SM-587 NPR17-20 (NPR345)

SM-587
NPR 17/20
CLRRK
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Service
Manual
SM -587
NPR-345 NPR-17
NPR-20
TABLE OF CONTENTS
w Group No-Section No.-Page No. Item Groun No-Section No.-Page No.
01 Planned Maintenance Procedures PM-l thru 29 3 1 Hydraulic Control Valves & Solenoid
02 Lubrication Charts 01-1-l Control Valves, Remove & Replace30- l- 1
03 Battery Service 12-1-1 32 Auxiliary Reach & Tilt Valve Overhaul 30-2- 1
04 Multi-Function Control Handle Switches 13-1-1 33 Lift Control Valve Overhaul 30-3- 1
05 Electric Motor Service -- General 16-2-1 34 Lowering Solenoid Valve 30-4- 1
06 Traction Motor Service 16-3-1 35 Auxiliary Solenoid Valve
07 Pump Motors 16-5-1 ( Reach & Tilt Control Valves) 30-5-l
08 Auxiliary/Steer Pump Motor Service 16-7-1 36 Reach & Tilt Selector (Solenoid) Valves 30-6- 1
09 Contactor Service 17-1-1 37 Side Shifter Solenoid Control Valve 30-7- 1
10 Electrical Sequence of Operation 19-2-1 38 Tilt Cylinder Overhaul 32-2-l
11 EV-T15 Solid State Control Status Code 19-3-1 39 Reach Cylinder Overhaul 32-3-l
12 Oscillator Card Settings and Tests 19-4-1 40 Upright & Pantograph Remove & Replace
13 Steering Control Adjustments (EV-T5PS)19-5-1 and Roller Shim Adjustments 34-l-l
14 Wiring Diagrams 19-6-1 41 Pantograph & Fork Carriage R&R
15 Directional, Lift & Lower Switches and and Roller Shim Adjustments 34-2-l
Transducer Adjustment 19-7-1 42 Rail Lift Cylinder Overhaul 34-3- 1
16 Periodic Electrical Checks 19-8-1 43 Free Lift Cylinder Overhaul 34-4- 1
17 Oscillator Card, Remove & Replace 19-10-l 44 Lift Fork Inspection 34-5- 1
18 solenoid Control Card Troubleshooting lo- 16- 1 45 Lift Chains 34-6-l
19 Axle Articulation Adjustment 20-l-l 46 Load Wheels 35-l-l
20 Drive Unit Overhaul 20-2- 1 47 Specifications 40-l-l
21 Traction Wheel & Tire 22-l-l 48 Service Weights 40-2- 1
22 Caster Wheel & Tire 22-2- 1 49 Lubricants and Shop Supplies 40-3-l
23 Motor Brake 23-l-l
24 Caster Brake 23-2- 1 NOTE
25 Brake Bleeding Procedure 23-3-l Pictorial Indexes are provided on

the following four pages.
26 Brake Pedal Adjustment 23-4- 1
26-l-l Index ............................ ....Page 6/7
27 Hydraulic Pressure Checks
28 Hydraulic Sump Tank, Filter and
Strainer(s), Service 29-l-l
29 Hydraulic Schematic 29-2- 1
30 Hydraulic Pump Overhaul 29-4- 1
SM-587 Copyrighted
Table of Material
Contents - 1 Dee 94
INDEX Pictorial Index
Pictorial Index #1
NPR-345
/ 23
Dee 94 Index-2 SM-587

Pictorial Index INDEX
Index 1 of 2
Pictorial Index
Contents
PM Planned Maintenance Procedures ........................... PM-01 thru 29
PM Caster Brake: Adjusting for Lining Wear; When to
Replace Brake Linings ........................................................... PM- 16
Motor Brake: Adjusting for Lining Wear When to
Replace Brake Linings ........................................................... PM-28
Group ........................................................................ Group-Section-Page
01 Lubrication Chart and Instructions.. ................................ .01-l-01 thru 07
12 Battery Service Instructions ............................................. 12-l-01 thrllO8
13 Multi-Function Control Handle Switches ....................... .13-l-01 thru 05
16 Electric Motor Service - General .................................... .16-2-01 thru 09
16 Traction Motor Service ................................................... 16-3-01 thru 11
16 Pump Motors 24 & 36 Volt.. .......................................... .16-5-01 thm 11
16 Auxiliary/Steer Pump Motor Service .............................. .16-7-01 thru 12
17 Contactors, Control Panel.. ............................................. .17-l-01 thru 09
19 Electrical Sequence of Operation .................................... .19-2-O 1 thru 5 1
19 Instructions - Status Codes for EV-T15 Control.. ............ .19-3-01 thru 15
19 Oscillator Card Settings ................................................... 19-4-01 thnlo4
19 Steering Control Adjustments.. ....................................... .19-5-01 thru 06
19 Wiring Diagrams ............................................................ 19-6-01 thru 03
19 F&R Switches, Up & Down Switches, Transducer Adjl . .19-7-01 thru 10
19 Periodic Electrical Checks .............................................. .19-8-01 thru 16
19 Oscillator Card Remove & Replace .............................. .19-lo-01 thru 04
19Solenoid Control Card Trouble Shooting.. ..................... .19-16-01 thru 06
20 Axle Articulation Adjustment .......................................... 20-l-01 thru 03
20 Drive Unit Disassembly & Reassembly .......................... .20-2-01 thm 19
22 Wheel & Tire, Traction ................................................... 22-l-01 thnlo3
22 Wheel & Tire, Caster ...................................................... 22-2-01 thru 04
23 Brake, Traction Motor ..................................................... 23-l-01 thru 08
23 Brake, Caster ................................................................. .23-2-01 thru 09
23 Bleeding Procedure, Brake ............................................. .23-3-01 thru 02
23 Brake Pedal and Cylinder(s) Check & Adjustment ........ ..23-4-O 1 thru 02
SM-587 Copyrighted Material

Index-3 Dee 94
INDEX Pictorial Index
Pictorial Index :#2

NPR-345
Dee 94 Index-4 SM-587

Pictorial Index INDEX
Index 2 of 2
Pictorial Index
Contents
Group .............................................................................................. Group-Section-Page
26 Pressure Check & Adjustment -Steering, Auxiliary, Reach & Tilt,
and Side Shift (If so equipped) ...................................... 26-l-l thru 05
29 Hydraulic Sump Tank, Filter and Strainer Service .......... ...29-l- 1 thru 07
29 Hydraulic Schematic Diagram ........................................ ..29-2- 1 thru 02
29 Hydraulic Pump Overhaul.. ............................................. ..29-4- 1 thru 05
30 Hydraulic Control Valves and Solenoid Control Valves,
Remove & Replace ..................................................... .30-1-l thru 14
30 Auxiliary, Reach/Tilt Control Valve Service ................... ..30-2- 1 thru 07
30 Lift Control Valve Service Procedures .............................. 30-3-l thrlll0
30 Lowering Solenoid Valve Service Procedures ................. ..30-4- 1 thru 06
30 Auxiliary Solenoid Valve (Reach/Tilt Control) ................. .30-5 1 thru 06
30 Reach & Tilt Selector Valve Service Procedures ............. ..30-6- 1 thru 13
30 Side Shifter Solenoid Control Valve (Optional Equipment) 30-7-l thru 09
32 Tilt Cylinder Overhaul Procedures .................................... 32-2-l thru 07
32 Reach Cylinder Overhaul Procedures ............................... .32-3- 1.thru 07
34 Upright, Pantograph Remove & Replace Procedures and
Roller Shim Check & Adjustment Procedures.. ............ .34-l- 1 thru 40
34 Pantograph & Fork Carriage Service Procedures ............. ..34-2- 1 thru 12
34 Lift Cylinder, Rail - Overhaul Procedures.. ....................... .34-3-l thru 05
34 Lift Cylinder, Free Lift - Overhaul Procedures.. ............... ..34-4- 1 thru 05
34 Lift Fork Inspection ......................................................... .34-5-l thru 04
34 Lift Chain Inspection, Lubrication and Specifications.. .... ..34-6- 1 thru 06
35 Load Wheel Service Procedures ....................................... .35-l- 1 thru 02
40 NPR-345 Specification Listing ........................................ ..40-l- 1 thru 13
40 Service Weights ............................................................... .40-2-l thru 04
40 Lubricants and Shop Supplies ........................................... 40-3-l thru 14

Index-5 Dee 94
INDEX
m Group No-Section No.-Page No. Ttem Grout No-Section No.-PaPe No.
Axle Motors
Articulation Adjustment 20-l-l General 16-2-1
Battery Traction 16-3-1
Remove & Replace 12-1-1 Auxiliary/Steer Pump 16-7-1
Service 12-1-1 Pantograph & Fork Carriage
Brakes Remove & Replace 34-2- 1
Motor 23-l-l Roller Shim Adjustments 34-2- 1
Caster 23-2- 1 Lift Fork Inspection 34-5 1
Bleeding 23-3-l Periodic Electrical Checks 19-8-1
Pedal Adjustment 23-4- 1 Cable & Wire Routing 19-8-1
Master Cylinder 23-4- 1 Planned Maintenance Procedures PM- 1 thru 29
Caster Service Checks PM-17 Caster Special Socket Adapter PM-24
Control Panel Pressure Checks
Contactors 17-1-1 Steering 26-l-l
Oscillator Card, Lift Circuit 26-l-l
Remove & Replace 19-10-l Auxiliary Reach & Tilt 26-l-l
Cylinders Pump Overhaul 29-4- 1
Tilt Cylinder Overhaul 32-2- 1 Sequence of Operation
Reach Cylinder Overhaul 32-3- 1 Electrical 19-2-1
Rail Lift Cylinder Overhaul 34-3-l Solid State Control
Free Lift Cylinder Overhaul 34-4- 1 Status Codes (EV-T15) 19-3-1
Diagrams Oscillator Card Settings/Tests 19-4-1
Electrical 19-6-1 Steering Adjustments
Hydraulic 29-2- 1 (EV-TSPS) 19-5-1
Drive Unit Switches
Overhaul 20-2- 1 Directional, Lift & Lower 19-7-1
Lift Chains Multi-Function Control Handle 13-l- 1
Inspection 34-6-2 Transducer Adjustment 19-7-1
Lubrication 34-6-6
Remove & Replace 34-6-6
Lubrication
Charts & Specifications 01-1-l
Dee 94 Index - 6 SM-587

INDEX
Upright & Pantograph
Lift Chains 34 - Manual Insert
Remove & Replace 34-l-l
Roller Shim Adjustments 34-l-l
Valves
Remove & Replace 30-l-l
Auxiliary Reach & Tilt 30-2- 1
Lift Control 30-3-l
Lowering Solenoid 30-4- 1
Auxiliary Solenoid Valve
( Reach & Tilt) 30-5-l
Reach & Tilt Selector 30-6-l
Side Shifter Solenoid Control 30-7-l
Specifications 40-l-l
Service Weights 40-2- 1
Lubricants and Shop Supplies 40-3-l
Sump Tank
Fluid Level 29-l-l
Filter and Strainer(s) 29-l-l
Wheel & Tire
Traction 22-l-l
Caster 22-2- 1
Load 35-l-l

index- 7 Dee 94
Cautions
The following is a list of CAUTIONS connected with the operation andmaintenance of trucks
equipped with Solid State Control Panels.
Safety Signs and Safety Messages

SAFETY SIGNS and MESSAGESareplaced in this manual and also on the truck to provide instructions and
to identify specific areas where potential hazards exist and special precautions must be taken. Be sure you know
and understand the meaning of these instructions, signs and messages. Damage to the truck or serious injury
to you or other persons may result if these messages are not followed. If warning decals are damaged they must
be replaced. Contact your Clark dealer for replacements.
NOTICE This message is used when special information, instructions or identification is

required relating to procedures, equipment, tools, pressures, capacities and other
special data.
IMPORTANT This message is used when special precautions should be taken to ensure a correct
action or to avoid damage to or malfunction of the truck or a component.
A! CAUTION This message is used as a reminder of safety practices which can result in personal
injury if proper precautions are not taken.
A WARNING This message is used when a hazard exists which can result in serious personal
if
injury or death, proper precautions are not taken.
A DANGER This message is used when an extreme hazard exists.
A WELDING ON TRUCKS
1. Make sure the truck has no grounds.
2 Disconnect truck battery.
3. Protect electrical wiring and components from weld spatter with
a shield.
4. Ventilate battery or remove battery from truck.
If the above is not followed, damage can result to wiring and electrical
components on a solid state control truck.

i Dee 94
CAUTIONS
A DO NOT STEAM CLEAN

Do not steam clean a solid state controlled truck as excessive moisture
will interfere with proper operation of the solid state components.
Solid State Controls should be cleaned at regularintervals. Blowing dirt off with an air hose (that
is restricted to 30 psi [207 kPa]) periodically will, for the most part, eliminate any serious
cleaningproblems. Should the need arise for a more thorough cleaning, water may be hosed over
the control and if necessary a mild detergent applied such as that used in washing dishes in our
home. The detergent should be rinsed off and the controls must be thoroughly air dried before
putting truck into service.
Periodic cleaning, such as those mentioned above, should preclude the need for using a
degreaser. However, if a degreaser is used we recommend the following:
Only approved solvents should be used to clean Solid State Control Components. Use Clark
#I1801146 Degreaser, or the equivalent to MS- 180 Freon TF Degreaser and Cleaner.
A CHECK POLARITY
Battery Polarity must be correct or the truck will not
operate.
A USE TRUCK BATTERY ONLY

Do not use a motor generator unit such as ready
power or a battery charger to move and/or check this
truck as serious damage may occur
IMPORTANT SAFETY NOTICE

Read and understand all Safety Precautions and Warnings before
performing repairs on lift trucks.
Appropriate servicemethodsandproperrepairproce- This manual cannot possibly anticipate all such varia-
dures are essential to the safe, reliable operation of tions and provide advice or precautions as to each.
industrial trucks as well as the personal safety of the Accordingly, anyone departing from the instructions
individual doing the work. This Service Manual provided in this manual through procedures used or
provides general directions for accomplishing service choice of tools, materials, and parts may jeopardize
and repair work with tested, effective techniques. his or her personal safety and/or the safety of the
Following them will help assure successful repair and vehicle user.
reliable truck operation.
Improper or careless techniques cause accidents. Dont
There are numerous variations in procedures, tech- take chances with incorrect or damaged equipment.
niques, tools and parts for servicing industrial trucks, Read and understand the procedures for safe opera-
as well as in the skill of the individual doing the work. tion and maintenance outlined in this manual.
Drive and work safely and follow the safety signs and their messages
displayed in the work area, on the truck and in this manual.
Dee 94 ii SM-587
Cautions
GENERAL PRECAUTIONS
Thefollowing list contains general precautions that should be followed when working
on a lift truck.
Service Electric Truck Batteries in a well-venti- Set the parking brake. Place chocks to the front
lated area to avoid the danger of lighting explo- and rear surfaces of the tires to provide further
sive gases, clear of pedestrians and with ad- restraint from inadvertent vehicle movement.
equate overhead clearance and on a flat, level Use safety stands or blocks whenever a proce-
surface. dure requires you to be under the vehicle.
Always wear safety glasses for eye protection. Follow the Safety Instructions outlinedin Group
Remove rings, watches, loose jewelry and open 12, Handling Storage Batteries.
clothing before working on a vehicle, to avoid Always Discharge the Capacitors prior to work-
serious injury. ing on or around electrical components. Refer to
Do not smoke while working on a vehicle. the instructions outlined in Group 19, Dis-
charging Capacitors.
Putpowerkey switchintheOFFposition,unless
otherwise required by the procedure.
A! CAUTION
Avoid contact with Battery Acid. The battery contains corrosive acid which
can cause injury. Follow the instructions outlined in Group 12 Handling
Storage Batteries and those instructions received with your battery and
charger.
...
III Dee 94
Foreword
This Service Publication provides information Procedures have been made easier to use by
covering normal service, maintenance and repair of providing specific steps only when necessary and
the Clark industrial lift trucks noted on the cover. It general instructions required to explain the activity,
has been specifically prepared to help owners and component, assembly, or process being worked on.
service personnel maintain these trucks in efficient The technician is expected to include obvious addi-
and safe operating condition. tional steps of standard procedure for removal, disas-
This manual is intended for use by persons who sembly, cleaning, inspection, reassembly, installa-
are trained and authorized to do lift truck mainte- tion, etc., as needed.
nance. It is designed to provide essential information Tobe better prepared to do the necessaryservice
about the correct and safe service maintenance and work, take time to completely read the entire proce-
repair of the truck by trained mechanics or service dure, including any special instructions, before start-
technicians. ing any work.
The information is organized by use of the The technician is cautioned and expected
Basic Group Numbering System used in the to...
Master Parts Book and the Customer Parts Manuals.
The manual includes:
... before beginning to work.
P.M. *Take time to completely read (entire) procedures,
including any special instructions.
Planned Maintenance Procedures
including precautions and safe
maintenance recommendations.
ABOUT PLANNED MAINTENANCE
01-40
Service specifications, adjust- The Planned Maintenance Procedures
ments, maintenance and overhaul located in the front of this manual provide a basic step
procedures including lubrication by step guide which should be followed in servicing
charts, recommended lubricants the vehicle. Adjustment Procedures, Specifications,
and service weights, etc. Lubrication Guides, Overhaul Procedures and other
data are found in the rear of this manual listed under
General and detailed service and repair Group and Section Numbers. Refer to the index.
procedures are outlined (as required) for each Regular, correct maintenance and care of
component or subsystem. Some procedures include
industrial trucks is not only important for long and
explanations that are common to several components
efficient truck life but it is essential for safe operation.
or subsystems. The importance of proper maintenance through
The Pictorial Index lists components or systems planned service, inspection and qualified repairs can-
by Basic Group Number of Major Parts. Additional not be emphasized too strongly. Preventive mainte-
content listings are placed at the beginning of each nance instructions are provided for reference in set-
Section in the manual. ting-up and conducting a recommended periodic
Planned Maintenance (PM) program.
The Table of Contents list the pages in this
manual.
NOTICE
The descriptions and specifications included in this manual were in effect at the time of
printing. Clark reserves the right to discontinue models at any time, or make improvements
and changes in specifications or design without notice and without incurring obligation.
Specifications, torques, pressures, measurements, adjustments, illustrations and other
items may change at any time. Contact your authorized CLARK dealer for information on
possible updates or revisions.
Dee94 iv SM-587
Foreword
An effective PM program should incorporate Inspection Forms

two basic phases: ~
To insure that the daily inspection and PM are prop-
1. An insnection net-formed bv the driver or main- erly performed, we recommended the use of inspec-
tenance man at the beginning of each shift. This tion forms. Such forms not only provide a guide for
is a quick visual check for obvious damage and the inspections and maintenance requirements for
leaksandafunctionaltest...acheckoffluidsand eachvehicle, they will assist you in determining when
water levels, lights (if so equipped), instruments to schedule a vehicle for major repairs. Consequently
and warning devices. theserepairscanbedonewithoutthedisruptiveeffect
2. The Planned Maintenance routine is based on of unscheduled down time.
50 to 250 operating hours ... with the interval
being determined by operating conditions. NOTE
Refer to the Operators Manual,
located on the truck, for additional
Records will tell you how often PM information on the operation, care
should be done. and maintenance of your truck.
l If an oneration is clean and not strenuous, a PM Contact your authorized Clark

interval can be extended. dealer for more information on
l If an oneration is extremelv dirtv and strenuous, maintenance and repair of these
t?-UCkS.
the PM interval may have to be reduced.
If the PM is faithfully followed, needs for

repair, major adjustment and component replace-
ment will be discovered and such work can be
scheduled eliminating unnecessary downtime and
cost. For instance, brake checks which are part of the
PM will uncover the need for adjustments and/or
repairs which may be required periodically.
The objectives of PM are:

1. To reduce costly unscheduled downtime.
2. Reduce maintenance costs.
3. Increase vehicle productivity.
4. Increase personal safety of drivers and other
personnel.

V Dee 94
The Planned Maintenance Procedures

Outlinedon the following pages are organized in
five basic catagories. They are:
1. Walk Around Visual Inspection.
The nature of problems found during aP.M. shouldbe
2. Operational Tests.
noted in the comments portion of the check sheet.
3. Cleaning. Whenever a system or comnonent is faultv or unsafe,
it must be noted on the check sheet andreported to the
4. Checks and Minor Adjustments.
designated authority at the conclusion of the P.M.
5. Lubrication.
Each catagory is preceded with a summary of the
inspections, checks, tests, etc., that should be per-
formed in each catagory.
P.M. CHECK SHEET 1. Visual Inspection

A special coding system on the P.M. Check sheet
allowstmckcondition tobereportedwithaminimum
number of words. As the P.M. is performed, a mark
should be made in the appropriate box of the compo-
nent being checked.
l (4) indicates the particular truck component or
system has been checked.
l (x) indicates the component or system is in need
of a minor adjustment or service (not part of the
normal P.M.) that should be taken care of in the
near future.
l (r) indicates there is a potential problem that
couldresult in damage to acomponent or system
and requires attention.
Code
l (s) indicates the need for urgent repair or replace $ = O.K.
ment of a component or system and the truck 1 O.K. X = Adjust (Not P.M.) I
should be shut down as possible property dam- Potential r = Repair or Replace
age or personel injury may result. ~~~~~~~~ s =
.....:.:.:.:.:.:.:.:.:., Requires Shop Repair
..:.:.:.:.:.:.:.:.:.:.:.:.:.:.:
..v.:.
.(.,.,.(.(.,.,.,.,.,.
.,.,.
.,..,.,.
.,.

PM-l Dee 94
l Visible frame damage.

l Tire Wear and/or lodged foreign objects in tire tread and/or badly darnaged side walls.
l Overhead Guard for security of mounting (loose or missing fasteners) and damage.
l Visible fluid leaks.
l Presence and condition of covers, pads, floor mat, decals and truck data plate.
l Safety Screen and/or Glass for security of mounting and damage.
l Visible signs of wear and/or damage to upright.
l Load Back Rest for security of mounting and damage.
l Check that ground chain link is touching the floor.
Visual Inspection
1. Insuect Batterv Plugi BzTruck Receutacle Battery Plug 7
l Disconnect battery from truck. Pull back on the

battery disconnect lever located at the right front Truck
corner of the console.
l Inspect the spring loaded terminals in the truck
battery receptacle and check the battery plug
terminals. Burned or pitted terminals should be
noted on the P.M. check sheet.
tsconnect Batterv and check

Spring Loaded Terminals
Dee 94 PM-2 SM-587

2. Check for Obvious Oil Leaks and peneral

condition of Frame & Overhead Guard
. Make a quick overall inspection for oil leaks. If
oil leaks are found, at this time, or later in the
P.M., fuc the minor leaks and report on the check
sheet any leaks which will require major repair.
3. Check condition of covers, pads and floor mat.
. Inspect name plates, warning decals and truck
date plate for damage and to be sure none are
missing. Be sure warning and instructional de-
cals are readable.
4. Check safety screen and/or glass for security of
mounting and damage.
. Check overhead guard for damage and security
of mounting. Be sure the legs of the overhead
guard are mounted securely and are not dam- Check for Obvious Leakage
aged, cracked or bent.
5. Batterv Retainers
. Check battery retainers for damage. Make cer-
tain retainers are locked in position at each end
of the battery compartment.
SM-587 CopyrightedPM-3
Material Dee 94
6. Inmect Wheels & Tire

. Check for obvious damage to tires on the load,
caster and drive wheels.
Look for excessive tire wear, cuts, breaks,
chunking or bond failure between the tires and
wheels.
Remove objects that are embedded in the tire.
Make sure grease fittings are not damaged and
none are missing.
Be sure drive wheel fasteners are secure and
none are missing. If they are loose, torque them
to specifications. Fasteners must be tightened
using a diagonal sequence as shown below (let-
tered A through G).
Retorque drive wheel fasteners

afterthefirst2OOhoursofopera-
tion. Wheel
Wheel
& Tire & Tire
Fastener Tightening
Sequence
D
F
B
A
G
@ C
E
TORQUE FASTENERS
TO:
124 - 139 LB. FT.
(168 - 188 N*M)
Dee 94 PM-4 SM-587

Check Mullti-Function control for freedom of l Check brakes.

operation.
l Check hour meter.
Check battery connection.
l Check steering.
Check horn.
l Check control plugging.
Check key switch and dash display.
l Check acceleration.
Check upright operation.
l Check speed limit switch operation.
Operational Tests Move control through all

a. Check Controls functions checking for free-
dom of movemenet.
NOTE
Battery connector should be
disconnectedandkey switch turned
OFF before making these checks.
l Inspect multi-function control handle for free-

dom of operation. Move control to the full
forward and rearward positions. Then move it
into the full left and full right positions. The
control must operate freely without binding and
spring return to neutral.
Check the Multi-Function Control for
Freedom of movement. Control should spring
l Connect battery.
Material Dee 94
b. Check horn to be sure it operates.
c. Turn key switch ON.
Check the Diamostic Disdav & Kev Switch

l Digital readout should display 8888 for about
one second after you turn the key switch ON.
This indicates that the digital readout is okay.
then, either the battery symbol or the wrench Digital Readout
symbol light should come ON. \
l Battery Symbol: When the battery syrnbol light
comes on, the digital readout shows the percent-
age of usable remaining battery charge. If the
readout registers 19 or less, the readout will
flash.
l Wrench Symbol: If this light comes on, a status
code will appear on the digital readout. The
status code may indicate an easily correctable
operator fault or it may indicate that the truck
should be serviced.
l Fault Codes: Codes -01 through -03, -06 and
-08 are usually operator fault codes, and can be
corrected by the operator as explained in Group
19, Section 3. A momentary display of status
code -99 indicates that the truck hours exceed
the preprogramed maintenance reminder hours
and the functions must be reset after completing
the P.M.
I
Wrenchkymb
d. Check the hour meter. Turn the key switch to
the OFF position. The hourglass symbol light Battery Symbo
should come on. The hours registered on the
truck should appear on the digital readout for
about four seconds. Record this hour meter
reading on the PM check sheet.
Dee 94 PM-6 SM-587

e. Check Hvdraulic Function%

. Aftermaking sureyouhaveoverheadclearance, ReachControl
gently pull back on the Multi-Function Control.
The pump motor should turn on and the carriage Tilt Control
should begin to elevate. Release the control. It
should return to neutral without binding and the !SideShift Control
pump motor should turn off. The control should (Optional)
not bind when moving it any position.
Elevate the upright to maximum fork height. As
the upright raises, watch for mechanical binding
of rails, rollers and damage to hoses and lift
chains.
Lower the upright to full down position. As the
upright lowers, watch for mechanical binding of
rails, rollers and damage to hose and lift chains.
Watch the upright to make sure Multi-Function Control Handle
it operatessmoothly between the Switch Buttons
free lift and rail lift stages.
. Hold in one button at a time and check tilt, reach
and side shift (if applicable) for proper operation
andrange. Forks should tilt evenly and smoothly.
Pantograph should reach and retract smoothly
without hesitation. Fork Side Shift operation
should be smooth without binding.
Note any excessive slop or noise in the
upright that may indicate roller damage or roller
reshimming is required.
Record any malfunction and/or damage on the
P.M. Check List.
Check Brake
After checking that you have a clear travel path
ahead, move the truck forward at a slow speed.
Slowly lift foot from brake pedal. Drive motor
should cut off before the brakes apply.
Move truck in reverse at a slow rate of speed.
Slowly lift foot from pedal, the motor should cut
off before the brakes apply.
Ifoperation is notsatisfactory ... do not operate
the truck. Report condition to designated au-
thOIitJC

PM-7 Dee 94
h. Check Steerin
. While moving the truck at a slow rate of speed
in a forward direction of travel, turn hand wheel
slowly both clockwise and counterclockwise
while listening for unusual steering noise. The
steering should be smooth without hesitation. Direction of Travel
Next, turn the hand wheel rapidly in both direc-
tions. Note on P.M. Check List if steering locks
momentarily. This may indicate a malfunction
in the hydraulic steering system.
j. Check Controlled Plwwing (BrakiwI

. Operate truck at a slow speed in a forward
direction of travel. Reverse direction of travel.
The truck should slow down to a smooth con-
trolled stop, and accelerate normally in the op-
posite direction.
If plugging is as specified, then repeat the proce- l Now, after checking to see that you have a clear
dure at high speed. The truck should come to a path behind, drive the truck in reverse. Check
smooth controlled stop in approximately 20- acceleration from stand still condition through
feet (6.1Omm) with Multi-Function Control in top travel speed. Acceleration shouldbe smooth.
maximum travel position.
l Report condition on PM Check List.
. Repeat the procedure at high speed with the
1. Check Srxed Limit Switch Oneration
Multi-Function Control moved in reverse direc-
tion half way. l After checking for overhead clearance, elevate
upright until the intermediate rail operates the
If plugging (braking) is not as specified, refer to
speed limit switch attached to the outer rail
the adjustment instructions in Group 19 of this
assembly.
manual. Report condition to designated author-
ity. l Drive truck forward in a straight line of travel
with the control held in top speed position.
k. Check Acceleration
. Now, after checking to see that you have a clear
path ahead, drive the truck in a straight line at a
high rate of speed in a forward direction of
travel. Listen for unusual drive train noise. Stop
truck.
. Check acceleration from a stand still condition
to top travel speed. Acceleration should be
smooth without hesitation.
Dee 94 PM-8 SM-587

CLEANING
l Battery Compartment. l Caster Wheel and Brake.

l Lower Compartment. l Hydraulic Compartment.
l Drive Motor and Steer Motor. l Pump Motor.
l Brake Components. l Control Compartment.
l Axle Mounting. l Upright and Pantograph.
IMPORTANT
Do not clean electrical components with steam. Only approved solvents should be used to clean Solid
State components. Scheduled cleaning (as outlined) should preclude the need for using a degreaser. Not
all degreasers are acceptable. If a degreaser is to be used, we recommend Clark #1801146 degreaser or
the equivalent to MS-180 Freon TF degreaser and cleaner.
A WARNING
When cleanina with cornDressed air:
l Wear eye protection and protective clothing when cleaning or drying with air pressure.
l Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.
Normal Cleaning
Blowing dirt off with an air hose periodically will, for the most part, eliminate any serious cleaning problems.
Should the need arise for a more thorough cleaning, water may be hosedover the control and if necessary a mild
detergent applied such as that used in washing dishes in the home. This detergent should be rinsed off and the
control dried with an air hose. The control must be thoroughly dry before putting the truck back
into service.
Material Dee 94
a. Remove Batterv A WARNING

l Disconnect battery from truck receptacle. The battery contains corrosive acid which=
can cause injury. If acid contacts your eyes
l Remove battery retainers and inspect them for
or skin, flush immediately with water and gel:
damage.
medical assistance.
l Remove battery from truck. Refer to Croup 12
Do not smoke or allow open
for removal and safety instructions.
flame near the battery.
l Clean off deposits of corrosion on the battery. Explosive gas is always
present around batteries.
l Check battery cables for fraying and damage. A
frayed or damaged cable can cause a short.
Report condition on P.M. Check List.
Cap Vents Must Be Open At All Times

Damaged Cable
l Check battery vents for obstruction. The cap
vents must be open at all times. If any are found
to be plugged, they may be washed in a solution
of baking soda and water.
b. Access Internal Comr>onentq
l Remove fasteners securing front console cover
to truck.
Slip boot off cover lip and tuck bottom of boot
into cover hole.
Carefully lift cover a little forward and upward
until the cover is free of the control.
Remove console cover from truck.
l Remove fasteners securing the side cover to the
truck.
Lift cover off truck.
l Remove fasteners securing floor plate to truck.
Lift floor plate upward and over the brake pedal.
l Open Access Door. Loosen door fasteners until
the door is free to open exposing internal com-
ponents.
Dee 94 PM-l 0 SM-587

c. Discharm?the CaDacitors
. Be sure the battery is unplugged.
. Discharge capacitors using a 100 ohm, 10 watt
resistor connected between the Positive and
Negative power terminals on the Transistor
Control. Hold theresistorinplacefor2 seconds
before removing.
A CAUTION
Using a shorting device
without a resisfor/oadcould
cause damage to the control.
A WARNING
Discharging the capacitors
without using specified
resistor could cause serious
injury to yourself and
bystanders.
A Warning
When cleanina with
compressed air:
. Wear eye protection and protective clothing
when cleaning or drying with air pressure.
. Reduce air pressure to 30 PSI (207 kPa).
Debris removed with air pressure can cause
injury. Battery Roller
d. Air Clean
Battery RetainerL
. Using clean, dry air, and a nozzle extension on
the air compressor hose, air clean truck and
components.
Steer Control-! /-%I
e. Air Clean Batterv Comuartment
. Blow off rollers and roller wells.
. Inspect rollers for damage. Replace any that are
unfit for further service.
Be sure battery retainers are not damaged and fit
properly in their respective grooves.
Air Clean Lower Comnartment
Completely air clean the compartment. Blow
off the steer control, steer pump & motor, drive
motor, brake, cylinder and reservoir.
PM-l 1 Dee94
. Check condition of the steering slip shaft and the

universal joints. Clean area around the grease
fittings. Check their condition and be sure none
are missing.
. Checkcomponents for security of mounting and
general condition.
is* Air Clean Drive Unit

. Blow off the drive unit.Be sure all dirt and dust
is removed around the level and drain plugs.
Drive Motor and Steer Motor
. If the motors are equipped with brush covers,
remove the covers.
. Remove the brushes and inspect them for wear.
Refer to the Brush Inspection Chart in Group 16.
. Inspect commutator bars for bridging dust or
copper material while slowly rotating the brake
drum. If bridging exists, gently remove the
bridging dust using a sharp pointed tool such as
a scribe or ground off hacksaw blade. Air clean
the commutator after removing bridges.
. Reinstall brushes and brush covers (if appli-
cable).
. Recordcommutatorcondition and brush lengths
on the P.M. Check List.
Make certain that all dust is removed from both the outside and inside of the motor.

Brake Line Retainers (Bracket and Fastener)
I I
Artkula ting
Axle
Brake ComnonentS
l Air clean master cylinders located beneath the
brake pedal. Blow off the brake lines in the
operators compartment. If there is leakage at the connections, tighten the
fittings. If leakage still exists, replace darnaged
l Check brake cylinders, lines and fittings for
parts. If brake cylinder leakage exists, report
damage and leakage. Be certain the brake line
condition to designated authority.
retainer brackets are in place and tightened
securely. Tighten all fasteners and replace any
that are damaged or missing.

PM-1 3 Dee 94
Axle Mounting Block

(with Bushing)
Axle -to- Frame Retainment 601
h. Axle Mounting
. Be sure the axle to frame retainment
bolts are in place and tightened se-
curely.
......
.>>F.. . . . . .. .. . . . . . . . . . . .. . . ..~.~......
:~:~:::::jj,::~.~.~.~.::::~.~~.~:~:~
. Each axle mounting block is equipp- :::::::::::::::::::::::::::i:::.:;:~:~:~:~

iiiliii:i:i:i:i:i:i:i:i:i:ijii:i:,i:i: V Grease Fitting
::::::::i:i:i:i:i:l:~:~:~:~:~:::~:~:~~:~
...........:.
.......................................................................................
ed with one bushing and a flush type ..:.:.~,.:.:.:.:.:.:.:.:.:.:.:.:
................................,.. ...._. ,...
.......................,.,.,.(.,.,.,.(.,.(.,.,.,~,.,.,.
.......................:.:.:,:,: ....,...... ..,...
grease fitting. The grease fitting is ...,...,
.............,.,.,.....,.,.,.,...,.,...,.,.,
. . . . . . . . . . . . . . . . . . . . . . . . . . .. ....,.
...
.,...,
.....:.:
,.... .....,.,.,.(.,.,.,.,.(.,.,.........,.
..,.,.,.,.,.,.,.,.,.,...........
.,.,.,.,.,.,.,.(.,.,.,.....,...
.,.,.,.,.,.,.,.,.,.......,...
accessible through an opening in the f::::::::~:~:::::::::::~:~:~:~~:$~:~:~:
,...:... ...........
.:.:.:.:.~j::::jjjj::j)j:.:.:.:.:
.....................................................................................................,...,.
,....
.... Truck Frame .,.,.,.. ..,.. ,.......
,.,....
top side of the axle weldment or dog- :::::::::::::::::
:::::::::::::::::
:::::::::::::::::
house located just beneath the opera- :jj j:i:jj::
:::::::::::::::::
i;;;;>:;i;;;;;;;;
.y>;:::::,:::
tors compartment floor. Clean the area .:~l.,\di:;j
.....
aroundthefitting andwipe the fittings
clean. Be certain they are in good
condition.
Dee 94 PM-14 SM-587

j- Air Clean Caster Wheel & Brake

. Blow off the caster wheel assembly.
. Checkforobviousdamageandsecurityofmount-
ing.
. Check caster wheel for loose wheel bearings.
. Air clean the cover located on the back side of
the caster wheel and check it for damage.
. Remove the cover and air clean the caster brake Fasteners <u,_/
cylinder, spring and linkage.
. Inspect brake cylinder and lines for leakage.
. Check the brake spring, linkage and cylinder for
damage and security of mounting.
k. Check Brake Sm-iw Len&h
l Measure the distance between the inside of one
washer to the inside of the opposite washer (as
shown here). If spring length is not as specified,
an adjustment must be made.
l Using wrench, turn nut (1) against washer until
2-l/4 (57.2mm) can be measured between in-
side of one washer to the inside of opposite
washer.
l After obtaining correct spring adjustment, use a
second wrench and tighten jam nut (2) against
nut (1) without disturbing spring adjustment.
Be sure to Lubricate linkage. Refer to Croup 01.

PM-1 5 Dee 94
AdiustinP for LininP Wear

When to ReDlace Brake Lininps Lining Wear Check
As brake linings wear, the brake arm will move Brake

inward toward the caster weldment. When the arm
is within 3/16 of an inch from this weldment, move
arm 1-spline away from weldment.
Refer to Group 23, Section 2 for
CheckandAdjustmentPs.
IMPORTANT: This adjustment may be made a

maximum of four (4) times. When the brake arm
reaches the 3/16 measurement a fifth time, install
new brake linings.
Brake Pedal Up-Height should be checked after
installing new brake linings.
Refer to Group 23, Section 4 to the
CheckandAdjustmentProcedures.
-
Now install the cover onto the caster assembly

being certain the fasteners are tightened se-
curely. Never place truck into service with the
cover missing. It should be installed at all times.
Check the brake line for damage and security of
mounting.
Check to be sure lock ring is not missing or
damaged. I-
.-
b_
Make certain retainer plate is properly located
against the brake line fitting. \
Make certain the retainer plate is tightly secured

to the axle frame. -
Fa

. Check Caster (Stabilizer) Installation
for loose Trunnion Bearinas,
l Try to move the caster assembly up and
down and check for side to side movement.
If the bearings appear to be loose, they
should be inspected for damage and proper
adjustment( Refer to Group 01 for lubrica-
tion specifications.) If bearings appear to be
fit for further service, then adjust the pivot
(trnnnion) bearings as outlined here.
Adjustment
l Unlock bearing lock nut.
IMPORTANT
- Lock Nut
Be sure the lock nut is installed with the
chamfer side (UP) away from bearing.
M- Lock Washer
%323 l Using a torque wrench, torque nut to 30
lb.ft. (40.7 N*m).
M- Thrust Washer
&
l Next, rotatecaster assembly at least two (2)
full revolutions. Now, retorque nut to 30
_ Grease Shield lb.ft. Reneat nrocedure until toraue is stabi-
lized at 30 Ib.ft. (40.7 Nom).
+- bearing Cone
IMPORTANT
Bearing Cup The above procedure must be repeated

until bearing preload is stabilized (you
Axle can no longer turn the nutlat the 30 Ib.ft.
Frame torque. Once this has beenaccomplished,
tighten the lock nut (do not back off nut)
to the next available locking tab. Lock
the nut in place with washer locking tab.
NOTE
Check, adjust and lubricate
Thrust Bearing axle trunnion bearings every
P.M.. Refer to Lubrication
in Group 01.
Mounting Spindle

PM-l 7 Dee 94
Hvdraulic Comnartmen$
l Blow off the valves, pump and motor. horn,
and steering sensor. Air clean the complete
compartment.
l Blow off the filter, sump tank and hydraulic
lines.
l Be sure area around the sump breather fill cap
is clean.
l Clean area around the fluid level indicator.
l Visually inspect hydraulic hoses and clamps
for damage, leakage and security of mounting.
Tighten loose clamps and/or fittings. Note any
damage on the P.M. Check List. Valve & Lines
Puma Motor
l If the motor is equipped with a brush cover, remove the cover.
l Remove the brushes and inspect them for wear. Refer to the Brush Inspection Chart in Group 16.
l Inspect commutator bars for bridging dust (copper material) while slowly rotating armature. If bridging
exists, gently remove the bridging dust using a sharp pointed tool such as a scribe or ground off hacksaw
blade. Air clean the commutator after removing bridges.
l Reinstall brushes and brush cover (if applicable).
l Record commutator condition and brush lengths on the P.M. Check List.
Make certain that all dust is removed from both

the outside and inside of the motor.

Contactors
A WARNING
When clean with compressed
air:
Wear eye protection and,

protective clothing when
cleaning or drying with air
pressure
Reduce air pressure to 30 PSI

(207 kPa). Debris removed with
air pressure can cause injury.
Switches
Electrical Controls ComDartment.

. Completely air clean the compartment floor.
. Blow off the contactor panel, contactor tips
wiring and cables.
. Blow off the control cards, capacitors and th
steer control box.
Jeer . Air clean the Multi-Function Control Handle
switches, transducer, wiring, switches and harm
ness.
Umight
. Blow off the safety screen (or glass), upright
chains, lift cylinders and carriage.
. Check screen/shield for security of mounting.
. Air clean the packing glands on all cylinders.
. Air clean the pantograph, valves and piping.
. Air clean the cylinders and piston rods.
. Blow off the piston rods.
. Check rods and glands for obvious damage,
nicks, marring, scratches that might damage the
cylinder packings. Checkcondition of hydraulic
plumbing and connections. Tighten connec-
tions if loose. If the cylinders are leaking or rods
are damaged note condition on the P.M. Check
List.
* Check lift chains for damage.
. Check the chain anchor pins (7). Be sure the
cotter pins (6) are in place and not damaged.
. Examine the hydraulic plumbing and connec-
tions (5). Tighten loose connections.
. Check rods and glands for obvious damage,
nicks, marring, scratches that might damage the
cylinder packings. Checkcondition of hydraulic
plumbing and connections. Tighten connec-
tions if loose. If the cylinders am leaking or rods
are damaged note condition on the P.M. Check
List.
. Check theharness hold-down clamps (4), brack-
ets (2), andconnectors (3) for security of mount-
ing and damage.
1
l Note condition on P.M. Check List.
1. Fastener
2. Bracket
3. Connector
4. Clamp
5. Fitting
6. Cotter Pin
7. Chain Anchor Pin
-
Dee 94 PM-20 SM-587

l Inspect condition of fork retainment pins.

l Check the fork mounting bar to be sure it is
properly located. Be certain the snap ring and
retainment pins are in place and in good condi- f4- Retainment Pin
tion.
Snap Ring
Fork
RetainmentPin
+ Fork

PM-21 Dee 94
Checks 81Minor Adjustments
IMPORTANT
Anchor Cotter Pin Heads
must be to the inside of
Upright Lift Chains

Triple-stage uprights use two chain sets (refer to anchors at the base of the Inner Rail Assembly
illustration above); one set for carriage free lift and (see above).
one set for inner rail lift..
The Inner Rail Lift Chains are routed over
l Adjustment Chain Anchors (Al, located at the Sheaves (C) attached to the Intermediate Rail
back of the Free Lift Cylinder are used to adjust Assembly. As the Rail Lift Cylinders extend the
the carriage lift chains. These chains attach to Intermediate Rail elevates thus the lift chains
chain anchors at the base of the lift carriage. The routed over Sheaves (C) elevate the Inner Rail
carriage chain anchors are not adjustable. Assembly.
l Adiustment Chain Anchors (B), located at the l AllLiftChainsmustbeadjustedtoproperlength
back of the Outer Rail Assembly are used to and equal tension as outlined on the following
adjust Inner Rail Lift Chains attached to chain pages.
Dee 94 PM-22 SM-587

A CAUTION
Never tighten Chain Anchor against
weldment. To do so will result in
chain carnage.
Chain Anchors must be free to pivot Chain Anchor

in their mounting holes at all times.
Maintain Freedom of Movement Weldment

All Chain Anchors must be free
allowing their Spherical Bushings to
Spherical Bushing
self align in the machined surface of
their anchor weldments. This helps
prevent chain twist and excessive
chain stress that eventually results
in chain damage.
Chain Lubrication The frequency of lubrication will change with the

The most important consideration in field mainte- operation conditions and the environment. The best
nance of lift chains is lubrication. Hard-working, lubrication time is during each P.M. (50-250 hours or
heavily-loaded chains cannot give acceptable wear four weeks maximum actual truck operating time).
life without periodic lubrication. As with all bearing Trucks that are parked outdoors or in very severe
surfaces, the joint-wearing surfaces need a layer of oil service may need lubrication more often to keep a
between mating parts to prevent wear. layer of oil on all chain surfaces.
Keeping a layer of oil on all chain surfaces will: In dirty operating conditions, lubricated chains will
gather dirt. Even under these conditions, chain life
Keep joint wear (chain wear) to a minimum.
will be increased by periodic lubrication. Joints get a
Prevent or reduce the rate of corrosion. pasteof oil and dirt, but joint wear will still be much
Reduce the chance of pin turning. less than if the chain is permitted to operate dry with
metal-to-metal contact between pins and plates (pin
Keep tight joint in chains to a minium number. and bushing in roller chain).
Help give smooth, quiet chain action. In dirty operating conditions, leaf chain can be more
Lower the chain tension by reducing internal easily lubricated than roller and rollerless chain. The
friction in the chain. plates in leaf chain give more paths for the lubricant
__ .
to reach the pin.
Use Clark Chain and Cable Lubricant, uart number
886399, for lubrication of chains. Heavy motor oil is At every P.M. or four week intervals, clean the chains
also a very good lubricant. The lubricant will pen- in a Stoddard type cleaning solvent to remove dirt.
etrate into the chain joint to prevent wear. Applying Lubricate immediately after the chain is dry. Steam
lubricant to external surfaces willpreventrust, but the cleaning is not recommended because some clean-
lubricant must flow into the bearing surfaces for ing solutions contain chemicals which can cause
maximum chain life. linkplates to crack.

PM-23 Dee 94
Lift Chain Adjustment Step 2: Adjustment Procedure

Step 1: Adjustment Check 1. Loosen jam nut on each chain anchor.
l With the upright fully lowered, check to see if 2. Rotate chain adjustor nut on each chain anchor
the inner rails protrude l/8 inch above the inter- the same number of turns to position the Inner
mediate rails (both sides). Rail l/g-inch above the Intermediate Rail.
l If they do, check tension of both chains on the 3. After completing adjustment, check for equal
longest span. Chain tension should be the same. chain tension ... they should be the same. If not,
make a minor adjustment to the chain that has
If the above checks are as specified, the Inner
the least tension.
Rail Chains do not require adjustment. Check
the carriage chains as outlined on the following 4. Finger tighten jam nuts against chain adjustor
page. nuts. Make sure the chains are not twisted and
torque jam nuts as instructed in illustration be-
If any one of the above checks are not as speci-
low. Again, check to be sure chains are straight
fied, adjust the chains as instructed on this page.
and not twisted.
Chain Tension should be the same for each

chain. You can feel chain tension by pushing
on each chain by hand.
+ Spherical Bushing
+ Chain Adjustor Nut
+ Jam Nut 4-b Torque Specifications
Using two wrenches, a torque wrench
on the Jam Nut and a second wrench
to hold the Chain Adjustor Nut, (A
third wrench on the chain anchor is
helpful) . .. Torque Jam Nut to:
100 - 200 N*m (74 - 148 Ib.ft.)
Dee94 PM-24 SM-587

Carriage Chains Step 4: Adjustment Procedure

Step 3: Adjustment Check 1. Loosen jam nut on each chain anchor.
l With the upright fully lowered and the panto- 2. Rotate chain adjustor nut on each chain anchor
graph fully retracted, check to see if there is l/2- the same number of turns until there is l/2-inch
inch clearance between the heel of the forks and clearance between forks and floor, see illustra-
the floor, see insert below. Check both forks. tion insert below.
Ifclearance is as specified, check tension of both 3. Once the l/2-inch clearance has been accom-
chains on the longest span. Chain tension should plished, check for equal chain tension ... they
be the same. should be the same. If not, make a minor adjust-
ment to the chain that has the least tension.
l If the above checks are as specified, follow the
carriage instructions outlined in Step 5 on the 4. Finger tighten jam nuts against chain adjustor
next page. nuts . Make sure the chains are not twisted and
then torque the nuts as instructed in the illustra-
l If any one of the above checks are not as speci-
tion below. Again, check to be sure chains are
fied, adjust the chains as instructed on this page
straight and not twisted.
and then continue to Step 6 on the next page.
u w Chain Anchor
+ Spherical Bushing
o + Chain Adjustor Nut
8
0 + Jam Nut 4-k Toraue Soecifications
f&a
[ Using two wrenches, a torque wrench
Lift Chains connect to
Pantograph Carriage. third wrench on the chain anchor is
helpful) ... Torque Jam Nut to:
100 - 200 Nom (74 - 148 Ib.ft.)

PM-25 Dee 94
Carriage Stop - to - Upright Stop IMPORTANT

The carriage stop must not be allowed to contact
Step 5: Adjustment Check
the upright rail stop under any circumstances
during normal operation.
A CAUTION
Make sure there is adequate
Step 6: Adjustment Procedure
overhead clearance. Loosen jam nut on each chain anchor.
Elevate upright to maximum fork height. Rotate chain adjustor nut on each chain anchor
the same number of turns until there is l/8- inch
Check to see if there is clearance between the clearance between these stops. Adjust no more
stop weldment on the Inner Rail and the stop than necessary to provide this clearance.
weldment on the Pantograph Carriage. For loca- Now, torque jam nuts as previously described.
tion of these stops, see illustration below. There
Again, check to be sure chains are straight and
must be some clearance ... approximately 15 mm
not twisted.
(S9 inch) ... between these stops.
If the carriage stop contacts the rail stop, adjust
chain anchors as outlined in next column .
Carriage stops must not make contact when upright is elevated to maximum
fork height.
l/O
Chain Anchor
+ Spherical Bushing
+ Chain Adjustor Nut
+ Jam Nut 4-k Toraue Specifications
Using two wrenches, a torque wrench
third wrench on the chain anchor is
helpful) ... Torque Jam Nut to:
100 - 200 Nom (74 - 148 Ib.ft.)
Dee 94 PM-26 SM-587

1. use nrotectivelubrication fluid. Clark Part Number 1803827. to coat terminals of followirw 111119s;
l EV-T15 A,B,Y and 2 Plugs (OSC or Traction Control Card)
l EV-TSPS PL4 Plug
l DashDisplay Plug - PL - DP Plug
l Key SwitchTerminals - Wire Spades 10 & 1OC and 12 & 12B
l HornTerminals - Wire Terminals 13 (or 13B) and 26
l Relay Terminals (for optional equipment only)
2. Check Contactor Tips for the following:
l Cleanliness
l Wear
l Metal transfer between stationary and movable tips.
3. Check Harness/Cable/Fuse Connections for securitv of mounting and condition of terminals,
l Check for frayed/broken cable strands at termi- l Check for oxidation (white/blue) and discolora-
nal crimp, see below. tion of cable edge on terminal barrel end. This
reflects high resistance joint
Broken Wires
Badly Damaged Casing
Cables having small cuts may be

repaired with electrical tape.
l Cables having damage as shown above should
4. Check for Grounds
be removed immediately and replaced with
new. Be certain the replacement cable is the l Meter should register 20,000 ohmsor greater
exact same length, size and has the proper when measured between truck frame and any
connector. Make absolutely certain the cable battery connector terminal.
endisproperly crimped anditsconnectionprop-
l Meter should register 20,000 ohms or greater
erly torqued during installation.
when measured between any EV-T15 control
Every cable and wiring harness on this track is power terminal and truck frame.
manufactured to an exact specification. A
l Meter should register 20,000 ohms or greater
shorter cable or harness willnotfit. If either a
when measured between any EV-TSPS control
harness or cable is routed improperly, it will
power terminal and truck frame.
not$t. Electrical shorts and damaged compo-
nents may result if the replacement part is the 5. Brake Insuection
wrong one, or if it is routed incorrectly. l Every P.M. check for brake lining wear and
adjust, if necessary. Refer to next page.

PM-27 Dee 94
Notice:
AS Brake Linings Wear:
l Brake Arm & Rod move
inward.
9 Pressure Spring Length
increases.
To Adjust for Lining Wear:

l loosen nut (I), as shown.
Nuts are used only

at time of new lining
Refer to Group 23.
- l Rotate Nut (2) inward

against the brake arm and
continue to tighten (T/T&
moves the actuating rod
outward compressing the
spring.) nut until . . .
_ . . . specified spring length is

obtained.
l Hand tighten nut (1)
against brake arm without
rotating the rod.
l Using two wrenches,
tighten nut (1) while hold-
ing nut (2) to secure adjust-
ment. Make certain nuts
are tight without disturb-
ing the spring preload
adjustment.
INSTALL
NEW BRAKE LININGS
when the brake arm
moves to within l/8-
inch of the boot.
Brake Cylinder A-+-
Dee 94 PM-28 SM-587

Every 1,000 Operating Hours
Check and Adiust the Followina:
l Forward & Reverses Switches

Multi-Function
l Lift & Lower Switches
l Transducer
NOTE
RefertoGroup 19,Section
Forward Switch Reverse Switch
7ofthismanualforspecific
procedures.
Transducer
&I Lubrication 0 Upright & Pantograph

Refer to Lubrication
Grow 01. Section 1
Chart(s) in
for all reauired lubrication Doin@

J
N- Hose Sheaves
and fluids,
<- Lift Chains
Control Handle Gears & Spring

Breather,
Hydraulic Filter - Steer Shaft & U-Joints
Sump Tank & Strainer -
Brake Reservoir -1
Caster Pivot Bearings
Motor Brake Linkage A
Drive Unit Pivot Bearing I Load Wheel

Drive Unit Crankcase
Drive Unit Wheel Bearings
Caster Axle Bearings

Caster Brake Linkage
Axle Pivot Block
SM -587 Copyrighted Material

PM-29 Dee 94
CLARKM$z;-ia;Handling GROUP01
Section 1
Lubrication Chart & Illustrations
NPR-345
Lube Chart& Specifications
SM-587 01-1-l
Copyrighted Material Dee 94
GROUP 01 Lubrication
Lubrication Chart Key
L18l L2 A multi-purpose grease of refined mineral oil
NLGI #I Grade blended with a lithium soap thickener or equal
Clark Spec. MS-107B
General Purpose Grease containing anti-wear, anti-rust and anti-oxidants
L3 with EP additive with EP additives, per Clark Specification MS-
NLGI #2 Grade Ir
107.
Clark Spec. MS-107C
A multi-purpose grease of refined mineral oil

L4
blended with a lithium soap thickener or equal
NLGI #2 Grade General Purpose Grease
containing anti-wearanti-rustandanti-oxidants
Clark Spec. MS-107D with EP and Moly additives
with EP and, 3 to 5% moly additives.
A smooth high quality grease of refined mineral

Cold Storage oilbase with a lithium soap thickener or equal
w Temp Grease
Applications compounded with corrosion and oxidation in-
ML-G-23827A hibitors and containing 1 to 3% moly (molybde-
num disulfide) NLGI #2.
L5 Drive Unit Crankcase: Drain when oil is at

MOCO
loo0
AMOCO 1000
operating temperature.
@ or equivalent
L6 Clark Part No. 886399 Chain & Cable Lubricant
B
Clark Part No. 885385 Use only high quality hydraulic fluid with Zinc
of 24 one qt. cans
l-case
or equivalent Anti-Wear additive which meets
L7
Clark Part No. 885382 the requirements of ASTM D-2882 pump wear
l-caseof 6 one gal. cans
test with 50 mg total weight loss maximum per
Hydraulic Fluid Clark Spec. MS-68
A straw colored hydraulic fluid composed of a

Royce 717 blend of highly refined hydrofined mineral oils
Cold Storage ::+.,. m::
or equivalent and additives to impart resistance to oxidation,
:::::::::::::::::::::::
Applications .:.:::::::::::,:.~
MIL-F-17111 corrosion, and rusting and to afford greater lu-
Ef?I
bricityandimprovedviscosity-temperaturechar-
Hydraulic Fluid acteristics. Fluid must meet M&F-1711 1.
Brake Fluid, Grade DOT 3, as specified by

L8 DOT 3
Federal MotorVehicle Safety StandardNo. 116.
L9 Acheson Gredag 2230

A specially formulated (tacky) grease with ex-
Special Grease Dow Coming Assy Paste
Texaco Texclad 2 cellent adherence capabilities.
or equivalent
Dee 94 01-l-2 SM-587

Lubrication Chart GROUP 01
Lube Key Chart
Caster Brake Linkage: Lubricate with engine oil at every PM Brake Inspection.
Note
Lubricate length of rails at point of roller Contact first P.M. only on new trucks.
LL = Lubricate each time a Load Wheel is replaced or squeaking

occurs.
Pack each time the Caster Wheel is replaced.

GROUP 01 Lubrication - Cold Storage & Standard Applications
Every P.M. (250 operating hours maximum)
Corrosion Protection
Mechanical Paste Lubricant
Using Clark Part No. 2802205 apply to the follow-

ing Power Cable and Screw-On type wire connec-
tions:
r
A,pply to electrical
CC
2nnections any time
ley are discon-
All Power Cable ConnectionS ected. Note: Reau-
lybeforemakinrrthe
l All Motor Cable Connections. Dnnection.
l All Control Panel Cable Connections.
All Screw-On Tme Wire Terminals
l All Card retainer screws.
l Motor Ground Wire (both ends), see below.
l Reverse Alarm (if so equipped).
l Strobe Light Connections (if so equipped).
c;I
Ground Wire -
Apply to wire con-
nections any time
they are discon- Pump Motor
nected. Note: ReaD-
plybeforemakingthe c
Dee 94 01-l-4 SM-587

Lubrication - Cold Storage & Standard Applications GROUP 01
Corrosion Protection
Mechanical Lubricant
Using Clark Part No. 1803827spray the following:

General Note
l Contactor Panel.
for
l Drive Control (EV-T15).
Part Numbers:
l Steer Control (EV-TSPS).
1803827& 2802295.
l PL and DP plug connections. Apply to electrical
IMPORTANT connections any time
Avoid direct spraying on contactor tips. they are discon-
nected. Note: Reau-
l Power Cable Connections.
plvbeforemakinethe
connection.
A CAUTION
Do not spray motor brushes
and commutator. Cover all
motor openings prior to
spraying.
l Wire Terminal Screws includinp the follow-

&
Control Card (1) and Control Card (2).
Brake Switch terminals.
Steer Interlock Switch on contactor panel.
Speed Limit Switch mounted on outer rail tie
bar. Switch cover must be removedfor access
to screw terminals.
l Push-On Connectors should be snravedt
l Horn terminals
l Key Switch terminals.
l Heater Thermostat (Cold Storage). Them0
stat located on contactorpanel.
Electrical Options (Spray all connections).
l Forward Pointing Head Lights (terminals).
l Strobe Light (terminals) Aux. Motor
l Reverse Alarm terminals (if applicable).

l Any and all switches used on the option(s).

01-l-5 Dee 94
GROUP 01 Lubrication - Cold Storage
COLD STORAGE LUBRICATION

Apply Anti-Corrosion Spray Clark Part No. 2794748 to the following:
l Reach and Tilt Cylinder Rod Ends

(spray threaded area only). See below.
l Motor brake adjustment linkages,

springs and bleeder screw (donot spray
directly into the bleeder screw). See
Threaded Areas
l Dowel Pin Retainers on panto-

graph. There are nine (9) pins total.
l Caster brake adjustment linkages,
springs and bleeder screw (do not spray
directly into the bleeder screw). See
above.
Dee 94 01-l-6 SM-587

Lubrication - Cold Storage GROUP 01
COLD STORAGE LUBRICATION
Hydraulic Sump Tank
Specifications: Use Hydratic Fluid which meets ML-F- 17 111. (Royce 7 17 or equivalent)
. A straw colored hydraulic fluid composed of a blend of highly refined hydrofined mineral oils and
\ additives to impart resistance to oxidation, corrosion, and rusting and to afford greater lubricity and
I
improved viscosity-temperature characteristics.
r
-
3
B
,
\
-
-T-
Grease Fittings
Sr>ecifications: Use an extreme low temperature aircraft quality grease meeting ML-G-23827A, or equivalent
product. Temperature range: - 100 to +250F.
Refer to Lubrication Chart on Page 3
for
remainder of instructions and time intervals.

