdiSplttyarrit
STATUS CODE DES-ON MEMORY No

RECALL
-01
No.scatswitchinput
I
cTIRCuIT TlZCtiCQ
-_ _- ._ __ *^a
SM!%W 19-13-z
Fonmddircctiodswitchisclcedonidialpowerup. RECALL4
=02 C’iRm Tramion
!ZMPTOM
SEAT
Forwaxd
amacmrwillnotpickupstatic
reunn
tooff (SRO) lock SWITCH
out. IF
USED
i 0
POSSIBLE CAUSE TB4 TB3
Forward &wtionai switch cbsed on initial power up (ClOs~n of
b
baaerypkg, key switch or scat switch).
- Return dirccrional SW&h lever to lxtm3.l and then &ct
a direction.
FWD
F~dircctionalswilchis weldcdcbscdurmis-adjustcdtoke
held closed. TBS
. R@ccrxadjustdircctionalswitchtoinsurc~it
apenswhendimiodswitchis-toneutral.
e-t
Shortcircuit betweenTB2 andm5.
. DlscoMawinefiommsandcheclrforshmchcuir
. L
bctweu4TB2audwk STATUS INDICATION CRITIWA
ThiStlUUiKdCWiUbCdiSplZipdWhUlTB5iSgnater~
Dczccti~Cafd 6O%banayYOltSatidi8lpOwfXUp.
* DisconncctwircatTB~Measnrem1tagcatTB5,
shouldbelessthan6O%ofbatmyvol*1.
DEXXIPTION MEMORY No
STATUS CODE
Rlxcr3c~switchisclosedmiarid RECALfL
-03 CIRCUIT TI8CtiOll
SYMPTOM
~~versccomac~~willnotpickupstat.icrapnato~(SRO)tack swrrai
IF
wt.
USED
POSSIBLE CAUSE
adirect&
SM548 19-15-3
STATUS CODE DESCRXPTION MEMORY yts
SCanSWiDAiIpUtlawaf!C?initialsantIrp RECALL
-04
L
-CUIT ‘Trauion
kwardorrevcrse confactor
-OMwill not pick-q. --I-~=-~
POSSIBLE CAUSE
Flxwardorrev~directionalswitchcloscdoIlinitialst;atup. .
f Depressaccclclamto close start switch. stanls code
v,achaqca,~ifrwersedinctionalswitchortoo2if
fmvaddimxionalswi~hisclosediftitherofthesc c
c&s appear, retinn dkctional switch to mxmal and
i I
theIlsclectthcdcsjrcddirection,
6
Exa%sive1akageliwlTB2tobat@ynntgative. TB2
* chcckvoltagcaTl32withkcyandseat~~dosed
& m switch in neutral. Voltage should be
gxcafcrr&ln6o%ofbattayvoltage. FiQIlrel. .
- Iflcssttian6o%bfmcxyYolmge.Removewireand
m~&micvaluCtiramWiTCtDSCRIlCpti%.VdUC STA%‘USMDICATION CRlTHUA
ShOUldbCk3Stbll22kO?lUlS. ~stamJc&istAisplaycdwhenTB2voltageisless~
@I%of batuy volts at initial start-up (scat switch do=&
STATUS CODE DESCRIPTION =ORy No

RECALL
-05
StanSWi!ChlXbrakeSWiiChEsilstoClOSC
CIRCUIT Traction
SYMPTOM
ForwardCnnveRe amQlcwrwilllnnpickqp.
POSSIBLE CAUSE
Dcfcctiveblakcswitch~
* c!lK%kbmke.?erdlto~closmcwittltnalapedal
STATUS INDICATION -
mlissmms&i$whaTB1is~tilan2.5vohrandTB2
Llesstbu6o%bamyvok
SM548 19-15-4
STATUS CODE DESCRIPTION
RECALL
Aiziewmdeprwscdwirhno-sc~
I 06
lKEMORY No
TE4CIiOll
SYMPTOM
ol-
comctorwiunotpickup.
ForarsrrdCUlEvMse SwlTcnEs
POSSIBLE CAUSE
Acceleraunpcdalisdepnsstdbefanciosingforwardarrcvtlse
l86
keclionalstitch.
. Statuscodewindisappearwhendimxionalswitchis
closedor whenacc&mor pedalis &cased.
Defective
dil?xtionalswiti
. checkfarwardorrc~switchIoins~clom
WtlCZldiXCCtbiS SCM
Spen circuit bcnvccn directional witch(s) andbatmy positiveor NEG
wwcm directional switch(s)andTB5 or TB6. F&-L

- chcckaucamolwinsandconaecrionsshowIlin
Figure 1.
STATUS INDICATION CRlTERIA
TbisstatuscodewillbcdisphyedwhenTBSandTB6mltss
tlliXI6t%aftfrebaneryVolTS,aedTBliSk!SStbl25volt9.
STATUS CODE
Aczc&mmiuptxvoltagcooollig
DESCRIPTION MEMoRy RECALL
No
I
07 ,
CIRCulT lfactioa
SYMPTOM TBl
FOlWd~WCSCCOllti4CtWpiCkSupbUtcannolWilleotapwn:
WhCXlacfClcratQp#ialiS~OfstamJUJdC-o7tidisplayed 0
tkndisapamwhenthcvchiclcsmiutoafcelaare.
POSSIBLE CAUSE
Atzc&aminputmis-sdjosador~veD
* I4nxtvoltagcatTBlshorrldbclss~3.7vola.
Aajost-W= aKxxkaxunittoiusllrethatthe
voltagcatTBlwinnayffotu3~vohrtoIws~.s
VOltSwkJltkpecttiSdepnssai.
opm~bawanbrtmy~snd~liU-illpUt NEG
c7imaiL
- c!hcck~brokalwinesarloose~oropul FbrprL
potauinmemr/~~yinthCCimlitShOWIliIl
F@lrc 1.
STATUS INDICATION CRITERfA
slxxt~fiuulbatrqypositi~,towilingiIlaccelasoDlrinprt
circmit. Thissfamscdaewinbcdisplryedwhmtherca~~~
volmgcatTB1ishi~thrm3.7vohSandr~
. *
Dl!ummawircfromTB1and maumtVOltl&lSatwin caanctarispidraiup.
toBcguiVc.slxnlldbctiVolrsfcirpormoiom#a:lypc
alxbsstban3.7valafoasalidsta!ctype~
iapnt.
SM548 19-15-5
STATUS CODE DESCRIPTION MEMORY
No
RECALL
108
~~VOi~tOOlOWOllpoWerupafteritlitikey
swifcb closule. I
am Tiaction
< 1
TB1
SYMPTOM
?xvmd or rcvcrsc amactor does not pick up.
POSSIBLE CAUSE
4ccduator input misadjusted or defective.
- Input voltage at TBI should bemore than 3.0 volts.
Adjust or replace acalcraoorunittoinsurctbatlhc
voltageatTB1ismonstban3.Ovoltsbcf~dcpxcdng I
Hmrtc&cuitbtrw#nbartuync?alivcandTBlindcratoriapm -
rAi
)
LircuiL NEG
. Dsonwctwircf&mTB1.Ch&forshortcircut&om
*
wirea,battctyncgativc.R&stawshouldbcgream FigUrtL ‘_
than 4.7K ohms.
Mectivecald STATUS INDICATION CRlTBUA
* Discomlcctwirc~TBl.Measpn:volragc~TB1 ThissaaUcodcwinbcdisplayc4iwhcnthe~iuput
to0gative.v01tageshoddbegwertbau45vohs, [email protected]&andauyoftkfoUowing
ifnotJeplacccald. connectiorwartOpUXdlUldcloyxs~pltIg~SearSWitdI
ackeywitc&
-09
Bothflxwaniandrevuse~switchesan:closedatthe RECALL
samelime.
ac!uIT Txstion
SYMPTOM
F~ornvase contacmwinnotpicklrp.
POSSIBLE CAUSE
FolwardormeRtctirraionalswitchwddpddasdormis-
adjnstedtobchddclmcd
* Replaceaar@!x~~tootbat ylfn
thcyopatahsndineaMlsniochisramnedtoncnuaL
SbjancircllitbetwembmergpasirivedTBSuwvOrTBa
. Dscunetntrafrom.TBsmiTB6aadckckwircs
*
forshoncixCuitopairkre*ddirectianalswitch
Det%ctivecd MEG
. Dlsamwxwir#arMi
- measamvdll&gcatTB5andTB6. piopr1.
V&gCShoddbCkJSStbUl6O%Ufbamgvoln
STATUS INDICATION CRfiERIA

missmls&winbcdisgkgafwhenTB5alldTB6an
g!wcr~~afbancryvoltsrrtlhcssmetima
-SM!348 19-15-6
STATUS CODE
Bamy
volrs
too
low. DESCRIPTION
Ri3cALL
MEMORY No
-15 -m Tmctim
BATT
SYMPTOM CONN
Fofwanl or lt.vcrst comactor will not pick up.
POSSE&E CAUSE
Dis~bargedbatmy BATTERY ++
. Check bamry for pmpm open cirmit voltage as outlined NOMINAL MINIMUM
infigpnl andcbargCbatmyiftcquirui
Dcfcctivc batmy T-
EATT
. CkckeachbattcryceUforpropmvoltage@eatcrthan
CONN
1.95 volts at cdl). Rcplacc OTrEpairbattery.
IlxxmxtcontrolciudadjusrmulL
- Check function 15 for properadjustmentfor battety
being used See handset instion sheet for &tails. F$m!l.
Adjust to proper settings.
STATUS INDICATION CRITERIA

Thisstamscodeisdispiayedwhcntbebaumyvoitsarclcss
than1.%voltspcrCcllatinitialstmup.(scetablciu
figme 1).
STATUS CODE
Battcryvola
toohigh. DESCRlPTION MEMORY
RECALL
No
-16
I
ClRm Traction
SYMPTOM
FQIWZiZdaIldtWUSCCosltacoorwillnotpiCkup.
POSSIBLE CAUSE
hlcomctconmlcaldaitjpstmau
* checkhnckJQ15fQprqxrdjosaeemforbanqy
bchgusdsallande~fardetBli15Adjtist
mpropasening. [-zq
m Ntult4am
3plcircpitinngensmsarcirwit
- C3~xkyduwwirek4nsaxd?2toPA4 farimkm
wir&loosc~q:~wcldatsmsar.cbcck
PA4fL1rla~cplogarpinaga#?rhxn.
BattcIyoveri2lmgcdarincaa#xbgmaymed
PiomcL
* chcckbamlyfixpxupcropencircuic~pa~
infigutc1.lfvolmgc-xaJsin_cbairbarmychrr
f=Fampromparv t3lXlVS INDICATION CRITERIA
Thissrams&is~whentttebatp?ry~cnt
grcamthan24O~paa;ltatinirialsWtrp.(s#~
infigtm.
SM548 19-l 5-7


InvalidcardLypesclccti~ RECALL
47 CIRCUI’I’ Tractkm
_.
SYMPTOM
%xw2Jdor-contanors willnotclose.
POSSIBLE CAUSE
[nvalidcardtypesekction.
- Reviewfimction17 in the Handset Instruction sheets.
Adjustandsctcanityperalueasins~byOEM
senricxmanuaL
STATUS INDICATION CRWERIA

TbiSStAWSCOdCiSdiSphpiWhCIlthCcardtype.SCldOO
valuefscttoaninvdidmmlber.
DESCRIPTION MEMORY No
STATUS CODE
FOnWRiOrrevaCanuactacoilclmtntlow. RECALL
23
‘
I
acul[T Trauion
) 4
SYMWOM
?aw&aICvasCconractatwillnotpiCkUp.Statnscode~
llluMtebetweenccde23aBdcule24.compbztt~facork? +
u,ifthepmblcmisnotfolmd~chcckfa‘coda24.
F +
PO!GIBLE CAUSE P04@

1)efectiveFandR axacuxcoilciroaa
- chlxkfaropendmtaaI#Jst~bawcal p85*
pB4aadpO&VCddeOfFCOilQkW CQilardbuwcQl PB6’
PB5andpUdtiVCSidCOfR~COiL
P02 *
- RemoveptosB.ChcckohmkvaincfromP84uqosi pl33*
tivesidcofFa%LVrtoesbaxJdk10-14ohms.W
WWCb&fQRCOiL PBl.
FIIcanL
IDefectivel&RB, sP,aFwcalmctacaiL
. -plugB.Cbeckohmicvalucfrompo&iveskk
OfCZIChCOiltOitrt@3pt&WphIgcarmeaiaaVahz STATUS IMlICATION CWTERIA
shcmldbelo-14ohms. Th%stamsC&iSdi@@XiWhCQtbCCmnmrd-indrt
fawardanvene- ~~iskgtbMlOOmb
SM548 19-15-8
STATUS CODE DEZSCRDPIlON MEMORY No
~voltagetoo~gh.(Or*loerthan12%ofbauuyvolts). RECALL
-24 CIRCUIT naction
SYMPTOM
SCR control does not operate. Status codemayaltcmatc bctwetn
code23andcode24.conipletechedcpfar24,iftheproblemisnot FH
found, pufotm code 23 check. 51 52
RM
F R c
POSSIBLE CAUSE F L
Defective
For R contacmr. .&I Q R l
w* UI
- ForRpowcrtipsfhiltoclosebecausc -NRE F85
Fe6 +
1) Welded nmmally closed power tips. *1 0)
2) Binding comactor tip assembly. p R ; wz -ilr:,
w
3)D&xiveForRcomacaxa~iL AZ w(
(Sccsmalscode23)
T
Dcfcctivc RB contactor.
. chcckRBamtacaxpowcrtipsforclos~andplupcr
ewe1.
pickup.
f ckckfcirupcncircuitarloosccdonsbetwcul
pOSitiVCSidCOfRBContactorCoilandPB2. STATUS INDICATION CRITERIA
lIi!ssmm!5codeisdisplaycdwhcnT2voltsisgratcrdrtm
Openmotorcircuit 12%ofbattctyvoltsandt&cFandRdti~crisenergiwt
- Chcckforopu.tckuitorloc4ccotmdoninmatDlr
circuithmtheA1 LxMcctiontothcA2comlcctionon
dlCSCRC4XIttOipatld.
Dcfectivc lA$RB,SPor Fw cotltactor

* R!rfomlckecksas~iustmu23.
STATUS CODE DESCRIPTION MEMORY yes

1Acomauordounotdmpotuac~~~ly. RECALL
,
125 am Trdun
P
SYMPTOM . _
S~tiplifconFandRor1Acwacmr. SQUUSCOdC46diSpllIyIXi
and no fault found.
POSSIBLR CAUSE
Notc:Thisstanscodecancdybcfodbynsingtbchandsaaad T--
lA
kxikingatfunction1.Thisstamsa&isfmnisbdasamm-
blehoiingaidfarsmmsade46.
Defcctive1Acontxxu T2
* ChaklA aammacfabindingorslow~whm
ctropping-”
r--4+
Q3-1.
!FI’ATUSINDICATION CXWERIA
ctlmamxdropfmttime
TbissmJscodcisctisplayedwhenlA
e-xeds.060sffondk
SM548 19-l 5-9

STATUS CODE DES-ON MzMo*y Yes

slKmedcoil~vuforRB,sP~Fwcontacax. RECALL
126 -m Traction
SYMPTOM
zB,sPormc~ picksupimmediateywhulhyswi~is
:lOSd.
POSSIBLE CAUSE
rxhctivecoil deer in& to logic cad
* Retplacelogiccald.

ThissprmJcodeisdisplaycdwhenthcreisash~BB,SP
txFwcoildxivcr.
STATUS CODE
openthumalprowcaxaramtr
DESCRIPI’ION MEMORY
RECALL4
No
-41
r
SM548 19-15-10
STATUS CODE
SCRmorarcuxxntscnsariupntmissin RECALL
I
42 -m Traction
SYMPTOM
~opowertoncrionmoiorinSCRrange.
A2
POSSIBLE CAUSE
2pensensorwirecircubtoPZ4. GRN
* check for loose COMC!dOtl Or brOlm wire (gncm wire) SCR 0 l PZ4
bmcu7entsenscrtoFz4imthelogicciud. CURRENT . *
NEG
F-%=~
STATUS INDICATION CRITFaRJA

‘I% status
codeisdisplayed
when voltage between PY7
and negative is gmatcr than 1.6 volts with no cmmnt flow-
inginthcmotarbxit.
STATUS CODE DESCRIPTION =ORy No

SCRmotarcutmntsensarinpmmissing. RECALL
143 mm Tmcth
SYMPTOM
StdcOmtItSiIlSCRIZitigChigbWhSllnamalimdrmColl~llablC
vithcYLadjWmcnt A2
POSSIBLE CAUSE o- Ir
)pcnscnsorti~topP. SCR
CURRENT o- 4 PZ3
- f2kk5aloosc- orblbnwiit(ycllow ,
Wil%)frweClJXUltspsorOPZ3UillOgiCcard SENSOR - YEL
hl
NEG
FisrnrL
STATUS INDICATION CRITXUA

Tltisstamscodtisdisplayedwbm~~pn
andqativeisks?timJl.s4vohwithzxxxmatflowing
inmotrJrcirca
SM548 19-15-l1
STATUS CODE DESCRIPTION lmMORY Yes

1REcdidnotturnoffprOpcrly. REXXLL
-44 mm Trdon
P
SYMPTOM
%3wardarmvezsecon~apenanddosc,thulcanonlybe
mEc,F-_L
bscdby openingandclosingthekey switch. 4’
POSSIBLE CAUSE
Icfective5 RECcircuit
- Cbcckfurshoned5REc.
- Checkfor shuned5 RECsnubber(25 REC).
M%ctivc2REcc+rcuiL
- Chcckforshoncd2REC.
- Checkfor shard 2 RECsnubber(22 RX).

QP-t
Ipen choke(lx).
- Chcckfaropcnc&uitbctwcenT5andT3.Obmmuex
shoddmadonoohms. STATUS INDICATION CRITERIA
I RECdcfcctivc.
- Tumofftimefor1RECoutofspccSdoaNofidd Thk§mmsuxkisdisplaycawhe~dtuingsCRapaatioa,
tcstispossibkRcp~1REcaftcrabovecbbcb,show l~Cfaits~~&.
nopblcmfound.

1REcdidnotmmonpmpdy. RECALL
=45 am Tract&i
P
SYMPTOM
Folwardor -CWtXUXXWill~andclwe,thenOpUld
thmCanonlybccloaedbyqJulingandCloSingthelayswikb
POSSIBLE CAUSE
Dcfaxive2REccirwit.
- ChakfarshaEd2REc
- cJhockfar~2~srmbba~REC).
DCfUXiVClRECCiKd
- Qeckfinrqrcn~arloorw--1
REcatldpzB(whialblowire)
22lEC
* ckktblrcYpaIfziccaffloose-bcawcen1‘
pbrpc1.
REc(3REcsmlbbw)andFa9.(blncwile)
DCfWiVClREC. STATUS INDICATION tXTERIA

T -’
cxopDlREceEsoeEjfMtMtmayormay Thissmtuscuieiadiclplrgcdwlwp1REc~a,grp:oa.
lmskowd&uRcphce1REc~abovcchecb,
ShOWIlOproblem~
SM548 19-1112

-ahead=stfarTzvolts. (Grca!crthmn85%ufbarmyvolts) RECALL
-46 -m Traction
SYMPTOM
%xwardar
revcrsccontaculswillnotpickup.
qOSSIBLE CAUSE
Icfective 1 REC.
. Checkforshortd 1 REC.
- check fordeftctivc 1 REC i.ns&nr (c*ttlclm) that

mayshonlRECluxusinktobaseplatc.
kfecdvt 1A contactor.
* Chcckforweldcd1A ContactorpowertipS.
STATUS INDICATION CRITERLA

ThissmtnscodtkdisplayedwhmtbcvoltageatT2i.l
gnatcrthan8596ofbattuyvoks.
STATUS CODE DEXRIPTION MEMORY yes

2REcdocsnotalmonpogerty. RECALL
,
-47 -m Trwtion
SM!548 19-15-13

LGokahcadtcstfornvala~ttlan12196bamayvolts~. RRCALL
-48 CUt- Traction
!3YMPTOM
%ilwardorreversecontactcxwillnotpickup.
P,OSSIBLE CAUSE
Defective
forward or reverse comactor.
+ Check for welded forward or reverse contactor power
tips.
- check for shlggish opentioll of fcmvald ar revtrse

comacmr.
wxtivc 3 REC &cd.

- Checkforshoncd3REc.
F-igllre 1.
- Check for shorted 3 REC snubber (23 REC).
STATUS INDICATION CRITERTA

Thisi3lamsaxicisdisp~yedwhcnthcvollageat?2islcss
than1296ofbatrcryvolrs.
STATUS CODE DESCRIPTION MEMORY y#

5RECdOCSlX%tU7?lOnproperly. RJSCALIL
I
-49 -m Trmion
SM548 19-15-14
STATUS CODE
c2apaci~volts DESCRIPTION MEMORY
RECALL
No
-50
low.
CIR- Traction
KS*
SYMPTOM
Fmvatdor rcYersccollafxor pick3up. amml daes not opetatc. c3 d a-ii Q - @
(D,QQ@ 0 5=
WB- me
POSSIBLE CAUSE
Defective2 REC circuit. a 2REc
q.,
open circuit or loose CoMectionbcrwcen spider
assemblyand 5 REC (BUS A).
opcncircuitorlooscc oIzwdon~nsREcand
2 REC. 1
opcncinxitQrioosccoMectionbetwcen2REcand q,
I-
PZll(rcdwin$andbetween2RECgatcandPZlO t z&c
(WbiW wile).
%W=L
Chc&2EZECtoinsurcthatitwillgatcon.
STATUS INDICATION CRITERLA

TbissTa#codcisdisplayedwhul2REccircrdt~to
amlonatiuitifJstmtup.
STATUS CODE DESCRIPTION MEMORY yts

RJ%cALL
-51
Extmsi~capacitorvolm~wknmotorcuuuttishigh.
c!IRm Tmction
SYMPTOM
?OlWZdfXICMJeCOIltaCtCRSOpUlanddosc,thQlCtmdybC
Wedbyqningandclosiagthekcyswitck.
PO!mBLE CAUSE
5xa!aivcsoulcc~
. TagliaawhfwrPr;5a1clxing~
STATUS INDICATION CRITERU

m3smaascuksistlhphydwhea~volrsd
mwltsandmaa%aurcntisgrmlertlml3oosmpr.
SM!548 19-15-15
SM548 19-15-16
STATUS CORE DESCRIPTION MEMORY yes
ShaPdF,R,arlAamtauorcoi.ldri~. RECALL
-54 CI[RC.tJIT Tract-h
ZwMPTOM
c!onuol will not OpmIc.
POSSIBLE CAUSE
Defectivelogiccad
Rcplaaslogic cad.
STATUS INDICATION CRZIXRIA

Thissramscodeisdisplaycdwhcnci~ttlef~
xwerscarlAanuactm caildrivcrissilonediutunaltothc
logiccad.
DESCRIPTION MEMORY yes

STATUS CODE
cmrentsensoroutpptvolcsgcpa .
RECALL
-57 CIRCUIT TlX!iOfl
SYMPTOM
bwardorrevaJe conolctonOpCJlandClO%theaCSUdyk
zloscdbyqYulingandcloaingtbcktyswitch.
STATUS INDICATION CRITERU

Thi!ist&usco&is~whaldlcvolmgcinplrmpz4
muwz3istbcwrongpt3mty.
SM!548 19-15-17
STATUS CODE
RECALL
RCgUlCUUUlt-inpPt_(yellow
-OR’ DESCRIPTION No
-70 a- Traction
SyMqMlM
conlroldccsnotoperaa: POS SENSOR 2
POSSIBLE CAUSE
DefectiveregalscnsixinputCinxiL
* checkycllo~scmmwireforopencircuitorloose
conLln~lion ilctween sensor (welti ccmImion~ and 7 REC
PA4.
STATUS INDICATION CRITERZA

Thisstatuscodc%~whcninputsignalatPA4k
missing.
Rcgcn-sensaainprnmissing
STATUS CODE DESCFUPTION MEMORY No
RRCALL
-71
I
C’IRm Ttacticm
POS SENSOR 2
tt ti
STATUS INDICATION CRlTHUA

l%iSSUltUSCOdCiSdjsplllycdWhUl~~atPM~
!ctisshg.
SM548 19-15-18
STATUS CODE
RImiLL
DESCRIPTION
Rcgcncontacmrdoesnotpi~.
MEMORY No
172 mcm Ttaction
POSSIBLE CAUSE
0
*ncoMcctioninrhcPA6ciTcuiL DRIVE
MOTOR Fe2 PA6
* check for open citcuit or bosc cotmeaion betwaxi PA6
and the A2 cotmcction of the RB contactar. A2
17
* checkforopetlcimuitatlooscconnecrionbetwecn7 (C
REcanddleA2aDneectionoftheRB~. - RBCOt&~CTOR
A2
@!w=L
STATUS MDICATION CRITERIA

ni3statuscodcisdisplaycdwhcnlogiccatdisintunmode
and25voltsccgmatcrgrram:isplwientatPA6.
_. - .-._

RcgcnaMtacaIrd4w?notdtupoutixdtupsautshvly. RECALL
173 CIRCUIT’ Traction
SYMPTOM
4xwadorrevanccon~opcnsdcl~t&ulopcnsandcan
lnlyclosebyupeningandclosingtkkcyswitch,
DRIVE
POSSIBLE CAUSE MOTOR PA6
)cfcaivc RB conmctm A2 .
- checkRBaxnxmfotswothaas dopcmtimaad l7
k?xKmivewarmmovingpmu. 1 .
0
tlmmimmt PA6 ilquu R0 Y%iFOR

- chc&*lalsc- kPA6circuitfromPA6to
A2
RBummctaA2#
$
Fpem*L
STATUS INDICATION -
Thissmalscodcis~ycdwhcntheRB-powa
tipSf8iltOapenadpet1OOm9ixcordsaftaposrrcris*
movai&cmtkRBcatacmrcoiL
‘SM!548 19-15-19
DESCRIPTION
STATZJSCODE
Rcgulcon~picicsuptos.low. MEMORY
RECALL
yes
-74 CIRCUIT Traction
SYMPTOM + RB
Forwaniar~~coa~opensanddosw,thenopc~andcan COIL
only close by opening and closing the key swin9~
DRIVE (L
POSSIBLE CAUSE MOTOR P%2 PA6
DcfectivcRB comactoi~
* chcckRBcontactorfclrsm~essofopcrationalld
17
exccssiwwearonmoviugpam.
&
rn-t PA6 iHpUL RB C$tT&CTOFi
. Chcckforlcosecd~inPA6&thPA6to
RR con*lctolA2- A2
Defective RB CoIsacm cd cimJiL +

* chcckRFJcon~coilforpropcrohmicvduc.It
QP=L
shouldbe lo-14 ohms.
* checkcod cxnmc&on~PB2mRBcoil(-)furloose STATUS INDICATION CWTERIA

c7oma3ioDs. ThiSstamsCOdCLdiS@JdWhCIlthCRBCXMlWpower
tipsdotKxclo#cwithin1oo-aftcrpowcris
- chcckcoilco~~~baacrypapitivetoRBccrii appliedtotfw:~contscoa~
(+) for loose ctxmcaioxls.
STAWS CODE DESCRIPTION MEMORY y#

