SM 715

SM-715
TMX12-25
EPX16-20s
Service Manual
November 2007
Technical
Publications
Lexington, KY 40510
www.Clarkmhc.com
REVISION HISTORY
When new or revised information is published to update Jul. 2005

this manual the action to be taken with the pages is Mark Indication Action required
indicated in the table. Page to be newly added Add
Pages not marked are not currently revised, but are Page to be replaced Replace
included for page numbering continuity.
( ) Page to be deleted Discard
Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision
number number number number
SA-1-1 13-1-2 13-3-24 13-5-1
SA-1-2 13-1-3 13-3-25 13-5-2
SA-2-1 13-1-4 13-3-26 13-5-3
SA-2-2 13-1-5 13-3-27 13-5-4
SA-2-3 13-1-6 13-3-28 13-5-5
SA-2-4 13-1-7 13-3-29
SA-3-1 13-1-8 13-3-30 16-1-1
13-1-9 13-3-31 16-1-2
PS-1-1 13-1-10 13-3-32 16-2-1
PS-1-2 13-1-11 13-3-33 16-2-2
PS-1-3 13-1-12 13-3-34 16-2-3
PS-1-4 13-1-13 13-3-35 16-3-1
PS-1-5 13-2-1 13-3-36 16-3-2
PS-1-6 13-2-2 13-3-37 16-3-3
PS-2-1 13-2-3 13-3-38
PS-2-2 13-3-1 13-3-39 17-1-1
PS-2-3 13-3-2 13-3-40 17-1-2
PS-2-4 13-3-3 13-3-41
PS-2-5 13-3-4 13-3-42 19-1-1
PS-2-6 13-3-5 13-3-43 19-1-2
PS-2-7 13-3-6 13-3-44 19-1-3
PS-2-8 13-3-7 13-3-45 19-1-4
PS-2-9 13-3-8 13-3-46 19-1-5
PS-2-10 13-3-9 13-3-47 19-1-6
PS-2-11 13-3-10 13-3-48 19-1-7
PS-2-12 13-3-11 13-3-49 19-1-8
PS-3-1 13-3-12 13-3-50 19-1-9
PS-3-2 13-3-13 13-3-51 19-1-10
13-3-14 13-3-52 19-2-1
12-1-1 13-3-15 13-4-1 19-2-2
12-1-2 13-3-16 13-4-2 19-2-3
12-1-3 13-3-17 13-4-3 19-2-4
12-1-4 13-3-18 13-4-4 19-2-5
12-1-5 13-3-19 13-4-5 19-2-6
12-1-6 13-3-20 13-4-6 19-2-7
12-1-7 13-3-21 13-4-7 19-2-8
13-3-22 13-4-8 19-2-9
13-1-1 13-3-23 13-4-9 19-2-10
SM 715, Jul 06 REVISION HISTORY - 1

REVISION HISTORY
19-2-11 20-5-8 25-3-1 25-11-7
19-2-12 20-5-9 25-3-2 25-12-1
19-2-13 20-5-10 25-3-3 25-12-2
19-2-14 20-5-11 25-3-4 25-12-3
19-2-15 20-5-12 25-3-5
19-2-16 20-5-13 25-3-6 29-1-1
19-2-17 20-5-14 25-3-7 29-1-2
19-2-18 20-5-15 25-3-8 29-1-3
19-2-19 20-5-16 25-3-9 29-1-4
19-2-20 20-5-17 25-3-10 29-1-5
19-2-21 20-5-18 25-4-1 29-1-6
19-3-1 25-4-2 29-1-7
19-3-2 22-1-1 25-5-1 29-2-1
19-3-3 22-2-1 25-5-2 29-2-2
19-3-4 22-2-2 25-5-3 29-2-3
19-3-5 22-2-3 25-5-4 29-2-4
19-3-6 22-2-4 25-5-5 29-3-1
19-3-7 22-2-5 25-5-6 29-3-2
19-3-8 22-2-6 25-5-7 29-3-3
19-3-9 22-2-7 25-5-8 29-3-4
19-3-10 22-2-8 25-5-9 29-4-1
19-3-11 22-2-9 25-5-10 29-4-2
19-3-12 25-6-1 29-4-3
19-3-13 23-1-1 25-6-2 29-4-4
19-3-14 23-1-2 25-6-3 29-5-1
19-3-15 23-1-3 25-6-4 29-5-2
19-3-16 23-2-1 25-6-5 29-5-3
19-3-17 23-3-1 25-6-6
19-3-18 23-3-2 25-6-7 30-1-1
19-4-1 23-3-3 25-6-8 30-1-2
19-4-2 23-4-1 25-7-1 30-1-3
23-4-2 25-7-2 30-1-4
20-1-1 23-5-1 25-7-3 30-1-5
20-1-2 23-5-2 25-8-1 30-2-1
20-2-1 23-6-1 25-8-2 30-2-2
20-3-1 23-6-2 25-8-3 30-2-3
20-3-2 23-6-3 25-9-1 30-2-4
20-4-1 25-9-2 30-2-5
20-4-2 25-1-1 25-10-1 30-2-6
20-5-1 25-1-2 25-10-2 30-2-7
20-5-2 25-1-3 25-11-1 30-2-8
20-5-3 25-1-4 25-11-2
20-5-4 25-1-5 25-11-3 32-1-1
20-5-5 25-1-6 25-11-4 32-2-1
20-5-6 25-2-1 25-11-5 32-2-2
20-5-7 25-2-2 25-11-6 32-2-3
2 - REVISION HISTORY SM 715, Jul 06