01-l-7 Dee 94
GROUP 12
SECTION 1
Battery
Contents
Battery Service Area .................................................................. 12-1-3 & 4
Handling Storage Batteries ........................................................ 12-1-3 & 4
Battery Removal & Installation ......................................................... 12-1-5
Battery Maintenance ......................................................................... 12-1-6
Battery Installation ........................................................................... 12-1-7
Battery Records ................................................................................ 12-1-8
(....i
, ...., / BATTERY
.- .._.___
_
:::;.y
SERVICE
;Y
L.
nnrr
I.. ._._.,
,<\
~. -.&.._..~.-;..
-.
Y\
,.,
D
Remove all jewelery

before working on
the truck

GROUP 12 BAllERY
A WARNING
SULFURIC ACID
THE BATTERY CONTAINS CORROSIVEACID WHICH CAN
CAUSE INJURY. IF ACID CONTACTS YOUR EYES OR SKIN,
FLUSH IMMEDIATELY WITH WATER AND GET MEDICAL
ASSISTANCE.
Disconnect battery before handling

electrical components. Polarity must
be correct to prevent damage.
1147748
l l
A WARNING
Electric truck batteries are heavy and awkward to handle. On

charge, they give off hydrogen and oxygen which, in certain
concentrations, are explosive. Electric truck batteries are also
costly, so before you remove, service, or install a truck battery,
consult BATTERY MANUFACTURER, for more recommenda-
tions and instructions on handling and charging batteries. Care-
fully read and follow recommendations and instructions.
Dee 94 12-l -2 SM-587

BAmERY GROUP 12
BATTERY HANDLING
Fire Extinguishe
-..__.+ Wash Stand
Change or service batteries only in an area designated
A&. ------4
for this purpose.
l Be sure this area has provisions to flush and
neutralize acid spillage.
l Be certain the area has proper ventilation to
ventilate fumes from gassing batteries.
l Check to see that there is fire protection. Fire
extinguishers should be properly maintained
and located in designated areas.
A DANGER
Explosive gas is always present around batteries,
especially when they are being charged. The fol-
lowing should be adhered to.
l No smoking shall be allowed in the charging
area.
l Battery electrolyte shall never be checked
with an open flame.
l Open flame, sparks, or electric arcs shall
never be allowed in the battery charging
area.
Persons maintaining storage batteries must wearpro-
tective clothing such as:
l Face and head shields
l Long shirt sleeves.
l Gaunlet gloves.
A WARNING - SULFURIC ACID

THE BAlTERY CONTAINS CORROSIVE ACID WHICH CAN CAUSE INJURY. IF ACID
CONTACTS YOUR EYES OR SKIN, FLUSH IMMEDIATELY WITH WATER AND GET
MEDICAL ASSISTANCE.
SM-587 Copyrighted12-1-3
Material Dee 94
GROUP 12 BATTERY
Be sure the battery service area is equipped with Overhead Hoist
- Safetv Hook /
material handling equipment designed for the pur-
pose of removing and replacing batteries, such as a
conveyer or overhead hoist equipped with safety
hooks
l When using an overhead hoist, be sure to use an
insulated spreader bar or similar lifting device.
To prevent side forcesfrom damaging the bat-
tery, the distance between the lifting hooks (of
the spreader bar) must be adjusted to the same
dimension as between the battery lijiting eyes.
Make sure the lifting hooks are the correct size
tofit the lifting eyes of the battery.
l Be sure the hoist is equipped with a chain sulated Spreader Bar

container to accumulate excess lifting chain.
When this is not possible, be sure the battery is
covered as shown below. Typical lllustratior
Plyw~ -
l If the battery does not have a cover of its own,
cover it with a non-conductive material such as (Non-Conductive Cover)
plywood-
Typical Illustration
* Never lay tools or other metal objects on a
battery. Metal objects contacting battery termi-
nals will cause short circuits. The shorted cir-
cuits could ignite battery fumes and cause the
battery to explode.
Dee 94 12-1-4 SM-587

BATTERY GROUP 12
Battery Removal Key Switch Off Brake Applied
1. Move truck to the designated battery service
area.
2. Turn key switch OFJ? and disconnect battery.
Battery Disconnected
.
3. Remove battery retainer plate. Removing Battery

4. The battery must be pushed out of the compart- Remove Battery
ment. A recommended method of handling the Retainer
battery is to use a platform equipped with rollers
similar to the one shown in opposite illustration.
Push Battery onto
l If the battery to be handled is uncovered, Platform
cover battery with a non-conducting material
(plywood, heavy cardboard, etc.) prior to re-
moval from truck.
NOTE
Do not wash battery in truck.
5. Once the battery is out of the truck, a lifting

device equipped with an insulated spreader bar Transporting
and safety hook(s) can be used to transport Battery
battery. Be sure battery is covered prior to
attaching lifting device. Chain/ 4
Container
l An overhead hoist (of sufficient lifting capacity, I
refer to Weights in Group 40) should be used
to lift battery. The safety hooks of the insulated
spreader bar should be attached to the lifting
eyes provided in the battery casing.
Insulated Spreader Bar
Uncovered Batteries:
Cover With
FVywood or Heavy Cardboard
../....
L
---I=
-
lad
:A =
-
---_
-ze
-_

12-l -5 Dee 94
GROUP 12 BATTERY
Battery Vents
l When ChargingBatteries:Theventcapsmust
be kept in place to avoid electrolyte spray. Care
must be taken to assure that vent caps are func-
tioning. The cap vents must be open to allow the
battery to breath. The battery cover must be
removed/opened to dissipate heat and explosive
gas.
l When Cleaning Batteries: The vents must be
tightly in place.
Battery Cleaning
The easiest and most satisfactory method of cleaning
a battery is to wash it with a low pressure cold water
spray. The battery top can also be washed with a
baking soda solution and rinsed with clear water.
l Check to be sure all vent caps are tight before
washing the battery.
l Fill a bucket with cold water while adding a box IMPORTANT
of baking soda to the pail. Stir the solution until Vent Caps must be free of obstruction and in good condition
dissolved. It is advisable to have this solution Battery top should be clean and free of cracks or breaks.
Battery terminals must be clean and solidly mounted.
around the battery service area at all times.
Damaged batteries should be repair or replaced.
l After washing battery, thoroughly rinse with Consult your battery vendor.
clear cold water.
Battery Charging
Follow theinstructions suppliedby theBattery Charger
Vendor.
I Battery Maintenance
To obtain maximum performance and
Battery Electrolyte battery life, the instructions supplied
l Always use a carboy tilter or siphon when by your Battery Vendor should be
handling battery electrolyte. adhered to.
l When mixing electrolyte, always pour acid into
water - never pour water into acid. Pouring
water into acid will cause a dangerous chemical
action.
Dee 94 12-l -6 SM-587

BATTERY GROUP 12
Clean Battery Compartment
Clean Battery Compartment
l Using baking soda and water solution, clean the
walls and floor of the compartment. Rinse with
clear water.
A WARNING
- Air Hose -
Wear eye protection and
protectiveclothing when drying
with air pressure. Reduce air
pressure to 30 PSI (207 kPa).
Debris removed with air
pressure can cause injury.
1Fl
::,..
l Blow off the compartment walls and floor with .P,...
an air hose. Allow to air dry.

sawa &
Water Solution
REPLACEMENT
BAlTERlES
Cautionshould beexercised to
use a battery properly sized to
the dimensions of the battery
compartment. Batteries too
small can shift and cause
damage to thetruckor injury to
the operator or bystanders.
For the NPR 17 a minimum battery size of 38.69 x

13.00x 31.50 inches (982,7 x 330,2x 800,l mm) and
aminimumweightof 1185lbs.(537,5kg)isrequired.
For the NPR 22 a minimum battery size of 38.69 x
15.75 x 3 1.50 inches (982,7 x 400,O x 800,l mm) and
aminimumweightof 14OOlbs. (635,Okg)isrequired.
Install Battery
If the battery is uncovered, cover the battery with a
non-conducting material (i.e.., plywood, heavy card-
board, etc.) prior to installation.
l Push battery into battery compartment.
l Install battery retainer.
l Remove non-conductive material from battery.
l Connect battery to truck.
Material Dee 94
GROUP 12 BATTERY
KEEPING BAlTERY RECORDS BAllERlES
Records should be kept to get the best service out of Industrial Batteries are used to supply the electrical
your battery and truck. power to operate an Electric Industrial Truck. Their
voltage depends on the number of individual cells
These records should contain: they contain. There are approximately 2 volts for each
cell in the commonly used lead-acid type battery.
l Test Date. Each test should be dated for future
Batteries normally range from 6 volts to 72 volts.
reference and comparison.
Their capacity varies depending on the application.
l Specific Gravity and Temperature readings. Only use batteries that comply withfactory spec@ica-
Each battery cell should be checked and re- tions as to size and capacity and weight.
corded before and after charging. The specific
gravity reading of the electrolyte should not be HOW TO GET MAXIMUM LIFE OUT
less than 1.260. If below 1.250, the battery OF YOUR BAITERY
should be recharged and tested.
. Do not add acid to a battery. Only qualified
l Variation between each cell tested. The varia- Battery Representatives should determine ijlhis
tion in specific gravity reading between cells
is necessary.
should not be greater than 15 points (.015). If
. When lifting a battery, use a lifting device
readings are greater, this indicates there are
defective cells. designed for this purpose
. Check the electrolyte level before placing a
Thepilotcellshould be changed occasionally to
distribute any electrolyte loss over the battery battery on charge. Add water, if required, before
when taking readings. charging the battery. The electrolyte level in a
battery should be slightly below the lower lip of
l Load Voltage Tests should be performed and the filling hole vent. Do not over fill. Over
recorded indicating the condition of a battery
flushing causes loss of electrolyte.
while it is performing work.
. Keep the battery clean, dry and in good condi-
l Actual Operating hoursof the battery.Record
tion.
the actual time the battery is in use before
. Keep metal objects and tools away from the top
putting it on charge..
of the battery. Short circuits will cause battery
l Charging Time. Keep an accuraterecordof the damage and could ignite battery fumes, explod-
actual time the battery is on charge. After each
ing the battery.
charge, check to see if the battery is fully
. Maintain good battery cable connections.
charged. Test the battery before placing it back
into service. Record these results. . Check power cables and wiring for damage.
l Visually Inspect for loose terminal connec- . Do not over charge a battery.
tions or posts, a cracked case, or damaged cell
. Do not under charge a battery.
vent caps and excessive corrosion. This data
should be noted to help ascertain work environ- . Follow the instructions provided by your
ment and possible trouble areas. supplier(s) of the battery and battery charging
For further information, refer to Croup 19, Section 4 equipment.
in this manual. . Maintain accurate battery records. If battery
Check with your local battery supplier for complete troubles occur, these records will help you and
battery maintenance procedures and their expertise. your battery representative determine the nature
of the problem.
Dee 94 12-1-8 SM-587

GROUP 13
Section 1
Multi-Function Control Handle
Switches
Contents
Reach, Tilt and Auxiliary Switches, Remove and Replace . .. .. . .. . .. .. .. .. . 13-l-2
Lift and Lower Switches, Remove and Replace . ... . .. .. .. .. .. .. .. .. .. ... . .. .. .. 13-1-3
Transducer; Forward and Reverse Switches, Remove and Replace..... 13-1-4
Switch Side) -)Q
PL-9
so-i0
Transduce- \\> Harness
so-7 sq7
Lift/Lower
Switch ~,
SM-587 Copyrighted Material Dee 94

GROUP 13 Reach, Tilt & Aux. Switches
REACH, TILT AND AUXILIARY
SWITCHES
Switch Remove & Replace

These switches (1) are located in a separate housing
within the control handle. The handle grip has two
halves (switch side and heel side).
Switch Removal
1. Remove fasteners (2 & 3), see opposite illustra-
tion.
2. Remove inner fasteners (4 & 5).
3. Pull harness wires free of their retainer slots in
handle (heel side).
3. Remove switch housing (6) from handle.
4. Provide some wire slack in the housing before
removing a switch.
5. Pull switch from housing.
6. Remove wires from switch connections.
switch Installation
1. Connect wires to the new switch and install
switch into plastic housing.
Multi-Function Control
2. Carefully pull wires taugt but not so tight as to
cause damage to the connections. Place housing ... using a blunt instrument so as not to damage
into handle (heel side). wire insulation.
3. Carefully push wires into their retainer slots ... 4. Assemble handle being certain to tighten fasten-
ers (2) thru (3) securely.
IMPORTANT
Connector Plugs and Receptacles are permanently labeled with the proper PL
(Plug) and SO (Socket/Receptacle) number for easy identification.
A CAUTION
If disconnected, match plug number with appropriate receptacle number before
making a connection. If not, electrical shorts and possible damage to equipment
may result. i.e., Plug #PL-6 plugs into pin socket ##SO-6,etc.
Clamps, Cable Guides and Marking Tapes:
IMPORTANT
Cables must be positioned so all tape markers
are aligned with or hidden under clamps or guides.
Dee 94 13-1-2 SM-587

Switches GROUP 13
UP (LIFT) AND DOWN (LOWER)
SWITCHES
Switch Remove & Replace

These adjustable switches control lift and lower func-
witch
tions of the upright and are mounted to a bracket on the
left side of the handle bracket. See opposite illustra-
tion.
switch Removal.
1. Remove cam fastener, washer and cam. See
illustration below.
2. Disconnect switch (to be removed) from the
wire harness.
3. Remove fasteners securing switch and switch
adjustor to bracket.
4. Remove switch adjustor bolt, both lock washers,
Installation
spring, and switch adjustor. Remove switch.
1. Install new switch assembly and route wires as
illustrated below and on Page 4.
/ Adjustor Bolt
2. Connect switch harness assembly Socket SO-7
to main wire harness Plug PL-7. See Page 1.
3. Refer toGROUP 19, Section7 for switch adjust-

ment procedures.
L Washer
GROUP 13 Switches
-#oG
ml -Y /
4
I IIl-I
Assemble horn switch
clearance for the reach,

tilt & aux. switch holder.
Route Harness
as shown -W
Wire #l OG Aux 2 Switch Wire #65 Aux 2 Switch
Route Harness
Tilt Switch Horn Switch
3-Wires Each Side
tioned with all
hidden under
Dee 94 13-l-4 SM-587

Transducer, F & R Switches GROUP 13
TRANSDUCER, FORWARD AND Transducer Installation
SWITCHES l Install new transducer to the transducer plate.
Install transducer and transducer plate assembly
Forward and Reverse Switch l
to bracket.
Remove & Replace
l Route the transducers wire assembly through
Two adjustable switches mounted to a
the clamp and securely fasten the socket clamp
bracket at the rear of the multi-function control pro-
as shown in illustration on page 1.
vide forward and reverse direction of travel. A trans-
ducer and adjustor plate are attached to a mounting l Connect transducer harness Socket SO- 10 to the
plate at the rear of the control. The transducer provides main wire harness Plug PL-10.
variable speed control. Refer to GROUP 19, Section 7 for switch and
Switch Removal transducer adjustment procedures.
l Disconnect switch harness assembly Plug PL-8

(to be removed) from the main wire harness
Socket SO-8. Refer to illustration on page 1.
l Remove clamp screw and remove the trans-
ducer clamp assembly harness from the clamp.
l Remove adjustor screw and lock washer secur-
ing the switches, switch adjustors, lock washers
and springs to the switch bracket.
Switch Installation
l Installnew switch, switch adjustors, lock wash-
ers and springs in the reverser order of removal.
Secure the sub-assembly with adjustor screw(s)
and lock washer(s).
l Route switch wires as shown in illustrations on
Page 1 and Page 4.
l Connect switch harness assembly Plug PL-8 to
main wire harness Socket SO-8.
Transducer Remove & Replace

Transducer Removal
l Disconnect transducer harness Socket SO-10
from the main wire harness Plug PL-10.
l Remove clamp screw and remove transducer
clamp assembly harness from the clamp.
l Remove fastener switch securing the transducer
and transducer plate to the bracket.
l Remove nut and washer securing transducer to
transducer plate.

13-1-5 Dee 94
GROUP 16
Section 2
Electric Motors
General
Contents
Safety . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . . .. .. .. .. .. .. .. . . .. . 16-2-2
Motor Inspection, Cleaning and Insulation . .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. . . .. .. 16-2-3
Testing Procedures . .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. . .. . . 16-2-4
Brush and Commutator Inspection . ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .. .. 16-2-5
Brush Inspection Chart . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . .. . .. .. .. .. .. .. .. .. .. .. . 16-2-7
Cable and Clamp Inspection . . ... .. .. .. .. .. .. .. .. .. .. .. .. . . ... ... . .. . .. .. .. .. .. .. . .. . .. .. . 16-2-9
CLEANING, INSPECTION & TESTING PROCEDURES
Torque Cable Fasteners

to:
150 lb.in. (16.9 N*m)
Refer to:
Group 16, Section 7

to:
75 lb.in. (8.5 N*m)
to:
150 lb.in. (16.9 N*m)
Dee 94 Copyrighted Material

16-2-l SM-587
GROUP 16 Motors
A WARNING
pressure. Reduce air pressure
to 30 PSI (207 kPa). Debris
removed with air pressure can
cause injury.
........ :.:
........ :.:~:::::::::::::::::.
.....................................
........ . . .. . . . . . . . . . . . . . . . . ..j.....:~:::::~::::::.
. . . . . . . . . . . . ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
Remove all Jewelry before

working on truck.
:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
..:.:.:.:.:.:.:.:.:.:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
:.:.:.:.:.:.:.:.:.:.....~.......:.:~.~.:~~~.:.:.~.:.!.:.:.~.:.:.~.~.:.:.:.:.~.~.:.:~.~~.~
:: :::: ::::::::<
.............. ..
Always wear Safety Glasses
DischargetheCaDacitorsbeforeworkinpontruck Discharge Capacitors
l Be sure the battery is unplugged.

l Discharge capacitors using a 100 ohm, 10 watt
Negative power terminals on the SCR control.
Hold the resistor in place for2 seconds before
removing.
A CAUTION
Using ashorting devicewithout
a resistor load could cause
damage to the control.
A WARNING
unplugged. _
without using specified resistor
could cause serious injury to
yourself and bystanders.
SM-587 16-2-2 Dee 94

Motors GROUP 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 correct P.M. intervals and to indicate maintenance required to prevent major problems from
occurring during operation.
Inspection Procedures The presence of any oil on or near motor could indicate
either bad bearings or leaking hydraulic system.
Determine cause and repair problem before extensive
To perform these service procedures, it is recom- motor damage occurs.
mended that you first:
Motor Insulation
Park truck safely.
Fully lower upright. If a reduction in motor performance has been
Apply parking brake. noted, it may be due to breakdown in motor insu-
lation causing internal grounding or a short circuit.
Turn key switch OFF.
Failures of motor insulation are due to:
Disconnect battery from truck recepatacle.
l (1) contamination
Discharge capacitors, see page 2.
l (2) mechanical factors
l (3) high temperatures
Motdr Cleanliness
Contamination includes dirt, moisture, oily va-
pors, metal chips, carbon dust from brushes, etc.
Electric motors should be kept clean at all times to
prevent shorting, minimize wear, and for best cool- Mechanical factors include shock, vibration, over
ing. speed, etc.
Operation at prolonged or excessively high tem-
l Wipe off all dust, dirt, oil, water, etc., from perature will cause insulation to become brittle and
outer surface of motor. crack leading to premature failure. The insulation
condition can be judged both visually and by test
l Remove any debris from cooling air vents and measurement. Regular, periodic measurements of
around motor frame to prevent overheating. insulation resistance can give a useful indication of
the rate of insulation deterioration.
l Air clean (blow out) open motors using clean,

dry (moisture-free) compressed air at [207 A sudden drop or consistent trend toward low
kPa] 30 psi. maximum air pressure. Air clean values of insulation resistance give evidence that
all inner areas around commutator and brushes, insulation is deteriorating and that failure may be
including cooling air vents and fan. Wear imminent.
safety glasses.
Material Dee 94
GROUP 16 Motors
TEST FOR MOTOR INSULATION TEST FOR MOTOR INSULATION
RESISTANCE TO GROUND RESISTANCE TO GROUND
(Using a 500 Volt Megger) (Using a Simpson 260-6~ Volt-Ohmmeter or
equivalent calibrated on the RxlO,OOOScale).This
(Test must be made with motor out of truck).
test may be made with motor in the truck.
1. Disconnect battery from truck receptacle. 1. Disconnect battery from truck receptacle.
2. Discharge the capacitors. Refer to Group 19. 2. Discharge the capacitors. Refer to Group 19.
3. Disconnect power cables from all motor termi- 3. Disconnectpowercablesfrommotorterminals.
ll&.
4. Connect the positive lead of the VOM to all
4. Connect one lead of a 500-volt megger to any terminal studs of test motor. Use jumperwires to
motor terminal. NOTE: Test ALL terminals connectbetweenmotorterminals.ConnectVOM
individually or by interconnecting with jumper negative lead to motor frame.
wires. Connect other lead to motor frame. Apply
NOTE
voltage.
Test all terminals individually, or
5. Resistance should be measure at least 1,OOO,OOO joined together, as noted.
ohms (1 megohm). If less than this, motor
should be air-cleaned or dried to attempt to 5. VOM must show 1,OOO,OOO ohms ( 1 megohm)
increase insulation resistance. resistance or higher for a good motor insulation.
6. If less than 1 megohm is measured, air clean motor and repeat test. If cleaning does not make an
improvement, the motor will have to be removed from the truck and disassembled for a closer
inspection.
Disconnect Truck Battery,

Discharge the Capacitors - Refer to Group 19
SM-587 Dee 94
Motors GROUP 16
BRUSH AND COMMUTATOR INSPECTION
The key to planned maintenance of the brush and commutator is recognizing the
undesirable brush and commutator conditions. If this is done, corrective action can be
taken before a major component is damaged beyond serviceability. The brushes and
commutator should be inspected for even wear and good commutation.
Good Commutation: A dark uniform coloring pattern at the brush wearing surface.
Poor Commutation: The surface of the commutator appearing rough, pitted, scored
or signs of burning or heavy arcing between bars. The
coloring pattern will be:
. Streaky film with commutator wear.
. Bar edge burning.
. Uneven film.
. Carbon dust bridging between bars
Different Grade Brushes; When the brushes being fitted are of a different grade from those
previously used, then it is advisable to remove the film left
by the previous grade brushes.
This film removal should be done by scouring with a strip of abrasive
cloth (do not use emery cloth) while the armature is rotating.
Do not finish with a lapped, highly polished surface. A
moderately abraded commutator surface will help
the new brushes to run in and the commutator will acquire
more readily the film appropriate to the new brush grade.
Operating Conditions
Operating environment of lift truck motors varies widely: The following recommen-
dations should be applied as actual conditions dictate.
Normal Service: Basically an eight- Severe Service: Extended operating
hour day of indoor hours, or constant us-
material handling. age.
Extreme Service: Dusty or Sandy Locations Flour Mills

Cement Plants Coal Dust Areas
Lumber Mills Stone-Crushing Areas
SM-587 16-2-5
GROUP 16 Motors
General Brush & Commutator 7. Check brush shunt for good contact with
Inspection brush holder. Be sure shunt is not damaged or
burned since this may cause brush spring to
1. Remove brush cover(s) and remove brushes carry current and lose tension.
from brush holders. Clean brushes and hold-
ers. Check brush holders for damage. 8. Clean and check brush box and connector
screws. Tighten if loose. Be sure brush box
2. Inspect condition of brushes. Remove each shunt connection is tight.
brush from brush holder and inspect brushes
and commutator for worn condition and 9. If brushes do not need to be replaced, and
uneven wear. commutator is in good condition, install
brushes and brush springs into brush holders.
3. Clean commutator surface. Wipe commuta-
tor with a dry, lint-free cloth.
DO NOT USE LUBRICANT OR SOLVENT Be sure brush spring is correctly placed on brush
ON COMh4UlYATOR. holder and that brush isfree to slide in brush
box.
4. Check appearance of commutator surface
where brushes ride Inspect commutator bars
for burned, damaged or raised areas. The best 10. Install brush cover on motor case.
signs of good commutation are a dark brown
highly-polished commutator and uniform 11. Check and tighten all motor bolts. Check
glossy brush-wearing surfaces. lower nut on each terminal post. It should be
installed finger-tight, then tightened another
5. Measure and make a record of brush length at 114 turn with a wrench.
each inspection. The record will verify amount
of brush wear and indicate if there is enough
brush length remaining until next scheduled
inspection.
6 In general brushes must be replaced when
worn to approximately half of original length.
IMPORTANT
NEW BRUSHES MUST BE OF
Shunt-\ \ f-Cross Connector
SAME SIZE AND GRADE
PressureSpring--+\A I~rBrush Box
(MATERIAL
SPECIFICATION)
REPLACED
AS T!/ 1
.I
Retainer
Screw
BRUSHES.
AWAYS REPLACE BOTH
Brush Box- CBrush Box
BRUSHES AND SPRINGS. DO p_
Brush - II I Brush 1
NOT REUSE OLD SPRINGS. I III
- 6rus.h BOB
AI
J
Retainer
Screw
Hammer Plate FJI-2
Observe how brushes are assembled in brush hold-
ers, and position of brush lead (pigtail). New
brushes must be installed in same manner.
rypical lllustation
Dee 94 16-2-6 SM-587

Motors GROUP 16
Brush Inspection Chart
REPLACE BRUSH
-i
IF SPRING TENSION IS NOT THE SAME

FOR EACH BRUSH, REPLACE SPRINGS.
REPLACE BRUSH IF IF BRUSH PIGTAIL

PIGTAIL IS LOOSE IS LOOSE AT THE
IN THE BRUSH. BRUSH HOLDER -
TIGHTEN SCREW.
REPLACE BRUSHES
WHEN WORN TO

16-2-7 SM-587
GROUP 16 Motors
Typical
Inch Pound
Pointer
Typical
Foot Pound
Pivoted
Torque Went h
Scale Handle
Pointer
IMPORTANT
Improperly Torqued Fasteners Can Cause Damage.
. Use an appropriate torque wrench and tighten all fasteners to the torques specified
in the illustation on the following page.
Dee 94 16-Z-8 SM-587

Motors GROUP 16
Cable (or) Wire Harness
IMPORTANT
Xamps must be
jositioned so all
rAPE MARKERS
ire aligned with
)r hidden under
he clamps or
:able guides.
\ /I i ! i \\
IL
2
Wire
Harness \
:;:>g#:;
::::::::::::::::
:::
j:::::::::::
::::::::::::::::
::::::::::::::::
y:::::::::::::
::::::::::::::::
::::::::::::::::
::::::::::::::::
::::::::::::::::
y:::::::::::::
TM- ?.Z.W:
IJ1Torque
------__--
Drive Motor Cable Fasteners
to: 150 Ib.in. (I 6.9 N*m)
Al
Torque Cable Guide Nut
to 100 Ib.in. (11.3 Nom)
-

16-2-9 SM-587
ELqRK Material Handling
Company GROUP 16
Section 3
Traction Motors
24 & 36 VOLT
Contents
General Information . .. .. .. .. .. .. .. .. .. ... . .. . .. . .. ... . .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. . 16-3-3
Motor Disassembly . .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. .. .. . . . . 16-3-5
Component Inspection & Trouble Shooting . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . 16-3-6
Testing . .. .. ...I..................................................................................... 16-3-7
Changing Brushes . .. .. ...f.................................................................... 16-3-8
Motor Reassembly . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. . . .. . 16-3-8
Specifications .. ... .. .. .. . ... .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . .. . .. .. .. .. .. . . 16-3-9 & 10
Inspection Charts . .. .. .. .... .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 16-3-11
24 & 36 Volt
Ventilated and Enclosed Motors
Note: Open Motor has no band.

tgl
m
3/8-l 6 UNC-2A Terminals
Dee 94 Copyrighted16-3-1
Material SM-587
GROUP 16 Motors
A WARNING
Wear eye protection and protective clothing when drying with air pressure. Reduce
air pressure to 30 PSI (207 kPa). Debris remoJed with air pressure can cause injury.
Remove all Jewelry before working on truck.
Use a Torque Wrench to tighten Terminal Connections.

Typical
Inch Pound
Torque Wrench
Pointer
SM-587
GROUP 16
GENERAL
Routine Maintenance Schedule with Recorded Findings is the best way to reduce costly
shut-downs and repair of equipment during operating hours
The goal of any maintenance program, long-life and trouble-free operations, is related to the
time spent making inspections and correcting minor problems as they occur.
Thekeytoplannedmaintenanceofthebmshandcommutatoris recognizingundesirablebrush
and commutator conditions. If this is done, corrective action can be taken before a major
component is damaged beyond serviceability. The brushes and commutator should be
inspected for even wear and good commutation.
Poor Commutation: The surface of the commutator appearing rough, pitted, scored or
signs of burning or heavy arcing between bars. The coloring
pattern will be:
. Bar edge burning.
. Uneven film.
. Carbon dust bridging between bars.
Operating environment of lift truck motors varies widely: The service frequency shall
depend upon the severity of operating conditions.
Extreme Service:
Dusty or Sandy Location Flour Mills

Cement Plants Coal Dust Areas
Lumber Mills Stone-Crushing Areas

16-3-3 SM-587
GROUP 16 Motors
3. Remove four screws

1. Remove brushes. c from drive end head.
2. Remove two screws
from commutator
end head.
4. Remove bearing cap (if

m equipped) from com- Remove drive end
mutator. head with bearing.
=S
6. Install jaw pullers as

shown,pusharmatureout
of bearing andco
tor end head
7. Remove commutator
end head and .... Q
Brush Holder
Field Coils & Pole Shoes
>ommutator End Head Motor Housing Armature Assembly Drive End Head
SM-587 16-3-4 Dec94

Motors GROUP 16
TRACTION MOTOR
Disassembly
Remove the cover band (if so equipped) from
the commutator end of the motor. Use a brush
hook to reach into the motor and lift the brush
springs. Pull the brushes out of the brush hold-
ers.Eitherpositionthebrushesoutsidethemotor
or remove the brush retaining screws and re-
move the brushes from the motor.
Scribe or center punch locating marks in the end
heads and the &me. Although locating marks IJ YJ II
are not always necessary because of locating

pins in some motors, they can save a lot of time
when the motor does not have locating pins.
Remove the commutator end head retaining
Ventilating Fan
screws or bolts. Almost all motors have a slip fit
bearing at the commutator end, andtheend head l There will be occasions when it will be neces-
canberemovedwithverylittletrouble. Remove sary to remove the ventilating fan and /or drive
end head. splines from the the armature shaft. Theventilat-
ing fan is, for the most part, cast iron or cast
Remove bearing from head.
aluminum. Once the fan has been pressed onto
Remove the drive end head retaining bolts or the armature, it must be heated to be removed
screws, itnecessary. without damage.
Remove the drive end head (the bearing may or Remove Fan
may not remain on the shaft).
A puller is installed and a slight pressure exerted
Pull the armature assembly from the housing against the fan. Use a small propane torch to heat the
and field coil assembly. area of the fan around the shaft.
When the fan becomes loose on the shaft, as evi-
If the bearing remained on the armature shaft,
denced by the puller becoming loose, it should be
remove bearing from shaft with a bearing puller.
removed as quickly as possible.
When a puller is used, protect the end of the
armature shaft with a nut or a thick flat washer. Remove Retainer Pin
If theshaft, or spline is damaged when removing
l Press or drive the spline retaining pin out of the
the end head, the armature or the drive spline
shaft and spline.
usually has to be replaced. Use caution and do
not damage the armature. Remove Spline
If the bearing remained in the end head, remove l Use a hammer and chisel or drift punch to drive
bearing from end head. On some motors the spline out of shaft.
bearing is retained with a snap ring. Remove the
snap ring, then press the bearing out of the end
head.

16-3-5 SM-587
GROUP 16 Motors
Component Inspection & Trouble Shooting
After the motor components have been thoroughly burning or heavy arcing between bars. The
cleaned and dried, they should be inspected for the coloring pattern will be:
following:
l Streaky film with commutator wear.
Drive End Head
l Bar edge burning.
1. Check bearing recess for any signs of wear.
l. Uneven film.
2. Checkmountingholesforany strippedorcmsed
l Carbon dust bridging between bars.
threads or broken studs.
Brushes should be inspected for uneven wear and
Commutator End Head
signs of overheating, i.e.
l Discolored brush shunts
2. Check brush holder insulation for cracks or any
l Discolored brush springs.
signs of burning.
Refer to the Brush Chart on page 16-3-11.
3. Check brush holders and springs for wear.
Armature
Bearings
1. Check security of fan.
1. Check bearings by turning them with your fin-
gers. Feel for binding or gritty effects and 2. Check for loose commutator bars. Loose com-
excessive looseness or wobble. A good bearing mutator bars will usually be indicated by exces-
should also have a small amount of drag or sive wearorbumingonone bar. The commutator
stiffness caused by the lubrication but should can be checked for loose bars by lightly tapping
turn smoothly. If the bearing turns very freely, all of the bars with the handle of a plastic or
it should be replaced. Bearings should also be wooden handled screwdriver. A contrasting
changed, if worn out, damaged or removed from dull thud or vibration will indicate a loose barin
armature shaft. which case, the armature must be replaced.
l Ball bearings that have been pulled off of shafts, 3. Check for grounded circuits using a test light.
pressed out of end heads, or side loaded in such Most commercial growlers incorporate a test
a way as to apply pressure on the balls and races light as shown in illustration below.
must be replaced. Although the bearing may . Check the armature for grounded circuits by
appear or feel good, the bearing races have been placing one test lead of the test lamp on the
brinelled and will fail within a relatively short commutator and the other test lead on the arma-
period of service. ture shaft. If the test light lights, the armature is
Brush and Commutator grounded.
The brushes and commutator should be inspected for

even wear and good commutation.
Good Commutation: A dark uniform coloring
pattern at the brush wearing surface.
Poor Commutation: The surface of the commu-
tator appearing rough, pitted, scored or signs of
SM-587 16-3-6 Dec94

Motors GROUP 16
4. Standard Winding Armatures are tested on a Frame and Field Assembly
growler (see illustration below) using a steel
strip or hacksaw blade to locate any shorted l Check the condition of all insulation. If the
windings. insulation on the field coils appears blackenedor
charred, the serviceability of the coils is ques-
l Check for shorted windings by slowly rotating
tionable. Burned or charred insulation is a result
the armature in the growler while holding the
of coil overheating due to overloading condi-
strip or blade so that it passes over each armature
tions, groundedor shortedcoil windings. Check
core slot. If a winding is shorted, the strip or
condition of all other insulation such as brush
blade will vibrate and the blade will get hot.
rigging, under coil connections and around ter-
minal studs.
Hacksaw Blade
TESTING
Frame and Field Assembly

After thorough inspection, the Frame and Field As-
Jre
sembly should be checked for grounded, open or
shorted circuits. Grounded and open circuits can be
Lights
checkedusinga test light. Most commercial growlers
incorporate a test light as shown in opposite illustra-
tion.
Grounded Circuit
l Touch one test lead to a clean bare metal spot on
NOTE the frame and check all terminals with the other
Ifthearmaturehasbeenturnedand lead. If a grounded condition exists, the test light
undercut prior to testing, check for will light.
and remove any copper buildup or
filings between commutator bars Open Circuit
and at the commutator riser. This
l Check between all connecting terminals with
condition will cause an armature
test leads. Ifthe bulb fails tolight, anopencircuit
tocheckshortedandusuallyresults
is indicated.
from a dull undercutting tool.
5. Check commutator bars for any signs of burn- Shorted Circuit

ing. If deep burned sections are evident, either in l Shorted windings in series coils are very diffi-
the brush track or on the riser ends of the
cult to detect. Generally, if the coil insulation is
commutator bars, an open or short circuit in the
sound and these are no signs of overheating, the
armature windings is indicated.
coil can be presumed good.

16-3-7 SM-587
GROUP 16 Motors
FRAME AND FIELD SERVICE NOTES REASSEMBLY
If theinside of the motor is exceptionally dirty and Reassembly is the reverse of disassembly.
there is evidence of a grounding condition caused by NOTE
the dirt, the inside of the motor can be given an
Bearing Installation
additional coat of insulating varnish. Red glyptol can
be used if a better material is not available, however, 1. Whenever ball bearings are pressed into an end
we recommend using a class H Polyurethane air head or onto a shaft, always press against the
drying insulating varnish. This is readily available race that is absorbing the pressure.
under various brand names from electrical repair or Press on the outer race when installing into end
parts houses in aerosol type dispensers. heads.
Before spraying field coils, make sure they are abso- Press against the inner race when installing on-
lutely clean anddry. Protect brush rigging, pole shoe to a shaft.
faces and end head seats to keep varnish off.
2. EndHeads having slip-fit bearings are normally
FIELD COIL INSTALLATION retained by a snap ring. Always install new snap
ring(s).
Good solder connections are important due to the
vibrationcharacteristicsencountered by thesemotors
After Assembly
which can cause cold or poorly soldered connections . The motor should be connected as specified in
to break. trouble shooting, and tested to the specifica-
l Prior to installing thejield coils, the connections tions.
which require soldering should be buffed or . When testing motors, the voltmeter connec-
wire brushed clean to remove any oxidation. tions must be made at the motor terminals.
The connections should then be tinned with a
soldering iron. When changing brushes
NOTE When changing brushes the commutator must be
We do not recommend using a serviced as follows:
soldering gun or torch. Soldering
l Resurface the commutator by taking only light
guns cannot provide the heat
cuts each time, 0.005.
concentration required and
soldering torches can damage the l If re-slotting/undercutting is necessary, the fi-
insulation. nal operation is to lightly sand the commutator
with a fine sandpaper to remove any burrs left
l After field coil installation, connect the solder from the undercutting operation.
joint making sure the solder is flowing properly
to avoid a cold soldered joint.
Pole Shoe Screw Removal & Installation

(Field Coil Removal & Installation)
SM-587 Dee 94
Motors GROUP 16
24-Volt Motor Specifications

This motor is equipped with Standard Winding Connections and meets latest revision of U.L. 583
Motor Specifications
l Frame Size: 6.7 (165.1 mm) Diameter
.
l Weight (Approx.): 43 lbs. (19.51 kg)
l Internal Bearings are sealed and lubricated with high temperature grease for the
life of the bearing.
Motor Insulation
l Armature components, Class H
l Commutator components, Class H
.
Commutator Servicing Diameters ROTATION: REVERSIBLE

l MaximmDiameter, NEW 2.92
C.W.D.E.
l Minimum Diameter for RESLOTTING: 2.80
l Min. Diameter for REPLACEMENT: 2.75 Forward Vehicle Direction
C.C.W.D.E.
Reverse Vehicle Direction
Brush Data
1 Brush per Holder
4 Brushes per Motor
Min. Length of Worn Brush
0.42 (10.67 mm)
Max. Force per New Brush
29 oz. (825 gm)
Max. Force per Worn Brush
12 oz. (340 gm)
Brush Drop Grade: H803
1.OVolts @ 7 1 Amps Motor Brush

16-3-9 SM-587
GROUP 16 Motors
36-Volt Motor Specifications

l Frame Size: 6.5 (165.1 mrn)Diameter
l Internal Bearings are sealed and lubricated with high temperature grease for the life of the
bearing.
Fsulation
l Armaturecomponents, Class H ROTATION: REVERSIBLE
C.W.D.E.
CommutatorServicing Diameters
Forward Vehicle Direction
Maximum Diameter, NEW: 2.92
I
Minimum Diameter for RESLOTTING: 2.80
Min. Diameter for REPLACEMENT: 2.75 C.C.W.D.E.
Reverse Vehicle Direction
Brush Data
l 1 Brush per Holder
l 4 Brushes per Motor
l Min. Length of Worn Brush
0.42 (10.67 mm)
l Max. Force per New Brush
29 oz. (825 5)
l Max. Force per Worn Brush
12 oz. (340 5)
l BrushDrop Grade H803
Motor Brush
1.0 Volts @ 71 Amps
SM-587 16-3-l 0 Dee 94

GROUP 16
REPLACE BRUSH
I
FOR EACH BRUSH, REPLACE SPRINGS. II
I I
REPLACE BRUSH IF OIL SOAKED
0.42"
REPLACE BRUSHES
WHEN WORN TO
*_, NEW BRUSHES
16-3-l 1 SM-587
GEA-7
COMMUTATOR CHECK CHART

FOR COMPARING COMMUTATOR SURFACE MARKINGS
SATISFACTORY COMMUTATOR SURFACES
LIGHT TAN FILM over entire commutator MOlYLED SURFACE with random film pot- BLOT BAR-MARKING, o sfiihdy do&f HEAVY FILM cpn oppeor over entire
swfoc* is one of many normal condtionl tam is pmbabfy most heqwdy obrmed fffm, pppmn on bon in o d&k panem preo of efficient and normal commute-
ohen seen on (I well-functioning machine. condition of rommutatorr in industry. nl0t.d to numb.l of condumm per dot. tar and, if uniform, b quite occ.ptobfc.
WATCH FOR THESE DANGER SIGNS
STREAKING on the commutator swfoce sipnols Ihe THREADING al tommutm~r whh firmlims rowIts GROOVING b o mechanical condition cowed
beg8nnmg of s*rios met01 nand*r to Ihe carbon whan lxmsiva mudnansfnoccum h usually kodr by abrasive motwiol in the brush or otmor-
brush. Check the chart below for possible muses. to rwnfocing of commutotw and mpid bwsh weor. phere. lf grooves form, start corrective action.
- --\ .
COPPER DRAG, on obnormol build-up of commutator PlYCH BAR-MARKING produces bw w burn... spots .- HEAVY SLOT BAR-MARKING con involve
mattiol, forms most often at Iroiling +* of bar. Con- on lh* commutota surfor*. The number of these mork- atching of hailing edgo of rommutotor bar. Pot-
dition is rare bui ton covu flashover if not hked. ingr equolr half or all 410 numbw of pohr on the motor. tern b r&ted to number of conductors per dot.
Carbon Products
General Electric Company
East Stroudsburg. Pa. 18301
Copyrighted Material c

El!!RIC
lVl;~pria~Handling
GROUP 16
Section 5
Pump Motors
24 & 36 VOLT
Contents
General Information . . . .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 16-5-3
Motor Disassembly . .. .. .. . ... .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. .. . . .. .. 16-5-5
Component Inspection & Trouble Shooting . .. .. .. ... . .. .. .. .. .. .. .. . ... .. .. .. .. . . 16-5-6
Testing . . ... .. . ... .. .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. . .. . . 16-5-7
Changing Brushes . .. .. .. .. . .. ... .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. .. . . 16-5-8
Motor Reassembly . . .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . . 16-5-8
Specifications . ... . .... ... . .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. . .. . . 16-5-9
Inspection Charts . .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. 16-5-11
24 & 36 Volt
Ventilated and Enclosed Motors
3/8-l 6 UNC-2A -
Bearing Bearing
I .;-. 17 -
Name Plate
0 0
Snap
-t
112-l 3 UNC-2B A - Mounting Bracket 3/8-24 UNF-2B -1

16-5-l SM-587
GROUP 16 Motors
A WARNING
air pressure to 30 PSI (207 kPa). Debris remo2ed with air pressure can cause injury.

Typical
Inch Pound
Torque Wrench
Pointer
SM-587 16-5-2 Dee 94

Motors GROUP 16
GENERAL
The goal of any maintenance program, long-life and trouble-free operations, is related to the
The key to planned maintenance of the brush and commutator is recognizing undesirable
brush and commutator conditions. If this is done, corrective action canbe takenbefore amajor
pattern will be:
. Bar edge burning.
. Uneven film.
Operating environment of lift truck motors varies widely: The service frequency shall
depend upon the severity of operating conditions.
Normal Service: Severe Service:
Basically an eight- Extended operating
Extreme Service: Chemical Processing

Freezer Operation
Processing Plants (Poultry, Meat)

16-s-3 SM-587
GROUP 16 Motors
1. Remove brushes. +
4
3. Remove
screws from
2. Remove screws-b
drive end
from commutator
head.
end head.
4. Remove
drive end
head with
bearing.
Screw
5. Remove the com- . pull arma-

mutator end head ture out of
and .. housing.
Disassembled View
T Bearing Bearing
Field Coils & Pole Shoes
Housing
Commutator End Head Drive End Head
SM-587 16-5-4 Dee 94

Motors GROUP 16
ELECTRIC PUMP MOTORS
Disassembly
l Remove the cover band (if so equipped) from
the commutator end of the motor. Use a brush
hook to reach into the motor and lift the brush
springs. Pull the brushes out of the brush hold-
ers. Either position the brushes outside the rush I prin! s
motor orremove the brush retaining screws and

remove the brushes from the motor.
l Scribe or center punch locating marks in the end
c-
heads and the frame. Although locating marks
are not always necessary because of locating
pins in some motors, they can save a lot of time
when the motor does not have locating pins.
l Remove the commutator end head retaining
screws or bolts. The motors have a slip fit
bearing at the commutator end, and the end head
can be removed with very little trouble.
l Remove the drive end head retaining bolts or
screws. Separate the armature and drive end
head as an assembly from the frame and field
coil assembly.
l Separate the armature from the drive end head.
This operation is usually accomplished by press-
ing the armature out of the drive end bearing.
The end head and bearing may have to be
removed with a puller. When a puller is used,
protect the end of the armature shaft with a nut
or a thick flat washer. If the shaft, coupling, or
spline is damaged when removing the end head,
the armature or the drive spline usually has to be
replaced. Use caution and do not damage the
armature.
l Separate the bearing from the end head. The
bearing is retained with a snap ring. Remove the
snap ring, then press the bearing out of the end
head.
Dee 94 Copyrighted18-5-5
Material SM-587
GROUP 16 Motors
After the motor components have been thoroughly burning or heavy arcing between bars. The
cleaned and dried, they should be inspected for the coloring pattern will be:
following:
l Streaky film with commutator wear.
Drive End Head
l Bar edge burning.
0. Uneven fti.
2. Checkmountingholesforanystrippedorcrossed
l Carbon dust bridging between bars.
threads or broken studs.
Brushes should be inspected for uneven wear and
Commutator End Head
signs of overheating, i.e.
l Discolored brush shunts
2. Check brush holder insulation for cracks or any
l Discolored brush springs.
signs of burning.
Refer to the Brush Chart on the following
3. Check brush holders and springs for wear.
pages.
Bearings
Armature
1. Check bearings by turning them with your fin-
gers. Feel for binding or gritty effects and
excessive looseness or wobble. A good bearing 2. Check for loose commutator bars. Loose com-
should also have a small amount of drag or mutator bars will usually be indicated by exces-
stiffness caused by the lubrication but should sive wearor burning on one bar. Thecommutator
turn smoothly. If the bearing turns very freely, can be checked for loose bars by lightly tapping
it should be replaced. Bearings should also be all of the bars with the handle of a plastic or
changed, if worn out, damaged or removed from wooden handled screwdriver. A contrasting
armature shaft. dull thud or vibration will indicate a loose bar in
which case, the armature must be replaced.
NOTE
Ball bearings that have been pulled 3. Check for grounded circuits using a test light.
off of shafts, pressed out of end Most commercial growlers incorporate a test
heads, or side loaded in such a way light as shown in illustration below.
as to apply pressure on the balls . Check the armature for grounded circuits by
and races must be replaced. placing one test lead of the test lamp on the
Although the bearing may appear commutator and the other test lead on the arma-
or feel good, the bearing races
ture shaft. If the test light lights, the armature is
have been brinelled and will fail
grounded.
within a relatively short period of
service.
Brush and Commutator

The brushes andcommutator should be inspected for
Poor Commutation: The surface of the commu-
SM-587 16-5-6 Dee 94

Motors GROUP 16
4. Standard Winding Armatures are tested on a
Frame and Field Assembly
growler (see illustration below) using a steel
strip or hacksaw blade to locate any shorted l Check the condition of all insulation. If the
windings. insulation on the field coils appears blackenedor
charred, the serviceability of the coils is ques-
l Check for shorted windings by slowly rotating
tionable. Burned or charred insulation is a result
of coil overheating due to overloading condi-
strip or blade so thatitpasses over each armature
tions, grounded or shorted coil windings. Check
condition of all other insulation such as brush
blade will vibrate and the blade will get hot.
rigging, under coil connections and around ter-
minal studs.
Hacksaw Blade
TESTING
Frame and Field Assemblv

After thorough inspection, the Frame and Field As-
Jre
sembly should be checked for grounded, open or
shorted circuits. Grounded and open circuits can be
Lights
checked using a test light. Most commercial growlers
incorporate a test light as shown in opposite illustra-
tion.
L Switch
/
Grounded Circuit
Growler
l Touch one test lead to aclean bare metal spot on
NOTE the frame and check all terminals with the other
Ifthearmaturehasbeentumedand lead. If a grounded condition exists, the test light
undercut prior to testing, check for will light.
filings between commutator bars Open Circuit
and at the commutator riser. This
l Check between all connecting terminals with
condition will cause an armature
testleads. Ifthebulbfails tolight,anopencircuit
tocheckshortedandusuallyresults
is indicated.
5. Check commutator bars for any signs of burn- Shorted Circuit

ing. If deep burned sections are evident, either in
l Shorted windings in series coils are very diffi-
cult to detect. Generally, if the coil insulation is
sound and these are no signs of overheating, the
coil can be presumed good.

16X3-7 SM-587
GROUP 16 Motors
FRAME AND FIELD SERVICE NOTES REASSEMBLY
If theinside of the motor is exceptionally dirty and Reassembly is the reverse of disassembly.
there is evidence of a grounding condition caused by NOTE
the dirt, the inside of the motor can be given an
Bearing Installation
additional coat of insulating varnish. Red glyptol can
be used if a better material is not available, however, 1. Whenever ball bearings are pressed into an end
we recommend using a class II Polyurethane air head or onto a shaft, always press against the
drying insulating varnish. This is readily available race that is absorbing the pressure.
under various brand names from electrical repair or Press on the outer race when installing into end
parts houses in aerosol type dispensers. heads.
Before spraying field coils, make sure they are abso- Press against the inner race when installing on-
lutely clean anddry. Protect brush rigging, pole shoe to a shaft.
faces and end head seats to keep varnish off.
FIELD COIL INSTALLATION retained by a snap ring. Always install new snap
ring(s).
Good solder connections are important due to the
After Assembly
vibration characteristics encountered by these motors
which can cause cold or poorly soldered connections l The motor should be connected as specified in
to break. trouble shooting, and tested to the specifica-
l Prior to installing thefield coils, the connections tions.
which require soldering should be buffed or l When testing motors, the voltmeter connec-
wire brushed clean to remove any oxidation. tions must be made at the motor terminals.
The connections should then be tinned with a
soldering iron. When changing brushes
NOTE When changing brushes the commutator must be
We do not recommend using a serviced as follows:
soldering gun or torch. Soldering
l Resurface the commutator by taking only light
guns cannot provide the heat
cuts each time, 0.005.
concentration required and
soldering torches can damage the l If re-slotting/undercutting is necessary, the fi-
insulation. nal operation is to lightly sand the commutator
with a fine sandpaper to remove any burrs left
l After field coil installation, connect the solder from the undercutting operation.
joint making sure the solder is flowing properly
to avoid a cold soldered joint.
Pole Shoe Screw Removal & Installation

(Field Coil Removal & Installation)
SM-587 16-5-8 Dee 94

GROUP 16
24-Volt Pump Motor Specifications

l Internal Bearings on Pump End and Commutator End. Bearings are double
sealed and lubricated with high temperature grease for the life of the bearing.
Motor Insulation
.Commutator Servicing Diameters
l Maximum Diameter, NEW 2.92
l Minimum Diameter for RESLOTHNG: 2.80
l Min. Diameter for REPLACEMENT: 2.75
Circuit and Rotation

l Single Rotation
l CCWDE, - to Battery Negative,
+ to Battery Positive.
Brush Data
l Max. Length of Worn Brush
0.42 (10.67 mm)
Length
l Min. Force per New Brush 11.13(28.7n n>
7
29 oz. (825 gm)
12 oz. (340 gm)
l Brush Drop Grade: H803
1.0 Volts @ 71 Amps Motor Brush

1 C-5-9 SM-587
GROUP 16 Motors
36-Volt Pump Motor Specifications

l Internal Bearings on Pump End and Commutator End. Bearings are double sealed and lubricated
with high temperature grease for the life of the bearing.
Motor Counlinz
l A coupler is used to connect the motor to the pump. One half the coupler attaches to the motor
and the other half to the pump.
Jnsulation
Single Rotation
l
CCWDE, -
l to Battery Negative,
Commutator Servicing Diameters
l Maximum Diameter, NEW: 2.92
l Minimum Diameter for RESLOITING: 2.80
Brush Data
0.42 (10.67 mm)
Length-6
l Max. Force per New Brush 1.13(28.7mm)
l
29 oz. (825 gm)
12 oz. (340 gm)
BrushDrop
1.0 Volts @ 71 Amps
7 Grade H803
Motor Brush
SM-587 16-5-l 0 Dee 94

Motors GROUP 16
REPLACE BRUSH
v
CHECK TENSION
OF EACH SPRING


TIGHTEN SCREW.
0.42"
1
REPLACE BRUSHES
WHEN WORN TO
HERE.
NEW BRUSHES

16-5-l 1 SM-587
GEA-7

LIGHT TAN FILM ov.r entire commutator MOYYLED SURFACE wf+ft mndom film pat- SLOT IAR-MARKING, a sfiphdy darker HEAVY FILM <on oppeor ov.r weire
surfoc* is one of many nomwl conditions +em is probably mod fmqwn+fy observed fib, appmm
onbanin a dafinih panem or.0 of efficient and normal commvto-
ohen seen on a well-funaioning machine. condition of commu+q+orr in industry. nl.a+ed +o numkr of <onduc+urI par Jo+. +or and, if uniform, is quite accep+abfc.
STREAKING on the ~ornrn~t~+or wrbre sign& the YHREADING of tommu+~+or with fine liner roruhs GROOVING is o mechanical condition caused
begmmng of r.riow m.+al nondw to the carbon whan lxcwsiw me+ol hondw occur. h usually fwdr by abrasive material in the brush or o+mos_
brush, Check the chart b4o.v for possible
cousm. +o resurfacing of ~ommu+a+w and rapid brush wear. pherm. If grooves form, s+w+ correc+iw action.
COPPER DRAG, on abnomwl build-up of comnw+&o~ PIYCH BAR-MARKING +x&w bw or burn... spo+s -- HEAVY SLOT BAR-MARKING can involve
mottiol, forms mos+ okm 01 boiling edgo of bar. Con- on +fw commu+a+or wfoc*. The numbw of +ft.s, mark- nching of hailing edge of ~ommu+a+or bar. Pot-
din is ram but can couw Rashorn if no+ &ted. ings wuofs half or all +fta numk of p&r on +fw motor. +em is r&+ed lo numbw of conductors per Jo+.
Carbon Products
East Stroudsburg. Pa. 18301
Material Handling
CMRK Company
GROUP 16
Section 7
Auxiliary/Steer Pump Motors
24 & 36 VOLT
Contents
General Information .......................................................................... 16-7-3
Trouble Shooting Prior to Disassembly ............................................. .l6-7-5
Motor Disassembly ........................................................................... 16-7-6
Component Inspection & Trouble Shooting ....................................... 16-7-8
Changing Brushes ............................................................................. 16-7-9
Motor Reassembly ............................................................................ 16-7-9
24-Volt Specifications and Brush Data ............................................ .16-7-10
36 Volt Specifications and Brush Data ............................................ .16-7-11
Brush Inspection Chart .................................................................... 16-7-12
24 & 36 Volt
Ventilated and Enclosed Auxiliary/Steer Motors
Post
Nut
Washer
Insulator
Motor Frame
-&-Terminal Kit
01 Armature Shafi
Bearing
Brush
Cover
16-7-l SM-587
Dee 94
GROUP 16 Motors
AWARNING
air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.
Typical
Inch Pound
Torque Wrench
Pointer
SM-587 Dee 94
Motors GROUP 16
GENERAL
The goal of any maintenance program long-lifeand trouble-freeoperations is related to the

The key to planned maintenance of the brush and commutator is recognizing the undesirable
brush and commutator conditions. If this is done, corrective action canbe takenbefore amajor
pattern will be:
. Bar edge burning.
. Uneven film.
Operating environment of lift truck motors varies widely: The service frequency shah
depend upon the severity of operating conditions. w

hour day of mostly hours, or constant us-
indoor or out door age.
material handling.
Extreme Service: Chemical Processing

Freezer Operation
ProcessingPlants (Poultry, Meat)

16-7-3 SM-587
GROUP 16 Motors
e
Br,ush Cover f
r1
, Name
+-
---
plate
L _--
*
Matching half of coupler
attaches to hydraulic pump
Dee 94
Motors GROUP 16
AUXILIARY/STEER MOTORS (PERMANENT MAGNET TYPE)
The permanent magnet motor differs from conven- impact, drop or squeeze the motors as this can
tional D.C. motors in that the field winding has been cause damage to the ceramic pole pieces and it will
replaced with ceramic magnet pole pieces. Do not make motor unfit for further use.
TROUBLE SHOOTING PRIOR TO DISASSEMBLY
1 Read the nameplate to become familiar with the enough to observe if the shaft turns. If it does
motor, especially the rated voltage. turn, then hold the motor leads on the power
supply for a longer time. If the motor sounds
2 Try to turn the shaft by hand. Keep motor leads
normal, go to item 3. If the motor sounds noisy,
separated while doing this. If the shaft turns
it should be taken apart as described herein.
freely go to item 3. If the shaft wont turn,
proceed to item 2A. 3. If the motor turned freely, connect an ammeter
in thecircuit as shown below. Withratedvoltage
2A The shaft could be tight for a number of reasons.
applied and the shaft running free, the ammeter
This check is to determine if the tightness is of a
should read less than 20% of the nameplate full
temporary nature only. Obtain a power source to
load current. If the motor meets the above con-
produce the rated voltage. Do Not Make A
ditions then it can be assumed the original
Permanent Connection. First touch the motor
problem is external to the motor. A higher
leads quickly to the power supply just long
current indicates a faulty armature.
Ammeter
PoDwcer
SUPPlY

16-7-5 SM-587
GROUP 16 Motors
MOTOR DISASSEMBLY . Disconnect brush assembly lead.
Caremust be taken when the permanent magnet . Lift brush assembly from brush holder.
motor is disassembled, since the magnet pole pieces
will attract ferrous metals. This fact dictates motors 5. Remove any carbon dust or dirt from brush ring
should be disassembled in an area free of ferrous assembly.
(iron, steel) metal chips. 6. Remove pump drive coupling segment from
motor shaft end.
A CAUTION
7. Loosen motor assembly thru bolts at commuta-
Do not place the stator ring tor end of motor and remove bolts from motor.
(motor housing) in any
mechanical holding device 8. Scribe a match mark on drive end cover and
(e.g., vise) during the dis- housing.
assembly or assembly opera-
. Remove drive end (pump mounting) cover.
tion. Permanent distortion or
other damage will result. With Using a pry bar, carefully pry on cover to loosen.
the motor disassembled, care Tap lightly on pry bar, if necessary.
must also be taken not to drop
9. The drive end bearing may now be inspected.
the stator ring assembly, since
it can be distorted. Motor may 10. Support and hold stator housing firmly on the
be held by clamping on the end cover (a second person is suggested).
mounting bracket.
11. Pull armature out of assembly in one quick
IMPORTANT motion.
Before disassembling motor, note that there are match
marks on the stator assembly housing and the com- A CAUTION
mutator cover. If marks are not visible, use a scribe It is important that the pulling
tool to make match marks. These marks will be used motion on the armature be
at assembly continuous. Do not pull part
way out and release. if this is
1. Loosen and remove clamping screw in brush done, the magnets will pull the
cover band. armature back into the stator
2. Remove brush cover band segments by prying and cause severe damage.
coverpins out of engagement in motor housing.
To avoid damage to either the
3. Air clean inside of motor around brushes and armature or the permanent
commutator, using dry (moisture-free) com- magnets, it is recommended
pressed air. that the armature be removed
only with the motor housing
. The armature should be blown off with com- and armature shaft positioned
pressed air to remove brush dust and dirt from vertically.
around the commutator and windings.
12. Remove commutator end cover.
NOTE
. Remove and save bearing spring washer fi-on
Observe how brushes are assembled in brush holders.
the cover bore.
Note position of the brush lead (shunt).
4. Remove the brushes as follows:
l Remove brush spring clip from its mounting on
top of brush assembly. Use a brush hook to reach
into motor and lift brush springs.
SM-587 16-7-6 Dee 94

Motors GROUP 16
16.:
16.208
16 .258 J
STEER PUMP MOTOR
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
16.232 Cover, Steer Pump Motor Brush Hole
16.234 Terminal Kit, Steer Pump Motor
16.238 Brush Holder Kit, Steer Pump Motor
16.258 Frame, Steer Pump Motor Drive End
16.259 Frame, Steer Pump Motor Commutator End
16.274 Stator, Steer Pump Motor

1 S-7-7 SM-587
GROUP 16 Motors
After the motor components have been thoroughly
cleaned and dried, they should be inspected for the
following: burning or heavy arcing between bars. The
Drive End Head coloring pattern will be:
1. Check bearing recess for any signs of wear. l Streaky film with commutator wear.
2. Checkmountingholesforanystrippedorcrossed l Bar edge burning.

threads or broken studs. l. Uneven film.
Commutator End Head l Carbon dust bridging between bars.
1. Check bearing recess for any signs of wear. Brushes should be inspected for uneven wear and
2. Check brush holder insulation for cracks or any signs of overheating, i.e.
signs of burning. l Discolored brush shunts
3. Check brush holders and springs for wear. l Discolored brush springs.
Bearings Refer to the Brush Chart on the following
1. Check bearings by turning them with your fin- pages.
gers. Feel for binding or gritty effects and Armature
excessive looseness or wobble. A good bearing
should also have a small amount of drag or
stiffness caused by the lubrication but should 2. Check for loose commutator bars. Loose com-
turn smoothly. If the bearing turns very fi-eely, mutator bars will usually be indicated by exces-
it should be replaced. Bearings should also be sivewearorbumingononebar. Thecommutator
changed, if worn out, damaged or removed from can be checked for loose bars by lightly tapping
armature shaft, all of the bars with the handle of a plastic or
wooden handled screwdriver. A contrasting
NOTE
dull thud or vibration will indicate a loose barin
Ballbearingsthathavebeenpulled which case, the armature must be replaced.
off of shafts, pressed out of end
3. Check for grounded circuits using a test light.
heads, or sideloadedin such a way
Most commercial growlers incorporate a test
as to apply pressure on the balls
light as shown in illustration below.
and races must be replaced.
Although the bearing may appear l Check the armature for grounded circuits by
or feel good, the bearing races placing one test lead of the test lamp on the
have been brinelled and will fail commutator and the other test lead on the arma-
within a relatively short period of ture shaft. If the test light lights, the armature is
service. grounded.
Brush and Commutator

The brushes and commutator should be inspected for
Poor Commutation: The surface of the cornmu-
SM-587 16-7-8 Dee 94
Motors GROUP 16
4. Standard Winding Armatures are tested on a NOTE
growler (see illustration below) using a steel Bearing Installation
strip or hacksaw blade to locate any shorted
1. Whenever ball bearings are pressed into an end
windings.
headorontoashaft,alwayspressagainsttherace
l Check for shorted windings by slowly rotating that is absorbing the pressure.
Press on the outer race when installing into end
strip or blade so that it passes over each armature
heads.
blade will vibrate and the blade will get hot. Press against the inner race when installing on-
to a shaft.
r Hacksaw Blade
retained by a snap ring. Always install new snap
ring(s).
After Assembly
. The motor should be connected as specified in
Jre
trouble shooting, and tested to the specifications.
Lights . When testing motors, the voltmeter connec-
tions must be made at the motor terminals.
L- Switch WHEN CHANGING BRUSHES

/ Growler
When changing brushes the commutator must be
NOTE serviced as follows:
Ifthearmaturehasbeenturnedand l Resurface the commutator by taking only light
undercut prior to testing, check for cuts each time, 0.005.
filings between commutator bars l If re-slotting/undercutting is necessary, the final
and at the commutator riser. This operation is to lightly sand the commutator with
condition will cause an armature a fine sandpaper to remove any burrs left from
tocheckshortedandusuallyresults the undercutting operation.
5. Check commutator bars for any signs of burn-

ing. If deep burned sections are evident, either in
stator
1. Check magnets to be sure they are securely

mounted and have no cracks.
REASSEMBLY
Reassembly is the reverse of disassembly.

