Clark Sm 714 Service Manual

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Service
Manual
SM-714 Revision 1

WHEE
LD
IR ECT
IO N

BA
TTE
RY
LEV
EL

OP15X

2317 Alumni Park Plaza

Suite 500
Copyrighted Material Lexington, KY, 40517-4288
USA
Intended for CLARK dealers only
Do not sell or distribute
This is the cut pages sample. Download all 528 page(s) at: ManualPlace.com
 is a trademark of Clark Material Handling Company.
©
2004 Clark Material Handling Co., Lexington, KY 40517-4288
All Rights Reserved. Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
 F-code Section C-code
PT
Standard Codes
Version no T-code
000

Standard Codes
B-Code = Business area
F-Code = Product family
C-Code = Component function

Worksheet standard

W-Code = Working code

R-Code = Reason code
SO-Code = Assortment

F-Code List

PT Order Picker Truck

T-Code List

No. Model

C-Code List

No Function Group C-Code

0 Chassis 0000
1 Motors 1000
2 Drive Gear / Transmission 2000
3 Brake / Wheel System 3000
4 Steering System 4000
5 Electrical System 5000
6 Hydraulic / Pneumatic System 6000
7 Operating Function-lifting Mast / Cylinders 7000
8 Peripheral / Installation Equipment 8000

© Clark
BT Products
Material Handling Co. SM-714 Copyrighted Material
Feb 2004 1
Intended for CLARK dealers only
Do not sell or distribute
F-code Section C-code
PT
Standard Codes
Version no T-code
000

9 Optionals / Attachments 9000

10 Tools 10000

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 Table of Contents

Table of Contents

Standard Codes ............................................................................................. 1

Warning Symbols ......................................................................................... 15

Warning Levels ......................................................................................... 15

Prohibitory Symbols .................................................................................... 16

Ordinance Symbols .................................................................................. 16

Safety ............................................................................................................ 17
General Safety .......................................................................................... 17

Battery Safety ............................................................................................... 21

Static Discharge Precautions ..................................................................... 26

Welding Safety ............................................................................................. 28

Introduction, Service Manual ...................................................................... 31

Contents, Section M ..................................................................................... 33

Machine Information ................................................................................. 33

General Product Information ...................................................................... 35

Truck Presentation .................................................................................... 35
Truck Side Views .................................................................................. 35
Intended Truck Application .................................................................... 35
Prohibited Truck Application ................................................................. 36
Truck Data ............................................................................................. 36
Dimensions ........................................................................................... 37
Data Plate ............................................................................................. 38
Main Components ..................................................................................... 39

Inch (SAE) and Metric Fasteners ................................................................ 43

Introduction ............................................................................................... 43
Nomenclature, Threads ............................................................................ 44
Strength Identification ............................................................................... 45
Conversion of Metric and English Units .................................................... 52

Technical Service Data ................................................................................ 55

Ordering Spare Parts ................................................................................... 59

Contents, Section P ..................................................................................... 61

Planned Maintenance ............................................................................... 61

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 Table of Contents

Introduction, Maintenance .......................................................................... 63

Jacking Truck Off The Floor ..................................................................... 64
Operator Platform .................................................................................. 64
Truck Frame .......................................................................................... 64
Baseleg ................................................................................................. 65
Lubricants ................................................................................................. 66
Standard ................................................................................................ 66
Cold Storage ......................................................................................... 66
Freezer .................................................................................................. 68

Service Schedule ......................................................................................... 69

Planned Maintenance Schedule ............................................................... 69
Planned Maintenance Procedures ............................................................ 73
Services Performed Daily or Every 8 Operating Hours ......................... 73
Battery Level (BL) ............................................................................. 73
Drive Wheel Indicator ....................................................................... 74
Hourmeter ......................................................................................... 74
Hydraulic System .............................................................................. 74
Frame/Sheet Metal ........................................................................... 75
Wheels/Tires ..................................................................................... 75
Functions/Operations ........................................................................ 75
Safety Belt, Tether, and Body Harness ............................................ 75
Services Performed Monthly or Every 120 Operating Hours ................ 75
Inspection ......................................................................................... 75
Transmission .................................................................................... 75
Battery .............................................................................................. 76
Electrical Connections ...................................................................... 76
Contactor Tips (NOT Sealed) ........................................................... 76
Motor Brushes .................................................................................. 76
Drive Motor ....................................................................................... 76
Hydraulic Reservoir .......................................................................... 77
Frame Lube ...................................................................................... 77
Pivot Points ....................................................................................... 77
Services Performed Semi-Annually or Every 720 Operating Hours ...... 77
Inspection ......................................................................................... 77
Transmission .................................................................................... 77
Hydraulic System .............................................................................. 78
Brakes ............................................................................................... 78
Lift and Platform Chains ................................................................... 78
Services Performed Annually or Every 1440 Operating Hours ............. 79
Battery .............................................................................................. 79
Brake ................................................................................................ 79
Hydraulic Fluid .................................................................................. 79