REVISION HISTORY
32-3-1 34-6-5
32-3-2 34-6-6
32-3-3 34-6-7
32-4-1 34-6-8
32-4-2 34-7-1
32-4-3 34-7-2
34-7-3
34-1-1 34-7-4
34-1-2 34-8-1
34-1-3 34-8-2
34-1-4 34-8-3
34-1-5 34-8-4
>?@AB51P
Q RST U
VWX 34-1-6
34-2-1 38-1-1
34-2-2 38-2-1
34-2-3 38-2-2
34-2-4 38-3-1
34-3-1 38-4-1
34-3-2 38-4-2
34-3-3
34-3-4 40-1-1
34-3-5 40-1-2
34-3-6 40-1-3
34-3-7 40-1-4
34-3-8 40-1-5
34-3-9 40-1-6
34-3-10 40-1-7
34-4-1 40-2-1
34-4-2 40-2-2
34-4-3 40-2-3
34-4-4 40-2-4
34-4-5 40-2-5
34-4-6 40-2-6
34-4-7 40-2-7
34-4-8 40-3-1
34-4-9
0 34-5-1
34-5-2
34-5-3
34-5-4
34-5-5
34-5-6
34-6-1
0 34-6-2
34-6-3
34-6-4
SM 715, Jul 05 REVISION HISTORY - 3

NOTE :
REVISION HISTORY SM 715, Dec 04

Truck Models Covered by this Manual
This manual consists of base module that pertains You may, however, purchase specific modules and
to all TMX12-25, ECX16-18 models and other mod- expand your manual to fully cover multiple models.
ules that pertain only to specific models. Manuals To do so, order the desired modules as you would
shipped with the truck contain the base module and any other Clark part.
the modules specific to the purchased truck.
Arrangement and Use of this Manual

Clark arranges parts and service procedures by stan- You can quickly locate a specific point in the manual
dardized Groups. In this manual, Groups are similar by using the headers and footers that appear on
to chapters. Groups are listed in the indexes on the every Section page. The following illustration points
next page. out these areas.
Each Group begins with a table of contents that
shows the Sections contained within the Group.
Lengthy Sections also begin with a table of contents.
Each Group and Section has an identifying name
and number, or ID.
Each page also has a unique ID. The page ID con-
sists of three numbers separated by hyphens. The
three numbers represent the Group number, the Sec-
tion number, and the page number. For example,
00-1-2 on the lower corner of the page indicates This manual is intended for the use of trained
Group 00, Section 1, page 2. service personnel. Please read Group SA, Safe
The Group number sometimes has a letter or letters Mainte-nance, and the Operators Manual before
added to it in parentheses if one or more variations working on or operating the truck.
of the Group exist. For example, if the truck has a
stan-dard transaxle, Group 06 is expressed as
06(S); if the truck has a hydrostatic transmission,
Group 06 is expressed as 06(H).
NOTE :
, SM598, Nov 00
CONTENTS
Contents by Group and Section

(Alphabetical listing of contents appears on next page.)
Contents are listed here by Group number and name followed by Section number and name:
SA SAFE MAINTENANCE 5. Parking Brake Removal, Replacement,

1. Safety and Adjustment
2. Lifting, Jacking, and Blocking the Truck 6. Brake Overhaul
3. Towing 25/26 STEER SYSTEM
PS PERIODIC SERVICE 0 Steering System Specifications and Description.
0 Maintenance Schedules 1 Steering System Troubleshooting
1 Planned Maintenance Program 2 Steering Column and Component Removal and
2 PM Inspection Form Replacement
3 Steering System Relief Pressure Check and
0 BATTERY Adjustment
4 Steering Gear Overhaul(TMX)
0 Battery Service
5 Steer Axle Service (TMX)
1 WIRING, SWITCHES, AND INSTRUMENTS 6 Steer Cylinder Overhaul (TMX)
7 Steering Axle Wheel Bearing Maintenance and
0 Schematic Electric Circuit Diagrams
Adjustment (EPX)
1 General Electrical Service Tips
8 Steering Axle Removal and Replacement (EPX)
2 Wiring and Cables
9 Steer Cylinder Removal and Replacement (EPX)
3 Switches and Sensors
10 Steering Gear Overhaul(EPX)
4 Instrument Panel
11 Steer Cylinder Overhaul (EPX)
0 ELECTRIC MOTORS 0 HYDRAULIC SYSTEM
0 Motor Specifications And Descriptions 0 Main Hydraulic System Specifications
1 Drive Motors Overhaul and Description
2 Pump Motor Overhaul 1 Fluids and Filters
2 Hydraulic System Troubleshooting
1 CONTACTORS Troubleshoot-ing
0 Contactors 3 Hydraulic System Pressure Checks and Adjust-
ments
5888 MOTOR CONTROLS 4 Hydraulic System Removal and Overhaul

0 Description 1 HYDRAULIC SYSTEM
0 Hydraulic System Schematic
1 Programming & 1 Main Hydraulic Control Valve Removal
Adjustments Using ZAPI Handset and Overhaul