16-7-g SM-587
GROUP 16 Motors
24-Volt Auxiliary/Steer Pump Motor Specifications

rhis motor is equipped with Standard Winding Connections and meets latest revision of U.L. 583
l Frame Size: 6.5 (165.1 mm) Diameter .
l Internal Bearings on Pump End and Commutator End. Bearings are double
sealed and lubricated with high temperature grease for the life of the bearing.
l Grade: M-8 Magnets l 4-Magnets l 4 Poles
MotorInsulation
l Commutator components, Class H.
l Single Rotation
CommutatorServicing Diameters
l CCWDE, - to Battery Negative,
l Maximum Diameter, NEW 2.92
l Minimum Diameter for RESLOTTING: 2.80
++
--
Brush Data
1 Brush per Holder
4 Brushes per Motor
Min. Length of Worn Brush
0.42 (10.67 mm)
Max. Force per New Brush
29 oz. (825 gm)
12 oz. (340 gm)
Brush Drop
Grade: H803
1.0 Volts @ 71 Amps Motor Brush
SM-587 16-7-l 0 Dee 94

Motors GROUP 16
36-Volt Auxiliary/Steer Pump Motor Specifications

S
Frame Size: 6.5 (165.1 mm) Diameter
Weight (Approx.): 43 lbs. (19.51 kg)
Internal Bearingson Pump End and Commutator End. Bearings are double sealed and lubricated
with high temperature grease for the life of the bearing.
Motor CouDling
l A coupler is used to connect the motor to the pump. One half the coupler attaches to the motor
and the other half to the pump.
Insulation Circuit and Rotation
l Armature components, Class H l Single Rotation
l Commutator components, Class H l CCWDE, - to Battery Negative,
Commutator Servicing Diameters + to Battery Positive.
. Maximum Diameter, NEW 2.92
. Minimum Diameter for RESLOTTING: 2.80
. Min. Diameter for REPLACEMENT: 2.75
Brush Data
.
Width
1 Brush per Holder
,
0.812 (20.8 mm)1
0.42 (10.67 mm)
l Max. Force per New Brush
29 oz. (825 gnI)
12 oz. (340 gm)
l Brush Drop Grade HO03
Motor Brush
1.0 Volts @ 71 Amps

16-7-l 1 SM-587
GROUP 16 Motors
I I
REPLACE BRUSH

REPLACE BRUSH IF OIL SOAKED

TIGHTEN SCREW.
0.42"
1
REPLACE BRUSHES
WHEN WORN TO
HERE.
NEW BRUSHES
SM-587 16-7-l 2 Dee 94

GEA-7053

LIGHT TAN FILM over entire commutator MOTTLED SURFACE with random film pat- SLOT BAR-MARKING, a slightly darker HEAVY FILM con appear over entire
surface is one of many normal conditions tern is probably most frequently observed film, appears on bon in a definite pattern areo of efficient and normal commute-
ohen seen on a well-fundioning machine. condition of related to number of conduc+ors per slot. tar and, if uniform, is quite acceptable.
STREAKING on the oxnmutctor surface signals the THREADING of commutator with fine lines resuhs GROOVING is a mechanical condition cowed
beginning of serious metal trander to the carbon when excessive metal transfer occurs. h usually leads by abrasive moteriol in the brush or otmos-
brush. Check the chart below for possible causes. to resurfacing of commutator and rapid brush wear. phere. If grooves form, star+ corrective qction.
COPPER DRAG, on abnormal build-up of commutator PITCH BAR-MARKING produces low or burned spots -- HEAVY SLOT BAR-MARKING can involve
mote&al, forms most ohen at hailing edge of bar. Con- on the ~ommutotor surface. The number of these mark- etching of trailing edge of commuta+or bar. Pot-
dition is rare but can cause Rashover if not checkd. ings equals half or all the number of poles on the motor. tern is related to number of conductors per slot.
CAUSES OF POOR COMMUTATOR CONDITION

F...q.,
hOI
i~pw+on
o+ WV-.a,+*
commwt* cgn..,ir.
Onion.
Tk.+I.
MaInO
in.
or..
<an worn
ywWk.
on*m.obondicot.
o+ som.p0.dL.l.
em...
d++I.
rmditions.
.ondition.
and.*.lopinQ
so
h7t
ou Mk. ,~rrinp
can tkprop.,
pmdunir.
m~innnar..
Carbon Products
East Stroudsburg, Pa. 18301
Material Handling
Cl!!JRK Company GROUP 17
Section 17
Contactors
Contents
Forward & Reverse Contactor Illustration .................................... 17-1-2
Disassembly ...................................................................................... 17-1-3
Parts Inspection ................................................................................. 17-1-5
Reassembly ....................................................................................... 17-1-7
lA, Line & Pump Contactor Illustration ........................................ 17-1-8
Disassembly ...................................................................................... 17-1-9
Parts Inspection ................................................................................. 17-1-9
Reassembly ...................................................................................... .17-l-9
Control Panel

17-1-1 Dee 94
GROUP 17 Contactors
r ---------- Lock Washer
Bolt
sclE%v-
Q%J- Lock Washel

I 82.7 Washer
I
l- ------_-- -I
Insulator
(If Conductor
* &
=;5
f
Support
Spring-&
L ----- J
Bracket (Not Serviceable)
Coil
Base
Forward I Reverse Contactors
Dee 94 17-l -2 SM-587

Contactors GROUP 17
Forward / Reverse Contactor
A WARNING 6. Press downward on Cover (A) and completely

back out cover screws until they are free of the
Disconnect battery before
contactor base. Do not remove cover yet.
working on contactor tips.
7. Press downward on Cover (B) and disconnect
Before attempting to disassemble a contactor screws from base. Hold pressure on Cover (B)
to install a new contace set, carefully observe
and then remove Cover (A) from the assembly.
location and orientation of each part. Set cover and screws to one side.
1. Check armature and movable contacts for free- 8. Now remove Cover(B) and screws. Again, note
dom of movement by depressing movable are location of the buss bars, contacts and the large
with a screwdriver or small rod. Refer to illustra- insulators (C)for ease of reassembly.
tion on page 2.
9. Remove and discard upper contacts.
. Check for any restrictions to movement and for
10. Remove and inspect Insulators (C) for cracks
retum of parts by action of spring.
and damage. An insulator found to lx cracked or
2. Inspect contact tips. Look for any worn or broken should be replaced with a new one.
eroded surfaces. Look for evidence of tip weld-
11. Remove and discard lower contacts.
ing. Inspectforevidenceof any contaminants on
tips (paint, dirt, paper or cloth material, etc.) 12. Hold Bracket (D) with one hand and remove
which would impair operation. support sub-assembly (armature, contacts, etc.).
The return spring should come off with the
. Do not use sandpaper or file tips. Any damage
armature as it fits into a recess in the bottom of
must be corrected by tip replacement.
the armature.
. Tips must be replaced before they wear through
13. Secure support in a vice equipped with soft jaws
and damage copper base.
using minimum pressure to hold support.
To remove and replace contact tips:
14. Loosen and remove nut freeing core parts
1. Disconnect power cables from contactors. Re- (washer, insulators, movable contacts, spring
movebolts with washers, lockwashers and spac- seats and spring). Not the position and location
ers from contacts. Move power cables out of the of each part for proper reassembly. Remove
way. these parts.
2. Disconnect connecting buss bars from contacts. 15. Pull insulator and core bushing from core.
3. Disconnect wiring from contactor coil termi- 16. Remove armature core with spring from bottom
nals. of support and remove support from vice.
4. Remove mounting bolts securing Forward & 17. Remove Bracket (D) from coil and base.
ReverseContactorAssembly tothecontrolpanel
18. Remove coil from base.
base plate that is attached to the truck. Remove
assembly fi-om truck. 19. Disassemble the opposite (Reverse) contactor
in same manner.
5. Disassemble the contactors. Loosen cover
screwson bothcontactors. There are four screws 20. Inspect armature core insulators for cracks,
per cover. Note location of contacts so the new breaks, etc. If parts are found to be damaged,
onesmay be installed to thesame location as the they should be replaced with new ones.
old ones. 21. Inspect springs for damage. Replace damaged
parts with new ones.

17-l-3 Dee 94
GROUP 17 Contactors
r
--------me
Lock Washer
Bolt
s Lock Washer
.z
E3 7 Washer
l- ----------
Conductor
p--
Insulator
L-_-_--l
Coil
Base
Forward / Reverse Contactors
SM-587
Contactors GROUP 17
Forward / Reverse Contactor-continued- 27. Now, secure the Forward Contactor Assembly
Support into the vise using minimumpressure to
22. Inspect spring seats for damage (cracks, breaks,
hold the support.
etc.). Replace damaged parts with new.
. Install spring into coil recess.
23. Inspect the thin washer located on the armature
for cracks, etc., and security of mounting.
. locate white bushing over armature stem and
insert armature thru bottom of support position-
. Material on the armature stem has been up set
ing armature tab into support slot.
in four places to retain the washer. Inspect all
four places to be certain this thin washer is . Install spring and upper spring seat, upper con-
properly retained and free to rotate about the tact, upper insulator, lockwasher and nut onto
armature stem. armature stem.
. Inspect the cone surface of the armature and IMPORTANT
the corresponding surface in the base plate for Torque Nut to: 18 to 20 lb. in. (2.0
scoring, etc. to 2.4 N*m).
. Inspect the small white bushing for wear. The 28. Remove support and movable contact assembly
bushing I.D. must be perfectly round. If the from the vice.
bushing becomes egg shaped (out-of-round),
it should be replaced with a new bushing.
29. Assemble the Reverse Contactor Support and
Movable Contact Assembly in the same man-
24. Inspect coil for damage. ner.
IMPORTANT 30. Now locate the Forward Contactor Support and
The coil has four blind alignment Movable Contact Assembly over Bracket (D).
holes in the top and two in the
IMPORTANT
bottom These holesmustproperly
Be certain the armature tab is
align with the off-set pins in the
pointing inward toward the center
bracket and contactor base at
of the contactor base when
reassembly.
positioning support over bracket.
. Inspect alignment holes to be certain they are Refer to the boxed illustration on
perfectly round and not egg shaped (dam- opposite page.
aged).
31. Now locate the Reverse Contactor Support and
. Inspect coil terminals for damage. Movable Contact Assembly over its bracket.
. Replace damaged parts with new ones. Again, be certain the armature tabispointing
inward toward the center of the contactor base.
25. Reassemble the contactors. Install both coils
onto contactor base. Terminal connectionsmust 32. Install the long lower buss bar and stationary
point outward - away from cent of base. Be contacts (having threaded holes in one end) into
certain the coils are properly located over the the grooves located on the top side of each
base alignment pins. contactor support The cable end of the buss bar
should extend outward on the right hand side of
26. locate Brackets (0) on each coil and onto the the forward contactor support and extend out-
base. Be certain the bracket alignment pins wardon thelefthandsideofthereversecontactor
properly seat in the holes on the top side of each support. Be certain the notches in the buss bar
coil. and stationary contacts properly seat with the
screw guides of each contactor support.

17-1-5 Dee 94
Contactors
GROUP 17
--
r __---- -- 1
Lock Washer
Bolt
GQ- Lock Washe

8g 7 WasheN
Conductor
III-
!
Insulator
k+ Fastener
m Lock Washer
Insulator
Contact
Spring Seat
Forward I Reverse Contactors
17-l -6 SM-587
Dee94 Copyrighted Material
Contactors GROUP 17
Forward / Reverse Contactor-continued-

33. Install the short buss bar and stationary contacts
(having threaded holes in one end) in the same
manner as previously described. Be certain the
notches in each bar-fit properly to the screw
guides of each support.
34. Position Insulators (C) over the buss bar/con-
tacts and supports as shown in illustration on
opposite page. Be certain the opening in the
bottom of the insulators face downward and that
the insulators are properly seated in the slots of
the supports.
35. Assemble spacer, upper buss bar/contacts over
the insulators. Make certain the contacts are
seated properly in the insulators.
36. Assemble covers (A & B). Make certain covers,
buss bars & contacts are in alignment and press
both covers downward with one hand ... hold in
this position and install all cover screws until
snug. Check to be sure all parts are in proper
alignment, and position the Power Cable Bolts
(with lo&washers, and washers) thru the upper
buss bar/contacts and spacers. Tighten bolts
finger tight into the lower buss bar/contacts.
37. Tighten cover screws to:
14 to 18 lb. in. (1.6 to 2.0 Nom).
38. 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 mat-
ing parts.
39. Install Forward &Reverse Contactor Assembly
to panel base plate.

17-l-7 Dee 94
GROUP 17 Contactors
&-Lock Nut
_ockWasher
Washer
Spring Seat
----
r 1
k
Insulator
-Armature Assembly
I
I
I
I
I tT----
I g-Spring
I
I
I
I
I Retainer
I
I
I
I
L -----
Base
I-A, Line & Pump Contactors
Dee 94 17-1-8 SM-587

Contactors GROUP 17
I-A, Line & Pump Contactors 7. Remove lock nut, contact set, insulating washer
A WARNING
and spring fi-om armature stem. Be careful not to
disassemble or loose other parts under contact
Disconnect battery before tips on armature assembly.
working on contactor tips.
8. Install spring, washer, new contact set onto stem
Before attempting to disassemble a contactor and secure with lock nut.
to mstall a new contace set, carefully observe 9. Assemble contactor by putting moving contact
ti
location and orientation of each part. assembly armature shaft into coil plunger with
1. Check armature tid movable contacts for free- return spring on top of armature shaft.
dom of movement by depressing movable are 10. Put top cover over spring and install cover
with a screwdriver or small rod. Refer to illustra- mounting screws. Be sure return spring is in the
tion on page 8. cover recess.
. Check for any restrictions to movement and for IMPORTANT
return of parts by action of the spring. When assembling cover to base
2. Inspect contact tips. Look for any worn or (frame) make sure it is installed
eroded surfaces. Look for evidence of tip weld- with thepositive sign (+) markings
ing. Inspect for evidence of any contaminants on located properly.
tips (paint, dirt, paper or cloth material, etc.)
Use a bar or rod to move contacts
which would impair operation.
and be sure movement is free of
. Do not use sandpaper or file tips. Any damage binding. Be certain contact tips are
must be corrected by tip replacement. in correct orientation and tips
. Tips must be replaced before they wear through contact correct mating parts.
and damage copper base.
To remove and replace contact tips:

1. Loosen andremove two cover moun ting screws
securing cover to coil frame. Observeposition of
positive (+) murking on the cover.
2. Removecover.Besure to note locationofspring
seat and spring under cover.
3. Remove lock nut and lockwasher from each
stationary contact stud.
4. Remove contact studs from cover.
5. Install new studs and secure with lock washers
and lock nuts. Tighten lock nuts firmly on each
stud.
6. Lift armature assembly with movable contact
set from coil frame. Observe location of compo-
nents upon removal.

17-l-9 Dee 94
MaterialHandling
CMRU
Company
Group 19
SECTION 2
ELECTRICAL
SEQUENCE OF OPERATION
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..Page
OPERATIONAL SEQUENCE #1....................................2

Connect the Battery ..................................... ...4
Close the Key Switch .................................... ...6
Close the Key Switch (Continued) ........................ ...8
Steering Function..........................................lO
Steering Function (Continued)..............................1 2
Brake Switch & Static Return to Off (SRO) Checks...........1 4
Energizing the Directional Contactors......................16
Turning ON the Transistors.................................1 8
Turning 'OFF' the Transistors, Capacitor Charging and
Flyback....................................................2 0
Accelerator, Thermal Protector and Pulse Monitor Trip
(PMT)......................................................2 2
1A Contactor Operation.....................................2 4
Plugging...................................................2 6
Plugging (continued).......................................2 8
Plugging (continued).......................................3 0
Travel Speed Limit.........................................3 2
Solenoid Functions.........................................3 4
Lift.......................................................3 6
Lower......................................................3 8
Reach / Retract............................................4 0
Reach / Retract (Continued)................................4 2
Tilt.......................................................4 4
Tilt (Continued)..........................................4 6
Side Shift (Optional)......................................4 8
Side Shift (Continued)....................................5 0
SM-587 19-02- 1 Material

Copyrighted Rev Aug 94
OPERATIONAL SEQUENCE #l
This standard schematic is shown with all switches and contactors

in their normal 'OFF' position. No circuits are operating. The
four basic areas of circuitry are identified.
TRACTION CONTROL
STEER and AUXILIARY CONTROL
HYDRAULIC CONTROL
ACCESSORY
Rev Aug 94 19-02-2 SM-587
2
r-
I f-
);
I j
;
li
12
12
12
.. , 2 .............. 12 .................. , 2 .................. , 2 ........................................... ,
EVT 15 CARD
:.......................:
................... 2 .................... 2 .................... * ..............)* pB, TB,
I ..... .... ...... 24 . . . . . . . . . . . . . ;..+
12
----41 Fp86
t.........., $
+XE 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 0 . . . . . . . .._......... 0 ..,........... m4 py,3 _.; . . . . . . . . . . . . . . . . . 6, . . . . . . . . . . . . . . . ..___.... 6, . . . . . . . . . . . . . . . . . . . . . . . . j__,
, ; SWITCH>;,
12
. . . . . . . . . . . . . . . . . . 2, .. . . . . . . . . . . . . ..____...
R
~15~------+ 23 ------23
G
1111111111111111__11I
10
12
. . . . . . . . . . . .. .. . . . . . . , .. . . . . . . . . . . . . . . . . . . . . . HYDRAULIC
lo- -45 45 ; cT810 FUNCTION
. . . . . . . . . . . . .. . . . . . .. .
_NO,D CONTROL
12
18 a FUNCTICN
. ..,. . . . . -... .,O . . .. . . . .+...%. _.:I . . . _.. . . . . ., 58 ,. . . . . ./.z CcnrrRcc
. ..,. . . . . . . . .,O . . .. . . . .,&..??... . ..58 ,. . ..i
_..___.____.._......., ._.__.____._..........
l2 I
I
... .
OPERATIONAL SEQUENCE #2
Connect the Battery
A. Battery positive will be applied to terminal PB-1 of the EV-T15

control card through wire #2.
B. The negative circuit will be completed from terminal PZ-3 of the

EV-T15 card through the brown wire, to the control panel negative
cable terminal.
C. The EV-T15 card, through an internal circuit, supplies a

controlled capacitor charging current through the white wire at
terminal PZ-14, to the positive side of the 1C capacitor of the
EV-T15 and PS-1C capacitor of the EV-T5PS power steer control.
D. The capacitors will charge to battery volts in approximately 2

seconds. When the 1C capacitors are charged to battery volts, the
flow of the charging current will stop.
Note: Status Code -51 will be displayed if the 1C capacitors

do not charge to above 85% battery volts. It is normal
for Status Code -51 to be displayed for about 2 seconds
during the charging time, when the battery is initially
plugged in.
E. Battery Positive will be applied to the accelerator through wire

#2, control fuse 2FU and wire #12 on trucks equipped with solid
state transducer accelerator.
Note: Trucks equipped with potentiometer will not have

battery positive connection.
F. The Negative circuit to the accelerator will be completed through

wire #13 to the control panel NEG cable terminal.
G. The accelerator will supply an output voltage corresponding to the

handle position through wire #29 to terminal TB-1 of the EV-T15
control card.
H. The horn is operated by pushing the horn button which will supply
battery voltage to the horn through wire #25, and negative through
wire #13.
J. Battery Positive is supplied through wire #2, control fuse 2FU and
wire #12 to the key switch.
Voltages Present:
A. Battery positive
B. Battery negative
C. Battery positive
D. Battery voltage across 1C capacitors
E. Battery positive
F. Battery negative
G. Approximately 3.7 Volts with handle in neutral
H. Battery positive on wire #25
J. Battery positive on wire #12
Rev Aug 94 19-02-4 SM-587
r2
24/M VOLTS
............................................... ................................ 6, ................... .

P_ PS-IC
:......................... 20 ..............
.
i i i
;.............
40.. .......................... .
...................... i30
i i
;3 304b ;O 61
iL---- 2-2-2 s-L29 -
f._ _...., 0 . . . . . . . . . . . . . +-c . . . . . . . . . . . . . . . . . 24 ._,30 .. .._........_..........~ 0 ............. I j
j----- 10 -/*
IA
PB6 pyo JlG
i
q, .: ..... ...4 o ........................ 4 o ................... .
0 ...................................... , 0 .................. , o .............. i.* TO4 py,3 0 i

61 61
SL-1
5 ......................................
, 5 .................. , 5 .............
{.*m3 PA6
,.j................. +-+........., 3 ........................
,4 ......... ...........
i.. ......., 5 ............... %. ............... . 5 .................. ,5 ............. j.* TB.2 pA,,_;. ........... 34 ..... Sk2 ...... . 3 __________I____
SL-3
; * TBS ,,,+_____ 54 ___+.&.____,3 ................. t.. ....
6-----6
................ 8 ................... 6 ............... i.* T86 PA3 -.I.. ............... 2 o ........................ 2 o ........................ i,
4.. ........ , 5 .............. ,,A!. ................ 27 .................. 27 .............. I.* p&( PAZ -_I.. .............. 26 ....................... 26.. ........ . j
23 -23 *Fe5 py5 y---y

iP,y P,M P;3 Pi! :
:.+ . . . . . . . . . . . . t . . . . . ;_; :
26 20 .13
. . . . . . . . . . . . . . ..___............... 0 .._.___...............,, 0 . . . . . ..___...i.<TB,s m, + . ..___.......... 26 . . . .._........._...... 26 .........

5 ; oTB,d TBge; ..20 .__._................. 20
;._ . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . &d&%...,, . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . +.Ta,a ,B, . . . . . . . . . . . . . . . . . , 3 . . .. . . . . . . . . . . . . . . .. .. , 3

1 AUX2
+______---,O_____+ a.----__65 _--_-----65-----~~T~,~
.J- + .__._........_.
0 . . . . . . . . . . . . _L RZbCH 55 . . . . . . . . . . . . .._____...55 ._........... +T6,,
1 TILT
* lo- -45 45 ; ST010
P
& _________....__..__.......,
0 . . . . . . . . . . . . . \/: . . . . . . . . . . . . . . . 26 .._................... 26 ______...._..
+a
SOLEN3lD
,2 i
10--x+ s1 16 16 jlTB6 FUNCTION
axrFcL
; _.,_ _ _... __._ . . ., 0 _.._ _ _... .,,4...??... . _,58 __ _ ..?. . . . . ., 56 . .+,S
{ _... . ..,. . . . . . . . _,O . . . ..,. .,p._.??.._. ..56

I
, 2 $ . . . . . . . . . . . . . . . . . . . ___.._., 0 . . . . . . . . . . -.._+r...S3
. . . . . . . .. . . . 3 6
. ..____.__._.
,/,...% . . . . . . . . 46
1_________._._.______------,
0 . . . . . . . . . . . . . v4_..?.! . . . . . . . . 46
12-25 13
Copyrighted
SWITCH
19-02-05
Material
K)RN
l-cm 94
Close the Key Switch
A. Closing the Key Switch will supply battery positive to terminal

TB-4 of the EV-T15 control card, Line and 1A contactor coils,
terminal TB-15 of the Solenoid Control, all hydraulic function
switches, Brake Switch, Pump Contactor coil and all solenoid coils
and the Steer Lock Switch through the #lO wires. The card will
check the battery volts at this time to see if it corresponds with
the voltage setting within the card.
Note: Status Code -15 or -16 will be displayed if the battery

voltage is less than or higher than the preprogrammed
battery voltage setting, function #15.
B. The negative circuit to the solenoid control will be completed

through wire #13 at terminal TB-1 of the Solenoid Control card.
C. If the 1C capacitors are fully charged, the EV-T15 control card

will complete the circuit from wire #24 at terminal PB-2 to
battery negative. This will energize the line contactor coil in
turn closing the line contactor power tips.
D. The closing of the line contactor power tips will release (close)
the steer lock switch.
E. The closure of the steer lock switch will supply battery positive
through wire #SO to terminal 4PLl of the EV-TSPS steer control.
F. The negative circuit to the steer control will be completed

through the internal black wire connected to the PS-NEG terminal.
G. The EV-TSPS control card will supply a positive voltage through

wire #92 from terminal 4PL5 to the steer transducer's red wire.
The negative circuit for the steer transducer is completed through
it's black wire and wire #91 to terminal 4PL7 of the EV-TSPS steer
control.
Voltages Present:
A. Battery positive on all #lO wires.

B. Battery negative.
C. Approximately 11 volts across the coil.
D. Battery positive.
E. Battery positive.
F. Battery negative.
G. Approximately 15 volts.
Rev Aug 94 19-02-6 SM-587
BATTERY
._ l_,. ._
24/36 VOLTS
1 FU
2FU
0
D
61
l-l0
12 10
12 10 10 2 !O 61
lx6
.................
.E?....................
........................
. ...........
w:
I
12 10 10 2
yfxI-;=.i 12v13J 1 1
10 p@j ,.; ............ .... . 3. ............... .. ...... 30 .. .... ......i ;

12 10
IA
10 cI_y* 41-41---+ pB6 PW *: 40 40:
I
10 10-10 6 1 ...................... 6, ......................_;
.....1
SL-1
15 ...................................... , 5 .... .... .... ... .. , 5 4 4 ....... .iw& ....... 13
-i_
t ......... 15 5 .... .... ... ...... , 5 .............j.* TB*
...... .. .. ...._FwD ___.____.___.., PA4,.j .. . . .. . . .34 . . . .-.... . .,a ,. . . . . . .i- ..
SL-3
i--_l5A 6-6 iaT PA+____ 54 ---..?a&.___., 3 . . . . . . . . . .t. ..
* .................. B...............i.* TB6 pAa*_I.__..._..........
;......... 1fj ..............F!0 ........_..._.... 20 ................._.....
2. .....................f
i .____..._., 27 ............_...2..............i.* pB4 ,,A*-_I..... .......... 26 ...._._.______.____....
5 ..............\$7 ......._......... 26 .........
R
:- 15 ,-p 23 -23
~
Ii 10 26 2; 13
.
I
.............. 26 ..................... .26 ........ .A
*lo-k5 5 j*TBM TB8 *. ................ 20 ..................... .20 ......................
...................... 35 .............i.:*,,I,~ -13 -13

L-lo _i.,6. ____
AUXZ--es -________ 65 -----;+TBZ
----,(,---
,(,,-a * ...FEPCH -- ..._.................. 55 .............;.<Tf,,,

... .. .... .. 55 0
B
J._ TILT
lo- -45 45 i_ TBtO I
1 0 ._\fi . . . . !! . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . &TO8
1;
SOLENOID
10---G 16 16 :*TB6 NNCTKMl
10 ---, . .,58 . ..?. . . . 56 . . ..,.. .j.<785
E\...%.. Oa-rRu
_____, 0 ___>p...%. . ..58 . . ..i

10 s3
$ .._.___..._.....
38 ...____.___...._......
38 .............+,,
1 i
- 1o ,&s6________.
4; ___..__.
i
46 .......0 .... ... ...... 46 .. .......... .;.+TBa
,~ :.......................;
112 12
SM-587 Copyrighted
H3RN SWITCH Material Aug 94
Close the Key Switch (Continued)
H. The EV-T15 control card checks the battery condition by checking

the battery volts between terminal PB-1 and battery negative. If
the battery is not discharged, the card will supply a voltage
signal from terminal PA-2 through wire #26 to terminal TB-7 of the
Solenoid Control.
J. The closure of the line contactor power tips will keep the 1C
capacitors charged to battery volts.
K. The BV-T15 control card will monitor the capacitor charge on the
white wire at terminal PZ-14.
Note: Status Code -50 will be displayed if the capacitor

voltage does not remain above 85% battery volts after
the line contactor closes.
L. The EV-T15 control card will send data signals on wires #80, #81,
#82, #83 and #13 to the dash display to light all the display
segments as a visual check for the operator. If all the segments
are working, 8888 will be displayed for about 1 second.
M. After the 1 second segment check, the EV-T15 control card will
sense the absence of battery voltage at terminal TB-2 indicating
that the brake switch is not closed. It will send a signal to the
dash display to show a -01 Status code representing an open brake
switch.
Note: If the truck hours exceed the preprogrammed maintenance

reminder hours (functions 19 & 20), a Status Code -99
will be displayed for about 1 second between the 8888
display and the -01 display.
Voltages Present:
H. Approximately 10 volts.
J. Battery volts across the 1C capacitors.
K. Battery positive.
L. NA
M. NA at dash display, approximately 2/3 battery volts at terminal
TB-2.
Rev Aug 94 19-02-g SM-587
BATTERY
r2 *HIwe
2 24136 VOLTS
S FUM?hKITORA
2FU
P \... . .. . .. . .. . . .. . . . .. . . . . . . . . .
PS-IC 61
:::::::::::%;:I PS-TP I
I
PSNEG
2 10 50 61
SrE ER m :......................... 2(J............
... .
TRAN>- :
CUXR s;
............................ i
. -.,
.....................
r
I I I
t
2
$FlELd
]
2
-12-12~12
:.EVT
.......15
....CARD
.. . ..:
t -2 2 2 j .PB1 TBI . ; 29-
10
AL
24-----24 ; .PE* pwc.j................ 3. _....____...............~~............
A i
IA pyg *.; . .._________.._._
4. ,....................... 4. . . . . . . . . . . . . . . . . . . ..
10 -/% 41-4, -----j-p86
10 lo-lO+TB4 PY13 0 : 61 61
3RAK!z
f .. . . .. . . , 5 . . . . . .. . . . . . . _....................... , 5 . . .. . . . . . . . . . . .. . j.. TB2 pAd._j

, 5 ..__......... . .. . . .. . . .J4 _..__.QPQ_...__l
3 ----------
SL-3
; * TM ,,+_____ 54 ___+.+.___.,3 . . . . . . . . . .
f-15-z 6-6
F
y . . . . . . . , 5 . . . . . . . . . . . . . . ,, A. . . . . . . . . . . . . . . . . . . . 2, . . . . . . . . . .._......2. . . . . . . . . . . . . . i.* m
-15 -+R p+s 26y
80 81 82 13 83 26
c 10 10 10 ---+TBlS~ 26 -26
j-b TB14 Two _..20 .._................... 2. . . . . . . . . . . . . . . . .._..... 1

,o-Es 5
1o ~_~...,5 . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . &,3 TBlC 13
-13
12
-I AUX2
___________,O_____+ b------65 ---------65-----~rTB,2
,O_, -J--w
* . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . f.cTB,,
1. TILT
lo- -45 45 ;snwo
10 P
\h .._._._..._..... 28 ._.___................ 28 . . . . . . . . . . . . . ;.oTBa
li
SOLENOID
12 18 FUNCTION
lO----v~ s1 18 j*TBs
a?NTRci.
___________,O . -58 . . ..-. . . . 58 . . . . .j..T&
_____+...S.?...
___________,o______+?.? . ..58 . ..i

12
10_$. ...__......_...38
s3 ...................... 38 .............&TB4 1;
, ,, _~/_..__._........
55 48 .......f ............. 48 .............+,a
I r
112
, 0 _v4 S6
.__..._........ 48 . . . . . . . i
II
:.. . . ........... ... ...;
12- l - 131
SM-587 Copyrighted
HORN SWITCH
Material
I&-09 - Rev Aug 94
Steering Function
A. Rotating the Steer Tiller turns the Steer Transducer, generating a

pulsed signal. This signal is sent to the EV-T5PS steer control
card through the transducer's white wire and wire #93 to terminal
4PL6.
B. The EV-T5PS card then supplies a gate voltage to the transistor

through the internal red wire turning the transistor 'ON'.
C. Current flows from the battery, through the line contactor,

current sensor, steer motor armature, transistor and back to
battery negative.
D. Current will also flow from PS-1C capacitor through the current
sensor, steer motor armature, transistor and back to battery
negative. The amount of current flowing out of the capacitor will
depend on the percent ON-Time of the EV-T5PS control.
E. The current flowing through the steer motor armature interacts

with the magnetic flux of the permanent magnets in the motor
causing the armature to rotate.
F. When the gate voltage to the transistor is removed, the transistor

turns 'OFF'.
G. Because the battery and capacitor no longer have a circuit through

the steer motor, the current stops. This induces a collapsing
magnetic field in the armature coils resulting in a voltage surge.
This voltage, opposite to battery voltage, is applied to the PS-
3REC.
H. This voltage forces current through the PS-3REC, PS-sensor and the
armature. This current, called Flyback Current, continues to
drive the Steer Motor Armature during the transistor's OFF-Time.
Voltages Present:
Too quick to measure.
NOTE: If the Brake Switch is open (operator not standing on

the brake pedal) and no signal is received from the
Steer Transducer or Solenoid Control, the Steer Motor
will not start.
Rev Aug 94 19-02-10 SM-587
r2
2
STEER
SXK
2FU
SWITCH
_,
t rI
12
12
ITCH
i 1
c
12 10
-10
12 10
12 10
12 10
1 -t LL
12
c 10 24-24 i.F-32 Fwrj 30 30- /
IA
-1 0 -/+ 41-41 ; * PB6 pyo*.!................ 4. .............___.__.....
4o ..................i
10
, 0 _, o+ Tm py,3*.I.................61 .............___._......
6, .....................
R4KE 0
PITCH>!<
SL-1
12
, 5 ......~...............................
~.________ m3 p*G+. .............__.
, 5 ................. , 5 _._____._____~.~ &++;...... , 3 ......................
44 ._......
m2 PA4,.j
5 ................. , 5 ________.._._~..
~...___.._, 5 ....""..""._..&...'............... .-.....,..,34 . . . iy3 __....13 ________-
; * TB5 pA5+______ 54 ___-"___.,3_________
6------6
f______.__., 5 . . ..__....... 4% . . . . . . . . . . . . . . . . . . 6 . . . . . . . . .. . . . .. . . .. 6 .. . . . .. . . . .. . . . i.&TB6 PA3 *_; . . . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . . . . .
1
i ~~~~~~~__.~ 5 . . . . . . . . . . . . . $ .__.__..._.__.___2, .____._.._.._.._..2, . . . . . . . . . . . . . i.* m PA2 ; 26 26
i R
,5w& 23-23
$iEf$-l
12 60 61 62 13 63 26
10 10 lo+TBl5 TB7. - 26 26- i

lo-L5 5 +oT014 TBOb -20 20
10_Jne??L35 . . . . . . . . . . . . . . . . . . . . . . 35 .............+B,3 TBl. -13 13
12
^t AUX2
___________,O_____ _* +______65-----____ 66 ____+,2
, 0 _, IFEACH
*_..__._.......'55
...................... 55 .............& TB,,
,0-G-GE45 45 i_cTBlO
P I?
, 0 _--L/c...............26 ...................... 26 .............+
.saENOlD
12 FUNCTDN
10-k s1 16 16 VT=
Cm-ma
___________,O ______,,4.__5?..._., 56 .. . ..+.._...._.
56 .. . .... ..~.r~~
____-______,O ______+.%.....56 .. . ..i

12
, 0 _$....S? ........ 38 .___.___.__.________..
38 .............j..,Te, 1:
, 0 .__---\&..S5 ..........46 .......y............

46 .............f+T&j
I r
112
, 0 __yI\ ...S6
........... 46 .......i
I
5...__.
. . ... ......
12 -L 13 1
SM-587 KIRNSWITCH
Copyrighted Material Rev Aug 94
Steering Function (Continued)
J. Current will continue to flow from battery positive through PS 1c

capacitor to battery negative during the transistor's OFF-time
This current will charge the capacitor back to battery voltage
K. The EV-T5PS card controls the transistor's ON-time to vary the RPM
of the steer motor. The percent ON-time depends on the signal s)
the control receives from one or more of the following:
1. Steer Transducer (Operator Steer demand).

2. PS-Current Sensor (Steering Load demand).
3. EV-T15 Control (Drive Ready signal).
4. Solenoid Control (Aux Hydraulic Function demand).
5. EV-T5PS Thermal Protector.
Note: When more then one signal is present, the highest RPM
demand signal has the- priority on ON-time demand.
L. The internal circuitry in the EV-T5PS card monitors the steer

motor current through the green and yellow PS-sensor wires and the
applied motor voltage through the white/red and white/green wires.
This circuitry will override any of the above first four signals
if the current exceeds a preset Current Limit value (non-
adjustable).
M. The EV-TSPS card monitors the temperature of the transistor

through the internal gray and black wires of the thermal
protector. If over-temperature conditions are detected, the card
will over-ride the percent ON-time control circuit to limit the
maximum current through the transistor.
N. If over-temperature conditions exist, the EV-T5PS card will send

a signal on wire #40 from terminal 4PL4 of the steer control to
terminal PY-9 of the EV-T15 control card. The EV-T15 control card
will sense the signal at terminal PY-9 and display a Status
Code -90 on the Dash Display representing that the steer control
is in thermal cutback.
P. Removal of the signal from the Steer Transducer (stop turning the
steer tiller) will cause the EV-T5PS control and the Steer Motor
to shut OFF in 2-3 seconds.
Voltages Present:
J. Battery voltage across the capacitors.

K. NA
L. NA
M. NA
N. Battery Negative
P. NA
Rev Aug 94 19-02- 12 SM-587
r2
2
2FU
B 1 FU
MC 6:l
TPS-TP
.I )R '+-m
*. I m s
r-i
12
SWITCH
12 10 6'1
12
rlo c
10 10
I 10 *#,L 24-24 ;.Paz pw *.~.__._..__........

30 ......_......._..___...3
0 .._..._...;
IO
IA
1
pys ,_.~-~..40*'-'--'40.-'~~
I t= 10 -$ 41------41 ;*Pm
fci
.
+---15A 6------6 lbTB5 PAS*:------ 54 L ^- - _ _ _., 3 ................. ...
2..0 ...............
i..........15.............. 8 ...................
B...............
i.. TB6 PA3
_.I.................
2o .....................
...20 ........................
F
f___._.,l5 ................. 27 ..................
................... . 7 ..............
..*pB4 PM* : 26 261
li 1; 8 i
10 10 lO+TBl5 Te.7. - 26 28-
lo-+=----5 5 ;o TOI4 T80. ................. 2. ._..__._.........._2

0 .......................
10 Ls?3??!...35 . . . . . . . . . . . . . . . . . . . . . . 35 .............;.*TB,3 TlJ,,

-13 13
.___________lO_____
_.i.s
AUX2
_,,b______65 _________ 65 _____+2
lo----+-- .,_____.___.._...5
5 ................_._...
5 5 _.._____.....~.~
TB(,
d._ TILT
, lo- -45 45 +%TEWJ
1,, _\/.. P
_____._........
28 ..........__.__.___...
28 .............j.+TBa
SOLENOID
12
10 -4% s1 18 18 ;+T86 FUNCTION
CONTROL
,,___________10_____+..??,_...58 "'"r'..."'. 58 . . . . . .i.(TBS
',___________lO ______~~...~.*.,.....5* .. . ...
12 1 0 -,r....s3 ...........38 ...................... 38 .............~.~

TB4
s5
1 0 -~~,...............48 .......y........48 .............& T&,
S6 K...................
1 0 -+._.___..____.4* .___..._i
I
12 12 131
HORNSWITCH
Copyrighted Material Rev Aug 94
SM-587
Brake Switch & Static Return to Off (SRO) Checks
A. Stepping on the brake pedal will increase the pressure in the

brake lines and closes the brake pressure switch.
B. Battery volts will be supplied through the #15 wires to terminals

TB-2 & TB-3 of the EV-T15 control card, common terminal of the
directional switches and the directional contactor coils.
C. The control will not allow the truck to start until the following
SRO checks are satisfied:
1) Voltage at terminals TB-2 and TB-3 of the EV-T15 control card

must be greater than 50% battery voltage. (Status Code -01)
2) Checks for open F & R switch inputs, terminals TB-5 and TB-6
must be less than 50% battery volts. (Status Code -02 or -03)
3) Checks the accelerator input voltage at terminal TB-1 of the

EV-T15 control card. Must be greater than 3.0 volts. (Status Code
-08)
Note: The EV-T15 control will repeat the above SRO checks
any time that the brake switch remains open for more
than 1.5 seconds.
D. If all of the above SRO checks are satisfied, the EV-T15 control
card will send a signal to the dash display to show the state of
battery charge.
Note: The battery state of charge is displayed as a 3 digit

positive number dependent on the battery condition, and
the LED above the battery symbol will be 'ON'.
E. The EV-T15 control card will send a Drive Ready signal from
terminal PB-3 through wire #30 to terminal 4PL3 of the EV-T5PS
steer control card.
F. The E!V-T5PS steer control will turn on the steer motor at idle
speed (825 - 875 RPM).
Voltages Present:
A. Battery Positive
B. Battery Positive
C. See explanations l-3 above.
D. NA
E. Battery Negative
F. 9.0-9.4 volts across the steer pump motor on 24 volt trucks.
13.4-13.8 volts across the steer pump motor on 36 volt trucks.
Rev Aug 94 19-02-14 SM-587
24/36 VOLTS
mER IFU s WM'PM3TORA
ax ........................................................................*.~~~.....
,......................................
2FU <\ f..!u
SWITCH
t r-r
12 1050
ri
12
%TCH
c
12 10
12
rlo
10 10
12 10 10
Rx
12 10 10 2
ACCELERATOR
7-T 7
li
12
..._............_.2.
23----23
12
, 0 -s??!K..35 ...................... 35 ......_.....+.

T6,3 =I*13 13
12
e-i_ AUX2
,___________,O _____ d b______65 ^________ 66 _____+Ta,s j
,O_, IFEACH
0 . . ..__......._. 55 . . . . . . . . . . . . . . . . . . . . . 55 ..___........ +,(f i
J_e TILT
lo- -45 45 ;-%Ttm
P
,O_$ . .._........_.. 26 ..__._..._..._.__..... 26 ______.......+a
/ SOLENOID
12 i FUNCTKN
lo-~ s1 16 16 ; *Tm
icxzsrrm
,,___________,o _____+..?.? .,.... 56 ..__.? _._...... 56 .. . . . . . . /..TBS
,.______--___,o _____+..S.?.._. ..66 . ..:

_~
lo-$ s3
,_.._...._______ j.+T&4
12 38 ___..__._____......... 38 . . . . . . . . . .._.
n.25 .......... 46 ....... y.. ........... 46 ............. ;+ TB3

t-10- S6 :....................... .
10 _v4 ............... 48 ....... .1
I
131
SM-587 Copyrighted Material Rev Aug 94
Energizing the Directional Contactors
A. Moving the multi-function control lever towards the front of the

truck will close the forward switch. With the forward switch
closed, battery positive will be applied to terminal TB-5 of EV-
T15 control card through wire #6.
B. The EV-T15 control will now make the following start-up checks:
1) T2 voltage must be above 12% battery volts. This checks for

shorted 1A contactor driver, shorted power transistors, or welded
1A contactor tips. (Status Code -46)
2) T2 voltage must be below 88% battery volts. This checks for

shorted forward or reverse contactor drivers, shorted #3 REC, 23
REC or welded forward or reverse contactor tips. (Status code -48)
3) The current sensor is present in the power circuit and the

green and yellow wires from the sensor are connected to terminals
PZ-12 and PZ-13 of the EV-T15 control card. (Status Code -42 or
-43)
C. When the EV-T15 control card senses battery positive at terminal

TB-5 and 0 volts at terminal TB-6, it will complete the circuit
from the forward contactor coil to battery negative through wire
#27 at terminal PB-4 of the EV-T15 control card.
Note: If battery voltage is applied to both terminals TB-5

and TB-6 at the same time, the control will be shut OFF.
(Status Code -09)
D. This will energize the forward contactor coil and in turn, open
the normally closed contactor tips and close the normally open
tips.
E. The BV-T15 control card monitors the current flowing through the
directional contactor coil circuits. Status Code -23 will be
displayed if the current is less than a preset value.
Voltages Present:
A. Battery positive at terminal TB-5

B. See explanations l-3 above.
C. lo-13 volts across the forward contactor coil.
D. NA
E. NA
Rev Aug 94 19-02-16 SM-587
BATTERY
r2 >wilc-<c
24136 VOLTS
EER I FU
_ax .. ..
2FU
SWITCH
t I-f-
10 50
ri
12
ETCH
12 10
12 10
rlo c 10
12 10 10
12 10 10 2 13
EVTl5CARD
........ ............!
__..
li
t
10 I
I
b 10
10 -/IA
*,L 24 -24
41-41
;*Fw
frm
Pea.;
PY8 l :
30
40
12
__________+___
__________e___
15 6-6
REV
15 xs . ... .............. ................... .......................I
1 I
*F
15 * 27-27
t-
15
12 li 1 26 2b
.+82
,311 I
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10 10 ,,~TB15 TB7. - 26 261 j

lo-k5 5 j eTB14 Tw* -20 20
,o_,++%?%..~~ . . .._................. 35 ....... .... ..+B,3 TBI. -13 13
12
,___________,O _-_-_.a 1- -______65_-----_-_65
AUX2 _____+TB,2
,O-----L IFEACH
* .......... .... 55 . ..... ............. .. 55 .............&TO,,
_J_ TILT
lo- -45 45 ;*TBiO
1 ,, _$
P
. . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . j.oTW
SOLENOID
12 ,a 10 FUNCTION
10-h s1 j+T*6
aavrROL
,p___________,~ _____+...??.,. . .,58 ._. ..?. . . . ., 58 . . .. . . ./.rTBs
,,___________,O ______+.?8 ...___.5 8 .. __.i
12 , 0 _$ ....s ........ 38 __.__................. 38 .............i_+TBd

, 0 ____.A...S5 ........ 48 __.___. T............. 48 .............;.QTB~
SM-587 I , 0 _y4 S6
. . . . . . . . . . . . . . 48 . . . . . ...!
l2 Copyrighted Material
; .... . .. ... ....
,&WiTCH
,&_,7

I
& l3 Aug 94

Turning ON the Transistors
A. The W-T15 control senses that the forward contactor has closed
and the motor circuit is not open when it senses that the T2
voltage, through the blue wire at terminal PZ-9, is at battery
positive.
Note: Status Code -24 will be displayed if T2 voltage is

less than 88% battery volts.
B. A signal from the accelerator at terminal TB-1 of the EV-T15

control card starts an internal time delay which controls the
oscillator in the card.
C. The EV-T15 control card applies a gate voltage from terminal PZ-4
and PZ-3, through the red and brown wires respectively, to the
gates of both transistors. The transistors turn 'ON' completing
the drive motor circuit to battery negative.
D. Current now flows from the battery, through the 1FU fuse, the line
contactor, sensor, drive motor armature and field windings, the
closed directional contactor tips and through the transistors to
battery negative.
E. Current will also flow from the 1C capacitors through the same
drive motor circuit to battery negative. The amount of current
flowing out of the capacitors will depend on the percent ON-time
of the control.
F. The interaction of magnetic energy between the motor fields and

the armature causes the armature to rotate.
Voltages Present:
A. Battery positive at terminal PZ-9 (T2).

B. Less than 3.5 volts at terminal TB-1.
C. Not measurable.
E. N/A
F. N/A
Rev Aug 94 19-02-18 SM-587
2FU
-;t t t T t I !I
Bu(
I a, 91 92 93 50 30 40 20 6'1
rlo
10
10
_~2+#+~---13- 1 ) ]
EVIlSLAHU
24-24
l5-15yTe2 PM,.;_.,......_.34 __________ .___

...__i~3...___13
6 6 : . TB5 pA5+_____ 54 ___-____,3__________ .___
6 ...._........__.._.
6 ___.______.__..~.
TB6 PA3 ..;.................20
.__..__.................2
o ,.......................
27-27+m PA2 ; 26 26~

I--_ 5-A R
23-23
12
10 10 10 ; .TB15 Twc - 26
lo-=5 5 ; *TB14 lBBS -20

,O _++?w. 35 .........._...........
35 ..__.._._....j.*
Ta,$ m, c
-13
12
_.i_ AUX2
,,___________,O_____ 4 b_-_---65~----____ 65-w--+(2
1-H'.....______._..55
..................... 5 5 _.._.........+
TB,,
lo-
_i.. TILT
lo- -45 45 j* TBlO
P lb
1 0 _&_.___.__......26 ..................____
26 ._..........+
TBB
SoLEralD
12 FUNCTKN
lO--.---v~ s1 16 16 i * ~6
aNma
,,___________,o______+S? .__.._ 56 .. ....,,.... 56 . . . . . ./.rT85
,,___________,o_____+...?. .. . ..56 . ..i
12
, 0 _,r....s3 ...........36 ...................... 36 ...............+184
, 0 ____._A...S5........ 46 .......p............. 46 .............j.*T&l

S6
, 0 __V4...._......_._48 ._....._i
.f
c.....................
I
1 12 12 d
SM-587 Copyrighted
I-DRNSWITCH Material
19-2052-19 i-cm Rev Aug 94
OPERATIONAL SEQUENCE #S
Turning OFF the Transistors, Capacitor Charging and Flyback
A. The control now removes the gate voltage and the transistors turn
'OFF'.
B. The current stops flowing because .the battery and capacitors no

longer have a circuit through the drive motor. The magnetic
energy of the drive motor field collapses. This collapsing
magnetic field induces a voltage across the field that is opposite
to battery voltage.
C. This reverse voltage forces current to flow through the #3 REC,

sensor and armature. This current, called 'FLYBACK CURRENT',
continues to drive the armature during the transistor's OFF-time.
D. Battery current will continue to flow into the 1C capacitors

during the transistor OFF-time because the line contactor is
closed and the 1C capacitors have been partially discharged. This
current will stop flowing when the 1C capacitors are charged to
battery voltage.
Voltage Sequence:
Too quick to measure.
Note: Average drive motor current, compared to battery

current, will be about two to three times as great when
operating in the transistor range.
Note: The purpose of the #23 REC is to filter the

generated voltage spikes created by the #3 REC turning
'ON' and 'OFF'.
Rev Aug 94 19-02-20 SM-587
r2T
2 2
STEER I
1 FU
24/36 VOLTS
_ WMMOTOR
2FU
k%
I ri
12 2 105(
r-i
12
SWITCH
12 10 2 10 5(
12 10
rlo -l-P 10 2
12 10 10 2
12
ACCELERATOR
--.- Y
t *L
E
10 24 -24 --+a P83.: 30 301
12 lb
IA
1 0 -/? 41-41 ------+Pfs PY8 . ; 40 40 --I
10 lo-lo+T84 py,3 *./ . . . . . . ..___._....61 ,....................... 6 , ......................

EIRAKE
8iWITCH
b
12 10
__-
___
12 10
10 10 104TB15 TB7* :
10-9-5 5 ;oTBM TBS* ; 20 20

,,~._.___~:.~...35 . . . . .._.._.__......... 35 . . . . . . . . . . . . . j.+TB,S 13
my13
12
_.i_ AUX2
_-________,o _----+ b______65 _________ 65 _____+,2
..I- * . . .FEPCH
. . . . . . . . . . . . 55 .._____.___.__.__......5
5 . . . . . . . . . . . . . +l,,
lo-
A TILT
lo- -45 45 j.%TBlO
,0-/t
P
._.._.____.....28 . ..__.._._.._......... 28 . . . . . .. . .. . . . ;.eTBB 13
j SOLENOID
10-----u s1 16 16-----f+TB6 ; FUNCTtCN
;ccNTRoL
__________,o ______+.5? .._._. 56 . . . .+. . . . . . 56 . . . . . .i.<T85
__________,o ______p...?? . . . 56 . ..i

_.
O- fi....s.. ...... 38 ...................... 38 ............. j.+,,.,
13
, 0 -&..S ...........
5 46 ..... ..?. ............ 46 ............. j.eT83
, 0 -v4.. .S6
........... .4a ........ I :.......................
.
- 1
112 12 d 13-
SM-587 Copyrighted
HORN SWITCH
Material
w-2d2-21 i-cm Rev Aug 94
Accelerator, Thermal Protector and Pulse Monitor Trip (PMT)
Turning the transistors ON and OFF produces a pulse. A switching

technique that controls the pulse rate and/or length of the pulse is
used to control the speed and/or power of the truck. Increased pulse
rate and/or longer pulses produces more speed and/or power.
A. The rate and length of pulses is governed by the accelerator and

the current sensor. Moving the multi-function control handle
farther towards the front of the truck changes (decreases) the
accelerator input signal at terminal TB-1 of the EV-T15 control
card. The internal oscillator circuit of EV-T15 control card will
increase the pulse rate and/or length of pulses as accelerator
input signal is decreased. The current sensor continuously
monitors the motor current and signals the control to shorten the
pulse length during high motor currents.
B. If the control is overworked, the transistors and the built-in

thermal protector (TP) will get hot. Resistance in the TP will
increase and reduce the current limit regardless of accelerator
position. This reduction in current limit is called 'Thermal
Cutback'. As the control cools, the TP will automatically return
the current limit to the preset value as defined by the C/L
setting of the EV-T15 control card.
Note: Even at reduced current limit during thermal cutback,

the truck should be able to reach sufficient speed for
1A contactor operation.
C. When the transistors are turned ON, the #3 REC stops conducting.
D. The blue wire to terminal PZ-9 of the EV-T15 control card allows
the control to sense pulsing. If the transistors fail to turn OFF,
the card opens the circuit from terminals PB-4 and PB-5 to battery
negative so the directional contactor coils de-energize, dropping
out (opening) the contactor tips.
E. The control will quickly re-close the proper contactor in a 'LOOK

AGAIN' mode and drop out the contactors (PMT) if the problem still
exists. To reset the PMT, the key switch must be opened and re-
closed with the directional switches and accelerator in neutral.
Voltages Present:
A. 3.5-4-O volts at creep speed. 0.5 volts or less at top speed.

B. Less than 0.5 volts across the TP is no cutback; greater than 3.4
volts across the TP is severe cutback.
Others N/A
Rev Aug 94 19-02-22 SM-587
r2 f
2 2 24/36 VOLTS
SEER
LCCK ........................................ .....................................................................
---a.....~ ---
_ PUMtvKITOR
1
r **.a
2FU
SWITCH P ................... ps-ic. 6, ...........................
. , .................................
, ...................
.
L
PS-3REC
t R--
li 2 10 50
ri
12
ETCH
12 10 10 50
Es_ $y. $ 1 1ri;; :......?n
................... 2 0
, ,
.. . . . . . . . . . .
rl c
11 - 50 50 501
I
12 10 10 2
24-24
SL-1
15-15 ;*m PA6 +..... . . . . . . . . . . 441.3......_.................
i.........
. . . . . . . . . u*- . . . . . . . . .
10
SL-2
l5-_15iT62 p*4 *_I. . . . . . . .34 . . 0s.e
_..__.,3 _____-____+____
SL-3
6 F TBS p+_____ 54 ___-____13 _--______+___
6
6 . . . . . . . . . . . . . . . . . . . 6 .. . . .. . . .. . . . . . $ TB6 p*3 ._; . . . . . . . . . . . . . . . . . 2. .. . . . . . . . . . . . . . . . . . . . . . . 2. .. . . . . . . . . . . . . . . . . . . . . . . j
27-27-m PAZ : 26 261 ;
2 10
10 10 1o+m5 Tw. j 26 26
1 10-x5 5 ;*TLw l-60, ; 20 20 ___
I ...................... 35 .............+J,3 781-13 13

12
65 _____+,2 ;
*........___....
55............_..........
55 .............i.<TB,,
45 ; *-WI0
13
....._._.......____...
26 .............+,?,~
; so!_EtalD
12 16 ;-* 1% i FUNCT!CN
56 . . . . . . j.rT65 ;coMRoL
12
...._____.__.____.._..
38 .............i.+W
._v4 . . . . . . . . . . . . . . . 46
12 - 13
-587 Copyrighted
I-iORN SWITCH Material
19-2d2-23 m Rev Aug 94
IA Contactor Operation
The transistor circuit is capable of delivering approximately 100% of

available battery voltage to the drive motor. For full speed and/or
power, the 1A contactor is closed to bypass the transistor panel and
apply full available battery voltage to the drive motor.
A. Moving the multi-function control handle fully forward will signal

the EV-T15 control for maximum drive motor speed / power demand.
B. The control will increase the rate and/or length of pulses at the
preset rate as defined by the Controlled Acceleration (C/A)
setting of the EV-T15 control card.
C. The control continuously monitors the change of motor voltage

through the blue wire at terminal PZ-9 of the EV-T15 control card.
When the motor voltage stops increasing, the card starts the 1A
time delay.
D. After a short time delay, the card completes the circuit from
terminal PB-6 through wire #41, to the 1A contactor coil negative
terminal. This energizes the 1A coil.
E. The 1A contactor power points (tips) close completing the bypass

circuit. The control will continue to pulse until the 1A
contactor tips are fully closed as sensed by blue wire at terminal
PZ-9 of the EV-T15 control card. This feature of EV-T15 is called
a Full Power Transition.
F. Moving the multi-function control handle partially back towards

neutral will signal the EV-T15 control card to turn 'ON' the
transistors and de energize the 1A contactor. Turning 'ON' the
transistors provides an alternate path (up to current limit) for
current to flow and thus, squelching (limiting) the arc at the 1A
tips as they begin to open.
Note: The EV-T15 has a built in thermal hold-off feature.

1~ will not close if the control is in severe thermal
cut-back.
Voltages Present:
A. 0.5 volts or less.