1REcfaiL3mtumcadlltbgrcgcn. RECALL
-75 mm Traion
POS SENSOR2
SYMPTOM
Fofwardarrevcrseunl~ope.nsalmicla8es?thmopensandcan
lmlycloscbyapcxlingaedclosingthcktyswilch
POSSIBLE CAUSE
1REctlmofffailutetKxxlataitoItsm.
* StallvchidciJlbotild~~any~axlcs
displqaithazmaylnrxecloacly~thcfailmtmodc
TtOtlbkSbOOtpernCarSt?UttScode.
1REcttlmoffrtlapdto~ 4L
- chatkfoclac4a~aa8urrgrmpaarercicFpitt -RB CO&+CTOR
frombauexypiaivcmRBal¶lmuaA2-
* chcckfarloo@e-anthcfollowing~ilIpat A2
circuim. B
-YeIlowwi1efrpms~wr2mPA4
-GlealwiIeeolltsens4x2toPA5. FieacL
-Win17hnnRBccmta1~mPA&
-ATUS INDICATION -
Defaxivcmotort5mit ThiSStNlISCtldhdi@pZdWhUtappEaibmtOf1RECtO
* mxkmator~foropenarloo$ea*mcbiana
=Qffdmingrcfencycte
* chcdKmotor~for~scaIiIlg.
ForR-powor-gormdngapm.
. InsutctbatFauiR fzcmtawdoesnatbowxaQGn
dnringvchickaperation(ic::goverspecd
buIllpsanddofkPlrrw).
_.a_*- >_ *___
capacitorovuvoltagt
during
rcgm.
RECALL
I
76 CIRCUIT Tl7ictiol.l
SYl4PTOM
~orwadOTreversecontactoropensand closes, then apens and can
mly close by opening and closing the key switch
~~~~q_
POSSIBLE CAUSE
kncrmittcnt
conmctioniu battery power circuit. +
. Checkbattery power circuit, both positive and negative e BAllERf
-
for loose concctians.
BAT7
CUNN
. Checkpowerfuse,batrery connectors, line contacms, 1
and etc, for possible opening during ngen cycle.

LNEGAM
Zxcessive some inducmncc.
* ch&foralnmmedtagliQcs.
* check fop long balmy cables. r-1.

Thisstamscodeisdisplayedwhencapacitorvoltageis
greaterthall225v01tsdlIringlheregencycle.
uscrdeA5nai~code-sccoEM~onmaauaL
STATUS CODE DE!WRIPTlON MEMORY No
RECALL
-90 I CIRCUIT TMW
SYMPTOM
Stamsccdeflashesonandoff.Vebiclespecdmayormaynotbe
FJ I
BATTERY J-
NEGATIVE
* Dlecti~TMMlcard
F%3=L
N(XE%henSCRpumpamaolisusalwithiamnal~l
ftlll&%kpkIttnminalisPA3QnplUIlplogkcanl STATUS DUDICATIONCRITERfA
TlXiSwrmSCUiBiS~WhUltheMttagtatomsinal1
dTMMliSat~Wk3.
SM!348 19-l 5-21

UsadfacdstamsCOdt-sccOE
DESCRIPTION
STATUS CODE MEMORY
No
RECAJdL
-91 CIRcuiT TM&u
SYMPTOM
stanlscodeflashesollansioe
POSSIBLE CAUSE TRUCKMANAGEMENT

MODULE(TMMI)
U~defiaedstatuscodcisdisplay#ibyswitchclosuretone~v~ 13
. S~OEM~~onmannalforcomctive~on
rcquind
SW3 -
othachWeSI
- Terminal3shonaitoqative.
BATTERYJ-
* Dchtivc input sxvitch(shomd). NEGATIVE
* DldixliveTMMlcard.
NOTE%hcnSCRpumpconldisnscdwithinted~l FigmPL
hmcti~iapLulmmiaalisPA6onthcpmnplogiccaId
nisstamscodeisdisplaycdwha.ithcvoltagcatamninal3
ofTMMliSatmOWh.
STAWS CODE
RECALL
uscrdefincdstamscode-sceo
,-92 TMMl
SYMPTOM
statuscodctihcsonalldoff.
64
POSSIBLE CAUSE
USddiIldSCilllScOdCiSdiSplZtyCdbgswioch~to~galivc 4
- SccOEb+fiIlsmabmrmml~ ccmctivcacfion
w
SW4
otherc!ausa
- Tcrmid4shQaaitoncgatine.
BATTERY T
* DefaxiwinputswltEh(~~ NEGATIVE
* DefdveTMMlc8d.
NOTE%henSCRplmpaxm-disuscdwithinbernsi -1.
fmxxkms,iqmtfaminalisPB6ondrelogiccard
Thiss!8ttlscodtisdispkyedwbmtbevoltagcatacmrinal4
ofTh4h4lisatoerovoh
SM548 19-15-22
STATUS CODE
usadefitKdstaalscodc-seeoEM RECALL
-93 TM&f1
SYMPTOM
Statuscode flashes on and off. Vehicle speed may or may not be
POSSIBLE CAUSE 4,
Userde&cd stamscodeis displayedby switchclosureormotor 5 6
bIu& salsor closule to negative.
f SeeOEMillmlmion manualfor cantctiyt action
requireb SW5 SW6
3thcrczausa:
* Tzzminal5or6shoraedtoncgati~. BATTERY IJ I
NEGATIVE
- Defectiveinput switch (shorted).
Figmf,
* DefectivcTMMlcad.
s~:whellscRpumpcomrolis&titllimealTMM1func- STATUS INDICATION m

ioap,input~isPAlandPA;!~thep~pl~card TtlisstatascodeisdisplayedwhuItheti~attuminal5
or6@‘MA4lisatzcmvolts.
STATUS CODE
uscrdct%dstaelscodc-seeoEMi .
RECALL
-94 CIRCUlT TMMl
SYMPTOM
StUUSCOdt?fhSbSOllando&
POSSIBLE CAUSE
piz%Jq
Ustrdcfiazlstamscadcisdisplayalbyswitchclosme~motix 8 10
bnlsbscnsorclosun:tontgaoin.
- !he0EA4~manualfar ccmnaiveaaiinl
req,in& SW10
ckhcrcau¶e
- Tumiml8ar1Oshatcdmaegarine. BATTERY .T
NEGATIVE
- rzBcfMivcinpntswitch(shakd).
DU%CtiRTMMlC&.
FiaprrI.
NCYE:WhmSCRpmmp~isascdwith~~l
f~mctic4u,inp~tmminalLPA4sndPAsuatheprmq?logiccard STATUS INDICATION m
TbissmmscaicisdispliysdwiratkvoitagcrrtruntiMl8
a10cJfTMMlisamo~
SM548 19-15-23
STATUS CODE DESCIUPTION

RECALL
user-SFamscodt-seeoEMin
MEMORY No
-95 CIRcurr TMMl
SYMPTOM
stamsanicfia&c3manda&
POSSIBLE CAUSE lpiifi%J 11 12

Usadefincds*uMcodeisdisplayedbyswitchclosurcorm~
!Jrushsensorclosure to negative.
- seeOEM insrmctionmallllal fur cmrcctivc action
SW12
nqninb.
Dthcr-
- Tcrminalllor12sh~tonegativc.
- Dcfcctivc*tswi~(shaned).
- l3efe&eTMMlcard.
Figpre1.
KnEwhenscR pumpcoll~lisuscdwithin~TMMl
FImctioIls,inpmterminalisPB1alldPB2onthepumplogicd !3TATUSINDICATION CRITERIA
ThiSSCXtlLSCOdCiSdiSphpdWhZlthCVO~iUtC&Ml
11ar12ofnKMlisatmovolts.
STATUS CODE
Illvdidcardtypestlection.
DESCRIPTION MEMORY
RECALL
No
-117 CIRCUIT pump
SYMPTOM
hldwillnotopemc.
POSSIBLE CAUSE
balidcanitypcsc~
* RcvicwfImcta17inthcHiodsafasormctionskus.
Adjmtandsctcridtypcvahle~,insollaedbyoEM
serviamannrt
SM548 19-l 5-24

STATUS CODE DESCRIPTION

REXALL
-123
Pumpcontacxxcoilcmmltlow.
I
CIRCUIT Pump
!!JYMPTOM
Status code may altcmare between
nde 23 and code 24. Complete check for ccdc 23, if the problem is
lot fomld+puform check for code 24.
POSSIBLE CAUSE
kfcaivepump comactor coil CircuiL
* check fOrOpCn &Cllit 05 ~OCX COMCCliOll bCtWUll P04 l
PB4 and posirivc side of pump wmactor coil.
PB5 l
- RemoveplugB.CJskohmicvaluc&omPB4toprxi
tive side of plnnp CoiI.value should be lo-14 ohms.

Thisscatuscodeisdispla~whcntkc-dnrwinthc
pumPfxmmcmr~cinroitislcssdlan1ooma
STATUS CODE DESCRIPTION -OR’ No

RECALL
-124
T.2vokagctoobigh.(Chatcrthaa12%ofbancryvohs).
/
CIRCUIT Pump
POSSIBLE CAUSE
ckftaivcpmop~.
- Pumppowetipsfailmcloeckauue: *
1)wddodnmnlllht~pQwcI:tips bmanm
2)Bh&lgalomcmr tip aumibly. *2
3)Dcktivepmnpc~ I R)
(SCUrrtrtrmcode1l3)
A2
T
FbprcL
Ipcnmoux&uit
- checkforopalcircnitcrloosc-inmao?
&cuitfrranthcAl arrmtakmtotbcA2-on !3TAmS INDICATION CRHERIA
thCSCRCC4llIOlpanet lEisstatusu%leiscfisplayadwlwaT2vcdfsisgr#derthrn
12%ofbamxyvohaadtpumpdlivu~~
)efectvelA-
- Perfmmchccksas~instatns123.
.SM!548 19-l 5-25

STATUS CODE DESCRIPTlON MEMORY yej

RECALL
-125
1Aammcmrdoesnot~otuix~out~ly.
CfRcuIT Rmy,
qOSSIBLECAUSE
Notcz-lhisstamsccdccanonlybcfoimdbyusingthchandsetand r
1A
10okingatfmction1.Thisstatuscodcisfianishedasauou-
bleshooringaid for statuscock 46.
Defixtive1Aamacttu T2
- ChccklA ctmacKuforbitldingarslowoperatianwhcn
itropping-
T---+
STATUS INDICATlONCRlTERIA
lIisstamscodcis&playedwhcn1A ciomacmdtopotltiimc
cxccd.060d
STATUS CODE
opcntbcmlalpfoDxmrQQIltl
DESCRIPTION =ORy
RECALL
No
I
141 I
CIRCUIT Pump
SM548 19-15-26
STATUS CODE
scRmotcx-suisariapotmissi
DESCRIPTION
-OR’ RECALL
No
I
142 CIRCUIT Pump
SYMfTOM
sopowcrtopumplllotorins(=Rm~.
POSSIBLECAUSE
3pcns.xwxwincircuitmm.
* chcdrf~loosecaamctioilorh~~(gIccnwirc) l PZ4
fkomcuxemsuwxtoPZ4onthelogiccani.
NEG
STATUS INDICATION CRlTERIA

ThissQulucodcisdisplaytdwhulvoltagcbctwixnPY7
aadnqativeisgmerthan1.6volrswithm,cpzrmt flow-
ingintiKtmomrt.kuiL
STATUSCODE DESCRlP’IlON MEMORY No

RECALL
143
SCRmoarcuueatsauor~~g.
I
CIRCUIT Pump
“- .,.
=-@JF
smll&znenrsiuscR~~thandaQdImconaoabk:
A2
tic&arfjpsmrmt
mssIBLEcAusE *
3prxlsalsararirtcifalitlDpP. SCR
- aeck*toaenrnvnirm mtiaokulwirt(ycnow CURRENT e
Wil@fhlJlCWllUtt-tOPPCQlOgiCd
NEG
SM548 19-15-27
RECALL
-144
1RECdidnotDmloffpIql&y.
~~ Rsmp
)\
SYMPTOM
Pumpumzactorsopcnauddose,tbcncauodybcdosdbyopcn-
klgandclosingtbck!qswit&.
POSSIBLE CAUSE
Defecdvc
5 RECcircuit
* Cbbckfcrshacd5REc.
. C&k fca shomd 5 REC snubber(25 REC).
D&clive 2 RECcircuit.
- Cllcc.kforshoaed2REc.
. Ckckforsimted2RECsnnbbcr(22REC).
Fisunt
ZIpenchoke (1Q.
- C!heckforopmcircuitbmeenT5andT3.Ohmmctcr
shoddrcadzuoohau. STATUS INDICATION CRITERIA
1RECdefc#ivc.
. Tumofftimcfor1RECoutofqx&don.Nofield ThiSStWSCOdCiSdi?p~yC4iWhC~dUdgSCRapearxion,
tcstk3possiblcRcpklcclRECaftcrabovecheckshow 1~Cfails~~ofE
IlOpb~fOUd.
..
STATUS CODE DESCRIPTION n4EMoRy Yes

RECALL
-145
1REcdidnottumonpropdy.
CIRCum Pump
SYMPTOM
Rmlpanuaaorwillapmanddase,tbulopulendtbacancQlybe
closaibyopcaingandclosingthekeyswitch.
WkCtiVClREC STATUSINDICATIONCRWERIA
. *‘- ntQqm1REcgatesdd~iMyamay ThisspmsC&isdiSpl@WhUl1RECfdStOgrsQl.
nOtsbow&fazRepke1RECafmabovccbcck&
sbownoprobkmfumd.
SM!548 19-l 5-28

STATUSCODE
hokahdtestfbrTzvok9.(Gfca
, - DESCRWI’ION MEMORY
RECALL
No
-146
0 c
REC
-
IA __
0 *
- chc!ckfardcfcctivc1REcinsulator(tithum)that
may!&olt1REchcatsinku,baseplate. 0 1,
kfuxive IA cmtacm.
- Chcckfarwcldai1A (muacmfpowertips.
F%racL

Thisstams&isdisplay#iwhulthcvoltagea!nis
grcatcrrhanSS%ofbattayvolrs.

RECALL
-147
2REcdocsnottulnalpmpcdy.
CIRCUIT Pump
mu*
!3YMPTOM
bnpcolltactorwillapa!artdcloee,mmopaandthencanaailYk:
@@@cB*- a
hscdbyopcningandclosiugthcksyswitdr. 6@@8 e I=
al&S-
q- a 2= ,
PO!$SIBLE CAUSE
IcfcctkZREc~ Pm
* checkthat2REcwilllplltaL
- czIle&faqmcb?coitarlaosa~bawcen2 _L
REC gamdPz10. @dwraI wire)
- c!hxk~qmciraritaloo8ccaamection1REcd arc
1Cthm4$thc2RECc
EnolaeL
~contacrorpower~barmcEpgapaL
. Ctmcktba~powcrtipsonFrmdR -powertips
donotboimceopenQaingqnrMioncitranlovor STATUS INDICATION CIWERIA
spadbmnps@Qdq?lrar). Thisstamscodtisdiqpkgsdwhaltbe2REchtjscmm
an.
‘SM548 19-15-29
POSSIBLE CAUSE
-folwardar-contacmr.
* Chcckforweldadfdorxtvusccoamcmrpowu
tim
* cYK&forsluggiPhopaahionoffarwardamcne
amtaua.
Defasive3RECcimai~
- Ckckfixslld3REC.
- ChcckfcRsbixred3RECsnubber(23~
SIdtypeilIcowt
* Ifpumpamaolusdwitiloutpump-,
bcsctcalculy.sce-17facmeasetphg, ttWll2%OfbaaayVOb
STATUS CODE DESCRPTION MEMORY yes

RJZCALL
-149
5REcdoesnotmmonpropcrly.
CIRCUIT pmnp
knsract
aoltcd2REc&cait
’ Ckk2RECisd2REc!slmbber(22REC)fcir~
chlit. STATUS INDICATION tXTERIA
ThiSStSUSCOdCiSdiSplag#1Wbltk5RECCiICUitfaiistO
kfazivecIxpdor~ mLnon.
- acckfQapencapacitor.
’ uskforloose- atcapacim-
SM548 19-15-30
RECALL
-150
cJapacimrvolts low.
SYMPTOM
htlp conmctor piclcmp. Cotltlrll does not opemte.
POSSIBLE CAUSE
Defective 2 REC circuit
open circuit or loose cotmecdon between spider
assembly and 5 REC @US A).
Open c&nit or loose comwion between 5 REC and

ZREC.
Opencixnitorlooseconnectionbetween ZREC!
gate andPzl0 (wllitehzd wing.
Check2RECtoinsmethatitwillgaleon.
STATUS INDICATION -
kisstatllscodeisdisplayedwhen2REc~failsto
lrnonatiaitialstaltnp.
STATUS CODE DE!SCRJPTION MEMORY yes

REXXLL
151
L
E;xcestiVC*ip9dmrvoitsgeWhUlmotorcrehntiShi$l.
I CIRm Pnmp
SYMPTOM
bnpconractoropcnandclosejthulcanaillybedoaedbyopening
uxiclosiQgthekcyswitch.
SI’ATUS INDICATION CRlTERW
SM548 19-15-31
RECALL
-152
EXCCSiVCcapadtarVOi~gCWtlCll~cmreati$lOW.
CIR- pump
SYMPTOM
‘umpc~~openanddose,thmcanonlybecloscdby~
uldchJsiLlg
thekey switch.
POSSIBLE CAUSE
kaxsive soucc in-.
. un-filtend taglinesarcbeingwed.
. Batterycablesarctoo long.
kfcctivt4REcEirrmit
* chcdcforshmcd4RBc.
* chcckhropcncimlitor1oose-in4REc NE6
circuit.
%-L
kfaxive 3 Fux circuit.
* chcckforopenl5rcuitorloose-in3REc STATUS INDICATION -
circuit. Thisstatuscodeis~laycdwhcncapacitorvohexckd
225v0llsandnlomcuuunklessthaa200amps.

RECALL
-154
Shoncdpwnpor1Acon~coildriver.
I
- CIRCUIT mmp
!WMPTOM
2ontmlwillnotopmtc.
POSSIBLE CAUSE
DeflxtivelogiccaTd.
1 Rcplacelogiccad
SM548 19-l 5-32

STATUS CODE DESCRIPTION MEMORY’ yes
RECALL
157
Cllrrrntsenscr~volalgepolairychedc
I
m
ICIRCUIT Pump
SYMPTOM
c
htmp contacmropen and close. ttman ody k closedby apening Al
md closing tbc key swicb.
POSSIBLE CAUSE
Reversedydlow andgtwn curlentsalm wites
* Illslmrhatthe:-gr&nwifc ‘iOllW3rOpzAWith~O
Open circuits.
-pllOWWkCCOWCU tOpz3WithtlO
open circuia Or loose ctioxls.
STAWS INDICATION CRlTERU
SW48 19-15-33
CHECKING COMPONENTS
Main Logic Card
Ail ruble-shooting is written to check ail outside devices and elimime them as the source of the
symptoms. The conclusion being then that the card is faulty.
1. Instrucdons for Removal of Control card.
Remove control wim on the screw temimls 1 through 6 as required.
Unplug A, B, and 2 plugs by pressing down on tab with wide blade suewdriver
and rotating 90 degrees.
Remove the two mounting screws and lift & box &tic.
NOTE: Do not attempt to remove circuit broad &XII cami box.
Reverse pruxdms to install new control card,
Mounting AandBFlugs Teminalsl-6 YPlug 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 current. Check to see that
the 1A contactor drops out before the F or R contactor.
Most contact coils are polarity sensitive. The left-hand wrminal must be connected to
positive.
Potentiometer in Accelerator
To check opemtion of the potentiometer, disconnect the battery and disconnect the wire
at control card TBl. Connecta VOM to the wire that was removed from TBl and to
negative.Place the VOM on the R x 100 scale. With the acceleratorin the creep speed
position, the ohms reading should be 4800 to 6000 ohms. With the acceleratorin the top
speedposition, the ohm mading should be 50 ohms OTless.-Withthe wire disconnectedas
above, check for resistance of 1 megohmor higher from pot wire to the truck frame.
SCR’S(lREC, 2REc,5REC)
These arc silicon cuntrolledrec?Z&s. Befon checking,diswmcct the battery and

dischargeCagacitoa lc. DiscoMect gate leads Of SCR’S 8t the sa tU7llid
To check an SCR, it is necessary to have a 6 volt battery and 2 A-14 diodes.
Connect$w:positive lead to the anode, connect the negative lead to the cathode as shown
below. -
SK48 19-16-2
.
Rcctx&s(3REC!,4RIrXI,Dio&Bbdcs}
control card. Read the resistance between these two wires with the VOM set on the R x
100 scale. VOM should read 100 to 200 ohms if the ZREC heatsink is at room tempera-
ture (25C or 7%). Set the VOM to the highest ohm scale and read from each wire end to
the 1REC heatsink. Reading should be infinity.
Filter Block(23FIL,etc.)
To check, disco~ect all wires i?om the filter block on removal from. 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 terminal. The VOM needle will
deflect and return to i&&y. If this capacitor action is not observed replace the filter
block.
Filter Block(23FfLetc.)
Filter block test 4K is only to &tect an open or shorted filter. If the control has sympo-
toms as in lE, interchange 22REC and 25REC and try again. If the problem is comx@d, ’
the old 25REC is marginal and should be replaced. If the problem is not corrected, replace
both filters.
1X Choke and Reactor T3-T4
Refer 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
SM548 19-16-4
REPLACEMENT OF EV-100 CGMFWENTS
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 semiconductors such as lREC, 2REC or 5REC
Remove all module connections. (As required)
Remove module by backing out the two screws at the device sides.
Clean the insulator surface with a clean rag and isopropyl alcohoL
If defective, replace. Wipe a light layer

Inspect the insulator surface for tears or cracks.
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 sum 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 f%m.
Replace all connections removed in step 1.
Capacitor
Remove nuts from capacitor connections and remove wires.
Remove hold down brackets and lift out.
ReversepIlocedurctoreplacecapacitor.
22REC, 23REC and 25REC
Removemounting saws axidlift out
NO’IE When replacing these &vices, use the original hardware in the same holes, as the
inserts are used for electrical connections.
SM548 19-16-5
E235 TRUCKS ONLY

Traction Control
FUNCTION
I CODE I
SEll-ING
I
DESCRIPTION
1 001 FAULT CODE

2 018 - 022
3 004 - 006 C/A & IA TIME
4 250 - 255 C/L
5 148 - 152 PLUGGING
I 250 - 255 I ADO
I 7 001
I 8 I 001 NA
L 9 001 NA
10 nnf NA
I 11 001 NA
12 001 NA
13 -001 NA
14 14 IR COMP
15 184-250 BATT VOLTS
16 38 - 42 PEDAL PLUG
17 000 - 004 CARD TYPE
18 175 - 177 S/P TIMER
OCT91 SM548
19-l 6-6
EVl 00-LXT
CARD
FUNCTION
SET-UP
ECS Std TRUCKS ONLY

PUMP Control
FUNCTION SETTING DESCRIPTION
CODE
1 001 FAULT CODE

2 077 - 079 IR COMP START
3 038 - 040 C/A & IA TIME
4 250 - 255 C/L
5 001 NA
6 001 NA
7 001 NA
8 001 NA
9 001 NA
IO 001 NA
11 SEE NOTE: SPEED 1 (2nd AUX)
12 SEE NOTE: SPEED 2 (1st AUX)
13 SEE NOTE: SPEED 3 (TILT)
14 250 - 255 SPEED 4 (LIFT)
15 001 NA
16 009 - 011 IR COMP
I 17 I 063 - 071 I CARD TYPE
NOTE: SETTING BASED ON FLOW CARTRIDGE USED

1 FLOWCARTRIDGE 1 SEl-l-ING I MIN MOTOR VOLTS 1
I
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 BATTERY VOLTS
OCT 91 19-16-7 SM548
EVI 00-LXT
CARD
FUNCTION
SET-UP
ECS Std TRUCKS ONLY

Traction Control
DESCRIPTION
OCT 91 SM548
19-16-8
EVl 00-LXT
CARD
FUNCTION
SET-UP
ESM TRUCKS ONLY
f=uNC~ONSm-lNGS EXCEPT SElllNGS K)R DESCRIPTION

CODE ESM17125 W/EE ESM17/25 W/EE
1 001 FAULT CODE

2 018 - 022 CREEP
3 004 - 006 C/A & 1A TIME
4 250 - 255 C/L
6 250 - 255 106 - 110 lAD0
7 001 - 003 TURN SWITCH SPEED LIMIT
8 001 NA
9 001 NA
IO 001 NA
12 001 NA
13 001 NA
14 14 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
19-16-9
EVl 00-LXT
CARD
FUNCTION
SET-UP
TM TRUCKS ONLY
FUNCTlONSElllNGS EXCEFT SETTINGSFOR DESCRIPTION

CODE TM22/25 W/EE TM22/25 W/EE
.
1 001 FAULT CODE

.
2 018 - 022 CREEP

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

.
.
4 250 - 255 C/L
I
.
6 250 - 255 106 - 110 1ADO
.
10 001 NA
.

12 001 NA
.
13 001 NA
14 14 IR COMP
.
.
15 032 - 044 BATT VOLTS
16 038 - 042 PEDAL PLUG
.
I
17 000 - 004 CARD TYPE
18 175 - 177 S/P TIMER
I
OCT 91 19-16-10
I I
EVl 00-LXT
CARD
FUNCTION
SET-UP
_ OP15B ONLY
FUNCTION
SETTING .DESCRIPTION
CODE
1 001 FAULT CODE

2 200 CREEP
3 015 C/A & 1A TIME
4 095 C/L
5 080 PLUGGING
6 130 1ADO
7 010 FM/ 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 (1.0 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 bvnassed 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 1.0 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-l 6-l 1 SM548
EVl 00-LXT
CARD
FUNCTION
SET-UP
NPI 5/l 5D/20/22 ONLY

FUNCTION SETTING DESCRIPTION
CODE
I I
1 001 FAULT CODE

2 200 CREEP
3 012 C/A & 1A TIME
. 4 095 C/L
5 080 PLUGGING
L
6 130 IADO I
7 010 F/W PU
8 010 F/W DO
9 010 NA
10 010 NA
11* 114 SPEED LIMIT 1 (2.5 MPH) I
12* 001 SPEED LIMIT 2 (1 .O MPH)

13* 001 SPEED LIMIT 3 (0 MPH)
14 010 IR COMP I
15 024 BATT VOLTS I
16 040 PEDAL PLUG ’

I I
17 022 CARD TYPE

1 I
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 MFH 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 W-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
CLSRK 20
GROUP
20
SECTION
1
DRIVE AXLE MAINTENANCE

GROUP CUIRU
20
DRIVE AXLE MAINTENANCE/INSPECTION
Access To The Drive Axle

Refer to
The best procedure to use for access to the GROUP 38, Section 3
drive axle drain plug, and oil level check/ Machine Jacking and
filler plug is dependent upon the style of Blocking.
upriqht, carriase and attachments on the truck,
ai well'as the rhop facilities aV ailable. It
can generally be best determined by looking
at your specific truck model.
1 When suitable equipment is ava lable, the

truck may be raised by jacking or hoisting
up and
._ placed in a level posit on on wheel
cradles to allow access under the axle.
NOTE - Typical truck view shown.
'2Otherwise, when it is necessary to service

the drive axle from the front of the truck,
the upright carriage may be raised and blocked
up to provide access to the axle. Raise the
carriage only as high as necessary.
o APPLY THE PARKING BRAKE

AND BLOCK THE WHEELS.
o BE SURE TO PUT BLOCKING
T UALK OR STAND UNDER
UNDER THE CARRIAGE AND 0 FORKS. THE FORKS CAN
AND CAUSE INJURY OR
UPRIGHT RAILS.
85M630
NOTE - Cut blocking to the correct

length to suit.
85M627

EMRK GROUP
20
DRIVE AXLE FLUID LEVEL CHECK
Check the drive axle fluid level with:

NOTICE
l Truck on a level surface.
0 Oil at operating temperature. Check the planned maintenance
interval (operating hours),
or the condition of the oil
to determine if the drive axle
fluid needs to be changed.
1 Remove the fluid level inspection/fill

plug located in the front surface of
each drive unit housing (two places).
'2 The oil level is correct (FULL) when the

oil reaches to the lower edge of the
inspection plug opening.
85M876
IMPORTANT
3 Add recommended fluid only, as required.
Refer to GROUP 40, Sections 4 & 5, for

drive axle recommended oil specifications.
After adding oil to the drive axle, wait

several minutes until the oil has
distributed evenly throughout the unit,
and check for correct oil level. DO NOT
OVERFILL.
85M874
4 Inspect each fill plug for damage.

Replace as necessary.
5 Install and tighten the plugs.
85M875

GROUP Cl!!RU
-_
20
DRIVE AXLE FLUID CHANGE

NOT1 CE
It is recommended to: 7 ------l
Frequent changes of lubricant is
o Drain and replace the drive axle an inexpensive way to protect and
fluid every 1000 operating hours. prolong the safe operating life of
an essential and relatively costly
major component such as the drive
axle.
Extending the recommended intervals

at which drive axle fluid is changed
should be considered only after
careful evaluation of your oper-
ating conditions and/or analysis
To change oil in the drive axle: of the condition of the oil.
l The oil should be drained when it

is warmed to operating temperature.
l Put the truck in a level position.

1 I
l Apply the parking brake and block

the wheels to prevent the truck
from moving.
l Turn key switch "OFF" and disconnect

battery from truck receptacle.
NOTE - When suitable equipment is

available, the truck may be raised Refer to
or hoisted up and placed in a level GROUP 38, Section 3,
position on wheel cradles to allow Machine Jacking and
access under the axle. Otherwise, Blocking.
raise the fork carriage only high
enough to provide access clearance
to the axle. Please refer to pro-
cedure described above in "Access
To The Drive Axle", page 2.

CLFIRK GROUP
20
1 Place a low, flat drain pan beneath the

drive units. The pan capacity should be
more than [6.6 L] 14 pints (drive axle
total capacity).
85M629
2 Remove drain plugs (two) from bottom of

drive units, and fill plugs (two) from
front of drive units.
85M625
3 While the drive units are draining, check

the breather vents (two) to be sure they
are open and not damaged. Vents are
located in the top front corners of the
drive units.
85M633
4 After drive units have drained, install

drain plugs. Fill each drive unit to the
bottom edge of fill plug opening with
recommended fluid.
5 Remove drain pan. Remove blocking and

lower carriage.
85M874

CLRRH GROUP
20
GROUP
20
SECTION
10R
DRIVE AXLE REMOVAL

Park truck on a hard, level surface

in correct position for using an overhead
hoist, if available.
Fully lower the upright.
85M467
Truck Preparation
Open hood.
Remove floorboard and main valve cover.
Adjust front battery plate for access.
Remove upright.
Code: OH-540, MAR 86 GROUP 20, Section lOR, Page 1

GROUP
20
85M482 85M847
1 Turn key switch "OFF'". 5 Remove floorboard.

85M616 85M862
2 Open hood. Adjust front battery plate to

3 Disconnect battery from truck maintenance position. Refer to
receptacle. GROUP 38, Section 2.
85M752 85M894
4 Remove battery from truck. Remove the upright. Refer to

Refer to GROUP 12, Section 1. GROUP 34, Section 9R.
GROUP 20, Section lOR, Page 2 Code: OH-540, MAR 86

GROUP
CMRH 20
MOUNTING BOLT
MOUNTING NUT-. I*‘\ A--A\\I~
DRIVE
LDRIVE UNIT (RH)

\\ I
hRIVE MOTOR
DRIVE AXLE INSTALLATION
GROUP 20, Section lOR, Page 3

GROUP CLSRK
20
DRIVE AXLE REMOVAL
After battery and upright have been removed:
1 Drain the oil from drive units when

truck is in a level position. Install
the drain plugs, fingertight.
85M850
2 Attach a hoist with chains of correct

capacity, as shown.
NOTE - Watch truck for signs of lateral

instability. It may tip sideways.
You may have to support or guide the
sides of the truck or overhead guard
to prevent tipping.
(Typical TM truck views shown.)
3 Raise the truck and put wheel cradles

under the drive wheels, as shown.
Lower the truck (drive wheels) onto
cradles.
Leave chains and hoist attached.

GROUP
CMRH
20
4 Remove drive wheels. First, loosen the

wheel mounting bolts, then raise truck
slightly and remove both wheels.
Mounting Bolt Torque:

[255-275 N.m] 188-203 lbf.ft.
17056
5 Lower truck with wheel ends on cradles.
NOTE - Place blocks of wood under drive

motors to support them, if motors not
previously removed. See NOTICE below.
6 Disconnect power cables from drive motors

Attach tags to the motor cables for easy
and correct identification at assembly.
avoid losing them.
85M675
NOTICE - Alternative Procedure: It is

optional to remove drive motors before
removing drive axle from truck. Refer
to GROUP 16, Section 23R. Also see
Page 9.

GROUP CMRK
20
7 Release the parking brake hand lever to

provide freeplay in the brake cable for
removal of the parking brake cable yoke.
There should be enough freeplay of the
cable and the levers on brake assembly to
allow the yoke fingers to be disengaged.
If not, either adjust the cable at the
hand lever to release tension, and/or
loosen the parking brake adjustment
nuts on the sides of brake caliper
assembly, as shown.
8 Remove the yoke of parking brake cable

from the levers on brake caliper assembly.
(Typical procedure for TM truck shown)
9 Disconnect hydraulic brake line from

master cylinder. Put caps on fittings
to keep clean.
(Typical procedure for TM truck shown)
10 Inspect your truck model for any other

wiring leads or optional equipment that
may have to be disconnected before axle
is removed.

CLRRH GROUP
20
11 Loosen and remove axle mounting bolts

(nuts underneath) from axle on both
sides of frame.
Mounting Bolt Torque:

[550-600 N.m] 406-443 lbf.ft.
Refer to illustration, Page 3.
17063
12 Raise truck frame slightly off of drive

axle and move the truck backwards away
from axle assembly.
CAUTION- Truck may tip sideways.

side of the truck or overhead guard
to prevent tipping.
13 Lower front of truck frame to the floor.
NOTE - Truck frame may also be blocked

up under axle mounting surfaces. Block
the steer wheel and be sure blocking is
put safely under the frame.
14 Attach hoist and move drive axle assembly

to the overhaul disassembly area.

GROUP CMRU
20
NOTICE
The basic drive axle shown in this procedure is used in

several model versions of TM lift trucks.
Photos showing drive motors and methods for motor removal

may vary slightly from those found on the drive axle
assembly of your lift truck. However, the sequence of
disassembly/assembly and other overhaul procedures for the
drive units are identical.
BRAKE CALIPER ASSEMBLY REMOVAL
1 Loosen and remove the four mounting bolts.

Remove brake assembly from axle.
Note that mounting bolts and torques are

different on each side of brake unit.
As shown in photo, bolt torques are:
(Far side) [44-50 N-m] 33-37 lbf.ft.

(Near side) [70-80 N.m] 52-59 lbf.ft.
17078
Refer to GROUP 23, Section 17, for brake
caliper assembly overhaul.
26567

CLRRK GROUP
20
DRIVE AXLE DISASSEMBLY
USE ONLY APPROVED HOIST, CHAINS AND

STRAPS TO LIFT THE DRIVE AXLE AND
MOTORS. BE SURE HOIST AND ACCES-
SORIES HAVE CORRECT CAPACITY TO
SAFELY SUPPORT THE LOAD.
Weight of drive axle assembly with

motors is Cl91 kg] 420 lbs. approx.
1 Drive axle assembly may be suspended, as

shown, while resting on a steel table
(strong enough to support the load) or
a clean floor.
View showing
bottom of
axle assembly.
17072
2 Disconnect and separate the two drive unit

sections of drive axle assembly, as follows:
1) Loosen and remove bolts from bottom

flange of axle while drive units are
suspended.
2) Lower drive axle and motors down until

bottom side rests on bench or floor.

GROUP CLRRH
20
3) Remove remaining attaching bolts

from front flange of axle.
Drive units can now be separated.
View showing
top and front
sides of axle
assembly.
NOTICE - The following procedure shows drive motor removal

after separation of drive units from axle assembly. Drive
motors may, however, be removed at other stages of axle removal
from truck, depending on the need or interest. Refer to GROUP
16, Section 23R for drive motor removal when axle is installed
in truck.

CMRK GROUP
20
DRIVE MOTOR RMOVAL FROM DRIVE UNIT
PUT BLOCKS AT SIDES OF DRIVE UNIT

TO PREVENT ITS FALLING OR TIPPING
OVER WHEN MOTOR IS REMOVED.
1 Raise motor end to rotate drive unit

and motor to the vertical position while
on work bench or floor. Remove the two
motor mounting bolts.
Motor Mounting Bolt Torque:

[70-80 N.m] 52-59 lbf.ft.
2 Remove drive motor. Pry motor shaft out

of axle spline while lifting motor.
Drive motor weight is: [27 kg] 60 lbs,
approximately.
IMPORTANT
PRY EVENLY AROUND MOTOR FLANGE

TO PREVENT DAMAGE TO MOTOR SHAFT
OR SEALS.
3 Remove the O-RING seal from motor

flange and lay it aside.
4 Move motor to a safe storage position

until required for reassembly.
Refer to illustration, Page 12, for addi-

tional information on motor installation.

GROUP
20
DRIVE UNIT 20-212
16.OC0 DRIVE HOTOR ASSEflBLY
16.001 FASTENER, DRIVE MOTOR
20.275 SEAL, DRIVE AXLE HOUSING
20.370 AXLE ASSEMBLY, DRIVE LH
20.376 AXLE ASSEMBLY, DRIVE RH

CMRK GROUP
20
GROUP
20
SECTION
10
DRIVE UNIT OVERHAUL
NOTICE
The basic drive units shown in this procedure are used in

several model versions of TM lift trucks.
Some photos may show slight variations from the drive

units found on the drive axle assembly of your lift truck.
However, the sequence of disassembly/assembly and other

overhaul procedures for the drive unit are as noted.
Overhaul procedures shown are typical for each of the two
drive units of the drive axle assembly.
See Pages 2 and 3 for illustration and description of

components of current drive unit assembly.

GROUP
20
DOtiS NOT INCLUDE
DRIVE AXLE RH NOV a2
20.376 DRIVE AXLE ASSEBBLY,RB 20.371 FASTENER,DRIVE AXLE ASSEMBLY

20.201 SHIM, DIFFF.RERTIAI.
PINION BEARING CARRIER 20.387 HOUSING,'DRIVBAXLE K-l
20.212 SEAL,DI FFEREBTIALPINION BEARING CARRIER 20.424 PLUG, DRIVE AXLE HOUSING FILLER
20.221 FASTBNER, PINION BEARING CAGE 20.427 PLUG, DIFFERENTIALb AXLE HOUSING DRAIN
20.230 CORE, DIFFERERTIALPINION BEARING (OUTBOARD) 20.542 CONE, DRIVE AXLE SHAFT BEARING (OuTBoAB!J)
20.236 CARRIER,DIFFBRENTIALPINION BEARING 20.544 SEAL, DRIVE AXE SHAFT

20.238 SHI!f,RIFFERERTIAL PINION BEARING CARRIER 20.546 FASTENER,DRIVE AXLE END
20.239 FASTENER,DIFFF.RBNTIAL PINION BEARING CARRIER 20.573 CW, DRIVE AXLE SHAFT BEARING (OUTBOARD)
20.248 RING GEAR AND PINION SET, DIFFERENTIAL 20.586 SHAFT. DRIVE AXLB
20.252 BEARING,DIFFEREBTIALPINION (INNER) 20.648 LOCATOR,DRIVE ABLE SHAFT BEARING (OUTBOARD)
20.261 RETAINER,DIFFERERTIALPINION OUTER BEARING 90.358 NUT, DRIVE AXLB ASSEBBLY FASTENER
20.316 CUP, DIFFEREBTIALPINION BEARING (OUTBOARD) 91.169 LOCKWASHER,PINION BEARING CAGE FASTENER
20.373 GASKET, DIFFBRERl'IAL
HOUSING INSPECTIONCOVER 92.185 NUT. DRIVE AXLE BRD FASTENER
20.374 FASTENER,DIFFFRBNTIALHOUSING INSPECTIONCOVER 92.493 LOC;GWASHER,DIFFERENTIALPINION BRG CARRIER FAST
20.375 COVER, DIFFERENTIALHOUSING INSPECTION 92.600 LOCKWASHER,DIFF HOUSING INSPECTIONCOVER FAST

GROUP
20.636
L93.271
,-20.248
lTTE=l
-I
DRIVE AXLE RH NOV 82
20.376 AXLE ASSEHBLY,DRIVE RR 20.641 SHIM, DRIVE AXLE RING GEAR SRAFT BRG HOUSING
20.248 RING GEAR AND PINION SET, DIFFERENTIAL 20.642 HOUSING, DRIVE AXLE RING GEAR SRAFT BEARING
20.279 FASTENER,RING GEAR 20.643 SEAL, DRIVE AXLE RING GEAR SRAFT
20.384 PLUG, DRIVE AMLE HOUSING 20.645 RETAINER,LlRAXLF.R/GEAR SRAFT BRG RACE (INBOARD)
20.519 FASTENER,DiuvE AxLE mm GEAR RETAINER 20.646 OUTER ~CE,DR nME RING GEAR SHAFT BRG (INB0AR.D)
20.520 RETAINER,DRIVE AXLE SRAFT GFAR 20.647 LOCATOR,DRIVE AXLE SHAFT BEARING INBOARD
20.521 SHIH, DRIVE AXLE SRAFT CEAR 20.659 SHIM, DRIVE AXLE RING GEAR SHAFT BEARING CAP
20.522 GEAR, DRIVE AXLE SliAl?I' 20.832 CAP, DRIVE AXLE RING GEAR SHAFT BEARING
20.524 BEARING,DRIVE AXLF.RING GEAR SRAFT 20.837 CUP, DRIVE AXLE RING GEAR SRAFT BRG (OUTBOARD)
20.553 CONB, DRIVE AXLE SRAFI BEARING (INBoARD) 23.256 DISC, DRIVE WHEEL BRAKB
20.579 CUP, DRIVE AXLE SRAFT BEARING (INBOARD) 90.360 LOCK, DRIVE AXLB SHAFT GEAR RETAINERFASTENER
20.627 VENT, DRIVE AXLE 91.051 FASTENER,DRIVE AXLE RING GEAR SHAFT BRG CAP
20.628 ADAPTOR,DRIVE AXLE VENT 91.052 LOCIWASHER,D/AXLE RING GEAR SliAJ'T
BRG CAp FAST
20.636 SliAFT,DRIVE AXLF,RING GEAR 93.270 FASTENER,DRIVE AXLE RING GEAR SHAFT BRG ROUSING
20.638 CONE, DR AXLB RING GRAR WAFT BFARING (OUTBOARD) 93.271 FASTENER,DRIVE AXLE RING GEAR SHAFT BRG HOUSING
20.639 RETAINER,DRAXLE RING GEAR SHAFT BRG (OUTBOARD) 93.212 LOCKWASHER,DRAXIX RING GEAR SHAFT BRGHSG FAST
20.640 SEAL, DRIVE AXLF.RING GEAR WAFT BEARING HOUSING 93.273 NUT, DRIVE AXLB RING GEAR SHAFT BRG ROUSING FAST

GROUP CMRK
20
Drive Unit Cross-Section 26649
Drive unit disassembly and overhaul procedures are grouped according to the
following major sub-assemblies:
01 INTERMEDIATE (RING
shaft, ring gear, straight
GEAR) SHAFT ASSEMBLY,
and tapered
including bearing housing,
roller bearings, bearing cap, and
oil seal.
02 INPUT
carrier,
PINION GEAR CARRIER ASSEMBLY,
bearings, and bearing
including
retainer.
pinion gear, bearing
03 OUTPUT (DRIVE
retainer,
AXLE)
bearings,
SHAFT ASSEMBLY,
and oil seal.
including shaft, gear, gear

EMRK GROUP
20
DRIVE UNIT DISASSEMBLY
1 Be sure all fluid is drained from each

drive unit before starting disassembly.
2 Remove the inspection cover and gasket

from top of unit.
20458
3 Remove the brake disc by sliding

it off the intermediate (ring gear)
shaft spline.
01 INTERMEDIATE (RING GEAR) SHAFT DISASSEMBLY
1 Loosen and remove the ring gear bearing

housing mounting combination of bolts,
nuts and lockwashers. Then, remove the
housing assembly from the drive unit
main housing.
Bolt Torque: [54-62 N.m] 40-46 lbf.ft.
(Typical procedure shown, with similar-

model one-piece ring gear housing)
Refer to Figure 26649, Page 4. 20460
2 Remove the ring gear bearing housing

(ring gear position) shims.
20461

GROUP Cl!!lRn;
20
3 It is good practice to arrange parts in

the sequence of removal as an aid to
inspection and correct reassembly.
20462
4 Put the housing and shaft assembly, with

the ring gear up, in a vise. NOTE - Use
blocks of wood to protect the shaft
spline.
(Typical procedure shown)
5 Carefully inspect the ring gear for

wear and damage. Also, see inspection
of pinion gear.
20463
6 To remove ring gear, loosen and remove

the ring gear fastener bolts.
20464
7 Remove the ring gear from the shaft.
20465

GROUP
20
8 Remove the housing seal from groove

in bearing housing pilot flange.
20466
9 Turn the housing assembly over and clamp

the pinion end (showing) in the vise.
Use wood blocking to protect the pinion
gear teeth.
20467
10 Loosen and remove the mounting bolts

and lockwashers, then remove the bear-
ing cap and oil seal assembly from
housing.
Remove the bearing preload shims.
26662
11 Press, or pry and pull, the old

oil seal from the bearing cap.
26663

GROUP ELFIRK
20
12 Remove the outer bearing cup if it

is loose.
13 Remove the external snap ring from

shaft spline at end of outer bear-
ing cone.
20469
14 Remove housing assembly from the vise.

Support the bearing housing and press
the shaft out of the bearing cones.
This can also be done by holding the
housing and lightly tapping the shaft
end on a wooden block on the bench or
floor.
20470
15 Remove outer bearing cup, if not done

previously. Remove bearing cones.
Remove inner bearing cup from housing
by pressing or using a puller.
NOT1CE
Also remove, clean and inspect breather

vent in top side of ring gear bearing
housing. Replace vent, as needed.
26664
16 Arrange the parts in the sequence of

removal as an aid to inspection and
correct reassembly.
(Typical arrangement shown)
Also refer to Figure 26650, Page 9,

for current-model illustration.
20473
Refer to Page 17 for ring gear shaft
inboard bearing removal.

GROUP
CLflRl4 20
17 Ring gear shaft assembly components

are shown below:
26650

GROUP CLqRK
20
02 INPUT PINION GEAR CARRIER DISASSEMBLY
Refer to Figure 26665, Page 13.
1 Loosen and remove the five fastener

bolts and lockwashers from pinion
bearing carrier.
2 Tap lightly on the outer flange to

loosen the carrier pilot flange from
main housing.
3 Remove input pinion carrier assembly

and (pinion gear position) shims from
the main housing.
4 Remove the pinion carrier seal.
21284

CMRK GROUP
20
5 Clamp carrier housing flange in a vise.

Loosen and remove the recessed Allen-
head pinion bearing retainer bolts, and
washers.
21285
6 Remove the outer pinion bearing

retainer plate.
21286
7 Remove the pinion bearing retainer

(bearing preload) shims.
21287
,.\ * ;,,
8 Remove the outer pinion bearing cup.
Tap lightly on the back side (small
end) of the pinion with a hammer and
punch to move the pinion and bearings
outward and drive the cup from carrier.
21288

GROUP CMRW
20
9 Remove the pinion and bearings assembly

from the carrier housing.
21289
10 Clean and inspect the pinion tapered

roller bearings for wear and other
damage. Replace, as necessary.
Replace worn or damaged bearing cups
and cones as a set.
11 Clean and inspect the pinion gear teeth

and internal spline for wear and other
damage. Replace, as needed.
NOTICE - Replace ring and pinion

gears as a matched set.
12 Check both input pinion bearing cups

for wear, nicks or scratches that would
render them unsuitable for further
service. Replace bearing cups and
cones as a set.

GROUP
CLIIRK
20
13 Arrange the parts of the input pinion

gear and carrier assembly in sequence
of removal as an aid to inspection
and correct reassembly.
26665

GROUP CLqRK
20
03 OUTPUT (DRIVE AXLE) SHAFT DISASSEMBLY
1 Remove the formed plug, which seals the

hole in wall of main housing, for access
to the end of output (axle) shaft.
20475
2 Drive the plug from the opening by

lightly tapping with a hammer. A
large punch or rod with size to fit
the plug may be used to assist in
removal.
20476
3 The axle shaft output gear retainer is

held in place by three bolts in the end
of the axle shaft. The bolts are held
from loosening by bending a tab of the
fastener lock plate against a flat of
each bolt head. Unbend the tabs for
removal of the bolts by working through
the opening in the main housing and
using a hammer and a screwdriver or
punch to flatten the tabs.
20477
4 Loosen and remove the three gear

retainer bolts.

GROUP
ELfIRK
20
5 Remove the bolts, lock plate, gear

retainer plate, and shims. Then,
reach inside the main housing and
remove the drive axle shaft gear
by sliding it off the spline of
axle shaft. Lift the gear out of
the drive unit housing.
20480
6 Arrange these parts in the sequence of

removal as an aid to inspection and
correct reassembly.
Continue with disassembly and removal of

drive axle shaft from the drive unit
housing.
20481

GROUP CMRK
20
7 Working through the access hole where

the seal plug was removed, use a hammer
and a drift pin or heavy punch to drive
on the inner end of the axle shaft and
move the shaft out of the inboard roller
bearing cone. The shaft must be moved
at least [25 mm] 1 inch.
8 After moving the drive axle shaft

outwards sufficient to loosen the
bearing fit on shaft, remove the
inboard bearing cone.
21298
9 Then, remove the axle shaft and

outboard bearing cone assembly
from the housing.
20487
10 Inspect the shaft, spline, seal surface,

wheel mounting flange and holes, and
bearing for wear and other damage that
would require repair or replacement.
20489

CLSRK GROUP
20
11 Inspect the outboard bearinq cup for

wear and other damage, nicks, cracks,
scratches, and signs of failure from
excessive heat.
12 Remove the axle shaft oil seal.
If axle shaft bearings need to be

replaced, remove the bearing cups
(outer races) by pulling them from
drive unit housing bores.
.-
26666
Ring Gear Shaft Inboard Bearing Removal
.3 With axle shaft gear and input pinion

carrier assembly removed, the ring gear
shaft inboard bearing is readily
accessible. Remove the straight
roller bearing by pulling from
the outer race.
21301
14 Inspect the inner bearing-rolling

surface of the outer race of ring
gear shaft inboard bearing for
wear and damage. Look for nicks
and scratches, pitting or any
unusual wear pattern.
Replace, as needed.
21302

GROUP CLqRH
20
IF If bearing outer race requires removal

d
for replacement, remove the inner snap

ring.
16 Remove the outer race with an

extracting tool (puller).
17 Arrange the parts of the drive axle shaft assembly and

the ring gear inboard bearing for inspection.

CL!!R[H GROUP
20
CLEANING AND INSPECTION
Clean all parts with a good grade solvent and dry thoroughly.
Do not let bearings spin dry if drying parts with air pressure.
Inspect all parts for wear and other damage that could cause
malfunction or early failure.
- Gears and splines - Bearing cups and cones

- Seals and gaskets - Spacers and snaprings
- Bolts, nuts and washers - Shafts and machined surfaces
- Housings and covers
Replace all parts that have failed, including those parts

that are worn or damaged in such a way that further
serviceability is questionable.
It is recommended that all bearings, seals, and gaskets

be replaced at each overhaul.
DRIVE UNIT REASSEMBLY
e Use Permatex and Crane Sea ler only l All lead-in chamfers for oil seals
where specified. and O-rings must be smooth and free
from burrs. Inspect at assembly.
o Apply very light coating of Perma-
tex No. 2 to 0.0. of all oil seals a Lubricate all O-rings with oil
and hole plugs before assembly. before assembly.
o Apply light coating of Crane Sealer 0 Apply a thin coating of grease be-
to all pipe plugs. tween seal lips on lip-type seals
prior to assembly.
e Use Crane Sealer on all capscrews
and studs with thru holes (housing l Brush DEXRON II ATF oil on all
end only). tapered and straight roller bear-
ing cups and cones.
l After assembly of parts using Perm-
atex or Crane Sealer, clean all
surfaces. There must not be any
free or excess material that could
enter the oil system.

GROUP CLflRH
20
01 OUTPUT (DRIVE AXLE) SHAFT REASSEMBLY
26667
1 Press new axle shaft outboard bearing

cup (outer race) into housing bore
tight and square against snap ring.
2 Install new oil seal. Press seal into

bore until outer surface is flush with
end of housing.
21306
3 Install new axle shaft inboard bearing

cup. Press bearing cup into housing
bore until tight and square against
snap ring. NOTE - The use of a
73 mm O.D. piece of tubing or spacer
ring as a driver is suggested.

CLSRU GROUP
20
4 Next, install outer race for ring gear

shaft inboard bearing, if removed.
Press the outer race into housing bore
until tight and square against outer
snap ring.
20048
5 Install inner snap ring in housing

groove against bearing outer race.
21300
6 Install the ring gear shaft

inboard roller bearing.
21301
7 Then, put the axle shaft into the

drive unit ,housing end.
IMPORTANT
Be very careful not to damage seal
lips when inserting shaft spline
and bearing through the seal.

GROUP CLflRl4
20
8 Assemble the drive axle shaft inboard

bearing cone on the end of axle shaft.
20482
NOTE - Be sure to hold the axle shaft

firmly in place in the outboard bear-
ing. Support (back up) the outer end
of axle shaft to prevent shaft from
slipping out of outboard bearing while
tapping the inboard bearing into place.
Suggestion: Turn (rotate) housing up
and support it temporarily on axle
shaft outer end.
21308
9 Install axle shaft inboard bearing into

correct position using a special instal-
lation tool, as shown in photo.
See be1 ow.
10 A special tool for pressing or driving

the axle shaft inboard bearing cone into
place may be fabricated as shown by
drawing, Figure 26651, next-page.

Cl!!lRH GROUP
20
26651
11 Install axle shaft gear on spline

of axle shaft.
12 Install shims against end of shaft, then

gear retainer plate, lock plate, and the
three retainer bolts. Do not bend tabs of
lock plate until bearing preload has been
checked.
20480

GROUP CLqRlS
20
13 Torque gear retainer bolts to:
[44-49 N-m] 32-36 lbf.ft
14 Turn (rotate) axle shaft to check for

correct axle shaft bearing preload
setting.
See below for suggested adapter

tool and procedure.
2666L
15 Add or r.emoveshims at end of shaft under

the axle shaft gear retainer plate to
obtain bearing preload value of:
[0.68-1.13 N.m] 6-10 lbf.in. torque

required to turn shaft.
26652
16 As an aid for rotating the axle,shaft

when checking axle shaft bearing preload,
it is recommended that a special adapter
tool be constructed as shown by Figure
21311, Page 25.
This tool is designed to fit into the

wheel mounting flange bolt holes of the
axle shaft. Attach a torque wrench in
the 3/8-inch square drive hole at the
center. Turn shaft slowly to measure
torque required to rotate the shaft.

Cl!!lRK GROUP
20
----I rt- [ 130 ] 5.118 .
-196 - ')-[9,6] .377

I I
I
I
L-L
- * -B - - -a- -
. f [9,6] -377 ,
[76] 3.00 I I
I- [152] 6.00 -t
17 When the correct axle shaft bearing

preload has been set, be sure the
bolts are tightened to the correct
torque. Then, bend the tabs of the
lock plate against the bolt heads.