Lubrication Chart ......................................................................................... 81

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 Table of Contents

Oil and Grease Specifications .................................................................... 82

Approved Oils and Grease ....................................................................... 82
Grease Location Points ............................................................................ 83

Contents, Section S ..................................................................................... 85

Service Instructions .................................................................................. 85

Chassis ......................................................................................................... 87
Theory of Operation .................................................................................. 88
Maintenance ............................................................................................. 88
Troubleshooting ........................................................................................ 88
Repair and Rebuild ................................................................................... 88
Front Cover ........................................................................................... 88
Front Panel ............................................................................................ 89
Left-hand Cover .................................................................................... 89
Right-hand Cover .................................................................................. 90

Operator Platform ........................................................................................ 91

Theory of Operation .................................................................................. 92
Maintenance ............................................................................................. 92
Troubleshooting ........................................................................................ 92
Repair and Rebuild ................................................................................... 93
Console Cover ...................................................................................... 93
Floor Mat ............................................................................................... 94

Battery Compartment .................................................................................. 95

Theory of Operation .................................................................................. 96
Maintenance ............................................................................................. 96
Troubleshooting ........................................................................................ 96
Repair and Rebuild ................................................................................... 97
Battery Stop Plate ................................................................................. 97
Battery ................................................................................................... 98
Battery Rollers ....................................................................................... 99

Operator Controls ....................................................................................... 101

Theory of Operation ................................................................................. 101
Maintenance ............................................................................................ 101
Troubleshooting ....................................................................................... 101
Throttle Potentiometer Test .................................................................. 101
Repair and Rebuild .................................................................................. 102
Multi-Function Control Handle .............................................................. 102
Steer Wheel ......................................................................................... 104
Deadman Pedal ................................................................................... 105
Pallet Clamp ......................................................................................... 108
Tether ................................................................................................... 110

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Intended for CLARK dealers only
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 Table of Contents

Decals ........................................................................................................... 111

Decal with Protective Sheet ..................................................................... 111
Decal without Protective Sheet ................................................................ 111

Electric Motors ............................................................................................ 115

Theory of Operation ................................................................................. 115
Maintenance ............................................................................................ 115
Troubleshooting ....................................................................................... 116
Repair ...................................................................................................... 125
Brush Replacement .............................................................................. 125
Pump Motor .......................................................................................... 125
Drive Motor ........................................................................................... 129
Fan Motor Assembly ............................................................................ 131
Rebuild ..................................................................................................... 132
Pump Motor and Drive Motor Component Disassembly ..................... 132
Inspection ............................................................................................. 134
Drive End Head ............................................................................... 134
Commutator End Head .................................................................... 134
Bearings ........................................................................................... 134
Brush and Commutator .................................................................... 134
Armature .......................................................................................... 137
Frame and Field Assembly .............................................................. 138
Assembly/Testing ................................................................................. 139
Bearing Installation .......................................................................... 139
Testing ............................................................................................. 140
Fan Motor Rebuild ................................................................................ 140

Transmission ............................................................................................... 141

Theory of Operation ................................................................................. 142
Maintenance ............................................................................................ 142
Fluid Changing ..................................................................................... 142
Troubleshooting ....................................................................................... 142
Repair and Rebuild .................................................................................. 146
Transmission Disassembly .................................................................. 146
Pivot Ring ........................................................................................ 148
Drive Unit Gear Case ....................................................................... 152
Radial Ring ...................................................................................... 152
Axle Shaft and Bevel Gear .............................................................. 153
Spiral Gear and Helical Gear ........................................................... 155
Bearing Cup and Shim ..................................................................... 157
Spur Gear ........................................................................................ 159
Transmission Reassembly ................................................................... 160
Gear Case ....................................................................................... 160
Axle Shaft ........................................................................................ 160
Bevel Gear ....................................................................................... 162

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 Table of Contents

Spiral Gear ....................................................................................... 163

Gear Set .......................................................................................... 164
Calculating Shim Formulas .............................................................. 165
Gear Case Bearing Cup and Shim .................................................. 168
Helical Gear/Spiral Pinion Gear ....................................................... 170
Axle .................................................................................................. 173
Measuring Backlash ........................................................................ 177
Pivot Ring ........................................................................................ 179
Drive Unit ......................................................................................... 181
Gear Case Cover ............................................................................. 184