B. NA
C. NA
D. lo-13 volts across the contactor coil terminals.
E. Battery volts across the drive motor.
F. NA
Rev Aug 94 19-02-24 SM-587
r2
2 24/36 VOLTS
I
. .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . .
2FU
.. ..................ps_,c
.......... 6, ...........................
PSBREC I 61
I 1. IPS-TP
t
12 II II
rd
12
STEER
SWITCH
,,Q'
I.
12 10 -
92 93 50 io 40 20
12
r10L
10 10
12 10 10
12 la 61
I-t
12 ia 24 -24
41-41 401
10-10
.............. ... ... 6 , ......................
LRME
WITCH
SL-1
15-15 .._..... iyi . . . . . . . , 3 . .._.___________.___...
.,... i;;lj . . ..__. 3 __- _______
___+a# ___.,3 ___-___-__
,% _.._._..._........ . . . . . . . .. . . .. . . .. . . .. . . . . . .._.............. 2. . . . . . . . . . . . .. . . . . . . . . .
261
26 13
10 10 1o+T615 m7c - 26 26-
:oTFm TBoa- 2
lo-=5 5 -----20 20
10_+&?z?i..35 . . . . . . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . +j,3 TB1r 13
-13
1
12
-L AUX2
.__________,O _____ * o______65 __---_--- 65 ____+6,*
,0-I * . . .-Ii
. . . . . . . . . . . 55 ,...................... 55 . . . . . . . . . . . . j.*Ts,,
1 TILT
lo- -455-45 ;*TBIO
P 13
,O_,,/% .__.._.....____26 . . . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . ;.,T@
SOLENOID
12 _ Sl
lo----y4 18 16 j*T66 FUNCTtCN
CCNFRCL
,__________,O . _.58 . . ..f. . . . . 56 . . . . . .j.rTf,5
______,k...? . .
.__________,o______p..-s?.... ..58 .. . ..i

12 - 10 -&..S? .__.____ 36 _..................... 36 .............j..$Tw 13
10-$ ...s5
............ 46 .......f ............. 48 .............j.qTB3
i. . . . . . . . . . . . . . . . . . . . . .
,0.-v4 . . .S6
. . . . . . . . . . . 46 .. . . . . . . i
-I
112 12 d 131
SM-587 Copyrighted
I-DRN SWITCH Material
19-2052-25 m Rev Aug 94
Plugging
Controlled plugging (using the reverse power of the drive motor as a

brake) is attained when changing direction from forward to reverse (or
reverse to forward).
A. The multi-function control handle is moved from forward, opening

the forward switch.
B. While the handle is in it's neutral position, both the directional

switches are open.
C. The control stops functioning because the voltage has been removed
from terminal TB-5 of the EV-T15 control card.
D. The forward and IA contactor coils are de-energized and the

contactor tips return to their normal position, opening the drive
motor circuit.
Note: The truck will be coasting forward.
Rev Aug 94 19-02-26 SM-587
r2
2 24/36 VOLTS
I FU PUwmoR
( A
,...................................... r ;i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .s.>W-k . . . . . (Yi-
2FU
ret P \ . . . .._........................
ps_,c 6, . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, .. . . .. . . . . . . .. . . . ..
1 8 I
61
t
12
12
ro
10
c10
h-J 23 REC
12 10 10 m DRIVEMOTOR I:
A2%1 R
8.l
12 10 10 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 lo 61 13
ACCELERATOR
___- I I I :
-12-12-12
:.EVT15CARD
....................... 12+$f#-13--l 1
II 1-2 2 2----+al TB1 . ; 29-
24 -24 ;.pen Pm.; 30 301

li ,n
40
--I;
...................... 61 ..;
-; SL-1
........................f... .. .
;. c ,.; ....._.......... . . . . . . . . . ** . . . . . . . . . ,
P
TB3 44 3
SL-2
---p TBP p$$,
9.;... . . .. . . .3$ . . . .- . . . . , 3 ___-_--___;_ .__
SL-3
,--@ P,+______ 54 ___-*9___.,3 __________;_.__
._......____....... . . . . . . . . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . .. . . .
12 13
10 10 TB7. - 26 26-
TBo* 2
lo-E5 5 TTB14 -20 20
10~.w._QY...35 . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . &TB,3 TBI. -13 13

12
-I b______65_________65
AUX2 _____+,*
___________,o _----e
,9-, -J-Faux
* . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . ;.* TO,,
,o-G-d=-45 45 j.%TBlO
P 13
, 0 _# ._............. 26 . . . . . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . j.oT,M
SOLENOID
12 Sl
lo- 16 16 ; *KM FUNCTKZN
s7. . . . ..56 mRcc
______-____,O _____+.. . . . ..L. . . . . 56 t.. . . . .+
___________,O _____+..??.._. _.56 . . . ..:
, 9 --+...s3 ..__._..... 36 . . . . . . . . . . . . . . . ..___.. 36 . . . . . . . . . . . . . j..,TBa

12
, 0 .___+.s5 _..__._.._46 .._....? . . . . . . . . . . . . . 46 __.__.___._..
j_+TBJ
:___._... . . . . . . . . . . . . .
,O __/*\ . . .S6
. . . . . . . . . . . 46 .. . . . ...!
I
SM-587 l2 Copyrighted
wFz-w,TcH Material
,&_*7 H3R\l

OPERATIONAL SEQUENCE #ll
Plugging (continued)
E. The operator moves the multi-function control handle through

neutral to reverse, closing the reverse directional switch.
F. With the reverse switch closed, voltage is applied to terminal TB-

6 of the EV-T15 control card. The control senses that the truck
has been moving and that the handle has been moved through
neutral. This causes the plugging logic in the control to take
over.
G. The control now completes the circuit from the reverse contactor
coil to battery negative through wire #23 at terminal PB-5 of the
EV-T15 control card.
H. This will energize the reverse contactor coil and in turn, open
the normally closed contactor tips and close the normally open
tips. This will change the drive motor circuits to the reverse
direction.
J. The control now gates ON the transistors.
Rev Aug 94 19-02-28 SM-587
l-27
2 2 24/3i VOLTS
STEER 1FU
Loa< ......................................./.......................................................................
2FU
SWITCH P
61 61
t rr
12 2 1050
ri
12
ETCH
c
12 10 61
12
rlo
10 10
li 1IO 10 6i
12 1IO 10
BRAKE
SWITCH
10 10 lo+ TB15 m7- - 26 26-
5 ;-aTB14 ................ 2. ....._.__._......__.*O

________________._______)
lOLL5 TBs*
,o_+..-_~...35 ..____________.__.....~~...__.___.___ ;.*TB,3 m,-

-13 13
12
1- AUX2
,,___________lO_____ + +______65 ___-_____ 65 _____+,2
, 0 -, IFEACH .......................55 .............+ TB, ,

0...............55
10iTILT45 45 i-%TBlO
, 0 .-\/: ...P.._......... 28 .............+LB

28 ..._______._._........ 1 3
SOLENOID
12 16 FUNCTlON
10----v'\ s1 16 :eT86
cm-r&a_
,,___________jo _____+._57... ._.56 . . . ..?. . . . . 56 . . . . . .;.<TB5
,,_________-_10______+..S.?...._.56 .. . ..i
12
10 -h...SB _ __.......
36 .................__...
36 ._..........+
TB, 3
, 0 _\/,...S5 ..........46 .......f.............
46 .............~.~
TB3
S6 :......................
1 0 ~~4...~~..~~~~....4* ........!
I
SM-587 II* l2 HOFiiiWITCH

Copyrighted ,9$&g
Material & l3 Re ; I Aug 94
OPERATIONAL SEQUENCE #ll
Plugging (continued)
As the transistors are turned ON, the truck is continuing to travel in

the forward direction because of inertia. The motor armature now becomes
a generator because the drive motor fields have been reversed and the
armature is driven against the magnetic effects of the field.
K. The voltage polarity reverses across the armature of the motor,

changing the voltage of terminal Al to positive with respect to
terminal A2 of the drive motor. This voltage causes the #4 REC to
conduct and thus, provides a path for the generated current.
L. This generated current flows through the current sensor signaling

the W-T15 control card to over-ride the main oscillator section
of the control allowing only a predetermined slow pulsing, as
defined by the preset 'PLUG' setting of the control card and by
the accelerator position. The control is locked into the plugging
mode.
Note: The plugging distance can be controlled by changing

(regulating) the position of the multi-function control
handle (accelerator).
M. The control also over-rides the 1A timer section and will not
allow the 1A coil to be energized during the controlled plugging
operation.
N. This slow pulsing will bring the truck to a smooth, controlled

stop. The control senses that the truck has stopped by monitoring
nearly zero current through the current sensor. The voltage
polarity at the armature will return to normal and the truck will
start to accelerate normally in the opposite direction.
Rev Aug 94 19-02-30 SM-587
2413.6 VOLTS
STEER 1 FU
_CCK
2FU
SWITCI
PSBREC 61
t n
10 5 I
r-i
PS-POS PSNEG
mm
12
SWITCH
12 10
12 10
roc 10
3 30 40 20 6:l 13
-2 2 2 +mt TBI 0; 29-
-10 /,L 24-24 jrm? PB3.: 30 30

,IA
-10 " 41-41-p pyo.j 40 40-
....._..__......'._.6
, ......................
-10 10-10
3M
WITCk
3
SL-1
i . -ma PA6 *_+........___.
44 "'."...g&"'"" 3 ......................
-15 15-15
-15 y TB2 pnr..~............34 _..__.e...o..,..__13

-__------.
;.TBS pA5+______.54 ___s~-___,3_________.

6
I*~06 PA3 ._~_____........_._.20 o .......................

._._____.__....._.__....2
-15 6-6
*F
27-27+P84 PM*: 26
-15 " 261
,R
-15 Y 23 -23
-62
-63
10 10 10 ; .T81.5 lB7. - 26 26
lo-L5 5 ;DTB TBa* -20 20
, o _$..-:_~._.35 ...................... 35 . . . . . . . . . . . . . &,a lB1.
___________,O ----- 4L +______65

AUX2 _________ 65 _____ +2
* . . . . . . . ..__.... 55 . . . . . . . . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . +,,
lO----+- -
J_ TILT
lo- -45 45 i sTB10
P IP
, 0 _,,,L.............. 26 ...._................. 26 .............~ TB8
SOLENOID
104% " 16 la ; **I36 FUNCTlON
Cm-rRcc
___________,o_____.+...S? .. . ..sa . .. . . . . 56 . . . . . .j.(TB~
___________,o ______+.%...56 .. . ..i
1 0 _bh...s3........ 36 _____..___.._.........
36 .............~+ To, 13
/Lss..__.. 46 .......f.............
46 ............+ TB3
lo-
S6 !.....................
, 0 __+___________..46 ........1
- I
112 12 - 13A
SM-587 Copyrighted
K)RN SWITCH
Material
w-2052-31 Km Rev Aug 94
Travel Speed Limit
The EV-T15 control is capable of three (3) separate Speed Limit

functions. The truck is equipped with at least one speed limit switch
on the upright. The full speed range of the truck is achievable only
when the speed limit switches are closed or defeated by presetting the
'Speed Limit' control card settings with the proper values.
A. Raising the upright above the free-lift stage will open the SL-1
speed limit switch.
B. The E!V-T15 control card senses the absence of battery negative at

terminal PA-6 and will limit the drive motor voltage as defined by
the preset 'Speed Limit' setting of the control card thus limiting
the maximum speed of the truck.
C. The truck, when starting in a speed limit mode, may accelerate at

a slower rate than the normal C/A as defined by the preset 'Speed
Limit C/A' setting of the W-T15 control card.
Note: If the 'Speed Limit C/A' is set at a lower value than

the normal 'C/A', the truck will always accelerate at
the normal C/A rate.
Note: When the speed limit switch is re-closed the truck will
revert to the normal operation and speed.
Voltages Present:
A. Battery negative.
B. Approximately 6 volts.
C. NA
Rev Aug 94 19-02-32 SM-587
r2
2 24/36 VOLTS
STEER _ WtvPPMOTOR
LCCX
2FU SWITCH
61
t n-
I\ _JPS-TP
12 10 50 TFI s
rd
PSNEG
12
SWITCH
12 10
n--l
1 3 3040
..................................................................: 13 3040
ACCELER4TOR
--- 7
12-12-12
24 -24
41-41
15-15+T~2 PA, ..; .. . . .. . . 34 . . . .- _....., 3 - ---------

SL-3
6 pns,+_____.54 ___-____,3 ______----
6 i . TM
6 0 ;-TM PA3..I . ...... ..... .... 2. .__..................... 2. ............... ... ... ...
27-27-m PAZ : 26 261
6 2 13
10 10 10+ TBIS TM- - 26 26-

lo-~5 5 + TBI, TB6b -20 20
,0__-&.~...35 . . .._................. 35 ...... ....... &,a TB,r -13 13
12
,.___________,o _---- +_.i_ AUX2
b______65_-__-____ 65 _-_-+,2
v..!- FEKH 55 .................._.... 55 ..... ....... .+,,
0__.____._......
lo-
It. TILT
lo- -45 45 ; hTBl0
lo-$.
P
._............. 28 . .._.................. 28 . . . . . . . . . . . . . ;.eT66
13
SOLEmID
12 , 16 FUNCT!ON
lop4 s1 18 frTB6
Cama
,,___________,o _____+..S? . . . 5* .y . . . . . 5* . . . . . .j.rT85
,,_______-___,(I ____.+....?... . -58 . . ..i
12 10_/?...S? ........ 36 ...................... 36 .............i_9TB,
, 0 __t/\ .___.___.___.._
s5 46 .......f ............. 48 .............;+,3
SM-587 L12 10_v4 ...S6

... ... ...... 46 .......i
l2
I
Copyrighted
t0R%flTCH
:................. ..
Material
,&)5z_33

&&

Solenoid Functions
The Solenoid Function Control card in conjunction with the EV-TSPS steer control and
the EV-T15 control provides for lift, lower, extend, retract, tilt and side shift
function control and for lift interrupt.
A. In Operational Sequence #3, closing the key switch applied battery positive to
terminal TB-15 of the solenoid control. The solenoid control is connected to
battery negative through the #13 wire at terminal TB-1.
B. The EV-T15 control card will supply a voltage signal from terminal PA-2 through
wire #26 to terminal TB-7 of the solenoid control indicating the battery
status.
Notes LED #2 (RH5) of the solenoid control will be turned 'ON' if the
lift interrupt Is activated.
C. The solenoid control will not allow any solenoid functions to operate if any of
the following checks are not satisfied:
1) Checks for open hydraulic function switch inputs when the key switch is
first closed. Terminal TB-10 through terminal TB-14 of the solenoid control
must be at 0 volts.
Note: LED #1 (RH4) of the solenoid control will be turned 'ON' if

fault exists.
2) Continuously checks for invalid switch inputs. If both the up and down
switches are closed at the same time or if more than one of the tilt, reach or
aux 2 (side shift) switches are closed at the same time.

fault exists.
3) Checks for open solenoid and contactor coils or wires anytime that the
multi-function control handle is in hydraulic function neutral. For solenoid
coils connected in parallel, both coils must be open to be detected as a fault.
Terminals TB-3, TB-4, TB-5, TB-6 and TB-8 must be battery volts.

fault exists.
4) Checks for shorted drivers anytime that the multi-function control handle is
in hydraulic function neutral. Terminals TB-3, TB-4, TB-5, TB-6 and TB-8 must
be battery volts for fault not to exist.
Note: LED #1 (RH4) and LED #2 (RH5) of the solenoid control will
be turned 'ON' if fault exists.
Note: If any of the hydraulic control switches are closed within 1.5
seconds of closing the key switch, the control will not allow any
solenoid functions to operate.
Voltages Present:
A. Battery positive at TB15, Battery negative at TBl.

B. Approximately 10 volts.
C. See explanations l-4 above.
Rev Aug 94 19-02-34 SM-587
SAll-ERY
r2 b-w<
2 24/36 VOLTS
STEER I FU
.cxx
2FU
WITCH
...........................6
r-d
12
SWITCH
12 10
I i
12 10 10
12 10 10 ,......................................................................
ACCELERATOR
--- -
li 24 -24
41-41
12
12
to-=5 5 I
,,._?.p~._.,, .........
12
______.___.,o -.-.- + w._____65 _________65
,n--__r
.
..I-0 . . .RZACH
. . . . . . . . . . . c* . . . . . . . .
I < -.._ -
A.. IlLl
lo- -45 45 I
13
, 0 _$...! ........__
28 _____.____............
26 I
12 Sl
lo-----vh 16 16
__.______..,o ___._.,,4._-5-7- . . ..56 . . ..t. . . . . 56
__________.,o _..___p...%?_. ..5a . ..i

12
, 0 _$ ....s3
............ 3a ...................... 38.
, 0 _&..SS ........ 48 .......T .......... 48,
, 0 _$ ...S6
...._.......4a .......i
I
13-
SM.587 Copyrighted Material Rev Aug 94
Lift
A. Pulling the multi-function control lever towards the operator will

close the up switch. With the up switch closed, battery positive
will be applied to terminal TB-14 of the solenoid control through
wire #5.
B. When the solenoid control senses battery positive at terminal TB-

14, it will complete the circuit from the pump contactor coil to
battery negative through wire #28 at terminal TB-8.
C. This will energize the pump contactor coil and in turn, 'close the
normally open tips.
D. Battery positive will be applied to terminal PY-13 of the EV-T15

control card through wire #61. This signal will keep the internal
hour meter energized during lift operation.
E. Current will now flow from battery positive, through the 1FU fuse,
the now closed pump contactor tips to the pump motor and back to
battery negative. The interaction of magnetic energy between the
armature windings and the field coils will cause the pump motor
armature to rotate.
HYDRAULICS: As the armature rotates, it in turn will rotate

the hydraulic pump which will supply oil flow to the main
hydraulic lift valve. As the operator pulls farther back on
the multi-function control lever, the spool valve is opened
and diverts the oil to the lift cylinders causing them to
extend and raise the forks.
F. When the multi-function control lever is returned to neutral, the

up switch will open removing battery positive from terminal TB-14
of the solenoid control. The pump contactor will open and the
hydraulic pump motor will coast to a stop.
Voltages Present:
A. Battery positive.
B. 1.2 volts.
C. Battery positive.
E. Battery positive at the S terminal, battery negative at the A
terminal.
F. 0 volts at TB-14 and battery positive at TB-8.
Rev Aug 94 19-02-36 SM-587
r2
2 24/36 VOLTS
STEER
2FU
cacti
t ir
12 10 50
12 61
12
r
1IO
1
12 10 61
12 10 LT...; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : i0 61 13
ACCELERATOR
H-T
7-i 7
-12-12-12
/.Ry$q 12y-q-13J
2 2 2
12 10
10
VAL *IA
24-24 i'"2 m*; 30 301
10 " 41-41 i.PBG w9*; 40 40-

t-
ISW
SWITCH
12 10 15-15 i'T83 PM. ;

44-13
SL-2
lB-157~62 PA4..~........,._.34 .."__~_,....13 --_--___-- -_.
SL-3
6 6 ;*m PAS,&--___.54 ____k____,3__________ -_.
15 0 j.,, PA3 ..~.........._.____.20
........................2 o ........................
0 i
*F
15 * 27-27+FS4 PA2 * ; 26 26
*R
15 " 23-23
1
12 10 1:
. . . . . . . . . . . . . . . . . . . . . 20 .. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
___________,o ______,4,..S?......56 .. . ..f-..'..'..

5* .___.._._i..T85
.__________,o _____+...%....56 .. . ..i
, 0 -&..S?........ 36 ...................... 36 .............~..

T6,
, 0 _&.S5 ___._._._.46
.".."f""""""' 46 .............+
10_+ ...S6
........... 48 .....__.
i :........................
-12 12 - I
CI
SW587 KX=iNSWlTCH
19-262-37 m Rev Aug 94
Lower
A. Pushing the multi-function control lever away from the operator

will close the down switch. With the down switch closed, battery
positive will be applied to terminal TB-13 of the solenoid control
through wire #35.

13, it will complete the circuit from the Sl (lower) solenoid coil
to battery negative through wire #18 at terminal TB-6.
C. This will energize the Sl solenoid and in turn, open the oil's
path.
HYDRAULICS: As the multi-function control lever is pushed

further away from the operator, the spool valve will be
opened and allow oil to flow from the lift cylinders,
through the Sl lower valve and the spool valve to the
hydraulic sump tank. The cylinders will retract and the
forks will lower.
D. When the multi-function control lever is returned to neutral, the

down switch will open removing battery positive from terminal TB-
13 of the solenoid control. The Sl solenoid will open to close
hydraulic oil's path.
Note : The EV-T15 will not record operating time on the

internal hour meter for lower function. The hour meter
will accumulate hours independent of lower function, if
any of the motors is operating while performing lower
function.
Voltages Present:
B. 1.2 volts.
C. Battery volts across the solenoid coil.
D. 0 volts at TB-13 and battery positive at TB-6.
Rev Aug 94 19-02-38 SM-587
r2 t -
2 2 24136 VOLTS
ZEER _ WNPMOTOR
2FU
I CKX
WITCH
61 61-
f
t T-
12 2 50
i 1
mER~q~~ r*i ido
c
2 50
:....._..__._.............
4 D ~ ~ ! I 2 0 ............
1 - 50 50 50-
12
i-l0
10 10
c
2
IC
EG
12 10 10 2
12 10 10 2 h.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCELE,A?
12-12-12 f.y%?q 2~~q-- /1

2 2 2
r
*I.
PB3 -i 30
12 10 10 24 -24 $Fa2 1:II-I

10 AIA 41-41 ;*Pm Pm.: 40
; ;
15-15yTTB2 ___
. . . ..- . . . . .
12 1)
, 0 ~_$ ....s ........ 38 .................... . .~a.___._.......
+, 13
. . . . . . . f . . . . . . . . . . . . . 4a . . . . . . . . . . . . . +.T63
, 0 -$ ...S6
............4a ........! :........................
I
131
SM-587 Copyrighted
H;)RN SWITCH Material Rev Aug 94
Reach / Retract
A. Depressing and holding the reach button on the side of the multi-
function control lever will close the reach switch. With the
reach switch closed, battery positive will be applied to terminal
TB-11 of the solenoid control through wire #55.
Note: The reach switch must be held closed during the entire
reach/retract operation.

11, it will complete the circuit from S3 (aux) solenoid coil to
battery negative through wire #38 at terminal TB-4.
C. This will energize the S3 solenoid coil and in turn, open the oil
path to reach cylinders.
D. Still holding the reach switch closed and pulling the multi-
function control lever towards the operator will close the up
switch or pushing the multi-function control lever away from the
operator will close the down switch. With the up switch or the
down switch closed, battery positive will be applied to terminal
TB-14 or TB-13 of the solenoid control through wire #5 or wire
#35.
Voltages Present:
B. 1.2 volts.
C. Battery voltage across the S3 solenoid coil.
Rev Aug94 19-02-40 SM-587
r2 f
2 2
STEER
2FU
ILOCK
SWITCH
_.
BPS-TP I
r ir
12 2 I
PSNEG
r
.12
Y SEN-
Pi3 Pi Piipi2 Pi6 pi5 STEER
wEY c_____________________________-_ _Flx
8WITCH _ 16x7 4PL5 4PL6 4PL1 4PL3 4PL4 4PL2
+r
t T ? t 1 I !
12
i
10 2
yE& gz$ I)1loj :......~c
........3c
........... 2 0 .
,
..1.........
,
il
12
r
10
-10
I-w
10 2
-50 50 .^ 5oA
I
12 10 10 2 51
12 10
ACCELERATOR
r-i 7
I-t
12 10
I= 10 " ,.IA
*L 41-41
24-24 ids2
:*I?36 .w.;
PY8 l : 30
40 40
30
lo-l0+TB4 PY13 . ; 61 61
ERAKE
EiWITCH
SL-1
12 10 15-15 +33 PM. f 44-13

SL-2
15-15iTw P,4.)..&...._.34 .,,...-...___13 __________ ___.
SL-3
6 6 ; . TB5 PA5cf______ 54 _______.,Q __- _______ ___.
p*3 ..j . . . . . . . . . . . . . . . . 2. .._._................... 2. .. . . . . . . . . . . . . . . . . . . . . .
8 8 r_ 186
27-27+Pe4 PAZ : 26
261
12 10 1:3
/,P 113
10 " 20 28~T88
10 "" S' 18
,o _@ ...S6
........... 48 .......i
I
12 c=L ,,'i
SM-587 Copyrighted
HORNSWITCH Material
19-&41 mm Rev Aug 94
Reach / Retract (Continued)
E. When the solenoid control senses battery positive at terminal TB-

14 or TB-13 and also at terminal TB-11, it will send a signal from
terminal TB-9 through wire #20 to terminal PA-3 of the EV-T15
control card and to terminal 4PL2 of the EV-T5PS steer control.
F. When the EV-T5PS steer control senses the signal at terminal 4PL2,
it will turn ON the steer motor at maximum speed.
G. When the EV-T15 control senses the signal at terminal PA-3, it

accumulates hours on the internal hour meter during the reach
operation.
H. When the multi-function control lever is returned to neutral and

the reach switch is released, the reach and up or down switch will
open removing battery positive from terminals TB-11 and TB-13 or
TB-14 of the solenoid control.
J. After a short time delay the solenoid control will remove the
voltages from the 53 solenoid coil and the signal from terminal
TB-9 of the solenoid control. The S3 solenoid will open to close
hydraulic oil's path from the reach cylinders. The EV-T5PS steer
control will reduce the steer motor speed to idle speed or coast
to a stop. The EV-T15 control card will stop accumulating time on
the internal hour meter because of reach/retract operation.
Note : The EV-T15's internal hour meter will accumulate hours

independent of reach/retract function, if the steer
motor is operating while performing reach function.
Voltages Present:
E. 10 - 12 volts on wire #20.

F. NA
G. 10 - 12 volts.
H. 0 volts.
J. Battery voltage.
Rev Aug 94 19-02-42 SM-587
Tilt
A. Depressing and holding the tilt button on the side of the multi-
function control lever will close the tilt switch. With the tilt
switch closed, battery positive will be applied to terminal TB-10
of the solenoid control through wire #45.
Note: The tilt switch must be held closed during the entire
tilt operation.

battery negative through wire #38 at terminal TB-4 and from S5 and
S6 (tilt) solenoid coils to battery negative through wire #48 at
terminal TB-3.
C. This will energize the S3, S5 and S6 solenoid coils and in turn,
open the oil path to tilt cylinder.
D. Still holding the tilt switch closed and pulling the multi-
#35.
Voltages Present:
B. 1.2 volts.
C. Battery voltage across the solenoid coils.
Rev Aug 94 1g-02-44 SM-587
r2
2 24136 VOLTS
SEER _ PUM'PTOR
_ax /I s
2FU
SWITCH P\
61
PS-IC 61 611
61
t
12
li 10 6'1
12
r10c
10 10
~
12 10 10 2 61'
FKE
12 10 10 61
ttH-12-12-12
II t-2 2 2
.EVT!..S.CARD..
i .F%, TBI. i
12cnx-13_J
II 29- I I
10 " *L 24-24 ;*PEt2 Pl33.j 30
10 " ,IA 41-41 i*m PYB . ; 40
lo-10+TB4 WI3 -61 61
/
SL-1
1: 1'0 15-15 j . T03 PI%. j 44-13
SL-2
15-15yTB2 pA4..; . . . . . .. . . 34 .,....-_..__., 3 _________. .___
SL-3
6 6 i . TBS ,,,+____ 54 ___-____,3__________ .___
6-6 + T86 PM. : 20 20
27-27-a PAZ. : 26 261
10

Tilt (Continued)


accumulates hours on the internal hour meter during the tilt
operation.

the tilt switch is released, the tilt and up or down switch will
open removing battery positive from terminals TB-10 and TB-13 or
TB-14 of the solenoid control.
voltages from the S3, 55 and S6 solenoid coils and the signal from
terminal TB-9 of the solenoid control. The S3, S5 and S6 solenoids
will open to close hydraulic oil's path from the tilt cylinder.
The EV-TSPS steer control will reduce the steer motor speed to
idle speed or coast to a stop. The EV-T15 control card will stop
accumulating time on the internal hour meter because of tilt
operation.
Note : The EV-TlS's internal hour meter will accumulate hours

independent of tilt function, if the steer motor is
operating while performing tilt function.
Voltages Present:
E. 10 - 12 volts at terminal 4PL2.

F. NA
G. 10 - 12 volts.
H. 0 volts.
J. Battery voltage.
Rev Aug 94 19-02-46 SM-587
BATTERY
r2 bWlk-<(
2 24/36 VOLTS
STEER 1FU s WM'PMOTOR
/I w"
2FU
i%H
L lJ----EFl 61-
I i 161
t R--
12 1050
r/
12
ZTCH
12 lb 10 50
11
rlo I-
12 10 10
12
12
10
10
10
10
Rx
_d L.YG .i
T_Fm
r-3
G
: . . . . . . TR? . . . . . . :
5
i
g
. . . . . . . . . . . . . . . .~
, ai
lo-i-
1.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . :
ACCELERATOR
--.- -_
i3
10 1lJ-1()wm PYt3 _:6, 61
SL-1
&
112 12 -
HORNSWITCH 19-262-47 mw
SM-587 Copyrighted Material Rev Aug 94
OPERATIONAL SEQUENCE #I8
Side Shift (Optional)
A. Depressing and holding the side shift button on the side of the
multi-function control lever will close the side shift switch.
With the side shift switch closed, battery positive will be
applied to terminal TB-12 of the solenoid control through wire
#65.
Note : The side shift switch must be held closed during the
entire side shift operation.

battery negative through wire #38 at terminal TB-4 and from S5 and
S6 (tilt) solenoid coils to battery negative through wire #48 at
terminal TB-3. It will also complete the circuit from S7 and S8
(side shift) solenoid coils to battery negative through wire #58
at terminal TB-5.
C. This will energize the S3, 55 and S6, and S7 and S8 solenoid coils
and in turn, open the oil path to side shift cylinder.
D. Still holding the side shift switch closed and pulling the multi-
#35.
Voltages Present:
B. 1.2 volts.
C. Battery voltage across the solenoid coils.
Rev Aug 94 19-02-48 SM-587
l-27
2 2 24/36 VOLTS
STEER 1 FU ^ PuwIwroR
LOCK
2FU
SWITCH
-p+61 61
611
t rr
12 2 1050
rd
12
SM- L l L 1 1 1
PM PU PLl PI.2 FL6 PL5 STEER
r____-_______________-_________-
SWITCH +_ ;4PL7 ,PLS 4PL6 4PL1 iPL3 4PL. 4PL2
I? T T T 1 7 1
12 10 2 10 50
1A
T2
............................................. 61
ACCELERATOR
--*- 7
I
12
I
10 24 -24
41-41
BFlAK!Z I
61
SWITCH
SL-1
12 10 15-15 44-13 -
SL-2
___&____13 ---------. .__
SL-3
___-____13 ---------. .__
23 -23
1:
SM-587 Copyrighted
HORN SWITCH
Material
,,i Rev Aug 94

Side shift (Continued)


accumulates hours on the internal hour meter during the side shift
operation.

the side shift switch is released, the side shift and up or down
switch will open removing battery positive from terminals TB-12
and TB-13 or TB-14 of the solenoid control.
voltages from the S3, S5 and S6, and S7 and S8 solenoid coils and
the signal from terminal TB-9 of the solenoid control. The S3, S5,
S6, S7 and S8 solenoids will open to close hydraulic oil's path
from the side shift cylinder. The EV-T5PS steer control will
reduce the steer motor speed to idle speed or coast to a stop.
The EV-T15 control card will stop accumulating time on the
internal hour meter because of side shift operation.
Note : The EV-T15's internal hour meter will accumulate hours

independent of side shift function, if the steer motor
is operating while performing side shift function.
Voltages Present:
E. 10 - 12 volts at terminal 4PL2.

F. NA
G. 10 - 12 volts.
H. 0 volts.
J. Battery voltage.
Rev Aug 94 19-02-50 SM-587
t-2
2 24/36 VOLTS
STEER 1FU s FuwmToR
/I -4
2FU
%ki P\
Sl-
,
t r-r
12 10 50
ri
12
ETCH
12 10 10 50
12
rlo c
10 10
NZG
12 10 10 I
Fa
12 10 2
3
ACCELERATOR
-->-:
12-12-12 12 13-
EVTl5CARD
~"""""".."...""~
2 2 2*=1 TBI cf
t -10 Y AL 24-24 $PB2 PB3.i 30 30-

12 10
-10 " AlA 41-41 ;*pB6 PW l : 40 40-
-10 lo-_10+m PY13 . ; 61

I3FlAKE 61-------t
,3WlTCb
I
12 10 -15 15-15 +TEn PA6. ; 44+13d
-15 pn4hf______.34 ___sl;r__',3__________ __-_
-152-e PA5c;______.54 ___-___.,3__________ ____
-15
F
-15 "7 ~~~~,~~~~: ::r-_i
R
-15
10
;sMYp&;ggr j3 j3 26 2o
13
10
10
__________,O
.__________,. _____+_%____sB ---

10 13
II
10
10
131
SM-587 l2 &&/ITCH ,&$_5,
Copyrighted Material & Rev Aug 94
Material Handling
CMRIC Company
EV-Tl5
SM-587 19-03-O 1 Sept 93
MEMORY
STATUS CODE inp~ESCRPToN
-01
brake switch
No
No
RECALL
CIRCUIT Traction
SYMPTOM
Forward or reverse contactor will not pick up.
EVT 15 CARD
2 2 9 PBl
POSSIBLE CAUSE
*Defective brake switch or no brake line pressure. KEy
SWITCH c
/
- Check brake switch to insure proper closure.
*Open circuit between battery positive and terminal TB3.

BRAKE 10 10 -4 TB4
- Check for loose connections or broken wire between SWlTCH c
brake switch and terminal TB3. /-a
- Check for loose connections or broken wire between key 15 15 -q TB3
switch and positive side of the brake switch.
I-
*Defective brake system.
- Check that the brakes are releasing and no air in the brake STATUS INDICATION CRITERIA
system. This Status Code will be displayed when TB3 is less than 50%
battery volts.
- Check for hydraulic leaks in the brake system.
- Check for mechanical interference in the foot pedal

assembly.
STATUS CODE DESCRIPTION MEMORY

Forward directional switch is closed on initial power up. RECALL No
-02 CIRCUIT Traction
SYMPTOM EVT 15 CARD

Forward contactor will not pick up, static return to off (SRO) lock
2 2 -4 PBI
out.
SWITCH
4-
POSSIBLE CAUSE
*Forward directional switch closed on initial power up (closure
10 lo --. TB4
of battery receptacle, key switch or brake switch).
- Return directional handle to neutral and then select t

forward direction.
15 15 -4 TB3
*Forward directional switch is welded closed or misadjusted

15 15 --. TB2
to be held closed.
15 J-6 -4 TB5
- Replace or adjust forward directional switch to insure
that it opens when directional handle is returned to
neutral. P
*Short circuit between TB2 and TB5.

STATUS INDICATION CRITERIA
- Disconnect wire #6 from TB5 and check for short circuit This Status code will be displayed when voltage at TB5 is
between TB2 and wire #6. greater than 60% battery volts at initial power up.
*Defective oscillator card.
- Disconnect wire #6 at TB5. Measure voltage at TB5,

should be less than 60% of battery volts.
SM-587 19-03-02 Sept 93
No
-03
Reverse directional switch is closed on initial power up. RECALL
CIRCUIT Traction
SYMPTOM EVT 15 CARD

Reverse contactor will not pick up, static return to off (SRO)
2 2 -4 PBI
lock out.
SWITCH
+
POSSIBLE CAUSE
*Reverse directional switch closed on initial power up (closure
10 10 --. TB4
of battery receptacle, key switch or brake switch).
- Return directional handle to neutral and then select k

reverse direction.
15 15 -4TB3
*Reverse directional switch is welded closed or misadjusted to
15 15 -4 TB2
be held closed. REV
15 --s -4 TB6
-Replace or adjust reverse directional switch to insure that
it opens when directional handle is returned to neutral.
i
*Short circuit between terminals TB2 and TB6.
- Disconnect wire #8 from TB6 and check for short circuit STATUS INDICATION CRITERIA
between TB2 and wire #8. This status code will be displayed when voltage at TB6 is
greater than 60% battery volts at initial power up.
- Disconnect wire #8 at TB6. Measure voltage at TB6, should

be less than 60% of battery volts.
DESCRIPTION MEMORY
STATUS CODE
Accelerator input voltage is below threshold before the FWD RECALL No
-06 or REV directional switch closes.

CIRCUIT Traction
SYMPTOM ACCE!_ERAKR
Forward or Reverse contactor will not pick up. --------I

13 -
-1s+-&;
EVT 15 CAR0 L--_ .-A
TBl 29kci!!r
POSSIBLE CAUSE
*Accelerator (transducer / pot) is misadjusted or defective.
Status code disappears when directional handle is moved away swrr~
-/L
from neutral to close directional switch.
- Check accelerator input voltage at terminal TBl, should be

approximately 3.7 volts with directional handle in neutral.
Adjust or replace accelerator. 15d---6 TB5
*Defective directional switch. 15--/;---6 TB6

LLI
- Check forward or reverse switch to insure closure
when direction is selected.
)Open circuit between directional switch(s) and battery positive STATUS INDICATION CRITERIA
or between directional switch(s) and TB5 or TB6. This status code will be displayed when voltage at TB5 and TB6
are less than 60% of the battery volts, and TBl is less than 2.5
- Check all control wires and connections shown in Figure. volts.
SM-587 19-03-03 Sept 93

DESCRIPTION MEMORY
STATUS CODE
Accelerator input voltage too high. RECALL No
SYMPTOM ACCaEFATcFl
Forward or Reverse contactor picks up but control will not 13 -

operate when control handle is moved toward high speed or EVT,5cA;* *
L--- _.1
status code -07 is displayed then disappears when the vehicle
starts to accelerate. TBl 29 G!!-
POSSIBLE CAUSE
*Accelerator misadjusted or defective. swrrcH
-I,
- Input voltage at TBl should be less than 3.8 volts.
Adjust or replace accelerator to insure that the
voltage at TB1 will vary from 3.8 volts to less than 0.2
volts when the control handle is moved into high speed.
15---p;----6 TBS
*Open circuit between battery negative and TBl.
15~-----8 TB6
- Check for broken wires or loose connections or open :-;1
accelerator / voltage supply in the circuit shown in
figure.
- Check for broken wire or loose or corroded connection at
WHT / BROWN wire to terminal PZl.
*Short circuit from battery positive to TBl. This status code will be displayed when the accelerator input
voltage at TBl is higher than 3.8 volts.
- Disconnect wire #29 from TBI and measure voltage at wire
#29 to negative. Should be zero volts for potentiometer
type and less than 3.8 volts for transducer type
accelerator.
DESCRIPTION MEMORY
STATUS CODE No
Accelerator input voltage too low on power up after initial RECALL
-08 key switch closure or on re-closure of brake switch with

sufficient time delay to initiate SRO checks. CIRCUIT Traction
SYMPTOM ACCELERATOR
Forward or Reverse contactor does not pick up. r.._.._.._..-._.._.._..~
I
i
-12 13 -
EVT 15 CARD
POSSIBLE CAUSE
*Accelerator misadjusted or defective. TBl .
- Check accelerator input voltage at TBl, should be

approximately 3.8 volts with handle in neutral. Adjust or
replace accelerator.
*Short circuit between battery negative and TBl.
- Disconnect wire #29 from TBl. For transducer, check for

open circuit voltage from wire #29 to battery negative.
Should be greater than 3.0 volts. When potentiometer is
used, resistance should be greater than 4.7K ohms. Replace.
*Defective oscillator card. This status code will be displayed when the accelerator input
voltage at TBl is less than 3.0 volts and either the battery
- Disconnect wire #29 from TBl. Measure voltage from TBl receptacle or key switch has been opened.
to negative. Voltage should be greater than 4.5 volts, if
not replace oscillator card.
SM-581 19-03-04 Sept 93
Both Forward and Reverse directional switches are closed at RECALL bb
-09 the same time. 1

CIRCUIT Traction
SYMPTOM EVT 15 CARD

Forward or Reverse contactor will not pick up.
BRAKE
SWITCH
POSSIBLE CAUSE I,
*Forward or Reverse directional switch welded closed or mis-
adjusted to be held closed.
- Replace or adjust directional switches to insure that they

open when control handle is returned to neutral.
15 d-6 -e TB5
*Short circuit between battery positive and TB5 and / or TB6.
REV
- Disconnect wires #6 and #8 from TB5 and TB6 and check 15----lt-8-~~~6
wires for short circuit to positive side of directional -_
switches.
*Defective oscillator card. STATUS INDICATION CRITERIA
- Disconnect wires #6 and #8 and measure voltage at TB5 This status code will be displayed when voltage at TB5 and TB6
and TB6. Voltage should be less than 60% of battery are greater than 60% of battery volts at the same time.
volts, if not replace oscillator card.
MEMORY
STATUS CODE Battery
vo,tstoo,o~ESCR~PT~oN No
RECALL
SYMPTOM EVT 15 CARD

+I1
POSSIBLE CAUSE
*Discharged battery. f
Nominal Minimum
- Check battery for proper open circuit voltage as outlined
Battery Limit Volts
in figure and charge battery if required.
I Volts 0 1.95VICell
BA-TTERY <
*Defective battery.
- Check each battery cell for proper voltage, should be 24 23.4

greater than 1.95 volts per cell. Replace or repair battery. 1
36 35.1
*Incorrect oscillator card adjustment.
T i
- Check function #15 for proper adjustment for battery
being used. Adjust to proper settings (22 - 26 for 24 volt
battery and 34 - 38 for 36 volt battery). STATUS INDICATION CRITERIA
*Bad wire / connection on terminal PBl. This status code is displayed when the battery volts are less
than 1.95 volts per cell at initial start up. (See table in above
- Check voltage from terminal PBl to battery negative. figure.)
Should be greater than 1.95 volts per cell. Repair or
replace wire or connection.
sM-587 19-03-05 Sept 93

STATUS CODE Battery
vo,tstoohigDhESCRPTON MEMORY
RECALL No
CIRCUIT Traction
SYMPTOM
Forward and Reverse contactor will not pick up.
Nominal Maximum
Battery Limit Volts
Volts @I 2.4 V / Cell
POSSIBLE CAUSE
*Incorrect oscillator card adjustment.
- Check function 15 for proper adjustment for battery 24 28.8

being used. Adjust to proper setting (22 - 26 for 24 volt
BATTERY
battery and 34 - 36 for 36 volt battery). 36 43.2
*Battery over charged or incorrect battery used.
- Check battery for proper open circuit voltage per table in

figure. If voltage excessive, check battery charger for
proper output voltage.
*Open current sensor wire circuit.

- Check for loose plug or pin or corrosion at terminal This status code is displayed when the battery volts are
PZ12 on the oscillator card. greater than 2.40 volts per cell at initial start up. (see table in
above figure.)
- Check for broken wire (green wire) at weld to current
sensor and along length of wire.
DESCRIPTION 1 MEMORY
STATUS CODE 1
Invalid card type selection.
-17 i
SYMPTOM
Forward or Reverse contactors will not close.
POSSIBLE CAUSE
*Invalid card type selection.
- Check function #17 for proper card type. Adjust to proper

setting (22 - 24).

This status code is displayed when the card type selection
value is set to an invalid number.
5x-587 19-03-06 Sept 93
Forward or Reverse contactor coil current low. RECALL No
CIRCUIT Traction
SYMPTOM EVT 15 CARD

Forward or Reverse contactor will not pick up. Status code may BRAKE t
alternate between code 23 and code 24. Complete checks for
code 23, if the problem is not found, perform check for code 24.
POSSIBLE CAUSE
-Defective F or R contactor coil circuit.
- Check for open circuit or loose connection between PB4

and positive side of F contactor coil and between PB5 and
positive side of R contactor coil. Repair or replace.
I--- 15 -,/-27
F
_ 4 PB4
I--
- Remove plug B. Check ohmic value from PB4 to positive
side of F coil. Value should be lo-14 ohms. Make same 15 +L23 - 4 PB5
check for R coil. If value not correct, replace coil.
- Check for open circuit between positive side of F or R

contactor coil and terminal TB2. Repair.

- Check for status code in both directions of truck operation. This status code is displayed when the current draw in the
If status code 23 is present in both directions, continuity forward or reverse contactor coil circuit is less than 100 mA.
OK and checks for status code #24 OK, then replace
oscillator card.
STATUS CODE DESCRIPTION

T2 voltage too low. (Less than 88% of battery volts). No
-24 CIRCUIT
I
Traction
SYMPTOM
Control does not operate. Status code may alternate between
code 23 and code 24. Complete checks for 24, if the problem is
not found, perform code 23 checks.
POSSIBLE CAUSE
*Defective F or R contactor.
- F or R power tips fail to close because:
1) Welded normally closed power tips. BRAKE
2) Binding contactor tip or armature assembly.
3) Defective F or R contactor coil. (See status code 23)
SWITCH
1,
I
4) Loose contactor coil assembly.
a) Coil not locked into position.
*Open motor circuit

- Check for open circuit or loose connection in motor circuit
from the Al connection to the A2 connection on the
control panel and from the Sl connection to the S2
connection on the contactors.
Gpen circuit in the T2 sensing circuit.
- Check for broken wire (Blue wire) or loose or corroded STATUS INDICATION CRITERIA
connection and / or terminal at T2. Repair or replace. This status code is displayed when T2 voltage is less than 88%
- Check for loose or corroded connection at plug or pin at of battery volts and the F and R driver is energized.
terminal PZ9. . Repair or replace.
- If above checks are OK and checks for status code #23 are
OK, then replace card.
w-587 19-03-07 Sept 93

Shorted coil driver for Line contactor
-26
SYMPTOM
Forward or Reverse contactor will not pick up. EVT 15 CARD
t
jKc/ SWITCH
I
POSSIBLE CAUSE
*Defective coil driver internal to oscillator card.
- Replace oscillator card.

10 -& 24 ----j--o 132

This status code is displayed when there is a shorted Line
contactor coil driver.

Oscillator Card power supply is less than 14 Volts.
-27 CIRCUIT
I
1Traction
SYMPTOM
Forward or Reverse contactors open and close, then can only be
closed by opening and closing the key switch.
POSSIBLE CAUSE
*Discharged battery.
- Check battery to insure proper state of charge. Voltage

may be dropping below 14 volts at terminal PBl when one
of the motors is under load. Charge the battery.
*Loose connection at terminal PBl.
- Insure that the wire connection at terminal PBl is tight and EVT 15 CARD
not corroded.

This status code is displayed when the oscillator card power
supply is less than 14 volts.
SM-581 19-03-08 Sept 93
-41
Open Thermal Protector or Control Over Temperature. RECALL No
Cl RCU IT Traction
-
SYMPTOM
Reduced or no power to traction motor in control range. 6 ..-..,,7___..__,
r--- I
ITP 1 \ 1 I
I
I i
I I
POSSIBLE CAUSE i I
I I
*Open thermal protector circuit. I I
i.-..--.-.-.-..-.-.._.._.._I
- Check for loose or corroded connection or broken wire
between:
VI0 wire at thermal protector and PZ2. Q
WHTNIO wire at thermal protector and PZ5. 2
Repair or replace as necessary.
5 0
3 5
*Defective thermal protector (part of transistor).
0 0
PZ5 PZ2 OSCILLATOR CARD
- Disconnect wires from PZ2 and PZ5. At room temperature TCONNECTCR
(25 C or 75 F) measure resistance between VI0 and
WHTNIO wires. Replace transistor if ohmic value is
greater than 1300 ohms.
control is in thermal cut-back. This status code is displayed when the voltage between PZ2
and PZ5 is greater than 1.8 volts.
- Allow control to cool, status code should disappear. Review
duty cycle, application, motor current, brake drag and
ambient temperature etc.
-42
Motor current sensor input missing. RECALL No
CIRCUIT Traction
SYMPTOM
No power to traction motor in control range.
SENSOR ~2
0; . -
POSSIBLE CAUSE
Qpen sensor wire circuit to PZ12. EVT 15 CARD
- Check for loose or corroded connection at terminal PZ12.
v
- Check for loose connection or broken wire (green wire) l Pi!12
at weld on current sensor and along length of wire.
- Check for voltage between terminal PY7 and negative with

motor not operating. If greater than 1.6 volts, replace
oscillator card.
This status code is displayed when voltage between PY7 and
negative is greater than 1.6 volts with no current flowing in
the motor circuit.
SM-587 19-03-09 Sept 93

Motor current sensor input missing. RECALL No
-43 L
Cl RCU IT Traction
SYMPTOM A
No power to traction motor in control range.
POSSIBLE CAUSE
Qpen sensor wire circuit to PZ13. EVT 15 CARD
7
- Check for loose connection or broken wire (yellow wire)
at weld on current sensor and along length of wire. + PZ13
- Check for voltage between terminal PY7 and negative with

motor not operating. If less than 0.84 volts, replace
oscillator card.

This status code is displayed when voltage between PY7 and
negative is less than 0.84 volts with no current flowing in
motor circuit.
DESCRIPTION MEMORY
STATUS CODE
Transistors did not turn OFF properly. RECALL Yes
SYMPTOM r--- ..-. .-..-.._..

-._, I
Forward or Reverse contactors open and close, then can only be I r iiy --i i
closed by opening and closing the key switch. i I
,2 j --&- s 1
I q,NG
I
POSSIBLE CAUSE
*Transistors defective.
- Check for open circuit or loose or corroded connection

between the transistors and terminal PZ4 (red wire).
- Turn-off time for transistors is out of specification. No

field test is possible. Replace transistors. !.._.._.._.._.~~~._.._.._.._.._~
@
.
j l pz9 PZ4
EVT 15 CARD

This status code is displayed when, during control operation,
the transistors fail to turn OFF. Voltage from T2 to battery
negative as measured at terminal PZ9 is less than 12% battery
volts.
~~-587 19-03-10 Sept 93
DESCRIPTION MEMORY
STATUS CODE
Transistors did not turn ON properly RECALL YeS
SYMPTOM I----. .._. ._.._.._..

-._, A
Forward or Reverse contactor will open and close, then open and I
I f 4.4
3; --J I
then can only be closed by opening and closing the key switch.
T* i --&J s 1
N33
POSSIBLE CAUSE
*Defective transistor circuit.
- Check for open wire (red wire) or loose connection

between the transistor and terminal PZ4. Repair or replace.
- Check for corrosion on plug / pin at terminal PZ4. Repair or

replace. L.._.._.._.._.~._.._.._.-.-!
P
- Check for open wire (blue wire) or loose connection at .
terminal T2 (#3 REC power terminal). Repair or replace. PZ9 PZ4
- Check for corrosion on plug / pin at terminal PZ9. Repair or EVT 15 CARD
replace.
*Defective transistors. This-status code is displayed when the transistors fail to gate
ON.
- Intermittent or open transistor gate.
Field test may or may
not show defect. Replace transistors after above checks
show no problem found.
DESCRIPTION MEMORY
STATUS CODE I%
Look ahead test for T2 volts. (Less than 12% of battery RECALL
-46 volts.)
CIRCUIT Traction
SYMPTOM A-t/ A
Forward or Reverse contactor will not pick up. . 0
r-..-_...__.&.-._.._.._,
POSSIBLE CAUSE .
*Defective 1A contactor. I 7 I
:___-..-,,,.G__,~_i
- Check for welded 1A contactor power tips. .I
._.-4. _--_.~_-_-:
f :-- JG i
*Defective transistor. = ! !
I
l.._.._..__x!?__.-.-.-._:
- Check for shorted transistors. Replace transistors. R
.
*Defective oscillator card. j - PZ9 PZ4
- Check for 1A contactor coil being energized due to E.T 15 CARD

shorted driver. Replace oscillator card.
This status code is displayed when the voltage at T2 is greater
than 12% of battery volts.
SM-587 19-03-11 Sept 93

RECALL No
-48
Look ahead test for T2 volts (Greater than 88% battery
volts)
Cl RCU IT Traction
l-
SYMPTOM Fg;
POSSIBLE CAUSE
*Defective forward or reverse contactor.
- Check for welded forward or reverse contactor power

tips.
- Check for sluggish operation of forward or reverse

contactor.
*Defective 3 REC circuit.
- Check for shorted 3 REC.
- Check for shorted 3 REC snubber (23 REC).

*Defective oscillator card. This status code is displayed when the voltage at T2 is greater
than 88% of battery volts.
- Check for Forward or Reverse coil being energized due to
shorted driver. Replace card.
DESCRIPTION MEMORY
STATUS CODE
Capacitor volts low after Line contactor closes. RECALL No
SYMPTOM
Forward or Reverse contactor picks up. Control does not
operate.
POSSIBLE CAUSE
*Defective Line contactor.
- Check for open line contactor power tips and / or

contamination. Repair or replace.
- Check for adjustment of steer interlock switch holding Line

contactor power tips open. Readjust.
- Check for loose or open connection in cables from battery

positive to contactor panel positive. Repair or replace.
- Check for loose or open connection in bus bars from 1FU

power fuse to Line contactor power tips. Repair.
*Defective 1FU power fuse. STATUS INDICATION CRITERIA

This status code is displayed when capacitor volts are less than
- Check power fuse for open circuit. Replace. 85% battery volts at initial start up.
34-587 19-03-12 Sept 93
Capacitor volts low before Line contactor closes RECALL No
-51 (precharge).
Cl RCU IT Traction
SYMPTOM
Line Contactor does not close.
POSSIBLE CAUSE
*Defective capacitor.
- Check capacitor bank per component checking section.
- Check for loose or open connections in capacitor circuit.
*Misadjusted / defective steer interlock switch.
- Check to insure that the steer interlock switch closes after
the line contactoh power tips close. Repair or replace.
-Defective steer control.
- Disconnect the positive cable and 4PL plug from the steer
control. If status code disappears, repair steer control.
-Open circuit in capacitor precharge circuit.
- Check for loose connection or broken wire (WHT) at #3 REC
heat sink or along the length of the wire.
- Check for loose connection or broken wire (BLACK) at 1 FU
power fuse or along the length of the wire. STATUS INDICATION CRITERIA
- Check for loose or corroded connection at terminal PBl. This status code is displayed when capacitor volts are less than
*Unsuppressed voltage spikes. 85% battery volts at initial start up.
- Check that any and all coils, including horns, that are
present on the truck have the proper voltage suppression.
- Check that the static drag chain is present on the truck and
dragging on the floor so that it keeps static electricity
from building up in the truck.

Transistors fail to turn OFF during plugging cycle. Yes
SYMPTOM
Forward or Reverse contactor opens and closes, then opens and
can only close by opening and closing the key switch.
POSSIBLE CAUSE
*Open T2 circuit.
- Check for short from terminal PZ9 (blue wire) to battery

negative.
- Try to operate in opposite direction. If status code -44

does not appear, check for open motor circuit or
intermittent directional contactor power tips. Repair or
replace.
*Transistors defective.
- Turn-off time for transistors are out of specification. No

field test is possible. Replace transistors. STATUS INDICATION CRITERIA
This status code is displayed when the transistors fail to turn
- Check for open circuit or loose or corroded connection OFF during plug cycle.
between the transistors and terminal PZ4 (red wire).
34-587 19-03-13 Sept 93

Shorted F, R or 1A contactor coil driver. No
-54 CIRCUIT
I
Traction
SYMPTOM
Control will not operate
POSSIBLE CAUSE

This status code is displayed when either the forward, reverse
or 1A contactor coil driver is shorted internal to the oscillator
card.

Current sensor input voltage polarity check.
-57
SYMPTOM
Forward or reverse contactors open and close, then can only be
closed by opening and closing the key switch.
SENSOR A2
POSSIBLE CAUSE
*Unsuppressed voltage spikes. *~------- EVT 15 CARD
- Check that any and all external coils that are present on
the truck have the proper voltage suppression.
t
- Check that the static drag chain is present on the truck and
dragging on the floor so that it keeps static electricity
from building up in the truck.
*Reversed yellow and green current sensors wires (if wires are
reversed, truck will not run at all).
- Insure that the green wire connects to terminal PZ12 with

no open circuits and that the yellow wire connects to
terminal PZl3 with no open circuits or loose connections. STATUS INDICATION CRITERIA
Insure that the yellow wire, at the sensor, is at battery This status code is displayed when the voltage input to
positive. terminal PZl2 is positive in relationship to terminal PZ13.
*Reversed power cable connection.

- Insure that the battery negative cable connects to the
panel NEG terminal and the motor A2 cable connects to the
panel A2 terminal.
SM-587 19-03- 4 Sept 93
Maintenance Reminder code. RECALL bb
SYMPTOM
-99 status code is displayed for about 3 seconds when key
switch is first turned ON. Truck may run at a reduced speed and
status code -99 will flash on the display.
-99
POSSIBLE CAUSE
Truck has accumulated the number of hours as preset in
functions #19 and #20. Perform required PM maintenance and
reset functions 19 and 20 to next desired maintenance hour
number.
Note: Amount of travel speed reduction is determined by the

setting of function #21.
The EVlOO / EV-T15 handset is required

for all function setting changes.