20478
18 To complete the drive axle shaft

reassembly, install the plug in
access hole in wall of main housing.

GROUP Cl!!RK
20
02 INPUT PINION GEAR CARRIER REASSEMBLY
1 Arrange the parts of the pinion gear

bearing carrier for assembly.
21289
2 Install the tapered roller bearing

cones on the pinion gear by pressing
the inner races until firmly seated
square and tight against shoulders
on gear. Be sure to use a pressing
tool or tubing of the correct diam-
eter and press on inner race only to
prevent damage to the roller cages.

CMRK GROUP
20
3 Install the input pinion inner bearing

cup by pressing the cup into carrier
bore tight and square against the
shoulder.
4 Put the pinion gear and bearing

assembly into the carrier. Be
sure it is seated correctly into
inner bearing cup.
5 Then, using a pressing tool or a piece

of tubing of correct diameter for cup,
install outer bearing cup by pressing
or driving on cup until seated lightly
against outer bearing rollers.
20050
6 Install the input pinion bearing retainer

(bearing preload adjustment) shims. For
initial assembly, use same number of shims
as were removed at disassembly. Be sure
holes in shims are aligned with bolt
holes in carrier.
21287
7 Install the outer pinion bearing

retainer plate.
21286

GROUP CMRYC
20
8 Install and tighten the eight bearing

retainer plate bolts.
Bolt Tightening Torque:

[7-10 N-m] 5-7 lbf.ft.
9 After assembly, turn (rotate) the

input pinion gear in the bearings
to check for correct bearing preload
setting.
As an aid for rotating the pinion gear,

a temporary tool may be made using a
discarded drive motor shaft spline end
with a nut welded to it.
10 Put the tool into gear spline and turn

the pinion gear slowly with a torque
wrench to measure torque required to
rotate the pinion.
Add or remove shims at end of outer

bearing cup under retainer plate to
obtain bearing preload value of:
[O.ll-0.56 N.m] 1-5 1bf.ir-t.

torque
required to rotate pinion gear.
Available shim thicknesses: .003, -004

.007, .OlO and .020 inch.
11 When correct pinion bearing preload

has been set, be sure retainer bolts
are tightened to the correct torque.
12 Install new O-ring seal in groove of

carrier pilot flange.
21284

ELqRK GROUP
20
13 Put pinion bearing carrier (pinion gear

position) shims on the carrier mounting
surface. For initial assembly, use same
number of shims as were removed at dis-
assembly. Install several bolts to
align and hold shims in place.
21283
14 Put the pinion gear and carrier assembly

on drive unit main housing.
Be careful not to damage O-ring seal

surface when installing carrier pilot
flange into housing.
15 Install and tighten the carrier housing

mounting bolts.

[77-88 N.m] 57-65 lbf.ft.
21316
NOT1CE
After reassembly of the ring gear and shaft
assembly (see following section), check the
ring and pinion gears for tooth bearing
pattern (correct position) and backlash.
Add or remove carrier mounting shims

(noted above) as needed to adjust
pinion gear position. Be sure car-
rier mounting bolts are tightened to
correct torque after shim adjustment.

GROUP CMRK
20
03 INTERMEDIATE (RING GEAR) SHAFT REASSEMBLY
26669
1 Arrange the parts of the ring gear shaft

and bearing housing for assembly.
20474
2 Install new inner tapered roller bearing

cup by pressing into bearing housing
until firmly seated square and tight
against shoulder in housing.
3 Next, install bearing cones on ring gear

shaft by first assembling bearing housing
& inner cup assembly over spline end of
shaft. See Step 4, Page 31. Also, see
alternate procedure that may be used when
a press is not available.
26670

CLRRK GROUP
20
r
4 Put shaft spline end through bearing hous ing
(i.e., fit housing over spline end of sha ft).
Press inner bearing cone tight and square
against shoulder on shaft. Press outer
cone tight and square against inner cone.
26671
5 Install snap ring into groove in shaft

spline at end of outer bearing cone.
20469
NOTE - Alternate procedure for install-

ing bearing cones on ring gear shaft:
1) Install inner bearing cup, both bear-

ing cones, and outer cup into bear ing
housing.
2) Temporarily install the bearing cap

to clamp the bearings in place in housing.
Tighten bearing cap bolts to hold the
bearing cones tight and square.
26673
3) Put (start) the ring gear shaft
spline end into the bearing cones and,
holding the bearing housing with shaft
vertical, lightly tap the pinion end
of shaft on a wooden biock on the bench
or floor until shaft is installed in
bearings.
4) Remove bearing cap.

5) Install snap ring.
20513

GROUP CLSRK
20
6 Turn the shaft and housing assembly over

and clamp the spline end of shaft in a
vise. Use wood blocking in vise to
protect the spline.
7 Install new O-ring seal in groove of

bearing housing pilot flange.
20466
8 Install the ring gear on mounting

flange of shaft,
20465
9 Install and tighten the ring gear

mounting bolts.
[ZO-27 N.m] 15-20 lbf.ft.
10 Remove assembly from vise and reclamp

in vise on housing flange. Use wood
blocking to protect flange surfaces.
20514
11 Using a pressing tool or a piece of tubing

of correct diameter for cup, install the
outer bearing cup into bearing housing
bore by pressing or driving on cup until
it is lightly seated against outer bear-
ing rollers.
26672

CLflRK GROUP
20
12 Install new oil seal in ring gear hous-

ing bearing cap.
Press oil seal flush with end surface

of cap.
Apply a thin coating of grease

between seal lips.
26663
13 Put at least two bolts with lockwashers

in bearing cap. Then, install the bear-
ing cap (bearing preload) shims on
bearing cap. For initial assembly, use
same number of shims as were removed at
disassembly.
14 Install bearing cap and shims on ring

gear bearing housing.
26675
15 Install and tighten all bearing cap

fastener bolts and washers.
[44-49 N.m] 32-36 lbf.ft.
26675
16 After assembly of ring gear shaft and

bearings into bearing housing, and
installation of bearing cap, turn
(rotate) the ring gear shaft in the
bearings to check for correct bearing
preload setting. Use a thin-wall
socket, or make an adapter tool from
a discarded brake disc hub, to turn
the shaft by the spline with a torque
wrench.
26674

GROUP CMRK
20
17 Turn the ring gear shaft slowly with a

torque wrench to measure torque required
to rotate the shaft. Add or remove
shims under bearing cap to obtain
bearing preload value of:
[0.11-O.% N-m] l-5 lbf.in. torque

required to rotate shaft.
18 After correct bearing preload has

been set, be sure bearing cap bolts
are tightened to correct torque.
19 Then, install the ring gear bearing housing

(ring gear position) shims over studs on
drive unit housing. For initial assembly,
use same number of shims as were removed
at disassembly.
20461
20 Install ring gear shaft and bearing

housing assembly into drive unit
housing.
16136
21 Install and tighten the combination of

bearing housing mounting bolts, nuts and
lockwashers.
Tightening Torques:
Bolts [44-49 N.m] 32-36 lbf.ft.

Nuts [54-62 N.m] 40-46 lbf.ft.
18444

CMRK GROUP
20
NOTICE- Before proceeding further...
22 After installation of ring gear and shaft Refer to

assembly, and input pinion (earlier), check Tooth Bearing Contact
the ring and pinion gears for tooth bearing Charts, Pages 37 & 38
pattern (correct position) and backlash.
Add or remove ring gear bearing housing

shims (Step 19 above), as needed to adjust
ring gear position and backlash. Be sure
bearing housing mounting bolts are tight-
ened to correct torque after shim adjust-
ment.
23 Final adjustments in shim thicknesses under

input pinion carrier and ring gear bearing
housing should be made based on measurement
of gear mesh backlash with a dial indicator
and on visual check of gear tooth bearing
patterns. Gear mounting information is
etched on the ring gear.
24 Ring and pinion backlash of:
mm] .002-.005
[0,050-0,127 inch
should be measured with a dial indicator.

Put (set up) a dial indicator on the top
surface of the drive unit housing. Use
a long adapter to reach the gear tooth
surface inside the assembly. Backlash
should be measured at three places
around the ring gear (rotate the gear).
25 Check gear tooth bearing patterns by

applying a coating of gear checking
compound, e.g., red lead, to the ring
gear teeth. Rotate the ring and pinion
through a minimum of one revolution.
Temporarily install the brake disc to
provide a means for loading the gear
teeth. See Step 28, next page.
21318
After above checks and adjustments are made,
continue with final assembly of drive unit...

GROUP EMRW
20
26 Install new gasket on inspection cover

with Permatex (use Permatex to attach
gasket to cover only).
27 Install inspection cover to top of unit

and tighten bolts.
20458
28 Install brake disc by sliding on spline

of ring gear shaft. Apply a thin coating
of grease to outside of brake disc hub
before pushing through the seal. Be
careful not to damage seal lips when
installing disc.
29 Install and tighten drain plug.
30 Fill drive unit with recommended fluid.
31 Install and tighten fill plug.
Tighten fill and drain plugs to:
[54-61 N.m] 40-45 lbf.ft. torque.
DRIVE AXLE REASSEMBLY
Connect the two (right and left hand) drive

units together to form the drive axle assembly.
Install the fastener bolts in drive unit
flanges. Be sure drive units are aligned
with the top surfaces even and parallel
with each other. Locate on the top surfaces
while tightening the flange bolts. Hold top
surfaces within [1,02 mm] .040 inch before
torquing bolts of two units together.

[200-217 N.m] 148-160 lbf.ft.

CMRK GROUP
20
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
TOE 1 MOVE PINION TOWARD

GEAR !N THIS DIRECTION
.MOVE PINION AWAY FROM

GEAR IN THIS DIRECTION
MOVE GEAR AWAY FROM MOVE GEAR TOWARD
V PINION IN THIS DIRECTION PINION IN THIS DIRECTION A
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 BQTH 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.

GROUP CLqRK
20
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
MOVE GEAR AWAY FROM MOVE GEAR TOWARD

p PINION IN THIS DIRECTION PINION IN THIS DIRECTION A
LARGE END ALL CONTACT BEARINGS SHOWN BELOW ARE ON LEFT 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.

CLqRK GROUP
22
GROUP
22
SECTION
1
PNEUMATIC TIRE & WHEEL MAINTENANCE
Code: PMA-270, REV JUL 80 Section 1, Page 1

GROUP CLqRK
22
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."
Section 1, Page 2 Code: PMA-270, REV FEB 84

CLclRK GROUP
22
MAINTENANCE FOR PNEUMATIC TIRES:
! WARNING
-------
13
REMOVE THE AIR FROM THE TIRES BEFORE
YOU REMOVE THE WHEELS FROM THE TRUCK.
Check the tire air pressure. Low tire

pressure can decrease stability of the truck.
(Refer to the truck PMA Manual GROUP 40 for
the correct tire pressure specifications.) Fig. 21523
IMPORTANT
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 TREAD. REMOVE DEBRIS FROM ALL CUTS.
CHECKING, MINOR REPAIR & CLEAN-UP:
1. Check tires for cuts and breaks. Fig. 21521

2. Check for loose nuts or nuts not in
position.
3. Check the surface of the wheels for bent
flanges.
4. Check the nuts or bolts for damage.
5. Check all parts for rust or corrosion.
6. Mark the damaged are,aswith chalk so that
the parts can be removed from operation.
7. Remove all parts that have damage and
install new parts in the same position.
8. Replace parts with the correct sizes and
types. See your parts manual.
9. Include your truck serial number when Fig. A0821
ordering replacement parts.
TIRES INSTALLED ON LOCK RING TYPE WHEELS:
q ! WARNING
-------
BEFORE YOU LOOSEN THE WHEEL MOUNTING BOLTS OR

NUTS, REMOVE THE AIR FROM THE TIRE. FAILURE
TO REMOVE THE AIR FROM THE TIRE CAN RESULT IN
INJURY.
Remove valve core from the valve stem. Fig. 18631
Code: PMA-270, REV FEB 84 Section 1, Page 3

CUSTOMER SERVICES GROUP
After you remove air from the tire, then

loosen and remove the wheel bolts or nuts.
Remove the wheel.
Fig. 18924
Remove lock
ring.
Remove wheel
wedge.
Fig. 18630 Fig. 18316
Remove tire
from wheel.
Remove the
rubber tube
protector.
Repair tire
and/or tube.
-I
i, .I
Fig. 18314 Fig. 18629
CRACKS IN THE WHEEL ARE CAUSED Check for

BY: cracks in
the wheel.
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.
1
Fig. 18304
Section 1, Page 4 Code: PMA-270, REV JUL 80

GROUP
CMRK 22
CRACKS IN THE LOCK RING ARE Check for

CAUSED BY: cracks in
the lock
1. Deep rim tool marks. ring.
2. Too much load on wheels.
3. Too much air pressure in
the tires.
4. Using the wrong size tires.
Fig. 18305
CRACKS ARE CAUSED BY: Check for

cracks between
1. Loose wheel nuts. the stud holes
2. The wheel was not in the wheel.
installed correctly.
3. The wrong size or type
of parts were used.
Fig. 18306
TOO MUCH TORQUE ON THE TOO LITTLE TORQUE ON THE

WHEEL FASTENERS. WHEEL FASTENERS.
If the wheel mounting parts are If the wheel mounting parts

too tight, the studs or bolts are too loose, damage to parts
can break, causing cracks in and tire wear will result.
the wheel between the stud
holes.
Check wedge ring for wear or damage.
Q.
TOO MUCH CORROSION WILL,
CAUSE WEAR AND DAMAGE TO
THE WHEEL WEDGE RING.
Fig. 18307

Clean the
wheels. Re-
move rust
and dirt.
Clean the tire

bead seat area.
Remove all rust
and rubber.
Fig. 18308 Fig. 18309
Clean wedge and lock rings. Make sure the

seating surface and bead seat areas are
clean.
Fig. 18310
Apply paint to the tire rim with a brush.

Or, use an 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 or tire side of the rim. This is
important because air is on the metal surface
of the tire side of the rim.
Fig. 18311
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 DEALERS CAN SUPPLY THl;j

CORRECT LUBRICANT WHICH CONTAINS
A RUST INHIBITOR.
Fig. 18311

GROUP
CLSRK
22
Put the tube into the tire.
Install washer 22.095 on tube over valve

stem before flap is installed, if specified.*
Put the rubber tube protector (flap) over

the tube.
Fig. 18629
Install the tire onto the wheel rim, against

the bead seat area.
Fig. 18314
s >
,' Put the wheel
_j wedge over the
rim.
Install the
wheel wedge.
Fig. 18316 Fig. 18317
Put the side ring over the rim and install

the lock ring as shown.
Fig. 18627

Connect air
chuck and
put [21 kPa]
or 3 PSI of
air into
the tire.
Turn wheel to
the other side .
Check to make
sure lock ring
is in correct Fig. 18318
location.
Use a mallet and hit the ring to make sure

the ring is fully installed.
Disconnect the air chuck.
Fig. 18636
Put the tire in an OSHA approved safety cage.

Follow the procedures on the next two pages
when you put air into your tires. If your air
supply does not have enough pressure to fill
the tire, you can use a nitrogen cylinder to
get the correct tire pressure. Connect a
nitrogen cylinder to the valve stem with the
use of an air chuck. TIRE IS STILL LN SAFETY
CAGE! Refer to pages 11 and 12 on "How to
adjust the regulator on the nitrogen
cylinder".
WARNING
------_
MAKE SURE THE EQUIPMENT USED

(NITROGEN CYLINDER, GAUGES,
REGULATOR, HOSES) ARE ALL IN
GOOD CONDITION. MAKE SURE
THE EQUIPMENT IS U.L. APPROVED. Fig. 13985
USE THE CORRECT REGULATOR AND
HOSE FOR THE PRESSURES THAT WARN ING
---- ---
ARE NECESSARY.
USE NITROGEN ONLY. DO NOT USE OXYGEN
OR ANY OTHER GAS TO FILL YOUR TIRES.

GROUP
22
SAFETY
AIR
GAUGE
SHUTOFF
VALVE CORE
DEPRESSING
COUPLING
OF AIR
SUPPLY
Fig. 9702 Typical Tire Filling Procedure
Fillinq Tires With Air 3. At intervals, close the control

valve and check the pressure in the
All wheel and tire assemblies must be tire by reading the gauge. Do not
filled in a safety cage. The airhose put too much pressure into the tire.
and components should be arranged as
shown in Fig. 9702. The hose must 4. Continue to fill the tire to the
have an adapter that can be connected correct caoacity.
to the valve stem.
I M PO RT ANT
1. Attach an air hose to valve stem.
2. Open the control valve which will PUT EQUAL AIR PRESSURE IN BOTH
let compressed air into the tire. TIRES OF A DUAL ASSEMBLY. DO
NOT PUT AIR INTO A TIRE THAT IS
FLAT WITHOUT FIRST INSPECTING
IT AND THE WHEEL FOR DAMAGE.

RELIEF VALVE
- Model 25OV
[6.35 mm] or
l/4-INCH NPT
Humphrey Products
P.O. Box 2008
Kilgore at Sprinkle Road
Kalamazoo,Michigan
AIR PRESSURE GAUGE

MARSHALTOWN f23
[1,103 kPa] or 160 lb.
[6.35 mm] or
l/4-INCH NPT
[63.5 mm] DIAMETER

or 2-l/2-INCH DIAMETER
Kendall Industrial Supplies, Inc.

702 North 20th Street
Battle Creek, Michigan -49016-
SHUT-OFF CONTROL
IMPERIAL #77E
[6.35 mm] or
l/4-INCH NPT
SAFETY CAGE
(OSHA APPROVED)
Meyers Tire Supplies

6400 Epworth Blvd.
Detroit, Michigan
CLIP-ON AIR CHUCK
NOTICE: YOU CAN ORDER PARTS FROM THE DEALERS LISTED ABOVE OR FROM ANY
SUPPLIER.

WIRK GR202U
HOW TO ADJUST THE REGULATOR ON THE NITROGEN
CYLINDER:
Be sure cylinder valve is closed.
Turn the regulator valve counterclockwise

until you can feel no resistance from the
regulator.
This will adjust the regulator pressure to

a low pressure near zero.
Fig. 18324
Slowly turn the

cylinder valve
counterclock-
wise to open
position.
The tank gauge

will now show
tank pressure.
Fig. 18324
Fig. 18324
Turn the regulator valve clockwise until the

regulator gauge reads the correct tire
pressure. Fill the tire with nitrogen.
_
Fig.
Turn the tank valve clockwise and close the

valve.
Fig. 18324

GROUP CLqRK
22
Disconnect the air chuck from the valve stem.
Fig. 16141
Turn the regulator valve counterclockw ise to

the off position.
Use a tire pressure gauge to check the tire Fig. 18324

pressure. If neces-sary,put more air into the
tire. Do this as many times as necessary to
reach the correct tire pressure.
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. Fig. 21523

CL!Wn; GR202
PROCEDURES FOR ADDING AIR PRESSURE TO MOUNTED
TIRE AND WHEEL ASSEMBLIES:
A ! WARNING
-------
BEFORE YOU ADD AIR PRESSURE TO THE TIRE,

MAKE SURE THE LOCK RING IS CORRECTLY
POSITIONED IN THE RIM AND SIDE RING.
THE LOCK RING CAN SEPARATE FROM THE RIM
WITH ENOUGH FORCE TO CAUSE INJURY OR
DEATH.
Fig. 18924
Attach a clip-on air chuck to valve stem.

Stand by the side of the wheel and put the
correct air pressure in the tire.
Fig. 21524
If your air supply does not have enough

pressure to fill the tire, you can use a
nitrogen cylinder to get the correct pressure.
Put a clip-on type air chuck on the nitrogen

cylinder hose and attach it to the valve stem.
Follow the procedures on pages 11 and 12 for
adjustment of the nitrogen cylinder valves.
A! WARNING
-------
USE NITROGEN ONLY TO FILL YOUR TIRES.
DO NOT USE OXYGEN OR OTHER GAS.
Fig. 18927


SPLIT WHEEL ASSEMBLIES:
WARNING
-------
BEFORE REMOVING TIRES FROM SPLIT WHEEL

ASSEMBLIES, REMOVE ALL AIR PRESSURE
FROM THE TIRES. BEFORE YOU PUT AIR
PRESSURE INTO TIRES WITH SPLIT WHEEL
ASSEMBLIES, MAKE SURE THE SPLIT WHEEL
ATTACHING BOLTS ARE INSTALLED AND
TIGHTENED TO PROPER TORQUE VALUE.
ALWAYS USE A SAFETY CAGE WHEN INFLATING Fig. 13761
TIRES.
Outside (A) bolts hold split wheel together.

Inside (B) bolts hold wheel assembly on the
hub. (Fig. 13761)
DIRECTIONAL TREAD TIRES:
All directional tread tires are to be mounted in

the correct position with respect to the arrow
cast on the side of the tire as explained below.
Directional tread dual tires:
1. Inside dual tire arrow to point in the

direction of forward rotation, see Fig;
6422.
Rotate wheel to bring arrow on tire above the

wheel. Arrow must point toward front of
truck.
2. Outside dual tire arrow to point in the

direction of rearward rotation, see Fig. ._
6423. Fig. 6423
Rotate wheel to bring arrow on tire above the

wheel. Arrow should point toward rear of
truck.
Directional Tread Single Drive Tires:
1. Tire arrow to point in the direction of

forward rotation, see Fig. 6422.
Rotate wheel to bring arrow on tire above

the wheel. Arrow must point toward front of
truck, see Fig. 6422.

SAFETY PROCEDURES
1. Never attempt to weld on an inflated 7. Mixing parts of one manufacturer's

tire/rim assembly. rims with those of another is
potentially dangerous. Always ask
2. Always remove all air from a single manufacturer for approval.
tire and from both tires of a dual
assembly prior to removing any rim 8. Do not overload rims. Ask your rim
components, or any wheel components, manufacturer if special operating
such as nuts and rim clamps. conditions are required.
Make sure to remove the valve core 9. Do not fill a tire with air that
and remove all air from the tire. has been run flat without first
inspecting the tire, rim, and wheel
Remove the valve cores from both assembly.
tires of a dual assembly.
Double check the lock ring for
Check the valve stem by inserting a damage . . . make sure that it is
piece of wire through the stem to secure in the gutter before filling
make sure it is not plugged. the tire with air.
3. Check rim components periodically 10. Never run a vehicle on one tire of
for fatigue cracks. Replace all a dual assembly. The carrying
cracked, badly worn, damaged and capacity of the single tire and rim
severely rusted components. is dangerously exceeded, and
operating a vehicle in this manner
4. Clean rims and repaint to stop can result in damage to the rim.
detrimental effects of corrosion.
Be very careful to clean all dirt 11. Do not be careless or take chances.
and rust from the lock ring gutter. If you are not sure about the
proper mating of rim and wheel
This is important to secure the parts, consult a wheel and rim
lock ring in its proper position. expert. This may be the tire man
who is servicing your fleet, the
A filter on the air filling rim and wheel distributor in your
equipment to remove the moisture area, or the CLARK dealer.
from the air line prevents a lot of
corrosion. The filter should be 12. Do not use undersized rims. Use
checked periodically to make sure the right rims for the job.
it is working properly.
13. Do not seat rings by hitting with a
5. Make sure correct parts are being hammer while the tire is filled.
assembled. Ask your distributor or
the manufacturer if you have any Do not hit a filled or partially
doubts. filled tire/rim assembly with a
hammer.
6. Double check to make sure all the
components are properly seated prior 14. Do not let anyone mount or demount
to filling tire with air. tires without proper training.
1142-Z REV JUL 80

SAFETY PROCEDURES
15. Never sit on or stand in front of a Always stand to one side when you
tire and rim assembly that is being apply hydraulic pressure.
filled with air. Use a clip-on
chuck and make sure hose is long 21. When using a cable or chain sling,
enough to permit the person filling stand away ... it might break.
the tire with air to stand to the
side of the tire, not in front or
in back of the tire assembly.
16. Do not, under any circumstances,

attempt to rework, weld heat, or
braze any rim components that are
cracked, broken or damaged. Replace
with new parts or parts that are not
cracked, broken, or damaged, which
are of the same size, type and make.
17. Fill the tire with air in a safety

cage.
18. Regardless of how hard or firm the

ground appears, put hardwood blocks
under the jack.
19. Block the tire and wheel on the

other side of the vehicle, before
you place the jack in position.
Place blocks under the truck frame
as near as possible to the jack to
prevent the truck from falling, if
the jack should fail.
20. Remove the bead seat band slowly to

prevent it from dropping off and
crushing your toes. Support the
band on your thigh and roll it
slowly to the ground. This will
protect your back and toes.
21. Bead breakers and rams apply

pressure to bead flanges. Keep
your fingers away from the bead
flanges. Slant bead breaker about
10' to keep it firmly in place. If
it slips off, it can fly with enough
force to kill.
1143-Z REV JUL 80

CLqRK $Wttet\Handling
GROUP 23 (CARLISLE BRAKE)
GROUP 23
BRAKE SYSTEM
(CARLISLE BRAKE)
Brake Specifications ........................ ........ .... .... .... ........... Section 1
Brake System Bleeding ....r.......................................~*..... Section 2
Brake Pedal Removal, Replacement, and

Adjustment ... .... ......................... .... ..... ... ................ ... Section 3
Brake Removal and Replacement ........................ ...... ... Section 4
Parking Brake Removal, Replacement, and

Adjustment ....... ......................... .......... .. ...... ............. Section 5
Brake Overhaul . .............*..*............................................ Section 6
SM 555, Jan ‘97 Brake System (Carlisle Brake)

CIHRK Group 23 (Carlisle Brake)
Section 1.
Brake
Specifications
Specifications Service Requirements

Service Brake: Operational checks and inspection of linkages, brake pads,
and brake lines are specified in the Periodic Service Chart
Type: Caliper
in Group PS.
Minimum lining/pad thickness (when replacement is nec-
Service brake linkage adjustment and lube are not normally
essary): 0.67 mm (0.06 in).
required.
Fluid: Capacity 0.256 L (0.06 gal); SAEJ1703 (DOT-3)
Brake pads are self-adjusting.
brake fluid only.
A leaking brake cylinder should be overhauled or replaced.
Pedal Freeplay: l-3 mm (0.039-o. 118 in; measured at stop
screw). Parking brake should be adjusted if indicated by opera-
tional check.
Parking Brake:
The sections following in this Group provide service proce-
Type: Lever-type mechanically linked to brake assembly.
dures for the service and parking brake assemblies.
Holding Test: Rated load on 15% grade
SM 555, Jan ‘97 Brake Specifications l 23 (Carlisle Brake)-l-l

CUlRK Group 23 (Carlisle Brake)
Section 2.
Brake System
Bleeding
Bleed brakes when: Depress the brake pedal and watch fluid (and bubbles)
flow into the jar. Tighten bleed screw with pedal
l The brake pedal kicks back during braking or the pedal
depressed. Repeat until fluid is free of bubbles.
feels spongy.
Repeat steps 2-4 for right-side caliper bleed screw.
l The master cylinder or lines between have been leak-
ing and/or have been repaired or replaced. Operate the brake pedal at various rates. If you feel the
pedal kick back or if the pedal feels spongy, bleed the
l Troubleshooting otherwise indicates that air has been
system again.
introduced into the system.
To master 7
cylinder
Bleeder Screw \
Proceed as follows:
Park truck on level floor. Put direction control in
neutral. Lower forks to floor, tilt forward, and apply
parking brake.
Attach a clear hose to the bleed screw on the brake
caliper. Place the other end of the hose in a jar
containing fluid.
Open the left-side caliper bleed screw.
Bleeder Screw
SM 555, Jan ‘97 Brake Bleeding l 23 (Carlisle Brake)-2-l

ClMK Group 23 (Carlisle Brake)
Section 3.
Brake Pedal Removal, Replacement, and Adjustment
Introduction .................................................................................................................................... 2
Pedal Removal ................................................................................................................................ 2
Pedal Replacement ......................................................................................................................... 3
Pedal Adjustment ........................................................................................................................... 4
SM 555, Jan ‘97 Pedal R&R and Adjustment l 23 (Carlisle Brake)-3-l

Group 23 (Carlisle Brake) ClRRK

Introduction Pedal Removal
Figures 1 and 2 show: 1. Remove the floorboard from the operator’s compart-
ment.
l The brake pedal which controls the master cylinder.
2. Place a pan under the operator’s compartment. Re-
l The brake system connections from the fluid reservoir move the reservoir hose and brake hose from the
and master cylinder to the brake. master cylinder (Figure 2). Plug openings and cap the
The illustrations and accompanying text serve as guide to lines.
disassembly/assembly and adjustment. 3. Remove brake pedal components as required. Compo-
nents and their assembly are shown in Figures 1 and 2.
Hex nut: 40-45 N*m
(2’9.5-33 ft-lb)
Pedal pad --.,
/ ,- Master cylinder
Flanged capscrew
Stop screw and jam nut; free-play l-3 mm

(0.039-0.118 in) measured at this point.
Flanged nut; 20-25 Nom (14.7-18-5 ft-lb)
Extension spring
(6-7.3 ft-lb)
Brake assembly bracket
Figure 1. Brake Pedal and Linkage
23 (Carlisle Brake)-3-2 l Pedal R&R and Adjustment SM 555, Jan ‘97

CWRK Group 23 (Carlisle Brake)
Pedal Replacement 3. Adjust pedal free play and micro-switch as described

in Pedal Adjustment on page 4. After adjustment, the
1. Replace the brake pedal components as shown in brake system must be bled; see Section 2 in this Group.
Figures 1 and 2. Component names and fastener After bleeding, check all fluid connections for leaks
torques are shown in the illustrations. and test brakes completely before returning truck to
service.
2. Clean the reservoir and master cylinder hoses and
fittings. Make sure no contaminants enter the braking
system. Connect the brake hose as shown in inset of
Figure 2.
Steer column Reservoir hose
screw
Figure 2. Brake Fluid Reservoir and Connections
SM 555, Jan ‘97 Pedal R&R and Adjustment l 23 (Carlisle Brake)-3-3

Group 23 (Carlisle Brake) CUIRK

Pedal Adjustment
With all components replaced and fasteners tightened to
correct torque, adjust the pedal as follows:
1. Adjust stop screw on pedal to provide l-3 mm (0.039-
0.118 in) of free play.
2. When free play is adjusted, tighten the jam nut on the
stop screw to set the distance.
3. Adjust micro-switch to activate at the end of pedal
free play. See Group 13 for brake switch check and
adjustments.
4. Brakes must be bled after brake pedal removal and
replacement. See Section 2 in this Group for proce-
dures. If this is only a pedal adjustment, brakes do not
have to be bledifno system connections were opened.
23 (Carlisle Brake)-3-4 l Pedal R&R and Adjustment SM 555, Jan ‘97

CINRU Group 23 (Carlisle Brake)
Section 4.
Brake Removal and Replacement
Introduction Brake Replacement.

Figures 1 and 2 show: 1. To replace rotors:
l The brake mounting on the drive axle. a. Coat splines of brake rotor with an anti-seize
compound before installing in truck.
l The connections from the master cylinder to the brake.
b. Grasp rotor around the outer edge and line up with
The illustrations and accompanying text serve as a guide to the spline.
removal and replacement.
c. Push rotor onto splined shaft until it is fully
Before beginning this service procedure: engaged.
l Park the truck on a level surface and lower the upright d. Repeat for opposite rotor. Both rotors should be
completely. free to float on the splines.
l Return all controls to neutral and turn key switch to 2. Replace brake as shown in Figure 1:
OFF position.
a. Mount brake over disk.
l Block the wheels.
b. Set mounting bolts in place and torque to OS-2
See Section 3 for procedures to remove brake pedal and Nom (0.4-1.5 ft-lb).
master cylinder. See Section 6 for brake overhaul proce- c. Set park brake or press brake pedal to align brake
dures. and disk.
d. Torque mounting bolts to 60-65 N*m (44-48 ft-
Brake Removal lb).
1. Disconnect tube assemblies from brake at the com- 3. Replace tube assemblies at the compression fittings.
pression fittings shown in Figure 2. Move tubing out of Do not overtighten.
the way; disconnect from the tee if necessary. 3. Replace rear cover. Torque top bolts to 60-65 Nom
2. Remove the cotter pin from the parking brake caliper (44-48 ft-lb); torque bottom nut to 170-190 pm (125
clevis (see Section 5). 140 ft-lb).
3. Remove bolts and washers from brake mounting 4. Replace front cover. Torque top bolts to 60-65 Nom
bracket. Lift the caliper assembly from the transaxle. (44-48 ft-lb).
IMPORTANT
4. To remove the brake rotors:
Both sides of brake must be checked and
a. Place a pan under the truck to catch fluid. fully refilled with proper lubricant. See
b. Slide the left-side rotor off of the splined shaft and brake bleeding Section in this Group.
lift out.
c. Repeat for opposite rotor.
d. Inspect axle seals per procedures in Group
Transaxle. Replace if worn, leaking, or damaged.
SM 555, Jan ‘97 Brake R&R l 23 (Carlisle Brake)-4-l

Group 23 (Carlisle Brake) CIRRK
60-65 Bo’t;\
N*m ,--- Brake Assembly
(44-48 ft-lb)
Bolt;
Bolt;- 60-65 Nom
60-65 Nom / (44-48 ft-lb)
(44-48 ft-lb) I
4 r- Front Cover
I
I 7 Drive Axle
170-l 90 N*m
(125-140 ft-lb)
and Hubs
Figure 1. Brake Mounting
23 (Carlisle Brake)-4-2 l Brake R&R SM 555, Jan ‘97

CWRK Group 23 (Carlisle Brake)
Tube
Assembly
Brake -
Rotors
Figure 2. Brake Tubing Connections
SM 555, Jan ‘97 Brake R&R l 23 (Carlisle Brake)-4-3

CMRU Group 23 (Carlisle Brake)
Section 5. Parking Brake Removal, Replacement, and Adjustment
Removal and Replacement Adjustment

Remove and replace parking brake components as shown in Set lever assembly at return (down) position.
the illustration. Parking brake must be adjusted after re- Tighten adjustment set nut until all clearance is re-
moval and replacement and at every PM. moved.
Washer -
Nut; 20-25 Nom (14.5-l 8.5 ft-I b) Cheese-head screw
Washer
Switch
/-
Hand brake lever
Park brake cable
capscrew
Park brake bracket
Set Nut
SM 555, Jan ‘97 Parking Brake R&R and Adjustment l 23 (Carlisle Brake)-51
Group 23 (Carlisle Brake) ClMK

Loosen set nut l/2 turn. This allows approximately 1
mm (0.03 in) gap between brake and pad.
Tighten jam nut.
Adjust hand brake lever by tightening or loosening to
achieve hold on truck with rated load on 15% grade.
See Group 13 for parking brake switch check and
adjustment.
23 (Carlisle Brake)-52 l Parking Brake R&R and Adjustment SM 555, Jan ‘97
CUIRU Group 23 (Carlisle Brake)
Section 6.
Brake Overhaul
IMPORTANT
Brake carrier and lining assemblies must be replaced when lining material
is less than 0.67mm (0.060 in).
Use the Disassembly and Assembly procedures and the following illustration to overhaul the brake. Replace components
using the correct rebuild kit. Brake valves are not serviceable. See Group Sections for procedures to remove,
adjust, and bleed brake and components.
Pad Retainer Nut; torque 75-85 N*m -
Bleeder Screw; torque

4.5-l 1 N*m (3.3-8.3 Mb)
Parking Brake Adjustment and Jam Nuts

(Jam nut torque; 31-37 Nam [25-28 ft-lb])
Pivot Retainer Nut; torque 115

129 Nom (85-95 ft-I b)
Fastener
Bracket
Brake Lever
Assembly Bracket
Adjustment Bolt and

Washer
SM 555, Jan ‘97 Brake Overhaul l 23 (Carlisle Brake)-6-l

Group 23 (Carlisle Brake) CMRU

Disassembly Assembly
Carrier and Lining Removal Caliper Assembly
Remove parking brake jam and adjustment nuts from 1. Slide the brake valves in place on the brake shoepivots.
the adjustment bolt and washer. 2. Set the mounting brackets in position and install pivot
Remove the parking brake lever arm with adjustment retainer nuts; torque 115-129 Nom (85-95 ft-lb).
bolt and washer. Carrier and Lining Assembly
Remove the pad retainer nut from the sleeve and repeat 1. Insert the outer carrier and lining assembly between
for opposite side. the brake shoe pivots. Position the carrier against
brake valve.
Push brake sleeves into bushings and remove carrier NOTE
and lining assemblies.
Apply a thin coat of an anti-seize com-
Caliper Disassembly
pound to the brake sleeves before installing
1. Remove the nuts securing the brake valves and brake to carrier and liner assemblies.
shoe pivots in the mounting brackets.
2. Install the sleeves through valve bushings and insert
2. Pull the mounting brackets apart from the brake valves threaded end of sleeves through the outer carrier and
and brake shoe pivots. lining assembly.
Parts Inspection
3. Install pad retainer nuts to sleeves; torque 75-85 N*m
Brake carrier and lining assemblies must be replaced when (101-115 ft-lb).
lining material is less than 0.67mm (0.060 in).
4. Install spacer plate between two carrier and lining
All parts must be clean and free of dust and chips before assemblies and in the center groove of the actuating
assembly. Thoroughly clean all drilled passages, seal pins.
grooves, and threads in the brake valves. If parts are
5. Install the inner carrier and liner assembly between the
damaged or worn, replace the brake valve.
outer carrier and lining assembly and the center spacer
Clean brake valves with solvent: plate.
a. Check all cylinder bores for nicks, scratches, or NOTE
corrosion and blend with crocus cloth. Apply a thin coat of an anti-seize com-
pound to the actuator pins before installing
b. Check all fluid passages and grooves and clean
to brake valves.
remaining dirt and fluid completely out.
6. Install two actuator pins into brake valve on side of
Inspect piston assemblies for scratches and nicks and
parking brake lever arm.
blend with a crocus cloth. Replace the valve if piston
is badly scratched. 7. Install adjustment bolt and washer with parking brake
lever arm through brake sleeves, spacers, and carrier
Check actuating pins for grooves. Pins with light
and lining assemblies.
grooves may be rotated so grooved portion is opposite
the end of the carrier and lining assemblies. Replace 8. Install parking brake adjustment and jam nuts, do not
deeply grooved actuating pins. torque. See Section 5 for parking brake adjustment.
Bushings should be flush with inside machined surface If removed, install bleeder screws to valves (torque 4.5-l 1
of the valve. Press bushings flush if necessary. N*m [3.3-8.3 ft-lb]). See Section 4 for procedures to
replace and adjust the brake.
Lubricate piston seals lightly with automotive brake
fluid or silicon grease compatible with brake fluid. Do
not use petroleum-based oils or lubricants.
23 (Carlisle Brake)-6-2 l Brake Overhaul SM 555, Jan ‘97

GROUP
23
GROUP
23
SECTION
BRAKE BLEEDING PROCEDURE

c
(REMOVAL OF AIR FROM BRAKE SYSTEM)

l Park truck on a level surface.

o Return all controls to neutral and turn
o Disconnect battery from truck receptacle.
o Apply the parking brake.
l Block the wheels.
85M626

GROUP CLIRK
23
HYDRAULICBRAKEFLUID AND BLEEDINGINFORMATION
1. Do not mix different types or 12. Before bleeding, make all necessary
brands of brake fluid. adjustments to pedal travel and repairs
on lines, hoses, cylinders, etc.
2. Do not use brake fluid which is
contaminated. 13. Clean off bleeder screws before
bleeding brakes.
3. Do not use brake fluid that is
cloudy, opaque, an emulsion, separated 14. Do not use brake bleeding equipment
into layers, or contains any moisture. for any other purpose.
4. Always store brake fluid in the orig- 15. Use only pressure bleeders which
inal container and keep airtight. prevent aeration of fluid.
5. Clean the top and cap of brake 16. Be sure that pressure bleeder is
fluid containers before opening. in safe operating condition.
6. Do not use (reuse) brake fluid 17. Before attaching pressure bleeder
containers for any other purpose. to master cylinder, fill cylinder com-
pletely full, and also fill the
7. Use only new brake fluid for bleed- bleeder hose with fluid.
ing and cleaning of brake system parts.
18. Follow brake bleeding procedures
8. Never save or reuse brake fluid once exactly as described.
it has been in any brake system.
9. Clean the filler cap and top of

master cylinder or reservoir before
removing cap.
10. Do not open master cylinder in a

dusty area or where rain, snow and
other contaminants can enter the fluid.
11. Drain and flush the entire brake

system if the fluid in the master cyl-
inder or reservoir looks dirty, cloudy,
is emulsified, separated into layers, or
contains water or other foreign liquid.

GROUP
CLRRK
23
BRAKE BLEEDING PROCEDURE
NOTICE - The service brake system on this truck model uses conventional
SAE/DOT 3 heavy duty automotive hydraulic brake fluid only.
Normally a minimum of brake bleeding will be required. The brake system is

designed to place the master cylinder reservoir at the highest point in the
circuit. This ensures. that the major part of any air that has entered the
system will flow upwards and vent into the reservoir. The recommended
brake bleeding procedure outlined below is intended to dislodge and remove
any entrapped air from the circuit.
IMPORTANT - Service brake pedal free play must be correctly adjusted

before bleeding brakes.
Check frequently and keep master cylinder reservoir filled during bleeding.
Refer to Page 7 for illustration of brake lines installation.
1 Remove floorboard.
NOTICE - More space will be available

if brake bleeding is performed when
battery is removed and front battery
plate is adjusted for service access.
Refer to GROUP 38, Section 2,

Front Battery Plate Adjustment.
85M506
'2 Remove access cover from pylon.
85M510

GROUP CMRK
23
Clean all dirt and contamination from the

reservoir and cap. Check fluid level.
Fill the reservoir and add fluid, as
needed, to keep reservoir full during
bleeding.
Check brake lines and connections for

leakage. Be sure all connections are
tightened correctly.
85M645
Release the parking brake during the

bleeding procedure.
Check brake pedal for correct adjustment.

Adjust pedal stop screw, as necessary, to
provide "free play" of [l,O-3,0 mm]
.040-.118 inch clearance measured at the
stop screw.
85M621
7 Clean the brake bleeder screw.
Brake bleeder screw is located at the top

of brake caliper assembly.
85M672
8 It is recommended to install a temporary

bleed drain line on the bleeder screw. Use
an adequate length of flexible tubing (e.g.,
clear plastic tubing) having an inside diameter
to fit tightly over the bleeder screw opening
(to prevent air from entering). This will
allow bleeding to be done quickly and cleanly.
If drain line is not used, the bleed screw
must be alternatively opened and closed in
sequence while bleeding the system, as
noted below.

CLRRK GROUP
23
9 Install bleed drain line on bleeder screw.

Fit the drain line tube only over the
outer end of the bleeder screw,
leaving wrench clearance at the bottom.
Immerse the open end of the drain line in a BRA

FLUI AIR
jar partially filled with clean hydraulic BUBBLES
fluid. Put the jar of fluid in a position
above the level of the bleeder screw, and
where you can watch for air bubbles in the
J
fluid.
9746
10 Loosen and open the bleeder screw.

(Shown without drain line for clarity.)
Alternate Bleeding Procedure - When bleed drain

lines are not installed, the bleed screw must
be opened during brake pedal downward movement,
and closed before and during brake pedal upward
movement, to prevent air from entering the sys-
tem during pedal return stroke.
85M673
11 Push ("pump") the brake pedal fully down

slowly several times (5-6 times minimum).
When moving the brake pedal, be sure that
the open end of the bleed drain line is
always immersed in the jar of hydraulic
brake fluid to prevent air from re-entering
the system. Watch for air bubbles escaping
from the bleed drain line.
Check and fill brake reservoir with

recommended hydraulic brake fluid.
85M480
12 Continue brake bleeding until all air is

removed from the brake system.
When the bleeding fluid appears to be free

of air bubbles, close (tighten) the bleeder
screw, and test the brake pedal action.
85M673

GROUP CLqRK
23
.3 Push on the brake pedal and hold in the

fully-down position. Check for a feeling
of solid resistance when the brake pedal
stops. The pedal must feel firm and not
move down farther after it stops.
85M480
14 If the brake pedal motion or feel is not

correct:
l First, push the pedal fully down several

times, with the bleed screw closed. This
will give movement to the brake fluid and
brake cylinder pistons to aid in dislodging
any remaining entrapped bubbles of air.
Wait several minutes.
l Then, repeat the bleeding procedure, above .
o Test the brake pedal action.
15 If necessary, repeat the brake bleeding procedure, until brake pedal

action is correct.
NOTICE - If a faulty condition continues to exist, a complete

inspection and repair of the brake system must be made.
See PM Section, Page 5.9, for service brake inspection.
Refer to Overhaul Manual OH-540 for brake removal and overhaul.
16 When brake bleeding is completed satisfac-

torily:
l Remove bleed drain line and tighten

the brake bleeder screw.
l Check and fill brake reservoir with

recommended hydraulic brake fluid.
o Install the pylon access cover.

l Install front battery plate (as req'd).
l Install the floorboard.
85M645

CLflRK GROUP
23
23.7%
.23.186
q 23.150
23.175-
HYDRAULIC BRAKE LINES 23-262
22.338 CLAMP,BRARRFLUIDRESERVOIR
22.357 CAP, BRARRFLUIDRESERVOIR
23.150 RRAKR!!ASTRRCYLIRDRRMsmLY
23.173 FITTIKG,BRAKE MASTER CYLINDEROUEET
23.174 SW, RRAKRMASTERCYLINDRROUTLKPPIl?ING
23.175 FI'ITING
BOLT,BRAKEEASER CYLINDEROUTLET
23.176 SW, BRAKEMASTERCYLINDEROUTLRTFITTING