2 Control troubleshooting

3 TMX Factory Control Settings

5889 DRIVE AXLE

0 Drive Axle Specifications and

Description

1 Drive Axle Fluid Check and Change
0 TILT CYLINDERS

2 Drive Axle Troubleshooting
0 Tilt Cylinder Specifications and
Description
3 Drive Axle Removal and Installation

1 Checks and Adjustments
4 Drive Axle Overhaul

2 Tilt Cylinder Removal and Installation

3 Tilt Cylinder Overhaul
22 WHEELS AND TIRES 34 UPRIGHTS

1. Wheels & Tires Specifications and Description 1. Upright Specifications and Description
2. Wheels & Tires Mounting and Maintenance 2. Trouble shooting
23 BRAKE SYSTEM 3. Upright Inspection
4. Carriage and Upright Roller Clearance Checks
1. Brake Specifications and Shim Adjustment
2. Brake System Fluid Check, Fill, and Bleed 5. Cylinder Removal, Shimming, Overhaul and
Specifications and Description Replacement
3. Brake Pedal and Master Cylinder Removal, 6. Upright Chain Inspection, Adjustment and
Replacement, and Adjustment Replacement
4. Brake Caliper Removal and Replacement 7. Fork and Carriage Removal and Replacement
SM 715, Jun '05 CONTENTS -1

CONTENTS
8. Upright Removal and Replacement
0 COUNTERWEIGHT AND CHASSIS

0.0 Counterweight Specifications and Description
0.1 Counterweight Removal and Installation
0.2 Overhead Guard Removal and Installation
0.3 Floor Plate, Seat, and Seat Deck
Removal and Installation
0 SPECIFICATIONS
0 Nameplate and Decals
1 General Specifications
2 Hydraulic Fitting Tightening Procedure
CONTENTS -2 SM 715, Jun '05

CONTENTS
Alphabetical Listing of Topics

(Contents are listed by order of Group and Section numbers on previous page.)
Contents are listed here by topic followed by the Group#-Section# the topic appears in:
Battery Service.......................................................... 12-1 Nameplate and Decals.............................................. 40-1
Brake Caliper Removal and Replacement ............... 23-4 Overhead Guard Removal and Installation ............... 38-3
Brake Overhaul ......................................................... 23-6 "Parking Brake Removal, Replacement, and
"Brake Pedal and Master Cylinder Removal, Replacement, Adjustment" ............................................................... 23-5
and Adjustment " ....................................................... 23-3 Planned Maintenance Program................................. PS-2
Brake Specifications ................................................. 23-1 PM Inspection Form .................................................. PS-3
"Brake System Fluid Check, Fill, and Bleed Programming & Adjustments Using ZAPI Handset... 19-2
Specifications and Description"................................. 23-2 Pump Motor Overhaul ............................................... 16-3
Carriage and Upright Roller Clearance Checks and Safety ........................................................................ SA-1
Shim Adjustment ....................................................... 34-4 Schematic Electric Circuit Diagrams ......................... 13-1
Checks and Adjustments .......................................... 32-2
Steer Axle Service (TMX) .................................... 25/26-6
Contactors................................................................. 17-1
Steering Axle Wheel Bearing Maintenance
Control troubleshooting ............................................ 19-3
and Adjustment (EPX)......................................... 25/26-8
Counterweight Removal and Installation................... 38-2 Steering Axle Removal and Replacement (EPX) 25/26-9
Counterweight Specifications and Description.......... 38-1 Steer Cylinder Overhaul (TMX) ............................ 25/26-7
"Cylinder Removal, Shimming, Overhaul and Steer Cylinder Overhaul (EPX) .......................... 25/26-12
Replacement"............................................................ 34-5 Steer Cylinder Removal and Replacement
Description ................................................................ 19-1
(EPX) ................................................................ 25/26-10
Drive Axle Fluid Check and Change ......................... 20-2 Steering Column and Component Removal and
Drive Axle Overhaul .................................................. 20-5 Replacement ........................................................ 25/26-3
Drive Axle Removal and Installation.......................... 20-4 Steering Gear Overhaul (TMX) ........................... 25/26-5
Drive Axle Specifications and Description................. 20-1 Steering Gear Overhaul (EPX) ......................... 25/26-11
Drive Axle Troubleshooting ....................................... 20-3 Steering System Relief Pressure Check and
Drive Motors Overhaul .............................................. 16-2 Adjustment .......................................................... 25/26-4
"Floor Plate, Seat, and Seat Deck Removal and Steering System Specifications and Description. 25/26-1
Installation"................................................................ 38-4 Steering System Troubleshooting ........................ 25/26-2
Fluids and Filters....................................................... 29-2 Switches and Sensors............................................... 13-4
Fork and Carriage Removal and Replacement ......... 34-7 Tilt Cylinder Overhaul................................................ 32-4
General Electrical Service Tips ................................. 13-2 Tilt Cylinder Removal and Installation ....................... 32-3
General Specifications .............................................. 40-2 Tilt Cylinder Specifications and Description .............. 32-1
Hydraulic Fitting Tightening Procedure ..................... 40-3 TMX Factory Control Settings ................................... 19-4
Hydraulic System Pressure Checks and Adjustments29-4 Towing ....................................................................... SA-3
Hydraulic System Removal and Overhaul................. 29-5 Trouble shooting ........................................................ 34-2
Hydraulic System Schematic .................................... 30-1 "Upright Chain Inspection, Adjustment and
Hydraulic System Troubleshooting Troubleshooting.. 29-3 Replacement"............................................................ 34-6
Instrument Panel ....................................................... 13-5 Upright Inspection ..................................................... 34-3
"Lifting, Jacking, and Blocking the Truck" .................. SA-2 Upright Removal and Replacement .......................... 34-8
Main Hydraulic Control Valve Removal and Upright Specifications and Description ..................... 34-1
Overhaul ................................................................... 30-2 Wheels & Tires Mounting and Maintenance ............. 22-2
Main Hydraulic System Specifications and Wheels & Tires Specifications and Description......... 22-1
Description ............................................................... 29-1 Wiring and Cables..................................................... 13-3
Maintenance Schedules............................................ PS-1
Motor Specifications And Descriptions...................... 16-1
SM 715, Jun '05 CONTENTS -3