This status code is displayed when the number of accumulated
truck hours exceeds the preset maintenance hours as set in
function #19 and #20.
r
DESCRIPTION MEMORY
STATUS CODE
No display on Dash Display or Handset. RECALL No
Blank CIRCUIT Traction
SYMPTOM
Display screen on dash display or handset is blank.
F
EVT 15 CARD
POSSIBLE CAUSE
2 2 PBI PZl
*Positive or negative control voltage missing.
.r
SWITCH
i-
- Insure that with the key switch ON, voltage is present
between terminals PBl (positive) and PZl (Negative). f
- Check for broken wire(#2) or loose or corroded
connection from power fuse to terminal PBl.
- Check for open or intermittent key switch. 10 lo -4TB4
- Check for broken wire (#lo) or loose or corroded L
connection from key switch to terminal TB4.
- Check for broken wire (WHT / BROWN) or loose or corroded
connection from key switch to terminal PZl.
*Open circuit between oscillator card Y plug and dash display or

handset.
- If truck does run but no display, check for open circuit or This indicates a lack of voltage to the oscillator card and / or
loose connections between each wire between the Y plug dash display. Battery voltage must be present between
and dash display / handset. terminals TB4 and PZl of the oscillator card when the key
switch is turned ON.
*Defective dash display / handset.
- Replace dash display / handset.
SM-587 19-03-15 Sept 93

Cl!!lRKWl;&r&:Handling GROUP 19
Section 4
Oscillator Card Settings
GROUP 19 Oscillator Card
AWARNING
Drive wheel must be off the floor

before any adjustments are made.
Raise rear of truck and block it on
both sides.
Remove all Jewelry

working on truck.
before A Always wear Safety Glasses
Sep 93 1942 SM-587

EV-T15 Settings GROUP 19
NPR (24 Volt Truck)
EV-T15 Card Factory Settings
hnction
No. Description Actual Value Factory Setting
FOl Speed Limit C/A 006-008 0.6 - 0.8 Sec.
F02 Creep Speed 090-110 7.7% - 8-3%
F03 Controlled Acceleration & 1A Tiie 006-008 -
F04 Current Limit 218-222 -
F05 Plugging Distance (Current) 135-145 655 - 687 Amps
F06 1A Drop Out 255 Function Disabled
F07 Plug % On Time Adjustment 35-40 -
FOS N/A N/A N/A
F09 N/A N/A N/A
FlO N/A N/A N/A
Fll Speed Limit 1 154-156 -
F12 Speed Limit 2 000-001 Function Disabled
F14 Internal Resistance Compensation 026 0.88 Volts Drop
F15 Battery Volts 024 24 Volts
F16 Pedal Position Plug 095-105 -
F17 Card Type Selection 022-024 Std. C/L w/Speed Limit
F18 Steer pump Time Delay 001-003 l-2 Set
F19 Maintenance Hours (l=l hour) 050 50 hours
F20 Maintenance Hours (l=lOO hours) 002 200 hours
F21 Maintenance Speed Limit 000-001 Function Disabled
F22 N/A N/A N/A
F23 Speed Limit JR Compensation 005 -
F24 Speed Limit Comp Start 000-001 Function Disabled
F25 N/A N/A N/A
F26 N/A N/A N/A
F27 N/A N/A N/A
F28 Last Fault Flag 016-030 Next Fault Location
SM-587 19-4-3 Dee 94

GROUP 19 EV-T15 Settings
NPR (36 Volt Truck) EV-TIS Card Factory Settings

Function
No. Description Actual Value Factory Setting
FOl Speed Limit C/A 011-015 1.24 - 1.36 Sec.
F02 Creep Speed 045-055 6.35% - 6.65%
F03 Controlled Acceleration & 1A Time 008-011 0.856 - 1.024 Sec.
F04 Current Limit 218-222 -
F05 Plugging Distance (Current) 150-160 -
F06 1A Drop Out 255 Function Disabled
F07 Plug % On Time Adjustment 35-40 -
F08 N/A N/A N/A
F09 N/A N/A N/A
FlO N/A N/A N/A
Fll Speed Limit 1 (up to 270 MPH) 157-159 -
Fll Speed Lit l(271 MPH & above) 169-171 -
Fl2 Speed Limit 2 000-001 Function Disabled
(up to 270 MPH)
(271 MPH & above)
F15 Battery Volts 036 36 Volts
F16 Pedal Position Plug 095-105 -
F17 Card Type Selection 022-024 Std. C/L w/Speed Limit
F18 Steer pump Time Delay 001-003 1-2 Set
F19 Maintenance Hours (l=l hour) 050 50 hours
F20 Maintenance Hours (l=lOO hours) 002 200 hours
F21 Maintenance Speed Limit 000-001 Function Disabled
F22 N/A N/A N/A
F23 Speed Limit IR Compensation 005 -
F24 Speed Limit Comp Start 000-001 Function Disabled
F25 N/A N/A N/A
F26 N/A N/A N/A
Dee 94 19-4-4 SM-587
ELRRIC
~;t$h\Handling
GROUP 19
Section 5
Steering Control Adjustments
EV-T5PS
Contents
Preparation and Safety ....................................................................... 19-5-2
Adjustment Steps 1 - 3 ....................................................................... 19-5-3
Adjustment Step 8 ............................................................................. 19-5-6
SM-587 Dee 94
GROUP 19 Steer Control
A WARNING
both sides.
Remove all Jewelry

working on truck.
before
A Always wear Safety Glasses
Dee 94 19-5-2 SM-587

Steering EV-TSPS GROUP 19
Steer Control Adjustments SC-POS
1. Turn key switch ON and step on brake pedal.
2. TurnMaxSpeedtrimpotfullyclockwise(CW).
Maximum Speed
Trim Pot
Current Compensation
rypical Illustratiotl Steer Control
SC-POS
3. Turn Steer Comp trim pot fully clockwise
0%.
Steering Compensation Steer Compensation

Trip Pot
Steer Control
GROUP 23 Steering EWT5PS
SC-POS
4. Turn Current Comp trim pot fully counter-
clockwise (CCW).
Steer Compensation
Trim Pot
lypical Illustration Steer Control
SC-POS
5. Measure motor out voltage between M+ and
M- power terminals on steer control.
Steer Compensation
II III -------------_____
I
L-l l-l
Steer Control
Dee 94 19-5-4 SM-587
Steering EWT5PS GROUP 19
SC-POS
6. Turn Idle Speed trim pot until motor output
voltage is:
9.2 +/-0.2 (24~VoltTruck)

13.6 +/-0.2 (36-Volt Truck)
Idle Speed
Trim Pot
Steer Compensation
Steer Control
7. Rotate Steering Tiller clockwise (CW) or

Counter Clockwise (CCW) to the steer stop and
hold at steer stop.
SM-587 19-5-5 Dee 94

GROUP 23 Steering EV-TSPS
SC-POS
8. Turn Current Comp trimpot clockwise (CW)
until motor output voltage is:
12.4 +/-0.2 (24-Volt Truck)
17.5 +/-0.2 (36-Volt Truck)
M+
Steer Compensation
Current Compensation Current Compensation
Trim Pot
rypical Illustration Steer Control
9. Remove blocking and lower truck to ground.
Dee 94 19-5-6 SM-587

Cl!!lRK
Wl~~;~~Handling
GROUP 19
Section 6
Wiring Diagrams
NPR-345
WY TypicalIkstrario~~
SM-587 19-6-lMaterial Aug 93

Copyrighted
Wiring Diagram
Steer Lock Battery
Switch \
Accelerator 1 , 1
PYl3 81 61
I-
SL-l_
PM 44 13 -
6L-2
PM- ~~~.24~~-~~n~~~ 12 ____a__
PA6r ---.64-----d-B, 12-m-----*
16-=6 PA3 W W
10 10 10 llB16 l87* -28 28-