23.186 LINR,BRAyBHASlZRCYLINDERO~T
23.225 FIZTING,BOLT,SERVICRBRAKE INLRT
23.227 SEAL,SERVICRBibtKR
INLETFITTING
23.229 FIRING, SERVICRBRAKR INLRT
23.231 SW, SERVICEBRAKR INLETFITTING
23.792 RESERVOIR,BRAKEFLUID
23.793 FASTERER,BRMR FLUIDRESERVOIR
23.794 LINR,BRAKRMASTERCYLINDERINTAT
91.170 NUT, BRMX FLUIDRESERVOIRFASTENER

CLRRK GROUP
23
GROUP
23
SECTION
4
PARKING BRAKE ADJUSTMENT

l Park truck on a level surface.

l Return all controls to neutral and turn
l Disconnect battery from truck receptacle.
l Block the wheels.
85M626

GROUP CMRK
23
PARKING BRAKE ADJUSTMENT
1 Raise and block up the upright carriage, for

access to the parking brake adjusting screws.
o BE SURE TO PUT BLOCKING UNDER THE

CARRIAGE AND UPRIGHT RAILS.
If you are unfamiliar with this procedure

please refer to GROUP 38, Section 3,
Machine Jacking and Blocking.
85M630
FALLING FORKS
DO NOT WALK OR STAND UNDER

RAISED FORKS. THE FORKS CAN
DEATH.
/ I
Parking Brake Caliper (Puck) Adjustment
Step 1: Put brake hand lever in released

position.
85M519
Step '2: Turn adjusting screw at end of lever

counterclockwise to fully release cable tension.
85M648
Step 3: Loosen lock nuts (1) on each adjusting

screw (2) on brake caliper body.
Step 4: Adjust screw (2) until brake pads

(pucks) just touch brake discs (rotors).
Step 5: Back off adjusting screw (2) one full

turn, to give running clearance of brake pad at
rotor.
Step 6: Tighten lock nuts (1) securely.

21189

Emu GROUP
23
Parking Brake Lever Adjustment
Step 1: Put lever in released position.
Step 2: Rotate adjusting screw at end of lever

clockwise to tighten (increase) cable tension.
Step 3: Test for correct cable tension by

applying and releasing lever while adjusting.
85M648
Step 4: Tighten adjusting screw to increase

cable tension until lever snap-locks easily
into the over-center, brake-applied position.
85M512
Parking Brake Test
1 Test the function of the parking brake

after adjustments are completed.
Refer to PM-M section, page 2.6. A CAUTION
PARKING BRAKE MUST HOLD

TRUCK WITH RATED CAPACITY
LOAD ON A 15% GRADE.
NOTICE - If a faulty parking brake condition

continues to exist, a complete inspection and
repair of the brake system must be made.
See PM section, Page 5.9, for brake inspection.
Refer to Overhaul Manual OH-540, GROUP 23, Section 17,

Brake Caliper Assembly Overhaul.

CLRRYC GROUP
23
GROUP
23
SECTION
17R
SERVICE BRAKE CALIPER ASSEMBLY REMOVAL

l Park truck on a level surface and

l Block the wheels.
Truck Preparation
Open hood.
Remove floorboard.
maintenance access.

GROUP CMRK
23
85M482 85M849
1 Turn key switch "OFF". 5 Remove floorboard and cover

from main valve.
85M541 85M860
2 Open hood. 6 Adjust front battery plate to

3 Disconnect battery from truck maintenance position. Refer
85M750
4 Remove battery from truck. Refer


Cl!!lRK GROUP
23
BRAKE CALIPER ASSEMBLY REMOVAL
1 Disconnect parking brake cable yoke from the

levers on brake caliper assembly.
1) Release the parking brake hand lever to

provide freeplay in the brake cable.
85M519
There should be sufficient freeplay in

the cable and brake levers to allow the
yoke to be disengaged. If not, either
adjust the cable at the hand lever to
release tension, and/or loosen the parking
brake adjustment nuts on the sides of
brake caliper assembly, as shown.
17060
2) Remove the yoke of parking brake cable

from the levers on brake caliper assembly.
(Figures 17060 and 17061 show typical

procedures for TM truck.)
17061
'2 Disconnect hydraulic brake line from
brake caliper fitting.
Drain any residual brake fluid from the

line into a drain pan or absorbent shop
towel. Put caps on the fittings for
protection.
Refer to GROUP 23, Section 18R, Brake

Master Cylinder Removal, for information
on brake lines and fittings.
85M705

GROUP CLflRK
23
3 Loosen and remove the four mounting bolts

from brake caliper.
NOTICE - Mounting bolts and torques are

different on each side of brake unit.
As shown in photo, bolt torques are:
(Far side) [44-50 N.m] 33-37 lbf.ft.

(Near side) [70-80 N.m] 52-59 Ibf.ft.
17078
4 Remove brake caliper assembly from drive

axle.

CMRIZ GROUP
23
GROUP
23
SECTION
17
SERVICE AND PARKING BRAKE
BRAKE CALIPER ASSEMBLY OVERHAUL

GROUP
CLSRYC
23
LINING AXLE SET
23.262 -/
BRAKE ASSEMBLY 22-118
23.244 BRAKE ASSEMBLY 23.262 SPRING, PARKING BRAKE SHOE RETURN

22.339 SHOE, PARKING BRAKE (OUTBOARD) 23.289 LINING SET, PARKING BRAKE
22.340 SHOE, PARKING BRAKE (INBOARD) 23.297 LINING SET, BRAKE
22.343 CAM, PARKING BRAKE OPERATING (RR OUTBOARD) 23.352 LEVER, PARKING BRAKE CAM RR
22.344 CAM, PARKING BRAKE OPERATING (LH INBOARD) 23.357 ADJUSTOR, PARKING BRAKE SHOE
22.345 CAM, PARKING BRAKE OPERATING (LH OUTBOARD) 23.366 PIN, PARKING BRAKE LEVER PIVOT
22.346 LEVER, PARKING BRAKE CAM LH 23.461 SEAL, BRAKE CYLINDER
22.347 PIVOT, PARKING BRAKE SHOE 23.464 SEAL, BRAKE CYLINDER BLEEDER PORT
22.34.8 SEAL, SERVICE.BRAKE HOUSING 23.465 FITTING, BRAKE CYLINDER BLEEDER PORT
22.351 CAM, PARKING BRAKE OPERATING (P.li
INBOARD) 23.564 PISTON, BRAKE CYLINDER
22.353 FITTING, BRAKE INLET 23.730 FASTENER, BRAKE ASSEMBLY

22.354 SEAL, BRAKE INLET FITTING 91.193 NUT, PARKING BRAKE SHOE ADJUSTOR
22.355 DUST CAP, BRAKE CYLINDER BLEEDER SCREW 93.284 THRU FASTENER, SERVICE BRAKE
22.376 SPRING, PARKING BRAKE OPERATING CAM RETURN (LH) 95.088 RETAINER, BRAKE PISTON
22.377 SPRING, PARKING BRAKE OPERATING CAM RETURN (RH) 1N HOUSING, SERVICE BRAKE USE 23.244
23.223 BLEEDER, BRAKE CYLINDER 2N CYLINDER ROUSING, BRAKE (RR) USE 23.244
23.246 FASTENER, BRAKE ASSEMBLY 3N CYLINDER HOUSING. BRAKE (LH) USE 23.244

Cl!YRK GROUP
23
SERVICE BRAKE CALIPER DISASSEMBLY
Cyli
n
Pi
Cyl .
Cross-Section of Service Brake Caliper Assembly 26658
Disassemble the service brake caliper assembly

by removing both brake cylinder housings from
service brake housing (center section). All
photos show typical procedures. Refer to il-
lustration, Page 2, for parts identification.
1 Loosen and remove the two assembly thru bolts

from the left hand brake cylinder housing.
20452
2 Remove (separate) the RH and LH cylinder

assemblies from the center brake housing.
3 Please note and be careful to not lose

the small O-ring seals, one inserted in
each side of the center service brake
housing brake fluid ports.
20453

GROUP CLRRK
23
See Item 8 below, before removing pistons.
Remove (pry) the piston seal retainer

(split clamping ring) from its seat on
the outer lip of seal in machined groove
around each cylinder. Loosen (pry) the
outer edge ( lip) of piston seal from
the machined groove.
26654
Remove the brake lining pad (puck),
piston, and piston seal assembly from
each brake cylinder.
Adjustable pliers may be used to care-

fully rotate and remove the pad and
piston from cylinder. Clamp the pliers
carefully on edge of puck to avoid
damaging piston.
Separate the brake lining pad (puck)

and piston seal from each piston.
NOTICE - Be careful to not scratch or

damage the outer surface of brake pistons.
Remove the brake cylinder seal from

groove inside each brake cylinder.
20455
When only brake lining pads need to be re-
placed, they can be removed by prying them
from the brake pistons with a screwdriver.
Remove piston seals as noted above.
Install new piston seal by fitting over the

pad. Then, install the new pad by fitting
into piston end. The pads are fitted to
piston with a light press fit.
In the center brake housing, carefully push

the pistons together and support the oppo-
site piston when installing pads. Be sure 20456
piston seal is fitted correctly into groove
in housing. Then, install seal retainer.

CMRU GROUP
23
9 When all four brake cylinders and pistons

have been disassembled, arrange the parts
in the correct order of assembly for
cleaning and inspection.
(Typical arrangement shown)
Also see illustration, Page 2.
CLEANING
l All hydrau7ic brake parts must be IMPORTANT

cleaned and protected after cleaning,
from dust or other air-borne foreign DO NOT USE PETROLEUM (MINERAL-BASE)
material, until parts are reassembled. CLEANING SOLVENTS SUCH AS GASOLINE,
KEROSENE, DISTILLATE, CARBON TETRA-
l Brake cylinder castings and pistons CHLORIDE, ACETONE, PAINT THINNER,
may be degreased, or cleaned with most ETC. THESE SOLVENTS WILL DAMAGE
brands of commercial parts cleaners, RUBBER PARTS BY CAUSING THEM TO
provided they are thoroughly rinsed DETERIORATE AND BECOME ENLARGED,
with Stoddard-type solvent or brake SOFT AND TACKY WITHIN A VERY SHORT
fluid to remove all traces of solvent. TIME.
l Clean rubber parts by washing them

in clean Stoddard-type solvent or hy-
draulic brake fluid.
l Use only low-pressure compressed air

or a lint-free cloth to dry parts after
removal from the cleaning solvent. Do
not use rags that may leave particles
of lint or thread fibres to block fluid
ports and passages during operation.

GROUP C19RK
23
INSPECTION REPAIR KIT
Each brake overhaul should include an Certain parts, such as seals, should
inspection of the cylinder bores and always be replaced during brake cali-
operating parts, including removal of per overhaul and reconditioning. A
foreign deposits and mild corrosion packaged brake lining-axle repair kit
from the cylinder bores and pistons. is the most convenient method and
provides assurance that correct,
After cleaning, inspect the cylinder original-equipment replacement parts
bores for wear and damage. Damage, or have been used.
blemishes such as pitting, scratches,
and visible wear patterns, require IMPORTANT
replacement of the part.
ALWAYS USE GENUINE CLARK PARTS
Accumulations of dirt or gummy sub-
stances, not removed during the clean- BRAKE CALIPER REASSEMBLY
ing process, may be removed with crocus
cloth or jeweler's rouge. A hone may Reassemble the brake caliper in re-
be used to 'clean-up' a cylinder, verse order of disassembly. Be sure
providing its use does not substantial- all parts are installed in the correct
ly change (increase) the diameter of manner or direction as when removed.
the cylinder bore. NOTE-The possibil-
ity of the cylinder having been honed 1 Install new seals in cylinders. Be
during a previous overhaul should not sure they are installed facing in
be overlooked. the correct direction.
A cylinder bore diameter can be check- 2 Apply a coating of clean hydraulic

ed with a 'Go-No Go' gage or a microm- brake fluid to pistons and seals to
eter, and must not exceed the standard prevent damage during assembly and
(nominal) diameter more than 0.007 inch. to provide initial lubrication.
For example, a 1.125-inch diameter
cylinder must not exceed 1.125 + 0.007
or 1.132 inch. An alternate method of
checking a cylinder is to insert a pis- BRAKE BLEEDING
ton and check its clearance. Maximum
clearance checked with a wire gage is After installation into the truck
0.007 inch. brake system, be sure that you bleed
the brake caliper and lines according
Be sure that a honed cylinder has no to recommended procedures. Refer
'burr' at the inlet port. If a burr to GROUP 23, Section 3.
or sharp edge is present, remove it
with a deburring tool.
For a final inspection, be sure the in-

let ports are open (clean). A soft
small-diameter copper wire may be used
to probe the port without danger of
damage. Do not use a steel wire to
check the port.

ENIRK GROUP
23
GROUP
23
SECTION
18R
BRAKE MASTER CYLINDER REMOVAL

0 Park truck on a level surface and

l Apply the parking brake!.
0 Block the wheels.
85M626
_.-. .
Truck Preparation
lpen hood.
3isconnect battery from truck receptacle.
iemove battery from truck.
iemove floorboard.
iemove cover from main valve.
4djust front battery plate for
naintenance access.
See GROUP 23, Section 17R, Service Brake

Caliper Assembly Removal, Page 2, for 85M667
additional information.

GROUP CU7RH
23
23.114
c
.23.1't5
BRAKE PEDAL AND LINKAGE 23-062
13.142 BRAKE INTERLOCK SWITCH 23.136 SPRING, BRAKE PEDAL RBTURh'
13.143 BRACKET, BRAKE INTERLOCK SWITCH 23.139 STOP, BRAKE PEDAL
13.144 FASTENER, BRAKE INTERLOCK SWITCH BRACKET 23.145 RETAINER, BRAKE PEDAL
13.145 FASTENER, BRAKE INTERLOCK SWITCH 23.150 CYLINDER ASSEMBLY, BRAKE MASTER
13.169 FASTENER, BRAKE INTERLOCK SWITCH ACTUATOR 23.156 BOLT, BRAKE RASTER CYLINDER
22.057 FASTENER, BRAKE PEDAL PAD 23.434 BRACKET, BRAKE PEDAL PIVOT
23.059 SPACER, BRAKE MASTER CYLINDER 23.435 FASTENER, BRAKE PEDAL PIVOT BRACKET
23.085 LOCK, BRAKE PEDAL STOP 23.542 BOLT, BRAKE MASTER CYLINDER MOUNTING BRACKET
23.100 PEDAL, BRAKE 90.092 NUT, BRAKE MASTER CYLINDER ATTACRING FASTENER
23.101 SHAFT, BRAKE PEDAL 90.493 NUT, BRAKE PEDAL PIVOT BRACKET FASTENER
23.104 ACTUATOR, BRAKE INTERLOCK SWITCH 92.026 RETAINER, BRAKE MASTER CYLINDER ACTUATING ROD
23.105 BEARING, BRAKE PEDAL 92.823 NUT, BRAKE INTERLOCK SWITCH ACTUATOR FASTENER
23.114 PAD. BRAKE PEDAL 95.178 WASHER, BRAKE INTERLOCK SWITCH ACTUATOR FASTENER
23.118 PIN, BRAKE MASTER CYLINDER ACTUATING ROD

IWIRH GROUP
23
\\ r 23.225
.23.186
23.175-
HYDRAULIC BRAKE LINES 23-262
22.338 CMHP, BRAKEFLUIDRXSERVOIR

22.337 CAP, BRAKEFLUIDRESERVOIR
23.130 BRAKEMASTERCYLINDERASSEMBLY
23.173 FITTING,BRAKEMASTERCYLINDEROUTLET
23.174 SF&, BRAKEMASTERCYLINDF.ROWMXTFITTING
23.173 FITTINGBOLT,BRAKEMASTERCYLINDEROUTLET
23.176 SEAL,BRAKEMASTERCYLINDEROUTLETFITTING
23.186 LINE,BRAKEMASTERCYLINDEROUTLET
23.225 FITTING,BOLT,SERVICEBRAKE INLET
23.227 SEAL,SERVICEBRAKEINLETFITTING
23.229 FITTING,SERVICEBRAKE INLET
23.231 SEAL,SERVICEBRAKEINLETFITTING
23.792 RESERVOIR,BRAKEFLUID
23.793 FASTENER,BRAKEFLUIDRESERVOIR
23.794 LINE,BRAKEMASTERCYLINDERINLET
91.170 NUT, BRAKEFLUIDRESERVOIRFASTERER

GROUP ClRRl4
23
BRAKE MASTER CYLINDER REMOVAL
To remove the master cylinder, first remove

the brake pedal bracket assembly including
the brake pedal and master cylinder, from
the truck.
85M862
1 Disconnect the wiring leads from screw

terminals on drive motor cut-off switch
mounted on brake pedal bracket.
85M706
2 Disconnect (loosen) brake pedal bracket

assembly from frame mounting by removing
two attaching bolts and nuts from front
of frame (cowl) and one bolt from top of
flange near floorboard opening.
26585
3 Disconnect (unplug) connector in wiring

harness to accelerator control.
26586

23
4 Remove brake fluid supply line from

inlet of master cylinder. Put a clamp
on the supply hose before removal to
prevent fluid from draining out, or
drain brake fluid from reservoir into
a drain pan after removal of hose.
26587
5 Remove hydraulic brake line from master

cylinder outlet fitting. Option: First,
disconnect brake line from brake caliper
fitting, then remove from master cylinder.
26588
6 Brake pedal bracket assembly can now

be removed from truck.
7 Loosen and remove nut, spacer, and bolt

from master cylinder mounting in brake
pedal bracket.
8 Remove the retaining clip and pin from

master cylinder push rod clevis end at
attachment to brake pedal. Release
(unhook) pedal return spring, as needed.
9 Remove master cylinder from bracket

assembly.
Install master cylinder by reversal

of removal procedure.
26589

CMRK GROUP
23
GROUP
23
SECTION
18
MASTER CYLINDER OVERHAUL
Typical Overhaul Instructions

GROUP CMRK
23
23.795
/- SPECIFICATIONS:
Bore : [19,05 mm] .750 in dia.
30.092F Stroke: [ 20 mm] .787 in
!sc’I- m ,-23.168
23.150 -
I/
REPAIR
INCLUDES
KIT
ITEMS
\
NOTE:
NON SERVICEABLE
ITEMS MARKED ‘N”
MASTER CYLINDER 23-l 22 SEPT 73
23.150 CYLINDER ASSEMBLY, BRAKE WASTER
22.342 SEAL, BRAKE MASTER CYLINDER INLET FITTING
23.059 SPACER, BRAKE K4STER CYLINDER
23.156 FASTENER, BRAKE WSTER CYLINDER
23.159 REPAIR KIT, BRAKE IASTER CYLINDER
23.168 SPRING, BRAKE MASTER CYLINDER PISTON RETURN
23.795 FITTING, BRAKE MASTER CYLINDER INLET
so.092 NUT, BRAKE MASTER CYLINDER ATTACHING FASTENER
9N HOUSING, BRAKE MASTER CYLINDER USE 23.150
10N PISTON, BRAKE MSTER CYLINDER USE 23.150
11N ROD, BRAKE MSTER CYLINDER PUSH USE 23.150

CLRRK GROUP
23
MASTER CYLINDER DISASSEMBLY
1 The master cylinder may be held while

disassembling by clamping carefully on
the mounting bosses in a vise. Do not
use excessive clamping pressure which
will damage the cylinder bore or other
parts.
2 Remove the push rod and boot. Then,

remove the snap ring from groove in
end of cylinder.
Be careful when removing snap ring.

Piston return spring can force the
piston from the cylinder and cause
injury to personnel.
20448
3 Remove the piston assembly and return

spring.
NOTE - Before removing seals, carefully

observe the direction they face for
correct installation at reassembly.
4 Remove the seals from piston and

arrange the parts in correct assembly
order for cleaning and inspection.
20450

GROUP CMRK
23
CLEANING
l All hydraulic brake parts must be IMPORTANT

cleaned and protected after cleaning,
from dust or other air-borne foreign DO NOT USE PETROLEUM (MINERAL-BASE)
material, until parts are reassembled. CLEANING SOLVENTS SUCH AS GASOLINE,
KEROSENE, DISTILLATE, CARBON TETRA-
l Brake cylinder castings and pistons CHLORIDE, ACETONE, PAINT THINNER,
may be degreased, or cleaned with most ETC. THESE SOLVENTS WILL DAMAGE
brands of commercial parts cleaners, RUBBER PARTS BY CAUSING THEM TO
provided they are thoroughly rinsed DETERIORATE AND BECOME ENLARGED,
with Stoddard-type solvent or brake SOFT AND TACKY WITHIN A VERY SHORT
fluid to remove all traces of solvent. TIME.
l Clean rubber parts by washing them

in clean Stoddard-type solvent or hy-
draulic brake fluid.
l Use only low-pressure compressed air the cylinder bore. NOTE-The possibil-
or a lint-free cloth to dry parts after ity of the cylinder having been honed
removal from the cleaning solvent. Do during a previous overhaul should not
not use rags that may leave particles be overlooked.
of lint or thread fibres to block fluid
ports and passages during operation. The cylinder bore diameter can be check-
ed with a 'Go-No Go' gage or a microm-
eter, and must not exceed the standard
INSPECTION (nominal) diameter more than 0.007 inch.
For example, a 0.750 diameter master
Each master cylinder overhaul should cylinder must not exceed 0.750 + 0.007
include an inspection of the cylinder or 0.757 inch. An alternate method of
bore and internal parts, including checking a cylinder is to insert a pis-
removal of foreign deposits and mild ton and check its clearance. Maximum
corrosion from the cylinder bore and clearance checked with a wire gage is
piston. 0.007 inch.
After cleaning, inspect the cylinder Be sure that a honed cylinder has no
bore for wear and damage. Hold the 'burr' at the compensating port, since
cylinder casting toward a bright light this will damage the piston seal lip.
and look (sight) through the cylinder If a burr or sharp edge is present,
bore. Damage, or blemishes such as remove it with a deburring tool.
pitting, scratches, an,d visible wear
patterns, requires replacement of the For a final inspection, be sure the in-
cylinder. let and compensating ports are open
(clean). It will be difficult to see
Accumulations of dirt or gummy sub- the compensating port, but if a soft
stances, not removed during the clean- copper wire not larger than 0.020 inch
ing process, may be removed with crocus diameter is used, the port can be
cloth or jeweler's rouge. A hone may probed without danger of damage. Do
be used to 'clean-up' the cylinder, not use a steel wire to check the port.
providing its use does not substantial-
ly change (increase) the diameter of

CMRK GROUP
23
REPAIR KIT
Certain parts, such as seals, should

always be replaced during master cyl-
inder overhaul and reconditioning. A IMPORTANT
packaged master cylinder repair kit
is the most convenient method and ALWAYS USE GENUINE CLARK PARTS
provides assurance that correct,
original-equipment replacement parts
have been used.
MASTER CYLINDER REASSEMBLY
Reassemble the master cylinder in reverse order of disassembly.

Be sure all parts are installed in the correct manner or
direction as when removed.
1 Install new seals on piston. Be sure they are installed

facing in the correct direction.
2 Apply a coating of clean hydraulic brake fluid to all parts

to prevent damage during assembly and to provide initial
lubrication.
3 Install the return spr ing in the same direction as when removed.
4 Install the piston and sea 1 assembly into cylinder.
5 Press the piston into cylinder and install the snap ring
into groove in cylinder end. Be sure snap ring is
completely expanded and seated into the groove.
6 Install the boot into groove in cylinder end.
7 Install the push rod.
BENCH BLEEDING
It is recommended that the master cylinder be filled

with brake fluid prior to installation on the truck.
Attach the hose from a brake reservoir to the master
cylinder inlet or otherwise supply brake fluid to the
inlet. Push on the push rod and force the piston
through one full stroke. Repeat piston stroking
until fluid is forced past the check valve and from
the outlet port.
After installation into the truck brake system, be sure that

you bleed the master cylinder and lines according to recom-
mended procedures. Refer to GROUP 23, Section 3.

CMRK GROUP
25
GROUP
25
SEWON
5
PYLON RELEASE LEVER ADJUSTMENT
Code: PMA-501, MAR 82 P.S.L. Section 5, Page 1

GR205up CMRK
LEVER ADJUSTMENT:
1. Slowly pull up on the release lever. It

must release the pylon when the lever has
moved [25,40-31,75 mm] 1.00-1.250 inch
from its lock position. If this distance
is not correct, remove the pylon cover.
Fig. 20294
2. Hold the cable end, and adjust the release

lever position by adjusting the nut on the
top of the cable. Loosen the lock nut on
the release cable. If the lever moves less
than [25,40-33,75 mm] 1.00-1.250 inch turn
back the adjusting nut. If the lever moves
more than this distance, tighten the
adjusting nut. Adjust until within speci-
fications, then tighten the lock nut and
install the pylon cover.
Fig. 19477
3. Check the adjustment by raising the release

lever when the lever is at the specifica-
tions given above. The pylon must move
forward by spring action with no restric-
tion. Pull the pylon back to its operating
position. It must lock into position by
itself. Install the pylon cover.
Fig. 20283
THE PYLON TILT IS TO GIVE ENOUGH SPACE

TO IREMOVETHE BATTERY. DO NOT OPERATE
THIS MACHINE UNLESS THE PYLON IS LOCKED
IN THE FULLY BACK POSITION.
Section 5, Page 2 Code: PMA-501, MAR 82 P.S.L.

GROUP
CUIRK
25
GROUP
25
SECTION
10R
POWER STEERING CONTROL UNIT REMOVAL

Park truck on a level surface ?nd

Block the wheels.
85M626
Truck Preparation

GROUP CMRU
25
TILT STEERING COLUMN 25-022
25.001 GEAR ASSEMBLY, STEERING 37.34s COVER, TILT STEERING COLUMN

25.002 GROUP, HORN BUTTON 37.346 SPRING, TILT STEERING COLUMN COVER
25.003 NUT, HAND WHEEL 37.347 BRACKET, TILT STEERING COLUKP;COVER
25.004 HAND WHEEL 37.348 PYLON, STEERING COLUMN
25.034 FASTENER, STEER GEAR MOUNTING 38.256 BRACKET, STEERING GEAR MOUNTING
37.330 ARM TILT STEERING COLUMN LATCH CABLE 39.494 FASTENER, STEERING GEAR MOUNTING BRACKET
37.331 BUSHING, TILT STRG COLUMN LATCH OPERATING HANDL.E 39.552 COVER, STEERING GEAR ACCESS
31.332 HANDLE, TILT STEERING COLUMN LATCH OPERATING 39.553 FASTENER, STEERING GEAR ACCESS COVER
37.333 ACTUATOR, TILT STEERING COLUMN LATCH ARM 91.710 NUT, STEERING GEAR MOUNTING BRACKET FASTENER
37.334 BRACKET, TILT STEERING COLUMN LATCH (UPPER) 93.598 RETAINER, STEERTNG COLUMN TILTING SPRING
37.33s BRACKET, TILT STEERING COLUMN PIVOT 93.599 RETAINER, STEERING GEAR ACCESS COVER FASTENER
37.336 PIN, TILT STEERING COLUMN PIVOT 93.600 RETAINER, TILT STEERING COLUMN LATCH CABLE
37.337 CABLE, TILT STEERING COLUMN LATCH 93.601 FASTENER, TILT STEERING COLUMN LATCH CABLE ARM
37.338 PIN, TILT STEERING COLUMN LATCH (UPPER) 93.602 FASTENER, TILT STRG COLUMN LATCH BRKT (UPPER)
37.339 LATCH, TILT STEERING COLUMN 93.603 FASTENER, STRG COLUMN TILTING SPRING BALL STUD
37.340 ROD END, TILT STEERING COLUMN LATCH 93.604 LOCK, TILT STEERING COLUMN LATCH ROD END
37.341 PIN, TILT STEERING coLm4 LATCH (LOWER) 93.605 RETAINER. TILT STRG COLUMN LATCH PIN (LOWER)
37.342 BRACKET, TILT STEERING COLUMN LATCH (LONER) 93.606 FASTENER, TILT STRG COLUMN COVER BRACKET
37.343 BALL STUD, STEERING COLUMN TILTING SPRING 93.607 NUT, TILT STRG COLUMN COVER BRACKET FASTENER
37.344 SPRING, STEERING COLUMN TILTING 53.608 FASTENER, TILT STRG COLUMN LATCH BRACKET (LOWER)
93.609 FASTENER, TILT STEERING COLUMN PIVOT BRACKET

GROUP
EMRU 25
POWER STEERING CONTROL UNIT REMOVAL
1 Remove the access cover from the front of

steering pylon. Use a screwdriver to
release the l/4-turn fastener.
Adjust the pylon for best access to the

steering column parts inside.
85M510
To remove the power steering control unit

gear box, first loosen and remove the steer-
ing column and control unit subassembly
bracket which is bolted into the steering
pylon.
2 Remove brake fluid reservoir.
85M645
3 Disconnect all hydraulic hoses from the

steering control unit.
85M647
4 The hydraulic hoses may be tagged for

correct identification at assembly.

GROUP CLqRK
25
5 Loosen and remove the four bolts that

mount the steering column subassembly
(including instrument panel) in the
pylon.
18390
6 Move the top of the steering column

subassembly out of the pylon housing.
7 Loosen dnd remove the two hex-head bolts

and spacers that mount the bottom flange
of the steering column to the mounting
bracket and also to the top of the
steering control unit.
18391
8 Loosen and remove the two Q-point bolts

that mount the steering control unit to
the bottom flange of steering column.
18392

GROUP
Cl!!RK
25
9 Remove the steering control unit from

the truck.
18393
10 Install the steering control unit by

reversing the order of removal.
11 Refer to illustration below for infor-

mation on steering column.
25.001 GEAR ASSEMBLY, STEERING
r 25.001
25.013 CONNECTOR ASSEMBLY, HORN
25.014 SCREW, HORN CONNECTOR
25.018 CAPSCREW, COLUMN JACKET
25.026 CABLE AND CONTACT. HORN
25.027 FERRULE, INSULATING
25.030 SHAFT ASSEMBLY, STEERING GEAR
25.100 CABLE, HORN

-25.030
25.018
STEERING GEAR 25331-I
Code: OH-540, MAR 86 GROUP '25, Section lOR, Page 5

GROUP
CMRK
25
GROUP
25
SECTION
10
STEERING GEAR
Code: OH-520, FEB 85 Section 10, Page 1

GROUP
CMRK
25
Steering Contra
Srandard
Steering
Control
These Parts Common to Both Standard and

Integral Column Steering Control Units
Integral Column
Steering Control Unit
1. Dust Seal 13. Quad Ring Seal 24. Control Sleeve

2. Retaining Ring 14. Bearing Locator 25. Centering Springs
3. Seal Gland Bushing 15. Bearing Race 26. Pin
4. Retaining Ring 16. Needle Thrust Bearing 27. Control Spool
5. Retaining Ring 17. Set Screw 28. Seal, 3” 00
6. Control Column Bearing Ass’y 18. Seal, 518” OD 29. Spacer Plate
7. Control Shaft 19. Check Ball Seat 30. Drive
8. Steering Control Column 20. Seal, 7/16” DD 31. Meter (Gerotor)
9. Cap Screw 21. Check Ball 32. Spacer(s)
10. Sarina 22. Check Ball Retainer 33. End Cap
11. Seal, i-1/8”OD 23A. Standard Housing 34. Cap Screw
12. Seal, l-15/16” OD 238. f-b-b~g w/integral control
Reprint courtesy of EUTON Corporation
Section 10, Page 2 Code: OH-520, FEB 85

GROUP
CLSRK
25
Disassembly
Remove 5116” cap screws.
Cleanliness is extremely important when repairing a
steering control unit. Work in a clean area. Before dis-
connecting lines, clean port area of unit thoroughly. Remove end cap.
Use a wire brush to remove foreign material and de-
bris from around exterior joints of the unit. Remove seal from end cap.
Note: Trouble shooting information on pages 13, 14,

and 15 defines terms and problems, possible causes Seal
for problems, and recommends procedures for cor-
recting problems.
’ Although not all drawings show the unit in a

vise, we recommend that you keep the unit in
the vise during disassembly. Follow the clamp
ing procedures explained throughout the manual.
Meter (Gerotor)
Figure 3
5 Remove meter. Be careful not to drop star.
6 Remove seal from meter.
7 Remove drive spacer(s) (not used on 4.5 cu. in

disolacement units).
Figure 1
1 unit in vise, meter end Clamp light-

Iv on of mounting area, see Fig. 1. Use protec-
tive material on vise jaws. Do not overtighten jaws.
cei
ate
Figure 4
8 Remove drive.
9 Remove spacer plate.
10 Remove seal from housing.
Figure 2

GROUP ELFIRK
25
Disassembly
Control End Needle Bearing
Thrust Race
Figure 8
15 Remove 2 bearing races and the needle thrust

bearing from spool and sleeve assembly.
Figure 5
11 Remove housing from vise. Place housing on a

clean soft cloth to protect surface finish. Use a thin
bladed screwdriver to pry retaining ring from hous-
ing, as shown in Fig. 5.
Pin
Seal
Gland
Bushing
Figure 9
Figure 6
12 Rotate spool and sleeve until pin is horizontal.

Push spool and sleeve assembly forward with your 16 Remove spool and sleeve assembly from 14
thumbs just far enough to free gland bushing from hole end of housing, see Fig. 9.
housing, see Fig. 6. Remove bushing
Attention: Do not bind spool and sleeve in housing.
Rotate spool and sleeve assembly slowly when re-
moving from housing.
c_c_ Seal
17 Push pin from spool and sleeve assembly.
Dust Seal A
Figure 7
13 Remove quad ring seal from seal gland bushing.
14 Use a thin bladed screwdriver to pry dust seal

from seal gland bushing. Do not damage bushing.

CMRK GROUP
25
Disassembly
518” Seal
Ser Screw ,
(Not used >flkCheck
on
units with Ball Check Ball
integral column) Seat 7/16” Seal Ball Retainer
Figure 11
21 Remove set screw (not used on units with in-

tegral column) from housing, see Fig. 11.
18 Push spool partially from control end of sleeve,
then remove 6 centering springs from spool carefully 22 Screw a 118”-24 machine screw into end of
by hand, see Fig. 10. check ball seat. Then by pulling on screw, with a
pliers, lift seat out of housing.
19 Push spool back through and out of sleeve, see
Fig. 10. Rotate spool slowly when removing from 23 Remove 2 seals from check valve seat.
sleeve.
24 Tip housing to remove check ball and check
20 Remove seal from housing, see Fig. 11. ball retainer.
Control End
Reassembly
Check all mating surfaces. Replace any parts that
have scratches or burrs that could cause leakage. * I See Figure 12A 1
Clean all metal parts in clean solvent. Blow dry with
air. Do not wipe dry with cloth or paper towel be-
cause lint or other matter can get into the hydraulic
system and cause damage. Do not use a coarse grit
518” Seal
7116 ” Seal C
8
33 Check Ball Seat
or try to file or grind these parts.
Note: Lubricate all seals (with exception of new Retainer

quad ring seal) with clean petroleum jelly such as (Standard Steering
Vaseline. Figure 12 Control Umt)
Do not USCexcessive lubricant on seals for meter
section.
Refer to parts listings covering your steering control
unit when ordering replacement parts. A good ser-
vice policy is to replace all old seals with new seals.
ilntegral Column
Figure 12A Steerq Control UnIti

GROUP
25
Reassembly
1 Use a needle nose pliers to lower check ball re- tion tool through spring slots of both parts. Tool is
tainer rnro check valve hole of housing. Make sure available as part no. 600057. Position 3 pairs of cen-
retainer is straight (not tilted on edge) in housing, tering springs (or 2 sets of 3 each) on bench so that
see Fig. 12. extended edge is down and arched center section is
together. In this position, insert one end of entire
2 Install check ball in housing. spring set into spring installation tool, as shown in
Fig. 14.
3 Lubricate 5/8” diameter seal and 7/16” diameter
seal. Install seals on check bail seat as shown in On those units which use the low torque centering
Fig. 12. springs, there are 2 pairs of centering springs ( or 2
sets of each ) and one pair (two) spring spacers.
4 Lubricate check ball seat and seals thoroughly be- The spring spacers are installed together between
fore installing seat in housing. When installing seat do the two sets of centering springs. The installation
not twist or damage seals. Install check ball seat in procedure is the same as that used on the standard
housing, insert open end of seat first, see Fig. 12. Push ( 3 pairs of centering springs ) units.
check ball seat to bottom of hole.
8 Compress extended end of centering spring set
5 Install set screw (not used on units with inte. and push into spool sleeve assembly withdrawing
gral column, see Fig. 12A). Use a 5116” allen wrench installation tool at the same time.
to torque set screw to J.QQ inch pounds. To pre-
vent interference, make sure top of set screw is 9 Center the spring set in the parts so that they
slightly below housing mounting surface. push down evenly and flush with the upper surface
of the spool and sleeve.
Pin
Figure 15
Figure 13
IO Install pin through spool and sleeve assembly
until pin becomes flush at both sides of sleeve.
6 Assemble spool and sleeve carefully so that the
spring slots line up at the same end. Rotate spool
while sliding parts together. Some spool and sleeve
sets have identification marks, align these marks as
shown in Fig. 13. Test for free rotation. Spool should
rotate smoothly in sleeve with finger tip force
applied at splined end.
Figure 16
11 Position the spool and sleeve assembly so that

the splined end of the spool enters the 14 hole end
of housing first, see Fig. 16.
Figure 14 \ Attention: Be extremely careful that the parts do

not tilt out of position while inserting. Push parts
7 Bring spring slots of both parts in line and gently into place with slight rotating action, keep
stand parts on end of bench. Insert spring installa. pin nearly horizontal. Bring the spool assembly

CLSRK GROUP
25
Reassembly
entirely within the housing bore until the parts are with a rubber hammer. Make sure the bushing is
flush at the meter end or 14 hole end of housing. flush against the bearing race.
Do not pull the spool assembly beyond this point
to prevent the cross pin from dropping into the dis- On those units which use the Teflon seal, install the
charge groove of the housing. With the spool assem- Teflon back-up ring into the recess cut into the seal
bly in this flush position, check for free rotation gland bushing. Install the Teflon seal over the spool
within the housing by turning with light finger tip end, then carefully install the seal gland bushing
force at the splined end. over the spool end using a rotary motion.
12 Place housing on clean, lint free cloth. Install Note that the seal gland bushing which is used with
2-118” diameter seal in housing, see Fig. 17. the Teflon seal is not the same as the seal gland
bushing used with the standard quad-ring seal. The
seal gland bushing with the Teflon seal has an ident-
ification groove cut into the outer diameter of the
Bearing bushing. The grooved bushings can only be used
Race (2) with the Teflon seals and the non-grooved bushings
used only with the quad-ring seals.
Screwdriver m Teflon Seal
Figure 17
13 Install 2 bearing races and the needle thrust

bearing in the order shown in Fig. 17.
14 Install l-1/4” diameter dust seal in seal gland

bushing, flat or smooth side of dust seal must face
down towards bushing, see Fig. 19.
15 Install dry quad ring seal in seal gland bushing. Figure 19

Smooth seal in place with your finger. Do not use
any seal that falls freely into pocket of bushing, 17 Install retaining ring (see Fig. 18-19) in hous
see Fig. 19. ing. After installing ring, tap on ring end ot pry
with screwdriver around entire circumference of
ring to properly seat ring in groove.
Retaining
Ring
Seal
Gland
Bushing
(with seals)
Figure 18
16 install seal gland bushing over the spool end

with a twisting motion. Tap the bushing in place Figure 20

GROUP CLRRlt
25
Reassembly
18 Clamp housing in vise, as shown in Pig. 20.
Clamp lightly on edges of mounting area. Do not
over tighten jaws.
Note: Check to insure that the spool and sleeve are

flush or slightly below the 14 hole surface of the
housing.
Attention: Clean the upper surface of the housing

Seal
by wiping with the palm of clean hand. Clean each Figure 23
of the flat surfaces of the meter section parts in a
similar way when ready for reassembly. Do
use cloth or p_aper to clean surfaces. 22 Install 3” diameter seal in meter.
Meter (Gerotor) Star Valley .A
Figure 21
19 Install 3” diameter seal in housing, see Fig. 21.
20 Install spacer plate. Align bolts holes in spacer

plate with tapped holes in housing.
Pin Port Face
Figure 24
23 With seal side of meter toward spacer plate,

Figure 22 align star valleys (ref. A) on drive (ref. B). Note
the parallel relationship of reference lines A, 8.
C, and D- Fig. 24. Align bolt holes without disengag-
21 Rotate spool and sleeve assembly until pin is ing meter from drive.
parrallel with port face, see Fig. 22. Install drive,
make sure you engage drive with pin, To assure
proper alignment, mark drive as shown in Fig. 24
(ref. B). Note relationship between slotted end of
drive to splined end of drive when marking.
Section 10, Page 8 Code: OH-520, FE6 85

CLRRW GROUP
25
Reassembly
Drive Spacer(s)
24 Install drive spacer(s) when used, in meter,
see Fig. 25.
25 Install 3” diameter seal in end cap.
26 Install end cap on gerotor, align holes
Figure 26
27 Install 7 -cap screws in end cap. Pretighren

screws to m inch pounds, then torque screws to
Requires 2 Spacers 275 inch pounds in the sequence shown in Fig. 26.
Figure 25
Code: OH-520, FEB 85

Section 10, Page 9
GROUP CLRRK
25
25.001 GEAR ASSEMBLY, STEERING (CONTINUED)
25.021 RACE, STEER SHAFT THRUST BEARING
25.022 BEARING, STEER SHAFT THRUST
25.095 COVER, STEER GEAR PUflP END
25.097 CAPSCREW, STEER GEAR PUMP END COVER
25.105 VALVE ASSEMBLY, STEER GEAR

INCLUDES ITtMS
25.109 SEAL KIT, STEER GEAR
25.150 GEAR BOX ASSERBLY. POWER STEERING
25.271 SPRING, STEER GEAR VALVE CENTERING
25.275 RETAINER, STEER GEAR VALVE HOUSING COVE
25.277 COVER, STEER GEAR VALVE HOUSING
25.409 TRUNNION, STEER GEAR PUMP DRIVE
25.410 SHAFT, STEER GEAR PUHP DRIVE
-25.150 25.411 WEAR PLATE, STEER GEAR DRIVE
25.412 PUMP CARTRIDGE, STEER GEAR
25.469 SPACER, STEER GEAR PUMP DRIVE SHAFT
26.006 GALL, STEER GEAR CHECK VALVE
26.037 RETAINER, STEER GEAR CHECK VALVE
26.063 PLUG, STEER GEAR CHECK VALVE CHANNEL
26.253 SEAT, STEER GEAR CHECK VALVE
19N HOUSING, STEER GEAR VALVE USE 25.105
20N SLEEVE, STEER GEAR VALVE USE 25.105
21N SPOOL, STEER GEAR VALVE USE 25.105
R-25.410
STEERING GEAR

CLSRK GROUP
26
GROUP
26
SECTION
1
STEER AXLE TRUNNION BEARINGS
CHECK AND ADJUSTMENT


l Return all controls to neutral, and turn
l Lift and block the truck up to raise the
steer axle wheel off the floor.

85M775

GROUP
26
STEERING LINKAGE

CLSRK GROUP
26
26.224
STEERING AXLE
26-752
26.224 FORK, STEER AXLE

26.227 SEAL, STEER AXLE FORK HOUSING
26.228 CONE, STEER AXLE FORK LOWER

26.229 CUP, STEER AXLE FORK LOWER
26.234 CUP, STEER AXLE FORK UPPER
26.235 CONE, STEER AXLE FORK UPPER
26.238 FASTENER, STEER AXLE FORK UPPER BEARING
26.239 SEAL, STEER AXLE FORK COVER

GROUP CMRK
26
STEER AXLE TRUNNION BEARINGS CHECK
1 Be sure that truck is parked and blocked up

correctly to raise the steer wheel off the
floor.
See CAUTION note, Page 1.
2 Inspect the steer axle and trunnion for

damage and wear.
85M765
3 Check the steer axle trunnion bearings

for excessive free-play or looseness.
Hold the steer wheel with both hands and
try to move the entire steer axle in
the trunnion bearings. Be sure that any
movement that you feel is not due to
wheel bearing clearance free-play. If
the trunnion bearings have excessive
looseness, the bearings require
adjustment. Refer to following
procedures.
85M747
STEER TRUNNION BEARING ADJUSTMENT
1 Open the hood (seat deck/battery

compartment cover).
85M616
2 Remove battery from truck, for best

access to top of steer axle trunnion.

Removal.
85M750
GROUP 26,"Section 1, Page 4 Code: PMA-540, NOV 85

GROUP
26
3 It is not necessary to remove the hood

and counterweight. However, access to
the steer trunnion bearings will be much
easier if this work is done when the CWT
and SCR controls are removed.
Some of the following figures show the

steer trunnion with counterweight
removed for clarity.
85M807
4 If counterweight and SCR controls have not

been removed, remove the drive motor cut-out
switch assembly which is mounted over the
top of the steer trunnion:
NOTE - If SCR controls have been removed,

proceed to Step 5.
1) Disconnect (unplug) connector in CUT-OUTSWITCH

control wiring harness leading from MOUNTINGPLATE
cut-out switches to contactor panel.

GROUP CKIRK
26
5 Then, remove the cotter pin, loosen and

remove castellated nut from rod end ball stud
in steering arm, and disconnect steering
cylinder rod end from steering arm. This
will allow the steer axle to be moved
(rotated) freely while adjusting the
trunnion bearings.
6 Remove mounting bolt which holds drive

motor cut-off switch cam plate to top of - CAM PLATE
steer axle trunnion shaft. I CAPSCREW
I
I
CAM PLATE
7 Remove cam plate from top of trunnion

shaft.
GROUP26, Section 1, Page 6 Code: SM555, MAR 89

CMRK GROUP
26
8 Loosen and remove lock nut, then loosen

the steer axle trunnion shaft retaining
(adjusting) nut.
(Figure 17089 shows typical TM procedure)
Loosen the bearings by rotating the trunnion

shaft and/or shaking the steer whee from
right to left. This will unseat or free
the bearings from their running pos tion.
85M805
26532 17089
9 Now, tighten the retaining nut to

[15-20 N.m] 11-15 lbf.ft. torque (Figure
19498 shows typical TM procedure). Hold
steer axle from turning from below while
tightening the nut.
Check for free movement of the trunnion

shaft and bearings by turning (rotating)
the steer axle to the right and left.
19498
10 Check trunnion bearing preload.
Put a torque wrench on the retaining nut.

It should require [2-3 N-m] 1.5-2.0 lbf.ft.
rolling torque to rotate the steer axle in
the trunnion bearings. Tighten or loosen
the retaining nut to obtain correct pre-
load torque.
19498

11 Install steering cylinder rod end ball

stud to steering arm. Tighten nut to
[89-103 N.m] 65-75 lbf.ft. torque.
Install cotter pin, spread and bend

the ends over.
26530
1'2When trunnion bearing preload has been

set correctly, install lock nut on trun-
nion shaft. Tighten to [15-20 N.m]
11-15 lbf.ft. torque. Reference Figure
19498.
13 Install drive motor cut-out switch cam - CAM PLATE

plate. Be sure dowel pin is correctly I CAPSCREW
positioned in hole in trunnion shaft. II
I
I
14 Install cam plate mounting bolt. Tighten
bolt to [ZO-23 N.m] 15-17 lbf.ft. torque.
- CAM PLATE
I
DOWEL PIN
15 Install CWT and SCR controls, if removed.

16 Install the drive motor cut - out switch plate
assembly. Do not over-tightenswitch plate
mounting capscrews.
Refer to GROUP 13, Section 4, if

further adjustment of the cut-out
-L- CUT-OUT SWITCH
switch mounting is required. MOUNTING PLATE
17 Connect wiring harness (from cut-out

switches to contactor panel).
18 Install battery. Close the hood.
GROUP26, Section 1, Page 8 Code: SM555, MAR 89

GROUP
EMIlK
26
GROUP
26
SECTION
2
STEER WHEEL BEARING MAINTENANCE

o Park the truck on a level surface and

o Return all controls to neutral, and turn
e Apply the parking brake.
o Lift and block the truck up to raise the

85M775

GROUP CLqRK
26
26.224
26.133 SEAL, STEER WHEEL RUB

26.136
26.134 CONE, STEER WHEEL HUB BEARING (INNER)
26.135 CUP. STEER WHEEL HUB BEARING (INNER) /
26.136 HUB, STEER m=L 26.135-f / /
26.138 CUP, STEER WHEEL HUB BEARING (OUTER) 26.134 J /
26.133J
26.139 CONE, STEER WHEEL HUB BEARING (OUTER)
26.141 FASTENER, STEER AXLE WB
26.143 CAP, STEER WHEEL HUB
26.224 FORK, STEER AXLE STEER AXLE & HUB ASSEMBLY 26-752
26519

ELflRK GROUP
26
STEER WHEEL BEARING MAINTENANCE

floor. NOTE - It is optional to raise and
block up entire truck.
See CAUTION, Page 1.
Refer to PM section, Page 6.9, for addi-

tional steer axle inspection notes.
26520
2 To check the steer wheel bearings for exces-

sive free play or looseness, hold the wheel
with both hands and try to move it by a rock-
ing motion from side to side. Also, try to
pull it in and out along the wheel spindle.
There should be a small amount of free move-
ment. The maximum allowable end play is
[0,08 mm] .003 inch. If the wheel has
excessive end play, the bearings require
additional service and/or adjustment.
85M747
Steer Wheel Bearing Adjustment
The steer wheel bearings are retained and

adjusted by a self-locking bearing nut.
Step 1: Remove hubcap by tapping lightly

on the outer edge of hubcap. (Reference
Figure 85M883, shown here with wheel
removed).
85M883
Step 2: Loosen spindle (bearing adjusting)

nut.
NOTICE - After spindle nut is loosened, hit

the top of wheel (tire) to loosen (unseat)
the bearings. This moves the bearings free
of their seated, running position.
IMPORTANT - Spindle nut should be replaced