NOTE :
Alphabetical Listing of Topics SM 715, Dec '04

GROUP SA SAFE MAINTENANCE
GROUP SA
SAFE MAINTENANCE
Safety ................................................................. Section 1

Lifting, Jacking, and Blocking the Truck........ Section 2
Towing ............................................................... Section 3
SM 715, Dec 04 Group SA SAFE MAINTENANCE,

NOTE :
Group SA SAFE MAINTENANCE, SM 715, Dec 04

Group SA, Safe Maintenance
Section 1.
Safety
Safety Signs and Messages Safe Maintenance Practices

Safety signs and messages in this manual and on the lift The following instructions have been prepared from cur-
truck provide instructions and identify specific areas rent industry and government safety standards applicable
where potential hazards exist and special precautions to industrial truck operation and maintenance. These rec-
should be taken. Be sure you know and understand the ommended procedures specify conditions, methods, and
meaning of these instructions, signs, and messages. Dam- accepted practices that aid in the safe maintenance of
age to the truck, death, or serious injury to you or other industrial trucks. They are listed here for the reference
persons may result if these messages are not followed. and safety of all workers during maintenance operations.
Carefully read and understand these instructions and the
NOTE specific maintenance procedures before attempting to do
This message is used when special informa- any repair work.
tion, instructions or identification is required
relating to procedures, equipment, tools, When in doubt of any maintenance procedure, please con-
pressures, capacities, and other special data. tact your local Clark dealer.
0 Powered industrial trucks can become hazardous if
IMPORTANT maintenance is neglected. Therefore, suitable
This message is used when special precau- mainte-nance facilities, trained personnel, and
tions should be taken to ensure a correct procedures must be provided.
action or to avoid damage to, or malfunction
1 Maintenance and inspection of all powered industrial
of, the truck or a component.
trucks shall be done in conformance with the manu-
facturers recommendations.
0 CAUTION
2 A scheduled planned maintenance, lubrication, and
This message is used as a reminder of safety inspection program shall be followed.
hazards that can result in personal injury if
proper precautions are not taken. 3 Only trained and authorized personnel shall be per-
mitted to maintain, repair, adjust, and inspect indus-
trial trucks. Work should be performed in accordance
0 WARNING with the manufacturers specifications.
This message is used when a hazard exists
4 Properly ventilate work area, vent exhaust fumes,
that can result in injury or death if proper
and keep shop clean and floor dry.
precautions are not taken.
5 Avoid fire hazards and have fire protection
0 DANGER equipment present in the work area. Do not use an
open flame to check for level or leakage of fuel,
This message is used when an extreme haz- electrolyte, oil, or coolant. Do not use open pans of
ard exists that can result in injury or death fuel or flammable cleaning fluids for cleaning parts.
or serious injury if proper precautions are
not taken. 6 Before starting work on truck:
0 Raise drive wheels off of floor and use blocks or
The above terms have been adopted by Clark Material other positive truck positioning devices.
Handling Company. The same terms may be used in dif-
1 Disconnect battery before working on the electri-
ferent context in service literature supplied directly or
cal system.
indirectly by vendors of truck components..
7 Before working on engine fuel system of gasoline- or
diesel-powered trucks, be sure the fuel shut-off valve
is closed.
SM 715, Dec 04 Safety SA-1-1