10-1k6 6 OTB14 Tm* -20 w
1oyi=.!&26 26-*l813 lm. -13 13
,___~~~~~~~.lO~~~~~~ .-r-w,_ 66mm--w-m--w-66-w- ..m2
lo-Q=!&6 66 .lBll
10-I -46
TnT 46 lT8l0
10 . .P 26 26 l TB6
10 *6l
.67 16 16 *TM
~~~~~~~~~~.lo-~~~~-~L-----. 61)~_~_~___..~
~-~~_~~~~~.lo-~~---~PL----.~-~~r m
10 .62
I 10 .. s
.
10 rm Horn Switch
ckukMuterialHMdlingco. NPR 15D.17,20.22

..P Q-
: -
. _
. -
6
d
I
b
Lb!%
P
c-
%-
GROUP 19
Section 7
Forward & Reverse Switches,
Up (Lift )& Down (Lower) Switches
and
Transducer Adjustments
Contents
Safety................................................................................................ 19-7-2
Switch Adjustments ..... .......... ................................ .... .. .............. ........ 19-7-3
Transducer Adjustment ......................... ............ ................................. 19-7-4
Forward, Reverse Switch Voltage Check & Adjustments ......... .......... 19-7-7
Multi-Function Control Hand
Qble ,~
- Clamp
Tilt and Auxiliary Switches +
guide
x Markmg Tape
Clamps, Cable Guides and Switch Side) -)e

Marking Tapes:
IMPORTANT
Cables must be positioned
with all tape markers aligned
with or hidden under clamps
or guides.
SO-G
Latch plug number with socket number
jefore making a connetion. If you do not, c PL-9
Aectrical shorts and possible damage to
equipment may result. See below.
Arrows must face in direction shown p$TT%F

Switch -
SM-587
GROUP 19 Control Handle
A WARNING
both sides.
Remove all Jewelry

working on truck.
before
A Always wear Safety Glasses
Dee 94 19-7-2 SM-587

Control Handle GROUP 19
Forward, Reverse, Up (Lift) & Down (Lower) Switch Adjustment
Objective: Switch must fullv actuate when the roller is at the hiah noint of the cam.
l The lift pump will not operate until just before the lift valve is in position to start metering hydraulic flow
to the lift cylinders.
l The lower solenoid will not operate until just before the lift valve is in position to start metering hydraulic
Step 1
Each switch must be adjusted so that the ......
switch arm just touches the switch plunger
with the arm roller in contact with the cam

surJace, refer to example.
Just Touch
The adjusbnent ismude with the adjusting screw
of each switch. Do not over adjust.
m r Up (Lift) Switch Up and Down Switch Adjustment
1. Pre-adjust the switches so that the switch lever
roller iust touches the low m-ofile of the cam and
so that the switch lever, is just touching but not
depressing the switch plunger that is under the
lever. This will require moving the switches
toward or away from the cam with the screw
adjusterandmoving theswitchmounting bracket
upor downrelative to the cam. Tighten the
switch mounting bracket screws iust enough to
Cam Low Profile allow the bracket to be moved "LIDand down
bv hand but not so loose that the bracket will
move on its own.
2. Adjust each switch, with the screw adjuster, so
Reverse Suritch that the switch plunger is being fullv deuressed
when the switch lever roller is on the high hartof
scre the cam. (The switch lever will be parallel to the
switch body.) Do not adjust to the point where
the switch lever is being bent.
IMPORTANT: do not adjust the switch op-
erating (turn on) point with the switch screw
adjuster.
3. Set the truck up in operational condition
Truck Condition (battery plugged in, key switch ON, no load on
the forks and drive wheels off floor).
0 Truck on blocks, drive wheels off floor.
4. Loosen the switch mounting bracket screw on
l Upright fully lowered.
the UP (Lift) switch end. Move the up switch
l Key switch off . end of the bracket up or down as needed to
l Battery unplugged. operate the lift pump at a point just before the
SM-587 19-7-3 Dee 94

lift valve starts metering hydraulic flow to the 7. Recheck the UP (Lift) and DOWN CLowerl
cylinder. Tighten the bracket screw described in switch actuation noints. If the lift pump and
Step 1. lowering solenoid valve come on at the proper
5. Loosen the switch mounting bracket screw on time, proceed to Step 7. If one or both do not,
theDOWN switch end. Move thedown switch- repeat Steps 4,5 and 6. This may be necessary
end of the bracket up or down as needed to because the adjustment of the UP (or Down)
operate the lower solenoid valve at a point just switch is changing slightly as you are perform-
before the lift valve starts metering flow from ing the adjustment to the DOWN (or Up)
cylinder. Tighten the bracket screw. switch.
6. Check that the adjustments of both switch plung- 8. Securely tighten the switch mounting bracket
ers are operating as set in Step 2. If they are not, screws without distrubting adjustmenta.
repeat Step 2.
TRANSDUCER ADJUSTMENT
Step 2
l Measure accelerator voltage at wire #29 on terminal TE31 of traction control oscillator card and battery
negative.
#I 3 Battery Negative -,
A
TBl
lwl
Oscillator Card
Lock
Nut
l TLUTI
key switch ON.
DO NOT STEP ON BRAKE PEDAL.
l Loosen Lock Nut holding transducer to mounting plate.
Sep 4
l Measure voltage between wires #29 and #13.
A CAUTION
To prevent damage to wiring: Loosen wires #29 & #13 by pulling them part way
thru cam slot.
Usinczthe bodv of the transducer, slowly rotate body clockwise and then counterclockwise by hand
(voltage will increase and decrease as the body is rotated). Do not rotate the body to the extent thal
wires are pulled out (or damaged).
Stop rotation when voltage registers between 3.50 and 3.75 volts. This is know as the neutral point OI
maximum accelerator voltage position. Note when in this position the wire harness will be on the toI
Transducer
Wire Harness
1
Transducer
Body
SM-587 Dee94
itep 5
l With transducer at the neutral point, tighten Lock Nut securing transducer in position..
. Verify acceleratorvoltageis between 3.50 and 3.75 volts and, any handlemovement (in either direction)
results in reducing accelerator volts.
Lock
Nut
Step 6
l Move handle to maximum forward and maximum reverse direction positions. Verify accelerator volts
are less than 0.20 volts.
r
/
19-7-6 SM-587
Dee 94
=ORWARD AND REVERSE SWITCH ADJUSTMENT
Step 7
l Disconnect connectors SO-8 and PL-8.
NOTE
Forward and reverse switch voltages should be measured between wire #6 and wire #8
(alternately) on terminals TB-5 and TB-6 (on traction control oscillator card) and battery
negative, see below.
Battery Negative
TB6
Wire #F T2
TB5_
Wire #6
.lsdII Capacitor
SM-587 19-7-7 Dee 94

Step 8
l Step on brake pedal. Measure directional switches and accelerator voltages at wire #6, wire #8 and
wire #29 with respect to battery negative (wire #13).
Battery Negative --,

k- m
n
Capacitor l-l-l-
TB6
7
Wire #8 \
TB5
Wire #6
/
TBI _/
Wire #29
Step 9
. Move control handle to neutral posi-
tion,seeoppositeillustration.Direc-
tional switch voltage at wire #6 and
wire #8 must be zero (0). If voltage
at one and/or both wires is battery
volts, turn the adjustment screw(s)
as required to open (deactivate) the
forward and/or reverse switches.
NOTE
Adjusting the screw
counterclockwise will
operate the switch
closer to neutral posi-
tion of the control
handle.
Adjusting the screw

clockwise operates
switch further away ww
from neutral position.
Dee 94 19-7-a SM-587

ForwardandReverse Switch Adjustment-continued.
Step IO
l Move control handle extremely slowly to
operate the forward switch. When switch oper-
ates, hold handle in this position.
l Now, verify forward switch voltage is battery
volts (measure voltage at wire #6).
l Monitor and note specific accelerator voltage
corresponding to forward switch operating po-
sition. This accelerator voltage (wire #29) must
be between 3.40 and 3.60 volt. Forward
Switch
Step 11
l Move control handle extremely slowly to
operate the reverse switch. When switch oper-
ates, hold handle in this position.
l Now, verify forward switch voltage is battery
volts (measure voltage at wire #S).
l Monitor and note specific accelerator voltage
corresponding to reverse switch operation posi-
tion. This accelerator voltage (wire #29) must
be between 3.40 and 3.60 volts.
Reverse
Switch
SM-587 Dee 94
Step 12
To adjust actuation (operating) positions of Forward and/or Reverse Switches:
l Rotate the adjustment screw(s), as required to obtain specific accelerator voltage of
3.40 to 3.60 volts corresponding to the actuation positions of both switches.
The voltage measure at the actuation moment of each switch must be 3.40 - 3.60 volts
(+O.OSvolts apart maximum).

Adjustment Screw AdJustmentScrew
Step 13
l Plug in connectors.
Dee 94 19-7-l 0 SM-587

GROUP 19
Section 8
Periodic Electrical Checks
Contents
Preparation ..................... ................................................................... 19-8-2
Inspections . .. ...... ............ .......................................... ................ .... ..... 19-8-4

working on truck
GROUP 19 Periodic Electrical Inspection
1. Move truck to service area.
. Park truck on a flat level surface.
. Extend pantograph.
. Fully lower pantograph.
. Tilt forks forward until fork tips touch the floor.
2. Turn key switch off.

l Remove key.
l Disconnect truck battery.
3. Remove Front Console Cover

. Remove fasteners securing cover to truck.
. Slip boot off cover lip and tuck bottom of boot
into cover hole.
. Carefully lift cover a little forward and upward
until the cover is free of the control. Front Console\
Cover \
Dee94 19-8-2 SM-587

Periodic Electrical lnpsection GROUP 19
. Remove console cover from truck.
4. Discharge the CaDacitors Discharge Capacitors

Hold the resistor in place for 2 seconds before
removing.
A CAUTION
without a resistorloadcould
A WARNING
bystanders.
SM-587 19-8-3 Dee94

Electrical Inspections
IMPORTANT
IMPORTANT
Connector Plugs and Receptacles are perma-
Tape Markers are used to correctly position each
nently labeled with the proper PL (Plug) and SO
wire harness and electrical cable on the truck. When
(Socket/Receptacle) number for easy identification.
correctly installed, the tape marker will be hidden by
the mounting clamp (guide). Be sure to follow the
A CAUTION
instructions, where notedinthis manual, when install-
Match the plug number with the appropriate ing a wire harness or electrical cables. If you do not,
receptacle number before making a connec- ossible shorts and equipment damage may result.
tion. If you do not, electrical shorts and
possible damage to the equipment may re-
sult. i.e., Plug #PL-6 plugs into pin socket
SO-6. etc.
s must face in direction shown.
L-Tape Marker
(Stamping: DT06-6P)
PL-6 Plug I Pin(s) (Used on Wire Harnesss and Power Cables)

(Stamping: DT06-6S
Torque specifications (where noted) for mounting hardware, clamps, etc., must be adhered to or equipment
damage may result.
Special Instructions have been illustrated to show proper installation of multiple cable and wire connections.
If the instructions are not specifically followed, possible electrical shorts and control damage may result.
Assemble Front-to-Front
;semble Back-to-Back
TC-NEG. Cable
(Pump Motor A)
TC-NEG. Cable (BAT.NEG.)
TC-NEG. Cable (Steer Control Neg.)
ire 13C & 13D (Main Harness)

EXAMPLE
e 13B (Main Harness)
Dee94 19-8-4 SM-587

Power Cables
l Cables having small cuts in the casing may be
r Repairable Damage {n\
repaired with electrical tape.

l Cables having damage as shown in illustration
below should be removed immediately and re-
placed with new. Be certain the replacement
cable is the exact same length, size and has the
proper connector. Make absolutely certain the
cable end is properly crimped and its connection
properly torqued upon installation.
Everycableand wiring harness Power Cables having small

on this truck is manufactured
to an exact specification. A
shorter cable or harness will
not fit. If either a harness or
cable is routed improperly, it
will not fit. Subsequently,
electrical shorts and damaged
components may result if the
replacement part is the wrong
one, or if it is routed incorrectly.
Cable unfit for further service.
Broken Wires -I
SM-587 19-8-5 Dee94

IMPORTANT
Improperly Torqued Fasteners Can Cause Damage
l Use an appropriate wrench and tighten all fasteners to the torque specified
in the following inspection procedures.
Typical
Inch Pound
Torque Wrench
Pointer
Typical
Foot Pound
Pivoted
Torque Wrench
Scale Handle
Pointer
19-8-6 SM-587
Assemble Front -
Torque to: 100 lb. in.
TC-NEG. Cable
(Steer Control Negative) Buss Bar
Wire 13C & 13D (Main Harness)
e 138 (Main Harness)
1
\ \ -TC-P Cable,
able (or)
(Pump Motors) /
. Wire Harness
L Torque to: 100 lb. in.
5iiiiir (11.3 N-m) /
m
Clamp
5ii?IMPORTANT
lamps must be Terminal Barrels

lositioned so al must face opposite
-APE MARKERS each other.
,re aligned witk
lr hidden under
3e clamps 01
,lamp guides.
A! CAUTION
Wire harness, clamps (guides)
and terminal connections must
be installed exactly as shown.
ressure
If they are not installed as
illustrated here, you may
experience shorts and
component damage.
Cables & Wiring

l Make sure wire connections are secure.
l Check wiring for damage. Replace as
required.
l Check harness clamp/guides for secu-
rity of mounting. Be certain the clamps
and harness are installed as shown.
l Be certain power cables are tight and
installed properly as illustrated here.
SM-587 19-8-7 Dee94

26 20 20A 5
Solenoid Control Card
134568 IO II I2
I I I I I I I I I I I I\
13C 48 38 58 I8 28 45 55 65 35 IOC IOE IOF
l Check steering control connection PL-4 to be cy Q

sure it is securely ;ougged in and theat the wiring Main Harness
is in good condition. I
l Be certain all terminal connections are tight and
properly installed on the solenoid control card. l Be certain the steering control and control card
are securely mounted.
Dee 94 19-8-8 SM-587

GROUP 19 Periodic Electrical Checks
NOTE
Connect PL-DP to Display Unit
prior to assembling to bracket.
l Check Key Switch for security of mounting.

l Inspect wires 12 & 12B and 10A & 10 for
security of mounting and damage.
l Check the display unit for security of mounting
and damage.
l Inspect wire PL-DP for security of mounting
and damage.
l Check plugs, sockets and wiring for damage.
Replace damaged components with new. Inspect Plug & Socket Wires
for damage, cuts (exposed wire).
Repair or replace damaged wires.
Periodic Electrical Checks GROUP 19
z 6
hrkrng
-Clamp
Tape
or
Guide
Clamps, Cable Guides and

Marking Tapes:
IMPORTANT
Cables must be positioned
with all tape markers aligned
with or hidden under clamps
or guides.
Multi-Function Control Handle
l Inspect wire and harness clamps for security of damage and proper installation. Refer to following
mounting. Make sure the harness Marking Tape page for detailed drawings.
is in alignment with or covered by the clamp. .
Inspect wiring for damage (cuts, etc.). Repair or
This assures the harness is correctly positioned.
replace as required.
l Inspect the multi-function control handle for .
Report condition on the PM check sheet and
damage. The handle has two halves. Check to be
give to the designated authority.
sure thefasteners on the switch and heel sides of
the handle are secure.
/ .
Plug (or Socket) Housing
l Inspect handle switches for damage (Reach,
Tilt, ALIX.).Replace any that are damaged.
l Check the handle mounting bracket for security
of mounting. The bracket must be adjusted so
the handle is vertical and in line with the hydrau-
lic control valves. Make certain the mounting
bolts are tight.
l Check security of all mounting fasteners (bolts,
screws and C-rings). Replace any that are miss-
ing or damaged.
Seal should be pressed flush with housing.
l Inspect all connectors (plugs and sockets) for
Dee 94 19-8-l 0 SM-587

IMPORTANT
Typical Panel Firmly push plug into socket until
xeptacle & PI latch clicks locking the two com-
Assembly ponents together.
Ass$mbly
Rubber Seal
-----
r IMPORTANT 1
I End Seals must be 1
1 firmlysaatedwithin 1
I theassembly hous- I
ing.
L ----- i
E~8rvq30@
Pin
Retainer Plate (light orange)
rypical Illustration
The electrical connectors on this truck are equipped the end seals are seated flush with the end of the
with rubber seals to protect them from water and connector housing.
condensation. There is a seal at each end (wire end)
l The retainer plates snap into place to secure the
of the connector. The plug is equipped with a seal and
pins and their sockets.
retainer plate, see above. There is a pin retainer plate
in the socket sub-assembly. Check the plates for damage and security of
mounting.
l Check seals for damage that would make them
unfitforfurther service(cuts, etc.). Make certain
l Make certain connec-
tions are made as il-
Assemble Back -t lustrated or possible
electrical shorts and
component damage
TC-NEG. Cable l Ifanyconnectionsare

TC-NEG. Cable found to be loose, be
Steer Control Negative sure to torque them to
Wire 13C & 13D (Main Harness)
e 138 (Main Harness)
nections on the pump

motorandcontactorpanel
for damage and security
of mounting. Cables must
ue to: 100 lb. in.
Torque.yut to: 100 lb. in. -4 _\1

(11.3 N-m) ,
Guides and Markin!
IMPORTANT
Cables must be positioned so all tape markers
are aligned with or hidden under clamps or guides.
Cables mIlnt he rmltd ac chnwn
Dee 94 19-8-l 2 SM-587

l Inspect power cable connections on the drive motor and the contactor panel for damage and security of
mounting. Replace damaged parts. Tighten connections to the torque specified.
rorque Cable Mounting Nuts

to: 100 Ib.in. (11.3 Nom)
Cable (or) Wire Harness
IMPORTANT
Clamps must be
positioned so all
TAPE MARKERS
are aligned with
or hidden under
the clamps or
clamp guides.
Q../
/ Torque Motor Cable Fasteners
Cables must be routed as shown.
to: 150 Ib.in. (16.9 N-m)
19-B-l 3 Dee 94
- Rttrs Rar I ,<I
bsemble Front-to-Front
/sJ.. _ Pae,
-% TC-NEG. Cable
b (Pump Motor A)
c TC-NEG. Cable (BAT.NEG.)
_ TC-NEG.
7ack-to-Back
SC-POS. F
_ L hire 13C & 13D (Main Harness)
LTorque to: 100 lb. in. (11.3 Nom)
Control Panel 0
r.
Typical Illustration Cables must be installed as shown

. Inspect power cables on the control panel and security of mounting. Replace damage parts. Tighten
the power steering (aux.) motor for damage and connections to the torque specified.
Dee 94 19-8-14 SM-587

GROUP19 Periodic Electrical Checks
Assemble Front-to-Front
Assemble
A CAUTION
-% TC-NEG. Eable
(Pump Motor A) Cables, Wiring and Terminal
- TC-NEG. Cable (BAT.NEG.
Connections must beinstalled
as shown. If they are not, you
may experience electrical
hw- TC-NEG. Cable (Steer Control Neg.)
shorts and component
damage.
13C & 13D (Main Harness) CP-FU tF%

Wire 138 (Main Harness)
LTorque A
to: 100 lb. in. (11.3 Nom)
t
Inspect connections for

damage and security of
mounting. Replace dam-
aged parts.
Torque fasteners to speci-
fications listed.
Torque all connections to 100 lb.in\TC-NEG
(11.3 N*m)unless otherwise specified. (Bat. Neg.)
1r
Cables must be
routed as shown.
SM-587 19-8-l 5 Dee 94

Periodic Electrical Checks
GROUP 19
l Install truck battery. Refer to Group 12 for Tvoical Illustration
installation and safety instructions. Protective Cover
Cardboard or Plywood)
A WARNING
The battery contains corrosive
acid which can cause injury. If
acidcontactsyoureyesorskin,
flush immediately with water
and get medical assistance.
//
f
Do not smoke or allow open
flame near the battery.
Explosive gas is always
A& I
present around batteries.
l Install battery retainers.
I Battery
Retainer -
l Connect battery to truck receptacle.
El!!YRK
~;$ria\Handling
GROUP 19
Section 10
Oscillator Card Remove & Replace
/
J
SM-587 19-10-l Dee 94

GROUP 19 Oscillator Card
Truck Preparation
l Turn key switch OFF.
l Remove console cover.
l Discharge capacitors.
A
A
Removeall Jewelry before
working on truck. Always wear Safety Glasses
Dee 94 19-l o-2 SM-587

Oscillator Card R&R GROUP 19
Oscillator Card Removal
Disconnect Plugs
Disconnect PL-8 from SO-8.
Disconnect SO-10 fron n PL-10. Tilt and Auxiliary Switches
Disconnect SO-7 from PL-7.

Disconnect SO-9 from
so-9
PL-9
Remove Switch Actuator

l Remove Nut (A), see below.
l Pull Switch Actuator (l3) from
control and move downward on Bracket
the plastic wire looms. This is to
prevent component damage Switch Cam- 1
when pivoting control out of the
way.
l Remove Nuts (A) from control Fastener-
handle bracket, see above.
/I A
Switches
CAUTION
may be
II
damaged if the Switch UP (Lift) & Down (Lower)
Cam is not removed. Switches
Be very careful when
removing cam that you
do not damage the
switches.
SM-587 19-10-3 Dee 94

GROUP 19 Oscillator Card R&R
Remove Card Installation
l Using a 8 rnxn socket and a 6-inch extension, * Installation is the opposite of removal.
remove upper and lower mounting bolts secur-
ing card to panel.
l Disconnect plugs from card.
l Remove wiring from II3 l-TB6.
l Remove card from truck.
r Mounting Screew
TBl - TB6
- Mounting SC&w
Dee 94 19-l o-4 SM-587

El!!flRIC Wl;;;;;\Handling
GROUP 19
GROUP 19, Section 16
Solenoid Control Card Trouble Shooting
(Vol ta,oe Checks)
Voltage Data Sheet ..................... .. ..,.. .. .. .. .. ..... .. ., .. ... .. .. .. .. .. ... .. .. .... ... .. .. .. .. .. 19-16-2
RH5 Voltage Checks ............... ................. ..... ..................... ....... ................ 19- 16-3
RH4 Volatge Checks ............... ...... .. ... .. .. ., ... .. .. . ... .. .. ... ... . .. .. ..... .. .. . ... ... .. .. .. . 19-16-4
Indicator Lights (Leds)
It is normal for the indicator lights (leds) to flicker
when the different hydraulic switches are activated.
This does not indicate a problem. There is a problem,
however, when one or both lights illuminate with no
flicker (a solid glow). Refer to the procedures on the
Top View
SM-587 19-16-l Aug 94

GROUP 19 Trouble Shooting
-1OA Output 5011 Amp +lOA
Zero Ohms
: Common
Battery
Negative
n
Wire
arness
lo T.B.
indicator Lights (LEDS)

\ J
19-16-02 SM-587
Aug 94 19-l 6-2 SM-587

Trouble Shooting GROUP 19
NPR-345
Trouble Shooting Solenoid
Control Card
IMPORTANT
ItisnormalfortheIndicatorLights~EDs),seeoppositeillustration,
to flicker when any part of the hydraulic system is put into use.
This does not indicate a problem. There is a problem, however,
when one or both lights illuminate with no flicker.
All Hydraulic Functions Disabled:

Check Indicator Lights (RH4 & RHS)
1. Open door on Solenoid Control Card and check to see if the indicator lights (leds) are illuminated.
l Both Lights ON (RH4 & RH5)
If both lights are illimunitated, the Solenoid Card is defective and should be replaced with a new one.
l RH4 Light ON (Key Switch ON and all Hydraulic Switches Open.)
Checkforshorted switchorwire tocorosponding temlinal with avolt-ohm meter, seeopposite illustration.
Connect black (-) lead to ground and check each one of the following using red (+) meter lead [Meter
should be set on the 5OV +DC Scale):
Connect RED (+) to: Meter shoul read:
TBlO- wire#m ov If there is any voltage present
TBll- Wire#55 ov at any of these checks, there is a
short in the switch and/or wire.
TB12- Wire#65 ov
Repair or replace as required.
TB13- Wire#35 ov
TB14- Wire#5 ov
l RH5 Light ON (Key Switch ON and all Hydraulic Switches Open.)
Check for open solenoid or wires to corresponding terminals shown below:
TB3 - Wire #48 Battery Positive - 24 or 36 Volts
TB4 - Wire #38 Battery Positive - 24 or 36 Volts If voltage is other than specified
TB6 - Wire #18 Battery Positive - 24 or 36 Volts at any of these checks, the solenoid
is defective or there is a open in the
TB8 - Wire #28 Battery Positive - 24 or 36 Volts wiring. Repair or replace as re-
TB5 - Wire #58 *Battery Positive - 24 or 36 Volts quired.
*only when truck is equipped with side shift function.

Otherwise meter should register: - 0 Volts
- continued next page -
SM-587 19-16-3 Aug 94

- 13
- 48
SO// Amp +lOA

- 38
Zero Ohms
- 58
- 18
-26-
- 28
-2o-
SELECTOR nr nr - 45
Common
_ +
n1
- 55
._-
c
- -..-
- 65
B
_?A
Battery - 35
Negative -5-
- 10
Indicator Lights (LEDS)
Aug 94 19-l 6-4 SM-587

Trouble Shooting GROUP 19
Lift Function ONLY Disabled
(The remainder of the Hydraulic Functions should be operable.)

(Key Switch ON and all Hydraulic Switches Open.)
l RH5 Light ON
TB7 - Wire #26 10 to 12 Volts - Battery Charged indicating the Solenoid Card is receiving
BDI Signal from the EV-T15 Oscillator Card.
0 Volts means - Battery is below 80% Discharge and must be taken out of
service and fully charged or replaced if defective.
) RH4 & RH5 Lights OFF

TBl - Wire#13 Battery NEG. (0 V) Battery Charged
TB15 - Wire #lO Battery POS. (24 or 36 V)
When Installing a New Solenoid Control Card
Refer to the following page.
NPR-345
NEW SOLENOID CONTROL CARD INSTALLATION
When Installing a New Solenoid Control Card:

IMPORTANT
l Remove Jumper Plug JP2 ... if the truck is equipped with 2nd Auxiliary function.
See illustration below.
NOTICE
l If you have a truck without side shift function and the Jumper Plug JP2 is removed,
you will experience the following conditions:
-The hydraulic system will fail to function .. . there will be no hydraulics at all.
-The RI35 Indicator Light (LED) will be ON.
l If you have a truck equipped with side shift function and the Jumper Plug JP2 is in place, the
following conditions will exist:
-The monitoring function of the card for side shift solenoid circuit will not work.
-However, the side shift circuit will be operable.
Jumper Plug JP2 - Remove JP2 when truck is equipped

with Side Shift Function.
IMPORTANT
When replacing plug,
be certain it is installed
correctly as shown. -, \ NPR-345
against board.
Aug94 19-16-6 SM-587

CLqRIC
M$d$pk&Handling
GROUP 20
Section 20
Axle,
Articulartion Adjustment
Contents
Illustration . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .... . .. . .. .. .. . . ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 20-l-2
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . .. . . .. . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l-3
rC----- Mounting Block
Articulating Axle
GROUP 20 Axle
Dee 94 20-l-2 SM-587

Axle GROUP 20
Truck Preparation
1. Park truck on a flat level surface.
2. Retract and fully lower pantograph.
3. Place forks in forward tilt.
4. Turn key switch OFF.
5. Remove floor plate.
6. Open rear door.
NOTE
Batteryshouldbeinthetruckwhen
checking or adjusting axle
articulation.
\ Floor Plate /
Check Adjustment of Axle Stop

Bolts
1. Check clearance between stop bolt and axle at
Point A, refer to illustration on page 2.
l Clearancemay bechecked by using a 9/32twist
drill. The drill should just fit between the bolt
head and the top of the axle housing.
2. Check clearance at Point B using a 5/16twist
drill.
WI 6
If adjustment is required, loosen adjustor set
screw and rotate adjustor in direction necessary
to obtain proper adjustment. Tighten set screw
to secure stop bolt in the adjusted position.
SM-587 20-I-3 Dee 94

CLqRRlVl;~;;h\Handling GROUP 20
Section 2
Drive Unit
Contents
Lubrication ........................................................................................ 20-2-3
Removing the Top of the Gear Unit ................................................... 20-2-4
Dismantling the Housing Lid ............................................................. 20-24
Dismantling the Crown Gear and Wheel Shaft ................................... 20-2-5
Dismounting the Outer Race .............................................................. 20-2-5
Dismounting the Inner Race .............................................................. 20-2-5
Dismounting the Helical Spur Gear and the Conical Pinion Shaft.. ... ..20-2- 6
Mounting the Gear Unit - General Remarks ....................................... 20-2-7
Measuring the Assembly Dimension of the Conical Pinion Shaft ..... ..20-2- 8
Preassembly of the Conical Pinion Shaft ............................................ 20-2-8
Preassembly of the Wheel Shaft ......................................................... 20-2-g
Preassembly of the Wheel Shaft Bearing in the Housing ................... .20-2-g
Setting the Circumferential Backlash ............................................... 22-2-10
Checking the Tooth Pattern .............................................................. 22-2-10
Setting the Conical Pinion Shaft, Helical Gear, and Bearing Cle a. ....22-2-12
Mounting the Conical Pinion Shaft .................................................. 22-2- 12
Mounting the Wheel Shaft ............................................................... 22-2-14
Mounting the Housing Lid ............................................................... 22-2-16
Mounting the Top of the Gear Unit .................................................. 22-2- 17
Special Tools ................................................................................... 22-2-18
Drive Motor Removal
C=RnlIP
_.I__.
3fl
I_
Drive Unit
A WARNING
Wear eye protection and protective clothing when drying with air pressure.
Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can
cause injury.
Typical
Foot Pound
Pivoted
Torque Wrench
Pointer
Dee94 20-2-2 SM-587

Drive Unit GROUP 20
LUBRICATION Refer to the Lubrication Chart in Group 01 of this

manual. Fii unit to bottom of level plug opening with
First 500 Oueratiw Hours the drive unit in the vertical position.
Change oil after fust 500 hours of operation or ( 6 )
months , whichever comes first. INSTRUCTIONS FOR REPAIR
Fverv 2000 Oueratiw Hour3
General
After initial 500 hours, change oil after 2000 hours of
operation or once a year, whichever comes f?rst. Before disassembling the drive unit, drain the trans-
mission fluid.
Use AMOCO 1000 or equivalent.
l Place transmission on a clean work surface.
\ Seal
Drain Plug
Level Plus lbp3
SM-587 20-2-3 Dee 94

GROUP 20 Drive Unit
Dismantling the gear unit

Removing the top of the gear unit (300) from the basic gear unit (100).
1. Remove the screws (402/404/406). Loosen the top of the gear unit by tapping lightly (e.g., with a plastic
hammer) and lift it off.
Dismantling the housing lid (134).

1. Remove the screws (135), loosen the lid by tapping lightly, and lift off.
Drive Unit GROUP 20
Dismantling the crown gear (104) and wheel shaft (119)

1. Fasten special tool A (see page 18) with screws (135) to housing. If the conical pinion shaft (104) is
dismantled as well, it is recommended to loosen the hex nut (118) on the conical pinion shaft at the same
time (refer to dismounting the helical spur gear on the next page).
2. Hold the wheel shaft tight and remove the screw (129). Remove washer (128) with shims (130- 133) and
bind them together with a wire or the like.
NOTE
Surface X of the wheel shaft is used for setting the wheel shaft bearing and must not be
damaged.
3. Insert a g-mm diameter punch into the threaded hole of the wheel shaft and drive to dismantle the wheel
shaft.
4. The wheel bolts (120) can be removed by pressing them out when the wheel shaft is dismantled
5. Take the crown gear out of the gear unit.
Dismounting the outer race (122), shims (124-127), radial sealing ring (102).
1. Dismount the outer race (122 inside) by lightly tapping with a copper punch or the like. Make sum not to
damage the shims. Bind the outer race and the shims together with a wire or the like and place them with
the crown gear,
2. Pry out the sealing ring, dismount the outer race (122 outside) by lightly tapping with a copper punch or
the like, and place the outer race with the wheel shaft.
Dismantling the inner race.
1. The inner race should be dismantled only if the bearings am damaged and have to be replaced. If a new
wheel shaft or a new set of bevel gears is mounted, new bearings must be fitted.
2. To dismantle the inner race, cut open the bearing cage and extract the inner race via the small bearing collar
using the extractar.
SM-587 20-2-5 Dee 94

GROUP 20 Drive Unit
Dismounting the helical spur gear (201) and the conical pinion shaft (104).
1. Unscrew the hex nut, dismount the helical spur gear using the extractor, and drive out the conical pinion
shaft (e.g., using a copper punch).
2. Remove the top inner race (112) and place it with the helical spur gear. Press the lower inner race (105)
with spacer bushing (111) off the conical pinion shaft using the special tool B (see page 18) and place
them with the conical pinion shaft.
3. Dismount the top outer race (112) by lightly tapping with a copper punch or the like. Make sure not to
damage the shims (114-l 17). Bind the outer race and the shims together with a wire or the like and place
them with the inner race or the helical spur gear.
4. Dismount the bottom outer race (105) by lightly tapping with a copper punch or the like. Again make sure
nottodamagethe shims (107-l lO).Bindtheouterraceandtheshims togetherandplacethemwiththeinner
race or the conical pinion shaft and the spacer bushing.
Dee 94 20-2-6 SM-587

Drive Unit GROUP 20
Mounting the gear unit

General remarks
Before mounting the gear unit, the following points should be noted:
Clean all parts carefully and remove all traces of sealing compound.
Check all parts for wear, damage and cracks and replace them if necessary.
Hone the sealing surfaces with an oil stone or a smooth-cut file.
Wheel set components such as helical spur gears should be replaced in pairs, helical gears must be
replaced in pairs.
It is recommended to always replace seals and radial seal rings whenever repairs are made.
Cleaned anti-friction bearings should be lubricated before being mounted.
For sealing, use only elastic non-hardening sealing compound (e.g., Loctite 574).
SM-587 20-2-7 Dee 94

GROUP 20 Drive Unit
Mounting the basic gear unit (100)

Measuring the assembly dimension of the conical pinion shaft (104)
1. Insert special tool D (see page 19) into the bearing borehole of the housing and measure dimension F.
The housing dimension E is determined addcording to the following formula:
E=L-F+22.5
The thickness X of the shims (107-l 10) is calculated according to the following formula:
X=E-B-T
E = housing dimension
B = Assembly dimension of conical pinion shaft (marked)
T = Bearing width (105)
Pre-assembly of
1. Press the inner race (105) carefully with special tool C(see page 18) up to the limit stop.
Dee 94 20-2-8 SW587

Drive Unit GROUP 20
PI-e-assemblyof the wheel shaff (119)

1. Apply Loctite 242 to the knurled portion fo wheel bolt (120) and press into the holes providedon the flange
of the wheel shaft.
2. Rush the Nilos ring (121) onto the wheel shaft up to its stop at the flange.
3. Using special tool H (see page 20), press inner race (122) onto the wheel shaft up to the stop.
4. Grease the inner race of the taper roller bearing on the wheel shaft (cavities between rollers and cage and
between cage and Nilos ring; use Shell Alvania R3 or a grease of identical composition and specification).
Pre-assembly of wheel shaft bearing in the housing (101)
1. Apply Loctite 575 to the sealing ring (102) at its outside diameter and mount it using special tool E (see
page 19); the open side of the ring must point to the inside of the gear unit.
2. Applu Lock 242 to the Gamma ring (103) and press it onto the housing using special tool E (see page
19).
3. Insert the outer race (122 outside) into the housing and insert the outer race (122 inside) with shims (124
127) for the preliminary setting.
IIE"
@.
inside
SM-587 Dee 94
GROUP 20 Drive Unit
Setting the circumferentail backlash on the crown gear (104) and checking the tooth pattern
1. Press the inner race (122) onto the crown gear using the special tool H (see page 20).
2. Insert the crown gear (101) into the housing.
3. Push in the pre-assembled wheel shaft and use special tool J (see page 20) to pull together the crown
gear and the washer (128) until the bearing clearance is approximately zero.
4. For measuring the circumferential backlash at the crown gear, secure the conical pinion shaft against
turning, e.g., with a wooden wedge.
5. The circumferential backlash is corrected by adjusting with shims (124-127).
6. Admissible circumferentail backlash 0.1-O. 15 mm (0.004 - 0.006).
Checking the tooth pattern
NOTE
For checking the tooth pattern it is necessary to apply a thin coat of marking ink to 3-4 tooth
flanks of the crown gear.
1. Mesh the coated tooth flanks several times with the conical pinion. The pattern will show better if the
conical pinion is slightly braked while in mesh. Compare the pattern obtained with the Mounting
guideline below.
2. If a correction is necessary, its direction is indicated by the Mounting guideline.
3. Secure the hex nut (118) by staking. - ITY
Tooth pattern on the ring gear Correct pattern adjustment by

Defective patterns changing the mounting di- Setting instructions
Concave Flank 1 Convex Flank mensions in direction of arrow
Pattern at tip marked mounting dimen-
Pattern at root sions +_A a, and (.A, or

backlash S,). The mount-
ing dimensions may only
Note fig. 1 & 2
Dee 94 20-2-l 0 SM-587

Drive Unit GROUP 20
wooden wedge
circumferential backlash O.lOjO.15
SM-587 Dee 94
GROUP 20 Drive Unit
Setting the conical pinion shaft (KM), helical gear (201) and setting the bearing clearance
1. Position the shims (107- 110) according to instructions on page 8 and insert the outer race (105) into the
housing (101).
2. Insert the previously mounted conical pinion shaft.
3. Using the special tool F (see page 19), apply a light pre-stress to the conical pinion shaft via the housing
towards the stop.
Adjustment of bearing clearance.
1. The thickness of the top shims (114- 117) to be fitted can now be determined on the basis of the following
dimensions:
c= Distance between spacer bushing/conical pinion shaft and contact of outer race.
S= Distance between surface of outer race and surface of inner race.
NOTE
If the outer race is higher than the inner race (dimension as shown in detail Z), dimension X is determined
as follows:
Shim thickness X = C - S - 0.02
If the outer race is lower than the inner race, dimension X is determined as follows:
Shim thickness X = C + S - 0.02
2. Insert the shims and the top outerrace. Fit the inner race by tapping onto the pinion shaft using special tool
G(seepage19).Placethehelicalspurgear(201)ontotheconicalpinionshaftandscrewthehexnut(l18).
Hold the helical spur gear tight using the special tool (see illustration) and torque the nut to 60 + /- 5 Nom
(44+/- 3.7 ft-lb.). After checking the tooth pattern the shaft nut is locked by staking.
Checking the bearing clearance of the pinion shaft
1. Mark the measuring point on the helical spur gear with a grease pencil.
2. Press the conical pinion shaft downwards by hand, while turning it serveral times through approximately
180. Adjust the dial gauge to zero at the measuring point.
3. Pull the conical pinion shaft upwards via the helical spur gear, turning it as described above, and hold it
steady at the measuring point.
4. Read the bearing clearance off the dial gauge. Allowable clearance: O-0.05 mm (O-0.002).
NOTE
When taking this measurement it is important to turn the shaft several times so as to align
the rollers in the taper roller bearing.
Dee 94 20-2-l 2 SM-587

Drive Unit GROUP 20
detail ,. Z
Dee 94
GROUP 20 Drive Unit
Mounting the wheel shaft (119), crown gear (104), and setting the bearing clearance.
1. Use special tool J (see page 20) to pull together the mounted wheel shaft and crown via washer (128):
Torque to 10 Nom (7.4 ft-lb.) = approximately 5000 N bearing pm-stress
2. When doing so, turn the wheel shaft several times tin both directions to enable the bearing rollers to align
themselves.
3. Measure dimension Y via the hole of special tool J (see page 20).
4. Shim thiclcness X = Y - washer thickness of auxiliary unit.
5. Unscrew special tool J (see page 20) and remove.
6. Insert shims in accordance with dimension X.
7. Apply Loctite 242 to screw (129) and pull together the previously mounted wheel shaft and crown gear
via the washer (128). Tightening torque MA = 110 Nom (81 ft-lb.) +/- 10%.
NOTE
A direct check of the bearing pre-stress as not set is hardly possible. When checking
according to the measu.ring method described above, there should be no measurable bearing
clearance. Nevertheless, it should still be possible to rotate the wheel shaft easily by hand.
Dee 94 20-2-l 4 SM-587

Drive Unit GROUP 20
SM-587 20-2-l 5 Dee 94

GROUP 20 Drive Unit
Mounting the housing lid (134)

1. Coat the housing lid with loctite 574 and fit into position. Apply Loctite 242 to screws (135) and fasten.
Torque to 9.5 Nom (7 ft-lb.)
NOTE
If the basic gear unit is stored as an assembly group, e.g., for standby purposes, it should be
suitably protected against corrosion and be packaged accordingly.
Conservation can be carried out, e.g., by filling the unit with oil and draining it afterwards.
A closed plastic cover is sufficient to package the unit for storage.
Dee 94 20-2-l 6 SM-587

Drive Unit GROUP 20
Mounting the top of the gear unit (300)

Fitting the top of the gear unit to the basic gear unit (100)
1. Insert dowel pins (401) into the basic gear unit in such a way that they project from the sealing surface by
about 3 mm - l/8).
2. Coat the sealing surface of the top of the gear unit with Loctite 574 and place it onto the basic gear unit.
3. Screw in bolts (402 and 404).
4. Tighten bolts (402/406) with ti tightening torque of 23 N*m (17 ft-lb.).
5. Tighten bolts (404) with tightening torque of 46 N*m (34 f&lb.).
SM-587 Dee 94
GROUP 20 Drive Unit
SDecial Tool A
I 1 HFK 200 1 HFK 250/300 1 HFK 400/500 1
! A 1 180 I 210 I
B 167 178
C 152 165
0 46 65
E 1302 0.2 1692 0.2
F so,+s.z 4820.2
G 21 k3.2 42 20.2
1 H I 28 I 46 I
J I R90 R95
68 8
K 43
L 19 30
o( 7s I 7o
dent-h) 618 707 1 618 708 1 618 709 1
Special Tool B
HFK 200 HFK 250/300 HFK 400/500
Od 30-0.2 35.SQ.2 40.50.2
00 67.5 79.5 79.5
Jdcnt-Nr. 618 710 618 711 618 712
Special Tool C
HFK400/500
00
0d HFK
28.2200
23+O.2 f HFK 26'0.2
250/300 3oj;O.I 'F-F3
31.2 -2
L min. 95 170 17s
{dent-Nr. 618 713 618 7lL 618 715
Dee 94 20-2-I 8 SM-587

Drive Unit GROUP 20
Special Tool D
fl--L-?~
HFK 200 HFK 250/300 HFK 400/500
0D 46,5 51.5 63,5
L
Ident-Nr.
55
618.716
67.5
618.717
77s
618.718
Id _I&
W
Y
* rated dimension -<
II
-2 Actual dimension marked
on bushing
Special Tool E
pdent-Nr.1 618.722 1 618.723 1 618.724 ]
Special Tool F manufactured from

M 12 x L DIN 933 1779-1
Teil 1 Teil 2
,
Special Tool G
,
HFK 200 HFK250/300 HFK400/500
23-0.2 26+0.2 30.5'0.2 --.
0d
mm. L 35 35 35
Ident-Yr. 618.840 618.841 618.842
SM-587 20-2-l 9 Dee 94

GROUP 20 Drive Unit
Special Tool H
~1
l NennmaQ
Special Tool I
f7.2O.:
Special Tool J
hex nut
M 12 DIN 934
headless screw
M 12 55 DIN 939
Dec94
Drive Unit
GROUP 20
Special Tool K
HFK 300 HFK 400 1
0d 136 140
A 13.7+0,l 14,7+o;l
Ident-Nr. 450 685 450 688
28
Ir
max. 270
SM-587 20-2-21 Dee 94

GROUP 20 Drive Unit
DRIVE UNIT
-I--
303
407
408
304
402
Upper Half
Dee 94 20-2-22 SM-587

Drive Unit GROUP 20
SM-587 20-2-23 Dee 94

El!YRK
IVl~leri-i~Handling
GROUP 22
Section 22
Traction Wheel & Tire
Contents
Preparation ....................................................................................... .22-l-3
Illustrtion, exploded view .................................................................. 22-l-2
Pressing Tire .................................................................................... .22-l-3
Tracti
SM-587 22-l-l Dee 94

GROUP 22 Tires
Fastener
Tightening
Sequence
Tir
Wheel
Torque Fasteners
to:
124 - 139 Ib.ft.
(168 - 188 Nom)
Wheel & Tire A
Drive Unit
Dee 94 22-l -2 SM-587

Tires GROUP 22
Truck Preparation
4. Turn key switch OFF and disconnect truck
battery.
5. Elevate and block rear of truck.
6. Remove wheel fasteners
7. Remove wheel assembly.
- -_
_ of truck using
- - hardwood (oak)
blocks.
Replacing Traction Wheel Tire
1. A sleeve slightly smaller in diameter than the
wheel with a depth larger than the wheel should Press Direction
be used when pressing on a new tire, see oppo-
site illustration.
2. Install wheel fasteners and torque them to 124 - ~~~;~~~,~q :g#;:;:
......:.:+.
::::::::.:+:.
:::::::::::::::
;:{:;:;:$;:s:.
139 lb.ft. (168 - 188 N*m). Fasteners must be :::::::::::::::

:::::::::::::::
:::::::::::::::
.:.:.:.:.::::::
::::::::::+:.
v...: ,.... ,:
::::::::::::::: :K::.:::::::.
tightened using diagonal sequence shown in :::::::::::::::

:::::::::::::::
:::::::::::::::
.A..... . . .. . .
:F::::::::::;:
::::::::3>3
:::;::::,:.:.:,
:::::::::::::::
illustration on page 2. :::::::::::::::
;$$$g
:::::::::::::::
....y.:+:
:~$$:~:~:
press ~
:jjjjjjjjj
~
Old Tire
Table
SM-587 22-l-3 Dee94

CLSRKlflfx&$Handling GROUP 22
Section 2
Caster Wheel & Tire
Contents
Preparation ........................................................................................ 22-2-3
Illustrtion, exploded view .................................................................. 22-2-2
Pressing Tire ..................................................................................... 22-2-3
Bearing Adjustment Procedures ......................................................... 22-2-4
SM-587 22-2-l
GROUP 22 Tires
Refertoadjustmentprocedures and
torque specifications outlined on
Page 4 in this section.
Nut 1
Chamfer
Wheel & Tire Assembly
Dee 94 22-2-2 SM-587

Tires GROUP 22
Truck Preparation
4. Turn key switch OFF and disconnect truck
battery.
5. Elevate and block rear of truck.
6. Remove hub cap from caster wheel and loosen
nut.
7. Block the brake pedal in the down position to
release the caster brake.
8. Remove caster wheel assembly.
Replacing Caster Wheel Tire _ of truck using
1. A sleeve to fit wheeel as shown with a depth

larger than the wheel should be used when
pressing on a new tire, see opposite illustration.
2. The thin lipped section of the caster wheel must
be protected during handling and pressing. En- Press D,irection
sure that the tire is seated evenly on the wheel # 4
before starting to press.
3. Inspect bearings for further serviceability. If the
bearings areunfit for further service, they should
be replaced. Refer to Group 25 for overhaul
procedures.
4. If the bearings are fit for further service, then
install wheel assembly and adjust bearings as
outlined on the following page.
NOTE
Reused bearings should bewashed
in a non-flammable cleaning
solution and dried. New or cleaned
bearings must be carefully packed
with wheel beating grease prior to
reassembly.
SM-587 22-2-3 Dee 94

GROUP 22 Tires
Check Caster Wheel Bearings

Refer to Group 01 for proper lubrication.
IMPORTANT
Be sure the chamfer side of
nut is installed toward wheel
bearing. Refer to opposite
illustration.
Adjustment
l Spin wheel when torquing nut to specifications.
Chamfer To Face Inward
This is to insure proper seating of the wheel
bearings.
l Using a torque wrench and the special tool
shown below, torque the bearing nut to 300 lb.in.
(33.9 N*m) while spinning the wheel.
l Loosen nut and then retorque to 25 lb. in. (2.82
Nom) while spinning the wheel.
The wheel should spin freely, yet not have
more than 0.006 end play after adjustment.
l Tighten nut (do not loosen nut) to the first
available locking tab of the lock washer. Bend
lockwasher tab into nut slot to secure adjust-
ment. Install hub cap.
Special (Socket Type) Adapter
Applications:
Used to torque 24H Nuts.
May be purchased from
most engine or auto parts
stores.
Dee 94 22-2-4 SM-587

GROUP 23
Section 1
Brake, Motor
Contents
Motor Brake Service.. ....................................................................... .23-l-2
Brake Adjustment.. ........................................................................... .23-l-5
Final Brake Adjustment Specifications ............................................. .23- 1-8
Caster Brake (Refer to) ..................................................................... 23-2- 1
Brake Bleeding Procedures (Refer to) ................................................ 23-3- 1
Brake Pedal Check and Adjustment (Refer to) ................................... 23-4- 1
Brake System
The brake system consists of a brake mounted on top of the drive motor and a brake mounted in the caster wheel
assembly. Both brakes are spring applied and hydraulically released by a brake pedal and two master cylinders.
The caster brake service procedures are covered in Section 2 of this manual. Brake Bleeding Procedure is
covered in Section 3 and Brake Pedal Check and Adjustment Procedure is covered in Section 4 of this manual.
Drive Motor
SM-587
Brakes
GROUP 23
Motor Brake Service
Brake Pressure
A! CAUTION
Park truck on a level surface
and chock wheels.
NOTE
only be necessary to do the
It will
if
following two steps thecomplete
brake assembly is to be removed
l Disconnect wiring from brake pressure switch.

l Move wiring where it will not be damaged upon
removal of the brake drum.
NOTE
On 24 Volt models it is necessary
to perform the following two steps
to allow brake drum removal.
Loosen clamp (A) and pull hose (B) downward

approximately 1 - inch on pump elbow.
Tighten clamp (A).
l Remove brake drum nut from motor shaft.
23-1-2 SM-587
Brakes GROUP 23
. Depress brake pedal and place a block on the

pedal to retain it in the down position. Doing so
will release brake shoe pressure against the
brake drum.
l Now lift brake drum from motor shaft and brake

assembly.
l Bring drum to a vertical position and remove it
as shown here.
GROUP 23 Brakes
If brake assembly is to be serviced in the truck:

l Replace old shoes and spring with new ones as
required times.
If the brake assembly had to be removed from the
truck for service, then complete the following
steps. IMPORTANT
Ao~lv Anti-Seize. Cla
l Locate assembly onto drive motor as shown P&t No. 1802307 tb motor
below. Apply general Purpose Threadlocker, shaft, bore and threads
before assembling drum
Clark Part No. 1802300 to the mounting bolt
nut.
threads and install bolts finger tight. Tighten
Torque nut to:
bolts to soecifications using the diagonal se- 170 - 190 Nom
quence (A thru D) shown below. (125140 Ibf.ft.)
l Replace old shoes and springs with new ones as
required.
NOTE
Prior toinstally brake drum, check
brake cylinder mounting bolts for
proper torque.
l Apply Anti-Seize, Clark Part No. 1802307 to l Reconnect pressure switch wiring
motor shaft, bore and threads. Now install the l Replace hydraulic hose and retighten.
drum, key andnut. Torque to specification shown
above. l Release pedal and remove blocking.
IMPORTANT Install bolts using General Purpose

Torque bolts to:
Threadlocker, Clark Part No. 18Oi300
20 - 25 Nom 1
w v
to bolt threads.
(177 - 221 Ibf. in.)
Torque bolts to:
20-25 Nom (177-221 Ibf. in.)
Drive Motor
Dee 94 23-1-4
SM-587
Brakes GROUP 23
Brake Adjustment l Loosen and back-off jam nut (1) freeing brake
arm, see below.
Step 1
l Loosen nuts (2 & 3). Rotate them inward several
l Pull boot from cylinder exposing the cylinder turns. Now loosen nut (4) releasing spring pres-
piston and rod end, see below. sure.
Step 2
l Rotate actuating rod counterclockwise while l Now depress brake pedal several times to move
holding nuts (1,2, 3 & 4). Rotate rod outward piston outward until it is flush with housing
until piston is fully released (there must be some l Pedal will become very firm. Do not force pedal
gap between rod end and piston). Brake are must down. While holding light pressure on pedal,
be fleeto move in either direction. loosen bleeder to allow pedal to be depressed to
IMPORTANT the floor. Do not release brake pedal. Tighten
The brakearm must beallowed bleeder.
to float until adjustment is
made.
SM-587 23-1-5 Dee 94

GROUP 23 Brakes
Step 3 . Measure amount of rod protruding beyond the

back of the plate as shown below.
l Now, while holding nuts (2 thru 4) screw rod
clockwiseuntilitjust touches thecylinderpiston. l Release brake pedal.
You can do this visually or by feel. . Now, screw rod inward l/4 of an inch while
holding nut (4). This willmove thepistoninward
l/4 of an inch.
Step 4 l Next, tighten nut (2) against arm ... finger tight.
l Next, install the boot. l Using two wrenches, securely tighten both nuts
0 While holding arm in neutral (brake released), with&t moving brake are &t-of neutral.
tighten nut (1) against arm . .. finger tight.
Secure Adjustment
Tvnienl llhxtratinn
23-1-6 SM-587
Brakes GROUP 23
Step 5
l Fkeload brake spring. Tighten nut (4) against the
spring washer, as shown, until spring length is
44.5 mm (l-3/4). Measurement should be taken
from the inside of spring washer to inside of
spring washer as shown below.
Step 6
l Using two wrenches, tighten jam nut (3) while
holding nut (4) to secure adjustment. Make
certain jam nut is tightened securely without
disturbing the spring preload adjustment.
SM-587
GROUP 23 Brakes
Brake
Pressure Spring
Final
Adjustment Specification
Cooling Plate must

in place at all times
I to provide required
Drive Motor
El!!RKM$&ri;\Handling GROUP 23
Section 2
Caster Brake
Contents
Truck Preparation . .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .... . ... .. .. .. .. .. .. .. .. . .. .. .. . .. .. .. .. . 23-2-2
Service Procedure . .. .. .. .. .. .. .. .. .. .. .. .. . ... .. . . .... . . .. .. .. .. .. .. .. .. .. .. .. . . .. ... . .. .. .. .. . 23-2-2
Slave Cylinder Remove & Replace . .. .. ... . .... .. .. . . .. .. .. .. .. .. .. .. . ... ... . .. .. .. .. . 23-2-5
Brake Backing Plate Remove & Replace . .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 23-2-5
Brake Arm and Brake Shoe Installation . .. .. .. .. .. . .. .. . ... . .. .. .. .. .. ...I.......... 23-2-6
Caster Wheel Brake Linkage Installation ,.......................................... 23-2-7
Caster Brake Adjustment . .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. 23-2-8
Bleeding Brake System (Refer to) . .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. . 23-3-l
Brake Pedal Check and Adjustments (Refer to) . .. .. . ... .. .. .. .. .. .. .. .. . . .. .. .. . 23-4- 1
Brake System
The brake system consists of a brake mounted on top of the drive motor and a brake mounted in the caster
wheel assembly. Both brakes are spring applied and hydraulically released by a brake pedal and two master
cylinders. The motor brake service procedures are covered in Section 1 of this manual. Brake Bleeding
Procedure is covered in Section 3 and Brake Pedal Check and Adjustment Procedure is covered in Section
4 of this manual..
Caster Assembly
SM-587 23-2-l Dee 94

Brakes
GROUP 23
Caster Brake Service
Truck Preparation
l To service the caster brake, the truck should be
elevated so the caster wheel just clears the floor.
This allows rotation of the caster providing
access to each side of the assembly.
l Elevate rear of truck farenough to allow rotation
of the caster assembly.
l Place oak blocks beneath frame (as shown) on
each side of truck. Typical Illustration
Block Truck 2-inches off floor.
Remove Access Cover

l Remove two bolts and cover from caster assem-
bly.
Brake Spring
Release spring application pressure and remove
spring.
Loosen and back off jam nut (1).
Slowly rotate nut (2) away from the spring until
thecasterwheelis free torotate. Remove nut and
spring.
Caster Assembly
ypical Illustration
Dee 94 23-2-2 SM-587

Brakes GROUP 23
Disconnect Rods & Remove Brake Arm

2. Remove retainer pins and clips (1) securing the
spring and slave cylinderrod to the brake arm.
3. Remove clip lock (2), loosen brake arm clamp-
ing bolt (3) and remove brake arm.
Adjusting for Lining Wear

When to Replace Brake Linings
As brake Iiningswear, the brake arm will move
inward toward the caster weldment. When the
armiswithin3/16ofaninchfi-omthisweldment,
move arm 1-spline away from weldment.
IMPORTANT: This adjustment may be made
a maximum of four (4) times. When the brake
arm reaches the 3/16 measurement a fifth time,
install new brake linings.
Brake Brake Arm
Expose Brake Assembly

4. Remove caster wheel exposing the brake assem-
bly. The brake assembly does not have to be
removed to replace the brake shoes.
SM-587 23-2-3 Dee 94

GROUP 23 Brakes
5. Remove old brake shoes.
Spring
@ ~ -y;
f$$s
I
Retainer
Ring
c
6. Remove shoe actuating shaft. Clean the shaft

and bore in backing plate.
NOTE
Go to Step 7 if the Slave Cylinder
or Brake Backing Plate does not
require service.
SM-587
Brakes GROUP 23
SLAVE CYLINDER
If the cylinder needs to be replaced:

Disconnect brake line fitting at cylinder.
Loosen and remove cylinder mounting bolts.
Remove slave cylinder.
Remove cylinder push rod fkom cylinder.
Replace cylinder with a new one.
Tightenmountingboltsfingertight.Donot torque
bolts at this time.
Connect brake line fitting.
1 Tightening Sequence
BRAKE BACKING PLATE
If the brake assembly was removed:

Install the backing plate (less brake shoes) align-
ing bolt holes in plate with those in the caster
housing.
Install the six mounting bolts using General
PurposeLockthreader,ClarkPart No. 1802300
on bolt threads.
Tighten the bolts to a torque of 240-300 lbs. in.
Bolts must be tightened in the sequence shown
here.
SM-587 23-2-5 Dee 94

GROUP 23 Brakes
7. Sparingly grease the cam shaft and bore with

Moly grease.
8. Install cam shaft through bore.
9. Install brake shoes.
Brake Shoe & Lining
&+* Clip Lock

10. With brake arm held parallel to weldment, move

arm 1-spline away from weldment as shown.
Move Arm
1-Spline as shown
l Install clip lock over arm and onto cam shaft.
l Secure arm to shaft with clamping lock bolt.
Dee 94 23-2-6 SM-587

Brakes GROUP 23
11. Install caster wheel

. Replace shaft seal with a new one.
. Repack wheel bearings with lubricant recom-
mended in GROUP 01.
. Install wheel being careful not to damage seal.
. Install bearing locking washers and nut lock
over shaft. Install chamfer toward wheel.
. Tighten nut lock to the first available locking
tab. lock in place using tabs on lo&washer.
12. Install spring and cylinder rods to brake arm and

secure with retaining pins and clips.
SM-587 23-2-7 Dee 94

GROUP 23
13. Align push rod and slave cylinder.

l Rod and cylinder must be parallel with one
another. Loosen mounting bolts and locate cyl-
inder so it is absolutely parallel with the push
rod. The tighten bolts finger tight.
l Now, torque bolts to 240 - 300 lb. in. without
moving cylinder and rod out of alignment.
14. Adjust brake spring length.

l Using wrench, thrn nut (1) against washer until
2-l/4 (57.2 mm) can be measured between
inside of one washer to the inside of opposite
washer.
l After obtaining correct spring adjustment, use a
second wrench and tighten jam nut (2) against
nut (1) without disturbing spring adjustment.
Dee 94 23-2-8 SM-587

Brakes GROUP 23
15. Install cover and secure with the two bolts

previously removed
NOTE
Check brake pedal up-height for
correct adjustment.Refer to section
4.
Typical
SM-587 23-2-9
Cl!!lRK
Material Handling
Company GROUP 23
Section 3
Brake Bleeding Procedure
Contents
Bleeding the Brake ............... ............................ ........ .................. ....... 23-3-2
Brake System
Bleeder Screw - Bleeder Screw
Drive Motor
NOTE
&!.?a
:3
-3, It is not necessary to remove

3 i;
-- the cover to bleed the caster
\ /
\ :> -- / brake.
c:
--
SM-587 23-3-l Dee 94

GROUP 23 Brakes
Pump Brake Pedal
Keep Reservoir
* Master Cylinder(s) filled wi ith fluid.
Bleeder Valves
SlavXylinder
(Caster Brake)
Bleeding Brake System

Manual Method (as illustrated) l Repeat above (checking reservoir fluid level
Fill the brake reservoir full of brake fluid. Keep full frequently) until air bubbles cease to appear in
during bleeding operation. the glass jar.
l Wipe bleeder valve(s) with a clean cloth. Be l Go to the next cylinder and bleed in the same
sure debris is removed prior to attaching a manner described. Once the system has been
bleeder hose to the valve. bled, check the brake reservoir to be sure it is
full.
l Using a brake line hose (or a clear plastic
hose), place one end over the bleeder valve of IMPORTANT
the cylinder to be bled. Place opposite end of Check to be sure the brakes release when the pedal
hose into a clean, glass jar filled part way with is depressed. If they do not, then the pedal up height
brake fluid. Be sure end of hose remains should be adjusted. Refer to Group 23, Section 4.
submerged in brake fluid during bleeding
operation or air will be drawn into the brake Pressure Bleeder Method
system during the bleeding operation. Empty reservoir to l/4 full. Attach pressure bleeder
l Depress andrelease brake pedal several times. to motor brake bleeder valve. Turn on pressure
On the last stroke, hold pedal in the down bleeder. Open bleeder valve. Let fluid flow into
position, open the bleeder valve allowing air reservoir until it is nearly full. Shut off bleeder
to escape into the jar of fluid. Close bleeder. valve. Shut off pressure bleeder. Repeat at caster
brake bleeder valve.
Dee 94 23-3-2 SM-587

Cl!lRK
$at&rfi\Handling
GROUP 23
Section 4
Brake Pedal Adjustment
Contents
Brake Pedal Check and Adjustments . . ... .. .. . ... . ... .... . . .. .. .. .. .. .. .. . .. . .. .. .. .. . 23-4-2
* Master Cylinder(s)
SM-587 23-4-l Dee 94

GROUP 23 Caster Brake
Brake System
Pedal Up-Height Adjustment
rBrake Pedal
Measure the distance between the floor plate
and the bottom edge of the brake pedal as shown
below.
If measurement is not as specified, then an
adjustment should be made at the brake master
cylinder(s). See opposite illustration.
Adjusting Pedal Up-Height
l Using two wrenches, hold piston rod(s) and
loosen jam nut(s). Rotate piston rod(s) until
correct adjustment is accomplished.
l Tighten jam nut after making adjustment.
IMPORTANT
Be absolutely certain that both cylinders are ad-
justed evenly. Check by lifting pedal full up and
individually check piston for even tension. If one is / Master Cylinder
loose, adjustment is not even. Correct adjustment as
required. Again, be certain to secure adjustment with
jam nut(s).
ADJUSTING
NOTE
Checkthat both brakesrelease with PEDAL UP-HEIGHT
pedal down. If not, further brake
pedal height adjustment may be
necessary.
MEASURING -Pedal Up-Height
PEDAL UP-HEIGHT 112.5 mm (4-7/l 6)

to
114.0 mm (4-l/2)
Floor
Plate
* Master Cylinder(s)
Dee 94 23-4-2 SM-587

WIRU lVi;$Dri;/Handling
GROUP 26
Section 1
Hydraulic Pressure Checks
Lift, Steering, Auxiliary, Reach & Tilt
Side Shift (if so equipped)
NPR-345
Remove Cover
for access
to:
Press4 re
Check
Connections
Fork
Open Door
for access
to Auxiliary
Pump Relief
Valve
SM-587 26-l -1 Dee 94

GROUP 26 Hydraulic Pressure Checks
Test Port 1
l Auxiliary, Reach &Tilt, Steering and Side Shift
(if so equipped) pressure test port.
Test Port 2
l Refer to Group 30 for Lift Circuit Relief Valve
check and adjustment procedures.
IMPORTANT: Check system pressure with the
hydraulic fluid at operating temperature ...
110 to 130F.
(Clark Part No. 1800106)
HYDRAULIC PRESSURE CHECKS be checked with a Mica Quudrigage or with a

conventional pressure gauge having a scale of
0 to 3OOOpsi.
Check Relief Valve Setting for the
Auxiliary, Reach, Tilt, Steering and 5. Attach adaptor to test port #l.
Side Shift (if so equipped) Circuits. 6. Turn key switch ON.
NOTE 7. System relief setting may be checked by actu-
The therelief valve for these circuits is located in the ating the Multi-Function Control to place the
auxiliary pump. Refer to illustration on Page 3. pantograph forks in full reach, tilt, or side shift
(if so equipped) position. Hold control in the
1. Open truck door.
fully actuated position. When the system oper-
2. Remove console cover. ates over relief, immediately read the pressure
3. Remove cap from test port #l, see above. gauge and then release control. Do not operate
system over relief any longer than it takes to
4. Connect Adaptor (see above) to pressure gauge. read the pressure gauge.
Notice: The hydraulic relief valve setting may
Dee 94 26-l-2 SM-587

Hydraulic Pressure Checks GROUP 26
Relief Valve Adjustment
If adjustment is required, follow the procedures listed here. If adjustment is not required go to Step 3.
1. Remove cap covering the adjustor.
2. Rotate adjustor CLOCKWISE to increase pressure and COUNTERCLOCKWISE to decrease
pressure.
Adjust the relief valve to operate between 1550 and 1650 psi. Once adjustment has been attained,
install and securely tighten cap to secure adjustment.
3. Install console cover and close door.
NOTE
Relief valve(s) are factory preset
and shouldnotrequire adjustment.
However, if adjustment is required,
do not exceed specified setting.
elief Valve Sub-Assembly
Spring(s)
I
Relief Valve Configura-

tion may vary with pumps.
Auxiliary Pump
SM-587
GROUP 26 Hydraulic Pressure Checks
Test Port 1
l Refer to Group 26 for Auxiliary, Reach & Til
Steering and Side Shift (if so equipped) pressur
check and adjustment procedure.
Port 2
Lift Circuit pressure test port.
IMPORTANT: Check system pressure with th
hydraulic fluid at operating temperature:
110 to 130 F.
HYDRAULIC PRESSURE CHECKS 5. Attach adaptor to test port #2.

6. Turn key switch ON.
Check Lift Control Circuit Relief Valve
7. Move the Multi-Function Control to elevate
Setting.
upright to full maximum lift. Hold control in the
NOTE fully actuated position. When the system oper-
The relief valve is located at the top/rear of the lift ates over relief, immediately read the pressure
control valve. Refer to illustration on Page 3. gauge and then release control. Do not operate
system over relief any longer than it takes to
1. Open door.
read the pressure gauge. Turn key switch
2. Remove console cover. OFF.
3. Remove cap from test port #2, see above. If adjustment is required, refer to the adjustment
4. Connect adaptor (see above) to pressure gauge. procedures next page.
The hydraulicreliefvalvesetting may be checked If adjustment is correct, refer to S tep 6 next page.
with a Mica Quadrigage or with a conventional
pressure gauge haveing a scale of 0 to 3000 psi.
Dee 94 26-l-4 SM-587

Hydraulic Pressure Checks GROUP 26
Relief Valve Adjustment
1. Loosen lock nut securing the adjustor (see below).
2. Rotate adjustor CLOCKWISE to increase pressure and COUNTERCLOCKWISE to decrease
pressure.
Adjust the relief valve to operate between 2650 and 2750 psi.
4. Once adjustment has been attained, turn key switch OFF.
5. Now, using two wrenches, hold adjustor and tighten lock nut to secure adjustment.
6. Install console cover and close door.
NOTE
Relief valve(s) are factory preset
and should not require adjustment.
However, if adjustment is required,
do not exceed specified setting.
Adjustor -1
SM-587 26-l-5 Dee 94

Material Handling
CORK Company GROUP 29
Section 1
Hydraulic Sump Tank
Filter and Strainer
Drain, Clean and Refill
NPR-345
Open rear door to expose sump tank
SM-587 29-i-l Dee 94

GROUP 29 Hydraulic System
A WARNING
Hydraulic fluid is toxic to skin,
eyes, and respiratory tract.
Good ventilation is normally
adequate.
A CAUTION
Cleanliness is of extreme
importance. Before dis-
connecting the hydraulic
components, clean exterior of
plumbing and solenoid valve
to prevent dirt and foreign
matter from entering hydraulic
system.
A WARNING
When usina air pressure to clean off truck:
cause injury.
Removeall Jewelry
before working on
truck.
Always Wear
Safety
Glasses
Dee 94 29-l -2 SM-587

Hydraulic System GROUP 29
HYDRAULIC SYSTEM SERVICE
Drain Hydraulic Sump Tank

IMPORTANT
All cylinders should be fully
retracted. Be sure:
. Truck is on alevel surface. Set the parking brake.
Place chocks to the front and rear surfaces of the
tires to provide restraint from inadvertent ve-
hicle movement.
. Upright is fully lowered and pantograph re-
tracted.
. Forks are in full forward tilt and the side shifter
(if so equipped) is shifted fully to the right.
. Power key switch is OFF. (Key should be re-
moved from switch.)
1. Loosen and pull hose clamp downward on hose,
see opposite illustration.
2. Place a shop cloth behind hose and fitting. Pull
hose free of fitting using the cloth to retard fluid
leakage.
A CAUTION
Protect drive motor and brake
assembly from any oil spill.
3. Place end of hose into a 10 gallon container and

allow the sump tank to drain. Sump capacity is
approximately 8 gallons.
10 Gallon Capacity
SM-587 29-l -3 Dee 94

4. Place a clean plastic parts bag over end of hose.
. Secure bag with hose clamp.
. Tie hose to filter mounting bracket so it is out of
the way.
5. Place a container beneath hose and tube (18~ 2).

Loosen hose clamp (4).
Pull hose free of tube (5).
Place end of hose into container and allow fluid
to drain.
. Loosen clamp (3) and pull hose free of sump
outlet allowing remainder of fluid to drain from
sump tank.
. Loosen clamp (6) and pull hose from pump
fitting.
. Set tube with hoses andfittings to one side. Place
clean plasticparts bagsover hose ends to prevent
dirt from entering hoses and tubes.
Dee 94 29-1-4 SM587

6. Remove strainer (7) from sump outlet and allow
remainder of fluid to completely drain from
sump tank.
7. Remove fill breather cap and strainer from sump

filler tube.
8. Flush sump tank with two or three quarts of
hydraulic fluid.
. Remove pan and dispose of used fluid in ap-
proved manner.
9. Wash both tank strainers in a Stoddard type
cleaning solvent and allow to air dry.
10. Inspect breather cap for further serviceability.
11. Install strainers, hydraulic tube and lines.
. Secure hoses with clamps.
SM587 29-l-5
Using a filter wrench or a strap wrench, loosen

and remove the spin-on type filter cartridge.
Check Ground
Discard old cartridge and gasket. Wire to be sure it
13. Clean gasket surface on the filter base, see white

arrows.
14. Apply a light film of fluid to the new gasket.
. Locate gasket on cartridge as shown.
15. Install cartridge to filter base. Hand tighten until
gasket is seated.
. Then Tighten l/2 to 3/4 additional turn.
16. Fill hydraulic sump tank with hydraulic fluid
recommended in Group 01.
. Check fluid level as outlined on the following
page.
Dee 94 29-l -6 SM587

Check Sump Tank Fluid Level
IMPORTANT
All cylinders should be fully reacted. Be sure:

l Upright is fully lowered.
l Forks are in full forward tilt.
l If so equipped, side shifter is shifted fully to the
right.
Multi-Function
Control Handle
Refer to Group 01
for recommended
Hydraulic Fluid(s).
l Fluid level should be at the full mark on the

sump tank. If it is not, add fluid until it is. Use
Hydraulic Fluid recommended in Group 0 1.
l Purge air from the hydraulic system. Operate
the hydraulic controls through their cycle sev-
eral times forcing air from the lines into the
sump tank.
l Check sump fluid level again. Add fluid as
necessary to bring fluid level to the full mark on
the sump tank.
SM587 29-l-7 Dee 94

El!BRIC Material Handling
company
GROUP 29
Section 2
Hydraulic Schematic
NPR-345
w Typical Illustration
29-2-l Aug 93
Hydraulic Schematic
----_-__1 P
-v-e
1 i _
I 2gfi$s
A
I
( valve
I
~----------~--
i
I_ _s_-____
-4
Aux Control
I- L
T
2 1
Al IS
vl Lift
3
Sl
Front Buikhead LGzo

Plate of Truck
ReachIIin
Selector Valve
Reach Cylinders I I
r-i------iLz----F_l____;
mli2Y!~
b---a
I
-------
I Lift inder
i!l
:
:
L Flay ?!. imiter
I valves
:
I-
Mateftal Handling Co. NPR 150,17, 20,

Copyrighted Material -
GROUP 29
Section 4
Hydraulic Pump Overhaul
Contents
Disassembly ..................................................................................... .29-4-3
Parts Inspection ................................................................................ .29-4-3
Reassembly ...................................................................................... .29-4-5
SM-587
GROUP 29 Hydaulic Pump
Outlet
Do Not Force Seal

I
below-- surface
-_-_ --- --__
Bronze Face Torward Gears --(6)
High Pressure Side
Pressure Loading Seal (15)
Wear Plate (8) Dow Pin (7) Wasf7er (2)

-Bolt (1)
-Seal (5)
Dee94 29-4-2
Copyrighted Material SM-587
Hydraulic Pump GROUP 29
DISASSEMBLY l An alternate method of removing the rear cover
is to pry simultaneously with two large screw-
Preparation for Disassembly drivers in the relieved areas between body and
cover.
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
A CAUTION
in leakage or premature failure of the pump. At no timeshould screwdrivers
be inserted further into pump
body more than the depth of
Pump Disassembly the relieved areas. Any burr
NOTE must be removed from the
Allreferencenumbersrefertoitems body (14) and/or cover (3) after
thisoperationtoassureagood
illustrated in the illustrations on
seal between body and cover.
the opposite page.
4. Holding shaft end down, remove rear cover (3).
1. Clean outside of pump in a S toddard type clean-
Dowel pins (7) may remain either with the body
ing solvent and dry thoroughly.
or with the rear cover.
2. On models with splined drive shaft, proceed to
NOTE
Step 3. On models with keyed drive shaft,
Cover seal (5) and thrust plate (6)
remove drive key (11) from drive shaft. Using a
may or may not remain with rear
file or stone, remove any burrs from shaft end or
cover. Should they remain with
key way.
the body, remove seal and lift out
NOTE thrust plate before proceeding.
During disassembly, take special
note of the wear patterns on the 5. Lift out driven gear (13), drive gear (12), and
wear plate (8), thrust plate (6) and wear plate (8).
body (14). The large port in the 6. Invert pump body with shaft seal up. Remove
rearcover (34) always corresponds shaft seal (10) by prying it out with a large
to the inlet side of the pump. The screwdriver.
inlet side can be further identified
by the gear contact pattern in the .A CAUTION
body (gear) bore. The wear plate Care should be taken not to
(8) will have a somewhat heavier damage (gouge) the shaft seal
wear pattern on the inlet side. The bore, because this will result
thrust plate (6) will also have a in shaft seal leakage.
pattern than can be established for
reassembly. Also note that the long Parts Inspection
journal of the driven gear (13) is
toward the front of the pump. 1. Wash all parts and dry thoroughly with a clean
lint free cloth.
3. Separate rear cover (3) Ii-om body (14) by sup-
2. Inspect wear plate (8) and thrust plate (6). Re-
portingpump,shaftendup,onmountingflanges
place if scoring or uneven wear is observed.
andpressing on drive shaft end in arbor press, or
tap drive shaft with a plastic mallet. Use one NOTE
hand tosupport rear cover from underneath, Somewhat heavier wear pattern is normal on the
since cover and internal parts will drop sud- lowpressure (inlet) side of the plates (6 & 8). How-
denly when dowels are disengaged. ever, there should be no heavy scoring in this area.
SM-587 29-4-3 Dee94

GROUP 29 Hydaulic Pump
Do Not Force Seal ;

Gear Face below surface ;
(:3C)
a II
Bronze Face Tot-ward Gears --(6)
High Pressure Side
Pressure Loading Seal (15)
Wear Plate (8) Dow Pjn (7)

-Bolt (1)
Seal (5)
SM-587
Hydraulic Pump GROUP 29
3. Remove pressure loading seal (15) and seal (9) 2. Invert body so that gear boresare up. Install wear
from wear plate. The seals may be two-piece or plate (8) in bottom of bore, making sure that
one-piece design. In either case, discard old seal pressure loading seals (9 & 15) are positioned
or seals. All replacement seals are two-piece properly in seal grooves and installed against
design and should be installed into groove. See bottom of bore surface. Ensure outside of w
circled view in exploded parts illustration on seal is exposed to the discharge pressure. (Or
opposite page. The seal should extend a mini- legs of W seal pointing toward the suction
mum of 0.005 (0.127 mm) beyond surface of PO@.
wearplate. Do not push seals below wear plate
3. Lubricate the bushings in body (14) and wear
surface at any point.
plate (8) with SAE 10 engine oil.
4. Inspect bushings in body and cover. Replace
4. Apply Lubriplate or equivalent to outer surface
cover or body if bushings are heavily scored or
of drive shaft in installation sleeve. (Sleeve I.D.
burned.
should be slightly larger than the O.D. of the
5. Inspect gear journals and faces. Replace if faces shaft.)
or journals are scored or worn.
5. Lubricate rear gear faces and journals with S AE
6. Inspect body for wear and scoring. If gear con- 10 engine oil and install thrust plate (6) in its
tact wear on low pressure side (inlet) exceeds original position, bronze face toward the gears.
0.005 (0.127 mm) depth, replace body. If the
6. Apply a small amount of grease to rear cover
body is usable lightly remove/wipe burr with
seal (5) and install seal into groove.
suitable de-burring tool.
7. Lubricate bushings in rear cover (3) with SAE
Pump Reassembly 10 engine oil.
Cleanliness is of extreme importance. Prevent dirt 8. Position pump with shaft end down. Match
or foreign matter from entering hydraulic system. scribe marks on cover and body and install
cover.
1. Place body (14) on flat plate with shaft seal bore
up. Install new shaft seal (10). Press seal into 9. Install cap screws (1) and washers (2) finger
bore until it is to approximate depth shown tight. Torque bolts to: 34 - 38 lb.ft.
below. (The outside diameter of the sleeve should 10. On models equipped with keyed drive shaft,
be slightly smaller the outside diameter of the install drive key (11).
shaft seal.)
11. Check that drive shaft turns with adjustable
l Pack the area between the double lip of the seal wrench without evidence of mechanical bind.
with Lubriplate or equivalent grease.
*Sleeve wall thickness should be
approximately 0.25 mm (0.010).
rShaft Seal
-ing
.ess I-Mounting Face Bear ..-J--j\
-J
\
/&_JGearlShaft
-+
.. . ..V.C_ Installation
*Sleeve
-_Ekl.52 mm (l/l 6)
Figure 1 Figure 2 Figure 3
SM-587 29-4-5 Dee94

CUIRK~;~pri-i~Handling GROUP 30
Section 1
Hydraulic Control Valves
and
Solenoid Control Valves
Remove & Replace
Contents
Truck Preparation . .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. . ... .. .... .. . . .. .. .. .. .. .. .. . .. . .. .. .. .. . 30-l-2
Control Linkage . . . ., . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30- l-5
Removal of Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30- l-6
Lift, Auxiliary, Reach & Tilt Control Valves . .. .. .. .. .. .. .. .. . ... . . .. .. .. .. .. . ... . 30-l-8
Flow Regulator.. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .30- l-9
Auxiliary and Lowering Solenoid Valves ... .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 30-l- 10
Reassembly Suggestions . .. .. .. .. .. .. ... . .. .... .. ... . .. ... . .. .. .. .. .. .. .. .. . . ... . .. .. .. . .. 30-l-13
Hydraulic Tube Installation . .. .. .. .. .. .. .... .. ... . .... .... .. .. .. .. .. .. .. .. . . .. .. 30-l-13 & 14
7
Lift
I I Aux I
Aux Solenoid Valve
Solenoid Valve
SM587 30-l-l Dee 94

GROUP 30 Hydraulic Valve
1. Move truck to service area. r
l Park truck on a flat level surface.

l Extend pantograph.
l Fully lower pantograph.
l Tilt forks forward until fork tips touch the floor.
\...
,,
j
.\
A WARNING
:
:,
,j
Wear eye protection and protective clothing
@
when drying with air pressure. Reduce air
pressure to 30 PSI (207 kPa). Debris removed Typical Illustration
with air pressure can cause injury
v
Hydraulic fluid is toxic to skin, eyes, and