with a new one each time it is removed because
holding torque capability is partially 85M892
destroyed with each removal.

GROUP
26
Step 3: Then, tighten spindle nut to the

correct tightening torque while rotating
the wheel by hand:
Steer Wheel Spindle Nut Torque:

[230-244 N.m] 170-180 lbf.ft.
(Reference Figure 21185, showing typical
view using torque wrench.)
21185
NOTICE
The steer wheel bearings are designed to

be correctly adjusted by the specified
torque on the self-locking spindle nut.
Overtightening will cause drag and result
in lower travel speed and higher power
consumption. The specified torque value
may require adjustment for some bearing
installations. See Step 5 below.
Step 4: Install the hub cap by tapping

into place with a rubber or plastic-faced
hammer (Reference Figure 85M891, shown with
wheel removed).
Step 5: Check for correct bearing adjust-

ment by rotating the wheel by hand. Wheel
should rotate freely or with only slight
"drag". Readjust bearings, as necessary.
85M748

CLqRK GROUP
26
Steer Wheel Bearing Lubrication

(Clean, repack and adjust bearings)

floor.
Refer to pages 1 and 3 for additional

information.
2 Remove the wheel and tire assembly.

(Place a block of wood under the tire
to prevent rotation of the wheel when
loosening the lug bolts. Use a pry
bar under the tire to help move the
wheel on and off the wheel hub.)
85M882
IMPORTANT
Because of the heavy weight of the wheel

and tire, it is recommended to first
remove the wheel when servicing the bear-
ings to avoid damage to the grease seal
when the wheel hub is moved on the spindle.
It also makes the work simpler and easier.
85M885
3 Remove hub cap from wheel hub.
4 Clean the excess grease from around the

spindle nut.
85M883

GROUP CL!RK
26
5 Loosen and remove the spindle nut.
85M884
6 Remove the outer bearing cone.
85M886
7 Pull the wheel hub off the spindle.

Hold the hub firmly to avoid dragging the
grease seal at the back side across the
threads on spindle end.
85M887
8 Clean the old grease out of center of wheel

hub.
9 Clean and inspect the bearing cups and cones

for wear and other damage. Replace if
necessary. Replace damaged bearing
cups and cones as a set.
NOTE - If bearings require lubrication only,

repack bearings as noted in Item 12, Page 7.
Inspect the grease seal for wear and damage. 85M888

Replace as necessary. Refer to Items 10
and 13, Page 7.

GROUP
CLqRK
26
10 If bearings require replacement, remove

the grease seal and the inner bearing
cone, using a brass drift pin or rod to
drive the bearing and seal out of the hub.
Grease seal may be first removed by using
a puller or prying out of the bore in
hub (damage is unimportant; install
new seal at assembly). Use a standard
puller to remove the bearing cups.
(Figure 26526 shows bearing and seal
installation for reference.)
26526
11 Install new bearing cups by pressing into

wheel hub. Be sure cups are fully seated
in bearing bore.
26521
12 Pack the bearings with grease and install

the inner bearing in the hub.
Recommended greasing procedure:
1) Use Grade No. 1 Lithium soap base multi-

purpose grease, Clark MS-9B or equivalent.
2) Pack bearinqs with grease before assembly.
3j Pack cavity-in hub between bearings
one-half full with qrease at assembly.
26527
:‘ ” j’
13 Install a new grease seal.
Apply coating of Grade No. 1 EP Lithium

soap base grease, Clark MS-107C or equiv-
alent to inside diameter of seal lips
prior to assembly, then install seal in
hub bore. Carefully tap grease seal
into place with a soft-faced mallet until
seal face is flush with end of hub.
85M889

GROUP
26
14 Put the hub on the spindle. Be careful

not to damage seal lip when moving the
hub over the end of spindle and threads.
85M887
15 Install the outer wheel bearing after it

has been packed with grease.
See Item 12, greasing procedure.
16 Install new spindle nut.*
*IMPORTANT- Always replace with a new

bearing nut. The self-locking capability
is partially destroyed when nut is removed.
85M886
17 Tighten spindle nut, while rotating the

hub by hand, to a torque of:
[230-244 N.m] 170-180 lbf.ft.
DO NOT OVERTIGHTEN!
85M890
NOTICE - The steer wheel bearings are

designed to be correctly adjusted by the
specified torque on the spindle nut.
Overtightening will cause drag and result
in lower travel speed and higher power
consumption. The specified torque value
may require adjustment for some bearing
installations. See Step 21, Page 9.

CMRK GROUP
26
18 Carefully install the hub cap by

lightly tapping into place with a
rubber or plastic-faced hammer. Be
sure that cap is fully seated. Avoid
damage or bending that may cause
loose fit.
85M891
19 Install the steer wheel and tire

assembly. Use a pry bar under the
tire to help move the wheel onto
the hub while the lug bolts are
being started into place.
85M882
20 Tighten the wheel lug bolts to the

correct tightening torque:
[255-275 N.m] 188-203 lbf.ft.
(Place a block of wood under the

tire to prevent rotation when
tightening the mounting bolts.)
21 Check for correct bearing adjustment by

rotating the wheel by hand. Wheel should
rotate freely or with only a slight drag
felt on the wheel. Readjust bearings,
as necessary.
22 Remove the blocking and lower the

steer wheel to the floor.
85M748

CIIIRK GROUP
26
26
SECTION
3
POWER STEERING SYSTEM
RELIEF PRESSURE CHECK

l Put blocks under the upright rails, and
o Raise the drive wheels off the floor.
l Return all controls to neutral, and turn
e Apply the parking brake.
85M743

GROUP C19RK
26
POWER STEERING SYSTEM RELIEF PRESSURE CHECK
Refer to GROUP 40, Section 5 for power steering system relief pressure
specifications.
The following procedure may be used to check steering system relief

pressure only. No service adjustment of the pressure can be made.
If relief pressure is not correct, it may be from dirt in the valve

or worn parts. Refer to Overhaul Manual OH-540, GROUP 25, Section 7
for overhaul of power steering control. Also, refer to GROUP 26,
Section 14 for overhaul of power steering pump.
1 The power steering system relief valve

pressure setting may be checked with a
MICO QUADRIGAGE (Clark Part No. 1800106),
or a conventional pressure gauge with
pressure range scale from [O-20,700 kPa]
O-3000 psi.
11156
2 Remove the access cover from the front

of the pylon. Use a screwdriver to
release the l/4-turn fastener.
85M510
3 The power steering system pressure is

checked at the left (L) steer port
(upper right-hand side as you face the
valve from front of truck) of the
control valve located in the steering
column pylon.
85M635

GROUP
26
4 Disconnect the steer line from elbow

fitting on valve.
5 Remove the elbow fitting and install a

temporary Tee, or equivalent fittings
(e.g., Clark Part No. 3798165 and 12K5H
fittings) in the valve port. ALTERNATE:
Install a Tee fitting between the elbow
and the steer line.
6 Install the steer line.

85M647
Install a diagnostic check port with

quick-disconnect adapter fitting, Clark
Part No. 3798166, in the Tee fitting.
(Similar to Figure 19284.)
Connect the pressure gauge to the check

port fitting.
NOTE - Use quick-disconnect adapter

fitting, Clark Part No. 3797029.
19284
9 Turn key switch to "ON" position.
10 Release the parking brake.
11 Move direction control lever from neutral

to either "FORWARD" or "REVERSE" position.
The steer pump should begin operating.
85M495
12 Turn the steering handwheel in one direction

until steering cylinder reaches its stop
(relief position). Hold steering handwheel
in relief position until pressure reading
is taken, and then release.
IMPORTANT
DO NOT OPERATE SYSTEM OVER RELIEF

ANY LONGER THAN NECESSARY TO READ
THE PRESSURE GAUGE.
85M524

GROUP CMRK
26
13 When the relief pressure reading has been

obtained:
14 Turn key switch "OFF".

15 Move direction control lever to neutral.
16 Apply parking brake.
17 Disconnect pressure gauge, remove the

temporary Tee fitting, and install elbow
and steer line as initially installed.
Be sure to correctly tighten all fittings.
85M635
18 Install access cover on pylon.
20283
19 Remove blocking from under the upright.
NOTICE - If steering system relief pressure

setting is not correct, refer to Overhaul Manual
OH-540, for correct maintenance procedures.

GROUP
26
GROUP
26
SECTION
4
STEER CYLINDER LINKAGE


Lift and block the truck up to raise the
85M774
Alternate Procedure:
Also remove the counterweight to facilitate

access to and inspection of the steer linkage.
Refer to GROUP 38, Section 1, Counterweight

Removal.
85M806

GROUP
‘26
$193.31s
25.4437. !&----93.316
26.023
26.0
STEERING LINKAGE 25-196
25.080 ARM, STEERING 26.025 SHIELD, CYLINDER ROD END DUST

25.122 DRAG LINK ASSEMBLY, STEERING CONTROL 26.026 FASTENER, CYLINDER ROD END
25.162 LUB FITTING, STEERING LEVER 26.028 ROD END ASSEMBLY, CYLINDER (PISTON ROD END)
25.387 PIVOT, STEERING ARM 26.049 BALL STUD, CYLINDER ROD END (PISTON ROD mm)
25.390 BEARING, STEERING ARM PIVOT 26.056 RETAINER, BALL STUD B0USING PLUG
25.391 BEARING, STEERING ABM 26.057 LUB FITTING, STEERING CYLINDER ROD END
25.393 PIN, STEERING LINK 26.082 COVER, CYLINDER ROD END DUST
25.394 PIN, STEERING LINE AXLE 26.246 COVER, CYLINDER BALL STUD DUST SHIELD
25.4h3 LEVER, INTERLOCE SWITCH ACTUATOR 92.745 COTTER, POWER STEERING CYLINDER BALL NUT FAST
26.000 CXLINDER ASSEMBLY, STEERING 93.315 FASTENER, STEERING INTERLOCK SWITCH ACTUATOR
26.015 SEAT. BALL STUD 93.316 DOWEL, STEERING INTERLOCK SWITCH ACTUATOR
26.018 LIJBFITTING, BALL STUD HOUSING 93.317 RETAINER, POWER STEERING CYLINDER BALL
26.019 STUD, BALL 93.318 NUT, STEERING LINE PIN (STEERING ARM)
26.020 SHIELD, CnIBDER BALL STUD DUST 93.319 NUT, STEERING LINE PIN (AXLE END)
26.021 FASTENER, BALL STUD 93.793 WASHER, STEERING ARM PIVOT FASTWER
26.023 PLUG, BALL STUD HOUSING 94.295 FASTENER, STEERING ARM PIVOT PIN
26.024 LOCK, CYLINDER BALL STUD HOUSING PLUG 95.169 WASHER, STEERING LINK PIN
95.170 WASHER, STEERING LINE AXLE PIN

GROUP
Cl!!RIC
26
STEERINGLINKAGEINSPECTION
Inspect steer cylinder for any damage to

rod ends, cylinder barrel, piston rod and
rod wiper. Check for excessive looseness
in the ball joints. Inspect hydraulic
hoses, fittings and connections for leaks
and damage. Excessively damaged parts
must be repaired or replaced before further
adjustments are made.
Check the condition of steering linkage for

bent parts and signs of stress or unusual
wear. Check the condition of all steer
linkage pivot pins for binding or excessive
wear. Repair or replace any parts, as nec-
essary, before making further adjustments.
85M802
Check the two pivot pin bolts in each end

of the steering link for correct torque.
Tightening torque is [ZO-25 N.m]
177-221 lbf.in.
85M801
4 Check the steering arm pivot bolt mounting

steering arm to truck frame for correct
torque.
Tightening torque is [240-270 N.m]
177-199 lbf.ft.
85M795

GROUP CDFIRK
26
5 Check torque on adjustment plug of ball

stud on steer cylinder base end.
Remove cotter pin from ball stud housing
end, and torque adjustment plug to
[25 N.m] 220 lbf.in. Then, back off to
first cotter pin hole. Install new cotter
pin, spread and bend the ends over.
85M799

stud on rod end of cylinder.
Remove cotter pin from ball stud housing end,
and torque adjustment plug to
[lo N.m] 90 lbf.in. Then, back off to first
cotter pin hole. Install new cotter pin,
spread and bend the ends over.
85M796
Check ball stud bolt and nut at each end

of the steer cylinder for tight fit and
correct torque. Co,rrectnut tightening
torque is [89-103 N.m] 65-75 lbf.ft.
Be sure to install the ball bolt and nut,
at the base end of cylinder, with the
cotter pin in vertical position.
(Also see Figure 85M796 above.)
85M866
Check for wear and looseness of the steering

arm pivot bearing. Apply an upward and down-
ward force at the steer cylinder rod end
attachment to the steering arm. There
must be very little or no free movement or
looseness of the steering arm relative to
the pivot pin or trunnion. If there is,
the pivot bearing is worn or damaged and
must be replaced.
85M795

Cl!!!!RK GROUP
26
STEER CYLINDER ADJUSTMENT
If there is a problem with steering geometry,

check the steer cylinder rod end adjustment
for correct installed-length of steer cyl-
inder.
25473
Move (turn) steer wheel to the left so ste er

cylinder is fully extended. Measure from
the centers of the two ball studs.
Overall length between ball stud centers,

when cylinder is fully extended, should be
[700 mm] 27.5 inches. If installed length
is not correct , adjust the rod end on the
steer cylinder rod.
(See Page 6 for enlarged view of linkage 4

85M807
Loosen the clamp bolt of rod end on piston

rod. Rod end has right-hand thread.
Rotate piston rod to extend or shorten rod
end position until correct installed length
is obtained.
a5M798
Tighten clamp bolt in rod end to secure rod

end to piston rod, when adjustment is com-
pleted. Torque clamp bolt to [40-45 N.m]
30-33 lbf.ft. Be sure grease fitting
nipple on rod end is directed toward rear
of truck.

GROUP
26
25473

Code: PMA-540, NOV 85
CLqRK GROUP
26
GROUP
26
SECTION
8
STEER AXLE
STEERING LINKAGE
AND
STEER AXLE TRUNNION OVERHAUL

Park truck on a hard, level surface in

correct position for using an overhead
Truck Preparation
For best access to steering trunnion, the

following is also recommended:

Remove hood and overhead guard.
Disconnect SCR traction controls, and
Remove counterweight.
Lift and block the truck up to raise
26555

GROUP CLqRK
26
85M616 85M793
1 Turn key switch "OFF". 5 Remove overhead guard. Refer to

2 Open hood and disconnect battery GROUP 39, Section 1.
from truck receptacle.
85M751 85M812
3 Remove battery from truck. Refer 6 Disconnect power cables from SCR
to GROUP 12, Section 1. controls. (GROUP 19, Section 7)
7 Remove counterweight. (GROUP 38,
Section 1)
85M784 85M806
4 Remove hood. (GROUP 39, Section 2) 8 Lift and block the truck up to
raise steer wheel off floor.
(GROUP 38, Section 3)

GROUP
26
e---93.315
25.443, i&-- 93.316
STEERING LlNKAGE
25-196
25.080 ARM, STEERING 26.025 SHIELD, CYLINDER ROD END DUST

25.122 DRAG LINK ASSEMBLY, STEERING CONTROL 26.026 FASTENER, CYLINDER ROD END
25.162 LUB FITTING, STEERING LEVER 26.028 ROD END ASSEHBLY, CYLINDER (PISTON ROD END)
25.387 PIVOT, STEERING ARM 26.049 BALL STUD, CYLINDER ROD END (PISTON ROD END)
25.390 BEARING, STEERING ARM PIVOT 26.056 RETAINER, BALL STUD HOUSING PLUG
25.391 BEARING, STEERING ARM 26.057 LUB FITTING, STEERING CYLINDER ROD END
25.393 PIN, STEERING LINK 26.082 COVER, CYLINDER ROD END DUST
25.394 PIN, STEERING LINK AXLE 26.246 COVER, CYLINDER BALL STUD DUST SHIELD
25.443 LEVER, INTERLOCK SWITCH ACTUATOR 92.745 COTTER, POWER STEERING CYLINDER BALL NUT FAST
26.000 CYLINDER ASSEMBLY, STEERING 93.315 FASTENER, STEERING INTERLOCK SWITCH ACTUATOR
26.015 SEAT, BALL STUD 93.316 DOWEL, STEERING INTERLOCK SWITCH ACTUATOR
26.018 LUB FITTING, BALL STUD HOUSING 93.317 RETAINER, POWER STEERING CYLINDER BALL
26.019 STUD, BALL 93.318 NUT, STEERING LINK FIN (STEERING ARM)
26.020 SHIELD, CYLINDER BALL STUD DUST 93.319 NUT, STEERING LINK PIN (AXLE END)
26.021 FASTENER, BALL STUD 93.793 WASHER, STEERING ARM PIVOT FASTENER
26.023 PLUG, BALL STUD HOUSING 94.295 FASTENER, STEERING ARM PIVOT PIN
26.024 LOCK, CYLINDER BALL STUD HOUSING PLUG 95.169 WASHER, STEERING LINK PIN
95.170 WASHER, STEERING LINK AXLE PIN

GROUP
26
STEERING AXLE 26-752
26.133 SEAL, STEER WHEEL HUB

26.134 CONE, STEER WHEEL HUB BEARING (INNER)
26.135 CUP, STEER WHEEL HUB BEARING (INNER)
26.136 RUB, STEER WHEEL
26.138 CUP, STEER WHEEL HUB BEARING (OUTER)
26.139 CONE, STEER WHEEL HUB BEARING (OUTER)

26.141 FASTENER, STEER AXLE HUB
26.143 CAP, STERR WHEEL HUB
26.224 FORK, STEER AXLE
26.227 SEAL, STEER AXLE FORK HOUSING
26.228 CONE, STEER AXLE FOFX LOWER

26.229 CUP, STEER AXLE FORK LOWER
26.234 CUP, STEER AXLE FORK UPPER
26.235 CONE, STEER AXLE FORK LIPPER
26.238 FASTENER, STEER AXLE FORK UPPER BEARING
26.239 SEAL, STEER AXLE FORK COVER

CMRK GROUP
26
STEER WHEEL REMOVAL
IMPORTANT
Because of the heavy weight of the wheel

and tire, it is recommended to first re-
move the wheel when overhauling the bear-
ings to avoid damage to the grease seal
when the wheel hub is moved on the spindle.
It also makes the work simpler and easier.
1 Remove-the wheel and tire assemblY*

(Place a block of wood under the tire
to prevent rotation of the wheel when
loosening the lug bolts. Use a pry
bar under the tire to help move the
wheel on and off the wheel hub.)
85M882
2 Remove hub cap from wheel hub.
85M883
3 Clean the excess grease from around

the spindle nut.
4 Loosen and remove the spindle nut.
85M884

GROUP
26
5 Remove the outer bearing cone.
6 Pull the wheel hub off the spindle.

Hold the hub firmly to avoid dragging the
grease seal at the back side across the
threads on spindle end.
Refer to GROUP 26, Section 2, Steer Wheel

Bearing Maintenance, for additional infor-
mation on wheel bearing inspection, bear-
ing replacement, and lubrication.
STEER CYLINDER RENOVAL
Refer to GROUP 26, Sections 9 and 9R, for

additional removal and overhaul information.
Also see illustration, page 3.
26556

GROUP
El!!RK
26
STEERINGLINKAGEREMOVAL
Refer to PMA-540, GROUP 26, Section 4, for

additional information on inspection of
steering linkage.
1 With steer cylinder rod end removed,

loosen and remove the mounting bolts,
washers, and steering link pins. Then,
remove the steering drag link assembly
(with bearings).
Refer to Figure 26560, Page 8, for cross-

section of steering link and bearing
installation.
85M801 26557
2 To remove steering arm, loosen and remove

bolt and washer from top of frame socket
for steering arm pivot pin. Drive the
pivot pin downwards and out of frame
socket. Remove steering arm. See Fig-
ure 26560, Page 8, for cross-sectional
view, and Figure 26561, Page 8, for ex-
ploded view of bearings.
85M795

GROUP EMRU
26
STEER AXLE TRUNNION SHAFT
STEERING ARM
L-DRAG LINK
26560 Cross-seztion of steer axle

trunnion, steering arm pivot,
and drag link bearing mountings.
Steering arm
pivot bearing
installation.
26561

GROW
CWRK
26
STEER AXLE TRUNNION OVERHAUL
Refer to illustrations, Pages 3, 4 and 8.

Figure 85M807 shows complete steer axle
trunnion and steering linkage installation
(before removal of steer wheel) for refer-
ence.
NOTICE - Some photographs show a similar

truck model to illustrate typical TM
procedures.
85M807
1 Remove mounting bolt which holds drive

motor cut-out switch cam plate to top
of steer axle trunnion shaft.
2 Remove cam plate from top of trunnion shaft.

85M803
85M804 26531
2 Loosen and remove upper lock nut, then

loosen the lower trunnion shaft retaining
(and bearing adjusting) nut.
(Figure 17089 shows typical TM procedure.)
Loosen the bearings by rotating the trunnion

(axle) shaft and/or shaking the steer axle.
This will unseat or free the bearings from
their running position.
17089

GROUP Cl!qRK
26
26532
3 Attach a sling and hoist of correct capac-

ity to the steer axle trunnion, as shown
by Figure 17090. If necessary, hit the
_ spindle with a soft-face hammer to loosen
it from the upper bearing.
4 If the trunnion shaft is "seized" in the

upper bearing, put a brass hammer on top of
the spindle, as shown, and hit it with a
larger hammer to loosen the spindle. When
spindle is loosened, now remove the spindle
retaining nut.
5 Remove the steer axle and bearings. Lower

the hoist and let steer axle trunnion and
lower bearing cone drop out of frame sock-
et. Remove bearing cups with bearing
puller.
6 Clean and inspect all components for wear,

cracks, and other damage. Clean and in-
spect the bearing seals, cups and cones.
Repair or replace components, as necessary.
Replace damaged bearing cups and cones as
a set.

CMRH GROUP
26
STEER AXLE TRUNNION INSTALLATION
Install steer axle trunnion in reverse

sequence of removal. Refer to Figure
26562.
Install bearing cups (l)(Z) into fork hous-

ing in frame by pressing or driving into
place with a suitable bearing installation
tool. Be sure cups are fully seated in
bearing bores. (See Figure 26560, Page 8)
Pack the bearings with grease and install

lower seal (3) and bearing cone (4) on
trunnion shaft. Be sure bearing is fully
seated on trunnion.
Recommended greasing procedure:
1) Use Grade No. 2 Lithium soap base multi-

purpose grease, Clark MSSC or MS107C, or
equivalent.
2) Pack bearings with grease before assembly
Install trunnion (5) into fork housing (6)

in frame and install upper bearing cone (7)
and seal (8) on trunnion shaft.
26562
Install and lightly tighten (finger-tight)

trunnion shaft retaining (bearing adjusting)
nut (9). Rotate the trunnion to align and
seat the bearings.

GROUP CMRK
26
5 Now, tighten the retaining nut to

[15-20 N.m] 11-15 lbf.ft. torque (Figure
19498 shows typical TM procedure). Hold
steer axle from turning from below while
tightening the nut.
Check for free movement of the trunnion

shaft and bearings by turning (rotating)
the steer axle to the right and left.
19498
6 Check trunnion bearing preload.
With torque wrench on the retaining nut,

it should require [Z-3 N.m] 1.5-2.0 lbf.ft.
rolling torque to rotate the steer axle in
the trunnion bearings. Tighten or loosen
the retaining nut to obtain correct pre-
load torque. (See Figure 19498)
7 When trunnion bearing preload has been

set correctly, install lock nut (lo),
Figure 26562, on trunnion shaft. Tighten
to [15-20 N.m] 11-15 lbf.ft. torque (ref-
erence Figure 19498).
85M805
8 Install drive motor cut-out switch cam

plate. Be sure dowel pin is correctly
positioned in hole in trunnion shaft.
9 Install cam plate mounting bolt. Tighten

bolt to [ZO-23 N.m] 15-17 lbf.ft. torque.
85M803

CLclRU GROUP
26
STEER LINKAGE OVERHAUL AND INSTALLATION
1 Inspect all components of the steering

linkage for bent parts and signs of stress
or unusual wear. Check the condition of
all steer linkage pins and bearings for
binding or excessive wear. Repair or
replace any part, as necessary, before
reassembly is started.
Install in reverse order of removal. -M

26563
2 Install steering arm pivot bearing parts

in steering arm. Install snap ring in
center of arm. Then, install bearing cups
firmly against the snap ring. *Pack bear-
ings with grease. Install bearing seal,
lower bearing cone, and spacer on pivot pin.
Put pin into steerinq arm and install upper
,,
bearing cone and seai on pin.
*Lubrication - Recommended procedure:
1) Use Dow Corning Molykote Longterm 2, or

Molykste BR2 Plus grease, or equivalent.
2) Pack bearings with grease before assemb 1Y
26561
3 Install pivot in, with steering arm, into

frame housing socket). Install washer and
fastening bolt at top of frame housing into
steering arm p vot pin.
26564

GROUP CLqRK
26
4 Be sure the fastening bolt in the steering

arm pivot pin is tightened to the correct
torque.
Tightening torque:
[240-270 N.m] 177-199 lbf.ft.
5 Install new bearings (if required) in

steering drag link.
26572
6 Install drag link assembly to steering

arm and steer axle trunnion.
Lubricate bearings with recommended

grease (GROUP 40, Section 5).
26565
7 Tighten the pivot pin fastening bolt in each

end of the steering drag link to correct
torque.
Tightening torque:
[20-25 N.m] 177-2'21lbf.in.
85M801

GROUP
CMRK
26
GROUP
26
SECTION
9R
STEERING CYLINDER REMOVAL


Block the wheels.
,
85M626
Truck Preparation
1 Remove battery from truck.

2 Raise and block up rear of truck.
For best access to steering cylinder,

the following is also recommended:
3 Remove hood and overhead guard.

4 Disconnect SCR controls.
5 Remove counterweight.
85M806
See GROUP 26, Section 8, Page 2, for

GROUP cl!lmK
26
26.023
-'L 26.025
26.049
n 26.028
STEERING LINKAGE 25-196
26.000 CYLINDER ASSEMBLY, STEERING 26.025 SHIELD, CYLINDER ROD EM) DUST
26.026 FASTENER, CYLINDER ROD EN0
26.015 SEAT, BALL STUD 26.028 ROD END ASSEMBLY, CYLINDER (PISTON ROD END)
26.018 LUB FITTING, BALL STUD HOUSING 26.049 BALL STUD, CYLINDER ROD END (PISTON ROD END)
26.019 STUD, BALL 26.056 RETAINER, BALL STUD HOUSING PLUG
26.020 SHIELD, CYLINDER BALL STUD DUST
26.021 FASTENER, BALL STUD 26.057 LUB FITTING, STEERING CYLINDER ROD END
26.082 COVER, CYLINDER ROD END DUST
26.023 PLUG, BALL STUD HOUSING 26.246 COVER, CYLINDER BALL STUD DUST SHIELD
26.024 LOCK, CYLINDER BALL STUD HOUSING PLUG 92.745 COTTER, POWER STEERING CYLINDER BALL NUT FAST
93.317 RETAINER. POWER STEERING CYLINDER BALL

GROUP
CLqRU
26
STEERING CYLINDER REMOVAL
1 Disconnect hydraulic line from base end

of steering cylinder.
85M799
2 Disconnect hydraulic line from rod end

of steering cylinder.
85M798
3 Remove cotter pin and nut, and disconnect

steering cylinder rod end from steering
arm.
Bolt tightening torque:

[89-103 N.m] 65-75 lbf.ft.
85M796
4 Remove cotter pin and nut, and disengage

steering cylinder base end from the
mounting in frame.

[89-103 N.m] 65-75 lbf.ft.
NOTICE - Install ball bolt and nut with

cotter pin in vertical position with
split end pointing downwards.
Code: OH-540, MAR 86 GROUP 26,,Section 9R, Page 3

GROUP CLClRK
26
5 Remove steering cylinder from the truck.
26556
STEERINGCYLINDERINSTALLATION
1 Install steering cylinder in reverse

order of removal.
26555

Cl!!RYC GROUP
26
26
SECTION
POWER STEERING CYLINDER OVERHAUL

CMRKI
26
L26.298
26. 298
L 26.249
I I
L26.000
POWER STEERING CYLINDER 26-066
26.000 CYLINDER ASSEMBLY, STEERING

26.032 HOUSING, STEERING CYLINDER PORT END
26.033 SEAL, BODY TO HOUSING
26.089 BARREL. STEERING CYLINDER
26.090 ROD 6 PISTON ASSEMBLY, STEERING CYLINDER
26.093 GLAND, STEERING CYLINDER

26.094 SEAL, STEERING CYLINDER GLAND
26.210 WIPER, STEERING CYLINDER ROD
26.249 PACKING KIT, POWER STEERING CYLINDER
26.284 PACKING, STEERING CYLINDER GLAND
26.286 PISTON, STEERING CYLINDER

26.287 SEAL, STEERING CYLINDER PISTON
26.288 NUT, STEERING CYLINDER PISTON
26.289 EXPANDER, STEERING CYLINDER PISTON SEAL
26.298 LOCKWIRE, STEERING CYLINDER GLAND
26.330 RETAINER, STEERING CYLINDER GLAND

GROUP
26
STEERING CYLINDER ROD END (BALL SOCKET ASSEMBLY)
1 Remove rod end (ball socket assembly) from

steering cylinder piston rod.
Loosen the clamp bolt in the rod end on

piston rod. (Rod end has right-hand thread)
Rotate the rod end to remove from piston rod.
Be careful not to damage the rod end surface
while it is being held from rotating when
removing rod end.
26579
Inspect rod ends for wear and damage.
Replace components, as needed. See Page 8
for assembly adjustment information.
25-t%
BALL SOCKET ASSEMBLY
STEERING CYLINDER BASE ROD END
Refer to GROUP 26, Section 9R, Page 2, for component information.

GR0U.P Cl!!W
26
POWER STEERING CYLINDER OVERHAUL
TRUE LENGTH EXTENDED [700] 27.55

TRUE LENGTH CONTRACTED [465] 18.31
26580
IMPORTANT - When disassembling cylinder, it is necessary to have a clean

workbench. Cover parts if left exposed for any period, such as over-
night. Cylinder may be held by carefully clamping lengthwise in a vise,
as shown. Be careful to avoid damage to the cylinder barrel with too
much (excessive) clamping force.
1 Pry the tab of exterior lockring from hole

in cylinder tube and lift out to unlock
cylinder gland end from barrel. Rotate
ring slightly to move tab away from lock,
hole. Ring may be left on cylinder barrel,
except when replacement is required.
84M483
2 Clamp cylinder barrel in vise and rotate

gland to remove locking wire from inner
grooves of cylinder barrel and gland.
Lockwire easily "flows" out as gland is
rotated. Discard this wire. Use new
lockwire when assembling cylinder.
84M484

CMRK GROUP
26
3 Pull on cylinder rod to remove cylinder

gland. A screwdriver may be used to assist
in separating gland from barrel.
4 Continue pulling cylinder rod to remove

cylinder rod and piston from barrel.
84M485
5 To remove cylinder base end from barrel,

repeat the procedure of Steps 1 and 2, for
removal of exterior lockring and inner
lockwire. Remove the base end by pulling
from cylinder barrel.
NOTE - For replacement of high-wear parts,

e.g., piston seals, piston rod seal and rod
wiper, only the cylinder gland and the
cylinder rod assembly need be removed.
6 Remove and discard old seals. Install new

seals. Be sure seals are installed in the
correct position and direction on piston
and in cylinder end. Be careful to not
damage seal lips during installation.
Refer to illustrations, Pages 2 and 4.
26581

GROUP CLRRK
26
POWERSTEERINGCYLINDERASSEMBLY
Reassemble cylinder carefully to prevent

damage to seal lips and O-rings. Seals may
be lubricated with hydraulic oil to assist
assembly into cylinder barrel.
84M487
1 First, assemble base end, if removed, to cyl-

inder barrel. Carefullv move base end with
O-ring seal into barrel-bore. Install new
lockwire into inner groove and exterior
lockring into groove and locking hole.
26590
2 Install cylinder gland on piston rod.

Use gentle pressure and careful movements
to avoid damage to the rod seal and rod
wiper when these parts are moved over
the rod end.
I 1
26591
3 Install piston into cylinder barrel. Be

careful to not damage the piston seal
when installing ttiepiston into end of
cylinder.
NOTE - Cylinder barrel may also be held by

clamping in vise.
84M485

El!Mln; GROUP
26
4 Install gland into cylinder barrel.

Be careful not to damage O-ring seal.
84M486
5 Install new locking wire into inner groove

by reversing procedure of removal.
6 Install exterior lockring.
26592
7 Install rod end (ball socket assembly) on

cylinder rod. Adjust rod end for correct
installed-length of steering cylinder.
(See procedure below)
26579
Overall length between ball stud centers,

when cylinder is fully extended, should be
[700 mm] 27.55 inches*. Adjust rod end on
cylinder rod, as necessary. Tighten clamp
bolt in rod end to secure rod end to piston
rod, when adjustment is completed. Torque
clamp bolt to [40-45 N.m] 30-33 lbf.ft.
*Refer to Figure 26580, Page 4.
25473

GROUP GL9RK
26
When overhauling the rod ends or install-

ing new parts:

stud on steer cylinder base end.

end. Torque adjustment plug to
[25 N.m] 220 lbf.in., then, back off to
first cotter pin hole. Install new cotter
pin, spread and bend the ends over.

stud on rod end of cylinder.

end. Torque adjustment plug to
[lo N-m] 90 lbf.in., then, back off to
first cotter pin hole. Install new
cotter pin, spread and bend the ends
over.
26594

CLRRK GROUP
26
26
SECTION
14R
POWER STEERING PUMP REMOVAL
(Motor Installed In Truck)


_
l Block the wheels.
85M626
Truck Preparation
Remove floorboard.
Open hood.
maintenance access.
See GROUP 16, Section 'ZR, Page 2, for

additional information. 85M711

n 16.200
STEER PUMP AND MOTOR 26420
16.200 MOTOR ASSEMBLY, STEER PUMP
29.200 PUMP ASSEMBLY, STEER
29.269 FASTENER, STEER PUtQ
90.891 LOCKWASHER, STEER PUMP FASTENER

CMRK GROUP
26
POWER STEERING PUMP REMOVAL

Motor Installed In Truck
NOTE - Refer to GROUP 16, Section ZR, for

removal of steer pump and motor assembly
from truck.

This part is held in place by fitting
over tabs projecting from the front
battery compartment plate.
85M671
2 Loosen and remove the nuts from the

mounting bolts, then remove hydraulic
oil f4lter mounting bracket from the
battery plate.
85M707

85M682

from pump.
85M695

GROUP CWRK
26

line from pump.

protection.
85M696.

85M697
7 Remove the four pump mountjng bolts.
Pump mounting bolt torque:

[40-45 N.m] 29-33 lbf.ft.
8 Remove the pump from motor.
9 Install steering pump on motor in truck

by reversal of removal procedures.
Please refer to GROUP 16, Section ZR,

pages 6, 7, and 8, for additional pump
removal and installation procedures. L
26582

CL~RU GROUP
26
26
SECTION
14
POWER STEERING PUMP OVERHAUL

GROUP
26
29.208 \
NOTE:
NON SEEVICEMLE
IYEMS MARKED k”
ASSEMBLY
I COMPLETE -29.200
POWER STEERING PUMP 26190-l

JAN 86
29.200 PUnP ASSEKBLY, STEER 29.282 KEY, STEER PUM? DRIVE GEAR
16.227 COUPLING, STEER PUMP DRIVE 29.283 GEAR, STEER PUMP DRIVE
29.102 SEAL, STEER PUMP DRIVE SHAFT 29.284 GEAR, STEER PtiW IDLER
29.206 BEARING. STEER PUKP WAFT 29.205 RETAINER, STEER PUMP IDLER GEAR
29.208 FASTENER, STEER PUMP COVER 29.286 SHAFT, STEER FQlP IDLER
29.211 PLUG, STEER PUKF RELIEF VALVE 29.287 KEY, STEER PUKP IDLER GEAR
29.215 SHAFT, STEER FUMP DRIVE 29.288 ADJUSTOR, STEER PUMP RELIEF VALVE
29.217 DOWEL, STEER PUN? COVER WSEMBLY 29.209 SEAL,STEERPLMPRELIEFVALVEPUm
29.228 VALVE SUB-ASSMBLY. STEER PUKF RELIEF 29.325 SW. STEER PUMP BODY
29.229 SPRING, STEER PUMP RELIEF VALVE 29.328 SPRING, STEER PUHP RELIEF VALVE INNER
29.270 GASKET, STEER PUMP MfNJNTING 24N COVER, STEER puplp(OUTLET) USE 29.200
29.281 RETAINER, STEER PUKF DRIVE GEAR 25N COVER, STEER PUHP (SHAFT END) USE 29.200

ClflRK GROUP
26
PREPARATION FOR DISASSEMBLY
1 Overhaul pump only in a clean, dust-free location, using clean tools

and equipment. Dirt or grit will damage the highly machined surfaces
and will result in leakage or premature failure of the pump.
2 Clean outside of pump with a good grade solvent, e.g., Stoddard-type

solvent or equal, and dry thoroughly.
3 Before beginning disassembly, scribe match marks on the body and

cover to ensure that the pump will be reassembled in the same manner
as it was shipped from the factory. If the body or front cover is
replaced during overhaul, scribe a match mark on the new part as
on the part it replaced.
Typical Pump Cross-Section 26583
PUMP DISASSEMBLY
1 Remove pump drive coupling segment from

pump drive shaft. Loosen and remove bolt
from end of shaft and lift coupling from
pump. Also see Page 10.
2 Clamp the pump in a vise with shaft end

down. Use light clamping pressure to
avoid damage to the pump.
26644
3 Then, loosen and remove the eight 12-point
pump assembly fastener bolts from the
pump body (outlet cover).

GROUP Cl!!RK
26
4 Carefully separate the pump gear housing

body from the shaft end cover. Clamp or
hold the pump with the shaft end cover
facing downwards. Lift the pump body
from the assembly. It may be necessary
to lightly tap the housing with a soft-
faced hammer until the parts separate
from the alignment dowel pin.
5 Remove the gasket, then idler shaft and

gear assembly from the end cover.
6 Disassemble idler shaft and gear assembly

only as necessary for replacement of gear
or shaft. See "Cleaning and Inspection"
notes.
26678
7 Remove retainer snaprings, drive gear and

key from drive shaft.
26679
8 Remove pump drive shaft from end cover by

pulling it through the oil seal from the
mounting flange side.
26646

CLqRK GROUP
26
9 Remove needle bearings by pulling from

pump body and end cover.*
*It is suggested that you check the

bearings first, to confirm the need
for removal and closer inspection
and possible replacement. It is
common practice to replace the com-
plete pump when the bearings are
worn to require replacement. See
4
Item 8, Page 6.
26647
10 Turn pump end cover over and clamp in

vise with input drive shaft seal up.
Remove shaft seal by prying it out with
a large screwdriver.
IMPORTANT
Be careful not to damage the shaft seal
bore in end cover. Nicks or scratches
in the surface where seal is press fit-
ted will result in leakage.
26648
11 Disassemble pump relief valve. Loosen

and remove cap nut and seal. Remove
adjustor, springs and valve ball.
26645
CLEANING AND INSPECTION
1 Carefully wash all parts with clean

solvent and dry thoroughly.
2 Inspect the bearing journals on both gear

shafts for wear. Replace if journals
are scored or worn, or if shaft journal
wear exceeds 0.001 inch.
3 Replace complete pump if bearing journals

on shafts show signs of unusual wear.

GROUP CMRK
26
4 Check drive shaft for wear in the seal

lip contact area. If 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.
7 Check fit of idler gear on shaft and key.

Remove idler gear if necessary. Remove
idler gear retainer snapring with screw-
driver, then remove gear. If key (pin)
is worn or pin hole elongated in shaft,
replace as needed.
8 Check needle bearings. The needle rollers

should roll freely. If they bind, skew, Refer to Page 9 for
or fall out, replace the bearing. needle bearing instal-
NOTICE - If the bearings are excessively lation specifications.
worn to require replacement, it is recom-
mended that the complete pump be replaced.
9 Inspect gear bores in pump body 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 and damage. Replace, as needed.

EMRK GROUP
26
PUMP REASSEMBLY
NOTICE
The installation of new shaft seal and

gaskets is recommended at each overhaul
of the pump.
1 Install new shaft oil seal.
Put end cover on flat plate with shaft

seal bore up. Place the oil seal in
position with the lip of the seal and
spring facing into the pump. Install
the shaft seal using a suitable seal
pressing tool and an arbor press.
26648
Press seal until top edge is located

[2,794-3,048 mm] .llO-.120 inch below
top edge of seal bore (dimension E,
Figure 26676). Put a light coating of
Lubriplate grease, or equivalent behind
the seal lip and spring and on the lip.
26676
If arbor press is not available, seal may
be installed by driving into place with a
seal seating tool and a mallet. Always use
a tool with a diameter smaller than the
seal 0.0. to press the seal into the cover.
Do not drive on the seal directly with a
hammer. Put the oil seal into position in
end cover bore. Place the seating tool
over the seal. Then, using a mallet, tap
squarely on the tool until the seal is
located correctly as noted above.

GROUP CMRK
26
2 Reassemble the pump relief valve. NOTE -

Adjust (set) relief valve after pump assem-
bly and test. Install adjustor only par-
tially (2-3 threads engaged) and cap nut
temporarily, until pump can be operated
and correct (final) relief setting
checked and adjusted. See Page 9.
26677
3 Apply Lubriplate 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.
26646
4 Lubricate gears, shafts, bearings and pump

housing and cover inner surfaces with hy-
draulic fluid. Assemble and install gears
and shafts into end cover.
IMPORTANT - When replacing gasket, new

gasket must be the same color as the one
removed. This is critical since it
establishes the gear clearance.
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 fas-
tener 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 N.m] 9.5-10.5 lbf.ft.
Check again that pump shaft turns freely.
26644

CL!RK GROUP
26
Relief Valve Setting Adjustment
After overhaul and reassembly, pump relief valve setting check and
adjustment can be made by either:
Installation in truck and perform power steering system relief pressure

check. Refer to PMA-540, GROUP 26, Section 3. Adjust relief pressure
as noted below.
Bench set-up simulating truck installation.
4 Arrange mounting and drive for pump.

b) Install hydraulic plumbing lines, including oil supply (sumpj.
c) Connect control valve to simulate steering cylinder in stopped
(relief) position.
d) Connect pressure gauge in pump outlet circuit.
d Operate pump at rated speed. DO NOT OPERATE SYSTEM OVER RELIEF
ANY LONGER THAN NECESSARY TO READ THE PRESSURE GAUGE.
f) Remove cap nut from relief valve. Turn (rotate clockwise to increase
pressure) relief valve adjustor until correct relief pressure is
measured with pressure gauge.
Install cap nut on relief valve to lock adjustor.
Check relief pressure again. Readjust, as necessary.
DO NOT EXCEED THE SPECIFIED RELIEF PRESSURE SETTING.
Pump Specifications
Displacement Pressure Rating Relief Setting Flow & Pressure @ Speed

[cc/rev] cu.in/rev [kPa] psi [kPa] psi gpm psi rpm
P
[8.4793] -51744 *[ 79291 1150 [8618] 1250 3.36 1000 1725
**[13790] 2000
I I I 1 I
*Continuous **Intermittent
Rotation, viewing drive end: Clockwise
Inlet & Outlet Ports: 3/4-16 SAE O-ring
NEEDLE BEARING INSTALLATION SPECIFICATIONS
Shaft Diameter, A Dimension B (Inches)
-4387 .045-.050
.5000 .058-.063
NOTE - A shoulder is machined in bearing bore

to ensure correct depth of bearing seating.
Press bearing fully against this shoulder.
26682

GROUP
26
PUMPDRIVE COUPLING- TYPICAL INSTALLATION
1 Install one half of drive coupling on pump.

Put elongated hole of one half of drive
coupling over matching shape on pump drive
shaft, with flat side towards pump.
Install lockwasher and short bolt furnish-
ed with the coupling. Torque to:
[9.6 N.m] 85 lbf.in.
2 Similarly, install other half of

coupling on motor shaft. Put coupling
half on motor shaft with flat side
towards motor. Install square washer,
lockwasher, and bolt into motor shaft.
Torque to C9.6 N.m] 85 lbf.in.
3 When installing pump to motor, install

the rubber coupling insert (cross)
into either the motor or pump half of
coupling, with slots in the insert
over the tangs of coupling half.
IMPORTANT
Do not lubricate or pack coupling with

grease or oil, which will cause rubber
insert to soften and be damaged.
4 Install gasket between pump and motor,

and bolt pump to motor with coupling
tangs aligned in the remaining two
slots in rubber insert. Be sure tangs
are aligned correctly before final
tightening of mounting bolts.
5 Tighten pump mounting bolts to the

correct torque value.

ELFIRK GROUP
29
GROUP
29
SECTION
1
HYDRAULIC SYSTEM FLUID AND FILTER CHANGE
m
Park truck on a level surface.

Put the upright in a vertical position
and lower the lift carriage fully down.
Block the wheels.
1 Open the hood.

3 Remove valve cover from main valve.
4 Remove battery from truck.*
5 Adjust front battery plate for access.*
*See NOTICE, page 3.
85M642

GROUP
29
HYDRAULIC SUMP PARTS

29-166
29.701 TANK, HYDRAULIC SW
29.702 FASTENER, HYDRAULIC SUMP TANK
29.728 CAP, SUMP FILTER
29.766 COVER, SUMP TANK
29.767 SEAL, SUMP TANK COVER
29.768 FASTENER, SUMP TANK COVER
29.798 SCREEN, HYDRAULIC SUMP PRE-FILTER
29.809 DIPSTICK, SUMP LEVEL

GROUP
ELRRH
29
HYDRAULIC SYSTEM FLUID AND FILTER CHANGE
Please refer to Planned Maintenance Program, PM-540, Pages 6.3, 6.4 and
6.5 for other important information on hydraulic sump tank fluid level
check and fluid change. Also refer to GROUP 01, Section 1, Recommended
Planned Maintenance Schedule.
There is no drain plug in the hydraulic sump tank. 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:
A. Removal of the hydraulic sump cover assembly and

pumping the fluid out by suction using a separate
pump and hose.
B. Pumpfng the fluid out by using the truck hydraulic

system. This method, described below, may be used
most easily and satisfactorily for routine changes
of the fluid.
1 Remove the floorboard for access to the

hydraulic sump and filter.
85M506
2 Remove the cover enclosing the main hydrau-
lic valve for access to the hydraulic system
pressure diagnostic check port located on
outer right-hand side of valve.
NOTICE - Servicing of the hydraulic fluid

filter is more easily done when the battery
is removed and battery plate adjusted to
the maintenance position. This action moves
the filter up where it is more readily acces-
sible.
85M849
Refer to PM section, Page 5.8, and
GROUP 38, Section 2, Battery Plate Adjustment.

GROUP LSRK
29
3 Remove the snap-on cap and connect a suit-

able drain hose line to the diagnostic
check port fitting located on side of main
hydraulic valve. NOTE - Use quick-disconnect
adapter fitting, Clark Part No. 3797029.
85M552
4 You wil 1 need a drain pan of [9.8-17 L]
2.6-4.5 gal 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.
12171
5 Turn key switch to “ON” position.
6 Move tilt control lever to the back tilt

position to start the 1 ft pump. Hold
tilt lever in this posi:. ion until sump
tank is emptied. See below.
A steady stream of used hydraulic oil

should flow from the drain line.
85M489
7 Continue operation until the sump tank is

emptied. This point will be reached when
the pump starts to cavitate. When cavita- IMPORTANT
tion occurs the pump speed will increase.
A change in pump speed pitch will be heard. BE CAREFUL WHEN SUMP IS NEARLY
Also, watch the drain line. The oil flow EMPTIED. WATCH FOR SIGNS OF
will become erratic or will stop when the PUMP CAVITATION. DO NOT
pump can no longer pick up oil from the OPERATE PUMP AFTER CAVITATION
sump tank. OCCURS.
8 Release the tilt lever immediately when

pump cavitation occurs.

Cl!!WK GROUP
29
10 Disconnect drain hose from the truck.
11 Replace cap on the hydraulic valve

pressure check port fitting.
85M552
12 Remove used hydraulic oil filter.
(Shown with battery plate adjusted

for maintenance access.)
13 Install a new oil filter.
IMPORTANT
ALWAYS USE GENUINE CLARK PARTS.
85M641
14 Remove the used sump fill cap/breather.
15 Fill sump tank with new fluid.
Hydraulic Sump Tank Capacity,

Useable Volume: [9.84 L] 2.6 gal.
Total Volume: [17.0 L] 4.5 gal.
85M864
NOTE - Remove or pull dipstick part way