0 Operation of the truck to check performance must be manufacturers prior written approval. Capacity, opera-
conducted in an authorized, safe, clear area. tion and maintenance instruction plates, tags, or
decals must be changed accordingly. This is an
1 Before starting to drive truck: OSHA requirement.
0 Be in operating position with seat belt fastened.
0
1 Be sure parking brake is engaged. Care must be taken to assure that all replacement parts,
2 Put direction control in neutral. including tires, are interchangeable with the original
3 Start engine. parts and of a quality at least equal to that provided
in the original equipment. Parts, including tires, are
4 Check functioning of direction and speed controls, to be installed per the manufacturers proce-dures.
steering, brakes, warning devices, and any load Always use genuine CLARK or CLARK-approved
handling attachments. parts.
2 Before leaving truck
0 Stop truck. 1 Use special care when removing heavy
components from the truck, such as counterweight,
1 Put directional control in neutral.
seat deck, upright, etc. Be sure that lifting and
2 Apply the parking brake. handling equip-ment is of the correct capacity and in
3 Stop the engine by turning off the key switch. good condition. Also, this removal may upset the
4 Put upright in vertical position and fully lower the stability of the truck. The frame must always be
forks or attachment. safely blocked for major component removal.
5 Put blocks at the wheels if truck is on an incline. NOTE
3 Brakes, steering mechanisms, control mechanisms, You should also be familiar with additional
warning devices, lights, governors, guards, safety operating and maintenance safety instruc-
devices, and frame members must be carefully and tions contained in the following publications:
regularly inspected and maintained in a safe operat-
ing condition. ASME B56.1 - 1988: Operator Control-Industrial Tow
Tractors (Safety Standard For Powered Industrial Trucks).
4 Special trucks or devices designed and approved for Published by: American Society of Mechanical
hazardous area operation must receive special atten-
Engineers, Three Park Avenue, New York, NY10016.
tion to ensure that maintenance preserves the origi-
nal, approved, safe-operating features. NFPA 505-1982: Fire Safety Standard for Powered Indus-
trial Trucks: Type Designations, Areas of Use, Mainte-
5 Fuel systems must be checked for leaks and condi-
nance and Operation. Available from: National Fire
tion of parts. Extra special consideration must be
Protection Assoc., Inc., Batterymarch Park, Quincy, MA
given in the case of a leak in the fuel system. Action
02269.
must be taken to prevent the use of the truck until
the leak has been corrected. General Industrial Standards, OSHA 2206: OSHA Safety
and Health Standards (29 CFR 1910), Subpart N-Materi-
6 The truck manufacturers capacity, operation, and als Handling and Storage, Section 1910.178 Powered
maintenance instruction plates, tags, or decals must Industrial Trucks. For sale by: Superintendent of Docu-
be maintained in legible condition. ments, U.S. Government Printing Office, Washington, DC
7 Batteries, motors, controllers, limit switches, protec- 20402.
tive devices, electrical conductors, and connections
must be inspected and maintained in conformance
with good practice. Special attention must be paid to
the condition of electrical insulation.
8 To avoid injury to personnel or damage to the equip-
ment, consult the manufacturers procedures in
replacing contacts on any battery connection.
9 Industrial trucks must be kept in a clean condition to
minimize fire hazards and help in the detection of
loose or defective parts.
10 Modifications and additions that affect capacity and
safe truck operation must not be done without the
SA-1-2 Safety SM 715, Dec 04

Section 2
Lifting, Jacking, and Blocking
Raising Drive Wheels.........................................................................2

Chaining the Upright in Raised Position......................................2
Raising Rear of Truck.........................................................................3
Raising Entire Truck...........................................................................4
Shipping Tie-Down Instructions.....................................................4
0 WARNING
Lifting or jacking any large piece of equipment such as a fork truck presents obvious hazards. It
must be done with great care and forethought. Consult the truck weight information in Group 40,
Specifications, to ensure that your lifting equipment is of adequate capacity.
SM 715, Dec 04 Lifting, Jacking, and Blocking SA-2-1

0 CAUTION 23Lower the drive wheels to the floor by reversing this

procedure.
To perform these service procedures, first: . Turn key switch ON.
. Park truck on a level surface. . Tilt upright fully back.
. Put the upright in a vertical position and . Turn key switch OFF.
lower the carriage fully down.
24 Remove the blocks from under the frame and upright
. Return control handle to neutral and turn rails.
key switch OFF.
0 WARNING
Chaining the Upright in Raised
Defective equipment can cause accidents. All Posi-tion
tools and lifting equipment must be in good This procedure provides safe clearance for access from
condition, meet the load capacity require- the front of truck to components on or near the drive axle.
ments and have OSHA labels when required.
23Park truck safely.
Tools with defects can fail, causing severe
injury or death. 24Put blocks at front of and rear of drive wheels.
25Raise upright carriage.
Raising Drive Wheels 26Chain the center inner rail tie bar to the top outer rail
tie bar as shown.
This procedure uses the upright to lift the drive wheels
off the floor.
23 Park the truck safely.
24 Turn key switch ON. Tilt the upright fully back.
25 Put a solid 100 x 100 mm (4 x 4 inch) hardwood
block under the front section of each upright rail. Put
a 3.6 mm (0.125.0.250 inch) steel plate on top of
each block.
Triple Stage Uprights: Chain the center intermediate
26 Tilt the upright fully forward. This will raise the rail tie bar and the lower inner rail tie bar to the top
drive wheels off the floor. outer rail tie bar.
5. Reverse the procedure to remove the chains.
5888 WARNING
23 Block the truck under the frame behind the drive Keep hands, tools, etc. out of upright.
wheels with solid blocking.
24 Turn key switch OFF.
25 Check for safe clearance between drive wheels,
block and floor.
26 Check the stability of the truck. Be sure that the
blocks are located securely under the frame before
operating the drive motor or working on truck.
SA-2-2 Lifting, Jacking, and Blocking SM 715, Dec 04

Raising Rear of Truck side to side, increasing elevation not more than 50
23 (2 in) each time. Raise the truck no higher than
The truck may be raised at the rear by jacking and block- necessary to perform the maintenance work.
ing under the frame just beyond the counterweight. Make sure the left and right sides of the truck are
finally blocked in a level working position.
Refer to truck data plate for truck weights.
23 WARNING
An incorrectly installed counterweight can
move or fall unexpectedly. NEVER LIFT OR
BLOCK A TRUCK USING THE COUN-
TERWEIGHT. Failure to follow procedures
outlined in this manual can result in injury
or death.
23Park truck safely.