Electric Brake .............................................................................................. 185

Theory of Operation ................................................................................. 185
Maintenance ............................................................................................ 185
Brake Air Gap Adjustment .................................................................... 185
Troubleshooting ....................................................................................... 186
Repair and Rebuild .................................................................................. 187
Brake Assembly ................................................................................... 188
Brake Friction Plate (Rotor) .................................................................. 189

Drive Wheel .................................................................................................. 191

Theory of Operation ................................................................................. 191
Maintenance ............................................................................................ 191
Troubleshooting ....................................................................................... 191
Repair and Rebuild .................................................................................. 192

Load Wheels ................................................................................................ 195

Theory of Operation ................................................................................. 198
Maintenance ............................................................................................ 198
Troubleshooting ....................................................................................... 198
Repair and Rebuild .................................................................................. 198
Single Load Wheel ............................................................................... 199
Tandem Articulated Load Wheel .......................................................... 200
Side Guide Rollers (Optional) .............................................................. 202

Steering Unit ................................................................................................ 203

Theory of Operation ................................................................................. 206
Maintenance ............................................................................................ 206
Troubleshooting ....................................................................................... 206
Repair and Rebuild .................................................................................. 207

Steering Arm / Wheel / Lever ..................................................................... 209

Theory of Operation ................................................................................. 210
Maintenance ............................................................................................ 210
Troubleshooting ....................................................................................... 210

Copyrighted Material
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 Table of Contents

Steer Encoder Test .............................................................................. 210

Repair and Rebuild .................................................................................. 212
Steering Wheel ..................................................................................... 212
Steering Encoder ................................................................................. 213

Steering Bearing ......................................................................................... 215

Theory of Operation ................................................................................. 216
Maintenance ............................................................................................ 216
Troubleshooting ....................................................................................... 216
Repair and Rebuild .................................................................................. 216

Electrical Functions .................................................................................... 219

Theory of Operation ................................................................................. 219
Battery Plugged In ................................................................................ 220
Deadman .............................................................................................. 226
General ............................................................................................ 226
Closing Deadman Switches (S2 and S23) ....................................... 226
Steering ................................................................................................ 232
Travel ................................................................................................... 234
Lift/Lower .............................................................................................. 240
Lift (S5) ............................................................................................ 240
Lower (S4) ....................................................................................... 244
Maintenance ............................................................................................ 266
Horn Button Pass Codes ...................................................................... 266
Wiring ................................................................................................... 272
Definitions ........................................................................................ 272
Shorts to Frame Test ....................................................................... 273
Troubleshooting ....................................................................................... 278
Maintenance (Chirp) Mode ................................................................... 280
Entering Maintenance Mode Using Deadman Pedal ....................... 280
General Testing ............................................................................... 280
Platform Manager Fault Codes ............................................................ 282

Electronic Components .............................................................................. 319

Theory of Operation ................................................................................. 321
Maintenance ............................................................................................ 322
Troubleshooting ....................................................................................... 322
Repair and Rebuild .................................................................................. 322

Battery .......................................................................................................... 325

Theory of Operation ................................................................................. 325
Maintenance ............................................................................................ 325
Inspection and Care ............................................................................. 325
Exterior Cleaning .................................................................................. 326
Charging ............................................................................................... 326

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 Table of Contents

Storage ................................................................................................. 327

History Record ..................................................................................... 327
Troubleshooting ....................................................................................... 328
Repair and Rebuild .................................................................................. 329

Battery Connector ....................................................................................... 331

Theory of Operation ................................................................................. 331
Maintenance ............................................................................................ 331
Inspection ............................................................................................. 331
Troubleshooting ....................................................................................... 332
Repair and Rebuild .................................................................................. 332

Lights (Optional) ......................................................................................... 335

Theory of Operation ................................................................................. 335
Maintenance ............................................................................................ 335
Troubleshooting ....................................................................................... 335
Repair and Rebuild .................................................................................. 335
Overhead Guard Light .......................................................................... 335
Adjustable Lights (Optional) ................................................................. 338
Warning Light ....................................................................................... 339

Horn and Travel Alarm ................................................................................ 341

Theory of Operation ................................................................................. 341
Maintenance ............................................................................................ 341
Troubleshooting ....................................................................................... 341
Repair and Rebuild .................................................................................. 342
Horn ..................................................................................................... 342
Travel Alarm ......................................................................................... 343

Instrument Panel and Displays .................................................................. 345