respiratory tract. Good ventilation is normally
Q:: :
adequate. I /i
.:.. . ..

working on truck.
,.>;.-
Always wear F?+.,
ih.
L ;;:.F ,,+Y
;......Y
Safety Glasses
-.c
l
Remove key.
. &connect truck battery.
l-
3. Remove Front Console Cover Typical Illustration

into cover hole.
Hydraulic Valve GROUP 30
. Remove console cover from truck. Refer to
opposite illustration.
4. Open Access Door

. Remove door latch bolt.
. Remove bolt securing left overhead guard leg to
the overhead guard.
. Open door.
NOTE
TheFrontHipPadmayberemoved
for easier access to components.
5. Discharge the CaDacitorS Discharge Capacitors

l Be sure the battery is unplugged.
l Discharge capacitors using a 100 ohm, 10 watt
Negative power terminals on the solid state
control panel. Hold the resistorinplacefor two
( 2 ) seconds before removing.
A CAUTION
without a ~esisfor/oadcould
A WARNING
Discharging the capacitors \ unplugged. )
injury to yourself and Typical Illustration
bystanders.
SM587 30-l -3 Dee 94

/d CAUTION
Cleanliness isof extremeimportance. Beforedisconnecting hydrauliccomponents,
clean exterior of plumbing, valves and compartment to prevent dirt and foreign
matter from entering hydraulic system. Immediately cap fittings as lines are
removed to prevent fluid leakage and contamination.
Lowering Solenoid Valve
Lift Control Valve
Aux Reach & Tilt Valve
ux Solenoid Val
Viewed from Right Rear Comer of truck.
Twical illustration
Step 1
A CAUTION
Switches may be
damaged if the Switch
Cam is not removed.
Be very careful when
removing cam that you
do not damage the
switches.
0 Remove Switch Cam. Loosen and remove fastener, see above.

Carefully pull switch cam away from bracket and switches.
i
Step IA .:j::
.::I.,
.j$, Truck Mounting Bracket

/- - ::$:,
\+
r Mounting Pin
&&Control Linkage
Control Linkage
0 Remove retainer from each lever mounting pin.

l Push pins free of valve spools and control linkage.
SM587 30-l-5 Dee 94

Lowering Solenoid Valve.

Disconnect Lift Line from valve and tee fitting.
- Bulkhead Fittings
Retu
Disconnect Return Line from lift valve. Disconnect Tube #l from Aux Valve and Bulkhead Fitting.
Disconnect Return Line from Aux. Sollenoid Valve. Disconnect Tube #2 from Aux Valve and Bulkhead Fitting.
Dee 94 30-l -6 SM587

Hydraulic Valve
GROUP 30
Dismnect Tube #I from the Lowering Solenoid Valve and Flow Regulator.
Disconnect Tube #2 from the Aux Solenoid Valve and the Lift Valve.
Aux Soienoid Valve
Disconnect Tube #1 and #2 from P.S. Control and Aux. Solenoid Valve.
SM587 30-l-7 Dee94

Step 8
Tag each tube 2

upon removal.
\ ,
\I a\ve \JT
Tag and disconnect Tube #I and #2 from control valves.
Step IO
Remove Lift Control Valve

Remove Auxiliary Control Valve.
Step 11
)
*
Flow Regulator
I.Jc
L
r--------7
Remove Flow Regulator from valve.
Step 12
- ---
If removed, be sure to install Harness Clamp/Guide as shown here

or harness will not fit resulting in possible shorts and component failure.
0 Disconnect Electical Connectors
Step 13
Nuts
1 Lowering Solenoid
Aux Solenoid
Valve e
nting Bolts <\
Remove nuts from mounting bolts.

Lift retainer plate from bolts.
Lift aux solenoid valve from bolts.
Typical illustration
SM587 30-l -11 Dee 94

Step 14
Loosen nut and back off several turns.

Slide bolt and valve free of bracket.
V&e S8nrfce ProcedUreS are covered

in the following sections. Refer to the
appropriate section.
30-2-l Auxiliary Reach & Tilt Control Valve

30-3-l Lift Control Valve
30-4-l Lowering Solenoid Valve
30-5-l Auxiliary Solenoid Valve
Note: The following valves are located on

the Pantograph and include remove
and replace procedures.
30-6-l Reach & Tilt Solenoid Valve

30-7-l Side Shifter Solenoid Valve
Dee 94 30-l -12

Copyrighted Material SM587
REASSEMBLY SUGGESTIONS Hydraulic Tube Installation
1. Lubricate all O-rings slightly with hydraulic
Mounting the Lift and Tilt Control fluid.
Valve Assemblies
IMPORTANT
1. Initially, tighten the valve mounting bolts only O-ring Face Seal Fittings
finger
- tight.
- Do not tighten them at this time.
Check to be sure the O-ring face
2. Insert control linkage into slot of each valve
seal is lubricated, seated and
spool.
properly retainedin fitting groove,
l Insert l/4-inch rod through the holes provided in see below. If the seal is missing or
the slotted end of each valve spool. This is to not fitted properly in its groove,
temporarily hold linkage in place within the in the connection will leak.
slots.
2. Align the tube, or hose nut to the mating fitting
3. Realign the multi-function control handle as
(or align the fitting to the port) and check to see
instructed in Group 13.
that the threads seat properly ... tighten finger
4. Now, tighten valve mounting bolts. tight .. . until it stops turning whilemoving fitting
(or nut) lightly side to side to prevent cocking, or
5. Remove l/4-inch rod and install linkage mount-
thread damage.
ing pins and retainers.
l Usiw finger tins only, lightly snug
fitting (or nut) with a wrench until it
bottoms out on the seat or port.
Tube or Hose Fitting Connector
SM-587 Dee 94
3. Using a pen or marker,
mark a line on the nut
STEP 1 Assembly Instructions
and extend onto the
adapter (or connector) as
shown.
rl
II c
for
Fittings equipped with
1
4. Holdconnector withone -! O-Ring Face Sea/s
wrench and tighten the
cap with a second
wrench.
l Rotatenutjustoneflatas
shown.
STEP 2 Tighten
One (1) Flat
from finger tight
(bottomed out)
position
using
I I second wrench.
Initial
osition
-
IMPORTANT
Hold connector with one wrench while tighten-
ing the nut with a second wrench, see above.
30-l -14 SM-587

CLqRK
M$d$;\Handling
GROUP 30
Section 2
Auxiliary, Reach & Tilt Control Valve
Contents
Valve Cut-A-Way with Specifications .............................................. .30-2-2
Disassembly ...................................................................................... 30-2-3
Cleaning, Inspection and Reassembly ................................................ 30-2-4
Lift Control Valve
Viewed from Right Rear Comer of truck. _

SM587 30-2-l Dee 94

AUX VALVE - SIDE VIEW Plug Torque to: 8 - 10 Lb. Ft. (10.8 - 13.6 N-m)
7 Breather
(Must be open at all times.) r
-Bushing
/ LSpacer Ls2asher
!- Body I_ O-Ring
- Cap Torque to. 20 - 25 Lb. Ft. (27.1 - 33.9 N-m)

Tvoical Illustration
AUX VALVE - TOP VIEW
l Flow Rate : 3 Gal / min. (11.4 Lhnin)

Dee94 30-2-2 SM587

Port PlUCJ Torque to: 8 - 10 Lb. Ft. (10.8 - 13.6 Nam)
Cap Torque to: 20 - 25 Lb. Ft. (27.1 - 33.9 Nom)
Disassembly 4. Remove wiper seal from valve body. Discard

1. Placevalve assembly in avise with softjaws, do the seal.
not over tighten, and remove the spool cap. 5. Remove port plug and O-ring. Discard the O-
2. Remove spool from valve body as shown. ring.
A CAUTION
Be extremely careful when
removing spool and O-rings
from valve body. Do not
scratch, nick or m ar the spool
or the body bore. To do so will
make the valve unfit for further
service.
NOTE
Do not remove spring retainer ring
unless the spring is broken and
needs to be replaced
3. Using a brass tool similar to that shown, care-

fully remove spool O-rings from valve body Brass Tool
bore. Discard the O-rings. Typical Illustration
SM587 30-2-3
Copyrighted Material Dee94
Cleaning and Inspection
l Wash all parts in a Stoddard type cleaning
solvent and place them on a clean surface for
inspection. Inspect the cap breather to be sure it
is not obstructed with dirt, paint or debris. Be
certain all foreign matter has been removed
from the spool and valve body. Air dry parts
A WARNING
AIR PRESSURE
pressure. Reduceair pressure
cause injury.
l Discard all old seals and the spool wiper ring.

l Inspect valve spool and bore for burrs and
scoring. Use a light to inspect the body bore.
Look for loose chrome plating, cracks or other
damage caused by foreign material in the hy-
draulic system. If scoring is not deep enough to
cause objectionable leakage, the surfaces can be
stoned or polished with a crocus cloth. Be care-
ful when polishing that you do not remove the
chrome plating.
Any surface having deep cuts, nicks or scratches
make the part unsuitable for further service and
the valve should be replaced. The spool and
body are a matched set and cannot bereplaced as
indivudal parts. Port Plug-
Valve Reassembly 8 - 10 lb.ft. O-Ring
l Lubricate all parts with clean hydraulic fluid to (10.8 - 13.6 N*m)
facilitate reassembly andprovide initial lubrica-
tion.
Port Plug
l Install a new O-ring on the port plug and screw
the plug into the appropriate port - finger tight.
l Torquetheplug to: 8- lOlb.ft. (10.8 - 13.6Nem)
Dee94 30-2-4 SM587

Hydraulic Valve GROUP30
Valve Spool Spool flush with back side of groove.
l Install O-ring into cap end ov valve.

l Insert clevis end of spool into the back end of
valve body bore. Push spool inward until it is
even with the back side of the seal groove
located at the front of the valve body bore. See
l Pinch lubricated O-ring (as shown) so it can be
inserted into the groove. Let loose of O-ring.
l Using brass tool as shown, carefully seat the O-

ring completely into groove.
l Now, slowly rotate spool (as required) pushing
Carefully seat O-ring.
spool until it is through O-ring.
l Continue to move spool until the spring bushing

is seated in the valve bore.
l Install spool cap and torque to 20 - 25 lb.ft. Body
l Install wiper.Using a sleeve with an O.D. slightly

smaller than the O.D. of the wiper seal, tap the
seal inward until seal is flush with the outside of
the body.
SM587 30-2-5 Dee 94

Pklg Torque to: 8 - 10 Lb. Ft. (10.6 - 13.6 Nom)
open at all times.)

-Bushing
/ LSpacer
~s~asher
- Cap Torque to: 20 - 25 Lb. Ft. (27.1 - 33.9 Nem)
Spool Spring Assembly

If the spool spring assembly was disassembled
for parts replacement, lubricate the parts with
clean hydraulic fluid.
Install bushing over spool and into body.
Install spring over spacer.
Place washer over end of spool.
Now, install the spacer with the spring onto the
valve spool and secure components in position
with the retainer ring.
Install cap and torque to: 20 - 25 lb.ft. (27.1- 33.9
Nom).
L
Dee94 30-2-6 SM587

Check Sump Tank Level
Hydraulic Fluid per Clark Specification MS68.
l Now, purge air from the hydraulic system.
Operate the hydraulic controls through their
cycle several times forcing air from the lines
into the sump tank.
Multi-Function
Control Handle

necessary to bring fluid level to the full mark on \ Clark Part No.885385
\
the sump tank. Hydraulic Fluid
7-ypical Illustration \
L

GROUP 30
Section 3
Lift Control Valve
Contents
Specifications ............................................................................ .30-3-2 & 3
Pilot Operated Relief Valve Assembly with Schematic ..................... .30-3-5
Cut-A-Way View of Valve ................................................................ 30-3-6
Lift Control Valve ...................................................................... 30-3-7 & 8
Valve Disassembly ............................................................................ 30-3-g
Valve Reassembly .......................................................................... .30-3-10
Lift Control Valve
SM587 30-3-l Dee 94


l Tilt (if so equipped) forks forward until fork tips
touch the floor.
A WARNING
When usina air oressure to clean off truck:
pressure to 30 PSI (207 kPa). Debris removed
with air pressure can cause injury
Hydraulic fluid is toxic to skin, eyes, and
respiratory tract. Good ventilation is normally
adequate.

working on truck.
@
Always wear
Safety Glasses

. Remove key.
. Disconnect truck battery.
into cover hole.
Front Console
. Remove console cover from truck. Cover \
Dee94 30-3-2 SM587

Hydraulic Valve
/@ GROUP 30
Q
e
4. Remove Side Cover

. Remove fasteners seuring side cover to truck. ide Cove
. Lift cover off truck.
5. Dischawe the CaDacitorq

Discharge Capacitors
Hold the resistor in place for2 seconds before
removing.
A CAUTION
without a ~esisforloadcouid
A WARNING
bystanders.
SM587 30-3-3 Dee 94

Torque to: 8 - 10 Ib.ft. (11 - 14 N*m) After Setting Relief
TorqueDrive Screw
to: 20 -
- 35 lb.ft. (41- 47 N*m) 11
Relief Valve Adjustor

2650 - 2750 PSI (183 - 190 bar)
@ 8.5 GPM (32.2 l/min)
NOTE
f? : Liquid Lock Threads1
Spool and Body are a
matched set and cannot
4
s,,,,,
Torque to: 2 - 3 Ib.ft. (3 - 4 N*m)
bepurchasedseparately. T
Dee 94 30-3-4 SM587

SM587
Load Check Poppet 1 r-Washer

Spacer
I O-Ring O-Ring 1
Return Spring
Liquid Lock Threads

ue to: 2 - 3 Ib.ft. (3 - 4 N-m)
Dee94 30-3-6 SM587

Spring T I
LIFT CONTROL VALVE
Load Check Valve Reassembly
Disassembly Lubricate the poppet and spring with clean

hydraulic fluid.
l Remove hex plug.
Install poppet into cavity center.
l Remove spring and poppet. If poppet is to be
used again, care must be taken not to damage it. Next insert spring into poppet hole.
l Remove O-ring from hex plug. Discard O-ring. Lubricate new O-ring withclean hydraulic fluid.
Install O-ring onto hex plug. Take care not to cut
Inspection or over-stretch the O-ring.
l Clean all parts in a Stoddard type cleaning Install plug (finger tight) into valve body over
solvent and allow to air dry. poppet and spring.
l Inspect poppet for scratches or nicks. If found, Torque hex plug to 30 - 35 lb.ft. (41 - 47 N*m).
replace poppet with a new one.
SM587 30-3-7 Dee 94

Hydraulic Valve
GROUP 30
O-Ring I
7 O-Ring
To remove (or install) Screw A,

you must keep valve spool from
rntntinn 3
2 rod as shown.
-.--
(Washer) m
hywu w-w.. . . . . .rw.w_ ,

Torque to:
2 - 3 Ib.ft. (3 - 4 N-m)
30-3-8 SM587
Cleaning and Inspection
Valve Disassembly
Wash all parts in a Stoddard type cleaning
Ceanliness is of extreme importance. Before dis- solvent. Be certain all foreign matter has been
connecting hydraulic components, clean exterior removed from the spool and valve body. Air dry
of plumbing, valves and compartment to prevent parts.
dirt and foreign matter from entering hydraulic
system. Immediately cap fittings as lines are re- Discard all seals, spool seals and springs.
moved to prevent fluid leakage and contamina- Reassemble only with new seals and springs.
tion. Inspect the surface of the spool and body bore
End Cap Removal for cuts, scratches, nick etc. Examine the spool.
Look for loose chrome plating, cracks or other
l Remove both mounting screws securing end damage caused by foreign material in the hy-
cap to valve body using a Phillips screwdriver. draulic system. Use a light to inspect the spool
l Insert a rod with an O.D. only slightly smaller bore in the valve body. Nicks on the spool can
than the hole in the end of the valve spool. Too be removed with a crocus cloth. Any surface
small a diameter rod will cause damage to the having cuts or scratches makes the part unsuit-
spool cross hole bore. able for further service and the valve should be
replaced. The spool and body are a matched set
l Retain spool with rod and using a standard type
and cannot be replaced as individual parts.
screwdriver, remove screw (A).
NOTE
This may require heavier than
normal forces since the screw has
been installed using loctite.
l Remove spacer, spring and washer.

Spool and Seal Removal
l Remove spool from valve body.
A CAUTION
Be extremely careful when removing spool and O-
rings from the valve body. Do not scratch, nick or
mar thespool or the body bore. To doso,will make
the valve unfit for further service.
l Using a brass tool similar to that shown, care-
fully remove O-rings from valve body bore.
Discard these seals.
A WARNING
AIR PRESSURE
pressure. Reduce air pressure
cause injury.
SM587 30-3-g Dee 94

Valve Reassembly Flush with Back Side of Groove
Spool and Seals

1. Lubricate valve spool and a new O-ring with
clean hydraulic fluid.
2. Carefully insert spool into the bore at the cap end
of the valve body. Continue to push the spool
inward until the front (clevis) end of spool is
flush with the inward side of the front O-ring
groove as shown here.
3. Next, pinch (as shown) a new lubricated O-ring
so it can be partially inserted into the groove.
4. Using a brass tool, completely push the O-ring
into the groove. Be extremelycarefulthatyoudo
not damage (cut or nick) the O-ring during
installation.Be extremelycarejidthatyoudo not
damage the body bore. To do so will make the
assembly unfitfor service. 4. Install Screw A through the spacer(andspring)
5. Now, slowly rotate the spool while gently mov- into the base end of the spool finger tight.
ing it on through the front O-ring. Continue to 5. Position rod (described in Disassembly, on
push the spool inward until the end of the spool page 8 & 9) into the hole of the spool.
is flush with the inside edge of the grove located
6. Hold rod and spool from turning and using a flat
at the cap end of the valve.
bladed screwdriver, securely tighten Screw A.
6. Lubricate and install a new O-ring into this
Check Spring Operation
groove. Follow the same procedure described in
Steps 3 & 4. . Push down on Screw A. The spring should
compress and upon releasing the screw, the
7, After the O-ring is installed, use the procedure
spring should return to its original position.
previously described and push the spool back
through the valve and the newly installed O- . Apply a mediumcoating of lubricant (Lubriplate
ring. Continue this process until the end of the or equivalent) to the spring and spacer.
spool is flush with the casting at cap end of body.
7. Sparingly apply Loctite to the threads of both
End Cap Assembly (Refer to Illustrationon Page 8) end cap mounting screws.
1. Install washer onto the end of the valve spool. 8. Align the mounting holes of the end cap with
those in the valve body. Install mounting screws
2. Insert the spacer into the spring.
finger tight. Now tighten screws to specifica-
3. Place one drop of Loctite onto the threaded end tions.
of Screw A.
Torque Screws to:
IMPORTANT
2 - 3 lb.ft. (3 - 4 Nom)
Threads of Screw A and those in the valve spool
should be free of dirt and grease before applying 9. Install port plugs into valve openings until
Loctite and assembling the components. Sparingly such time as the valve is installed onto the
apply Loctite to the screw threads. Too much Loctite truck.
could hamper proper operation.
Dee 94 30-3-l 0 SM587

Cl!!!!RK
Ma~pri-i~Handling
GROUP 30
Section 4
Contents
Specifications, Wamings and Caution . .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. . ... .. .. .. .. . 30-4-2
Hydraulic Schematic . .... . ... . ... . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. ... ... .. .. 30-4-3
Disassembly .. . .. .. .. .. ... . .. .. .. . . .. ... . .. . ... .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .. .. .. .. .. .. .. . 30-4-4
Reassembly . .. .. .. .. .. .. .. .. .. ... . ... .. . .. .. .. .. . ... . ... .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. ... .. . .. .. 30-4-5
Installation Notations (refer to Section 1 for Removal Instructions) . ...30-4-5
Lift Control Valve

SM587 30-4-l Dee 94

GROUP 30 Solenoid Valve
A WARNING
adequate.
A CAUTION
matterfromentering hydraulic
system.
A WARNING
When using air pressure to clean off truck:
cause injury.
Removeall Jewelry
before working on
truck.
Always Wear
Safety
Glasses
Dee 94 30-4-2 SM587

Solenoid Valve GROUP 30
LOWERING SOLENOID VALVE
Description
A solenoid-operated, 2-way, normally closed, IMPORTANT
poppet-type, screw-in hydraulic cartridgevalve, Coil must be installed with the
designed to function as a load-holding or block- lettering side out as shown here.
ing Valve.
\/
Operation
When de-energized, the solenoid valve acts as
a check valve, allowing flow from 1 to 2, while
blocking flow from 2 to 1, see below.
When energized the poppet lifts to open the 2 to
1 flow path. In this mode, flow is also allowed
from 1 to 2.
Toraue: 5 Ib.ft. (6.8 Nom) max.
twist counterclockwise 180

and release. In this position
the valve will remain open.
To return to normal opera-
tion, push button in, twist
clockwise 180 and release.
Override will be detented in
this position.
Torque: 35 Ib.ft.
---
1 I
I II
1 io
II
li
II
2
-J
-+ p-1
----- 4
II
1 I
I ----
L__,__ $
0 1
Rated Flow: 114 L/MIN (30 G.P.M.)
Rated Pressure: 24132 kPa (3500 PH.)
Minimum Pull-in Voltage: 85% of nominal @ 20685 kPa (3000 PSI).
SM587 30-4-3 Dee94

Manual Override
ACAUTION Retainer Control
Thevalvestemisveryfragile. Beverycareful Nut Torque: 5 Ib.ft.
when handling the valve that you do not L (6.8 Nom) max.
dent or bend the stem.
Over torquing the coil nut or Over torquing

the valve at installation will cause damage
to the valve.
Torque: 35 Ib.ft.
-----
(47.4 NVTI)9.
BodyT-
Vave
Lead Wires-,,
1
(I) O-Ring
Back-Up Ring
(3) L__//-(21 O-Ring
ACAUTION
Valve is not serviceable. Do
not take apart.
A CAUTION
system.
Wire Leads
DISASSEMBLY
l Remove nut and coil from solenoid valve stem.
l Remove solenoid valve from valve body.
l Remove fittings from valve body. l Wipe all parts dry with a clean lint-free cloth.
Allow components to airdry beforereassembly.
Cleaning & Inspecting Solenoid l Replace al seals with new ones.
l Wash all parts but the coils in a Stoddard type
l Inspect wire leads and plugs for further service-
cleaning solvent.
ability. Replace defective parts.
Dee94 30-4-4
Copyrighted Material SM587
A CAUTION Typical Illustration
Be certain coil is positioned as shown below so wire leads may be connected

without causing damage to the wiring.
Be certain to tighten coil retainer nut to 5lb. ft. (6.8 Nom) maximum. If you over-
tighten the nut damage to the valve stem will result.
rWires IOL & IOM
18
HARNESS CLAMP/GUIDE
must be installed as shown or the harness will not fit resulting in possible
shorts and component failure.
REASSEMBLY
INSTALLATION
Lubricate all parts in clean hydraulic fluid prior
to installation. Reassemble only with new seals.
Install large O-ring (1) into its groove being IMPORTANT
Inspect hoses, hydraulic connections and their seals
verycarefulthatyoudonotnickorcuttheO-ring
for damage. Replace defective parts.
making if unfit for service as it will leak.
Prior to attaching hose ends and connections to the
Install O-ring (2) and backup ring (3) as shown
fittings on the solenoid valve, clean and lubricate
on opposite page. Again, be very careful you do
them with new hydraulic fluid.
not nick or cut the O-rings or leakage will occur.
Remove caps just prior to installation.
Install solenoid valve into body bore. Be certain
solenoid valve is tightened securely to the body.
Torque to 36 ft lb (47,4 N*m).
Install coil onto valve stem. Position the coil to When Mounting Solenoid Valve:
allow easy connection of the electrical plugs as l Align valve body slot with mounting bolt on
shown in above illustration. truck. Locate valve over bolt and install retainer
Install coil retainer nut and torque to 5 ft lb (6-8 nut finger tight. Refer to Section 1.
Nom)
Install hydraulic fittings install finger tight.
SM587 30-4-5 Dee94

When Connecting Hydraulic Plumbing:

l Be certain valve fittings and hose ends are in
proper alignment and then install each one
finger tight until all connections have been
made.
l Tighten valve body mounting nuts securely.
Now go back and securely tighten each hy-
draulic connection.
l Tighten coil retainer nut.
l Connect coil plugs to their receptacles in the
wire harness.
IMPORTANT
Allelectricalplugsandtheirreceptaclesarematched
labeled for easy connection. Check to be sure each
plug and receptacle match before attempting to
make connections.
l Check wire harness clamps for security of
mounting. Be certain the harness is in good
condition and that it is routed properly.
l Replenish hydraulic system. Refer to instruc-
tions in Section 1.
Dee 94 30-4-6 SM587

CORKMaterial
Company
Handling
GROUP 30
Section 5
Auxiliary Solenoid Valve
(Reach and Tilt Control)
Contents
Specifications, Warnings and Caution ......................................... .. ..... 30-5-2
Hydraulic Schematic , . . . , . . , . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. .. . . .. . . . . . . . . . . . . .. . . 30-5-3
Disassembly . . . . . . . . . . . . . . . . . . . . . ,. . . ..,.........,................................................ 30-5-4
Reassembly ... ...... .................................................. .... .... ................ .... 30-5-5
Installation Notations (refer to Section 1 for Removal Instructions) .... 30-5-5
Lift Control Valve
ux, Reach & Tilt Control Valve
11Auxiliary Solenoid Valve 11

SM587 30-5-l Dee 94

A WARNING
adequate.
A CAUTION
system.
A WARNING
When usina air Dressure
to clean off truck:

drying with air pressure.
Reduce air pressure to 30 PSI
A CAUTION
Cap all ports to prevent dirt and foreign debris from entering assembly.
Always Wear
Remove all Jewelry

before working on Safety
truck. Glasses
Dee 94 30-5-2 SM587

AUXILIARY SOLENOID VALVE

0
IQ
IMPORTANT
All wiring, plugs and Torque: Slb.ft. (6.8 N*m) Max.
receptacles are labeled for -
easy identification.
careful when making
Be 1
connections. You will
experience shorts and
component failure if the orque: 35 lb.ft. (47.4 N*m) Max
wiring, (harness routing) I
plugs,and receptacles are
not correctly installed.
_-I
--
--
Hydraulic Schematic
Rated Flow: 114 L/MIN (30 G.P.M.)
Rated Pressure: 20685 kPa (3000 P.S.I.)
Minimum Pull-in Voltage: 85% of nominal @ 20685 kPa (3000 p-s-i.).
-ypical Illustration
O-Ring(s)
/-
Typical Cartridge Kit
Disassembly
l Unplug Coil S3 from wire harness.
res 10K & IOL
* Remove nut and coil from solenoid valve.
l Remove solenoid valve from valve body.
l Remove fittings from valve body.
Cleaning & Inspection
Wash all parts except coils in a Stoddard type
cleaning solvent. Wipe coils with a clean cloth.
Wipe all parts dry with a clean lint-free cloth.
Allow components to airdry before reassembly.
Replace all seals with new ones.
Inspect wire leads and plugs for further service-
ability. Replace defective parts .Use Service l
Parts Kit(s). I
Body @I
Inspect wire leads and plugs for further
l- -----
servicability. If damaged, replace the coil.
L 1rypical Illustration
Dee 94 30-5-4 SM587

REASSEMBLY
A CAUTION Wires 1OL & 10M
importance.Before
disconnecting the hydraulic
components, clean exterior of Wires 10K & 1
to prevent dirt and fqreign
system.
Take particular care not to

damage the coil stem.
l Lubricate all parts in clean hydraulic fluid prior When Mounting Solenoid Valve:
to installation. Use only new seals.
l Align valve body slots with mounting bolts on
l Install large O-ring into its groove being very truck.Locatevalveoverboltsandinstallretainer
careful that you do not nick or cut the O-ring nuts finger tight. Refer to Section.
making if unfit for service as it will leak.
When Connecting Hydraulic Plumbing:
l Install three O-rings and six backup rings as
l Be certain valve fittings and hose ends are clean
shown on opposite page. Again, be very careful
and in proper alignment and then install each
you do not nick or cut the O-rings or leakage will
one finger tight until1 all connections have been
OCCUT,
made..
l Install solenoid valve into body bore. Be certain
l Tighten valve body mounting nuts securely.
solenoid valve is torqued correctly to the body.
Now go back and securely tighten each hydrau-
l Next, install coil over solenoid valve. lic connection.
l Installcoilretainernut and tighten to5 lb.ft. (6.8
A CAUTION
N*m).
Be certain coil is positioned so
l Lubricate fittings with clean hydraulic fluid and wire leads may be connected
install them finger tight to the valve body. to the harness leads without
causing damage to wiring.
INSTALLATION l Connect coil plugs to their receptacles in the
IMPORTANT wire harness.
Inspect hoses, hydraulic IMPORTANT
connections and their seals
All electrical plugs and their
for damage. Replace defective
receptacles are matched labeled
parts.
for easy connection. Check to be
sure each plug and receptacle
Prior to attaching hose ends
match before attempting to make
and connections to the fittings
connections.
on the solenoid valve, Clean
and lubricate them with new l Check wire harness clamps for security of
hydraulic fluid.
mounting. Be certain the harness is in good
Remove caps just prior to condition and that it is routed properly.
installation.
SM587 30-5-5 Dee 94
Wires 1 OK & 1 OL
resulting in possible shorts and com-
Check Sump Tank Level r

Hydraulic Fluid per Clark Specification MS68.
into the sump tank.
the sump tank.
Multi-Function
Control Handle
Use
. ..-_I
I22
MS68
Clark Part No.885385
\
Typical lllustratior jpical Illustration 1 Hydraulic Fluid
Material Handling
C19RK Company GROUP 30
Section 6
Reach & Tilt Selector Valve
Contents
Truck Preparation ............... .. .................................... .................... ..... 30-6-2
Discharge Capacitors ... .............. .................................. .. .................. .. 30-6-3
Hydraulic Plumbing Diagram ........................................................... . 30-6-6
Specifications and Hydraulic Schematic ............. ...........I........ ........... 30-6-6
Location and Mounting Illustration ... ................ ...............I...... ........... 30-6-9
Removal, Disassembly & Reassembly . .......... .................................... 30-6-9
SM-587 30-6-l Dee 94

GROUP 30 Selector Valve
. Extend pantograph.
. Fully lower pantograph.
. Tilt (if so equipped) forks forward until fork tips
touch the floor.

l Remove key.

into cover hole.
Carefully lift cover a little forward and upward
. Remove console cover from truck. Refer to
Front Console
Cover \
Dee 94 30-6-2 SM-587

Selector Valve GROUP 30
4. Open Access Door

. Remove door latch bolt.
. Remove bolt securing left overhead guard leg to
the overhead guard.
. Open door.
NOTE
TheFrontHipPadmayberemoved
for easier access to components.
5. Dischawe the Car>acitoq Discharge Capacitors

Negative power terminals on the solid state
control panel. Holdthe resistorinplacefor two
(2 ) seconds before removing.
A CAUTION
without a resisforloadcould
A WARNING
bystanders.
SM-587 30-6-3 Dee 94

A WARNING
adequate.
A CAUTION
system.
A WARNING
When usina air Dressure to clean off truck:
cause injury.
Removeall Jewelry
before working on
truck.
Always Wear
Safety
Glasses
Selector Valve
(Reach & Tilt)
Valve Mounting Fastener Pantograph
IMPORTANT
ROUTE HOSING AS SHO
Grease
Fitting
WARNING
Place a 4x4 support between front and
rear members of pantograph (as shown).
This is to prevent retraction of the
pantograph when disconnected from the
upright.
BEFORE WORKING ON PANTOGRAPH, BE CERTAIN IT IS BLOCKED AS SHOWN.
SM-587 30-6-5 Dee 94

#5 SAE o-Ringport For. Tilt (S.S.Right)

#4 SAE o-RingPODReach, Pantograph
#5 SAE o-RingPOTRetract, Pantograph
#5 SAE o-Ringport Retract, Pantograph

#5 SAE o-Ringport Reach, Pantograph
~4 SAE o-Ringport Back Tilt (S.S.LA)
#6SAEO-RingPort(ConnectstoAuxContmlValve
Hydraulic Circuit
u* = Counterbalance Valves
s5 = Solenoid Valve
S6 = Solenoid Valve
s5 (Vl) C2 Port = Back Tilt or Side Shift Right control circuit
S6 (172) C4 Port = Forward Tilt or Side Shift Left control circuit
s5 (Vl) Cl Port = Reach (Pantograph) control circuit
S6 (172) C3 Port = Retract (Pantograph) control circuit
Over torquing the coil nut or the valve at
9&10-
8
A Selector Valve
B Pantograph Frame
C Reach Arms
D Carriage Frame
REACH 81TILT SELECTOR VALVE 7. Removevalve from the pantograph. Place com-
ponents on a clean work bench.
A WARNING DISASSEMBLY
Be sure pantograph is blocked
l Remove coils and solenoid valves S5 & S6 from
as illustrated on page 5.
valve body.
REMOVAL l Remove both counterbalance valves fromvalve

body.
A WARNING NOTE
Hydraulic lines may have It will not be necessary to separate
trapped pressure. Crack the valve bodies unless there was
fittings to release pressure leakage between the two. If the
before disconnecting. valve was leaking between the
bodies, then remove four l/4-20
screws and separate the bodies.
Discard the six O-ring seals located
A WARNING between the bodies.
When trapped pressure is
relieved, the pantograph may
settle. Beware. Cleaning
l WashallpartsexceptthecoilsinaStoddardtype
cleaning solvent. Wipe coils with clean cloth.
1. Loosen guard mounting bolts and remove guard. l Wipe all parts dry with a clean lint-free cloth.
2. Unplug connectors #l from coil S6 and unplug Allow components to airdry before reassembly.
connectors #2 from coil S5. l Replace all seals with new ones. Be sure to use
3. Remove fasteners #4 from clamps #3. Move a brass tool when removing seals.
wiring out of the way.
4. Tag hoses and disconnect h ydraulic connections
#5 and #8 from valve A. Remove hoses 6,7,
9 & 10 from each reach cylinder. Cap all hose
ends.
A CAUTION
Residual pressure will be
pressent when disconnecting
lines. Use caution when
disconnecting fittings.
5. Tag tubes and disconnect fittings #ll & #12

from bottom side of valve A. Cap both hose
ends.
6. Remove both mounting fasteners from panto-
graph frame B and valve A.
.
Dee 94 30-6-8 SM587

Solenoid Valves
es
Cleanliness is of extreme importance. Before

disconnecting hydraulic components, clean exterior
of plumbing and solenoid valve to prevent dirt and
foreign matter from entering hydraulic system
SM587 30-6-9 Dee 94

REASSEMBLY Receptacle Leads

Lubricate all parts in clean hydraulic fluid prior
to installation.
Install large O-ring into its groove being very
careful not to nick or cut the O-ring making it
unfit for service or it will leak.
Install O-ring and backup ring as shown above.
Again, be very careful not to nick or cut the O-
rings or leakage will occur.
Install the solenoid valves into their respective
bores in the valve body. Be certain the solenoid
valve is torqued correctly to the body.
Next, install the coil over the solenoid valve.
Torque: 5 Ib.ft.
Install coil retainer nut and torque to 251b. ft. *6.8 N-m) Max.
(33.9 N*m)maximum. This will allow thecoil to Torque: 25. Ib.ft.
be correctly positioned at time of installation to (33.9 N-m) Max.
the truck.
Dee94 30-6-l 0 SM587

A CAUTION
Cleanlinessisof extremeimportance. Before
(NON-ADJUSTABLE) dis-connecting the hydraulic components,
If thevalve has been tampered with 9c 1eanexteriorof plumbing and solenoidvalve
itmustbereplaced with anew one. to prevent dirt and foreign matter fr
entering hydraulic system.
- Back-Up Kings Typical lllustratio
REASSEMBLY INSTALLATION
l Lubricate all parts in clean hydraulic fluid prior IMPORTANT

to reassembly. Use only new seals1 Inspect hoses, hydraulic connec-
tions and their seals for damage.
l Install large O-ring into its groove being very
Replace defective parts.
careful not to nick or cut the O-ring making if
unfit for service or it will leak. Wipe hose ends and connections
l Install O-rings and backup ringsas shown above. clean prior to installing them to the
Again, be very careful not to nick or cut the O- solenoid valve.
rings or leakage will occur.
Remove hose caps just prior to
l Install the counter balance valves into their installation.
respective bores in the valve body. Torque them
to 35 lb.ft. (47.4 Nom) to valve body.
SM587 30-6-l 1 Dee 94

Valve Mounting Fastener
Nui
A Solenoid Valve
B Pantograph Frame
C Reach Arms
D Carriage Frame
Typical lllustratior
Dee 94 30-6-q 2 SM587

Mounting Selector Valve
1. Position valve to the pantograph frame aligning
holes in frame with those in the valve. Refer to
A CAUTION
opposite illustration. Replenish hydraulicfluid in the
sump tank before putting the
2. Install mounting fasteners finger tight. Do not truck into service.
tightenfasteners until after the hydraulic hoses
are installed. The system must be purged of air before putting truck
back into service or damage to the hydraulic system
Connecting Hydraulic Plumbing may result.
3. Remove cap, hose tag and then install connec- 9. Install and tighten clamp bolts #M.
tion #l 1 to valve finger tight.
4. Remove cap, hose tag and install #12 connec-
tion finger tight.
4. Install connections #5 and #8. Then install con-
nections #6,7,8,9 & 10 to the reach cylinders
finger tight.
5. Now, securely tighten each hydraulic connec-
tion to the valve body and the reach cylinders.
IMPORTANT
Be sure the hoses are routed
correctly before attempting to
connect them to the valve. Refer to
page 5 for correct routing.
Installing clamps, connect wire

plugs, tighten nuts and bolts.
6. Next, be sure the valve guard is located properly
and securely tighten both solenoidvalvemount-
ing bolts.
7. Install wire clamps #3 with bolts #4.
8. Connect coil plugs to their receptacles.
IMPORTANT
All electrical plugs and their
receptacles are matched labeled
for easy connection. Check to be
sureeachplugandreceptaclematch
before attempting to make
connections.
SM587 30-6-I 3 Dee 94

Material Handling
EllFlRH Company GROUP 30
Section 7
Side Shifter Solenoid Control Valve
(Optional Equipment)
Contents
Truck Make Ready ........................................................................... .30-7-2
Removal ............................................................................................ 30-7-4
Specifications and Hydraulic Schematic.. ................................... .30-7-5 & 6
Disassembly and Reassembly ........................................................... .X&7-7
Installation ........................................................................................ 30-7-8

Hose Routing .................................................................................... 30-7-g
SM587 Dee 94
l Tilt (if so equipped) forks forward until fork tips
touch the floor.
2. Turn key switch off.,

* Remove key.
Dee 94 30-7-2 SM587

SM587 30-7-3 Dee 94

Removal
Refer to Illustration on opposite page.
l Unplug connectors from S7 coil.

l Unplug connectors from S8 coil.
l Tag each hose as to its location.
l Disconnect hydraulic connections
Vl, V2, C6, C5, C2 and C4 from the side
shift selector valve.
AWARNING
When usina air Dressure
A CAUTION
to clean off truck:
Hydraulic lines may be
under pressure. Crack Wear eye protection and
fittings slowly. protective clothing when
drying with air pressure.
l Cap each hose when disconnected. Reduce air pressure to 30 PSI
NOTE
There will be some fluid Always Wear
leakage upon disconnectin
g each fitting. Place a rag
beneath the fitting to be
removed.
l Remove mounting fasteners securing the
selector valve to the pantograph. Remove all Jewelry
before working on Safety
l Remove valve and place on a clean work truck. Glasses
bench.
Refer to page 7 for valve service instruc-
tions. A WARNING
Pages 6 & 8 provide diagrams and hy- eyes, and respiratory tract.
draulic schematic. Good ventilation is normally
l Replace all O-rings with new ones. adequate.
l Inspect hoses and connections for further

serviceability. A CAUTION
l Replace defective parts. Cleanliness is of extreme
system.
Dee 94 30-7-4 SM587

Solenoid Valve
S8
.
~--~--_-_-_---_rxrr~~~
Top view
[ Solenoid j
I I
_-_-_-I
j
r Valve t
c2 #5 SAE O-Ring Port
c4 #4 S AE O-Ring Port
C5 #I4SAJZO-Ring Port C6
C6 ##4SAE O-Ring Port . ...

Vl
Vl ?&I
SAE O-Ring Port
f
v2 ##4SAE O-Ring Port
NOTE
Refer to Hydraulic Schematic on
the next page.
Fmnu Back
SM587 30-7-5 Dee 94

Hydraulic Schematic
0*
Vl _-._
...........
4 Hydra-
.........
...........
c2
0**
c4
...............
..........
Hydraulic Circuit
tv2 C6
J
______-___r-_l---I- _I_ . . .._-_.....
Schematic Side Shift Cylinder
0* Return to VI/C2/SS Circuit
u** Return to V2/C4/S6 Circuit
30-7-6
jlpical Illustration
Disassembly
l Remove nut and coil from each solenoid valve. Torque nuts Receptacle Leads
8 - IO lb. ft.
l Remove both solenoid valves from valve body.
------
(11 - 14 Nom)
r
f-l1
Wipe coil(s) clean using aclean shop rag. Inspect wire r...........< .. .. .. .. .. .. .. .. . .. .. 11..
leads for damage. Wash hydraulic components in a 22 Coil

Stoddard type cleaning solvent and wipe dry with a j
clean shop rag. Discard old seals. Replace defective
parts Use Service Parts Kits.
Reassembly
l Lubricate seals, valves and body in clean hy-
draulic fluid.
l- ---- -l
l Install seals and backup rings as shown above. - Retainer Nut
Becarefil that you do not nick or cut seals upon r
installation. Body--l
l Install cartridge valve into valve body and torque
to 8 - 10 lb. ft. (11 - 14 N*m).
30-7-7
Dee94
Installation
I Mount Selector Valve

l Line up mounting holes in selector valve with
those in mounting bracket. Install fasteners fin-
ger tight. (see below)
Install Hoses
l Wipe hose ends and connections clean. Remove
hose caps just prior to installing connection to
valve. Be certain all connections are tight.
Connect Coils
Plug connectors to S8 and S7 coils. See illustra-
tion at left.
. Tighten all mounting fasteners.
. Install guard.
Mounting Fasteners
IMPORTANT
All Wiring, Plugs and
Side
Receptacles arelabeledfor
easy identification. You
must install cables and
wiring exactlly as shown
or you will experience
shorts and component
failure.
Side Shift Selector

Valve
II
Mounting Bracket
Dee 94 30-7-8 SM587

Solenoid Valve GROUP30
Important
Route Hosing As Show
Side
Shift
Cylinder
Grease XT/ $$#!p&&
Reach & Tilt Solenoid

Valve
Greast
Fitting
I
Grease
Fitting
SM587 30-7-g Dee 94

Material Handling
Cl!!IRIC Company GROUP 32
Section 2
Tilt Cylinder Overhaul
Contents
Safety ............................................................................................... .32-2-2

Preparation Cleaning and Inspection suggestions ............................... 32-2-3
Disassembly ...................................................................................... 32-2-4
Cleaning & Inspection ....................................................................... 32-2-5
Reassembly ................................................................................ 32-2-5 & 6
Sump Tank Fluid Level ..................................................................... 32-2-7
Models Equipped
with
1
Side Shift
SM-587
GROUP 32 Tilt Cylinder
Air Hose
A WARNING
When using air pressure to clean off truck:
air pressure to30 PSI (207 kPa). Debris removed with air pressure can cause injury.
Remove all Jewelry before Always wear Safety Glasses

working on truck.
A WARNING
Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is
normally adequate.
A CAUTION
Cleanlinessisof extreme importance. Before disconnecting hydrauliccomponents,
clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter
from entering hydraulic system. Typical Illustration
Dee 94 32-2-2
Tilt Cylinder GROUP 32
Preparation Cleaning & Inspection 1
Suggestions
l The exterior surface of a cylinder should be
thoroughly washed before disassembly.
l A soft fiber brush should be used to remove
debris and foreign objects from grooves and
threaded areas, etc.
l A Stoddardtype cleaning solvent should be used

to wash the cylinder. Soft Fiber Brush
Nut
Rod En d
Cylinder Piston Rod
NOTE
PressBushings flush with rod end.
l Threaded area of piston rod should be examined for damage,

stripping or marring after removal of rod end and jam nut. The
bushing in rod end should be inspected for further serviceability.
l All foreign objects should be removed from between threads on
the piston rod, in the nut and rod end.
l Any part unfit for further service should be replaced with a new
Pm*
SM-587 32-2-3
Copyrighted Material Dee94
Split Retainer Ring
Disassembly (Refer to illustration above.) are free of cylinder housing. Remove gland.
Wash exterior of the tilt cylinder in a Stoddard type Gland Assembly
cleaning solvent before disassembly. Use a brush to
1. Remove wiper ring.
remove grease and grime from the cylinder tube,
anchor and rod ends. Remove rod end and jam nut. 2. Remove seal from inner groove. Be careful that
you do not nick or scratch inner sutiace if gland
1. Placecylinder in avise equipped with softjaws.
assembly.
Do not over-tighten - distort barrel
3. Remove outer O-ring and backup ring from the
2. Push piston rod all the way into cylinder.
gland assembly.
3. Using a narrow blade screwdriver, remove the
4. Discard seals, wiper and backup rings.
split type retainer ring.
Piston Rod & Piston
4. Remove washer.
1. Insert a 12 to 15 inch holding rod into the hole
5. Remove white backup ring.
provided just below threaded area of piston rod,
6. Remove O-ring. see arrow (4) above. Now install a l-l/S socket
7. Using a bronze drift, gently tap gland assembly onto the piston rod nut.
into cylinder housing clear of the shear ring. 2. Remove nut from piston rod while holding
8. Using screwdriver, carefully lift end of shear retainer rod.
ring from its groove. Becareful you do not nick 3. Pull piston free of piston rod.
or scratch the piston rod.
4. Remove O-ring from piston rod and discard.
9. With a pair of pliers, carefully pull shear ring 5
Remove sealing ring (Glyde Ring@) and the
from cylinder tube. Again, be carejXyou do not
energizer from piston. Use care not to nick or
nickor scratch the piston rod. Discard the shear
scratch piston surfaces.
ring.
6. DiscardO-ring, sealing ring (Glyde Ring@) and
10. Pull outward on piston rod until rod and gland
energizer. Always install new seals.
Dee 94 32-2-4 SM-587


1. Discard old seals, wiper and shear ring.
2. Wash all parts in a Stoddard type cleaning
solvent and dry with a clean lint free shop rag.
3. Inspect cylinder mounting bushings for dam-
age. Both the rod and anchor ends have two
bushings each end. If they are unfit for further
service, they may be pressed out and new bush-
ingspressedin. New bushings should be pressed
flush with outer surface of the anchor and rod
ends. Refer to opposite illustration.
4. Inspect threaded parts for damage. Examine
cylinder barrel for scoring, nicks or scratches. A
crocus cloth may be used to clean up light
scratches, etc. Be car@2 not to remove the
chrome plating when polishing surface. Re-
place all damaged or unserviceable parts.
5. Inspect surfacesofthepistonandpistonrod to be
sure they are clean, smooth and free of damage.
8. Using a torque wrench and the l-l/S socket,
torque nut to: 201 to 2301b.ft. (273 - 312 N*M).
Reassembly
9. Now, lubricate piston and piston rod with clean
Piston Rod & Piston
hydraulic fluid
1. Using only new seals and O-rings, lubricate all
10. Startpistonintocylindertube whilegentlypush-
parts with clean hydraulic fluid.
ing and rotating piston rod until piston and seal
2. Lubricate and install the square energizer ring have passed the shearring groovein the cylinder
into the groove in the piston. Refer toillustration tube. Be careful you do not damage seal.
on opposite page.
11. Shovethepistonrodallthewayintothecylinder
3. Lubricate and install the Glyd Ring@ over the tube until it bottoms.
energizer. Be careful that you do not nick or cut
Gland Assembly
the seals making them unfit for service.
1. Lubricate new seals, wiper ring and gland as-
4. Place a plastic parts bag over the threaded area
sembly with clean hydraulic fluid.
of the piston rod (to protect seal). Slide a new O-
ringoverthebagandintothegrooveinthepiston 2. Install the inner seal, with the sealing lip faced
rod. inward, into the gland groove. Becareful that
you do not cut or nick the sealing lip upon
5. Remove bag and install piston onto rod. Care-
installation.
fully slide piston over the O-ring and up against
rod shoulder. 3. Install a new wiper ring into the gland.
6. Install nut onto rod finger tight against the 4. Lubricate and install a new backup ring into the
piston. outer groove on the gland..
7. Install the 12 to 15 inch rod back into the hole

provided in the piston rod.
SM-587 32-2-5 Dee 94

Back-Up Ring
O-Ring-, 1 r Split Retainer Ring
-Nut
lRod
5. Lubricate and install a new O-ring in the grove 12. Lubricate a new backup ring and place it over the
next to the backup ring. Note position of backup O-ring just installed.
and o-ring per above diagram.
13. Install the washer over the gland and next to the
6. Place a plastic parts bag over the threaded end of backup ring previously installed.
the rod (to protect seals) and carefully slide the
14. Install a new split retainer ring into its groove in
gland over the rod and into the cylinder housing.
the gland assembly. Be sure it is completely
7. Push gland as far as it will go into the housing. seated in its groove.
8. Insert the open end of a new shear ring into the 15. Install jam nut and rod end to the same location
cylinder housing while pushing on the ring with it was when removed from the piston rod.
your fingers. Push ring inward as far as you can.
16. Cap cylinder ports until such time as the cylinder
9. Now, using a bronze punch, gently tap ring the is installed in the truck.
rest of the way into the tube and groove. Be sure
the shear ring is fully seated in its groove.
10. Next, pull piston rod out as far as it will come.
This will position the gland so the retainer ring
groove is located above the cylinder housing.
11. Lubricate a new O-ring and place it over the
gland and into the housing on top of the gland.
Dee 94 32-2-6 SM-587

Hydraulic Fluid per specifications in Group 01.
into the sump tank.
Multi-Function
Control Handle

the sump tank.
SM-587 32-2-7 Dee 94

EMIRK~z$e;;k&Handling GROUP 32
Section 3
Reach Cylinder Overhaul
Contents
Safety ................................................................................................
32-3-2
Preparation Cleaning and Inspection Suggestions .............................. .32-3-3
Disassembly ...................................................................................... 32-3-4
Cleaning & Inspection ...................................................................... .32-3-5
Reassembly ................................................................................ 32-3-5 & 6
Sump Tank Fluid Level .................................................................... .32-3-7
)_
0
JQ
0
,==z\
I, II
II II
II II
II II
Ii Ii r
SM-587 32-3-l Dee 94

GROUP 32 Reach Cylinder
A WARNING
When usina air Dressure to clean off truck:
Wear eye protection and protectiveclothing when drying with air pressure. Reduce

working on truck.
A WARNING
normally adequate.
A CAUTION
Cleanlinessisofextremeimportance. Beforedisconnecting hydrauliccomponents,
from entering hydraulic system. Cap all ports (after overhaul) until assembly is
ready for installation.
Dee 94 32-3-2 SM-587

Reach Cylinder GROUP 32
Preparation Cleaning & Inspection
Suggestions
l The exterior surface of a cylinder should be
thoroughly washed before disassembly.
-
l A Stoddard type cleaning solvent should be used
to wash the cylinder. Soft Fiber Brush
Nut
Rod En d
Cylinder Piston Rod
l Threaded areas should be examined for damage, stripping or

marring after removal of rod end and jam nut. The bushing in rod
end should be inspected for further serviceability.
l All foreign objects should be removed from between threads on
the piston rod, in the nut and rod end.
l Any part unfit for further service should be replaced with a new
Part*
SM-587 32-3-3 Dee 94

a, :::.
[ii
.::
Y:..
,:,,,:C.~.../ ..,;
0 v.:..:.;,:,:..
:....
f,
,.:::z
ILSdf-Alionino
Energizer,
.::
ii;
F Anchor End
Piston Seals1
1
I I { flllTop View11 Rod End
I Piston Seal- I- Snap Ring

I
Shear Ring -
Disassembly (Refer to illustration above.) Gland Assembly

Wash exterior of the reach cylinder in a S toddard type 1. Remove wiper ring.
cleaning solvent before disassembly. Use a brush to 2. Remove seal from inner groove. Becareful that
remove grease and grime from the cylinder tube, you do not nick or scratch innersurfaceof gland
anchor and rod ends. assembly.
1. Placecylinder in aviseequipped with softjaws. 3. Remove outer O-ring and backup ring from the
Do not over tighten - distort barrel. gland assembly.
2. Push piston rod all the way into cylinder. 4. Discard seals, wiper and backup rings.
3. Using snap ring pliers, remove snap ring from Piston Rod & Piston
cylinder gland.
1. Insert a 12 to 15 inch holding rod into the hole
4. Remove washer. provided just below threaded area of piston rod.
5. Using a bronze drift, gently tap gland assembly Now install a 1-l/8 socket onto the piston rod
into cylinder housing clear of the shear ring. nut.
6. Using screwdriver, carefully lift end of shear 2. Remove nut from piston rod and remove hold-
ring from its groove. Be carefulyou do not nick ing rod.
or scratch the piston rod or cylinderbore 3. Pull piston free of rod.
7. With a pair of pliers, carefully pull shear ring 4. Remove O-ring from rod.
from cylinder tube. Again, becarefil you do not
nick or scratch the piston rod or cylinderbore. 5. Remove seal ring (Glyde Ring@) and the ener-
Discard the shear ring. gizer from piston.
8. Pull outward on piston rod until rod and gland 6. Discard O-ring, sealing ring (Glyde Ring@) and
are free of cylinder housing. Remove gland. energizer. Always install new seals.
Dee 94 32-3-4 SM -587

1. Discard old seals, wiper and shear ring.
2. Wash all parts in a Stoddard type cleaning
solvent and dry with a clean lint free shop rag.
3. Inspect cylinder mounting bushing for damage.
If it is unfit for further service, it may be pressed
out and new bushing pressed in. A sleeve to fit
over spherical inner bushing will be needed. Do Bushing
not press out by pressing on the inner bushing.
4. Inspect threaded parts for damage. Examine
cylinder barrel for scoring, nicks or scratches. A Grease
Fitting
crocus cloth may be used to clean up light
scratches, etc. Be careful not to remove the
chrome plating when polishing surface. Re-
place all damaged or unserviceable parts.
5. Inspectsurfacesofthepistonandpistonrod to be
sure they are clean, smooth and free of damage.
Reassembly
Piston Rod & Piston 10. Start piston into cylinder tube while gently
pushing and rotating piston rod until piston and
1. Lubricate all parts with clean hydraulic fluid.
seal have passed the shear ring groove in the
2. Lubricate and install the square energizer ring cylinder housing. Becarefulyou do not damage
into the groove in the piston. Refer to illustration seal.
on previous page.
11. Push the piston rod all the way into the cylinder
3. Lubricate and install the GlydeB over the ener- Housing until it bottoms.
gizer. Be careful not to nick or cut the seals
Gland Assembly
making them unjit for service.
4. Place a plastic parts bag over the threaded area
of the piston rod (to protect seal). Slide a new O-
ring over the bag and into the groove in the rod. 2. Install the inner seal, with the sealing lip faced
inward, into the gland groove. Be careful not to
5. Remove bag and install piston onto rod. Care-
cut or nick the sealing lip upon installation.
fully slide piston over the O-ring and up against
rod shoulder. 3. Install a new wiper ring into the gland.
6. Install nut onto rod finger tight against the 4. Lubricate and install a new backup ring into the
piston. outer groove on the gland..
7. Install the 12 to 15 inch rod into the hole pro- 5. Lubricate and install a new O-ring in the grove
vided just below threaded area of piston rod. next to the backup ring as shown in illustration
on opposite page..
8. Using a torque wrench, torque nut to:
6. Place a plastic parts bag over the threaded end of
115 to 132 lb.ft. (156 - 179 N*m).
the rod (to protect seals) and carefully slide the
9. Now, lubricate piston and piston rod with clean gland over the rod and into the cylinder housing.
hydraulic fluid.
SM-587 32-3-5 Dee94

Wiper
l- Piston Seal -I l- Snap Ring

Typical Illustration Shear Ring -_I
7. Push gland into the thousing until it is clear of 11. Lubricate and install the washer over the gland
shear ring groove. next to the housing.
8. Insert the open end of a new shear ring into the 14. Install a new snap ring into its groove in the
cylinder housing while pushing on the ring with gland assembly. Be sure it is completely seated
your fingers. Push ring inward as far as you can. in its groove.
9. Now, using a bronze punch, gently tap ring the 15. Install jam nut and rod end in the same location
rest of the way into the groove. Be sure the shear it was when removed from the piston rod.
ring is fully seated in its groove. 16. Cap cylinder ports until such time as the cylinder
10. Next, pull piston rod out as far as it will come. is installed in the truck.
This will position the gland so the retainer ring
groove is located above the cylinder housing.
Dee 94 32-3-6 SM-587

Hydraulic Fluid per specification listed in Group
01.
into the sump tank.
Multi-Function
Control Handle

I-
the sump tank.
SM-587 32-3-7 Dee 94

CUFIRIC
lVlz$?;~%&Handling
GROUP 34
Section 1
Upright & Pantograph
Remove & Replace
Roller Shim Adjustments
Contents
Pantograph ....................................... ............ ........................ ............ . 34-l-2
Upright ....................................... .................. .................................... . 34-l-7
Cables, Hose & Chain Sheaves ............. .............................. .. .......... . 34-1-18
Pantograph Carriage Rollers ............................................................ 34-l-23
Upright Rollers ................................. .................................. .............34- l-29
Overhead Guard
Upright
Pantograph & LBR
SM-587 34-l-l Dee 94

GROUP 34 Upright
PANTOGRAPH REMOVAL
Preparation
NOTE
Iftheupright is to be removed, a
5ton chain hoist equipped with
safety hooks is required. Upright
weights are provided in
Specifications, Group 40 of this
manual.
l Be sure truck is parked on a flat level surface.

2. Fully extend pantograph.
l Lower the pantograph onto hardwood (oak)
blocks as shown.
l Place a support (2 x 4 or 4 x 4) between the front
andrearmembersofthepantograph (asshown).
Thisistopreventthepantographfromretracting
when disconnected from the upright and hy-
draulic plumbing.
3. Now, actuate the lowering control long enough
for the primary cylinder to collapse providing
some slack in the lift chains. Release control.
l Remove key from switch.
5. Disconnect truck battery at the battery discon-
nect lever.
Wear Safety Glasses
Remove jewelery
before working
on truck
Dee 94 34-1-2
SM-587

Upright R&R GROUP 34
t Upright
4J Pantograph \ Lift Chain
6. Remove two bolts (1) from cable retainers (2). 11. Remove cotter pins (6).
7. Remove front and rear retainers. 12. Remove chain anchor pins (7) securing the lift
chains to the carriage chain anchors.
8. Disconnect electrical plug (3).
9. Remove both harness clamp bolts (4). NOTE
10. Disconnect hydraulic hoses from tube connec- Lift Chains may be disconnected
tions (5) using two wrenches. One wrench to at the Primary Cylinder Piston
hold the tube connection(s) while loosening the Head (see next page) or from the
hose connection(s). There will be some hydrau- carriage as shown here.
lit fluid leakage upon disconnecting fittings.
SM-587 34-l -3 Dee 94

GROUP 34 Upright R&R
Cylinder Piston Head II))
Chain Anchor --Bw
NOTE
Carriage chains may be dis-
connected at the primary cylinder.
l Remove cotter pins and anchor pins securing lift

chains to the chain anchors. Remove lift chains
one at a time from the chain anchors.
IMPORTANT
Once a lift chain has been
disconnected, lay it over the
pantograph. Then, using wire, tie
the chain end to the LBR. This
will keep the chains out of the way
and from falling to the ground.
Dee 94 34-l -4 SM-587

Upright GROUP 34
I
.
.
;
i
. Hooks
. 13
.
.
..
..
.
.
F Raise both inner and
intermediate rails until the
. inner rail channels are
clear of the carriage
rollers.
1 Hardwood (Oak) Blocking 1
13. Using a 5ton chain hoist, attach hoist to the .4. Raise both inner and intermediate rails until the
inner and intermediate rail assemblies, see illus- inner rail channels clear the carriage rollers.
trations above. Be sure hoist is equipped with
safety hook(s).
SM-587 34-l -5
GROUP 34 Upright
15. Move truck away fi-om pantograph just far NOTE
enough to allow the intermediate and inner rails If the upright or rail lift cylinders
to clear the pantograph. are to be removed, refer to the
16. Completely lower the intermediate and inner following pages.
rail assemblies.
The free lift (center) cylinder may
17. Disconnect chain hoist and move truck away be removed without removing the
from pantograph. upright.
l Backup truck just enough to to provide clearance

between pantograph and upright rails
INRails
a Fully lower intermediate & inner rails
l Disconnect hoist safety hook from lifting device
l Move truck away from pantograph 1 1
Hardwood (0ak)Blocking
Dee 94 34-l -6 SM-587

Upright GROUP 34
UPRIGHT REMOVAL
Preparation
NOTE
If the pantograph has not been
removed, refer to pages 2 thru 6 for
removal instructions. Pantograph
must be removed from upright
before attempting to remove
upright.

l Remove key from switch.
2. Disconnect truck battery at the battery discon-
nect.
3. Remove battery from truck. Refer to Group 12.
Wear Safety Glasses
Remove jewelery
before working
on true
L
importance. Before disconnecting
hydraulic components, exterior
surfaces to prevent dirt and foreign
mater from entering the hydraulic
system.
SM-587 34-l -7 Dee 94

GROUP 34 Upright
4. Remove Console Cover, see above. Remove fasteners securing cover to truck. Remove cover. Open rear
door.
5. Remove Center Pad, see below. Loosen bolts located beneath the pad at the lower edge. Lift pad upward
and remove from truck.
Hook(s)
Center
Pad
3i0tf S Etsoo
L.H. Side Center Hanger
Dee94 34-l -8 SM-587

Upright GROUP 34
6. Overhead Guard Removal
. Attach lifting straps to all four comers of the
overhead guard (as shown).
. Connect straps to a chain hoist equipped with a
safety hook.
. Adjust hoist to support overhead guard upon
removal of mounting bolts.
. Remove upper and lower mounting bolts secur-
ing legs to overhead guard..
. Remove mounting bolts securing the overhead
guard to the upright, see arrows.
. Remove and set the overhead guard to one side.
7. Remove fasteners securing safety screen to the

upright.
8. Remove screen and set to one side.
SM-587 34-l -9 Dee 94

GROUP 34 Upright
beneath frame on
both sides of truck
-- just behind the
Butriggers.
9. Elevate and support each side of truck with suitable hardwood (Oak) blocking,
see above.
A WARNING
Make certain upright lift cylinders are fully lowered before
disconnecting hydraulic lines.
10. Disconnect the bulkhead fittings, see illustration below and on the following
pages.
IMPORTANT
Cap all Hydraulic Fittings upon
removal of tubing.
Cbnnections \
!Pl Y\i \\
Dee94 34-l -10 SM-587

Upright GROUP 34
.I Bulkhead Fitting
T Fitting Connecti
11. Disconnect hydraulic tube from lift valve and T fitting (at the bulkhead
fitting), see above.
12. Disconnect hydraulic tube with 7 fitting from lowering solenoid valve and
bulkhead fitting, see below.
I
Dee 94
GROUP 34 Upright
13. Disconnect hydraulic tubing from the auxiliary

valve and the bulkhead fittings.
l Cap each tube to prevent dirt and foreign debris
from entering.
l Be sure all bulk head fittings are capped.
Hydraulic y
Connections \ \
Dee 94 34-l -12

Upright GROUP 34
14. Disconnect Electrical plugs and tie them out of

the way with a tie wrap, as shown below.
Rail Cylinder
SM-587 Dee 94
GROUP 34 Upright
2 1. Move upright away from the truck so it may be

lowered to the floor.
IMPORTANT
Chain all three rails together at
the upper tie bars so they do
LiftingStraps not move independently. See
below.
ChZns
15. Place lifting straps beneath the upper tie bars of

the outer, intermediate and inner rail assemblies
(one strap at each side of upright as shown here).
Connect strap ends to the chain hoist. Be certain
the hoist is equipped with a safety hook.
16. Actuate lift hoist until straps are taunt. You will
want enough strap tension to support the upright
after it is disconnected from the truck.
17. Loosen the upper (four) capscrews (1). These
are accessible from the front of the truck.
NOTE
The upper bolts (1) are torqued
to: 200 lb.ft. (lightly oiled)
18. Loosen retainer bolts (2). These are accessible

from within the battery compartment.
NOTE
The lower bolts (2) are torqued
to: 375 lb.ft. (lightly oiled)
19. Remove retainer bolts (2).

20. Remove capscrews (1).
NOTE
Some trucks will be equipped with
spacer blocks. These blocks will
drop free upon removal of the
upright. Be certain the blocks are
installed when reassembling the
upright to the truck.
Dee 94 34-1-14 SM-587

Upright GROUP 34
Outrigger(s)
d
Inner Rail Assembly
t Floor
22. Next, using hardwood (oak) blocks, space them

equally on the floor to support the upright (as
shown above). The upright should be lowered \\
onto the blocks (truck side facing downward)
outriggers pointing upward.
This will allow the rail assemblies to be pulled
out of the outer rail assembly providing access to
rail rollers and secondary cylinders.
A CAUTION
Be careful not to damage
hoses.
Rail Cylinders
Pulling the inner and intermediate rail assem-
blies part way out of the top of the outer rail
assembly will allow removal of the secondary
cylinders. The rail cylinders must beremoved to
adjust or replace the lower rail rollers.
Rollers & Shims
Access to the rollers and their shims is accom-
plished by pulling the rail assemblies part way
outthebottomoftheouterrail assembly after the
rail cylinders have been removed.
SM-587 34-1-15 Dee 94

GROUP 34 Upright
!3. Loosen and then remove hydraulic fittings at the 24. Remove snap ring located at the base of eacl
base of the L.H. and R.H. Rail Lift Cylinders. cylinder, see below.
Discard old O-ring seals. Use new seals at time
of installation.
Outrigger
7
Inner Rail Assembly
L-
Rail Assembly ;semblv Oak Blockinae
t Floor
Dee94 34-1-l 6 SM-587

Upright GROUP 34
25. Remove the external snap ring from the top of each piston rod.
26. Remove washer from each rod.
27. Support the cylinders, and move the rails outward far enough to
allow removal of the cylinders.
NOTE
Each cylinder is equipped with a weldment near the
top end of the barrel assembly. This weldment fits
over an alignment pin that is part of the upright.
Move cylinder off pin and out of upright.
A WARNING
Rail cylinders weigh between QQQ and ooo
pounds each. Exercise care when removing a
cylinder from the upright.
Rail
Cylinder
SM-587 Dee 94
GROUP 34 Upright
Cable, Hose & Chain Sheaves
Remove snap rings (6) and sheaves (5).
Remove screws (4) securing mounting plates to
block (16) and remove assembly from block.
Remove pin (15) and block (16) from cylinder
rod.
Loosen and remove nuts (l), bolts (3), and spac-
ers (2). 16
5
Disassemble assembly. Replace any damaged
6
components.
Installation is the reverse of removal.
7
Free Lift Cylinder Cylinder 8
l Remove cotter pins (7), jam nuts (1 l), nuts (lo),
centering bushings (9).
l Remove chain anchors and lift chains (items 8 &
13).
l Remove snap ring (14). Lift cylinder off center-
ingpin (12) andout of upright. Installation is the
reverse of removal.
NOTE
Free Lift Cylinder may beremoved
with upright attached to truck.
A WARNING
Free Lift Cylinder weights
between ooo and ooo pounds.
Excercise care when removing
cylinder from upright.
r Inner Rail Assembly
t Floor
Dee 94 34-1-18 SM-587

Upright GROUP 34
Cable, Hose & Chain Sheaves
Nut (1) -
+- Screw (4)
Block (11
Secures Block to Cylinder Rod
Sheave (5)
SM-587 34-l-19 Dee 94

GROUP 34 Upright
l Remove washer, sheaves and spacer.
Cable and Chain Sheaves
l Replace damaged components.
Removal
Installation is the reverse procedure of removal.
l Loosen andremoveretainerbolt from stub shaft.
rmediate Rail Assembly
Chain Sheave
13ait I Intermediate Rail
Dee 94 34-l -20 SM-587

Upright
GROUP 34
Inside Spanner Tool
Outside Spanner Tool
SM-587 34-1-21
Upright
GROUP 34
Carpenter Square
34-1-22 SM-587
Upright GROUP 34
Pantograph Assembly
SM-587 34-1-23 Dee 94

GROUP 34 Upright
Inner Rail Assembl
t Floor
PANTOGRAPH CARRIAGE ROLLERS

The clearance between the upright innerrails and the pantograph carriage rollers must be checked and adjusted.
(Checks and Adjustment)

NOTE
Roller Clearance Check and Adjustment may be accomplished with upright mounted to the
truck or removed and laying on the floor as shown above.
Spanning Inner Rail Assembly

1. Span inner rail with inside spanner tool.
l Find the smallest distance between the rails.
l After finding the smallest distance, place a roller shim between the spanner tool and the inner rail. Then
lock tool in position.
Inner Rail
Step 1
Span Rail i
to find
narrowest
point.
Step2
Insert
Dee94 34-l -24 SM-587

GROUP 34
Outside Spanning Tool
Inside Spanning Tool
2. Set outside spanning tool to match the adjusted

inside spanning tool.
3. Lock the outside spanning tool in the adjusted

position.
4. Span upper carriage rollers at their outer most

camber point. Add or remove shims at roller
shaft to match tool size.
5. Center carriage rollers by counting the total of
shims used on both right and left upper rollers
and then dividing them in half.
. Place half the total on the right and half on the left
roller shaft. If there was an odd number of shims,
install the odd shim on the right roller shaft.
IMPORTANT
When upright is fully extended,
the upper carriage rollers extend
beyond the inner rail assembly. To
allow therollers toretract smoothly
back into the rail, one shim should
be removed from each side.
6. Installuppercarriagerollers and securely tighten

the Allen head retaining bolts.
SM-587 34-l-25 Dee 94

GROUP 34 Upright
7. Span center carriage rollers at their outer most

camber point. Add or remove shims at roller Carriage Rollers
shaft to match tool size.
8. Center carriage rollers by counting the total of
shims used on both right and left center rollers
and then dividing them in half.
l Placehalfthetotalontherightandhalfontheleft
roller shaft. If there was an odd number of shims,
install the odd shim on the right roller shaft.
9. Place square at the outer most camber of the

centerandlowerrollers. Holdsquare tight against
rollers and take the following measurements.
l Measure the distance between the top of the
square and straight edge at point (A).
l Take a measurement at point (B). These mea-
surements should be the same. If they are not,
add or remove shims from the lower roller shaft
until distance measured at each point is equal.
Dee 94 34-l -26 SM-587

Upright GROUP 34
10. Spanlower rollers. Addor subtract shims to (the Spanning Lower
roller that has not been squared)match the size Carriage Rollers
of the outside spanning tool.
11. Now check and adjust rollers on opposite side of

carriage. Place square at the outer most camber
of the center and lower rollers. Take measure-
ments as before. This side will be square within
l/32; if not, return to Step 9 and repeat proce-
dure. Make certain rollers are centered as pre-
viously describbed.
SM-587 34-l -27 Dee94

GROUP 34 Upright
12. The top carriage rollers are checked last. Re-

member that the top carriage rollers extend out
of the inner rails when the pantograph carriage
is fully elevated. To make re-entry of these
rollers into the inner rails easier, additional
clearance is required for the top carriage rollers.
(Refer to steps 4,5 & 6).
l Place the square directly through the centers of
the rollers as shown in opposite illustration.
l See if a l/32 roller shim will fit between the
outer most camber of the roller and the square.
There must be some clearance between the
square and the side surface of the top roller. This
clearance should not exceed l/32 or one shim.
l If adjustment is necessary, remove Allen screw
and roller. Add or remove shim as necessary to
acquire correct adjustment.
l Install Allen screw and check adjustment again.
13. Check opposite upper roller in the same manner,

adjust if necessary.
NOTE
Upper Rollers only are retained
with Allen head screw. Center and
lower rollers are always captive
within the upright rails.
Dee 94 34-l-28
SM-587
Upright GROUP 34
The triple stage upright, as the name implies, As the free lift cylinder fully extends, the rail lift
has three sets of upright rails. The rails are identified cylinders and lift chains elevate the intermediate and
as: inner rails to maximum fork height.
. Outer Rails The upright is equipped with 8 rollers. This diagram
. shows the position of therollers within the triple stage
Intermediate Rails
upright.
. Inner Rails
Therearefourrollers that workbetweentheouterrails
When the free lift (center) cylinder is fully extended, and the intermediate rails.
the pantograph carriage elevates through what is
Four more rollers work between the intermediate rails
called free lift portion of upright travel. Just beyond
and inner rails.
themaximumfi-eeliftposition, therollerson top ofthe
carriage are visible as they extend out the top of the The pantograph has six rollers that work within the
inner rails. inner rail. The top two are retained by Allen screws.
SM-587 34-l -29 Dee 94

GROUP 34 Upright
Uprights are not

manufactured with
rails parallel.
Upright Rails to Rollers

The following procedure explains how to:
l lst-Measure rail-to-roller clearance.
l 2nd-Adjust rail-to-roller clearance.
34-l-30
GROUP 34
Triple Stage Upright
mmmmm
m
m
c 3
Point of Roller Contact.
IMPORTANT
With age and wear, clearance between upright rails can increase and cause excessive
looseness between rails and rollers. Upright rollers become worn, rail surfaces wear, and
stress relieving due to handling of heavy loads over a period of time may cause slight
dimensional changes between upright rails. The white arrows show clearance between rails
and rollers. The dotted lines indicate roller operating channels.
A roller clearance inspection should be performed if, during an operational check of the
upright, you note excessive looseness or binding between rail sets, or if scoring is evident
on the rails.
Properroller clearance should be maintained because the system is designed to nest the rails
snugly while providing smooth extensions.
SM-587 34-1-31 Dee 94

GROUP 34 Upright
usec-&Imp
to force roll-
ers to one
side. Torque
on C-Clamp
shouldnotex-
teed 20 Ib.ft.
Shim
Check Roller
\
ii..:.:.:.:.:.:.):.:.:.:.:.: .,.,.,.,.,.,.,.,.,.(,.,.
::::::a:::::::~:::::::~.~:~.~:~:~:~:~:~:~~:~:~
:.:.:i...A.... . . ...... . ,. ,. ,.
I
Point of roller contact.
Inner Rail
t Floor
Dee 94 34-l -32 SM-587

Upright GROUP 34
Checking roller clearances:
CAUTION Evaluation of shim requirements generally dictates

that a specific roller is acceptable until 0.040 clear-
Watch for overhead clearance
ance is exceeded, meaning adjustment requires one
when extending upright.
standard l/32 shims toreducerail-to-rollerclearance
to proper tolerances.
A WARNING
ROLLERS SHOULD BE ADJUSTED
LINE TO LINE WITH
0.020 MINIMUM CLEARANCE
PINCH POINTS
Adjustmentreference chart when usingfeelergauges.
Useextremecarewhenworking
on the upright to avoid placing IFeeler 1 Gauge will I Shimmed 1 Shim
hands or fingers into potential Step; Gauge I pass / not uass I Correctlv
pinch points. Unexpected I
movement of upright 1 l.020 I PASS I check with al
components can cause serious
injury
1.050 I not nass I Yes I 0
2 ;.050 ; PASS check with a
I I
I.080 I not pass I No, add I 1
I 1 PASS 1 check with al
Roller Clearance Inspection 3 soso I I
1.120 I notpass I No, add
Before checking roller clearance, place the intermedi-
ate rail approximated 6 inches outof the outer rail and
the inner rail approximately 6 to 12 inches out of the
intermediate rail as illustrated on opposite page. If the
upright is mounted and you are elevating the rails
hydraulically, the inner rail will automatically assume
its correct position. Note the procedure for checking
clearance is basically the same whether the upright has
been removed or is mounted on the truck.
There are two methods covered, one is using a pry bar
to position rails and rollers and the other is using a C-
clamp.
If the upright is mounted to the truck, the use of an
approved safety platform or step ladder is recom-
mended when making inspections and checking clear-
ances at the upper levels.
If the upright has been removed and placed flat on the
floor, proper blocking of hard wood (oak) or steel
supports must be used to keep the upright horizontal
with thejloor. This is especially important when fully
extending the intermediate and inner rails.
SM-587 34-l-33 Dee 94

GROUP 34 Upright
When using a pry bar:

C-Clamp Method
l Insert pry bar between the outer and intermedi-
Install C-Clamp at the location shown in the
ate rail on the right side (as shown on page 32).
illustration on page 32. It may be necessary to
Pry with moderate pressure moving intermedi-
use a block on the inside of the channel rail as
ate and inner rails left at top end of upright.
shown.
l Using a 0.020 feeler gauge, see if you can insert
Tighten C-Clamp to displace roller clearanceon
the shim between the roller and rail. There is to
that side of the upright. Now, check roller clear-
be some clearance but it is not to exceed0.040.
ance on opposite side of upright.
If the space between roller and rail will accom-
modate two or more shims, record the number of Using a 0.020 inch feeler gauge, try to insert it
shims that will fit in the open space between rail between the roller and rail at point of roller
and roller. Refer to chart on page 33. contact as shown on opposite page.
l Now pry the intermediate rail away from the If a 0.020 will pass between roller and rail, and
inner rail. Check clearance between the inter- 0.040 will not fit between rail and roller, it is
mediate rail roller and the inner rail. correctly adjusted. If the clearance exceeds
0.040, refer to the chart on page 33.
l Record the number of shims to be used on the
outer and intermediate rails opposite the rollers Record the number of shims to be used on the
checked. outer and intermediate rails opposite the rollers
checked.
IMPORTANT
There is to be some clearance but it
should not be less than 0.020 or
more than 0.050.
Dee 94 34-1-34 SM-587

Upright GROUP 34
Checking Lower Rollers
Now check the lower rollers in the same manner as

you did for the upper rollers.
outer and intermediate and inner rails opposite
the rollers checked.
$T C-Clamp
Bottom Roller
View
Check
Feeler Gauge Point of roller contact
r Inner Rail
Intermediate Rail
t Floor
SM-587 Dee 94
Upright
GROUP 34
Checking Upper Rollers with Upright Ex-

tended approximately one half of maxi-
mum lift.
Check roller clearance in this area using the same
procedure as before.
Top View 7 Roller

I Rail
/
I
Shim Check

LINE TO LINE WITH
Adjustmentreferencechartwhenusingfeelergauge:
) Feeler ) Gauge will i Shimmed i
Stepl Gauge pass I not pass Correctly I Q

1 .020 i PASS check with a I
.0.50 1 not pass 1 Yes i 0

2 / ,050 j PASS ,; check with a!
I
1.080 1 not pass 1 No, add 1 1
3 i .080 1 PASS 1 check with al
, .120 fnotpass 1 Noadd
3 f 2
Dee 94 34-l -36 SM-587

Upright GROUP 34
-
Checking Lower Rollers with Upright Ex-

tended approximately one half of maximum
lift.
_..W_A_ *v-I* ~A--.~~ A._ C... . ....
l Record the number of shims to lx used on the