24Put blocks at front and rear of drive wheels.
23 CAUTION 23 CAUTION
If possible, remove the battery from truck to Before performing any maintenance work,
reduce weight for added safety and ease of check the truck for stable condition on the
jacking. blocking by determining that it will not rock
on blocks.
23 Put a floor jack under the frame just beyond the
coun-terweight. 23When maintenance work is completed, lower the
rear of truck to the floor by reversing the above
23 WARNING procedure and lowering each side of the truck 50
mm (2 in) at a time:
Never lift the truck by the counterweight.
23 Put jack under frame and raise truck.
24 Carefully remove blocks and lower truck.
25 Remove jack and blocks from drive wheels.
NOTE
If there is insufficient clearance under frame
for your jack, the truck may first be driven
onto shims, such as 25 x 150 x 300 mm (1 x 6
x 12 in) pieces of board, to increase the truck
frame under-clearance.
23Jack up one side of the truck about 50 mm (2 in) and

put a block under the frame to hold that elevation.
Then move the jack to the other side and jack and
block it. Continue to alternate the procedure from
SM 715, Dec 04 Lifting, Jacking, and Blocking SA-2-3

Raising Entire Truck ! CAUTION
Refer to truck data plate for truck weights. Before performing any maintenance work,
5888 Park truck safely. Lower upright fully. If check the truck for stable condition on the
necessary, drive truck onto boards to increase under- blocking.
clearance.
5888 When maintenance work is completed, lower the
23 WARNING entire truck to the floor by reversing this procedure.
SIDE-TO-SIDE TIPOVER. When jacking Lower the truck one side at a time, while carefully
side of truck, be sure upright is lowered fully. removing the blocks. Be sure no tools or equipment
Do not raise one side of the truck more than are under the truck or wheels.
about 50 mm (2 in) higher than the other, to NOTE
avoid tipping truck over laterally.
Depending on jack height, shims under the
END-TO-END TIPOVER. If the upright and
tires may be needed for clearance to allow
drive axle are removed while the truck is
removal of jack.
blocked up, the truck will tip backward due
to the heavy counterweight. Upright and
counterweight must both be removed before Shipping Tie-Down Instructions
attempting to raise the truck for drive axle
removal. The back of the truck must be sup- 23Front of Truck
ported by blocking under the steer axle to a. With Upright and Carriage Installed
prevent movement.
If the counterweight is removed while the Lower the carriage fully.
truck is up on blocks, the weight of the
5888 Put a tie-down (e.g., chain) between the
upright and drive axle will cause the truck to
carriage fork bars.
fall forward.
5888 Put the jack under side frame, near the center of
the truck.
IMPORTANT
Be sure to put the jack squarely and fully
under the main side structure of the frame.
23 Carefully raise the truck one side at a time, only as

high as necessary to do the maintenance work, and
not more than 150 mm (6 in) total.
24Put blocks under the side frame, at each side of the
jack. Spread the blocks close to the steer and drive b. Without Upright and Carriage Installed
wheels for maximum stability. 23 Put a chain across the truck floor plate. Protect
25If using one jack, lower the truck onto the blocks and truck from chain damage by using covered chain
move the jack to the opposite side. Repeat the lifting or protective material under the chain at contact
procedure. points.
26Put the same size blocks under each side of the truck 24Rear of Truck
so it will be leveled. 23 Attach the tie-down to the toe-pin in top of coun-
terweight.
SA-2-4 Lifting, Jacking, and Blocking SM 715, Dec 04

Section 3
Towing
If your truck is disabled but can be moved freely on its 5888 Release the parking brake on the towed
own wheels without further damage, use the following vehicle. Place directional control lever in neutral.
procedures to tow the truck safely to a repair area. 5889 Tow the disabled truck backwards. An
operator must be on the disabled truck.
5888 WARNING
It is important for your safety and to the 23 CAUTION
care of your lift truck to use the proper The power steering and braking will not
equipment and carefully follow these operate on the disabled truck. The steering
recommendations for safe towing. handwheel will be difficult to turn and the
Do not tow a lift truck if there is a problem service brakes will require additional pedal
with the brakes or tires, or if the steering
force.
cannot be operated.
Do not tow the disabled truck up or down
5888 Tow the truck slowly. Careful towing is
ramps or steep inclines.
necessary to prevent injury to personnel or damage to
Do not attempt to tow the disabled truck if
the disabled truck. The truck should be towed at a speed
traction or weather conditions are poor.
of less than 8 kph (5 mph, or a moderate walking
23 Be sure to apply the parking brake or block the drive speed) with a driver in place and steering the disabled
wheels on the disabled truck while working around it. truck.
24When possible, raise the carriage (forks) on the dis- IMPORTANT
abled truck 300 mm (12 in) from the floor or ground. Do not lift the disabled truck or any wheels
Secure the carriage on the upright with a chain. off the floor while the truck is being towed.
25 Use a truck for towing that is of equal or larger
capac-ity than the disabled truck. Carry a partial load 23Park the disabled truck in authorized areas only.
on the tow truck for improved traction. Fully lower the forks on the floor, leave the
26 Check that the counterweight bolts on both trucks directional control in neutral, turn the key switch to
are in place and properly torqued. These bolts are OFF, and engage the parking brake. Remove the key
made of special, high-tensile steel and are not and, when necessary, block the wheels to prevent the
commer-cially available. When necessary, replace truck from rolling.
these bolts only with a genuine Clark replacement
part. 5888 WARNING
27 Use an approved, solid metal tow bar with towing Always engage the parking brake when
couplers that connect to the towing pins in the coun- park-ing a lift truck. The truck can roll and
terweights. cause injury or death to personnel near it.
NOTE
DOT-approved towing equipment is
available from your Clark dealer.
SM 715, Dec 04 Towing SA-3-1