Theory of Operation ................................................................................. 345
Start Up ................................................................................................ 345
Battery Level Display LED Messages .................................................. 347
Steering Indicator Messages ................................................................ 350
Display Messages ................................................................................ 351
Hourmeter ............................................................................................ 351
Sounder ................................................................................................ 352
Maintenance ............................................................................................ 353
Troubleshooting ....................................................................................... 353
Display ................................................................................................. 353
Hourmeter ............................................................................................ 354
No Display ....................................................................................... 354
Hourmeter Glass Icon Does Not Flash ............................................ 354
Hourmeter Glass Icon Always Flashes ............................................ 354

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 Table of Contents

Start/Stop Switches .................................................................................... 355

Theory of Operation ................................................................................. 356
Maintenance ............................................................................................ 356
Troubleshooting ....................................................................................... 356
Repair and Rebuild .................................................................................. 357
Key Switch ........................................................................................... 357
Emergency Power Off (EPO) ............................................................... 358
Contact Block ................................................................................... 358
EPO Actuator ................................................................................... 360
Deadman Switches .............................................................................. 360

Mast Switches ............................................................................................. 361

Theory of Operation ................................................................................. 362
Maintenance ............................................................................................ 363
Adjustment ........................................................................................... 363
Troubleshooting ....................................................................................... 366
Repair and Rebuild .................................................................................. 366

Steer Switches ............................................................................................. 367

Theory of Operation ................................................................................. 368
Maintenance ............................................................................................ 368
Troubleshooting ....................................................................................... 369
Repair and Rebuild .................................................................................. 370

Fuses ............................................................................................................ 371

Theory of Operation ................................................................................. 372
Maintenance ............................................................................................ 372
Wiring Harness ..................................................................................... 372
Power Cables ....................................................................................... 373
Troubleshooting ....................................................................................... 373
Repair and Rebuild .................................................................................. 373

Contactor Panel ........................................................................................... 375

Theory of Operation ................................................................................. 376
Maintenance ............................................................................................ 376
Contact Tip Inspection ......................................................................... 377
Resistance Testing ............................................................................... 377
Troubleshooting ....................................................................................... 377
Repair and Rebuild .................................................................................. 378
Contact Assembly ................................................................................ 378

Traction Power Amplifier (TPA) [Transistor Controller] .......................... 381

Theory of Operation ................................................................................. 381
Basics Of Circuit Operation .................................................................. 381
Interface ............................................................................................... 383

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 Table of Contents

Control Features .................................................................................. 383

Motor Circuit ......................................................................................... 385
Control Circuit ...................................................................................... 386
Definitions ............................................................................................ 387
Maintenance ............................................................................................ 388
Safety ................................................................................................... 388
Cleaning ............................................................................................... 388
TPA Adjustable Settings ...................................................................... 389
Troubleshooting ....................................................................................... 390
Diagnostics and Troubleshooting ......................................................... 390
Handset Diagnostics ............................................................................ 390
Fault Codes .......................................................................................... 393
Troubleshooting Chart .......................................................................... 394
Repair and Rebuild .................................................................................. 396

Hydraulic System ........................................................................................ 397

Theory of Operation ................................................................................. 397
Lift ........................................................................................................ 397
Lower ................................................................................................... 399
Maintenance ............................................................................................ 401
Changing Hydraulic System Fluid ........................................................ 401
System Draining ................................................................................... 402
Refilling System ................................................................................... 402
Bleeding Hydraulic System .................................................................. 403
Troubleshooting ....................................................................................... 404
Repair and Rebuild .................................................................................. 404
Lift Manifold .......................................................................................... 407
Hydraulic Reservoir .............................................................................. 410
Manual Release Valve ......................................................................... 411
Lift Pump .............................................................................................. 414

Two Stage Mast Staging Cylinder ............................................................. 417

Theory of Operation ................................................................................. 418
Maintenance ............................................................................................ 418
Troubleshooting ....................................................................................... 418
Repair and Rebuild .................................................................................. 418
Bearing and Seals ................................................................................ 419

Three Stage Mast Staging Cylinder ........................................................... 427

Theory of Operation ................................................................................. 428
Maintenance ............................................................................................ 428
Troubleshooting ....................................................................................... 428
Repair and Rebuild .................................................................................. 428
Bearing and Seals ................................................................................ 429

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 Table of Contents

Three Stage Mast Freelift Cylinder ............................................................ 437

Theory of Operation ................................................................................. 438
Maintenance ............................................................................................ 438
Troubleshooting ....................................................................................... 438
Repair and Rebuild .................................................................................. 439