out to vent air from tank while filling.
00 NOT OVERFILL.
IMPORTANT
USE RECOMMENDED FLUID ONLY.
Refer to GROUP 40, Sections 4 & 5,

for hydraulic oil specification.
85M848

GROUP CMRK
29
16 Install new sump breather cap.
NOTICE - If truck battery is removed

and battery plate adjusted for access,
install the battery plate. Use an
adapter cable for powering the truck
when battery is removed (see Page 4).
85M863
17 Turn key switch to "ON' position.
18 Operate the truck hydraulic system.

Cycle the hydraulic system several times.
Raise the lift carriage to the highest
position and lower fully down. Check
for leaks.
BE SURE THERE IS ADEQUATE OVERHEAD

CLEARANCE BEFORE RAISING UPRIGHT.
85M865
^_ Turn key switch

19 to "OFF" position.
85M482
20 Check hydraulic sump fluid level again.

Add fluid as required to fill sump to the
"FULL" level on dipstick. DO NOT OVERFILL.
21 Install cover enclosing main hydraulic valve.
22 Install floorboard.
23 Install battery, as applicable.
85M848

GROUP
29
SECTION
10R
LIFT PUMP REMOVAL
(MAIN HYDRAULIC PUMP)


0 Block the wheels.
85M626
Truck Preparation
lpen hood.
disconnect battery from truck receptacle.
iemove battery from truck.
iemove floorboard.
iemove cover from main valve.
ldjust front battery plate for
naintenance access.
See GROUP 16, Section 24R, Page 2, for

85M862

GROUP
CMRK
PUMP MOTOR MOUNTING 16-222
16.500 MOTOR ASSEMBLY. RYDRAULIC PUMP

16.700 BRACKET. PUMP MOTOR MOUNTING
16.704 DAMPENER. PUW MOTOR VIBRATION
16.706 FASTENER, PKMF MOTOR BRACKET
16.715 STRAP, F'UMPKOTOR MOUNTING
29.100 PUMP ASSEMBLY, HYDRAULIC

29.106 FASTENER, HYDRAULIC PUMP MOUNTING
39.420 SEIELD, PUMP MOTOR
39.421 FASTENER, PIMP MOTOR SHIRLD
92.591 NUT, PUMF MOTOR BRACKET FASTENER
93.278 NUT, PUblPMOTOR SHIELD FASTENER

ElfIRK GROUP
29
LIFT PUMP REMOVAL

NOTE - Refer to GROUP 16, Section 24R,

for removal of lift pump and motor
assembly from truck.
1 Remove plastic strip (floorboard support)

from front battery plate.
85M671
2 Loosen the bolt in pump motor mounting

strap. Loosen mounting strap to allow
motor to be adjusted for best access to
hydraulic lines, pump mounting bolts,
and removal of pump from end of motor.
85M686
3 Clean the fittings and disconnect the

hydraulic lines from the lift pump.
Put caps on all fittings to protect
from dirt and damage
1) Loosen the hose clamp and remove the

intake (suction) line from pump fitting.
85M713
2) Loosen and remove the output (high-

pressure) line from pump fittjng.
85M714

GROUP CLqRK
29
4 Loosen and remove the pump mounting

bolts from motor flange, using an
internal hex wrench.
85M902
5 Remove lift pump from motor. Move pump

away from motor flange until pump drive
shaft is disengaged from motor shaft.
26584
6 Refer to GROUP 16, Section 24R, for

removal of pump from motor when motor
is removed from tctick.

EMRK GROUP
29
GROUP
29
SECTION
10
LIFT PUMP OVERHAUL
(MAIN HYDRAULIC PUMP)
Typical Overhaul Instructions
See Page 9 for Troubleshooting Guide

29.123
2Y.260-, 1
HYDRAULIC PUMP 29-550 JUN 85
29.100 PUMP ASSEMBLY, HYDRAULIC
29.117 WEAR PLATE & SEAL KIT, HYDRAULIC PUMP
29.123 DOWEL, HYDRAULIC PUMP COVER
29.129 PLUG, PUMP CONTROL VALVE
29.171 GEAR ASSEMBLY, HYDRAULIC PUMP DRIVE
29.187 GEAR ASSEMBLY, HYDRAULIC PUMP IDLER
29.198 CAPSCREW, HYDRAULIC PUMP HOUSING
29.259 COVER ASSEMBLY, HYDRAULIC PUMP OUTLET
29.260 COVER ASSEMBLY, HYDRAULIC PUMP (SHAFT END)
91.147 WASHER, HYDRAULIC PUMP HOUSING FASTENER

ELRRK GROUP
29
PREPARATION FOR DISASSEMBLY
1 Overhaul pump only in a clean, dust-free location, using clean tools

and equipment. Dirt or grit will damage the highly machined surfaces
and will result in leakage or premature failure of the pump.
2 Clean outside of pump with a good grade solvent, e.g., Stoddard-type

solvent or equal, and dry thoroughly.
3 Before beginning disassembly, scribe match marks on the body and

cover to ensure that the pump will be reassembled in the same manner
as it was shipped from the factory. If the body or rear cover is
replaced during overhaul, scribe a match mark on the new part as
on the part it replaced. NOTE - This ensures that inlet and outlet,
with respect to rotation, is kept the same.
PUMPDISASSEMBLY
NOTICE
All reference numbers in the following text refer to items

illustrated in exploded view, Figure 26603, Page 4.
During disassembly, take special note of the wear patterns on

the wear plate (8) and thrust plate (6). (Wear plate contains
seal grooves and thrust plate is flat steel-backed bronze.)
Relate these patterns to the inlet and outlet sides of the pump.
The large port in the rear cover (3) always corresponds to the
inlet side of the pump. The inlet side can be further identified
by the gear contact pattern in the gear bore. The wear plate (8)
will have a somewhat heavier wear pattern on the inlet side.
The thrust plate (6) will also have a pattern that can be estab-
lished for reassembly. Also note that the long journal of the
driven gear (13) is toward the front of pump.
1 Clamp the pump in a vise with shaft

end down. Use light clamping pres-
sure to avoid damage to the pump.
2 Loosen and remove cap screws (1)

and washers (2).
See Figure 26683 at right for

cross-sectional view of pump.
26683

GROUP
29
DO not force
seal below surface
BRONZE FACE
TOWARD GEARS
13
Nylatron 16
26603
3 Separate rear cover (3) from body (15) by supporting pump,

shaft end up, on the mounting flanges and pressing on drive
shaft end in arbor press.
IMPORTANT - Use one hand to support rear cover from underneath,

since cover and internal parts will drop suddenly when dowel
pins are disengaged.
4 An alternate method of removing the rear cover is to pry

simultaneously with two large screwdrivers in the relieved
areas between body and cover.
IMPORTANT - At no time should screwdrivers be inserted farther

into pump than the depth of the relieved areas. Any burr or upset
metal must be removed from the body (15) and/or cover (3) after
this procedure to assure a good seal between body and cover.

GROUP
Cl!!RK
29
5 Holding pump with shaft end down, remove rear cover (3).
Dowel pins (7) may rema in e ither with body or rear cover.
6 Cover gasket (5) and thrust plate (6) may cling to the rear cover.
If they remain with the body, remove gasket and lift thrust plate
out before proceeding.
7 Remove (lift out) driven gear (13), drive gear (14), and wear
plate (8) including pressure loading seal (9).
8 Turn pump body over and clamp in vise with shaft seal up. Remove
shaft seal (10) by prying it out with a large screwdriver.
NOTE - Take notice of the depth to which shaft seal is
installed prior to removal.
IMPORTANT
Be careful not to damage the shaft seal bore in pump

body because this would result in seal leakage.
PARTS INSPECTION
1 Wash al parts with clean solvent and dry thoroughly.
2 Inspect wear plate (8) and thrust plate (6). Replace both
if scori ng or uneven wear is in evidence.
NOTE - A somewhat heavier wear pattern is normal on the

low pressure (inlet) side of the wear plate (8). However,
there should be no heavy scoring in this area.
3 Remove pressure loading seals (9) and (16) from wear plate.
Discard old seal(s). NOTE - This seal may be of two-piece
or one-piece design. All replacement seals are two-piece
and should be installed into groove. See view. The seal
should extend a minimum of [.127 mm] 0.005 inch beyond
surface of wear plate. Do not push seals below wear plate
surface at any point.
4 Inspect bushings in body and cover. Replace cover and/or body

if bushings are heavily scored or burned.

GROUP CLqRK
29
Inspect gear journals and faces. Replace if faces or

journals are scored or worn, or if shaft journal wear
exceeds [.025 mm] 0.001 inch.
Inspect body for wear and scoring. If gear contact wear

(gear wipe) on low pressure.side (inlet) exceeds C.127 mm]
0.005-inch depth, replace body. If the body is usable,
remove wipe burr with suitable burring tool.
PUMP REASSEMBLY
NOTICE
The installation of new parts contained in wear plate and

seal kit is recommended at each overhaul of the pump.
Put body (15) on flat plate with shaft

seal bore up. Install new shaft seal (lo),
using a suitable seal pressing tool and an
arbor press. Press seal until it is approx.
[1.52 mm] l/16 inch below edge of seal bore.
Pack the area between the double lip of
seal with Lubriplate grease, or equivalent.
NOTE - Do not press seal to bottom of bore.

Position new shaft seal no deeper than
original seal as noted during disassembly.
26681
Turn (invert) pump body so that gear bores are up. Install
wear plate (8) in bottom of bore, making sure that pressure
loading seals (9) and (16) are positioned properly in seal
grooves and installed against bottom of bore surface.
Lubricate bushings in body and face of

wear plate with SAE 10 engine oil.
Apply Lubriplate grease or equivalent to

seal surface area of shaft of drive gear.
Install drive gear (14) into pump body
and sha ft seal.
Install driven gear (13), with long

journal toward front of pump.
26653

CLRRK GROUP
29
6 Lubricate rear gear faces and journals with

SAE 10 engine oil and install thrust plate
(6) in its original position, bronze face
toward gears.
7 Apply a small amount of grease to rear cover

seal groove and install new rear cover seal
(5) into groove.
26655
8 Lubricate rear cover bushings with SAE 10

engine oil and assemble rear cover (3) to
pump body, matching scribe marks on cover
and body.
9 Position pump with shaft end down, and

complete the installation of rear cover.
26656
10 Install cap screws (1) and washers (2).

Tighten the cap screws in sequence to pull
cover down evenly into place. Torque to
[46-51 N.m] 34-38 lbf.ft.
18239
11 Check that drive shaft turns freely

without evidence of mechanical binding.
(Use an adjustable wrench to,turn shaft,
if necessary.)
Code: OH-540, MAR 86 GROUP '29,Section 10, Page 7

GROUP CWRK
29
BREAK-IN PROCEDURE
Test Stand Method:
Run pump for 1 minute at minimum pressure.
Raise output pressure to [3448 kPa] 500 psi for 5 seconds,

then lower to minimum pressure for 5 seconds. Continue
cycle for 1 minute.
Repeat Step 2, but increase pressure in [3448 kPa] 500 psi

increments until maximum operating pressure, or [20685 kPa]
3000 psi is obtained.
Check flow by best method available.*
With pump running at idle speed (approx. 500 rpm),

check pump for leaks. No shaft seal leakage suffi-
cient to form a drop is permissible. No external
leakage is permissible.
NOTICE - Break-in of the pump if (a new) body was replaced could

result in wipe chips (normal) to be in the output flow from pump.
Since these small aluminum chips could go through the system,
precautions should be taken to assure that these chips will not
result in other component failure. Pump should be operated for
several minutes with clean hydraulic fluid before installation.
*Output flow of an overhauled pump should meet or exceed the following:
Model Displacement Speed Pressure Flow (Minimum)

cu in/rev rpm psi gpm
s15s-9 1.00 1800 2500 6.8
Rotation viewing drive end: Clockwise

Inlet port: l-1/16-12 UN Outlet port: 7/8-14 UN

ELclRK GROUP
29
GUIDEFOR GEAR-TYPE
TROUBLESHOOTING PUMPS
TROUBLE PROBABLE CAUSE CORRECTIVE ACTION

*ow flow Gear face, body or cover nicks Remove, inspect & rebuild
Pressure loading seal collapsed Replace, remove wipe burr & rebuild
Wear plate tight in body bore Remove wipe burr & rebuild
Unit out of alignment Inspect and rebuild
Excessive pressure - System Correct, inspect & rebuild

relief valve (R/V)
Contaminated fluid Correct, inspect & rebuild
Excessive side loading Correct, inspect & rebuild
System R/V stuck or leaking Correct R/V, pump may be OK
Pinched thrust plate Inspect and rebuild
Shaft seal Faulty seal Replace

leakage
Pump unloading Review steps for low flow
Pressurized inlet Max [172 kPa] 25 psi allowable
Pump run w/wrong rotation Replace shaft & pressure

loading seals
Cover drain hole omitted Replace cover & shaft seal
Contamination Inspect & rebuild
Cavitation Review causes of cavitation
Shaft scratched Correct if posssible (polish)

or replace shaft seal & gear
seal gasket Faulty seal Replace

eakage
Nicks on body or cover Correct & replace as required
Pinched seal gasket Correct & replace as required
Excessive system pressure Correct & replace as required

GROUP
CLRRK
30
GROUP
30
SECTION
HYDRAULIC SYSTEM RELIEF PRESSURE

Put blocks under the upright rails, and
Raise the drive wheels off the floor.


GROUP Cl!!RK
30
HYDRAULIC SYSTEM RELIEF PRESSURE CHECK AND ADJUSTMENT
Following is the general procedure for checking and setting main hydraulic
valve lift/tilt and auxiliary relief prssure, for all TM 15-20 36-volt
trucks.
Refer to GROUP 40, Section 5 for relief pressure specifications.
IMPORTANT
IF ADJUSTMENT IS NECESSARY, DO NOT
EXCEED THE RELIEF PRESSURE SETTING HYDRAULC FLUID PRESSURE
SPECIFIED FOR THE TRUCK MODEL DO NOT USE YOUR HANDS TO CHECK
CAPACITY RATING. CHANGING THE FOR HYDRAULIC LEAKAGE. FLUID
PRESSURE WILL NOT INCREASE LIFTING UNDER PRESSURE CAN PENETRATE
CAPACITY OR LIFTING SPEED. YOUR SKIN AND CAUSE SERIOUS
INJURY.
1 Hydraulicsystem relief pressure setting may

be checked with a MICO QUADRIGAGE (Clark Part
No. 1800106), or with a conventional pressure
gauge having a suitable pressure range scale.
To cover all models including TM 20 model
with the highest pressure setting, a gauge
with a capacity range of [O-27,580 kPa]
O-4000 psi minimum, is recommended.
11156
2 First, remove floorboard.
3 Then, remove the enclosing cover from main

hydraulic control valve for access to
the hydraulic system pressure diagnostic
check port located on outer right-hand
side of valve. Loosen and remove the two
bolts at top front of cover and lift
cover out of the truck.
85M534

GROUP
30
4 Remove the snap-on cap and connect the

pressure gauge to the check port fitting
on outside of main hydraulic control
valve.

85M552
85M483
6 Move tilt control lever to the full back-

tilt relief position. Hold tilt lever in
relief position until pressure reading is
obtained, and then release.
IMPORTANT
THE PRESSURE GAUGE.
85M551
If relief pressure is not correct, refer
to the following adjustment procedure.
Relief Pressure Adjustment
1 On the main valve, the hydraulic system

relief valve (1) and auxiliary relief
valve ('2)adjustment screws are shown in
Figure 83M477.
83M477
Code: PMA-540, NOV 85 GROUP 30, Section i, Page 3

GROU CLqRYC
30
2 The relief-pressure adjustment screws are

located at the top front side of the main
hydraulic valve.
To adjust, loosen the lock nut, reset and

tighten lock nut. Turn adjustment screw
clockwise to increase pressure. Turn
counterclockwise to decrease pressure.
85M851
3 When either main hydraulic system or auxil-

iary relief pressure needs to be adjusted:
Step 1: Loosen the lock nut.
Step 2: Hold the respective (tilt or aux)

control lever in relief position.
85M489
Step 3: Turn the relief pressure adjustment

screw until pressure gauge reads the
correct relief pressure setting.
Step 4: Tighten the lock nut.
85M550
4 Check relief pressure setting. Move the

tilt lever to relief position and read
the pressure gauge. This is to verify
that relief pressure setting has not been
changed during tightening of the lock
nut.
85M551

CL!RK GROUP
30
5 If relief pressure setting is not correct,

repeat the adjustment procedure.
85M550
6 When relief pressure setting is correct,

turn key switch to "OFF" position and
disconnect the pressure gauge. Put the
cap on quick-disconnect fitting.
85M851
7 Install the cover enclosing the main valve.
85M617

Cl!!Wn; GROUP
30
GROUP
30
SECTION
9R
MAIN HYDRAULIC VALVE REMOVAL

o Park truck on a level surface and

o Return all controls to neutral and turn
o Block the wheels.
Truck Preparation
1 Open hood.
3 Remove battery from truck.
6 Adjust front battery plate for
maintenance access, as needed.

GROUP Cl!lRl4
30
85M482 85M849
1 Turn key switch "OFF". 5 Remove floorboard and cover

from main valve.
85M541 85M861
2 Open hood. 6 Loosen front battery plate for

3 Disconnect battery from truck adjustment, as needed. Refer
85M751 20921
4 Remove battery from truck. Refer 7 Put a drain pan under truck at
to GROUP 12, Section 1. main hydraulic valve position.
(Typical view)

CLqRU GROUP
30
13.114 SWITCH, LIFT VALVE PUMl'OPERATING

13.115 FASTENER, LIFT VALVE PUMP OPERATING SWITCH
13.150 SWITCH, TILT VALVE PUMP OPERATING
13.152 FASTENER, TILT VALVE PUMP OPERATING SWITCH
28.752 SEAL, HYDRAULIC LINES PRESSURE ‘BECK FTG PORT
28.829 SEAL, HYDRAULIC PRESSURE CHECK FTG DUST CAP

30.000 VALVE ASSEMBLY, HYDRAULIC
30.087 PIN, VALVE CONTROL LEVER PIVOT
30.088 RETAINER, VALVE CONTROL LEVER PIVOT PIN
30.089 LEVER, LIFT CONTROL
30.090 LEVER, TILT CONTROL

30.091 PIN, VALVE CONTROL LEVER TO SPOOL
30.094 KNOB, LIFT CONTROL LEVER
30.097 KNOB, TILT CONTROL LEVER
30.102 BRACKET, PUMP OPERATING SWITCH MOUNTING
30.146 BRACKET, VALVE CONTROL LEVER MOUNTING

30.148 FASTENER, VALVE CONTROL LEVER MOUNTING BRACKET
30.195 FASTENER, HYDRAULIC VALVE
30.945 LOCKOUT, VALVE LEVER
30.949 PIVOT, VALVE LEVER LCCKOUT
30.952 DUST CAP, HYDRAULIC LINES PRESSURE CHECK FTG

31.480 FITTING, HYDRAULIC LINES PRESSURE CHECK
37.114 FASTENER, VALVE LINKAGE ACCESS COVER
39.556 COVER, VALVE LINKAGE ACCESS
91.983 NUT, TILT VALVE PUMF OPERATING SWITCH FASTENER
92.558 NUT, LIFT VALVE PUMF OPERATING SWITCH FASTENER

92.781 NUT, VALVE LINKAGE ACCESS COVER FASTENER
93.391 FASTENER, VALVE CONTROL LEVER KNOB
93.392 NUT, VALVE CONTROL LEVER KNOB FASTENER
93.393 FASTENER, HYDRAULIC VALVE SWITCH BRACKET
93.610 RETAINER, VALVE LEVER LDCKOUT PIVOT

95.171 NUT, HYDRAULIC VALVE SWITCH BRACKET FASTENER
95.172 RETAINER, VALVE LINKAGE ACCESS COVER FASTENER
VALVE CONTROL LINKAGE

GROUP ClclRK
30
MAIN HYDRAULIC VALVE REMOVAL
1 Air clean the hydraulic valve and

fittings.
85M851
2 Disconnect (unplug) connector in wiring

harness to lift pump motor switches
attached to valve control lever mounting
bracket.
26595
Remove the main hydraulic and lift lines

from the valve. Put covers on the fittings
to keep them clean.
Refer to GROUP 31, Section 1, Page 3, for

additional information on main hydraulic
and lift lines.
Disconnect return-line to sump, from valve.
26596
Remove the hydraulic tilt lines from the

valve. Put covers on the fittings to
keep them clean.
Refer to GROUP 32, Section llR, Page 5,

for additional information on tilt lines.
26597

CLqRK GROUP
30
5 Loosen and remove the nuts from the two

mounting bolts at underside of plate and
remove valve lever top plate from the
main valve.
85M817
6 Remove spring clip retainer and remove

valve control lever pivot pin.
7 Remove valve levers by rotating forward

to disengage from valve spools.
Be careful not to lose the small pins

that connect the valve levers to the
valve spools.
26598
8 Remove fastener bolts and lift off the

valve control lever mounting bracket
assembly. (NOTE - This assembly
includes the valve lever lock
mechanism.)
26599
9 Loosen and remove the valve fastener bolts

from rear side of battery plate.
Remove valve assembly from the truck. e
26600

GROUP
30
MAIN HYDRAULICVALVE INSTALLATION
1 Installation is in reverse order of

removal.
2 Be sure to check for free movement of

the levers and linkages, and leaks
from all hydraulic fittings after
installation.
85M490
3 Connect the plug in wiring harness to s$lFT SWITCH

I
switches on control lever mounting
plate.
26595

CMRK GROUP
30
GROUP
30
SECTION
MAIN HYDRAULIC VALVE OVERHAUL
o Refer to Page 7 for Parts Illustration
o Refer to GROUP 31, Section 1, for Hydraulic System Schematic
l Refer to System Diagnostic Manual SDM-543, Hydraulic Sequence

of Operation and Troubleshooting Guide, for detailed informa-
tion on troubleshooting of the TM 15-17-20 36-volt hydraulic
system.

CLqRU
30
MAIN HYDRAULIC VALVE DISASSEMBLY:
1. Clean the outside of valve before starting

disassembly.
83M477
2. Position valve as shown and as you remove

each part, arrange it in a line exactly as
removed so reassembly will be easy. 3n the
top of each spool is a letter designation:
W = Lift Spool
A = Tilt Spool
D = Aux. Spool
Fig. 20430
3. Remove the retainer, sleeve and O-ring.

The torque for these bolts is [lo N'm]
88 lbf. in.
Fig. 20431
4. Tap li,ghtlyon the top of the valve spool

to drive it out of the valve body.
Fig. 20432

GROUP
ClRRn; 30
5. Arrange the parts in the order of removal.
Fig. 20433
_,I
,, >
“5” *m,,,z ‘gn-,’
6. Loosen and remove the bolts on the next \~‘

retainer.
Fig. 20434
7. Arrange the parts in the removal sequence.
Fig. 20435
8. Loosen and remove the bolts on the next

retainer.
Fig. 20436
Section 9, Page 3
Code: OH-510, FEB 84
GROUP
30
9. Arrange the parts in removal sequence.
Fig. 20437
10. Next remove the hydrostat. The torque on

this plug is [34 N.m] '25lbf. ft.
Fig. 20438
11. From left to right is the plug, O-ring,

spring, hydrostat and quad seal.
The flow control cartridge plugs

have left hand threads.
Fig. 20439
12. Both of these are flow control cartridges.

The torque is [34 N.m] 25 lbf. ft.
FOR TILT SPEED CONTROL, MAKE SURE THAT

YOU USE THE CORRECT FLOW CONTROL CARTRIDGE
FOR THE UPRIGHT HEIGHT INSTALLED ON THE
TRUCK. REFER TO UPRIGHT DECK NUMBER
STAMPED IN THE OUTER RAIL ASSEMBLY.
Fig. 20440

Cl!!lRK GROUP
30
13. Loosen the load drop check valve plug.
Plug Tightening Torque:

[34 Km] 2.5 lbf.ft.
14. Remove the load drop check valve plug,

spring, and poppet.
20442
15. To remove the adjustable pilot relief

valve parts, loosen the locknut (at
bottom) and then turn the adjustment
screw out of the valve body.
NOTE - The pressure relief setting

must be reset after reassembly and
installation in truck. Refer to
Page a.
20443
16. Then, remove the pilot relief valve

plunger, spring, and poppet.
NOTICE - Be sure that the relief

valve adjustor shims are saved and
correctly installed when valve is
reassembled. These shims must al-
ways be in place for correct
operation of the valve.
Code: OH-540, MAR 86 Section 9, Page 5

GROUP CLCfRW
30
CLEANING, INSPECTION AND REPAIR
1. Discard all old seals. Wash all parts in a clean mineral oil
solvent and place them on a clean surface for inspection.
2. Carefully remove burrs by light stoning or lapping. Be

sure there is no paint or burring on mating surfaces ???
valve bodies.
3. Inspect valve spools and bores for burrs and scoring. If

scoring is not deep enough to cause objectionable leakage,
the surfaces can be stoned or polished with crocus cloth.
If scoring is excessive, valve body and spool must be re-
placed. Check each valve spool for free movement in its
bore.
4. Check the relief valve for smooth, free movement in its bore.
The valve poppet should move easily from only the force of
its own weight.
MAIN HYDRAULIC VALVE ASSEMBLY
Assemble the valve in reverse order of disassembly.
Coat all parts with clean hydraulic oil to facilitate assembly

and provide initial lubrication. Petroleum jelly can be used
to hold seal rings in place during assembly.
Install seal rings and the seal ring retainer in the grooves
in body of each inlet and center section. Use petroleum jelly
to hold the seals in place. Carefully place the sections
together in the same order in which they were removed.
Section 9, Page 6 Code: OH-540, MAR 86

CLSRK GROUP
30
30.000 VALVEASSEMBLY,HYDRAULIC
30.001 FASTENER,HYD VAL SPOOLCENTERINGSPRINGCOVER
30.002 COVER,HYIIVALVESPOOLCENTERINGSPRING
30.006 SPRING,HYDRAULICVALVE SPOOLCENTERING
30.016 NUT, HYD VAL RELIEFVAL POPPETADJ SCREWLOCK
30.017 SCREW,HYD VALVERELIEFVALVEPOPPETADJUSTING
30.020 SPRING,HYDRAULICVALVERELIEFVALVEPOPPET
30.021 POPPET,HYDRAULICVALVERELIEFVALVE
30.032 SEAL KIT, HYDRAULICVALVE
30.055 PLUNGER,HYDRAULICVALVERELIEFVALVEPOPPET
30.063 PLUG,HYDRAULICVALVEPRESSUREPORT
30.101 RETAINER,RYD VALVE SPOOLCENTERINGSPRING
30.104 POPPET,HYDRAULICVALVE CHECKVALVE

30.105 SPRING,RYDIiAULIC CHECK VALVEPOPPET
VALVF,
30.106 PLUG,HYDRAULICVALVE CHECKVALVE
30.107 FASTENER,HXXAULIC VALVETRXU
30.113 POPPET,HYDRAULICVALVECHECKVALVE
30.114 SPRING,HYD VALVE CHECKVALVE POPPET

30.756 FLOW CONTROL,HYDRAULICVALVETILT SECTION
30.757 PLUG,HYDRAULICVALVE CHECKVALVE

30.758 BACK-UPRING,BYDVAL FLOW CONTRCARTRIDGESEAL
30.759 BACK-UPRING,HYDVAT,FLOW CONTRCARTRIDGESEAL
30.762 END COVER,HYDRAULICVALVE
30.923 SiiIH,
RYDRAULICVALVERELIEFVALVEADJUSTOR
93.387 WAXER, HYD VAL SPOOLCENTERINGSPRINGCOV FAS

25N SPOOL,HYDRAULICVALVE USE 30.000
26N BODY,HYDRAULICVALVE USE 30.000
HYDRAULIC VALVE 30-444

GROUP
30
HYDRAULIC VALVE RELIEF PRESSURE SETTING
When overhauling the main hydraulic valve,

the hydraulic system relief pressure setting
must be checked and reset after reassembly of
the valve and installation in the truck. Be
sure all hydraulic fittings have been tight-
ened correctly.
Install and tighten front battery plate.

Install and connect battery.
26601
Refer to GROUP 40, Section 5, for relief

pressure specifications. _
IMPORTANT
DO NOT EXCEED THE RELIEF PRESSURE

SETTING SPECIFIED FOR THE TRUCK
MODEL CAPACITY RATING. CHANGING
THE PRESSURE WILL NOT INCREASE
LIFTING CAPACITY OR LIFTING SPEED.
Hydraulic system relief pressure setting may

be checked with a MICO QUADRIGAGE (Clark
Part No. 1800106), or with a conventional
pressure gauge having a suitable pressure
range scale. A gauge with a pressure
range of [O-27,580 kPa] O-4000 psi min-
imum, is recommended.
11156
2 Remove the snap-on cap and connect the

pressure gauge to the check port fitting
on outside of main hydraulic control
valve.


GROUP
CUIRK
30

4 Move tilt control lever to the full back-
tilt relief position. Hold tilt lever in
relief position until pressure reading is
obtained, and then release.
IMPORTANT
THE PRESSURE GAUGE.
85M551
5 Adjust relief valve to the correct

pressure setting, as follows:
The relief-pressure adjustment screws are

located at the top front side of the main
hydraulic valve.
To adjust, loosen the lock nut, reset and

tighten lock nut. Turn adjustment screw
clockwise to increase pressure. Turn
counterclockwise to decrease pressure.
85M851
6 When either main hydraulic system or auxil-

iary relief pressure needs to be adjusted:
Step 1: Loosen the lock nut.
Step 2: Hold the respective (tilt or aux)

control lever in relief position.
85M489
Step 3: Turn the relief pressure adjustment

screw until pressure gauge reads the
correct relief pressure.
Step 4: Tighten the lock nut.
85M550

GROUP
30
7 Check relief pressure setting. Move the

tilt lever to relief position and read
the pressure gauge. This is to verify
that relief pressure setting has not
been changed during tightening of the
lock nut.
8 If relief pressure setting is not correct,

repeat the adjustment procedure.
85M551
9 When relief pressure setting is correct,

turn key switch to "OFF" position and
disconnect the pressure gauge. Put the
cap on quick-disconnect fitting.
85M851
10 Install the valve cover.
85M617

CLqRK GROUP
31
GROUP
31
SECTION
HYDRAULIC SYSTEM
SCHEMATIC DIAGRAM

HYDRAULIC SYSTEM SCHEMATIC DIAGRAM

TM 15-20 36-Volt
TILT
CYLINXR
SiEiQ
lCONTHOL M AIN VALVE
____--+__-___---_++__
T’
IVALVE
--
ILE!
TFER PUMP
-_
1
*I
--.I
I-----=
LIFT
PUMP
BREATHER ..
,‘t----
I I
SUMP TANK
-----_I
Oi q---
STD. TRUCK DIAGRAM
TWO SPOOL VALVE
IN-19169B

CbFlRK GROUP
31
TO UPRIGHT ONLY)
MAIN HYDRAULIC AND LIFT LINES

31-618
28.838 SEAL, HYDRAULIC VALVE LIFT FORT FITTING 31.036 FITTING, HYDRAULIC VALVE INLET PORT
31.006 LINE, HYDRAULIC PUMP INLET 31.037 FITTING, HYDRAULIC VALVE DISCHARGE PORT
31.007 LINE, PUMP INLET 31.038 SEAL, HYDRAULIC VALVE DISCHARGE FORT
31.008 FITTING, HYDRAULIC P'tJtQ

INLET PORT 31.109 LINE, HYDRAULIC VALVE DISCHARGE
31.010 SEAL, HYDRAULIC PIJMFINLET PORT 31.195 LINE, VALVE TO SUMP RETURN
31.013 SEAL, HYDRAULIC PUMP OUTLET PORT 31.200 FITTING, HYDRAULIC VALVE LIFT PORT
31.014 FITTING, HYDRAULIC PUMP OUTLET PORT 31.387 CLAMP, VALVE TO SUMP RETURN LINE
31.018 LINE, HYDRAULIC PUMP OUTLET 31.39s CAP, LIFT CYLINDER VENT SUMF INLET
31.023 SF&, HYDRAULIC VALVE INLET PORT 31.421 SEAL, PUMP OUTLET PORT FITTING
31.026 SEAL, HYDRAULIC VALVE LIFT FORT 31.627 SEAL, LIFT VALVE RETURN PORT
31.028 CLIP, VALVE OUTLET LINE SUPPORT 31.628 SEAL, LIFT VALVE INLET PORT
31.030 LINE, HYDRAULIC VALVE LIFT

GROUP
31
POWER STEERING LINES

26-144
26.652 FASTENER, POWER STEERING LINES CLAM' 31.150 FITTING, STEER VALVE DISCHARGE FORT
28.500 HOSE COUPLING, FILTER INLET LINE 31.164 LINE, STEER VALVE DISCHARGE
28.760 SEAL, STEER VALVE OUTLET PORT 31.373 SEAL, STEER PUMF OUl'LJiT
PORT
28.795 PROTECTOR, POWER STEERING LINES 31.399 SEAL, STEER VALVE DISCHARGE PORT
28.801 SEAL, HYDRAULIC PUHP OUTLET FORT FITTING 31.449 SEAL, STEER PLMP INLET PORT
28.839 SEAL. STEER CYLINDER ROD PORT FITTING 31.460 SEAL. POWER STEERING INLET PORT
28.840 SEAL, STEER ClLINDER ANCHOR PORT FITTING 31.461 SEAL, STEER VALVE DISCHARGE FORT
29.000 FILTER, HYDRAULIC OIL 31.462 SEAL, STEER VALVE OW!JLETPORT
29.002 FASTENER, HYDRAULIC OIL FILTER 31.465 SEAL, STEER VALVE OUTLET PORT
29.014 BRACKET. HYDRAULIC OIL FILTER HOUNTING 31.466 SWL, STEER VALVE INLET PORT
29.015 FASTENER. HYDRAULIC OIL FILTER MOUNTING BRA(
XET 31.479 CLAELP,POWER STEERING LINES
31.043 FITTING. IiYDRAULICOII;FILTER INLET PORT 31.499 FASTENER. POWER STEERING LINES CLMP
31.044 SEAL, HYDRAULIC OIL FILTER INLET PORT 31.606 LINE, STEER PUHF INLFl
31.047 SEAL, WDRAULIC OIL FILTER OUTLET PORT 31.664 LINE, STEERING CYLINDER ANCROR END
31.050 FITTING, RYDRAULIC OIL FILTER OUTLET FORT 31.666 FITTING, STEERING CYLINDER ANCHOR PORT
31.098 CLAMP. STEER PUMP INLET HOSE 31.667 SEAL, STEERING CYLINDER ANCHOR PORT
31.100 LINE, STEER PUMP INLET 31.668 LINE, STEERING CYLINDER ROD END
31.102 FITTING, STEER PUHF INLET PORT 31.669 FITTING, STEERING CYLINDER ROD PORT
31.104 FITTING, STEER PuElpOUTLET FORT 31.670 SEAL, STEERING CYLINDER RDD FORT
31.115 LINE, STEER PUW OUTLET 31.749 CLAMP, POWEZRSTEERING LINES
31.120 LINE, SUMP RETURN 31.793 CLAM, WWER STRERING LINES
31.122 HOSE COUPLING, POWER STEERING RETURN LINE 31.885 HOSE COUPLING. STEER PLMP RETURN
31.138 FITTING, STEER VALVE OUTLET PORT 90.764 NUT, WVER STEERING LINE CLAMP FASTENER
31.139 FITTING, STEER VALVE OUTLET PORT 93.275 NUT, RYDRAULIC OIL FILTER HOUNTING BRRCKET FAST
31.107 LINE, STEER PUMP INLET 93.276 NUT, HYDRAULIC OIL FILTER FASTENER
31.149 FITTING, STEER VALVE INLET PORT 93.277 NUT, POWER STEERING LINES CLIP FASTENER

CMRK GROUP
32
GROUP
32
SECTION
1
TILT CYLINDER ADJUSTMENT
Code: PMA-500, FEB 80 Section 1, Page 1

TIL,T CYLINDER RACKING ADJUSTMENT:
1. Check condition of the tilt cylinder,

rod end, mounting pins, piston rod, rod
wiper, cylinder gland, etc., for excessive
wear or damage. Make repairs before
making racking adjustment.
Fig. 20280
2. With a capacity load (raised only high

enough to clear the floor) slowly tilt
upright fully forward, watching both piston
rods for equal movement and upright for
racking. Forward racking must be adjusted
before backward racking. If forward
adjustment is not needed, continue with
Step 5.
Fig. 19495
3. Loosen rod end clamp bolt, on the tilt

cylinder, that extends the farthest,
and turn piston rod.
4. Continue to turn rod into rod end until

upright racking is corrected. Tighten
rod end clamp bolt.
5. Slowly tilt upright fully backwards while Fig. 19496

watching piston rods. They should both
bottom out at the same time. If they
don't, adjust backward tilt as follows.
6. Stop the upright when the first tilt

cylinder bottoms out against its rod
spacer. Use rod shims to fill in the
space between the rod end and spacer on
the other tilt cylinder.
7. After the excess space is taken up by the

'adjusting shims, test the full forward and
backward tilt for proper adjustment. Fig. 19497
Section 1, Page 2 Code: PMA-500, AUG 80 REV

GROUP
eLfIRK 32
GROUP
32
SECTION
2
TILT CYLINDER DRIFT TEST
Section 2, Page 1
E'MA-510,DEC 80
GROUP
32
UPRIGHT TILT CYLINDER DRIFT TEST
To check for drift, a TEST LOAD should be made and

the TEST LOAD should be equally distributed on a
48" by 48" pallet. The TEST LOAD should be a full
rated capacity load. Refer to the Serial Number
Plate on your truck for capacity rating.
The TEST LOAD must be secure on the pallet. The

material used to make up the TEST LOAD must be
arranged (stacked) to provide load stability and
the TEST LOAD must not extend beyond the pallet.
First, make a TEST LOAD as stated above, then

position the load on forks.
1. Adjust fork width to maximum which will

accomodate TEST LOAD. Space forks as wide
as possible to provide even distribution
of weight.
2. Keep forks level during pick up.
3. Enter pallet and TEST LOAD as far as possible.

TEST LOAD and/or pallet should be in contact
with 1 oad back rest.
4. Raise carriage and TEST LOAD approximately

[305-381 mm] 12-15 inches off the floor.
Tilt the upright to full back position.
Shut off the truck. Turn key switch to
"Off" position.
5. Measure and mark the initial position

of the tilt cylinder rod (see Fig. 14886).
An alternate procedure is to measure the
change in the inclined angle of the upright,
using a protractor and level, or inclinometer. Fig. 14886
6. Let upright with test load stand for the

specified test time. Mark the new position
of the tilt cylinder rod or upright. Measure
the change in dimension or angle from the
initial reference mark.
7. Refer to GROUP 40, Section 5 for tilt

cylinder drift specifications.

CUIRK GROUP
32
GROUP
32
SECTION
11R
TILT CYLINDER REMOVAL


Apply the parking brake. ,^ \\,
Block the wheels.
85M626
Truck Preparation
NOTE - Front battery plate may also

be adjusted for easier maintenance
access. Refer to GROUP 38, Section 2.
85M506
Code: OH-540, MAR 86 GROUP 32, Section llR, Page 1

32.034
,/’
n 32.000 7
n INDICATES AN ASSEMBLY 34091 --J 32.053 --!

HAVING SERVICEABLE
COMPONENlS ILLUSTRATED 34.090
ELSEWHERE.
TILT CYLINDER MOUNTING
32.000 CYLiNDER ASSEMBLY, TILT

32.014 SPACER, TILT CYLINDER FRONT
32.027 ROD END, TILT CYLINDER
32.029 FASTENER, TILT CYLINDER ROD END CLAMP
32.032 LUB FITTING, TILT CYLINDER ROD END
32.033 PIN, TILT CYLINDER TO FRAME

32.034 RETAINER, TILT CYLINDER TO FRAME PIN
32.035 LUB FITTING, TILT CYLINDER ANCHOR END PIN
32.043 BEARING, TILT CYLINDER FRAME MOUNTING
32.053 BEARING, TILT CYLINDER ROD END
32.102 SHIM, TILT CYLINDER STROKE ADJUSTING

34.090 RETAINER, TILT CYLINDER TO UPRIGHT
34.091 FASTENER, TILT CYLINDER TO UPRIGHT RETAINER
90.438 NUT, TILT CYLINDER ROD END FASTENER
GROUP 32, Section 11 R, Page 2 Code: SM555, MAR89

Cl!lRK GROUP
32
TILT CYLINDER REMOVAL
1 Be sure to secure and support the upright

from falling before removing the tilt
cylinders.
ATTACH A CHAIN OR SLING TO THE UPRIGHT

AND A HOIST AS SHOWN BEFORE REMOVING ANY
TILT CYLINDER ATTACHMENT PARTS.
85M893
Refer to GROUP 34, Section 9R, Upright

Removal, for additional information.
85M624
2 Loosen and remove each,tilt cylinder rod

end to upright retainer fastener bolt
and washer.

[ZO-25 N.m] 177-221 lbf.in.
26573
3 Remove each tilt cylinder rod end by pull-

ing it off the upright attachment pin.
17066

GROUP ELRRK
32
4 Under the floorboard, at the anchor end of

each tilt cylinder, remove both spring clip
retainers from ends of mounting pin.
85M622
5 Drive the mounting pin from tilt cylinder

end and frame brackets.
26577
NOTE - Put a drain pan under the truck at

each tilt cylinder position when removing
hydraulic lines.
6 Disconnect the hydraulic lines from the

tilt cylinder fittings.
(RH tilt cylinder shown)
Refer to illustration, Page 5.
26578
1)1
7 Remove each tilt cylinder from the truck.
TILT CYLINDERINSTALLATION
1 Install each tilt cylinder by reversing

above removal procedures.
26571
GROUP 32, Section llR, Page 4 Code: OH-540, MAR 86

CLqRK GROUP
32
HYDRAULIC TILT LINES

31-560
28.830 SEAL, RR TILT CYLINDER ANCHOR PORT FITTING 31.152 SEAL, HYDRAULIC VALVE TILT PORT "A"
28.831 SEAL, RH TILT CYLINDER ROD PORT FITTING 31.156 LINE, TILT CYLINDER CROSS
28.832 SEAL, TILT CYLINDER ANCHOR PORT LINE FITTING 31.160 FITTING, LH TILT CYLINDER ANCHOR FORT
28.833 SEAL, RR TILT CYLINDER ROD PORT FITTING 31.162 FITTING, RH TILT CYLINDER ANCHOR PORT
28.834 SF&L, LH TILT FYLINDER ANCHOR PORT FITTING 31.175 LINE, VALVE TILT FORT "B"
28.835 SEAL, LH TILT CYLINDER ROD PORT FITTING 31.182 LINE, VALVE TILT FORT "A"
28.836 SEAL, TILT CYLINDER ROD PORT LINE FITTING 31.364 SEAL, LH TILT CYLINDER ROD PORT
28.837 SEAL, TILT CYLINDER ROD PORT LINE FITTING 31.365 SEAL, RH TILT CYLINDER ROD PORT
30.563 SEAL, VALVE FORT "A" FITTING 31.366 SEAL, LH TILT CYLINDER ANCHOR PORT
30.565 SEAL, VALVE PORT "B" FITTING 31.367 SEAL, RH TILT CYLINDER ANCHOR PORT
31.061 FITTING, HYDRAULIC VALVE TILT PORT "A" 31.370 FITTING, TILT CYLINDER ROD PORT LINE
31.062 FITTING, HYDRAULIC VALVE TILT PORT "B" 31.372 FITTING, TILT CYLINDER ANCHOR PORT LINE
31.065 SEAL, HYDRAULIC VALVE TILT PORT "B" 31.442 STRAF, TILT LINE
^. ^_^
3l.UI1) LINE, TILT CYLINDER ROD PORT 31.600 FITTING, RH 'TILTCYLINDER ROD PORT
31.077 FITTING, LH TILT CYLINDER ROD PORT

TILT CYLINDER ROD END REMOVAL
1. Fully loosen the tilt cylinder rod end clamp

bolt and nut.
2. Remove the rod end from the tilt cylinder rod.

Note the number of turns required for removal.
This will aid initial setting at installation. Keep
the tilt cylinder rod from turnning with a wrench
on the flat portion of the rod at the end of the
threads.
3. Remove shim(s) and spacer (if used) from tilt

cylinder rod. Note location and number of shims
removed. This will aid initial setting at
installation.
TILT CYLINDER ROD END INSTALLATION
Install each tilt cylinder rod end by reversing the

above procedures.
GROUP 32, Section 11 R, Page 6 Code: SM555, MAR 89

GROUP
CL!!lRK 32
GROUP
32
SECTION
11
TILT CYLINDER OVERHAUL

GROUP ELFIRK
32
L- 32.024
TI’LT CYLINDER 32-020
32.000 TILT CYLINDER ASSEMBLY
32.002 BARREL, TILT CYLINDER
32.005 SEAL, TILT CYLINDER PISTON
32.006 RING, TILT CYLINDER PISTON BACK-UP
32.015 SEAL, TILT CYLINDER GLAND
32.017 GLAND, TILT CYLINDER
32.019 PACKING, TILT CYLINDER GLAND
32.023 WIPER, TILT CYLINDER PISTON ROD
32.024 NUT, TILT CYLINDER GLANl?
32.036 ROD & PISTON, TILT CYLINDER
32.072 PACKING KIT, TILT CYLINDER
32.105 PLUG, TILT CYLINDER PORT FITTING
32.106 SEAL, TILT CYLINDER PORT FITTING PLUG

CEIRU GROUP
32
TILT CYLINDEROVERHAUL
Tilt Cylinder Cross-Section 26633
The tilt cylinder assembly can be held by clamping the base end or
the barrel in a vise while disassembling.
Be careful not to use excessive force
when clamping on the barrel.
1 Loosen and remove the g and nut. Use a

spanner wrench.
I I
26634
2 Remove the gland and sea assembly from

tilt cylinder barrel.
NOTE - It is optional to remove the gland

assembly by pulling the tilt cylinder rod
and piston out, thus also pulling the
gland out when the piston is removed from
the barrel. See Step 3, Page 4.
26635

GROUP
CMRK
32
3 Pull the tilt cylinder rod and piston

assembly from the barrel.
26636
4 Remove both sets of piston seals and

back-up rings. Discard old seals.
Install new seals and back-up rings.
26637
5 Remove the tilt cylinder gland seal,

gland packing and piston rod wiper.
Discard old seals.
Install new gland seal, packing and

rod wiper.
26638
6 Inspect the tilt cylinder barrel internal

bore for wear, scratches or other damage.
Check the outside for damage. Inspect
all welds for cracks. Check the gland
nut and base end and ports for cracks or
damage that could cause failure or leaks.
26639

ClLclRK GROUP
32
TILT CYLINDERREASSEMBLY
Reassemble cylinder carefully to prevent

damage to seal lips and O-rings. Seals IMPORTANT
may be lubricated with hydraulic oil to
assist assembly into cylinder barrel. Be sure inside of cylinder
and all parts are clean
before assembly is started.
1 Install cylinder gland on piston rod.

Use gentle pressure and careful movements
to avoid damage to the gland packing
and rod wiper when these parts are
moved over the piston rod end.
26659
2 Install piston into cylinder barrel. Be

careful not to damage the piston seals
when installing the piston into end of
cylinder.
3 Then, install gland into cylinder. Be

careful not to damage gland seal.
26660
4 Install and tighten the gland nut.
Tightening Torque:
[67-81 N.m] 50-60 lbf.ft.
26661

GROUP
Cl!!L!RH 34
GROUP
34
SECTION
UPRIGHT LIFT CHAIN
CHECK & ADJUSTMENT PROCEDURE
PMA-510, DEC 80 Section 1, Page 1

GROU
34
LIFT CHAIN CHECK AND ADJUSTMENT PROCEDURE
The lift chains are mounted to the chain anchors

on the lift carriage and at the chain anchor
rods near the lift cylinder piston head.
If it becomes necessary to adjust the lift

chains, proceed as follows:
WARNING
---__--
TO AVOID INJURY, DO NOT GET UNDER

THE LOAD AND CARRIAGE WHEN CHECKING
THE CHAINS OR MAKING ADJUSTMENTS.
1. Elevate carriage to about [1219 mm]

4 feet.
2. Apply grease to the innerslide channel

as shown in Fig. 8622.
Fig. 6634
3. Make sure upright is either vertical or
slightly aft of vertical.
4. Pick up a capacity load. Then, lower load

to the fully-down position.
NOTE
It is important that the chain adjust-
ment check be made with a capacity load
to allow for chain stretch.
5. Remove capacity load.
6. Raise carriage and measure the distance

from where the center of the BOTTOM
CARRIAGE ROLLER stopped to the edge
of the inner slide. Distance must not
be less than C12.7 mm] 0.50 inch.
Adjust lift chains as necessary.
7. Be sure to wipe grease from rail.
8. As a check procedure it may also be noted

that upright lift carriage chains should be
adjusted so that bottoms of forks are [12.1 mm]
0.50 inch above the floor with the upright Fig. 8622
vertical.
Section 1, Page 2 PMA-510, REV FEB 84

Cl!!RK GROUP
34
GROUP
34
SECTION
3
UPRIGHT DOWNDRIFT TEST
PMA-510, DEC 80
Section 3, Page 1
GROUP Cli!!WK
34
UPRIGHT DOWNDRIFT TEST
To check for drift, a TEST LOAD should be made and

the TEST LOAD should be equally distributed on a
48" by 48" pallet. The TEST LOAD should be a full
rated capacity load. Refer to the Serial Number
Plate on your truck for capacity rating.
The TEST LOAD must be secure on the pallet. The

material used to make up the TEST LOAD must be
arranged (stacked) to provide load stability and
the TEST LOAD must not extend beyond the pallet.
First, make a TEST LOAD as stated above, then

position the load on forks.
1. Adjust fork width to maximum which will

accomodate TEST LOAD. Space forks as wide
as possible to provide even distribution
of weight.
2. Keep forks level during pick up.
3. Enter pallet and TEST LOAD as far as possible.

TEST LOAD and/or pallet should be in contact
1
with load back rest.
4. Raise carriage and TEST LOAD approximately CAPACITY

[305-381 mm] 12 - 15 inches off the floor. LOAD
\
Tilt upright slightly backward
(approximately 1 de;;;; fY~t;;r;~;;:)
at the same time. .
Turn key switch to the "OFF" position.
5. Stand at one side of the upright, not under

the load, and mark all upright rails with a
pencil.
Fig. 14887
6. Let the upright hold the test load in the
raised position for the specified test time.
Then check the movement of the reference mark.
Make new mark on movable rail in line with
original mark on fixed rail. Measure distance
between marks on rails and make a record of
this dimension.
7. Refer to GROUP 40, Section 5 for upright

downdrift specifications.

CMRK GROUP
34
GROUP
34
SECTION
4
FORK MAINTENANCE
FORKS ARE AN IMPORTANT SAFETY ELEMENT OF

THE LIFT TRUCK. THEY MUST BE CAREFULLY
INSPECTED AT EACH PM INTERVAL AND ALWAYS
MAINTAINED IN A SAFE CONDITION.
FORKS THAT ARE BENT OR TWISTED WILL CAUSE

THE LOAD TO SHIFT OR SLIDE OFF AND BE DROPPED.
FORKS THAT ARE CRACKED OR WORN EXCESSIVELY
CAN BREAK SUDDENLY AND CAUSE SEVERE INJURY
OR DEATH.

GROUP
34
FORK MAINTENANCE
1 Inspect the lift forks for cracks, breaks

bending, and wear. Check for cracks and
wear all around the fork heel area.
Move the fork blades together (side-by-

side). Check the fork blades for bent
or twisted condition, with respect to
each other and also to the fork shank.
18046
2 The fork surfaces should be level and

even with each other. The height differ-
ence between both fork tips should be
no more than [6mm] 0.25 inch maximum.
25455
3 Inspect the forks carefully for twists

and bends. Put a Z"x4"x24" metal block
on the blade of the fork with the 4" sur-
face against the blade. Put a carpenter's
square on the top of the block and against
the shank of the fork. Check the fork
18" above the blade to be sure it is not
bent more than specified in the chart lade
below.
25456
Fork Bl ade Bending Chart
Fork Size Allowable "Y' value (inches) for fork blade lengths
Cross-section 42" blade 1 48" blade 1 54" blade 1 60" blade

GROUP
ClclRK 34
FORK WEAR INSPECTION