NOTE :
Group SA, Safe Maintenance SM 715, Dec 04

GROUP PS PERIODIC SERVICE
GROUP PS
PERIODIC SERVICE
Maintenance Schedule .................................... Section 1

Planned Maintenance Program ...................... Section 2
The PM Inspection Form ................................. Section 3
SM 715, Dec 04 Group PS PERIODIC SERVICE,

NOTE :
Group PS PERIODIC SERVICE, SM 715, Dec 04

Group PS, Periodic Service
Section 1.
Maintenance Schedule
Periodic Service and Planned Maintenance..............................2

Determining Maintenance Intervals.....................................................2
TMX Service Chart/Lubrication Points................................................3
EPX Service Chart/Lubrication Points................................................4
Recommended Periodic Service Schedule........................................5
SM 715, Mar 05 Maintenance Schedule PS-1-1

Periodic Service and Planned Determining Maintenance Intervals

Main-tenance Time intervals on the charts on the next four pages and
elsewhere in this manual relate to truck operating hours as
The term periodic service includes all maintenance
recorded on the hourmeter, and are based on experience
tasks that should be performed on a regularly scheduled Clark has found to be convenient and suitable under nor-
basis. mal operation. Standard operating condition classifica-
The term Planned Maintenance indicates a formalized tions are:
program of basic inspections, adjustments, and lubrica- Normal Operation: Eight-hour material handling, mostly
tions that the Clark service organization provides custom- in buildings or in clean, open air on clean, paved surfaces.
ers at a prescribed interval, usually 50-250 hours. The
recommended basic Planned Maintenance procedure is Severe Operation: Prolonged operating hours or constant
given in Section 2 of this Group. usage.
The current Section,Maintenance Schedules, specifies Extreme Operation:
all maintenance tasks.including Planned Maintenance In sandy or dusty locations, such as cement plants,
tasks.that should be performed periodically, and suggests
lumber mills, and coal dust or stone crushing sites.
intervals at which they should be performed.
High-temperature locations, such as steel mills and
foundries.
Sudden temperature changes, such as constant trips
from buildings into the open air, or in refrigeration
plants.
If the lift truck is used in severe or extreme operating con-
ditions, the maintenance intervals should be shortened
accordingly.
IMPORTANT
MAINTENANCE INTERVALS. If the lift
truck is used in severe or extreme operating
conditions, the maintenance intervals should
be shortened ace. Put upright in vertical posi-
tion and fully lower the forks or attachment.
Service Chart/Lubrication Points

A decal, similar to the illustration below, is located on the
underside of the seat deck. This decal is a basic guide to
periodic
maintenance intervals and tasks. A more detailed chart is
supplied on the next page.
PS-1-2 Maintenance Schedule SM 715, Mar 05

TMX Service Chart/Lubrication Points

A decal, similar to the illustration below, is located on the underside of the seat deck. This decal is a basic guide to peri-
odic maintenance intervals and tasks. A more detailed chart is supplied on the next page.

EPX Service Chart/Lubrication Points
PS-1-4 Maintenance Schedule SM 715, Jun 05

Recommended Periodic Service Schedule

This chart lists maintenance tasks that should be done periodically, the suggested time intervals, and the service manual
Group in which the task is covered. Refer to Operators Manual for Daily Checks.
Every Every Every

Every 450- 500 Hours 900- 1000 Hours 2000 Hours
TASKS 1st 50 Hours 50-250 Hours (or 3 months) (or 6 months) (or 1 year)
Group PS - Periodic Maintenance
Perform Planned Maintenance .
inspections, lubrications, and adjust-
ments
Group 12 - Battery
Battery electrolyte level - check/add .
Battery load voltage test .
Battery terminals/cables - clean/ .
tighten
Group 13 Wiring and Instruments
Hourmeter - check .
Lamp check - at start-up .
Wiring harness - inspect . .
Instruments/accessories
Group 16 - Electric Motors
Drive motor - check/air clean .
Lift pump motor - check/air clean .
Group 17 -Contactors
Contactor tips - check/air clean
Group 19 - Motor Controls
Display - check display for error .
codes
Controller - air clean .
Controller connectors - check .
and lubricate
Group 20 - Drive Axle
Air vent - inspect, clean or replace .
Axle mounting bolts - inspect/tighten .
.Pressure checks .
Fluid change - drain/fill .
Fluid filter - replace . .
Fluid level/condition - check/sample . .
Group 22 - Wheels And Tires
Wheel mounting bolts - tighten . .
Tire pressure/condition - check . .
Group 23 - Brakes
Operation - check .
Service brake - check wear .
Brake lines - check . .
Parking brake - check/adjust . .