Mast .............................................................................................................. 447

Theory of Operation ................................................................................. 447
Maintenance ............................................................................................ 448
Visual Inspection .................................................................................. 448
Chain Inspection .................................................................................. 448
Lubrication ............................................................................................ 452
Adjustment ........................................................................................... 454
Troubleshooting ....................................................................................... 455
Repair and Rebuild .................................................................................. 455

Platform ........................................................................................................ 483

Theory of Operation ................................................................................. 485
Maintenance ............................................................................................ 486
Platform Shimming ............................................................................... 486
Troubleshooting ....................................................................................... 488
Repair and Rebuild .................................................................................. 488

Lifting Gear (Crosshead), Three Stage Mast ............................................ 495

Theory of Operation ................................................................................. 497
Maintenance ............................................................................................ 497
Troubleshooting ....................................................................................... 497
Repair and Rebuild .................................................................................. 497

Fork Assembly ............................................................................................ 499

Theory of Operation ................................................................................. 500
Maintenance ............................................................................................ 500
Troubleshooting ....................................................................................... 500
Repair and Rebuild .................................................................................. 500
Forks .................................................................................................... 500
Pallet Clamp ......................................................................................... 502

Handset, Old ................................................................................................ 505

Operating Modes ..................................................................................... 508
Revert to Previous Settings ..................................................................... 511
Handset Self Test .................................................................................... 511

Handset, New ............................................................................................... 513

Display Screen ......................................................................................... 514
Menu Navigation Key ........................................................................... 514

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 Table of Contents

Data Inc/Dec Key ................................................................................. 514

Bookmark Keys .................................................................................... 514
Operation ................................................................................................. 515
Menu Structure ..................................................................................... 515
Main Menu ........................................................................................... 516
Interface Protocols and Backward Compatibility .................................. 517
Parameter Changing ............................................................................ 517
Real-Time Monitoring ........................................................................... 518
Reading Faults and Diagnostic History File ......................................... 518
Cloning and Restoring the Previous Programming .............................. 519
Information Displays ............................................................................. 519
Programmer SetUp .............................................................................. 520

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 Table of Contents

This page is intentionally left blank.

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Do not sell or distribute

 F-code Section C-code
PT
Warning Symbols
Version no T-code
000

Warning Symbols
Always follow the warnings given in this Service Manual
and on the truck to avoid accidents from occurring.

1. Warning Levels
Warning text is given in four levels and provides information
on the risks, describes the consequences, and instructs how
to avoid accidents.

DANGER
Warns that an accident will occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or extremely severe material damage.

WARNING
Warns that an accident can occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or severe material damage.

CAUTION
Warns that an accident can occur if the instructions are not
followed.
The consequences are personal injury and/or material
damage.
NOTE!
Marks the risk of an accident or breakdown if the
instructions are not followed.

Copyrighted Material
© Clark Material Handling Co. SM-714 for CLARK Feb
Intended 2004only
dealers 15
Do not sell or distribute
F-code Section C-code
PT
Prohibitory Symbols
Version no T-code
000

Prohibitory Symbols

NO SMOKING
If smoking occurs in situations where a restriction against
smoking is stated, a serious accident can occur.

OPEN FLAMES PROHIBITED

If open flames are used in situations where open flames are
prohibited, a serious accident can occur.

GENERAL PROHIBITION
If the prohibition is ignored, a serious accident can occur.

1. Ordinance Symbols

SAFETY SHOES
When the directive for safety shoes is given, safety shoes
shall always be worn to reduce personal injury.

PROTECTIVE GLASSES
When the directive for protective glasses is given,
protective glasses shall always be worn to reduce personal
injury.

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 F-code Section C-code
PT
Safety
Version no T-code
000

Safety
1. General Safety
Do NOT operate or work on this truck unless trained,
qualified, and authorized to do so and have read the
Operator’s Manual.

Know the truck controls and what they do.

Do NOT operate truck if it needs repair or if it is in any way

unsafe.

Copyrighted Material
Intended for CLARK dealers only
© Clark Material Handling Co. SM-714 Do not sell or distribute
Feb 2004 17
Clark Sm 714 Service Manual
Full download: http://manualplace.com/download/clark-sm-714-service-manual/
F-code Section C-code
PT
Safety
Version no T-code
000

Do NOT operate truck unless the safety belt or harness is

securely fastened around you.

Operate truck from the position of the Operator.

Before working on this truck, always turn the key switch to

OFF and disconnect truck’s battery connector (unless this
manual states otherwise).

Do NOT wear watches, rings, or jewelry when working on the

truck.

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