NOTICE - At each planned maintenance interval, an inspection and

measurement of the forks must be made to check for wear.
REFER TO FIGURE 25457 BELOW.
lO%of"A"max.wear
25457
1 Allowable wear of fork thickness at the heel of the fork is as follows:
10% WEAR (90% thickness remaining): Forks must be scheduled for replacement.
With 10% wear, the forks are adequate for only 80% of rated capacity. Forks
may by used only until replacements are available.
20% WEAR (80% thickness remaining): Forks are unsafe and must be removed
from service immediately.
WEAR FACTOR CHART
* NEW * ** REPLACE ** *** SAFETY HAZARD ***

Standard Fork Nominal 10% Wear Nominal 20% Wear
Thickness, inches Thickness, inches Thickness, inches
1.25 1.12 1.00

1.50 1.38 1.19
1.75 1.56 1.38
2.00 1.81 1.62
2.25 2.00 1.81
2.50 2.25 2.00
NOTE - The percent capacity reductions are based upon wear only.
Other factors such as cracks, cuts, holes, etc., may further
reduce fork capacity.

ELqRK
GR30b
GROUP
34
SECTION
7
LIFT CHAIN MAINTENANCE
Code: PMA-416. REV MAR 82 P.S.L. Section 7, Page 1

CONTENTS:
I. LIFT CHAIN INSPECTION

11. LIFT CHAIN LUBRICATION
III. LIFT CHAIN REPLACEMENT
IV. CHECK LIST
FOREWORD:
Lift chains are very important components on fork lift

trucks. The chain system on your upright was designed
for efficient, reliable transmission of lifting force
from hydraulic cylinder to the forks. Safe use of your
lift truck with little down-time, 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 main-
tenance to give maximum service life.
Section 7, Page 2 Code: PMA-416, REV MAR 82 P.S.L.

CLqRK GROUP
34
I. LIFT CHAIN INSPECTION:
Inspect and lubricate the lift chains

every truck PM (So-250 hours). See
Section II for lubrication details.
When operating in corrosive environ-
ments, inspect the chains every 50
hours.
The maintenance person doing the

inspection should look for the
following chain conditions.
1. Wear
As the chain rolls on and off the
sheaves, the joints wear very slowly.
This increased length that occurs in a
chain in service is caused by material
being worn off the bearing joints.
Chain wear can be measured by using a

steel tape (Fig. 23832). When chains
have worn 3%, they must be discarded.
For example, [305 mm] one foot of BL634
chain contains 16 pitches (links).
0
When 16 pitches measure [314,6 mm] Fig. 23830
12.375 inches, the chains must be
replaced. When checking chain wear, A. Leaf Chain
make sure you measure a segment of 1. Inner Linkplate
chain that moves over a sheave. Do not Outer Linkplate
repair chains by cutting out the worn :* Riveted Pin
section and joining a new piece. If 8. Roller Chain
part of a chain is worn, replace all 4. Riveted Pin
the chains on the truck. Roller
Z: Bushing
2. Rust and Corrosion 7. Pin
Corrosion will reduce the load carrying 8. Inner Linkplate
capacity of lift chain because corro- 9. Outer Linkplate
sion causes sideplate cracking. It is C. Rollerless Chain
very important to protect lift chains 10. Riveted Pin
from corrosion whether in service or in 11. Bushing
storage. The factory lubrication on 12. Pin
chains is a very good rust and corro- 13. Inner Linkplate
sion inhibitor. The factory lubrication 14. Outer Linkplate
is applied in a hot dip tank to make
sure there is complete penetration into lubricant and corrosion inhibitor.
the joint. After the chain has been
put in service, there must be addi- During inspection, check for a layer of
tional lubrication so there is a layer oil on the external chain surfaces.
of oil on the chains at all times. Under some operating conditions it will
Heavy motor oil is used both as a be necessary to lubricate chains
between P.M.'s.
Code: PFIA-416,REV FEB 84 P.S.L. Section 7, Page 3

GROUP CLqRH
34
In all instances, the external surface

of the chain must be protected with a
Layer of oil. Chains with corrosion
must be inspected for cracked plates.
Outside plates are especially suscepti-
ble to stress-corrosion cracking. If
chains have heavy rust or corrosion
they must be removed from the upright
for a complete inspection for cracked
plates. If the plates are cracked,
all chains on the truck must be
replaced. Lubricate chains when they
are installed on the upright.
3. Cracked Plates Fig. 18376

The most common cause of plate cracking
is fatigue failure. Fatigue affects Typical examples of stress-corrosion
most metals and many plastics. After cracks on the lift chain. Similar
many repeated heavy loads the plates cracks are sometimes caused by:
will crack and the chains will break. 1. Sub-zero applications
Fatigue cracks are almost always found 2. Applications where acid vapors
through the pitch holes, perpendicular are present.
to the pitch line. Compare this fail- 3. Applications where corrosion is
ure to the failures caused by stress- present.
corrosion cracking. (See Fig. 18376).
Cracked plates can also be found where

chains are subjected to:
1. Chemical vapors
2. Sub-zero temperatures
If cracks are found, replace all chains

on the truck. Many plates that appear
good may be ready to crack, making
chain failure very likely.
4. Strength Failure
This type of failure is caused by over-
Loads that far exceed the truck design.
Chains subjected to such loading must
be replaced. _-
Do not try to repair
them.
Cracked plates resulting from
5. Tight Joints fatigue failure
All Lift chain joints must flex freely. Fig. 18377
Tight joints resist flexing and
increases internal.friction, which
increases chain tension needed to lift
a given load. Increased tension
accelerates wear and fatigue problems.
Section 7, Page 4 Code: PMA-415, REV NAR 82 P.S.L.

ELqRH
GR304u
In roller or rollerless chains, tight
joints are caused by rust or inside
plates moving outward on the bushing.
Loosen chains with rust by lubricating
heavily.
If tight joints, due to plate "walking"

are found, it is recommended that
chains be replaced, not repaired. This
type of link plate displacement is
accelerated by poor lubrication. Most
roller and rollerless chains with tight
joints have been found to have operated
with little or no lubrication. Broken plate caused by overload.
Fig. 18378
Tight joints in lift chains can be
caused by:
1. Bent pins or plates
2. Rust in the joints
3. Peened plate edges
Lubricate chains that have rust, and

replace chains with bent or peened
components. Peening of plate edges may
be caused by worn sheaves, very heavy
loads, or the chains sliding past a
guide on the upright. Such conditions
must be corrected to prevent damage to
replacement chains, also.
6. Raised or Turned Pins

Heavily loaded chains operating with
little-lubrication generate friction
between pin and plates (pin and bushing Example of how tight joints prevent
in roller and rollerless chain). In flexing of rollerless chain.
some instances, the torque created in Fig. 18379
the joint can turn pins in the outside
plates.
If chain is permitted to operate in

this condition, the pins slowly work
out of the chain, causing chain
failure. Turned pins can be easily
seen because the flats on the "V" heads
are no longer aligned. See Fig. 23831.
Chains with turned or raised pins must
be replaced immediately. --
Do not repair
cc0 8 0 8 0 0 CD
the chain by pushing pins back into the

chain.
J
Fig. 23831
Code: PMA.-416,REV MAR 82 P.S.L. Section 7, Page 5

GROUP
34
7. Chain Side Wear

A wear pattern on the pin heads and
outside plates indicates poor align-
ment. This condition damages chain
and sheaves, as well as increasing
internal friction in the chain system.
8. Chain Anchors and Sheaves

Check chain anchors for wear, damage,
and alignment that is not correct.
Anchors with worn or broken fingers
must be replaced. Anchors must be
adjusted to remove twisting or poor
alignment in the chain. When chain is
poorly aligned, the load is not
balanced among the plates. Long
periods of operation will result in Bent or peened plates on lift chain can
fatigue failure. cause tight joints and prevent flexing
Fig. 18380
Sheaves with badly worn flanges and
outside diameter must be replaced.
Heavy wear on the flanges indicates
poor alignment of the chains.
II. LIFT CHAIN LUBRICATION:
The most important consideration in

field maintenance of lift chains is
lubrication. Hard working, heavily
loaded chains cannot give acceptable
wear life without periodic lubrication.
As with all bearing surfaces, the
joint-wearing surfaces need a layer of
oil between mating parts to prevent
wear.
Raised pins caused by heavy loading of
Keeping a layer of oil on all chain chain without enough lubrication.
surfaces will: Fig. 18381
1. Keep joint wear (chain wear) to a
minimum
2. Prevent or reduce the rate of
corrosion (see Section 1)
3. Reduce the chance of pin turning
4. Keep tight joints in roller and
rollerless chains to a minimum
number
5. Help give smooth, quiet chain
action
6. Lower the chain tension by reducing
internal friction in the chain
Section 7, Page 6 Code: PPMA-416,REV MAR 82 P.S.L.

CL!!RK ijROUi
34
Use Clark Chain and Cable Lube 8886399 Ij
for lubrication of chains. Heavy motor LUBR!CANT

oil is also a very good lubricant.
Whatever method is used, the lubricant
must penetrate into the chain joint to
prevent wear. Applying lubricant to
external surfaces will prevent rust,
but the lubricant must flow into the
bearing surfaces for maximum chain
life.
The frequency of lubrication will

change with the operating conditions
and the environment. The best lubri-
cation time is during each P.M.
(50-250 hours or four weeks maximum Section view of roller chain showing
actual truck operating time). Trucks path of lubrication to bearing surface
that are parked outdoors, or in very (area between O.D. of pin and I.D. of
severe service, may need lubrication bushing).
more often to keep a layer of oil on Fig. 18383
all chain surfaces.
In dirty operating conditions, lubri-

cated chain will gather dirt. Even
under these conditions chain life will
be increased by periodic lubrication.
Joints get a "paste" of oil and dirt,
but joint wear will still be much less
than if the chain is permitted to oper-
ate dry with metal-to-metal contact
between pins and plates (pin and
bushing in roller chain).
In dirty operating conditions, leaf

chain can be more easily lubricated
than roller and rollerless chain.
The plates in leaf chain gives more
paths for the lubricant to reach the Section view of leaf chain showing
pin (See Fig. 18384). At every P.M., bearing surface (area between O.D.
or four week intervals, clean the of pin and I.D. of plate holes).
chains in kerosene or mineral spirits Fig. 18384
to remove dirt. Lubricate immediately
after the chain is dry. Steam cleaning
is not recommended because some
cleaning solutions contain chemicals
which can cause linkplates to crack.
Code: PMA-416, REV MAR 82 P.S.L. Section 7, Page 7

III. LIFT CHAIN REPLACEMENT: Use new anchor pins when installing new
chains. Old pins may contain fatigue
Find the manufacturer's stamped number cracks that could cause failure. After
on the links of the chain. Your Clark the chains have been connected to the
Dealer will need this number to make anchors, adjust the chain tension.
sure you are getting the correct chain
for your truck. Leaf chain is avail- Correct chain installation and upright
able in lengths up to [7,62 m] 25 ft. adjustment will increase chain service
Short sections of leaf chain must never life.
be jloined together to form a longer
length. Roller and rollerless chain is
available in [3,05 mm] 10 ft. sections. CHECK LIST
Never join new chain sections to old LIFT CHAIN MAINTENANCE
chain sections.
A. LIFT CHAIN INSPECTION:
Lift chains must always be replaced as Every truck PM (So-250 hours) check
pairs. It is impossible to keep a for:
balanced load between chains if a new 1. Cracked Plates
chain is put into service opposite an 2. Rust and Corrosion
old chain. The joints in the old chain 3. Turned Pins
may have worn through the hardest layer 4. Tight Joints
of the case-hardened pins, and the old 5. Wear - measure portion of chain
chain will wear much faster than the that flexes over sheaves using
new chain, causing problems keeping a steel tape.
chain tension equal. Also, the new
chain will wear more slowly, causing B. LIFT CHAIN LUBRICATION:
it to hold most of the load, resulting Every truck PM (So-250 hours) 50
in early wear and failure. hrs. in corrosive environment
1. Apply Clark Chain and Cable
Do not remove the lubricant from new Lube f886399
chains. The manufacturer's lubricant 2. Lubricate full length of all
helps prevent wear and corrosion. If strands.
the original factory lubrication has
dried or been removed, apply Clark C. LIFT CHAIN REPLACEMENT:
Chain and Cable Lube t886399. 1. All chains must be replaced if
any strand has wear of 3% or
After the old chains have been removed more or if any of the condi-
from the upright, very carefully tions listed in Section I are
inspect the chain anchors and sheaves. found during inspection.
Broken, cracked, or worn anchors must 2. Order replacement chains from
be replaced. Replace worn sheaves, your Clark Dealer.
and check the sheave bearings for wear. 3. Replace all chains as a set.
4. Do not remove lubricant or
Do not paint new chain before or after paint new chains.
installation. Paint will help prevent 5. Replace anchor pins and worn or
corrosion, but will also prevent lubri- broken anchors when installing
cant from reaching the pin surface for new chains.
good joint lubrication. 6. Adjust tension on new chains.
Section 7, Page 8 Code: PXA-416, REV MAR 82 P.S.L.

CL!‘RK GR&uP
ROLLER AND ROLLERLESS CHAIN
Rollerless Roller
Chain No. Chain No. Pitch Span Worn Chain Length
40 45 [12,70 mm] 0.500 inch 25 [314,32 mm] 12.375 inch

50 55 [15,87 mm] 0.625 inch 21 [327,02 mm] 12.875 inch
60 65 [19,05 mm] 0.750 inch 17 [314,32 mm] 12.375 inch
80 85 [25,40 mm] 1.000 inch 13 [314,32 mm] 12.375 inch
100 105 [31,75 mm] 1.250 inch 11 [327,02 mm] 12.875 inch
120 125 [38,10 mm] 1.500 inch 9 [314,32 mm] 12.375 inch
140 145 [44,45 mm] 1.750 inch 8 [320,67 mm] 12.625 inch
160 165 [50,80 mm] 2,000 inch 7 [314,3% mm] 12.375 inch
200 205 [63,50 mm] 2.500 inch 6 [327,02 mm] 12.""5 inch
LEAF CHAIN
Chain No. Pitch Span Worn Chain Length
BL400 [12,70 mm] 0.500 inch 25 [314,32 mm] 12.375 inch

BL500 [15,87 mm] 0.625 inch 21 [327,02 mm] 12.875 inch
BL600 [19,05 mm] 0.750 inch 17 [314,32 mm] 12.375 inch
BL800 [25,40 mm] 1.000 inch 13 [314,32 mm] 12.375 inch
BLlOOO [31,75 mm] 1.250 inch 11 [327,02 mm] 12.875 inch
BL1200 [38,10 mm] 1.500 inch 9 [314,32 mm] 12.375 inch
BL1400 [44,45 mm] 1._750inch 8 [320,67 mm] 12.625 inch
BL1600 [50,80 mm] 2.000 inch 7 [314,32 mm] 12.375 inch
PITCH - The distance from the center of

one pin to the center of the next pin.
SPAN - The number of pins in the length

of chain to be measured.
WORN CHAIN LENGTH - The distance from

the first pin counted to the last pin
counted in a span while the chains have
lifted a small load.
Code: PMA-416, REV MAR 82 P.S.L. Section 7, Page 9

MRK
GR304UP
PROCEDURE TO CHECK FOR CHAIN WEAR: EXAMPLE OF THE CHECK FOR CHAIN WEAR:
(See Page 11, also)
A mechanic measures from the center of
1‘ Find the pitch of the chain. one pin to the center of the next pin
a. Measure from the center of one and finds the PITCH of the chain to be
chain pin to the center of the [25,40 mm] 1 inch. After looking at
next chain pin. the chain charts, he must align the end
2. Locate the specifications (Page 9). of the steel tape with the center of
a. Locate the pitch of the chain. one pin, and counting to the thirteenth
b. Find the number of pins to be pin (counting the pin he started with
counted (span). as number one) measures the length to
c. Find the maximum worn length of the center of the thirteenth pin and
a selected span. finds it to be [316,0 mm] 12.437 inch.
3. Select an area of chain to be Again, looking at the chart, he finds
measured. the maximum worn length to be [314,32 mm]
a. Use a section of chain which 12.375 inch. From this he decides that
moves over sheaves. both chains on this truck must be
b. Lift a small load. replaced.
C. Count the number of pins needed
for a length measurement.
4. Measure the chain.
a. Use a steel tape to measure
from the first pin counted to
the last pin counted.
b. The length measurement must be
more than the actual span of
the chain section being
measured.
c. Any chain span which is worn to
the length measurement or
beyond must be replaced.
Section 7, Page 10 Code: PMA-416, REV MAR 82 P.S.L.

GROUP
CL!RIlC
Measuring BL846 chain for wear, using tape measure

Fig. 23832
1. New Chain Length 3. Span

2. Worn Chain Length 4. Pitch
Code: PM&416, REV MAR 82 P.S.L. Section 7, Page 11

GROUP
CMRK
34
GROUP
SECTION
9R
UPRIGHT REMOVAL


Block the steer wheel.
Truck Preparation
1 Remove the forks.

2 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.
3 Remove the drive wheels for access to
upright mounting pins and lock fastener
bolt.
85M778

GROUP CLSR
34
34.600 SUPPORT, UPRIGHT

I
, 34.605 FASTENER, UPRIGHT SUPPORT LOCK
95.180 WASHER. UPRIGHT SUPPORT LOCK FASTENER
1
UPRIGHT MOUNTING 34-702

ClilRK GROUP
34
UPRIGHTRf3OVAL
Typical TM TSU upright assembly weight, USE APPROVED HOOKS, CHAINS AND
less forks, is approximately [680 kg] CONNECTING LINKS WHEN REMOVING
1500 lbs. 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 cy?inder rod

end to upright retainer fastener bolt
and retainer washer.
85M624

[ZO-25 N.m] 177-221 lbf.in.
26573

GROUP LSRK
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 Remove upright mounting (pivot) pins:
1) Loosen and remove each mounting pin

lock fastener bolt and washer.

[ZO-25 N.m] 177-221 lbf.in.
26575
2) Remove each upright mounting pin.
5 Remove upright from truck.
Move upright carefully away from truck

and to a safe storage position.
26576

Cl!!~RK GROUP
38
GROUP
38
SECTION
COUNTERWEIGHT REMOVAL
IMPORTANT
l The counterweight must be in good condition REMOVING THE COUNTERWEIGHT

and securely attached to the lift truck. CAN CAUSE LIFT TRUCK
o Because of its heavy weight and bulky mass, TO BE UNSTABLE.
the counterweight must be carefully supported DO NOT OPERATE A LIFT TRUCK
and handled.
o Always store counterweights at floor level
in a stable position to be sure they will not
fall or tip causing either damage or injury.

Park truck on a solid, level surface.

Lower forks or attachment fully down.
Put all controls in neutral and turn
Put chocks at the drive wheels. ,i;_,?, i
85M626

GROUP
38
FRAME AND COUNTERWEIGHT 38-194
38.020 FRAME ASSEMBLY
38.869 COUNTERWEIGHT, REAR
38.870 FASTENER, COUNTERWEIGHT
38.871 FASTENER, COUNTERWEIGHT
38.876 FASTENER, AUXILIARY COUNTERWEIGHT
38.886 COUNTERWEIGHT, AUXILIARY
38.895 RETAINER, AUXILIARY COUNTERWEIGHT
91.204 NUT, COUNTERWEIGHT FASTENER

CLRRK GROUP
38
NOTICE
The following components must be

disassembled or removed before
counterweight can be removed.
1 Battery (See GROUP 12, Section 1).
2 Hood (GROUP 39, Section 2').

85M781
3 Overhead guard (GROUP 39, Section 1).
85M793
'X
4 Disconnect power cables to SCR controls
(See GROUP 19, Section 7).
5 SCR controls (optional depending on need).

If counterweight is to be repaired or
replaced: Refer to GROUP 19, Section 7,
Control Panel Removal.
NOTE - If counterweight is to be removed

only for access to service other components,
the SCR controls may be left installed on
the CWT. Disconnect power cables only
(Item 4 above).
85M831

GROUP CLqRu
38
COUNTERWEIGHT REMOVAL
Counterweights can be removed by one of two

methods: 1) Using a hoist or overhead crane, AN IMPROPERLY INSTALLED
or 2) using another lift truck as a hoist. COUNTERWEIGHT CAN MOVE OR
FALL UNEXPECTEDLY
BEFORE REMOVING MOUNTING
BOLTS, SECURE COUNTERWEIGHT
FOR REMOVAL. DO NOT REMOVE
WITH BLOCKS UNDER COUNTER-
WEIGHT SUPPORTING TRUCK.
FAILURE TO FOLLOW THE
PROCEDURES AS SHOWN IN
THIS MANUAL CAN RESULT
IN SEVERE INJURY OR DEATH.
See NOTICE, Page 3, for truck components which must be

disassembled before counterweight can be removed.
M :NIMUM TOOLS REQUIRED:
o Wheel blocks. Refer to

l Eye bolts. GROUP 40, Section 2,
l Lifting chains, sling or spreader bar. Suggested Equipment for
o Torque wrench, [O-1356 N.m] O-1000 Electric Truck PM,
lbf.ft. capacity. for information on load
l Overhead hoist, with adequate capacity capacities for various styles
to lift the load. of hoisting chains and slings.
Refer to
GROUP 40, Section 5,
ALL TOOLS AND LIFTING COMPONENTS Truck Specifications,
USED IN THESE PROCEDURES MUST BE for information on
IN GOOD CONDITION, MEET THE counterweight weights.
LIFTING CAPACITY REQUIREMENTS,
AND HAVE OSHA APPROVAL LABELS
WHEN REQUIRED.

38
Counterweight Removal
Using A Hoist Or Overhead Crane
IMPORTANT
Use lifting hooks with safety latches

to prevent hook from slipping from the
lifting eye.
25432
Move the lift truck as required into the

correct position under the hoist. APPlY
the parking brake and put blocks at the
front and rear of drive wheels.
NOTE - Some illustrations show typical

procedures as applicable to TM.
25433
2 Install lifting chains, sling or spreader

bar on the hoist hook.
3 Install eye bolts in the lifting holes

of the counterweight (overhead guard
rear leg mounting holes at top of CWT).
Bolt thread size: Ml2 [12 mm]
85M809

38
4 Attach the lifting chain hooks to eye

bolts in counterweight. Raise hoist as
necessary to remove (take up) slack in
lifting chain to support the weight of
the counterweight.
85M81O
5 Remove the counterweight mounting bolts.

Refer to illustration, page 2.
26522
6 Lift counterweight from the truck.
85M811
7 Move counterweight away from the truck.
Refer to Page 10 for counterweight

inspection procedure.
85M812

GROUP
Cl!lRU 38
8 Move counterweight for storage. It is

recommended to use a load platform (pallet,
or equivalent) of adequate (correct) con-
struction and capacity for temporary or
permanent storage, and for movement
(transport) of the counterweight.
9 Carefully lower the counterweight onto

the load platform or floor. When storing
on a platform or the floor, always put
the counterweight in a stable condition
with the broad, flat side down.
10 Remove the lifting chains or sling.

Remove the eye bolts if counterweight
is to be stored permanently (not
immediately used).
25438
11 If counterweight must be stored on its

curved side for inspection or servicing,
be sure to put adequate blocking at each
side to prevent rolling or shifting.

GROUP L9R
38
Counterweight Removal
Using Another Lift Truck As A Hoist
NOTE - It is recommended that this Refer to

procedure be conducted by a crew of two. GROUP 40, Section 5,
One crewmember should attend the coun- Truck Specifications, for
terweight while the other operates the information on
hoist truck. counterweight weights.
1 Be sure that hoist lift truck has enough

capacity to lift the counterweight.
2 Move the lift truck into a convenient

position with adequate clearance for
maneuvering of the hoist truck.
Be sure that the parking brake is

applied and blocks put at the front
and rear of drive wheels.
25433
3 Install lifting chains, sling or spreader

bar on the forks of the hoist truck. Be
sure to wrap chain around the forkbars
to prevent hoist chain from slipping off
the tip of the fork.
25440

of the counterweight (overhead guard
rear leg mounting bolt holes).
85M809

GROUP
CMRK
38
5 Attach the lifting chain hooks to the

eye bolts in counterweight. Raise the
forks of the hoist truck, as necessary,
to take up (remove) slack in lifting
chains.
25474
Loosen and remove counterweight mounting

bolts. Refer to illustration, page 2.
Be sure that forks of hoist truck are

adjusted to remove all slack in the
lifting chains and pick up (support)
the weight of the counterweight before
bolts are removed.
85M866
Carefully lift counterweight from the

truck.
CAUTION - Stand away from the path of

the counterweight as it is being lifted
and moved. Watch the lifting chains
and hooks for any unusual twisting or
movement. 00 NOT WALK OR STAND
UNDER THE FORKS.
25441
Move the truck slowly to prevent

swinging of the counterweight.
25442

GROUP LrlRK
38
9 Refer to previous procedures for moving

and storing counterweight, pages 6 and 7.
25438
Counterweight Inspection
Perform a complete inspection of the

entire counterweight when it is removed
from the truck.
The inspection may most easily be made

while the counterweight is supported by
the hoist during removal. LOWER THE
COUNTERWEIGHT TO THE FLOOR. BE CAREFUL
WHEN NEAR A COUNTERWEIGHT WHILE IT IS
ATTACHED TO A HOIST. DO NOT WALK OR
STAND UNDER RAISED FORKS. 25443
Inspect all surfaces for damage and cracks,

particularly the inner areas which may be
inaccessible when installed. Carefully
check all areas around bolt holes, openings
and cast-in thread inserts for loose sec-
tions of material, looseness of the inserts,
and damaged threads. Inspect the mounting
bolts for worn condition and damaged
threads.

CLSRK GROUP
Counterweight Installation
1 Apply the parking brake and put blocks

at the front and rear of drive wheels.
2 Move and position the counterweight

correctly near the truck.
25444

(OHG mounting holes) of the counter-
weight.
25446
4 Attach the lifting chain hooks to the eye

bolts in counterweight. Be sure that the
lift hooks are correctly installed and
latches are undamaged and operating cor-
rectly. Raise hoist (or hoist truck forks)
to take up (remove) slack in the
lifting chains.
25437
5 Carefully operate the hoist (or hoist-

truck) to lift and move the counterweight.
Keep the counterweight close to the floor
while moving. Move the hoist (or truck)
slowly to avoid swinging of the counter-
weight.
25442

GROUP CL!lRU
38
6 Carefully raise the counterweight into

position and align the nounting holes.
IMPORTANT
Do not use substitute, defective or

incorrect mounting bolts. Be sure
that the mounting bolts are undamaged
and have the correct material (strength
and hardness) specification. Replace
worn or defective bolts with genuine
Clark parts.
INJURY OR DEATH.
7 Install the counterweight mounting bolts

(one outer and two inner) and tighten
sufficiently to draw the counterweight
into position. Check the counterweight
for correct position and alignment when
26523

GROUP
CL9RK 38
8 Tighten inner counterweight mounting

bolts to correct torque specification.
Mounting Bolt Tightening Torque:

[340-380 N.m] 251-280 lbf.ft.
85M650
9 Tighten outer counterweight mounting

bolt to correct torque specificatiion.
Mounting Bolt Tightening Torque:

[340-380 N-m] 251-280 lbf.ft.
85M649
10 Lower the hoist and disconnect the

lifting chains or sling. Remove
the eye bolts from counterweight.
85M809
11 Remove the chocks from drive :qheels.
12 Install SCR controls, if removed.
13 Connect power cables to SCR controls.
14 Install overhead guard.
15 Install hood.
16 Install battery.
25447
17 Close hood (battery compartment cover).

CLflRK GROUP
38
GROUP
38
SECTION
FRONT BATTERY PLATE ADJUSTMENT
(FOR MAINTENANCE ACCESS)

Park truck safely in the selected

maintenance area.
Block the wheels.
85M626
Turn key switch to "OFF" position.

Open battery compartment cover (hood).
Remove floorboard.
See Page 2 for additional details.

GROUP El!!lWK
38
85M482 85M755
1 Turn key switch to "OFF" pbsition. 4 Remove battery from truck.

Refer to GROUP 12, Section 1.
85M505 85M651
2 Open hood (battery compartment cover). 5 Remove floorboard.
85M541 85M849
3 Disconnect battery from truck 6 Always remove valve cover before

receptacle. moving battery plate to prevent
damage to cover lower flange.

CLRRK GROUP
38
Battery Compartment Front Plate Installation

GROUP CL!!RlS
38
85M762
85M862

CWRW; GROUP
38
FRONT BATTERY PLATE ADJUSTMENT FOR MAINTENANCE ACCESS
The front battery plate is hinged at the bottom and adjustable for main-
tenance access to drive motors, brakes.,hydraulic pumps, motors and piping
components installed in the compartment under the floorboard. When this
plate is loosened and pivoted towards the rear of truck, added clearance
between components is provided and the main hydraulic pump and motor, and
hydraulic oil filter are rotated to a position where they may be more
easily serviced.
Truck battery must first be removed, to

provide access to the battery plate
mounting bolts and to allow movement of
the plate into the battery compartment.
See Page 2.
Remove floorboard. See Page 2.
Remove valve cover. See Page 2.

Always remove valve cover before moving
battery plate, to prevent damaging lower
flange of cover (fits under frame edge).
85M764
From the battery compartment side, loosen

and remove the four (4) bolts which mount
the battery plate at its sides to the frame.
85M665
5 The battery plate may now be adjusted to

the maintenance position by moving the top
of the plate towards the rear of truck.
See NOTICE, Page 6.
85M861

GROUP CLSRK
38
NOT1CE - Travel of the battery plate is normally limited by the

length of the lift line hose from main valve to the upright.
IMPORTANT - The plate may require blocking at the rear to limit

its maximum travel, to p,revent the valve control levers from
striking the SCR controls.
6 To block the batte,ry plate, use a piece of

wood, e.g., a Z"x4"x12" (approximate
length) block, placed behind the rear top
side of the plate and against the top front
of the counterweight or frame structure.
Place the block where it will be out of the
way of the necessary work.
7 Be sure the battery plate is supported

securely by the block before starting
any maintenance work.
85M760
8 When required, remove the plastic strip

(floorboard support), as shown. This
strip is held in place by fitting over
the tabs projecting from the battery
plate.
85M671
9 Install the battery plate in operating

position by reversing the above procedure.
Install all four bolts and tighten to the
correct torque specification (page 5).
Be sure to install the plastic floorboard

support strip by pressing over the tabs
on battery plate and adjusting to the
width of the frame.

CLflRlG GROUP
38
GROUP
38
SECTION
MACHINEJACKINGAND BLOCKING
TM Models
To perform these service procedures, it is

l Park truck on a hard, level and solid

surface, such as a concrete floor with
no gaps or breaks.
e Put upright in vertical position and
fully lower the forks or attachment.
a Put all controls in neutral and turn
85M467
DEFECTIVE EOUIPMENT I
CAN CAUSE ACCIDENTS
ALL TOOLS AND LIFTING EOUIPMENT
MUST BE IN GOOD CONDITION, MEET
THE LOAD CAPACITY REQUIREMENTS
AND HAVE OSHA LABELS WHEN
REQUIRED. TOOLS WITH DEFECTS
CAN HAVE FAILURES CAUSING SEVERE
INJURY OR DEATH.

GROUP CMRK
38
To Raise Drive Wheels Off The Floor
This procedure uses the upright as a lever

to lift the drive wheels off the floor and
prevent accidents due to inadvertent
powering of the drive wheels.
1 Park the truck safely. See page 1.
2 Turn key switch "ON" and tilt upright

fully back.
85M489
3 Put a solid [100x100 mm] 4x4 inch hardwood

block under the front section of each
upright rail. Put a [3,1-6,4 mm] .125-
.250 inch thickness steel plate on top
of each block.
Also see Figure .19519, page 3.
85M741
4 With key switch "ON", tilt the upright

fully forward. This action should raise
the drive wheels off the floor. Release
the tilt control lever.
5 Turn key switch "OFF".
85M742

GROUP
38
6 Check for safe clearance between drive

wheels and floor.
85M744
7 Check for stable condition of the truck.

Be sure that the blocks are located
securely under the upright rails before
operating the drive or working on
truck.
85M743
8 Lower the drive wheels to the floor and

remove the blocks by reversing the above
procedure.
e Turn key switch "ON".

e Tilt upright fully back.
l Turn key switch "OFF".
85M742
9 Remove the blocks from under the

upright rails.
(Typical truck view shown.)

GROUP
38
Blocking The Upright In Raised Position
This procedure is used to safely provide

clearance for access from the front of truck
to components on or near the drive axle. DO NOT STAND UNDER THE FORKS
WHEN BLOCKS ARE PUT UNDER THE
Park truck safely. See page 1. RAILS. THE FORKS CAN FALL
Put blocks in front of and behind drive AND CAUSE INJURY OR DEATH TO
wheels. PERSONNEL.
Put wooden blocks conveniently near rails
before raising the upright. Use two 4x4
hardwood blocks, or equal, of approximate
lengths shown in Figure 85M630.
Turn key switch "ON" and raise the upright

carriage.
Hold the tall block against inner rail and

lower the upright until carriage rests on
block.
85M630
Hold the short block against the outer rail

and lower the upright until inner rail rests
on the block. NOTE - For STD UPR, block
may need length cut to suit.
85M627
7 For HVTSU upright, the carriage may be

blocked up, as shown by Figure 85M852.
85M852

fxmu GROUP
38
To Raise The Rear Of Truck
Refer to GROUP 40, Section 5, AN INCORRECTLY INSTALLED

Specifications for truck weights. COUNTERWEIGHT CAN MOVE
OR FALL UNEXPECTEDLY.
The truck may be raised at the rear by jack- NEVER LIFT OR BLOCK A TRUCK
ing and blocking under the sides near the USING THE COUNTERWEIGHT.
rear section of the frame. FAILURE TO FOLLOW PROCEDURES
OUTLINED IN THIS MANUAL CAN
RESULT IN INJURY OR DEATH.
1 Park truck safely (see page 1). Put blocks

at front and rear of drive wheels.
NOTICE - When convenient, it is

recommended to first remove the battery
from truck, to reduce weight for both
safer and easier jacking.
85M626
2 Put a floor jack under the rear side of
truck frame. NEVER PUT THE JACK UNDER THE
COUNTERWEIGHT.
NOTE - If there is insufficient clearance

under frame for your jack, 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 perform the maintenance work.
85M780
4 Put blocks at both sides of the truck,

fully under the frame main side structure.
Put the blocks in front of but close to
the counterweight and steer wheel for best
truck stability.
Put an equal amount of blocks under each

side of the truck to provide a level
working position. Individual pieces of
blocking with minimum length equal to the
width of the truck are recommended.
85M775

GROUP CMRK
38
5 Lower the truck onto the blocks and remove

the jack. Before performing any mainte-
nance work, check the truck for stable
condition on the blocking.
6 When maintenance work is completed, lower

the rear of truck to the floor by reversing
the above procedure.
l Put jack under frame and raise truck.

o Carefully remove blocks and lower truck.
o Remove jack and blocks from drive wheels.

Cl!!lRK GROUP
38
To Raise Entire Truck (Front and Rear)
Refer to GROUP 40, Section 5,

Specifications for truck weights.
1 Park truck safely (see page 1).
2 Check and be sure all tools are in good

condition and have enough capacity to
lift the loads.
85M777
NOTICE - When convenient, it is recommended to first remove the battery

from truck, to reduce weight for safer and easier jacking.
If there is insufficient clearance under frame for your jack, truck may
first be driven onto thin shims, e.g., l"x6"x12" pieces of board, to
increase the truck frame underclearance.
Two jacks (if available) may be used, one on each side of the truck.
3 Put the jack(s) under side frame near

the center of the truck.
- Be sure to put the jack(s)

squarely and fully under the main side
structure of the frame.
85M780
4 Lift the truck one side at a time, only as

high as necessary to do the work and not
more than a maximum of 6 inches.
5 Put blocks under the side frame, at each

side of the jack. Put (spread) the blocks
close to the steer and drive wheels for
maximum stability.
85M779

GROUP CMRK
38
6 Lower the truck onto the blocks arId move

the jack to the opposite side. Repeat the
lifting procedure.
7 Put the same size blocks under each side of

the truck so it will be level.
85M778
CAUTION- Before performing any mainte-

nance work, check the truck for stable
condition on the blocking.
85M776
8 When maintenance work is completed, lower

the entire truck to the floor by reversing
the lifting procedure.
Lower the truck one side at a time, while

carefully removing the blocks. Check to
be sure that no tools or equipment are
under the truck or wheels.
NOTE - Depending on jack height, shims

under the tires may be needed for clear-
ance to allow removal of jack.
GROUP 38, Section 3, Page 8 Code: PM&540, NOV 85

ELflRK GROUP
38
Raising The Truck With A Hoist
1 When suitable equipment is available, the

truck may be raised by means of a hoist
and wheel cradles placed under the wheels.
Figure 17053 shows typical TM truck being

raised at the front (with upright removed).
2 Attach a hoist with chains of correct

capacity as shown.
NOTE - Watch truck for signs of lateral

instability. It may tip sideways.
sides of the truck or overhead guard
to prevent tipping.
3 When required to raise only the front of

truck, lift truck up and place wheel
cradles under the front wheels as shown.
Lower truck onto the cradles.
Typical truck view shown.
4 When working on components other than

the steer axle or drive wheels, raise
the truck and put stable wheel cradles
under all wheels.
Typical truck view shown.

CMRK GROUP
39
GROUP
39
SECTION
OVERHEAD GUARD REMOVAL

*Park truck on a hard, level surface in

correct position for using an overhead
lFully lower the upright.
oReturn all controls to neutral and turn
@Apply the parking brake. 85M626
*Block the wheels.
oRemove floorboard, for access to OHG

front mounting bolts.
@Remove hood. See Page 3.
*Battery may also be removed, as in the

illustrations shown here.
85M506

GROUP
39
OVERHEAD GUARD
12.170 BUMPER, BATTERY COVER
39.932 GUARD, OVERHEAD
39.933 FASTENER, OVERHEAD GUARD (FRONT LEGS)
39.934 FASTENER, OVERHEAD GUARD (REAR LEGS)
90.963 NUT, OVERREAD GUARD FASTENER
90.958 DAMPENER, OVERHEAD GUARD VIBRATION

GROUP
CLqRK 39
OVERHEAD GUARD REMOVAL
NOTICE: First, remove hood (battery cover) from OHG. If OHG (or hood)
needs to be repaired or replace'd, the hood must always be removed
from its mounting on overhead guard. Refer to GROUP 39, Section '2,
for hood removal.
CAUTION: It is recommended to never attempt to remove the OHG with hood

attached because of the difficulty of securing the hood to OHG
and the danger of damage or injury from the hood falling.
Remove front OHG leg mounting bolts from

the frame. NOTE - Clearance for access
to nut or bolt on right-hand side is
lim ited and requires use of a long box-
end wrench, or similar tool, at the
ins ide of frame. Best hand access is from
the front side at tilt cylinder opening.
Bo It Torque: [70-80 N.m] 52-59 lbf.ft.
85M791
2 Remove rear OHG leg mounting bolts

from the counterweight.
85M789
3 Use an approved lifting sling of correct

capacity to attach an overhead hoist to
the OHG.
OHG weight is [68 kg] 150 lbs,

approximately.
85M793

GROUP CWRK
39
4 A large sling may also be placed in

the longitudinal position. This may
give better balance when position-
ing or carrying.
I,
84M582
5 Raise OHG assembly up and away from

truck.
6 Lower the OHG assembly to the floor and

store in a safe position until required
for reassembly.
85M794
7 Reverse the above procedure for

installation of OHG.
8 Torque mounting bolts to the correct

torque specification.
85M790

GROUP
39
GROUP
39
SECTION
HOOD REMOVAL
(SEAT DECK/BATTERY COMPARTMENT COVER)

GR$UP
CWRK
PART NUMBER
(UNLESS NOTED)
' 38.104----
I
SHEET METAL AND TRIM

39-325
36.211 BUSHING, PIVOT PIN 39.641 BARDLE, TOP ROOD LATCH

37.128 PLUG, TILT CYLINDER ACCESS HOLE 39.643 CATCH, TOP LATCH
37.312 STOP, TOP ROOD 39.644 LATCR. TOP ROOD
37.544 ANCHOR, TOP HOOD PROP 39.648 FASTENER, TOP EOOD LATCH CATCH
38.104 PLATE, BATTERY COMPARTI4RNTFRONT 39.653 SPRING, TOP ROOD LATCH
39.475 PLATE, FRONT FLOOR 39.656 PIN, TOP HOOD LATCH

39 -471 FASTENER, VALVE COVER 39.662 FASTENER, TOP ROOD LATCH
39.478 PLATE, REAR FLOOR 39.702 PROP, TOP BOOD
39.497 FASTENER, VALVE COVER 39.705 FASTENER, TOP HOOD PRO9
39.535 BRACKET, TOP EOOD MOUNTING LB 39.978 PIVOT, TOP HOOD
39.536 BRACKET. TOP HOOD MOUNTING RB 91.269 NUT, TOP ROOD FASTENER
39.544 COVER, HYDRAULIC VALVE ACCESS 92.982 WASHER. TOP ROOD LATCE FASTENER
39.564 TRIM, BATTERY RECEPTACLE ACCESS 93.399 FASTENER, TCJPIKJOD STOP
39.594 RCCD, TOP 95.179 FASTENER, BATTERY COMPARTMENT FRONT PL
39.595 FASTENER, TOP HOOD

CL’IRK GROUP
39
HOOD REMOVAL
NOTE - Removal of the seat is optional. The weight to be handled will be

less if the seat is removed. Hood removal and installaticn is best done by
two persons working together.
1 Unlatch and raise hood to the

fully-open position.
NOTICE - Discharge the capacitor on

SCR control, for safety while
working near the controls.
2 Disconnect both gas spring assist/support

cylinders from their attachment to the
hood. CAUTION - Be sure to hold and
support hood from falling when support
cylinders are loosened and removed.
Bolt Torque: [20-X N.m] 117-2'21lbf.in.
85M782
3 Loosen and remove gas springs from their

mounting on counterweight, if they need
to be removed for inspection, repair,
or replacement.
Bolt Torque: [20-25 N.m] 117-221 lbf.in.
85M783

GROUP CMRK
39
4 Carefully lower the hood to the closed

position.
85M476
5 First, loosen the two mounting bolts of

one hinge bracket from the tapping
block at underside of hood. Then,
complete the removal of the mounting
bolts. Reach under the hood to hold
the tapping block from falling into
the SCR controls.
Bolt Torque: [ZO-25 N-m] 117-221 lbf.in.
85M797
6 Remove the hinge bracket by sliding it

off the hood hinge pin on OHG leg.
NOTE - It is necessary to only remove

one hinge bracket for temporary removal
of hood from truck. See below.
85M784
7 Disengage hood from OHG.
Lift the hood slightly and move sideways

to slide the remaining hinge bracket on
opposite side off of its hinge pin on
OHG leg.
85M786

El!!!!RH GROUP
8 The hood may now be removed from truck.
Note - Hinge bracket and tapping block

may be temporarily reinstalled on hood
for safe storage.
9 If required, remove the hood pivot pins

from the OHG legs. Loosen and remove
the mounting bolt from each pivot pin.
Put a match-mark on each pivot pin and
OHG leg for adjustment of hood when
installed.
25472
Hood Install ation
Reverse the above procedures for hood

installation.
1 Lift hood assembly and set it tempo-

rarily into place on truck, in the
lowered position. Engage hood hinge
bracket (attached to hood) to hinge
pin on OHG leg.
2 Carefully rest hood in lowered position

without latching. Slide the other hinge
bracket onto hinge pin on OHG leg (Fig-
ure 85M784), install and tighten the two
hinge bracket mounting bolts with tapping
block (underside of hood).
Bolt torque: [ZO-25 N.m] 117-221 lbf.in.
85M797

GROUP CLqRK
39
3 Raise hood to the open position,

and install both gas springs.
NOTE - The gas springs, when released,
will extend slightly. They may require
prying to compress them into place when
installing. If necessary, the hood
hinge brackets may be loosened at the
hood mounting, and the hood raised up
slightly in the slotted holes in the
mounting surface, until the spring
mounting bolts can be installed.
85M781
Hood Adjustment
Adjustment of hood fit-up when installed

is provided for by:
1) Oversize slotted holes in mounting of

hinge to top of hood sheetmetal:
Loosen the bolts in the hinge brackets
when major hood adjustment (fore-and-aft
or sideways) is required for alignment at
the front edge or along the sides).
85M797
2) Eccentric hood hinge pins in OHG leg:
Loosen the mounting bolts and rotate the

hinge pins for further adjustment of the
hood (e.g., centering alignment with
latch pin at front).
85M785
3) Adjustable hood stop screws which rest
against fixed brackets on the frame
inside controls/ battery compartment.
The hood stop screws are a type of set
screw using a hex wrench for adjustment:
Loosen the locknut on underside of hood,

and using a hex wrench inserted in the
opening on top of hood, adjust each stop
screw for correct contact with the stop
brackets on frame, for leveling and
support of the hood (seat support).
85M788
Be sure to correctly tighten all bolts
after adjustment of hood.

Cl!!RK GROUP
40
GROUP
40
SECTION
TRUCK DATA PLATES AND DECALS
NAMEPLAES 8 DECALS
M) NOT OPERATE A LIFT TRUCK
._- -
WITH DAMAGED OR LOST CECALS
AND NAMEPLATES. RFPLACE THEM
IMMEDIATELY. THEY CONTAIN
I
IMPORTANT INFORMATION.

GROUP
40.0101,40.012
1 -
40.13
07
L-37.205
L-93.575
L40.006
TM
40.014 _I
0
Gig
40.145
-I
.a_..eL1J__
0
_-.^Y_-
.-..".-olrr
r"3
1 40.049
40.163 DATA PLATES AND DECALS L-40.062
40-19s
37.205 TRAY, LITERATURE

40.000 LEGEND, CAPACITY & SERIAL NUMBER
40.001 FASTENER, CAPACITY & SERIAL NUMBER
40.006 LEGEND, PATENT