miter 2nd intmnwdi~t~ mfl inner railc nnnnci+a
w_.__ .+.._ ^..._-A.UI.I _.._. a . . . .
----v -rr ..LC
Top View
Shim Check
reeler tiauge
Point of roller contacT

LINE TO LINE WITH
Adjustmentreferencechartwhenusingfeelergauges
Feeler i Gauge will 1 Shimmed
I I
Shim
I I I I
SteplGauge lpass / not pass I Correctlv I QJ
; PASS I check with a I
I I
1.050 I not pass I Yes I 0
I I I I
I I
SM-587 34-l -37 Dee 94
GROUP 34 Upright
Checking Upper Rollers with Upright Ex-

tended to within 6 of maximum lift.
Now chek roller clerance in this area using the same

. Record the number of shims to be used on the
Top View I Rail 1 ,7 Roller

------cf----AL r
Fe&x Gauge
Point of rot ler contact.

L
-1 Shim Check I-
LINE TO LINE WITH
IFeeler I Gauge will Shimmed I

I I I I
SteplGauee I pass / not uass I Correctlv I Q
1 j.020 I PASS I check with a i
I
I .050 , not pass Yes I 0
1 Pry Bar
2 I .050 1 PASS
f .080 f not pass
I checl
1 No, add
al
1 1
I I I
3 1.080 I PASS 1 check with a I
/.120 1 notpass I No, add 1 2

I I
bottom Insde \\ Pry Bar /
L
Dee 94 34-l -38Material SM-587

Copyrighted
Upright GROUP 34
Checking Lower Rollers with Upright Ex-

tended to within @ofmaximum lift.
Now chek roller clearance in this area using the same

Intermediate
Top View 7 Roller
Check
j ,
Point of roller contact.

LINE TO LINE WITH
IFeeler Gauge will ;-Shimmed i
ass / not uass 1 Correctlv LQQ

9-9 I
1 , .020 I PASS 1 check with a l
I .050" I not uass I
I Yes I 0
Pry Bar I I
2: ;.050" ; PASS 1 check with a
\ I
I.080" 1 not uass No, add 1 1
I
I
3 ; .080 ; PASS check with a
I
I .120 I not pass No, add 1 2
SM-587 34-l -39 Dee 94

GROUP 34 Upright
Determine Number of Shims needed to

make roller adjustments
Refer to Step 3. Look at the three numbers you
have recorded at each roller on the rails. The ;nims = u.ubW 1
smallest of these numbers is the total number of Etc.
shims to be added. A 0 means DO NOT add
shims.
If any of the rollers require adjustment, refer to
adjustment procedures on next page.
If the upright roller clearance was checked with
the upright mounted to the truck, and roller
adjustment is required, remove the upright as
outlined at the beginning of this section.
.0.040 - 0.060
Do not attempt to adjust shims with upright
mounted on truck.
Rails Extended Rails Extanded Rails extended to

6-l 0 inches approximately within 6-10 inches
Typical Illustration l/2 wav of maximum fork heiaht
Dee 94 34-l -40 SM-587

Upright GROUP 34
Shim Adjustment
With the upright laying horizontal on blocking.
Expose the rollers by pulling the rails part way
out the bottom as shown in opposite illustration.
Pull rollers (one set at a time) from their sheaves.
Count the number of shims used on each shaft.
Add shims as indicated in the roller clearance
check.
If the check indicates that an even number of
shims are needed (2 etc), split the number be-
tween the right and left roller. If the check
indicates that an oddnumberof shims are needed
(1,3 etc), place the odd shim on the right shaft.
Always keep the odd number of shims to one
side.
Your target for adjustment is to have the same
number of shims at each roller set (right & left ,
per rail assembly). An odd or extra shim must be
placed on the same side as the one before.
Reposition eachrolleron itsshaft using a plastic
or hard-rubber mallet. Gently tap the roller to
seat it evenly and snugly against the shims.
Upper Roller Sets
Left
9
Right
*
Intermediate Rail
i
Left
@
Left
@
1
II
Lower Roller Sets
SM-587 Dee94
El!!!!Rl5
lVl;~;~-i~Handling
GROUP 34
Section 2
Pantograph & Fork Carriage Assembly
Contents
Safetyand Preparation . .. . . .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. 34-2-2
Remove Forks .. . .. .. . . .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. 34-2-4
Servicing Carriage . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. .. . ... .. .. .. .. .. 34-2-6
Servicing Pantograph Arm Rollers . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 34-2-9
+ Upright kUpright
oClra..h r Inner Arm
Outer Arm
Servicing the Pantograph
The Pantograph Assembly may be serviced while installed in the upright with two exceptions:
The carriaee rollers and the inner and outer arm bushinps must be serviced
with the
pantograph removed from the upright.
Refer to GROUP 34, Section 1 in this manual for adjustment and service procedures.
SM-587 34-2-l Dee 94

GROUP 34 Pantograph
A WARNING
When using air pressure to clean off truck.

pressure to 30 PSI (207 kPa). Debris removed
with air pressure can cause injury.
A WARNING
Hydraulic fluid is toxic to skin, eyes and respiratory tract. Good ventilation is
normally adequate.
0q?gJ@&
A WARNING
A WARNING
Always wear Safety Glasses when working on truck.
Dee 94 34-2-2 SM-587

Pantograph
GROUP 34
Preparation
. Move truck to service area.
. Extend and lower pantograph.
. Turn key switch OFF.
All Models
1. Remove Load Back Rest Extension

. Remove bolts from LBR Extension and lift the
extension free of the fork carriage.
Bolt
Torque-l
Specification
2. EIevate and Block Pantograph. 17 - 190 Nom
. (125 - 140 Ib.ft.)
Turn key switch ON and elevate pantograph
approximately 3 to 4 feet.
Fork Chriage
. Place oak blocking (hardwood) between panto-
graph carriage and fround. Lower pantograph
until carriage rests on 4x4 blocking as shown
here. I II it
. Tilt forks forward.
. Turn key switch OFF and remove key.
. Disconnect truck battery.
as shown.
SM-587 34-2-3 Dee 94

GROUP 34 Pantograph
Standard Models Only
3. Remove forks.
. Remove fork lock
pins and snap ring
from the fork bar.
. Now, remove fork
bar from carriage
and forks. Using a
hammer and brass
drift, drive the fork
bar in direction of
arrows until free of
carriage and forks.
. Remove forks.
A WARNING
Support forks as
fork bar is removed
so they cannot fall.
Side Shift Models Only
3A. Remove Forks. Snap Ring

l Remove snap ring
from fork bar (B).
l Remove fork lock
pins from fork
guides (C). Side Shift Cylinde
Fork Guide
34-2-4
Pantograph GROUP 34
Side Shift Models Only - continued -
l Drive fork bar (B) in direction of arrows (with a
A WARNING
brass drift). When bar (B) is free of carriage,
remove forks.
Support forks as fork bar is l. Examine bushings in fork guides (C) for damage. If
removed so they cannot fall.
bushings are unfit for further service, install new
bushings.
l Check fork bar (B) for burrs or excessive wear.
f-ork,Bar (B) I Pin
Fork Bar (B)
Connects to Side Shift Cylinder
SM-587 34-2-5 Dee 94

GROUP 34 Pantograph
SERVICING
FORK CARRIAGE
Bushings
Dee 94 34-2-6 SM-587

Pantograph GROUP 34
SERVICING
FORK CARRIAGE
1. Remove retainer bolt (1 & 2) securing

pivot shafts (3 & 4) in position.
?
d. Remove Roll pin (5) from Tilt Cylinder
Rod End Mounting Shaft (6).
3. Using a brass drift, drive shaft (6) out of
each bell crank (3A) freeing cylinder
rod end from both bell cranks.
Bell Crank (3A) -
34-2-7 Dee 94
GROUP 34 Pantograph
4. Using a brass drift, drive shaft (4) out of

roller (4A) and bell crank.
_.
5. Now, drive shaft (3) outwardfree of bell crank :, : . . ,, ,. .

: ., ,, r ,, - :
, ., ; ,I i
(3A).Remove shaft and bell crank.
0
Bushinas
6. Remove old bushings and press in new ones.
NOTE
The bell crank with tilt roller (or
block) may be removed as a sub-
assembly. Removing shaft (3) will
allowbothbellcrank(3A)&roller
(4A) to be removed as a sub-
\Shaft (3)
assembly.
7. Installation is the reverse of removal.
Dee 94 34-2-8 SM-587

Pantograph GROUP 34
Fork Carriage Removal Trucks

Equipped
with
Side Shift
Solenoid Valve
Fork Carriage Removal

Side Shift Models Only
1. Remove cover bolts and cover (1).
2. Remove harness clamp (3)
3. Remove both cable and hose covers (4)..
4. Disconnect electrical plugs (2) from their con-
nectors at the solenoid valve.
5. Disconnect hydraulic connections (5) from the
solenoid valve. Cap open ports and connections.
6. Move each hose and wiring toward the rear of
the pantograph and tie them out of the way at
point (6) with tie wraps.
SM-587 34-2-9 Dee 94

GROUP 34 Pantograph
Fork Carriage Removal

Models equipped with Tilt Only
1. Remove both cable and hose covers (4), see
below.
2. Disconnect hydraulic connection (A) from the
tilt cylinder.
All Models
3. Install lifting straps as shown to chain hoist
equipped with safety hook.
4. Remove retainer bolts and pins (C) securing
scissor arms to the fork carriage.
\*
* 5. Slowly elevate carriage until free of arms. Con-
*\
tinue to elevate carriage until lower scissors
> rollers are free of carriage channels. Then set
*@)I carriage to one side.
I
b Liftingztraps
Safety Hook
Dee 94 34-2-l 0 SM-587

Pantograph GROUP 34
SERVICING PANTOGRAPH ARM ROLLERS

Thrust Pads (Scissor Arm Roller B or C) roller and thrust pad without removing scissor
assembly from carriage.
1. Disconnect reach cylinders. Refer to illustration
on opposite page. Remove retainer bolts and 3. Inspect the thrust pads for further service as
pins (item B) securing reach cylinders to shown below. Pads that are damaged or worn to
pantograph arms. their wear limit should be removed and new
pads installed.
2. Refer to illustration on this page, lift reach arms
(A) upward while pivoting arm (B) in direction 4. Remove Allen screw and pad. Install new pad.
shown by arrows. This will allow access to arm Be certain same number of shims are installed
on shaft if they were removed.
Scissor Arm Roller B & C
When pad is worn near Flush

with carriage roller, new pads
should be installed.
rotating Arm B ( as shown) to move km

roller upward and out of the carriage channel.
Be extremely careful that you

do not pinch your hands or fingers.
SM-587 34-2-l 1 Dee 94

GROUP 34 Upright
\ Inner Arm Pivot Bearings
Pivot Bearing
L Shield
Prepack bearing cup & cone assemblies

prior to installation.
Nut (*)
Install with chamfer towards nut lock. Torque to: 27 - 41 lN.m (20-30 Ib.ft.
5. Disassemble the outer arm assembly. NOTE

6. Replace seals with new ones.
If the Inner Arm Pivot Bearings
need to bereplaced, the pantograph
7. Wash bearings (cups & cones) in a Stoddard carriage must be removed from
type cleaning solvent. Inspect parts for further the upright. Refer to Group 34,
serviceability. Replace any part that is nicked or Section 1.
having rough spots in the cones or cups. Cones
and cups must be replaced together. Do not 7. Reassemble to the reverse of disassembly.
install a new cone in an old cup. Lubricate parts with clean chassis grease
6 Check grease fitting for damage and to make prior to assembly.
certain none are missing.
IMPORTANT
Prepack bearing cup & cone assemblies prior to installation
Dee 94 34-2-l 2
SM-587

EMIRKlVl;t$;\Handling GROUP 34
Section 3
Rail Lift Cylinder Overhaul
Contents
Disassembly ...................................................................................... 34-3-3
Inspection ............................................................. ............................. 34-3-4
Reassembly ................................... ...... ...... .. .... .................... .............. 34-3-5
Cylinder Removal Instructions are
Snap Ring -ba
Rail Lift
Cylinder --)
\
Alignment
Pin
SM-587 34-3-l Dee 94

GROUP 34 Lift Cylinder
A WARNING

working on truck.
A WARNING
normally adequate.
A CAUTION
Cleanliness isof extremeimportan ce. Beforedisconnecting hydrauliccomponents,
from entering hydraulic system.
Dee94 34-3-2 SM-587

Lift Cylinder GROUP 34
Disassembly _-;
_____--- A
Wiper I
1. Wash exterior surface of cylinder thoroughly I
before disassembly. I
Seal ,
G3
l A Stoddard type cleaning solvent should be used 0 Ian Spring
to wash the cylinder.
8
Plunger m)
GI
Back-Up: 1
Soft Fiber Brush
2. Place gland end of cylinder in a vise equipped

with soft jaws. Do not over tighten.
l Using a bronze (or brass) drift, unlock the lock-
washer fom the gland and the cylinder barrel.
I :
I :
Install
i Back-Up & O-Rings
asshown.
Barrel
SM-587 34-3-3 Dee 94

r Plunger
7 I r.
Washer
Spring
SnaD Ring7 ---Barrel
Piston Rod
LRing
Mounting
Groove
L Split Piston
Washer Bleeder L u-cup
3. Using a spanner wrench or a bronze (brass) drift,

remove gland assembly from cylinder barrel.
. End View
Remove lock washer, back-up ring and O-ring
from cylinder gland Cylinder Gland
. Remove rod wiper and seal from cylinder gland.
4. Pull piston rod from barrel assembly.
. Remove spacer and split piston from piston rod.
5. Remove snap ring, retaining washer, plunger
and spring from base end of piston rod.

1. Discardold seals, O-rings, back-up rings, wiper
and lock washer.
2. Wash remaining parts in a Stoddard type clean-
ing solvent and dry with a clean shop rag.
3. Inspect threaded parts for damage.
4. Examine the piston rod, inner surfaces of the
gland assembly and cylinder barrel for scoring,
5. Inspectsurfaceofthepistontobesuretitisclean,
nicks or scratches. A crocus cloth may be used
smooth and free of damage.
to clean up light scratches, etc. Be careful that
you do not remove the chrome plating when l Replace all damaged or unserviceable parts.
polishing surface.
Dee 94 34-3-4 SM-587

Reassembly Hydraulic Cylinder Seal Tool
Piston Rod & Piston
Clark Part No.s: 1801783 and 1801784
Avail from: Central Parts Divn.
2. Lubricate and install the spring, plunger, washer
7300 South Cicero Ave.
and snap ring into base end of the piston rod.
Refer to illustration on page 34-3-3. Chicago, Ill. 60629
3. Lubricate and install spacer onto the piston rod. Example
Refer to illustrtion on page 34-3-3.
4. Now, lubricate and place split piston onto the
piston rod. Start piston rod into cylinder barrel
and gently push rod inward until it bottoms out.
Be careful that you do not nick or scratch
chrome surJace.
Gland Assembly
2. Install the inner seal into the gland groove. Be
certain the sealing lip faces inward. Use tool
shown in opposite column. Be carejiil that you
aonot cut or nick the sealing lip upon installa-
tion.
3. Install a new wiper ring into the gland.
4. Lubricate and install a new O-ring and backup
ring into the outer groove on the gland. Install
lock washer on outside of gland.
NOTE
Placing a plastic parts bag over the
gland threads when installing the
O-ring and back-up ring will help
protect parts against damage,
cutting, etc.
5. Now, carefully start the gland assembly over the

piston rod and screw it into the barrel finger
tight. Do not cut or nick sealing lips upon
installation.
6. Using a bronze (or brass) drift, tighten gland
against barrel assembly.
7. Next, using drift as shown in opposite illustra- Set Lock Washer into Grooves provided.
tion, deform lock washer into the grooves pro-
vided in both the gland and barrel to securely
lock them together.
SM-587 34-3-5 Dee 94

CLSRK
~#$?ri;\Handling
GROUP 34
Section 4
Free Lift Cylinder Overhaul
Contents
Disassembly ...................................................................................... 34-3-3
Inspection .......................................................................................... 34-3-4
Reassembly ...................................................................................... .34-3-5
Cylinder Removal Instructions are

covered in Group 34, Section 1.
SM-587 34-4-l Dee 94

A WARNING
Wear eye protection and protectiveclothing when drying with air pressure. Reduce

working on truck.
A WARNING
normally adequate.
A CAUTION
Cleanlinessisofextremeimportance. Beforedisconnecting hydrauliccomponents,
from entering hydraulic system.
Dee 94 34-4-2 SM-587

Disassembly I
1. Wash exterior surface of cylinder thoroughly Wiper

before disassembly.
Scarf Cut
l A soft fiber brush should be used to remove Back-Up Ring
threaded areas, etc. Install
Seal F3 Back-Up & O-Rings
l A Stoddardtypecleaning solvent should be used Q as shown.
to wash the cylinder.
Washer :
Soft Fiber Brush
2. Place gland end of cylinder in a vise equipped

with soft jaws. Do not overtighten.
l Using a bronze (or brass) drift, unlock the lock-
washer fom the gland and the cylinder barrel.
I-
SM-587 34-4-3 Dee 94

Reassembly Hydraulic Cylinder Seal Tool
Piston Rod & Piston
Clark Part No.s: 1801783 and 1801784
Avail from: Central Parts Divn.
2. Lubricate and install wear ring onto the piston
7300 South Cicero Ave.
rod. Refer to illustration page 34-4-3.
Chicago, Ill. 60629
3. Now, start piston rod into cylinder barrel and
gently push rod inward until it bottoms out. Be Example
careful that you do not nick or scratch chrome
sueace.
Gland Assembly
1. Lubricate new seals, O-rings, back-up rings,
wiper ring and gland assembly with clean hy-
draulic fluid.
2. Install back-up ring and the inner seal into the
gland groove. Be certain the sealing lip faces
inward. Use tool shown in opposite column. Be
careful that you do not cut or nick the sealing lip
upon installation.
. Lubricate and install (large) O-ring into the
outer groove nearest top end of gland.
NOTE
Placing a plastic parts bag over the
gland threads when installing the
O-rings and back-up rings will help
protect parts against damage,
cutting, etc.
. Next, lubricate and install a new back-up ring

and O-ring into the outer groove at the base end
of the gland.
3. Install a new wiper ring into the gland.
4. Now, carefully place the gland assembly over
thepiston rod and, after applying lube to threads,
screw it into the barrel finger tight Do not cut or
nick sealing lip(s) upon installation.
5. Using a bronze (or brass) drift, tighten gland
against barrel assembly.
7. Next, using drift as shown in opposite illustra-
tion, deform lock washer into grooves provided Set Lock Washer into Grooves provided.
in both the gland and barrel to securely lock them
together.
SM-587 34-4-5 Dee 94

EMRKMaterial
Company
Handling
GROUP 34
Section 5
Lift Fork Inspection
Contents
Inspection Procedure ........................................................................ .34-5-2
Fork Wear Caliper .......................................................................... ...34-S-2
For Inspection Illustrations .......................................................... 34-5-3 & 4
Lift Forks
Shank
SM-587 34-5-l Dee 94

GROUP00 Component
FORK WEAR INSPECTION Inspection Procedure

ITA Recommended Practices for the inspection and l Set the top jaws by measuring the thickness of
repair of Forks on Fork Lift Trucks require that a fork the shank, see Figure 2 (reference measure-
be removed from service when the thickness of the ment).
blade has worn by 10% of its original thickness. The calipers should be squeezed by hand until
the top jaws make contact with both sides of the
Fork Wear Calipers shank.
The forks can be checked for wear by using a IMPORTANT
Fork Wear Caliper which is a go-no go gauge that The amount of force used to
will clearly indicate when the fork does not comply squeeze the tips of the top jaw
with standards, The design of the caliper is based on against the fork should be very
the assumption that on a new fork, the cross section of slight as caliper distortion can
the fork arm blade between the end of the taper and the occur if excessive force is used.
heel is the same as the shank. Because the middle of
the shank is not in contact with the top or bottom Care should be taken when using
members of the carriage and therefore not subject to the calipers to hold them square
wear, it can be used as a reference point to set the across the shank or an incorrect
calipers. reading will be obtained.
NOTE Once the top (outside) jaws are set to the thick-
Fork Wear Calipers (Clark Part No. 1803641) ness of the shank, the calipers are then ready to
havetwomeasuringpointsorjaws(Figure 1,opposite check the blade of the fork.
page), they are:
l Check Fork Blade against Shank Thickness
l The outside or top jaws are used to set the in the area shown in Figure 2.
calipers.
Carefully fit the caliper over the fork blade. Ifthe
l The inside or lower jaws have been fixed at a inside or lower iaws of the calipers pass over the
point on the caliper legs that will always mea- flanks of the fork blade at any point between the
sure 10% less than the reading recorded by the end of the taper and the heel of the fork, the forks
top jaws (Figure 3, opposite page). should be replaced.
Incorrect Readings
Incorrect readings may be mistakenly made by accidentally altering the setting of the calipers when
laying them down or when checking the blade. If is good practice to recheck caliper setting on the shank
each time before checking a fork blade.
Accuracy in caliper measurement depends on the sense of touch. To get a delicate touch of
the caliper on the fork, the caliper should be held lightly and not with a grab grip. With a
little practice the required skills can be easily acquired.
Fork Wear
The most common cause of fork wear is when the fork is allowed to drag the floor due to misadjusted
chains,chainstretch,tirewear,etc.Carriagechainsshould beadjustedso theforkis 1/2offthefloorasmeasured
at the heel of the fork. The area that fork wear usually appears is illustrated in Figure 4.
Dee 94 34-5-2 SM-587

GROUP 34
Fork Wear Caliper Area of Fork Shank
Clark Part Number 1803641 to be measured as
t f
Area of Fork Blade to
- be measured for wear.
Figure 2
Figure 3
Cross Section
Figure 4
Fork Blade
Area of Typical Fork Wear
SM-587 34-5-3 Dee94

GROUP 00 Component
The fork top surface should be level and
Inspect Fork Condition l
even with each other. The height differ-

l Inspect forks for cracks, breaks, bending ence between both fork tips should be no
and wear. more than 3% of the fork length.
r 3% of B Maximum Difference
... __..._._.-..._..__._________
...._ ....~......._._
.......__.
.. -
/ +ForkTps
bent or damaged, have them

inspected by a trained mainten-
1 Maximum -, ance person before operating the
Carpenter
Inspect Forks for Twists and Bends Square
l Place a 2 thick metal block, at least 4 wide by
24 long on the blade of the fork with the 4
surface against the blade.
l Put a 24 carpenters square on the top of the
block and against the shank.
l Check the fork 20 above the blade to make sure
it is not bent more than 1 inch maximum.
Dee94 34-5-4
SM-587

CMRH~de;dx\Handling GROUP 34
Section 6
Upright Chain Inspection; Adjustment & Replacement
Contents
Periodic Inspections .. . ... ... .. .. .. .. .. .. .. ... .. .. ... .. .. .. ... ... .. .. .. .. .. .. .. .. .. .. . .. ... .. . . 34-6-2
Chain Length Adjustments . .. .. .. .. .. .. .. .. ... .. .. ... . ... .. .. .. .. .. .. .. .. .. .. . ... .. .. . . .. . 34-6-3
Triple-Stage Upright (TSU) Chain Length Adjustments . .. .. .. .. .. .. . ... .. .. 34-6-4
Chain Lubrication .. . ... . .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . ... .. .. .... .. .. .. .. .. .. .. .. . . .. .. ... . .. . 34-6-6
Chain Removal and Replacement . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . . 34-6-6
General Guidelines . .. .. .. .. .. .. .. .. .. .. .... .... .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . 34-6-6
Lift Chains . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. . 34-6-6
Primary Cylinder/Carriage Chains (T.SUs) . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 34-6-7
Other Chain Service Notes . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 34-6-7
Primary Cylinder Piston Head 111))
Chain Anchor W
SM-587 34-6-l Dee94

GROUP 34 Chains
Periodic Inspections allowed to operate in this condition, a pin, or series of

pins, canbegin to twist out of a chain resulting in failure.
Each 50-250 hours of operation (more frequently in The pin head rivets should be examined to determine if
severe or extreme environments), chains should be the TEE flats are still in correct alignment. Chain with
inspected and lubricated. Inspection should focus on rotated/displaced heads or abnormal pin protrusion
the following: should be replaced immediately. Do not attempt to
repair the chain by welding or driving the pin(s) back
Elongation into the chain. Once the press fit integrity between
When a length of 12.00 inches (305 mm) of a new chain outside plates and pins has been altered, it cannot be
has elongated to a length of 12.360 inches (315 mm), it restored. Any wear pattern on the pin heads or the sides
should be discarded and replaced. It is important to of the link plates indicates misalignment in the system.
measure the chain in the section that moves over the Thisconditiondamagesthechainandincreasesfiictional
sheaves becauseit receives themost frequent articulation loading, and should be corrected.
Measuring the chain near its clevis terminals could give
an erroneous reading as it would not have flexed as
frequently, if indeed at all, as nearer the middle of the
assembly.
Turned pins and abnormal pin protrusion.
Chains should be replaced when wear exceeds 3% of Cracked Plates

the pitch or when I2 inches (305 mm) of chain is The chains should periodically be inspected very
stretched 318 inch (IO mm). carefully, front and back as well as side to side, for any
evidence of cracked plates. If any one crack is discovered,
thechain wouldbereplaced. Itisimportant,however,
Edge Wear to determine the causes of the crack before installing
Check the chain for wear on the link plate edges caused new chain so the condition does not repeat itself.
by running back and forth over the sheave. The maximum
reductionofmaterial shouldnotexceed5%.Thiscanbe . Fatigue Cracking - Fatigue cracks are a result of
compared to a normal link plate height by measuring a repeated cyclic loading beyond the chains endurance
portion of chain that does not run over the sheave. limit. The magnitude of the load and frequency of
Distorted or battered plates on leaf chain can cause tight its occurrence are factors which determine when
joint and prevent flexing. fatigue failure will occur. The loading can be
continuous or intermittent (impulse load).
k5X of H
Worn contours and worn sulfates on the outside links
G3
Fatigue cracks generally run from the pin hole toward
or pin heads should not exceed 5% of new link height. the edge of the link plate approximately 90 from the
line of pull.
Turning or Protruding Pins Fatigue cracks almost always start at the link plate
pin hole (point of highest stress) and are
Highlyloadedchainopemtedwithinadequatelubncation
perpendicular to the chain pitch line. They are often
can generate abnormal frictional forces between pin
microscopic in their early stage. Unlike a pure
and link plates. In extreme instances, the torque could
tensile failure, there is no noticeable yielding
surpass the press fit force between the pins and the
(stretch) of the material.
outside plates, resulting in pin rotation. When chain is
Dee 94 34-6-2 SM-587

Chains GROUP 34
l Stress-Corrosion Cracking-The outsidelinkplates, Ultimate Strength Failure

which are heavily press fitted to the pins, are
particularly susceptible to stress corrosioncracking. This type of failure is caused by overloads far in excessof the
Like fatigue cracks, these initiate at the point of design load.
highest stress (pin hole) but tend to extend in an arc-
like path between the holes in the pin plate.
Broken plate caused by overload.
Tight Joints
All joints in leaf chain should flex heely. Tight joints resist
Arc-like cracks in plates are a sign of stress corrosion. flexure and increase internal friction, thus increasing chain
tension required to lift a given load. Increased tension
More than one crack can often appear on a link accelerates wear and fatigue problems.
plate. In addition to rusting, this condition can be
caused by exposure to an acidic or caustic medium
or atmosphere.
Stress corrosion is an environmentally assisted

failure. Two conditions must be present: a corrosive If lubricationdoes notloosena tightjoint,thechainmayhave
agent and static stress. In the chain, static stress is corrosion and rust problems or bent pins and must be
present at the pin hole due to the press fit pin. No replaced.
cyclic motion is required, and the plates can crack
during idle periods. The reactions of many chemical
agents (such as battery acid fumes) with hardened Chain Length Adjustments
steel can liberate hydrogen which attacks and
weakens the steel grain structure.
An upright
Aor
WARNING
carriage can move
For this same reason, never attempt to electroplate
a leaf chain or its components. The plating process unexpectedly:
liberates hydrogen, and hydrogen embrittlement
cracks will appear. These are similar in appearance l Do not walk or stand under raised forks.
to stress corrosion cracks.
If a plated chain is required, consult Clark. Plated l Keep clear of load and carriage when
chains are assembled from modified, individually making any check or adjustment.
plated components which may reduce the chain
rating. l Keep your arms and fingers away from
moving parts of the upright.
l Corrosion Fatigue - Corrosion fatigue cracks are
very similar (in many cases identical) to normal l Block the carriage or upright when
fatigue cracks in appearance. They generally begin working with the components in a raised
at the pin hole and move perpendicular (90) to the position.
chain pitch line.
l Do not reach through open areas of the
Corrosion fatigue is not the same as stress corrosion. upright.
Corrosion fatigue is the combined action of an
aggressive environment and a cyclic stress (not a l Never attempt to move or align the rails
static stress alone, as in stress corrosion). by hand. Use a prybar.
Failure to follow these warnings can result

in serious injury.
SM-587 34-8-3 Dee 94

GROUP 34 Chains
IMPORTANT Triple-Stage Upright (TSU) Chain

For all chain adjustments: Length Adjustments
l Threaded chain anchors must be left free to Triple-stage uprights use two chain sets; one set for carriage
pivot in mouting hole. lift and one set for rail lift. Adjustment anchors for the lift
cylinder stage are located at the back of the outer rail.
l Anchor cotter pin heads must be to the inside of Adjustment anchors for the primary lift stage are behind the
the upright. primary cylinder. Carriage chain anchors are not intended for
adjustment.
l Torque jam nuts to adjustment nuts to 100-200 For TSU inner rail lift chains, chain length must be adjusted
Nom (74-l 48 ft-lb). if the difference between the bottom of the inner rail and the
outer rail is greater than 10 mm (0.40 in).
l Make sure chain anchors are secured so that no
twist is evident in the chains. For the TSU primary cylinder lift chain, the chain length must
be adjusted if:
l The fork-to-ground clearance is less than 5 mm (0.20 in)
or more than 25 mm (1.0 in) when the upright is vertical.
IMPORTANT l The center of the bottom carriage roller comes within 20
The carriage stop must not be mm (.80 in) of the bottom edge of the inner rail.
l The carriage safety stop hit the inner rail stop at full lift
allowed to contact the upright
height.
stop under any circumstance
To adjust the cylinder lift chains on a TSU use the following
during normal operations.
illustration and procedures:
Dee 94 34-6-4 SM-587

Chains GROUP 34
IMPORTANT
For all chain adjustments:
l Threaded chain anchors must be left free to

pivot in mounting hole.
l Anchor cotter pin heads must be to the inside of

the upright.
l Torque jam nuts to adjustment nuts to 100-200

Nom (74-l 48 ft-lb).
. Make sure chain anchors are secured so that no

twist is evident in the chains.
Adiust chain length h
LTo inner rail 2. Carriage roller position:
a. Raise carriage about 1 m (3.2 ft) and smear a bead of
grease on the bottom 75 mm (3 in) of the inner rail in
the area of the roller pattern.
b. Tilt upright fully back and completely lower.
C. Measure the distance from where the center of the
1. Set the upright in the vertical position. bottom carriage roller stopped to the bottom edge of
2. Break the jam nuts loose on the chain anchors. the inner rail. Distance should not be less than 20 mm
3. Adjust the chain anchor adjustment nuts until the bottom (0.80 in) or chain length adjustment is required.
of the inner rail is within 2.5 mm (0.10 in) of the bottom 3. Carriage stop-to-upright:
of the outer rail. a. Lift upright to its full height and check for clearance
To adjust the primary cylinder lift chain on a TSU use the on the carriage safety stop.
following illustration and procedures: b. If the carriage stop hits the upright stop, adjust the
chain anchor adjustment nuts out until there is at least
3 mm (0.12 in) clearance between the stops.
IMPORTANT
The carriage stop must not be
allowed to contact the upright
stop under any circumstance
during normal operations.
If all three chain length requirements listed above cannot be

met,thetirediametermaybeoutofthedesignrangeallowance.
Also, excessive tire wear will decrease carriage stop clearance.
Adjust chain length here-

To carriage
1. Fork-to-ground clearance:
a. Set the upright to vertical position.
b. Break the jam nuts loose on the chain anchors.
c. Tumthechainadjustmentnutsuntilclearancebetween
forks and ground is lo-20 mm (0.40-0.80 in)
SM-587 34-65 Dee 94

GROUP 34 Chains
Chain Lubrication General Guidelines

Like all bearing surfaces, the precision-manufactured, Chain Movement - Make sure that the chain operating
hardened-steel, joint-wearing surfaces of leaf chain require a path is clear and that the chain articulates freely through
film of oil between all mating parts to prevent accelerated its full range of operation.
WM.
Lubrication - Assure that the chain is well lubricated
Maintaining a lubricant film on all chain surfaces will: with the heaviest oil that will penetrate the void between
l Minimize joint wear. the link plate apertures and the pins.
l Improve corrosion resistance.
l Reduce the possibility of pin turning. Paint - Make sure the chain does not get painted over at
l Minimize tight joints. any time.
l Promote smooth, quiet chain action.
l Lower chain tension by reducing internal friction in the Protection - Where necessary, as a protection from
chain system. atmosphere or sliding wear, the chain may be covered
Laboratory wear tests show #40 oil to have greater ability to with a layer of grease. It should be noted, however, that
prevent wear than #lO oil. Generally, the heaviest (highest the grease will have to beremoved at a later date for chain
viscosity) oil that will penetrate the joint is best. inspection and relubrication.
Whatever method is used, the oil must penetrate the chain Chain Mountings - Double check to be sure all chain
joint to prevent wear. Applying oil to external surfaces will fastening devices are secured and all adjustments have
prevent rust, but oil must flow into the live bearing surfaces been made to assure uniform loading of multiple chain
for maximum wear life. applications. Check chain anchors and pins for wear,
breakage and misalignment. Damaged anchors and pins
To prepare the chain for oiling, the leaf chain plates should be should be replaced.
brushed with a stiff brush or wire brush to clear the space
between the plates so that oil may penetrate the live bearing Sheaves - Sheaves with badly worn flanges and outside
area. diameter should be replaced. This wear may be due to
chain misalignment or frozen bearings.
Oil may be applied with a narrow paint brush or directly
poured on. Chain should be well flooded to be sure the oil
penetrates the joint.
In locations difficult to reach, it may be necessary to use a Lift Chains (Standard and TSUs)
good quality oil under pressure such as an aerosol can or
pump pressure spray. To remove and replace the lift cylinder and/or carriage chain
set on standard and triple-stage uprights (TSU):
Chain Removal and Replacement
1. Attach a hoist strap on the carriage of the standard
A WARNING
upright or inner rail of the TSU.
The procedures for removing and replacing chain set 2. Lift the carriage or inner rail slightly to create slack in
involve hoisting and blocking components. the chains. Block the carriage or inner rail up for safety.
Do not walk or stand under raised forks.
Keep your arms and fingers away from moving 3. Remove the chain anchor pins on the outer rail and pull
parts of the upright. the chains off of the sheaves on the inner or intermediate
Do not reach through open areas of the upright. rails.
4. Remove the chain anchor pins from the carriage on the
Failure to follow these warnings can result in serious standard upright or the inner rail on the TSU. On the
injury. See Lifting, Jacking and blocking for safe TSU, the inner rails must be lowered to the floor to
blocking procedures. access the chain anchor pins.
Dee 94 34-6-6 SM-587

Chains GROUP 34
NOTE Other Chain Service Notes

If a hose adapter is used, the chain . Use lengths of factory assembled chain. Do not build
sheaves must be loosened and lengths from individual components.
removed to prevent the hoses from
stretching when the inner rails of . Do not attempt to rework damagedchains by replacing
the TSU are lowered to access the only the components obviously faulty. The entire chain
chain anchor pins. may be compromised and should be discarded.
. Never electroplate assembled leaf chain or its

components. Plating will resultin faihrre from hydrogen
5. Use the steps in reverse order to replace the lift chain
embrittlement. Plated chains are assembled from
set.
modified, individually plated components.
Primary Cylinder/Carriage Chains Welding should not be performed on any chain or

components. Welding spatter should never be allowed
(TSUs) to come in contact with chain or components.
1. Tilt the upright forward, lower it and completely
collapse the primary cylinder to create slack in the Leaf chains are manufactured exclusively from heat
chains. The carriage may also be lifted and blocked in treated steels and therefore must not be annealed. If
position and the primary cylinder completely collapsed heating a chain with a cutting torch is absolutely
to create slack in the chains. necessary for removal, the.chain should not be reused.
2. Remove the chain anchor pins from the back of the

primary cylinder. Pull the chains through the chain
sheave and lay over the carriage load backrest.
3. Remove the chain anchor pins from the back of the

carriage.
4. Use these steps in reverse order to replace the primary

cylinder/carriage chain.
Perform the chain length adjustment and chain tension check
before returning the truck to service.
SM-587 34-6-7 Dee 94

Material Handling
El!!YRK Company GROUP 35
Section 1
Load Wheels
Contents
Remove & Replace.. ......................................................................... .13- 1-2
Inspection .......................................................................................... 13-1-2
Installation and Lubrication ............................................................... 13-1-2
Articulating Axle 2

SM-587 35-1-1 Dee 94

GROUP 35 Load Wheels
LOAD WHEELS
Remove & Replace

Prenaration
2. Disconnect battery andremove key from switch.
3. Elevate outrigger approximately 3-inches and
levate 3-inches and block
block in this position. outrigger here
Removal
1. Remove snap ring and shim(s) from each axle. 4. Install rocker arms. Point on rocker arm must
IMPORTANT face downward.
Note the number of shims used on each shaft so that IMPORTANT
the same number is used at reassembly. These shims After load wheels androcker arms are installed, locate
are used to properly locate the load wheel sub- a C clamp near the rocker arm pivot pin and tighten
assembly so that the wheels do not rub against the slightly.
outrigger.
5. Install snap ring on each rocker arm shaft.
2. Pull rocker arm shafts out of the wheels and
outrigger. IMPORTANT
Always use new snap rings. Install snap ring so the
3. Remove load wheels. sharp edge is located away from the rocker arms.
Inspection 6. Clean any dirt and grime from the grease fittings
1. Wipe bearings clean. Remove grease, dirt and and grease wheel bearings until the grove be-
debris from bearings. tween bearings is full.
. 2. Rotate bearing by hand. Note any rough spots l Elevate outrigger and remove blocking. Lower
while rotating bearing. outrigger until load wheels are flat on the floor.
3. Examine seals for signs of damage.

Bearing
4. Replace bearings that have rough spots or dam-
aged seals.
Load Wheel, 1
5. Examine grease fittings to be sure that they are
in place and not damaged.
Installation & Lubrication
1. Install new bearings into wheels.
IMPORTANT
Extruded edge of bearing must face outward.
2. Fill groove between bearings with grease.
3. Locate wheels in outrigger with extruded side
(seal side) of bearing facing outward.
Dee94 35-1-2 SM-587

CLSRIC,
~lt&ria:Handling
GROUP 40
Specif icatio ns
N -345
Narrow Aisle Electric Stand-Up Rider Reach Trucks
Wiring is Color Coded

Color Code
Black 0
Brown 1 Example
Red 2 Reference Wiring Schematic
Grange 3
Yellow 4 Wire No. 6 is a Solid Blue Wire.
Green 5 Wire No. 13 is a orange wire with a brown stripe.
Blue 6 Wire 33 is a solid orange wire.
Violet 7
Gray 8
White 9
Note
Data listed on the following pages is based on:
N-PR-17 3500 lbs (1600 kg) @ 24-inch (600 mm)
NPR-20 4000 lbs (1800 kg) @ 24-inch (600 mm)
198 MPH Upright, with or without sideshift as noted.
42.0 Forks
Hvdraulic Performance and Pressure Checks published herein is
with Clark MS-68 Hydraulic Fluid @ Operatering Temperature
of 120 F.
GROUP 40 Specifications, Truck
Ikavel Speeds with Capacity Load

N-PR-17 with 170 & 198 MPH Uprights: 5.8 mph 24-Volt Models 6.7 mph 36-Volt Models
NPR-20 with 210MFH Uprights : 5.7 mph 24-Volt Models 6.6 mph 36-Volt Models
navel Speeds without Load
NPR-17 & 20 with all MPH Uprights: 6.3 mph 24-Volt Models 7.2 mph 36-Volt Models
Performance may vary +5% and -10% due to motor and system efficiency tolerance. The
performance shown represents nominal values obtained under typical operating conditions.
Lift Speeds with Capacity Load (MS68 Hydraulic Fluid should be at operating temperature 120F. when
making test.)
NPR-17 with 170 & 198 MPH Uprights: 42 fpm 24-Volt Models 62 fpm 36-Volt Models
NPR-20 with 210,240,258 & 270 MPH: 40 fpm 24-Volt Models 60 fpm 36-Volt Models
Lift Speeds without Load (MS68 Hydraulic Fluid should be at operating temperature 120F when
making test.)
NPR-17 & 20 with all MFH Uprights: 65 fpm 24-Volt Models 95 fpm 36-Volt Models
Lowering Speeds with Capacity Load: 80 fpm ( all models and uprights)
Lowering Speeds with out Load: 90 fpm ( all models and uprights)
(MS68 Hydraulic Fluid should be at operating temperature 120F. when making test.)
r
Wheels & Tires (Type & Size)
Drive/Steer: 13.5 x 5.5 Rubber
13.0 x 5.5 Polyurethane
Nut Toraue: 168 - 188 Nm (124-139 lbf. ft.)
Nuts must be tightened using diagonal
sequence shown here.
1
Load Tires:
Articulated 5 x 3.76 Polyurethane
5 x 3.01 Polyurethane
Single 10.5 x 4.5 Polyurethane
/
Caster (Stabilizer): 8.0 x 4.0 Polyurethane
Dee 94 40-l -2 SM-587

Specifications, Truck GROUP 40
r
Fork Stwead 1 2 3 4 I 5
33 Wide Pantograph 330.6n-m 577nx-n 682mm 787mm
13 22.73 26.86 31
37 Wide Pantograph 330.6mm 574.6mn-r 677.6nx-n 784mm 889mm
13 22.62 26.68 30.87 35
33 Wide Pantograph 482.6mm 582.6mm 677.6mn-1
with Sideshift Forks 19 22.94 26.68
37: Wide Pantograph 559mn-l 703mm
with Sideshift Forks 22 27.68
Reference numbers relate to Adjustment-Pin Holes (l-5), see below.
FORK SPREAD 939.8mm (37)Wide Pantograph
838.2mm (33)Wide Pantograph
101.6mm (4.00) y 9 Or
Top View
NOTE
All dimensions are in inches unless otherwise specified.
NPR- 17 Data is based on 3500 lb. load, 42.0 forks, 198 MFH Upright with no sideshift.
NPR-20 Data is based on 4000 lb. load, 42.0 forks, 198 MFH Upright with no sideshift.
SM-587 40-l Material

-3 Dee 94
Copyrighted
GROUP 40 Specifications, Truck
A B C D E
5232mm 4318nx-n 1814kg 2260mm 2209mm
206 170 40001bs 89 87
5943mIn 5029mn-l 1814kg 2260mm 2209mm 1372mm 814kg 449kg
234 198 4OOOlbs 89 87 54 17951bs 18001bs
6248nxn 5334nxn 1814kg 2413mm 2362mm 1524mm 853kg 449kg
246 210 40OOlbs 95 93 60 18801bs 18OOlbs
701Omm 6096mm 1814kg 2718m.m 2667mm 1828nx-n 982kg 449kg
276 240 4OOOlbs 107 105 72 21651bs 18OOlbs
t
7468mm 6553mm 1588kg 2870mm 2819mm 1981mm 1069kg 449kg
294 258 35001bs 113 111 78 23571bs 18OOlbs
t
7772mm 6858mm 1361kg 3022mm 297 lmm 2134nx-n 1108kg 449kg
306 270 30001bs 119 117 84 24431bs 18001bs
A Overall height (less load back rest extension)
B Maximum Fork Height
C Maximum Capacity @ 600 mm (24 inch) Load Center
D Overall down height
E Rail length
F Maximum Free Lift (Fork Height)
Refer to Dimensional Chart on the opposite page.
Dee 94 40-l -4 SM-587

Specifications - Truck
GROUP 40
Refer to Chart o n opposite page.
1219.18mm (48.00)
Load Backrest Extension
Pantoiraph
Extended I
........
I
:...... .
+
Pantograph B/C
Retracted
-e
I
Roller(s)
. ..---
...~~
..x ;,y,.,::::~:.,:.:
:::.!.. x.: ..... -2
==-I+
I,..
.. .,
,.,.,.,.,....
~,.,,..,,...,.,.,.,.,...
E
.I . . . . . . . .
..A A.
1
t
50.8mm (2.00) f
38.4mm (1.51 I) J
Center of roller to bottom
of inner rail.
40-l -5 Dee 94
GROUP 40 Specifications - Truck
Overall Dimensions
Ground Clearance minimum with 4 Dia. Load Wheels: 1.OO
Ground Clearance minimum with 5 Dia. Load Wheels: 1.75
Ground Clearance minimum with 10.5 Dia. Load Wheels: 1.75
Length to fork face (13.38 & 13.88 Battery Compartment Width):- 47.9
Length to fork tip (16.13 Battery Compartment Width): 50.1
Turning Radius:
Outside:(13.38 & 13.88 Battery Compartment Width): 66.5
Inside: (13.38 & 13.88 Battery Compartment Width): 36.9
Outside:(16.13 Battery Compartment Width): 68.7
Inside:(16.13 Battery Compartment Width): 36.9
Width: 53.0
Battery Compartment Size Maximum Battery Size Min. Weight
N-PR-17 38.75 W x 13.38 L x 32.0 H 38.69 W, 13.00 L, 31.5 H 1400 pounds
NPR-17 & 20 38.75 W x 13.88 L x 32.0 H 38.69 W, 13.50 L, 31.5 H 1590pounds
NPR-17 38.75 W x 16.13 L x 32.0 H 38.69 W, 15.75 L, 31.5 H 1885 pounds
(Maximum size including cover if required)
Battery
T-e - Lead-Acid Canacity (6hr. rate) Maximum: KWH (6hr. rate) Maximum
NPR-17 (Battery Compartment Length x Width X Height)

Bat. Comnartment 38.75 x13.38 x 32 38.75 x 13.88 x 32 38.75 x 16.13 x 32
Max. Capacity 108.5- 24V 1240 - 24V / 775 - 36V 1395-24V/980-36V.
Max. KWH Rating 25.1 28.9 - 24V 127.0 - 36V 32.3 - 24V / 34.0 - 36V
Min. Weight lbs. 1400 1590 1885
NPR-20 (Battery Compartment Length x Width X Height)

Bat. Compartment 38.75 x 13.88 x 32 I 38.75 x 16.13 x 32
Max. Capacity 1240 - 24V / 775 - 36V 1395 - 24V / 980 - 36V
Max. KWH Rating 28.9 - 24V / 27.0 - 36V 32.3 - 24V 134.0 - 36V
Min. Weight lbs. 1590 1885
Steering Type: Hydraulic Assist Turns (Lock to Lock): 4.25
Dee 94 40-l -6 SM-587

SDecifications - Truck GROUP 40
Lift Cylinder Downdrift Test
(Make test withfluidMS-68at operatingtemperature120F.) Mark Rail
Cvlinder drift should not exceed e Check drift here
1.0 inch in a five minute period.
Test Load: a capacity load

evenly distributed on lift forks.
(If a pallet is used, load should
not extend beyond pallet. Load - 48 x 48 Pallet
should be stacked to provide

maximum stability.) Forks must
completely engage load and be
adjusted as wide as possible to t
provide even distribution of Elevate Carriage & Load 1O-l 5 inches and
weight. approximately 1 in Back tilt.
Tilt Cylinder Drift Test

Pantograph w/
(MaketestwithfluidMS-68atoperatingtemperature120F.) Tilting Carriage
Cvlinder drift should not exceed

ref. 1 0.040 inch in a five minute period.
ref. 2 0.1 degree in a five minute period.
Test Load: a capacity load

evenly distributed on lift forks.
(If a pallet is used, load should
not extend beyond pallet. Load Checking drift at Forks
should be stacked to provide

maximum stability.) Forks must
completely engage load and be
adjusted as wide as possible to Elevate carriage and load 12 to 15 inches
provide even distribution of and place mast in full back tilt postion.
weight.
SM-587 40-lMaterial
-7 Dee 94
Copyrighted
Service/Parking Brake(s)
Spring Applied and Hydraulically Released. Brakes must be capable ofholding truck, with
a full rated capacity load on a 15% grade minimum.
.:.:,:,::::::
Brake PedEiI i rPedal Uo_Heiaht
112.5 mm (4-7/16)
41 Master Cylinder(s)
One cylinder connects to the Motor Brake.
I
170 - 190 Nom
(125~1401bfft)
IMPORTANT
Apply1802397
(Anti-Seize) to Install bolts using
motor shaft, bore and Loctite 242 on threads.
20 -25 Nom
(177 - 221 Ibf. in.)
Dee 94 40-l -8 SM-587

Sr>ecifications - Truck GROUP 40
Brake OFF
BrakeON
L
BrakeOFF _____-_
Brake ON
l- 114- Brake OFF
\ Cover must be
in place at all times
to provide required
SM-587 40-l -9 Dee94

Caster Brake
Brake Swing: SDecification

l A correctly adjusted Brake Pressure Spring:
2-l/4-inches as measured between washers
(spring in the applied positioned). Refer to oppo-
site illustration.
(1) Pressure Spring Adjustor
(2) Jam Nut (Locking Nut)
Caster Wheel Assembly
Tighten Sequence
Brake Assembly (Caster Brake Mounting Bolts)
Mounting SDecification 1
l Install Capscrews using General Purpose

Threadlocker (Clark #1802300) and torque to
25 lb.ft. (34 N*m), using a diagonal tightening
sequence shown in opposite illustration.
Dee 94 40-l -10 Material

Copyrighted SM-587
Specifications - Truck GROUP 40
ELECTRICAL SYSTEM SPECIFICATIONS
Voltage 24V 36V
IA Free Wheeling Drive Motor Current 50 TO 60 AMPS 40 TO 50 AMPS
Lift Pump Motor @ By-Pass

(MS-68 OIL @ 120 F) 490 TO 510 AMPS 520 TO 540 AMPS
Steer / Auxiliary Pump Motor @ By-Pass

(MS-68 OIL @ 120 F)
Operating Aux Function 95 TO 105 AMPS 60 TO 70 AMPS
Operating Steering 95TOll5AMPS 90TOllOAMPS
Ground Tests (New & Used Trucks) 20,000 OHMS MINIMUM
Meter set on Rx10,OOOScale, measure from Negative battery connector to truck frame.
Solid State Traction Control Specifications

Type Transistor
System Voltage 24 OR 36 VOLTS D.C.
Low Voltage Cut-Off 16 VOLTS D.C.
Accelerator Input Voltage 3.5V TO 0.2V Controlled Thermal Cut-Back 194 F.
Speed Control Solid State
Solid State Steer Control Specifications

Type Transistor
Controlled Thermal Cut-Back 194F.
Solid State Solenoid Control

Lift Motor Control Contactor
Motor Diameters ( Inches )

Drive (Traction ) Motor 6.7
Lift Pump Motor 8.0
Steer/Auxiliary Pump Motor 6.4
SM-587 -11
40-l Material
Copyrighted Dec94
Hydraulic System Specifications
24 Volt System Voltage 36 Volt

LifI Pump TYPe Gkar ------I
Flow (GPM) 6.9 10.1
@RPM 1185 1720
@ Pressure (PSI) 1910 2020
1Relief Valve Settinp (PSI) 2650 - 2750 @ 8.5 GPM
24 Volt System Volta e
Steer /Auxiliary Pump Type G&r -1
Flow (GPM) 2.4 2.5
_ @RPM 2130 2200

@ Pressure (PSI) 1000 1000
1Relief Valve Setting (PSI) 1550 - 1650 @ 1.9 GPM
Hydraulic Valve / Lift Control
I Auxiliary Control
I
Spool
I
Filters Suction Strainer TYPe Cleanable 100 Mesh SS Screen

Micron Rating 149 Absolute
Fill Strainer TYpe Cleanable 30 Mesh SS Screen
Micron Rating 533 Absolute
Return Line TYpe 10 Micron Cellulose Spin On
beta Rating beta 5=2, beta 13=20, beta 17=75
Reservoir Breather TYPe 10 Micron Cellulose Push On

Micron Rating 10 Nominal
___.- ---____
[System Reservoir Capacity (Gallons) 7.7 -1
Hydraulic Fluid MS68
Dee 94 40-l -12

SM-587
Specifications - Truck GROUP 40
Critical Fastener Torque Specifications

[Tightening Torque WET, SAE 301
example
Artculating.Axle Mounting Bolts 60 Ib.ft. (81 N*m)
(Refer to illustration in Group 22, Section 1, Page 2)
Articulating Axle Stop Bolt Set Screw 35 Ib.ft. (47 Nom)
Brake Assy to Drive Motor Bolts (Diagonal Sequence)240 - 270 lb. in. (27 - 31 N*m)
Brake Drum to Drive Motor Shaft Nut (125 - 140 lb.ft. (170 - 190 Nom)
Drive Motor Mounting Bolts 25 lb.ft. (34 Nom)
Drive Unit to Axle Mounting Bolts 74 - 81 lb. ft. (100 - 110 N*m)
(Refer to illustration in Group 20, Section 2)
Drive Wheel Mounting Bolts (Diagonal Sequence) -124 - 139 lb.ft. (168 - 188 N*m
Truck to Upright Mounting Bolts w Lower 375 lb.ft. (508 N*m)
Truck to Upright Mounting Bolts w Upper 200 lb.ft. (271 N*m)
Load Backrest Extension Mounting Bolts 125 - 140 lb.ft. (170 - 190 Nom)
Oil Filter Assembly Refer to the instructions found in
Group 29, Section 1, Page 6.
Overhead Guard Mounting Bolts 177 to 199 Ib.ft. (240 - 270 N*m)
OHG Leg to Overhead Guard Bolt 30 - 33 lb.ft. (40 - 45 Nom)
OHG Leg to Truck Frame Bolt 75 - 80 lb.ft. (102 - 108 N*m)
SM-587 40-l Material

-13 Dee 94
Copyrighted
C19RK
M&f?;~-i~Handling
GROUP 40
Section 2
Service Weights
Contents
Service Weights in Pounds . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. . ... .. .. .. .. .. 40-2-2
SM-587 40-2-l
GROUP 40 Specifications
SERVICE WEIGHTS IN POUNDS

MODEL NPR-17
I BATTERY COMPARTMENT 13.38 13.88 16.13
UPRIGHT MINIMUM 1400 1590 1885

BATTERY WEIGHT
LOAD 0 3500 0 3500 0 3500

170 TOTAL WEIGHT 6381 9881 6571 10071 6938 10438
FRONT AXLE WEIGHT 2348 6293 2400 6345 2573 6501
I REAR AXLE WEIGHT I 4033 3587 1 4171 3725 1 4365 3937
I LOAD I 0 3500 0 3500 I 0 3500

198 TOTAL WEIGHT 6381 9881 6571 10071 6938 10438
REAR AXLE WEIGHT 4033 3587 4171 3725 4365 3937
LOAD 0 3500 0 3500 0 3500

210 TOTAL WEIGHT 6471 9971 6661 10161 7029 10529
REAR AXLE WEIGHT 4076 3631 4214 3769 4407 3979
LOAD 0 3500 0 3500 0 3500

240 TOTAL WEIGHT 6753 10253 6943 10443 7310 10810
REAR AXLE WEIGHT 4223 3778 4361 3916 4549 4120
I LOAD I 0 N/A I 0 N/A I 0 3300

258 TOTAL WEIGHT 6948 7138 7505 10805
FRONT AXLE WEIGHT 2620 2672 2856 6559
REAR AXLE WEIGHT 4328 4466 4649 4245
LOAD 0 N/A 0 N/A 0 2800

270 TOTAL WEIGHT 7034 7224 7592 10392
REAR AXLE WEIGHT 4370 4508 4690 4347
NOTE: DATA IS BASED ON 42.0 ID OUTRIGGERS WITH SIDESHIFT.
DEDUCT 50 lb FROM TOTAL WEIGHT IF SIDESHIFT IS NOT PRESENT.
24.0 LOAD CENTER.

N/A _______ DATA NOT AVAILABLE, CONFIGURATION HAS NOT BEEN TESTED
Dee 94 40-2-Z SM-587

Specifications GROUP 40
SERVICE WEIGHTS IN POUNDS

MODEL NPR-20
BATTERY COMPARTMENT I 13.88 16.13
UPRIGHT MINIMUM 1590 1885

BATTERY WEIGHT
LOAD 0 4000 0 4000

170 TOTAL WEIGHT 6846 10846 7213 11213
REAR AXLE WEIGHT 4371 3862 4568 4079
I LOAD I 0 4000 I 0 4000

198 TOTAL WEIGHT 6846 10846 7213 11213
REAR AXLE WEIGHT 4371 3862 4568 4079
LOAD 0 4000 0 4000

210 TOTAL WEIGHT 6936 10936 7304 11304
I REAR AXLE WEIGHT I 4414 3905 1 4610 4121
LOAD 0 3900 0 4000

240 TOTAL WEIGHT 7218 11218 7585 11585
REAR AXLE WEIGHT 4561 4052 4751 4262
LOAD 0 N/A 0 3500

258 TOTAL WEIGHT 7413 7780 11280
FRONT AXLE WEIGHT 2747 2928 6856
1 REAR AXLE WEIGHT I 4666 I 4852 4424
LOAD 0 N/A 0 3000

270 TOTAL WEIGHT 7499 7867 10867
FRONT AXLE WEIGHT 2791 2974 6341
REAR AXLE WEIGHT 4708 4893 4526
NOTE: DATA IS BASED ON 42.0 ID OUTRIGGERS WITH SIDESHIFT.
DEDUCT 50 lb FROM TOTAL WEIGHT IF SIDESHIFT IS NOT PRESENT.
24.0 LOAD CENTER.
N/A _______ DATA NOT AVAILABLE, CONFIGURATION HAS NOT BEEN TESTED
SM-587 40-2-3 Dee 94

GROUP 40 Specifications
Pantograph Assembly
I Location of:
Pantograph Serial Number
(You must refer to this number when
ordering parts for the Pantograph).
r
Dee 94 40-2-4 SM-587

CORKMaterial
Company
Handling
GROUP 40
Section 3
Lubricants and Shop Supplies
Easy Referene Listing
Lubricants ......................... ................ ...... .. .... .... .................................. ................ .. 3
Gasket Materials ................................... .... ........................ .......................... .... ..... 1
Threadlocks and Threadsealers ......................................... ................ ................. 4
Adhesives . .............................................. ........ .... ...................... .. .. .......... ................ 2
Cleaners ......... ................ .................... ................ .. ........................ ............ .............. 2
Detailed Product Descriptions ............................... .... ......................................... 4
These products are available through your local Clark dealer.
GASKET PRODUCTS
Part No. Size Quantity
1802303 Gasket Maker 50 ml. IO/case
1803252 Ultra BlueX 3.35 oz. 12/ease
1803253 RTV High Temp 3 oz. 12/ease
1803254 Form-A-Gasket-2 3 oz. 12/ease
1803255 Form-A-Gasket- 3 .25 pint 12/ease
1803256 High TackTM 6 oz. spray 12/ease
1803257 CopperCoat 12 cz.spray 12/ease
1802308 Gasket Remover 18 oz. spray IO/case
- continued -
SM-587 40-3-I Dee 94

GROUP 40
CLARK PRODUCTS -continued-
ADHESIVE PRODUCTS
1802306 Silicone Adhesive Sealant 3 oz. IO/case
1803259 Fast Cure Epoxy 1 O-4 gm. cups IO/case
1802309 Superbonder-Gel 3 gm. IO/case
1802304 Bearing Mount 10 ml. IO/case
1803260 SprayAdhesive 16 oz. 12/ease
1803261 Steel and Aluminum Epoxy 1 oz. 1 / Pkg
1803262 Loctite Weld 2 oz. 12/ease
1803263 Loctite Weld Stick 11.8 oz. 12/ease
CLEANING PRODUCTS
Part No Size Quantity.
1803264 Natural BlueTM 4 oz. spray 24 / case
1803265 Natural BlueTM 24 oz. 12/ease
1803266 Natural BlueTM 1 gal. 6 / case
1803267 Locquic PrimerN 6 oz. spray 1 /pkg
1803268 Brake and Parts Cleaner 20 oz. spray 12/ease
1803269 EnviroSafeTM B & P Cleaner 20 oz. spray 12/ease
1803270 Carb and Choke Cleaner 16 oz. spray 12/ease
- continued -
Dee 94 40-3-2 SM-587

GROUP 40
CLARK PRODUCTS -continued-
CLEANERING PRODUCTS
Part No Size Quantity.
1803271 EnviroSafeTM C & C Cleaner 6 oz. spray 12/ease
1803272 EliminatoTMr 11 20 oz. spray 12/ease
1803273 EnviroSafeTM Degreaser 20 oz. spray 12/ease
1803274 RadiatorCleaner 1 qt. 12/ease
LUBRICANTS
1802307 Anti-SeizeTM 1 lb. can IO/case
1803275 Super Lube- 4.5 oz. spray 12/ease
1803276 Super Lube- .25 oz. oiler 12/ease
1803277 Silicone Lube 16 oz. spray 12/ease
1803278 Water Pump Lube 12 oz. 12/ease
1803279 HydraulicJackOil 1 qt. 1 /pkg
1803280 Tune-upGrease .33 oz. 1 /pkg
1803281 Ultra SlickTM 4 oz. 1 /pkg
1803282 Prussian Blue -75 oz. 1 /pkg
1803283 Valve Grind 34 B 1 /pkg
continued -
SM-587 40-3-3 Dee 94

GROUP 40
CLARK PRODUCTS - continued -
THREADLOCKER PRODUCTS
1802300 Gen. PurposeThreadlocker IO ml. IO/c&e
1802302 Heavy Duty Threadlocker IO ml. IO/case
1811140 Teflon- Pipe Sealant 50 ml. IO/case
1803258 Form-A-Thread .32 syringe 6 / case
Descriptions, Classifications, Specifications

of Lubricants and Shop Supplies
The following lists descriptions as well as part numbers of lubricants, sealants, gasket materials, threadlocks
and threadsealers, adhesives, cleaners, and miscellaneous shop compounds recommended for servicing Clark
industrial trucks. These products are available through your local Clark dealer.
Lubricants
Part Number Description
1802153 - 1 Qt. Motor Oil lOW30
Clark all-season lOW30 motor oil is unexcelled for keeping Clark engines clean. It
protects against formation of sludge, varnish and harmful deposits which cause
sluggish performance. Clark premium lOW30 motor oil is made from high-quality
solvents and refined neutral stocks and is especially suited for gasoline engines which
include emission-control systems. Specially formulated additives prevent rust and
provide effective detergent action. This superior oil product meets API service
classifications SE, SD, SC, SB, CC, CB, CA andmilitary specification MILL-46152
and exceeds hUL-L-2104B.
1802152 - 1 Qt. Motor Oil Extra-Duty 30W
Clark extra-duty 30W motor oil was developed for the lubrication of gasoline, diesel,
Ll?G, and natural-gas engines for which MIL-L-2140B products are recommended.
This oil also meets or exceeds API service class CD, CC, CB, CA, and SB. Clark 30W
oil may be used in stationary, automotive, fzum, and marine-engine service use. It is
especially effective wherever the use of heavy-duty motor oil is recommended.
Suitable for oil-bath aircleaners, chain drives, hydraulic systems, and general lubrica-
tion service.
Dee 94 40-3-4
GROUP 40
Lubricants
2776236 - 1 Gal Transmission Fluid Specifically recommended for Transmission Models:
916027 - 1 Qt H2OO,H210andH211
HR500 and HR600
TA-12 and TA-18
This product provides proper frictional characteristics, superior wear protection
for gears, excellent water tolerance to avoid excessive foaming and rusting within the
system, good filterability, and low temperature fluidity. These fluids meet CMHC
MS-276A and the requirements for the following:
John Deere Quatt-ol Q-41 Catepiller TO-2
Allison C-3 International Harvester Hy-Tran B-6
Abex Dennison IV-0 Hydraulic Fluid Specification

1801708 - 2 Gal. Special Purpose Transmission/Hydraulic Fluid
Increased demands for performance and protection of fluids used in equipment with
common hydraulic and transmission oil reservoirs have brought about thedevelopment
of Clark SpecialPurposeTransmission/HydraulicFluid. This qualityproductmeets the
service-refill requirements for the following tractor manufacturers:
John Deere J20A, 303 J.I. Case JlC143, TFD
Navistar B-6 Massey Ferguson 1138
Allis-Chalmers PF821 White-Type 56
1802536 - 1 Gal. High-Performance Transmission Fluid
Clark High-Performance Transmission Fluid is made of selected, highly-refined base
oils blended with a specially-balanced additive combination. This product has out-
standing high-temperature oxidation resistance, dispersancy, and detergency. It pro-
vides anti-corrosion and rust protection, and is compatible with the various automatic
transmission components such as elastomeric seals andplastic parts. Its high-viscosity
index permits use over a wide temperature range by providing excellent low-
temperature fluidity while retaining desired viscosity in high-temperature conditions.
This fluid meets all of the requirements of the GM DEXTRON specification. It is
recommended for use in all types of automatic transmissions for which DEXT.RON
products are required.
SM-587 40-3-5 Dee 94

GROUP 40
1800236 - 1 Qt.; Hydraulic Fluid
1802155 - 1 Gal. Clark premium anti-wear hydraulic fluid is tailored to meet the special requirements
of Clark hydraulic systems. Clark hydraulic fluid will not oxidize to form sludge and
guards against rust by plating all metal parts with a film that is impervious to moisture.
It stands up to high-heat ranges and pressures andprotectsprecision-tunedparts against
abnormal wear. Above all, it is compatible with the chemistry of the seals, packings,
and hoses so it cannot cause deterioration of these vital components. Every hydraulic
fluid formulated for Clark hydraulic systems must pass strict tests complying with
Clark specification MS-68 which calls for an anti-wear additive plus many other
properties. This fluid also meets the stringent requirements of the Denison HF-2 and
Lee Norse lOO-1 specifications.
1802200 - 1 Qt.; Transmission/Converter Fluid
1802154 -1 Gal. Clark transmission-converter fluid is compounded with the special properties required
for Clark torque converters and automatic transmissions. This superior fluid has been
developed to meet General Motors DEXTRONII specifications and equals or exceeds
all requirements for Type A Suffrx A automatic-transmission oil. Genuine Clark
transmission-converter fluid flows freely in low temperatures, yet resists high tempera-
tures, pressure, and oxidation while preventing corrosion and seal deterioration.
801167 - 1202.; Super Heavy-Duty Brake Fluid
850487 -1 Gal. Clark Super Heavy-Duty Brake Fluid protects the vital metal and rubber components
found in your equipments brake system. It is non-corroding and lubricates all metal
parts while keeping the rubber parts from shrinking or becoming brittle. To insure
quality performance, Federal regulations VV-H-9 1Oa Amendment I and SAE speci-
fications70R1,70R3,andJ70BaresurpassedbyClarkSuperHeavy-DutyBrakeFluid.
1802307 Anti-SeizeTM
Lubricates to protect against galling, pitting, and corrosion on equipment subject to
temperature extremes (up to 2OOOOF)or in corrosive applications. Assures easy
disassembly of components. Use for wheel lug nuts and fasteners, upright and frame
mounting bolts and in corrosive environments.
1803275 - .25 oz.; Super-lubeSynthetic Lubricant With Teflon
1803276 - 4.5 oz Multipurpose lubricant for machinery and equipment. Compatible with other lubri-
cants and is safe on metal, rubber, plastics, wood, leather and painted surfaces. For
cables, hinges, locks, linkages, gears, and pulleys.
Dee 94 40-3-6 SM-587

GROUP 40
1803277 Silicone Spray Lubricant
Stops friction and squeaks. Silicone formula does not attract dirt or dust. Protects and
renews rubber mountings, bushings and weather-stripping. Prevents deterioration due
to sunlight. Use to lubricate door locks and rubber moldings for doors or windows.
1803278 Water Pump Lube And Radiator Anti-Rust
Lubricates to prevent squeal and pump corrosion in the engine cooling system.
Disperses rust. Protects metal parts with a corrosive resistant film.
1803279 Hydraulic Jack Oil
Improves lubrication in all types of hydraulic units. Prevents rust and sledge build-up.
Contains anti-oxidant, anti-rust and anti-wear additives to maximize service life. Use
in bottle jacks, arbor presses, Port-A-Powers, and hand pallet trucks.
1803281 Ultra SlickTMEngine Assembly Lube
Proper lubrication of metal mating surfaces is essential prior to starting anew or rebuilt
engine. Ultra Slick has superior adhesion to component surfaces to prevent scuffing and
galling during initial startup. Use on engine bearings, camshafts, lifters, valves, guides,
and rocker-arm shaft assemblies.
1800636 Ignition Distributor, Cam Lube
A must for long ignition-cam follower life. Cam Lube is a high-temperature grease
which does not conduct electricity.
617410 Lubriplate
A white grease for clutch throwout bearings, Lubriplate withstands high temperatures
and increases the life of bearings.
886785 Spray Lube
Spray Lube is easy to apply to open gears and reaches hard-to-get places. It acts as a
rust preventive and does not drip off.
886396 Innerslide Lubricant
This lubricant is a dripless grease, ideal for sliding tandems and fork trucks. Cuts
greasing time, prevents rust, and provides constant lubrication to minus 60 F.
SM-587 40-3-7
GROUP 40
886399 Chain and Cable Lubricant
Chain and Cable Lubricant provides constant lubrication by penetrating chain links,
andreducesfrictiondragsonsuddenoverloads.It alsopreventsdrippingonsloworidle
chains.
Sealants
886398 Battery Saver
Battery Saver preserves battery power by retarding acid action, preventing corrosion,
and sealing vibration cracks.
886784 Spray - Kote
Spray-Kote renews, insulates, and protects. It seals electrical wires and keeps them
pliable while preventing rust and corrosion. Resists extreme heat or cold and requires
no pre-cleaning before use.
1801146 MS 180 Freon Degreaser
Non-flammable and non-conductive, MS 180 Freon Degreaser is ideal for SCR
controls and panels, harness plugs for electrical wiring, and SCR terminal strips.
1801145 Conquer-3
Conquer-3 is a water dispersive and corrosion preventive that protects against
oxidation. It displaces water and moisture, even from wet insulation, and leaves a
protective film. Excellent for protecting SCR control panels
1801480 GE Silicone
Protects SCRs by weatherproofing and sealing while resisting chemicals, oils, and
solvents.
1803280 Electric Tune-Up Grease
Protects electric connections and wiring from salt, dirt, and corrosion. Extends the life
of the bulb sockets. Prevents voltage leaks around any electrical connection. Also
prevents spark plugs from fusing to boots. Use in extremely dusty, dirty, or corrosive
applications.
Dee 94 40-3-8 SM-587

GROUP 40
1802306 Silicone Adhesive Sealant
General purpose, clear RTV indoor/outdoor sealant. Seals, bonds, mends, and secures
glass, metal, plastics, fabrics, vinyl, and weather-stripping. Protects electrical wiring.
Waterproof and flexible. Seal windows, electrical connections, vinyl tops, and seams.
Gasket Materials
1802303 Gasketmaker
Flexible, non-corrosive gasketing material for use on rigid machined flanges with less
than .OlO (.25 mm) gap. Use where anaerobic (cures in the absence of air) gaskets
are specified. Seals transmission cases, transaxle castings, waterpumps, andotherrigid
covers and plates.
1802308 Gasket Remover
Quickly removes baked-on gaskets and all types of gasket adhesives. Prepares metal
parts for new gaskets and assembly. For all metal parts.
1803252 Ultra Blue@
High performance, oil resistant RTV silicone. Low odor, low volatility. Eight times
more flexible than cork/composite gaskets and three times more oil resistant than other
silicones. Forms in-place gaskets on valve covers, oil pans, intake manifold and seals,
timing covers, water pumps, and thermostat housings. Use as a gasket dressing to
upgrade conventional metal and pre-cut gaskets.
1803253 Hi-Temp RTV Silicone
For very high temperature applications. Replaces cut gaskets. Makes reliable formed-
in-place gaskets that resist cracking, shrinking, and migrating caused by thermal
cycling. The temperature range is - 75 F to 650 F. Form in-place gaskets on valve
covers, oil pans, intake manifolds and seals, timing covers, water pumps, and
thermostat housings. Use to coat pre-cut gaskets to increase reliability.
1803254 Form-A-Gasketa No. 2
Slow drying, non-hardening sealant designed for sealing cut gaskets and stamped parts.
Allows for easy disassembly if required. Use where sealing is more important than
adhesion. Temperature range is - 8.5F to 4ooOF. For valve-cover gaskets and oil-pan
gaskets.
SM-587 40-3-9 Dee 94

GROUP 40
1803255 Form-A-Gasket@No. 3
Slow drying, non-hardening, brush-top sealant for close fitting machine surfaces.
Temperature range -659 to 400 F. Use for sealing hoses and as a cut gasket dressing.
1803256 High TackTMSpray-A-Gasketa
Fast drying adhesive for holding gaskets in place during assembly and sealing. Remains
effective under extreme temperature of - 65 F to 4500 F. Holds and seals all felt, cork,
metal, paper, rubber, and asbestos gaskets.
1803257 Copper Spray-A-Gasket@
Fast drying, metallic-copper sealant helps dissipate heat, prevents gasket burnout and
improves heat transfer. Fills minor surface irregularities and seals instantly. Tempera-
ture range - 50 F to 500F. For cylinder head gaskets, carburetor gaskets, exhaust
manifold gaskets, and other high temperature applications.
Threadlocks and Threadsealers

945945 Loctite Nut Lock
LoctiteNutLockturnsordinarynutsintovibration-prooflocknuts. Itreducesassembly
costs by eliminating expensive lock nuts and prevents machinery from vibrating
loose.
1802300 General Purpose Threadlocker
For locking and sealing smaller (l/4-3/4; 6- 18 mm) threaded fasteners that will
require removal. Blue in color. For valve cover bolts, water pump bolts, oil pan bolts,
or rocker-arm adjustment nuts.
1802302 Heavy Duty Threadlocker
For locking and sealing heavy-duty, large, orperrnanent threaded assemblies. Use with
large studs and fasteners (3/g- 1; 9-24 mm). Red in color. Use on cylinder block studs,
ring gear bolts, frame bolts, and upright mounting bolts.
1801140 Pipe Sealant With Teflona
Seals plugs and tapered pipe threads instantly. Will not shrink or dry out and will not
shred to contaminate systems. For pipe plugs above l/8 (3 mm), water pump plugs,
fuel fittings, coolant fittings, hydraulic system fittings.
Dee 94 40-3-l 0 SM-587

GROUP 40
1803258 Form-A-Thread@
Makes reliable, permanent thread repairs without drills, taps, tools or inserts. Restores
worn, stripped, or damaged threads; effective up to 128 ft-lb of torque. Use for intake
manifold bracket fasteners, threads, water pump bolt threads, or front cover bolt
threads.
Adhesives
1802304 Bearing Mount
Anaerobic adhesive helps restore the fit between replacement bearings in worn
housings or worn shafts. Fills clearance to .OOS (.015 mm) and will disassemble.
Mounts and retains ball bearings in housings or on shafts, roller bearings, plain
bearings, and bushings.
1802309 SuperbonderR
Revolutionary thick no-run formula developed specifically for making fast heavy duty
repairs. For metal, plastic, rubber, leather, paper, wood or cork. Use to repair broken
or loose trim, dash panels, seat cushions.
1803259 Fast Cure Epoxy 45
Easy to use pre-measured epoxy mixer cups. Ideal for bonding glass, plastics, rubber,
and metal. Bonds in 5 15 minutes. Useon loose trim, broken grilles, casting cracks, and
holes.
1803260 Spray Adhesive
Dries clear with superior bonding strength. For permanent or repositionable applica-
tions. Resists water, humidity, and heat. Used for attaching cloth, carpeting, sound
insulation, and floor coverings.
1803261 Steel And Aluminum Epoxy
Grey epoxy adhesives for metals, concrete, and many plastics. When cured, can be
drilled, sanded, threaded, or filed. Resistant to fuels and solvents. Fills gaps and bonds
trim. Use on casting cracks and holes, auto trim, and ornaments.
1803262 Loctite Weld - An Alternative To Welding
A 15minute, 2-part adhesive and tiller system that eliminates the need for welding or
brazing. Once cured, it can be drilled, sanded, filed, or painted. Use on aluminum, steel,
brass, bronze, casings, stampings, etc. Over 3000 psi shear strength.
SM-587 40-3-l
Copyrighted 1
Material Dee 94
GROUP 40
1803263 Loctite Weld Stix
SimilartoLoctite Weldonly inpre-measuredribbons. Sets in 5 minutes andcures fully
in 1 hour. Fills gaps to 2 (50 mm) and is ideal for under water applications. Use on
aluminum, steel, iron, wood, glass, masonry, ceramic, gas tanks, oil pans, and most
plastics.
Cleaners
886397 Penetrating Oil
An easy-to-use penetrating oil that cuts rust, paint, and grease and is effective on hot
surfaces. Saves time, labor, and broken parts; contains Moly.
1800330 Degreaser
This easy-to-use degreaser is water soluble, safe for paint, and does not rust.
1802522 Brake Cleaner
This brake cleaner provides fast, complete cleaning, removing oil, dirt, and grease,
leaving no film. It is non-flammable and can be used on brake parts, and electrical and
ignition accessories. An effective, thorough, safe, and economical parts cleaner.
1803264 - 4 oz.; Natural BlueTMCleaner/Degreaser
1803265 - 24 oz.; General purpose, biodegradable, cleaner for removing grease, grime, oil, and mildew,
1803266 - gal. food or other stains from any washable or metal surface. Non-toxic, non-corrosive,
U.S.D.A.-authorized, contains no butyl. Dilutes with water. Great for pressure washers
and steam cleaners. Also cleans engine parts, floors, porcelain and more.
1803267 Locquic@ Primer N
Degreases oily parts and speeds the curing ofanaerobic products such as threadlockers,
pipesealant,bearingmount, andgasketmaker.Recommendedforcoldweatheruseand
quick repairs. Use with anaerobic products to speed assembly in all applications.
1803268 Brake dz Parts Cleaner
Quickly dissolves and removes oil, grease, brake fluid, and oxidized oils. Dries fast
without leaving a residue and is non-corrosive.
Dee 94 40-3-l 2 SM-587

GROUP 40
1803269 Enviro-SafeTMBrake & Parts Cleaner
Environmentally safe formula. Biodegradable natural citrus solvents dissolve and
remove oil and grease from brake systems and metal parts. No CFCs or chlorinated
solvents. Low toxicity.
1803270 Carb And Choke Cleaner
Super jet spray quickly cuts and removes grease, gum and varnish from chokes, baffle
plates, and carburetor linkages.
1803271 Enviro-SafeTMCarb And Choke Cleaner
Biodegradable formula safely cleans using citrus solvents. Environmentally friendly
- no CFCs or chlorinated solvents.
1803272 EliminatorTM11 Engine Degreaser
Quickly dissolves and removes grease, oil, and dirt from all types of equipment. Cleans
iron, steel, aluminum, magnesium, and copper. Not harmful to metal, rubber, plastics,
or concrete. Rinses off easily with water.
1803273 Enviro-SafeTMCleaner And Degreaser
Biodegradable. Safely removes grease, dirt, and oil with the power of natural citrus
solvents.
1803274 Heavy Duty Radiator Cleaner
Removes rust and scale from automotive and industrial engines, radiators and water
jackets. Cleans and unclogs steam cleaner and pressure washer coils. Safe for
aluminum.
917330 - 7.5 oz.;
917329 - 1 Gal. Natural Citrus Hand Cleaner
An environmentally safe hand cleaner that harnesses the cleaning power of natural
citrus extracts rather than petroleum solvents. Formula tackles the toughest dirt and
leaves hands clean and fresh smelling. Fortified with lanolin, aloe, and jojoba oils for
skin care.
SM-587 40-3-l 3 Dee 94

GROUP 40
Miscellaneous Shop Supplies
1800078 Belt Dressing
Thetractive qualities of this belt dressing on flat,round, and V-belts can increase power
by 50% without collecting dirt For use on truck, auto, farm, and industrial machinery.
1803282 Prussian Blue
Aids precision fitting of machined surfaces. Locates high spots on bearings, valves,
gears, and other close-to-tolerance components. Non-drying and easy to clean-up.
1803283 Valve Grinding Compound
Aids valve grinding and seating operations to remove burrs, surface defects, carbon,
gum, and corrosion. Can be used for lapping and grinding chromium. Mixes with water
to form an easy-to-use paste.
Dee 94 40-3-l 4 SM-587


SM-587 NPR17-20 (NPR345)

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SM-587

25 Brake Bleeding Procedure 23-3-l Pictorial Indexes are provided on

30 Hydraulic Pump Overhaul 29-4- 1

Dee 94 Index-2 SM-587

SM-587 Copyrighted Material

Pictorial Index :#2

Dee 94 Index-4 SM-587

SM-587 Copyrighted Material

Dee 94 Index - 6 SM-587

SM-587 Copyrighted Material

Safety Signs and Safety Messages

NOTICE This message is used when special information, instructions or identification is

A DANGER This message is used when an extreme hazard exists.

SM-587 Copyrighted Material

A DO NOT STEAM CLEAN

A USE TRUCK BATTERY ONLY

IMPORTANT SAFETY NOTICE

An effective PM program should incorporate Inspection Forms

l If an oneration is clean and not strenuous, a PM Contact your authorized Clark

If the PM is faithfully followed, needs for

The objectives of PM are:

SM-587 Copyrighted Material

The Planned Maintenance Procedures

P.M. CHECK SHEET 1. Visual Inspection

SM-587 Copyrighted Material

l Visible frame damage.

l Disconnect battery from truck. Pull back on the

tsconnect Batterv and check

Dee 94 PM-2 SM-587

2. Check for Obvious Oil Leaks and peneral

6. Inmect Wheels & Tire

Retorque drive wheel fasteners

Dee 94 PM-4 SM-587

Check Mullti-Function control for freedom of l Check brakes.

l Check speed limit switch operation.

Operational Tests Move control through all

l Inspect multi-function control handle for free-

b. Check horn to be sure it operates.

c. Turn key switch ON.

Check the Diamostic Disdav & Kev Switch

Dee 94 PM-6 SM-587

e. Check Hvdraulic Function%

SM-587 Copyrighted Material

j. Check Controlled Plwwing (BrakiwI

Dee 94 PM-8 SM-587

l Battery Compartment. l Caster Wheel and Brake.

a. Remove Batterv A WARNING

Cap Vents Must Be Open At All Times

Dee 94 PM-l 0 SM-587

. Check condition of the steering slip shaft and the

is* Air Clean Drive Unit

Dee 94 PM-l 2 SM-587

Brake Line Retainers (Bracket and Fastener)

SM-587 Copyrighted Material

Axle Mounting Block

Axle -to- Frame Retainment 601

. Each axle mounting block is equipp- :::::::::::::::::::::::::::i:::.:;:~:~:~:~

Dee 94 PM-14 SM-587

j- Air Clean Caster Wheel & Brake

Be sure to Lubricate linkage. Refer to Croup 01.

SM-587 Copyrighted Material

AdiustinP for LininP Wear

As brake linings wear, the brake arm will move Brake