40.008 LEGEND, UPRIGHT CONTROL LEVER
40.010 DECAL, CLARK LOGO

40.012 DECAL, CLARK LOGO
40.014 DECAL, MODEL NAME
40.024 PLATE, UNDERWRITERS LABEL
40.025 FASTENER, UNDERWRITERS LABEL PLATE
40.049 LEGEND, INSTRUCTIONS

40.062 DECAL, DRIVERS WARNING
40.071 LEGEND, SAFETY PARKING BRAKE
40.089 DECAL, WARNING
40.130 DECAL, CAUTION FORKS
40.131 DECAL, HANDS OFF

40.138 DECAL, WARNING
40.145 LEGEND, WARNING
40.163 DECAL, VALVE LEVER LOCK
93.575 FASTENER, LITERATURE TRAY

GROUP
CLflRK 40
WARNING DECAL
L PYLON RELEASE
LEVER POSITION
LOCATION FOR
AUX. VALVE DECAL
WHEN REOUlRED
MANUAL CASE
BATTERY SPECIFICATIONS)
L OPERATOR INSTRUCTIONS \
CLARK LOGO- BOTH
SIDES OF HOOD.
NOTE: ADO INFORMATIONAL PACKETS,
TO MANUAL CASE, FOR OPTIONAL
EQUIPMENT USED ON TRUCK. UL CLASSIFICATION PLATE

GROUP CMRK
40
L POSITION DECAL
LETTERS ON EMBOSSED
LETTERS OF OVERHEAD GUARD
_-
_/= ,
*--
/’
,: / 25
/ /’ (2)-CENTER DECAL ON RAIL
,’ /
/ / WIDTH % POSITION LETTERY NEAREST
/
/ FLOOR, BOTH SIDES OF UPRIGHT
/
/’
/ CENTER
DECAL ON OUTERRAIL
WIDTH BOTH SIDES
OF UPRIGHT.
TM 17-2 REQ’D
1200 FkOM FLOOR TM 20-2 REQ’D
AND WITH FORKS DOWN

Cl!!!!RIK GROUP
40
GROUP
40
SECTION
2
SUGGESTED EQUIPMENT
FOR
ELECTRIC TRUCK P.M.

GROUP C19RW
40
1. To perform the electrical tests, you will

need a volt-ohmmeter (V-O-M). Make sure
the V-O-M is recalibrated when choosing
different range setting. For further
information refer to GROUP 40, Sections
17 & 18. Also recommended for controls
testing: Digital Multi-Meter (Simpson
D.M.M. Model 461 or equivalent), two
current monitoring shunts (500 amps, 50
mV rating), and digital stop watch (0.01
set resolution).
Fig. 22236
2. Have a standard set of metric and SAE

tools, consisting of combination wrenches,
screwdrivers, pliers, socket set, Allen
wrenches, etc.
Fig. 19523
3. Three torque wrenches will also be

required of either metric or SAE
calibration.
[O-6 N'm ] O-50 lbf. in.

LO-339 N'm ]O-250lbf. ft.
[O-1356N'm] O-1000lbf. ft.
Fig. 14844
4. For battery maintenance, you will need a

hydrometer, a battery water filler, battery
post, cable terminal cleaners and some
Clark Battery Saver, Part No. 886398.
Fig. 19526

GROUP
CLflRK
40
5. An air hose and gun will be required to

blow off truck parts. Tire pressure gauge
and tire inflation tool will be used to
check and adjust pneumatic tire pressure.
Fig. 19528
6. For lubrication you will need grease, a

grease gun, oil and suction gun, brake
fluid, hydraulic oil, chain and cable
lube spray and an oil can that meets
recommendations for oil and grease, from
GROUP 40, Section 4.
Fig. 19529
7. To check hydraulic pressure, you will need

a MICO quadrigage.
Fig. 11156
8. For jacking up the truck, you will need an

approved floor jack, 4 x 4 hardwood blocks
and approved safety wheel blocks.
Fig. 19531

GROUP
40
CLqRK
-- -f-
IAMETER 'ERTICALCHOKER BASKET 2 LEGS 3 LEGS 4 LEGS
IN
INCHES
TECORDINGS BELOW ARE: Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig.
nm reads in Kg (A) (B) CC) (A) (B) cc> (A) @) cc>
inches read in Lbs. See figures below for chain spread.
*These capacities are only this high when load is equally distributed to each leg.
T I 1
j.5n-m 1250 2500 930 2160 1770 1250' 2700 2200 1545 3245 2655 1885
l/4" 2750 5500 2050 4750 3900 2750 5950 4850 3400 7150 5850 4150
___-__._-_____-.----- _______---________-____________------ ________-_---_l____l
---__--,.
lOmIll 2950 5900 2200 5125 4150 2950 6400 5215 3675 7665 6260 4445
318" 6500 13000 4850 11300 9150 6500 14100 11500 8100. 1 16900
____---~-~___-----_____------~~~~~~~~~
_-----_,
___-__._-_____-~----- J-._______li"""___""""
13mm 4990 9980 3745 8665 7075 4990 10795 8800 6260 12975 10570 7485
l/2" 11000 22000 8250 19100 15600 11000 23800 19400 13800. 28600 23300 16500
___-_-._-_____-.----- _____-----_________,-_________-------~~
___-_--. ______----_-I_______
16mm 7400 14745 5535 12745 10435 7400 15965 13020 9210 19145 15650 i107c)
5/8" 16300 32500 12200 28100 23000 15300 35200 28700 20300 42200 34500 24400
_-_-____-_-___-.----- ________--_________,-________________~_
____---, _____--_--__-_______
19mm 10205 20410 7665 17690 14425 10205 22090 18055 12745 26535 21635 15330
314" 22500 45000 16900 39000 31800 22500 48700 39800 28100I 58500 47700 33800
___-__._-_____-.__--- ------____--------_.-________---------~
-___I--. ______----_-__-_____
22.5mm 13155 26310 9890 22770 18600 13155 28485 23270 16465 34155 27895 19730
J/8” 29000 58000 21800 50200 41000 29000 62800 51300 36300 75300 61500 43500
__----._-_-___-___-- ___-------_______-_,-__________------~~~___---------~~~~~~~-
_____-_..
25.4mm 17375 34700 13020 30255 20000 17375 37560 30660 21680 45090 36790 26035
111 38300 76500 28700 66200 54100 38300 82800 67600 47800 99400 81100 57400
_____-.__---___.----- _____--_--_________,_______________----
_--__-_, ----------__--------
32mm 25855 5170 19415 44770 36595 25855 55790 45810 32340 67130 54885 38780
l-1/4" 57000 11400 42800 98700 80600 57000 123000 101000 71300 148000 121000 85500
__--____-____------- _______---________ -____________---___-----------------I--
__^____,
38.4mm 35380 70760 26535 61235 49895 35380-I76660 62500 44225 92080 74843 53070
l-1/2" 78000 156000 58500 135000 110000 78000 169000 138000 97500 203000 165000 117000
Fig. (A) I
A
Fig. (B)
60'
Sec,tion2, Page 4 PMA-510, DEC 80

GROUP
CLRRK 40
GROUP
40
SECTION
3
FIRE EXTINGUISHER RECOMMENDATIONS
Section 3, Page 1
Code: PMA-510, FEB 84
GROUP CMRK
40
FIRE EXTINGUISHERS FOR TRUCKS WITH SOLID-STATE CONTROLS
APPROVED FIRE EXTINGUISHERS:
Two types of fire extinguishers are Dry-type fire extinguishers work by

approved for use on trucks with covering the fire (and controls) with
solid-state controls: a layer of chemicals. This shuts out
the air (oxygen) needed for burning
1. CO2 (carbon dioxide) and smothers the flames. After using
a dry-type fire extinguisher, the
CO fire extinguishers are best used chemicals must be cleaned up and
fo$ Class 'C' fires (*) in electrical washed off the controls. The controls
wiring and controls. Carbon dioxide must be completely cleaned and dried.
is an inert gas which puts out a fire
by replacing the air (oxygen) around
the flames. With C02, no cleanup is
needed. Since carbon dioxide is a gas CAUTION
and leaves no residue, you do not have
to clean the controls after using a CO2 THE BATTERY MUST BE DISCONNECTED
fire extinguisher. There is a danger, BEFORE CLEANING THE CONTROLS AND
however, from using a CO fire MUST NOT BE CONNECTED AGAIN UNTIL
extinguisher in small, e 6 closed places THE CONTROLS ARE COMPLETELY DRY.
where a large amount of carbon dioxide (.
gas could be left in place of the clean
air needed for people to breathe safely. The Ansul Company dry-type fire
extinguisher is recommended by
I I General Electric.
FIRE EXTINGUISHERS NOT APPROVED:

DO NOT ENTER OR WORK IN AN AREA
WHERE A CO FIRE EXTINGUISHER HAS Pyrene fire extinguishers are not
BEEN USED UNTIL THE SPACE HAS BEEN approved for use on trucks with
COMPLETELY VENTILATED. solid-state controis.
1
General Electric has found that the
2. Dry chemical (Class 'B' and 'C' chemicals in Pyrene extinguishers
fires)* destroy the insulation on electrical
cables and wiring, and can damage
The chemical used in'the dry-type plastic parts of the solid-state
extinguishers is either sodium controls.
bicarbonate or potassium bicarbonate,
which has been made water-resistant.
*U "Class A fires" are fires in ordinary combustible materials, such as wood,

cloth, paper and rubber.
"Class B fires" are fires in flammable liquids, gases and greases.
z,’
"Class C fires" are fires which involve "hot" (energized) electrical
equipment. The use of a fire extinguishing material that does not
conduct electricity is important.
Section 3, Page 2 Code: PMA-510, FEB 54

CLSRU GROUP
40
GROUP
40
SECTION
4
LUBRICANT SPECIFICATIONS
AND RECOMMENDATIONS
LUBRICATION CHART KEY
Code: PMA-322, FEB 84 REV Section 4, Page 1

FOREWORD
THIS LISTING OF LUBRICATION SPECIFICATIONS HAS BEEN COMPILED FOR THE REFERENCE OF
CLARK ENGINEERING AND SERVICE PERSONNEL, DEALERS AND CUSTOMERS. THE LIST OF PRODUCTS
IS INTENDED AS A GUIDE IN THE SELECTION OF A LUBRICANT TO MEET THE REQUIREMENTS OF
CLARK INDUSTRIAL TRUCK OPERATION.
CLARK makes no representation as to the relative merits of any commercial

oil product. With the exception of MS-68 Hydraulic Fluid, CLARK has no
formal system for approving oil products, but has published herein
general specifications which it believes will provide adequate or superior
component lubrication and life.
It is the PREROGATIVE of each user to choose suppliers and products as

they feel necessary for proper operation of the equipment under the
conditions of the individual application. RESPONSIBILITY for the quality
of the product and its performance in service must remain with the oil
supplier, in agreement with the user.
SYNTHETIC HYDRAULIC FLUIDS AND ENGINE OILS
With the recent advertising and promotional emphasis on synthetic engine

and hydraulic oils, CLARK EQUIPMENT COMPANY has received many questions
regarding approval of their use in CLARK products. CLARK does not follow
a formal test and approval procedure for specific branded products.
Rather it is CLARK policy to establish basic specifications for oils
which have demonstrated suitable performance for the application. In
general these specifications follow the recommendations of the major
component manufacturer, such as engines and hydraulic pumps. Any oil
which meets the respective specification is considered acceptable for use
in CLARK products. Component operation should not be affected as long as
the oil meets the stated specification and the recommended oil and filter
change intervals are followed. For EXTENDED OIL DRAIN INTERVALS, periodic
oil analysis by a reputable testing laboratory should be made. It is the
responsibility of the manufacturer or supplier of the oil to insure that
his product meets the specifications and gives the expected performance.
TECHNICAL SOCIETIES IN REFERENCE ON FOLLOWING PAGES
AGMA ___---_- American Gear Manufacturers Association

API American Petroleum Institute
ASTM ___---SW
American Society for Testing Materials
EMA Engine Manufacturers Association
MIL Military Specification
NGPA Natural Gas Processors Association
NLGI National Lubricating Grease Institute
SAE Society of Automotive Engineers
Section 4, Page 2 Code: PMA-322, JUN 80 REV

GROUP
CLflRH
40
LUBRICATION CHART KEY

LUBRICANT SPECIFICATIONS & RECOMMENDATIONS
PRODUCTS AVAILABLE UNDER

CLARK PART NUMBER Page 4
Ref No's
FILTERS 18. Transmission, Manual Shift Page 11

1. System Filters-Oil & Fluid Page 5
TRANSMISSION FLUIDS
ENGINE OILS 19. Transmission, Power Shift, Page 11
2. Gasoline & LPG Engines Page 6 & Torque Converter
3. Diesel Engines Page 6 20. Special Applications, Page 11

Powrworker, NS, NSP, NST,
GREASES Power Steering Reservoirs
4. General Purpose MS-107C Page 7
21. Ford Transmissions Page 12
5. General Purpose MS-107B Page 7
BRAKE FLUIDS - LUBRICANTS
6. Low Temp.-Cold Storage Page 7 22. Hydraulic Brake Systems Page 12
7. Spec Applications-Carriers Page 8 23. Hydraulic Brake Systems, Page 12

Cold Storage Applications
8. Ignition Distributor Cams Page 8 MS-92
9. Starter, Generator Frame Page 8
Bearings 24. Power Brake Vacuum Cyl. Page 13
10. High Temperature Page 8 HYDRAULIC FLUIDS

25. Hydraulic Systems, Normal Page 13
11. Motor Shaft Splines & Page 9 Applications, MS-68
Drive Tangs
26. Hydraulic Systems, Cold Page 13
12. Slip Tubes, Sleeves, Ball Page 9 Storage Applications,
Joints MS-226
PROTECTIVE SPRAYS 27. Hydraulic Systems, Fire Page 14

13. Cold Storage & Other Page 9 Resistant
Applications
FUELS
14. Contactors & SCR Controls Page 10 28. Gas, LP Gas, Diesel Page 14
Engines
SPRAY LUBRICANTS
15. Cable Lube., Electrical Page 10 29. Products & Technical Page 14
Societies in Reference
16. Throwout Bearing Carrier Page 10
Rails, Attachments, Slides, DEGREASERS
Bushings 30. For Electrical & SCR Paae 14
d
Components, For Non-

GEAR LUBRICANTS Electrical Components
17. Drive Axle, MS-8 Page 10

GROUP
40
DESCRIPTION SYMBOL CLARK PART NUMBER
HYDRAULIC BRAKE FLUID 1801167 1 - case of 12-ounce cans

850487 1 - case of 6 one-gallon cans
HYDRAULIC SYSTEM FLUID 1800236 1 - case of 24 one-quart cans

1802155 1 - case of 6 one-gallon cans
AUTOMATIC TRANSMISSION 1802200 1 - case of 24 one-quart cans

FLUID 1802154 1 - case of 6 one-gallon cans
962669 1 - five-gallon can
BATTERY CLEANER 886398 1 - case of 12 one-pint cans
LUBRICANT - INNERSLIDE 886396 1 - case of 12 one-pint cans
PENETRATING OIL 886397 1 - case of 12 one-pint cans
BELT DRESSING 1800078 1 - case of 12 one-pint cans
CHAIN & CABLE LUBE 886399 1 - case of 12 one-pint cans

(Roller & Leaf Chain Lube)
886785 1 - case of 12 16-ounce cans

SPRAY LUBE FOR OPEN GEARS (Black Heavy-Duty "EP"
Lubricant.)
DEGREASER 1800330 1 - case of 12 one-pint cans
CONQUER SPRAY* 1801145 1 - case of 12 16-ounce cans
886784 1 - case of 12 16-ounce cans

SPRAY KOTE** (Transparent Protective
Insulating Sealer with
Clear Lube.)
DEGREASER*** 1801146 1 - case of 12 16-ounce cans
SCR HEAT CONDUCTIVE 1801480 1 - carton of 4 5-ounce tubes

THERMAL COMPOUND 1742787 1 - 5-pound can
*HIGH MOISTURE EXPOSURE ... Protective Spray Coating for SCR Cards.
**HIGH MOISTURE EXPOSURE ...Protective Spray Coating for Electrical Switches,
Contactors and Ignition Systems.
***Oily or Greasy SCR Control . . . CLARK #1801146 Degreaser (or the equivalent to
MS-180 Freon TF Degreaser).
Section 4, Page 4 Code: PMA-322, FEB 84 REV

CLflRK GROUP
40
CRANKCASE I.!OTOROIL CLARK PART NUMBER
(SE/CD) S.A.E. 30 1802152 1 - case of 24 one-quart cans

(SF/CC) S.A.E. lOW30 1802153 1 - case of 24 one-quart cans
LOW TEMPERATURE OPERATION (MULTI-VISCOSITY OILS)

____________________~~~~~~~~~~~~~~~~~~~~~~~~~~~~
IT IS RECOMMENDED THAT MULTI-VISCOSITY OIL BE USED ONLY WHERE COLD STARTING

CONDITIONS, COMBINED WITH HIGHER OPERATING TEMPERATURES MAKE IT NECESSARY. THE OIL
SUPPLIER SHOULD ASSUME FULL RESPONSIBILITY FOR SATISFACTORY PERFORMANCE OF THE
MULTI-VISCOSITY OIL AT BOTH LOW AND NORMAL ENGINE OPERATING TEMPERATURES.
SERVICE CONDITIONS
__________________
OIL PERFORMANCE WILL REFLECT ENGINE LOAD, TEMPERATURE, FUEL QUALITY, ATMOSPHERIC
DIRT, MOISTURE AND MAINTENANCE. WHERE OIL PERFORMANCE PROBLEMS ARISE OR ARE
ANTICIPATED, THE OIL SUPPLIER SHOULD BE CONSULTED. WHEN EXTENDED DRAIN PERIODS ARE
CONTEMPLATED, HIS ANALYSIS OR THAT OF A REPUTABLE LABORATORY SHOULD DETERMINE THE
SUITABILITY OF OIL FOR FURTHER SERVICE.
LUBRICANT SPECIFICATIONS & CHART(S) KEY
LUBRICATION CHARTS - SEE GROUP 01
1. OIL & FLUID FILTERS
FOR .. TRUCK SYSTEM(S)
SPECIFICATIONS Replacement parts Oil Filter Cartridge Kits(s)

to be of a quality equal to that (Reference: Appropriate
provided in original equipment. Parts Manual)
Consult CLARK Service Parts
Publication(s) for recommended
replacement parts.
CAUTION The use of other than

CLARK approved filters may cause
oil pressure or flow changes which
could result in damage to the
system.

MIL-B 2. ENGINE CRANKCASE OIL
FOR ... GASOLINE, L P -GAS ENGINES AND NATURALLY ASPIRATED DIESEL
B*?I
cc
MIL-L-2104B
ENGINES.
SPECIFICATION TO MEET API Service classification "CC" and "SC"

per SAE Report 5183 and/or *MIL-L-2104B. Sulfated ash content
MIL-L-46152 1.00% weight maximum. Zinc content 0.06 to 0.10% weight maximum.
This specification includes "SE" oils meeting Specification

ENGINE MIL-L-46152 when applicable. Also, API Service "SC"/"SD"
CRANKCASE (formally "MS") oils may be preferred under stop-and-go or light
OIL service conditions.
*Although Specification MIL-L-2104B has recently been superceded,

oils of this quality will continue to be available, and are
preferred.
SERIES 3 3. ENGINE CRANKCASE OIL
FOR . . . TURBOCHARGED DIESEL ENGINES OR DIESEL ENGINES USING HIGH

SULFUR CONTENT FUEL (OVER 0.5% SULFUR).
SPECIFICATION TO MEET API Service Classification "CD" per SAE

MIL-L-45199B Report 5183 and equivalent Series 3 and/or MIL-L-45199B
Specifications. Also MIL-L-2104C when applicable. Sulfated ash
MIL-L-2104C content 1.65% maximum.
FOR ALL OPERATIONS WITHIN NOMINAL SAE 10W ... 0" to 32" F.
RANGES, THE USE OF SINGLE-GRADED OILS SAE 20/2OW ... 33" to 75" F.
IS RECOMMENDED. SAE 30 ... above 75' F.
A
SAE 30 OIL OF MIL-L-2104B PERFORMANCE Oil Change Intervals ... a helpful 2

LEVEL IS RECOMMENDED FOR YEAR AROUND guide in determining the intervals is q
USE IN DETROIT DIESEL ENGINES ... an engine oil analysis made several
2
(Limitations - Zinc 0.10% maximum, different times. Local oil distributors
sulfated ash 1.0% maximum). The use of offer this service. And by using it you
Multi-grade oils in Detroit Diesel can set P.M. intervals with greater
engines is not recommended. certainty.
Ref. 2 ENGINE CRANKCASE OIL

",
FOR . . . MISCELLANEOUS LINKAGE
SPECIFICATION Any good grade of motor oil in SAE 10, 20 or 30

weight as the temperature and conditions dictate.
Section 4, Page 6 Code: PM&322, JUN 80 REV

CLSRK GR&up
?
r
4. GENERAL PURPOSE GREASE
FOR . . . STEER AXLE TRUNNION BEARINGS

UPRIGHT MAST ROLLERS & SLIDES
UNIVERSAL JOINTS
WATER PUMP BEARINGS
GENERAL CHASSIS LUBRICATION
MS-107C *RECOMMENDATION Use Grade NLGI 12 per MS-107C.
*SPECIFICATION A multi-purpose grease of refined mineral oil

GENERAL blended with a lithium soap thickener or equal containing
PURPOSE anti-wear, anti-rust and anti-oxidants with EP additives. Per
GREASE CLARK Specification MS-107.
r
5. GENERAL PURPOSE GREASE
1
FOR . . . CLARK AXLE ENDS

WHEEL BEARINGS
STEERING GEARS
JOINTS, LEVERS & BUSHINGS
POWRWORKER & NARROW AISLE TRUCKS - ALL POINTS
MS-107B *RECOMMENDATION Use Grade NLGI #l per MS-107B
6. LOW TEMPERATURE GREASE

COLD STORAGE OPERATION
For ... GENERAL CHASSIS GREASE

UPRIGHT MOUNTING
UPRIGHT LIFT CHAINS
LOW TEMP ALL MOVABLE PARTS EQUIPPED WITH GREASE FITTINGS
BRAKE (AND CLUTCH) PEDAL LINKAGE
(Narrow Aisle Trucks 6 Powrworkers)
DRIVE UNIT FITTINGS
PANTOGRAPH
CASTER WHEELS
STEER CHAIN, ROLLERS & SPROCKETS
MIL-G-23827A LOAD WHEELS WITH FITTINGS
SPECIFICATION An extreme low temperature aircraft quality

grease meeting Specification MIL-G23827A, or equivalent product.
Temperature range - 100 to +250" F.
Code: PMA-322, JUN 80 REV Section 4, Page 7

SPECIAL GREASE
FOR . . . STRADDLE CARRIERS

EQUALIZING LINKAGE
HOOK & HANGER BUSHINGS
HOIST MECHANISM
MOLY GREASE SPECIFICATIONS A smooth high quality grease of refined mineral

oil base with a lithium soap thickener or equal compounded with
corrosion and oxidation inhibitors and containing 1 to 3% moly
(molybdenum disulfide). NLGI #2
8. SPECIAL GREASE
I‘s.,.,. FOR ... DISTRIBUTOR CAMS CLARK PART NUMBER 1800636
MOLY GREASE SPECIFICATIONS See above.
9. SPECIAL GREASE
FOR ... DELCO STARTER BEARINGS CLARK PART NUMBER 1800574

*GENERATOR/ALTERNATOR END
FRAME BEARINGS
MOLY GREASE SPECIFICATIONS See above.
10. HIGH TEMPERATURE GREASE $
FOR ... CLUTCH THROWOUT BEARINGS CLARK PART NUMBER 617410 2

CLUTCH PILOT BEARINGS I@.
0
DYNATORK PILOT BEARINGS
SPECIFICATIONS A high temperature grease of refined mineral oil

base with a lithium soap thickener or equal compounded with
additives to give high load-carrying ability and resistance to
water and high temperature. To withstand temperatures of -20' F.
(to) +300° F. NLGI Grade No. 2.
NOTE: Commercial products meeting MIL-G-3545C also meet this

requirement.

CMRK GROUP
40
11. SPLINE GREASE
FOR . . . MOTOR TO PUMP DRIVE TANG CLARK PAR T NUMBER 1800531

HYDRAULIC PUMP & MOTOR
SHAFT SPLINES
SPECIFICATIONS A lithium base or equal multi-purpose grease

MOLY GREASE blended with selected additives to provide high load-carrying
capacity with superior protection against corrosion and high-
temperature oxidation and containing 3 (to) 5% moly (molydbenum
disulfide). NLGI #2.
NOTE: Grease products under this specification are suitable for

use on ball and roller bearings operating under extreme
loads or in severe environments, and for extended
lubrication intervals including chassis, sleeve bearings,
cams and sliding mechanisms, etc., under heavy loads,
shock and vibration.
12. SPECIAL LUBRICANT

HAND APPLIED
For . . . SLIP TUBES, SLEEVES, CLARK PART NUMBER 617410

SPRING APPLIED SLEEVES,
LINKAGE BALL JOINTS, ETC.
SPECIFICATIONS A soft density, smooth lithium base or equivalent

grease with extreme pressure properties for use in adverse
operating conditions from 0' F. to 250" F. NLGI #l.
13. PROTECTIVE SPRAY COATING

- ELECTRIC TRUCKS IN COLD STORAGE
& OTHER APPLICATIONS
FOR . . . ELECTRICAL SWITCHES, CLARK PART NUMBER 886784

WIRING & TERMINALS,
AFTER ASSEMBLY.
SPECIFICATIONS A clear acrylic plastic protective coating which

acts as an insulator and corrosion preventative.

14. ELECTRICAL MOISTUREPROOFING

SPRAY COATING
FOR ... CONTACTOR/SCR PANELS CLARK PART NUMBER 1801145

SOLID STATE CONTROL CARDS
#l TIMER & OSCILLATOR CARD
SPECIFICATIONS A water displacing moisture-proofing and anti-

corrosion agent for electrical and electronic equipment. Must
not emulsify or harden. Non-insulating.
15. ELECTRICAL CABLE LUBRICANT

EC1
U FOR . . . LEVEL WINDING OF ROS CABLES ON REEL
SPECIFICATIONS A silicone jelly or equivalent to provide non-

sticking lubrication of external cable surfaces during rewinding
on reel.
16. SPECIAL LUBRICANT
FOR ... CLUTCH THROWOUT BEARING-CARRIER RAILS, SIDE SHIFTER

ATTACHMENT, CLAMP SLIDES, SLIDE BUSHINGS OF ANY TYPE
SPECIFICATIONS Use an approved Dry Film Type Lubricant or the

equivalent.
z
17. DRIVE AXLE GEAR LUBRICANT
;
API GL-4 FOR . . . DRIVE AXLES, HEAVY DUTY DIFFERENTIALS, PLANETARY &
0
WHEEL ENDS
SPECIFICATIONS Extreme pressure type gear lubricant with sulfur-

chlorine-lead (SCL) "EP" additive for API GL-4 service per SAE
Report J308a. To meet CLARK Specification MS-S.
Below 0 to -10" F. -- SAE 80

Normal Temperature -- SAE 90
100' F. and above -- SAE 140
MS-8 NOTE: SAE 80 and SAE 140 viscosities, when used, should contain
like additives as specified by MS-8 (SAE 90). DO NOT ADD
(MIX) DIFFERENT TYPES OF LUBRICANT.

CMRK GR400U
EP LUBE 18. TRANSMISSIONLUBRICANT
MIL-2105B FOR ... STANDARD MANUAL SHIFT (SYNCHROMESH)TRANSMISSIONk

GEAR BOXES.
SPECIFICATION
(1) MIL-L-2105B Extreme Pressure Lubricant for API GL-5 Service
per SAE Report J308b is preferred.
(2) Heavy Duty engine oil (API SD or SE) .issatisfactory.
(3) Straightmineral gear oil may be used. (Do not mix
lubricant types.)
API GL-5 ABOVE 20" F. -- Grade 90 (SAE 50)

BELOW 20" F. -- Grade 80 (SAE 30)
FOR 0 to -60" F. -- MIL-L-10324A
19. TRANSMISSIONFLUID
FOR ... TORQUE CONVERTERS CLARK PART NUMBER 879804

FLUID COUPLING DRIVES
AUTOMATIC TRANSMISSIONS
(EXCEPT FORD)
POWRSHIFT TRANSMISSIONS
POWRSHIFT FORWARD & REVERSE UNIT
HYDRATORK TRANSMISSION
HYDRACOOL (WET) CLUTCH
TRANSMISSION
ELECTRIC RIDER TRUCK DRIVE UNITS
(WHEN SPECIFIED ON LUBE CHARTS)
DEXRON*
OR SPECIFICATIONS DEXRON* OR DEXRON II* ATF (AutomaticTransmission
DE_XRONII* Fluid).
20. TRANSMISSIONFLUID
FOR ... HYDRAULIC SYSTEM AND DRIVE UNITS, POWRWORKERS,NS, NSP,

NST TRUCKS, ELECTRIC RIDER TRUCKS, POWER STEERING
RESERVOIRS.
SPECIFICATIONS DEXRON II* ATF (AutomaticTransmissionFluid)

containing zinc or equivalent anti-wear additive sufficientto
pass the requirementsof ASTM D-2882 pump wear test, with 50 mg
total weight loss maximum. Containermust carry GM approval
DEXRON II number (C-~~xxx/DEXRONII.)
Code: PMA-322, AUG 81 REV Section 4, Page 11

CMRK
GR40dJp
CAUTION 21. TRANSMISSION FLUID - FORD
; FOR ... ALL FORD AUTOMATIC TRANSMISSIONS AND CONVERTERS

F"1
FORD
%.‘I
L
tYM
SPECIFICATIONS Automatic Transmission Fluid, Type "F", which

meets FORD MOTOR COMPANY Specification: ESW-M2C33F (RED DYED)
TYPE "F"
CAUTION: DEXRON AND TYPE "A" FLUIDS ARE NOT COMPATIBLE
WITH TYPE "F" FLUIDS AND SHOULD NOT BE MIXED.
DEXRON FLUID OR TYPE "A" FLUID SHOULD NOT BE USED
IN FORD TRANSMISSIONS AND CONVERTERS (CTA "E"
MODELS) TO DO SO WILL RUIN CLUTCH DISC FACINGS.
22. HYDRAULIC BRAKE FLUID
HYDRAULIC FOR . . . HYDRAULIC BRAKE SYSTEMS CLARK PART NUMBER 884677

EXCEPT WHEN SPECIFIED
DIFFERENTLY ON THE
m LUBRICATION CHART(S) AND NOT
USED FOR COLD STORAGE.
SPECIFICATIONS Use only heavy-duty Hydraulic Brake Fluid which

meets or exceeds the requirements of SAE 51703 Specification, or
alternatively, Type DOT Brake Fluid, Grade DOT 3, as specified
BRAKE FLUID by Federal Motor Vehicle Safety Standard No. 116 (FMVSS 116).
Non-petroleum type.
23. HYDRAULIC BRAKE FLUID

COLD -COLD STORAGE OPERATION-
STORAGE
FOR ... HYDRAULIC BRAKE SYSTEMS, WHEN SPECIFIED SEPARATELY ON
LUBRICATION CHART(S).
SPECIFICATION Use Fluid per CLARK Specification MS-92:
Recommended Fluid: 85% by volume,

Isopropyl Alcohol: 15% by volume.
PRE-BLENDED ALTERNATE: Fluid meeting SAE 51702, Motor Vehicle Brake Fluid-
BRAKE FLUID Arctic, or Federal Specification MIL-H-13910, as available.
Section 4, Page 12 Code: PMA-322, AUG 81 REV

CWRH GR400U
24. POWER BRAKE VACUUM CYLINDER LUBRICANT
POWER BRAKE
FOR ... BENDIX HYDROVAC UNIT CLARK PART NO. 377299 (2 oz tube)
CLARK PART NO. 377300 (quart can)
SPECIFICATION Bendix Vacuum
Power Cylinder Oil or approved
equivalent.
LUBRICATION Apply after installation and

periodic maintenance per
instruction.
25. HYDRAULIC FLUID

HYDRAULIC
FLUID FOR . . . MAIN HYDRAULIC SYSTEMS CLARK PART NUMBER 885385
EXCEPT WHEN SPECIFIED
DIFFERENTLY ON THE
LUBRICATION CHART(S)
SPECIFICATIONS Use only high quality hydraulic fluid with Zinc

or equivalent Anti-Wear additive which meets the requirements of
NORMAL ASTM D-2882 pump wear test with 50 mg total weight loss maximum
APPLICATION per CLARK Specification MS-68.
26. HYDRAULIC FLUID

-COLD STORAGE OPERATION-
HYDRAULIC
FLUID FOR . . . MAIN HYDRAULIC SYSTEMS EXCEPT WHEN SPECIFIED DIFFERENTLY
ON THE LUBRICATION CHART(S).
SPECIFICATIONS Use Hydraulic Fluid which meets MIL-H-5606A per

CLARK Specifications MS-226.
A petroleum base hydraulic fluid with additives to improve

viscosity index, oxidation resistance and anti-wear
characteristics blended to form a stable product under storage
COLD and operational conditions between -65 and +160" F., meeting
STORAGE MIL-H-5606A* per CLARK Specifications MS-226.
OPERATION
*The restrictive cleanliness specifications
of later revisions is not required.
Code: PMA-322, JUN 80 REV Section 4, Page 13

27. HYDRAULIC FIRE RESISTANT FLUID
FOR . . . SPECIAL APPLICATIONS IN MAIN HYDRAULIC SYSTEMS EXCEPT

HYDRAULIC WHEN SPECIFIED DIFFERENTLY ON THE LUBRICATION CHART(S)
FLUID
SPECIFICATIONS High quality Water-Glycol Fire Resistant
Hydraulic Fluid composed of approximately 42% water and 58%
glycol with a nominal viscosity of 200 SUS at 100" F. Pour
point -35" F. min. To contain proper additive balance to impart
FIRE optimum stability, lubricity, wear and corrosion protection.
RESISTANT Approved by Factory Mutual Insurance Underwriters.
28. ENGINE FUEL - GASOLINE
FOR ... INDUSTRIAL GASOLINE ENGINES
SPECIFICATIONS Fuel to be Automotive Quality Regular Grade

Gasoline containing a corrosion inhibitor.
Minimum Motor Octane Number - 85
29. ENGINE FUEL - L P -GAS
FOR . . . INDUSTRIAL L P -GAS POWERED ENGINES
SPECIFICATIONS Use LPG meeting PROPANE HD-5 (NGPA Specification

2140-62) or ASTM D2154 (Special Duty Propane) requirements.
Minimum Motor Octane Number - 95
30. ENGINE FUEL - DIESEL
FOR . . . INDUSTRIAL DIESEL POWERED ENGINES
SPECIFICATIONS Fuel to be Automotive Quality Diesel Fuel Oil as

defined by ASTM D975, Grades No. 1-D and 2-D, and having a sulfur
content of less than 0.5% weight.
Recommended Cetane Number - 45 Minimum
NOTE: AN ASTM NO. 1-D FUEL IS PREFERRED WHERE MINIMUM SMOKE AND
ODOR IS REQUIRED OR WHERE LIGHT LOAD AND SPEED WITH
CONSIDERABLE IDLING IS ENCOUNTERED AND FOR COLD WEATHER
USE GENERALLY.

CLSRK GROUP
40
CLARK PART NUMBER 1801146

FOR ELECTRICAL e,SCR COMPONENTS
I M P 0 RTAN T
DO NOT CLEAN
ELECTRICAL COMPONENTS WITH STEAM.
ONLY APPROVED SOLVENTS SHOULD BE
0 NOTE USED TO CLEAN SCR COMPONENTS ...
USE CLARK #1801146 DEGREASER (OR
THE EQUIVALENT TO MS-180,
FREON TF DEGREASER).
CLARK PART NUMBER 1800330

FOR NON-ELECTRICAL COMPONENTS
FOR use on NON-ELECTRICAL
Components. CLARK iy1800330
Degreaser may be used to clean
outer surface of cylinders,
0 NOTE
valves and other components
as well as engines . . . may be
used on paint.

GROUP 40 SECTION 05
TRUCK DATA AND SPECIFICATIONS
Group
12 POWER SUPPLY - BATTERY Maximum Size and Rating
TM12/15S 36V, 18 cell, 11 plate, 24.3 kWh, 775 amp-hr @ 6 Hour rating
TM 15 36V, 18 cell, 13 plate, 38.9 kWh, 930 amp-hr @ 6 Hour rating
TM 17 36V, 18 cell, 15 plate, 38.9 kWh, 1085 amp-hr@ 6 Hour rating
TM 20,22,25 36V, 18 cell, 17 plate, 38.9 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 (CLARK 2394339) - 36V, 6.64 in. diameter, Series Wound.
Weight: 54 lb [24.5 kg]

Open Rating (60 Min.): 34.8V, 2160 rpm, 5.5 hp, 143 amps
Brushes: : 1.38 in. 135 mm], W 1.26 in 132 mm] T 0.498 in [12.65 mm]
No. per holder:
No. per motor: 4
Brush Grade: Morganite Hl 00
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]

Brushes: L 1.38 in. [35 mm], W 1.26 in 132 mm], T 0.498 in [12.65 mm]
No. per holder: 1
No. per motor: 4
Brush Grade: Morganite H800
Worn Length: 0.57 in 114.5 mm] on longest side.
WORN: 16 oz [453 g]

Brushes: L 1.38 in. [35 mm], W 1.26 in [32 mm], T 0.498 in 112.65 mm]
No. per holder: 1
No. per motor: 4
Brush Grade: Morganite H803
Worn Length: 0.57 in [14.5 mm)] on longest side.
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
Worn Length: 0.57 in [14.5 mm] on longest side.
WORN: 16 oz [453 g]
STEER - 36V 6.5 in. diameter , Permanent Magnet.

Enclosed Rating (Continuous): 36.OV, 1351 rpm, 0.95 hp, 28.1 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
Worn Length: 0.420 in [lo.65 mm] on longest side.
Brush Spring Tension (force per brush) NEW: 27.6-30.7 oz [782-870 g]
WORN: 11512.6 oz [326-357 g]
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 main pump motor idle current)

@ Battery: 75 amps
Main Pump Motor - Idle current @ Battery: 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: 5 (+/- 0.5) seconds

FUSES:
EllsE RATING FUNCTION

1FU 500 amp Drive, Pump
2FU 15 amp Control
CONTACTORS:
FUNCTION RATING COIL RESISTANCF

IA 150 amps 19.55 ohms
Forward/Reverse 150 amps 19.55 ohms
Power Steering 100 amps 49 ohms
DC 100 amps 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: 8 pints. [3.81 L]
Overall Ratio: 23.386:1 Reduction
23 WHEELS AND TIRES
Drive Tire Size: Cushion - 18x7x12.12 (TM 12,15S,15)

18x8x12.12 (TM 17, 20)
18x9x12.12 (TM 22, 25)
Pneumatic - 18x7~8 16 ply (TM 12,15S,15)
18x9x8 16 ply (TM 17, 20)
Tire Pressure: 140 psi 1970 kPa]
Steer Tire Size: Cushion 18x7x12.12 (TM12,15S, 15, 17, 20)

Cushion 18x6x12.12 (TM22, 25)
Pneumatic 18x8~8 16 ply
Tire Pressure: 140 psi [970 kPa]
23 BRAKES
Recommended Brake Fluid: Heavy-duty hydraulic brake fluid, SAE J1703b

specification, or Type DOT, Grade DOT3.
Master Cylinder: 0.75 inch diameter x 0.787 inch stroke
26 STEERING SYSTEM:
Power Steering System Relief Pressure Setting: 1250 psi [8620 kPa]
Recommended Power Steering Fluid: Uses main hydraulic sump oil supply
Steer Handwheel Turns, Lock to Lock: 5 (CCW),4 (Cw)

29130 HYDRAULIC SYSTEM
Recommended Hydraulic Fluid:

Normal Temperature Clark Specification MS-68 Hydraulic Oil with anti-wear additives
Cold Storage Clark Specification MS-226 Hydraulic Oil with anti-wear
additives
Sump Tank Capacity: Usable Volume: 2.6 Gal [9.84 L]

Total Volume: 3.6 Gal [13.6 L]
Main Relief Valve Pressure settings:

TM 12,15S 2100 - 2200 psi 114479 - 15169 kPa] (Hilo)
TM 12,15S 2450 - 2550 psi 116890 - 17580 kPa]
TM 15 2450 - 2550 psi 116890 - 17580 kPa]
TM 17 2700 - 2800 psi [18620 - 19306 kPa]
TM20 2950 - 3050 psi 120340 - 21030 kPa]
TM22 3000 - 3100 psi 120684 - 21374 kPa]
TM25 3000 - 3100 psi 120684 - 21374 kPa]
Equipped with Cascade Upright: 2300 psi [15856 kPa]
Aux Valve Relief Pressure Setting: Adjustable - Refer to attachment specifications
32 TILT CYLINDERS
Tilt 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 / 6 degrees forward

HV Triple - 5 degrees back / 3 degrees forward
Tilt Drift (in 5 minutes, with rated load, new truck):

Te pe atu e Drift
80;(2:.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 Upright at cut-offMFH
HI-VIS STD ft/min HI-VIS TSU ft/min

Liftina I owering Liftina Lowering
TM 12,15S,15 Loaded: 63 95 60 85
Empty: 101 80 93 80
TM 17 Loaded: 59 95 56 85
Empty: 101 80 93 80
TM 20 Loaded: 55 95 52 85
Empty: 101 80 92 80
TM 22 Loaded: 41 63 42 60
Empty: 85 60 75 60
TM 25 Loaded: 38 66 38 63
Empty: 80 65 80 65
40 RATED LOAD CAPACITY - @ Load Center:
TM 12 2500 Ibs @ 24 in (1250 kg @ 500mm)
TM 15s 3000 Ibs @ 24 in (1500 kg @ 500 mm)
TM 15 3000 Ibs @ 24 in (1500 kg @ 500 mm)
TM 17 3500 Ibs @ 24 in (1750 kg @ 500 mm)
TM 20 4000 Ibs @ 24 in (1815 kg @ 500 mm)
TM 22 4500 Ibs @ 24 in (2250 kg @ 500mm)
TM 25 5000 Ibs @ 24 in (2500 kg @ 500mm)
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).
40 TRUCK WEIGHTS - Approximate, with typical upright:
TM 12 15s 15 17 20 22 25
Service Weight
w/o load, Ibs 6627 7158 7205 7774 8305 8810 9305
Axle Loading:
w/o load, front, Ibs 3445 3359 4083 4079 4072 4335 4350
w/load, front, Ibs 8035 8867 9224 10097 10948 12114 12993
w/o load, rear, Ibs 3182 3799 3122 3695 4233 4715 5200
w/load,rear,Ibs 1092 1291 981 1177 1387 1436 1557

40 BATTERY COMPARTMENT SIZE
JM 17/l% 15.17.20.22.25
Length 13.75 in 20.5 in
Width 38.8 in 38.8 in
Height 31 .O in 31 .O in
40 WIRE CODES
Color Code
Black 0 Example:
Brown 1 Wire no. 13 is a orange wire.
Red 2 with a brown stripe.
Yellow 4
Green 5 Wire 33 is a solid orange wire.
Blue
Violet ;
Gray 8
White 9
GROUP 40,Section 5, Page 6 Code:SM555,MAR 89

40 TORQUE CHART
Critical Fastener Torque Specifications: Tightening Torque, Dry
tbfminI ibf*ft Nm
16 Steer Motor Mounting Nuts 14.8 - 18.4 Ibf+t [20 - 251
19 Motor Cable Connections 90 - 100 Ibfain. [lo - 121

Control Panel Cable Connections 100 - 120 Ibfein [ll - 141
20 Drive Axle to Frame Mounting Bolts 406 - 443 Ibf+t

Drive Motor Mounting Bolts 52 - 59 lbf*ft
23 Drive Wheel Mounting Bolts 188 - 203 Ibfmft I255 - 2751
26 Steer Wheel Mounting Bolts 188 - 203 Ibf*ft [255 - 2751

Steering Handwheel Retaining Nut 35 - 40 Ibf*ft [48 - 541
Steer Wheel Spindle {Bearing) Nut 170 - 180 Ibfaft [230 - 2441
Steer Axle Trunnion Retaining Nut 11 - 15 Ibfmft [15.-.20]
29 Main Hydraulic Valve Mounting Bolts 30 - 33 bf=in

Control Lever Knob Mounting Bolt 71 - 88 Ibfain
32 Tilt Cylinder Yoke Clamp Bolts 177 - 221 Ibf*in 120 - 251
Tilt Cylinder Pin Retainer Bolts 177 - 221 Ibfein [20 - 251
34 Upright Cylinder Retaining Bolts 125 - 140 Ibf*ft [170 - 1901

Load Backrest Extension Mounting Bolts 177 - 199 Ibf*ft [240 - 2701
38 Seat Mounting Bolts 177 - 221 Ibfein [20 - 251

Counterweight Mounting Bolt 251 - 280 Ibf*ft [340 - 3801
39 Overhead Guard Mounting Bolts 52 - 59 Ibf*ft [70 - 801
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.

40 LUBRICATION SPECIFICATIONS
Englne 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-l 07B, or equivalent
Steering Linkage, Uptight & Carnage NLGI Grade No. 2

Rollers, Upright Mounting Pins, Lithium soap base grease,
Trunnion Bushings, Tilt Clark Spec MS-9B and
Cylinder Rod Ends, Brake Pedal MS-1 078, or equivalent
Shaft
Chain Lube
Upright Lift Chains Clark #886399 Chain and
Cable Lube or equivalent
Dry-film Lubricant
Side Shifter, Attachments, Dow Corning Molykote 321 Bonded
Clamp Slides Lubricant, Graph-0-Kote #220,
Molub-Alloy #369 Dry 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

CLqRK GROUP
40
GROUP 40
MEASURING VOLTAGES WITH THE VOLT-OHM METER ( V-O-M j
SECTION 17
RESISTANCE SCALE
Refer to Section 18.
VOLTAGE SCALE
Code: PMA-336, REV JAN 77

Section 17, Page 1
USING THE METER: Connect Meter Leads:
A typical volt meter is equipped with Insert RED TEST LEAD in jack marked +
several voltage ranges to provide insert BLACK TEST LEAD in jack marked-
accurate readings over a wide voltage
range. In the absense of a specified
range to use, be sure to use a range
sufficiently higher than the voltage
to be measured to avoid damaging the
meter.
When measuring voltage, be sure the

truck battery is connected, and be sure
to observe voltage polarity when con-
necting the meter leads. Unless
directed to do so, do not disconnect
wiring to parts being tested.
IMPORTANT: THE MOST

ACCURATE READING OF ANY METER IS TOWARD THE CENTER OF ITS
SCALE, FOR EXAMPLE,
WHEN READING VOLTAGES UP TO 2.2, USE THE 2.Y RANGE, HOWEVER,
WHEN READING 2.5 VOLTS, USE THE 1OV RANGE. THIS BRINGS THE READING NEARER THE
CENTER OF THE SCALE AND PROVIDES A MORE ACCURATE READING. IT ALSO PROTECTS THE
METER FROM POSSIBLE DAMAGE IN THE EVENT VOLTAGES READ EXCEED 2.5.
VOLTAGE TO BE RANGE SWITCH USE

MEASURED SETTING DC VOLTAGE SCALE READING THE METER
WITH FIGURES BELOW
*Move the decimal point
from 0 to 2.5V 2.5V O- 250 two places to the left.
50 or ,504 100 or 1.004 150 or 1.50+ 200 or 2.00+ 250 or 2

X
HERE THE METER READS 2.29 or 2&V
RANGE SWITCH SETTING: 2.5V Read 1st Row of Figures with the DC Scale.
Section 17, Page 2 Code: PMA-336, REV JAN 77

CLSRK GR4%u
VOLTAGE TO BE RANGE SWITCH USE
MEASURED SETTING DC VOLTAGE SCALE READING THE METER
WITH FIGURES BELOW
from 2.5V to 1OV 1ov 0 - 10 Read directly

from 1OV to 5OV 5ov 0 - 50 Read directly
from 50V to 250V 250V 0 - 250 Read directly
4 RANGE SWITCH 10 V RANGE SWITCH SETTING

SETTING: 1OV I
AC/DC DIAL
SETTING: +DC
READ 3rd ROW

FIGURES WITH
DC SCALE, I)
METER READS 3 VOLTS
Fig. 17229 Fig. 16015
c RANGE SWITCH 50 V RANGE SWITCH SETTING

SETTING: 50V
AC/DC DIAL
SETTING: +DC
READ 2nd ROW

FIGURES WITH
DC SCALE. e
METER READS 15 VOLTS
Fig. 17229 Fig. 16015
RANGE SWITCH 250 V RANGE SWITCH SETTING

c SETTING: 250V
AC/DC DIAL
SETTING: +DC
READ 1st ROW

FIGURES WITH
DC SCALE. I)
METER READS 75 VOLTS
Fig. 17229 Fig. 16015
Code: PMA-336, JAN 77 Section 17, Page 3

1.25 OR 1.-l/4 VOLTS
2.5 VOLT SCALE
SOV
\ 250v
Section 17, Page 4 Code: PMA-336, JAN 77

CLflRU GROUP
40
GROUP 40
MEASURING RESISTANCE WITH THE VOLT-OHM METER ( V-O-M )
SECTION 18
Black
RESISTANCE
VOLTAGE SCALE
Refer to Section 17.
THIS SCALE NOT USED
Code: PMA-336, REV JAN 77 Section 18, Page 1

USING THE METER: To insure accurate CONNECT METER LEADS: Insert RED TEST
readings, and prevent possible damage LEAD in jack marked (+). Insert BLACK
to the meter, be sure to disconnect TEST LEAD in jack marked (--).
truck battery. Also, disconnect one
connection of any part being tested
from the circuit to prevent other cir-
cuits from affecting resistance read-
ings.
SETTING THE METER: Meter settings re-

ferred to in the PM procedures are:
Rxl, RxlOO, Rx10,OOO. Set the center
meter function switch to the specified
resistance range. If measuring an UN-
KNOWN RESISTANCE use the Rx100 range
first. If the indicator points near
center scale, then use this scale for ADJUST METER TO READ ZERO OHMS: Meter
reading. However, if the indicator must be calibrated each time it is set
drops to O-ohms, then use the Rx1 scale. to the ohms scale, and each time it is
If the indicator stays at or near the changed from one ohms scale to another.
infinity mark then use the RxlO,OOO To do this, connect the leads together
scale. and adjust ZERO OHMS KNOB for exactly
0 on the ohms scale.
TOUCH TEST LEADS ACROSS UNKNOWN RESISTANCE AND READ VALUE, USING THIS CHART.
Resistance Value Being Range Switch Setting ’ Reading The Meter
Measured
ZERO to 200 OHMS Rx1 Read ohms scale directly.
200 to 20,000 OHMS Rx100 Multiply ohms scale by 100.
20,000 to INFINITY RxlO,OOO Multiply ohms scale by 10,000
I I
Refer to ITEM 1 in opposite With the RANGE SWITCH set as indicated,

illustration. With meter the scale examples are read as follows:
indicator in this position,
the meter would be read as Rx1 50 OHMS 10 OHMS 5 OHMS
follows: Rx100 5000 OHMS 1000 OHMS 500 OHMS
RxlO,OOO 500,000 OHMS 100,000 OHMS 50,000 OHMS
RANGE SWITCH SETTING: Rx1
Read Scale from right to left.
The meter reads 12 OHMS.
RANGE SWITCH SETTING: Rx100

Read scale from right to left.
The meter reads 1200 OHMS. 50
:E
RANGE SWITCH SETTING: RxlO,OOO

Read scale from right to left.
The meter reads 120,000 OHMS.
REFER TO THE OPPOSITE PAGE FOR METER SCALE BREAK DOWN OF DIFFERENT RANGE SETTINGS.
Section 18, Page 2 Code: PMA-336, REV JAN 77

Code: PMA-336, JAN 77

Section 18, Page 3
I A 300 AMP FUSE IS SUBSTITUTED
FOR TM 12/l% ‘Es” T R U C K S O N L Y
F O R T M 12120 “EE” T R U C K S USE
T W O 3 0 0 AMPS FU S E S A S SHOWN
r
2 8 FU
SEE NJTE I
S
& -
SaSuQ
FL 52 FL
i
I2 ORIE Mm7
-12
i
SEL E E - - T M 12/20 TRUCKS ONLY.
I
@ 10
IO
IO
23
FL,
IS . 24
t-
15,-J4-26 l.!zFTaJT-
CFFsarG-l
PAh 52--,3-
t 15 a,
, 27 p&s PAS 51 --13-
RIMT arr-
=r$ OFF SWITCH
PD 13
I
B-B-
111 g-1 50-l
I6
c
1
II ]
-ts~-J i
L- -tOH
OXODE 10
3
+3llL
*'
sir
c
St%4 -
1 A 300 AMP FUSE IS SUBSTITUTED
?ATTERY FOR TM 12/15S “ES” T R U C K S ONLY
rr FOR TM l2/15S “EE” TRUCKS USE
3 6 “GLTS
-7, TWO 300 AMPS FUSES AS SHOWN
23 REC
E E - - T M 12/15S T R U C K S O N L Y .
RIGHT
ORIVE MoTrn
IO
IA.
10 .
DC.
10 ,
10
P.S.
I
0s HaRMsER
-71 72 GP -I3
a9 09
,oFTg%3
r-
--1o-+ 13-
/
IO
+
1
IO*.&-28
-4
5----zH--_i D,O
urxl
I
+-- ,o--
I
r-4-1
t __ ,o__- *
-r;____3,r-________________3,___ ~-~~-L__-__-_,,_,,-________
SWOID
BATTERY
FILTER
-
7k-----l;f-------?A
,
- 6
71
I:I-c
c---.3,
I ‘. I I
:
:I %%!4
31A 1
t r_____rx _______-__-__ -e-,x _________ - --_-_-_-_-_-_-__-_-_---_--_--_, x -___--_____ -_.
c F PD I N - 2 2 2 4 9 . 0 2
OF IN-22249.02A
I . A 300 AMP FUSE IS SUBSTITUTED
FOR TM 12/l% “ES” TRUCKS ONLY.
FOR TM 12/l!% “EE” TRUCKS USE
TWO 300 AMPS FUSES AS SHOWN.
I IA
23 GEC
EE--TM 12/15S TRUCKS ONLY.
RIMT
DRIvEnolcR
23
24
26 LEFT UJT-
oFFsuIm
27 -52--13-
L
IO
t : "IA -5,4~13-.-
RIQlTcm-
WF sirral
._ __
I ‘Ps
IO
I HOW?TER
I
.
-. I
._
v ._
i -_
j, v-*-.
! ___ ,o__Aux 2
~----3, 1-______""_"'~~~_~_.3, .___L_&_I_________.,3.___________
DI~IWICATCR Sad;010
-10
r________
i IIN-22124
12 25 .-_------
z&X'
Hem
OPTIONS
SO-6 :
1 2
:
S
PS
A
MOTJR
FOOT
BfiAKE
ti
SUfTCii
13 5
29 38
a----
1 i. 14
i231i
FL-S
“j._*.“so-s
~I-_________,_13f_________i
v
- 2s+>l+
fl r--
I 4-I
HORl
:
:
su I TCH ;I
II1
@
28C IOF
PO IN-2212(r .02
CJP IN-2212q .02?R
cl- rT

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Main Table of Contents

GROUP Section PROCEDURE

01 1 PLANNED MAINTENANCE SCHEDULE

13 1 LIFT PUMP MOTOR MICROSWITCH ADJUSTMENT

16 1 ELECTRICAL MOTOR MAINTENANCE

16 2 DRIVE MOTOR BRUSH REPLACEMENT

19 1 SCR CONTROL PANEL

19 2 SCR CONTROL OPRERATION AND TROUBLESHOOTING

20 1 DRIVE AXLE MAINTENANCE

25 1 OR/l 0 STEERING GEAR CONTROL

30 HYDRAULIC SYSTEM RELIEF PRESSURE CHECK AND ADJUSTMENT

40 1 TRUCK DATA PLATES AND DECALS

NOTE: “R” denotes Removal Procedure for components

Clark Equipment Company welcomes you to the growing group of professional

The mechanic is cautioned and expected to always work in a safe manner by

Planned Maintenance Program

In addition to the daily operator inspection, Clark recommends that a planned

This manual includes repair procedures as well as instructions for a periodic

HOW TO USE THIS MANUAL

0 Clark Equipment Company 1989

PICTORIAL INDEX TYPICAL FORK TRUCK

SAFETY SIGNS AND SAFETY USER SAFE INSPECTION

15. The truck manufacturer’s capacity, operation

DRIVER’S DAlFY CHECKLIST

TRUCK NO. OPERATOR: S”PERYISOR’SOK

START OF DAY ENDOFDAY HRS. FOR DAY

VISUAL CHECKS OPERATIONAL CHECKS

I, I OTHER GAUGES AND INSTRUMENTS II I I HYDRAULIC CONTROLS

1 1 OBVIOUSDAMAGEANDLEAKS SEAT BRAKE

ENGINE OIL LEVEL BA7TERY LOAD TEST

FORM NO. 597704937 HO” 80

e. Plugging & Directional Control i...

j. Seat Brake Operation I I 1&::::

d. Inspect Fan&Control ECAlEPA 1 f 1.x.:.:.:

PM - PLANNED MAINTENANCE PROGRAM

As an aid in performing and documenting the PM inspections, Clark has prepared

This manual is intended to be used in conjunction with the PM Report Form.

A check mark or entry is made on the

When you have finished the PM inspections,

Do not make repairs or adjustments

For safety, it is good practice to:

Always wear safety glasses. Wear a

DO NOT WORK ON THIS TRUCK

Code: PM-540, NOV 85 Page 1.1

The objective of the visual inspection is to be sure

Be sure to make a thorough inspection of the critical

Page 1.2 Code: PM-540, NOV 85

1 First, perform a visual inspection

o Walk around the truck and take note

When you find oil leaks due

2 Inspect the overhead guard for damage.

3 Inspect the load back rest extension

4 Inspect the fork carriage for damage,

5 Inspect the complete upright assembly; rails,

6 Check the lift cylinder piston rods for wear

rnr(a* PM-540. NOV 85 Page 1.3

7 Check the upright 1ift chains for equal

8 Inspect the condition of the carriage and

If the chains show slack due to an

Please refer to GROUP 34, Section 7,