TASKS Every Every Every

1st 50 Every 450- 500 Hours 900- 1000 Hours 2000 Hours
Hours 50-250 Hours (or 3 months) (or 6 months) (or 1 year)
Group 25/26 - Steer Axle and Lines
Operation - check .
Power steering relief pressure - check .
Steer axle mounting - inspect .
Steer wheel and trunnion bearings - .
check
Steer wheel and trunnion bearings - .
lubricate/adjust
Steering cylinder seals - check leakage .
Steering linkage - lubricate .
Group 29/30 - Hydraulic Lift System
Hydraulic fluid level/condition - .
check/sample
Hydraulic fluid change - drain/fill .
Hydraulic filler screen - clean .
Hydraulic fluid filter - replace . .
Hydraulic tank breather - clean/replace . . .
Control valve linkage - check/clean
Hydraulic system relief pressure - test/ .
adjust
Group 32 - Tllt Cylinders
Tilt cylinder adjustment - check/adjust .
Tilt cylinder drift - test .
Tilt cylinder mounting - check/tighten .
Tilt cylinder rod ends - check/tighten/ .
lubricate
Tilt cylinder rod/seals - check for leaks .
Group 34 - Upright, Lift Cylinders, Carriage, Forks
Operation - check .
Carriage and lift chain - lubricate .
Carriage chain condition - inspect/ .
adjust
Forks, latches, stop pin - inspect/check .
wear
Lift chain condition - inspect/adjust .
Load backrest .
Upright cylinder/mounting - inspect/ .
tighten
Upright lift cylinder downdrift - test .
Upright rollers - check .
Upright trunnion bolts - tighten .
PS-1-6 Maintenance Schedule SM 715, Mar 05

Section 2.
The Planned Maintenance Program
This Section defines a set of basic service procedures, known as the Planned Maintenance Pro-
gram,and describes a systematic approach for performing them.
Introduction to Planned Maintenance..........................................................................................2

PM Intervals.....................................................................................................................................2
The PM Form...................................................................................................................................2
The Basic PM Procedures................................................................................................................2
Truck Location and Parking.............................................................................................................2
External Inspection........................................................................................................................3
Decals...............................................................................................................................................3
Fittings and Fasteners.......................................................................................................................3
Overhead Guard and Chassis...........................................................................................................3
Lights and Safety Devices................................................................................................................3
Leaks................................................................................................................................................3
Carriage, Load Backrest, and Upright.............................................................................................3
Forks.................................................................................................................................................4
Wheels and Tires..............................................................................................................................4
Operational Checks........................................................................................................................4
Operators Environment...................................................................................................................4
Service and Parking Brake (Initial Check).......................................................................................5
Dash Display and Safety Lock-Outs................................................................................................5
Steering (Initial Check)....................................................................................................................5
Hydraulic System.............................................................................................................................6
Carriage, Upright, and Sideshifter..............................................................................................6
Control Levers............................................................................................................................6
Horn, Lights, and Alarms.................................................................................................................6
Traction and Braking System...........................................................................................................7
Brakes.........................................................................................................................................7
Controlled Reversal....................................................................................................................7
Acceleration................................................................................................................................7
Turning........................................................................................................................................8
Internal Inspection.........................................................................................................................8
General Checks................................................................................................................................8
Fluid and Filters...............................................................................................................................8
Battery..............................................................................................................................................9
Air Cleaning the Truck.................................................................................................................10
Minor Adjustments Covered by PM............................................................................................10
Switch Adjustments.........................................................................................................................10
Parking Brake Adjustment...............................................................................................................10
Racking Adjustments.......................................................................................................................10
Chain Adjustments...........................................................................................................................10
Missing or Loose Fasteners.............................................................................................................10
Chassis Lubrication.......................................................................................................................11
Drive Axle Lubrication....................................................................................................................11
Upright and Tilt Cylinder Lubrication........................................................................................... 11
Steer Axle Lubrication.....................................................................................................................11
Critical Fastener Torque Checks................................................................................................ 12
Wrapping Up the PM....................................................................................................................12
Clean Up..........................................................................................................................................12
Test the Truck..................................................................................................................................12
Report the PM..................................................................................................................................12
SM 715, Mar 05 The Planned Maintenance Program PS-2-1

Introduction to Planned Maintenance The PM procedure, in outline form, is as follows:
A program of regular, routine inspections, lubrication, External visual checks. Perform these as you walk
and other service tasks is important for the long life and around the truck with it turned off.
trou-blefree operation of the lift truck. Operational checks. Perform these while operating the
truck.
The Clark service organization offers customers a formal-
ized program.called Planned Maintenance, or PM.for Internal visual checks. Perform these after remov-ing
the floor board and cowl cover.
performing these tasks.
Air cleaning internal components. Do this while
performing the previous step.
PM Intervals Critical fastener torque checks.
The PM inspections, adjustments, and lubrications are Minor adjustments and repairs you found in your
typically performed on each covered truck at 50-250 hour inspection.
intervals. (See Section 1, in this Group about defining ser- Fluid level checks and fill.
vice intervals.) Chassis lubrication.
Final clean up.
The PM Form 10.Minor adjustments to the responsible party.
As an aid to service technicians performing and docu- Each of these steps is explained in detail beginning on
menting PM inspections, Clark has prepared a Planned the next page.
Maintenance Report form. A copy of this form is
inserted in Section 3 of this Group. CAUTION
We recommend that you use this form as a checklist and . Do not make repairs or adjustments unless
to make a record of your inspection and truck condition. authorized to do so.
This record can be used to inform the owner of needed . Disconnect the battery before you work
repairs and help establish the optimal PM intervals. on electrical components.
When you have finished the PM inspections, be sure to . Always wear safety glasses.
give a copy of the report to the person responsible for lift . Wear a safety (hard) hat in industrial plants
truck maintenance. and in special areas where protection is
necessary or required.
. Remove all jewelry (watch, rings, bracelets,
The Basic PM Procedures etc.) before working on the truck.
The basic PM procedure is to perform checks first,
repairs and adjustments last. As you go through each step Truck Location and Parking
of the PM, you should note all your findings on the PM
report form. Before starting the external inspection, make sure the
The PM report form serves as a record of what you did in truck is parked on a clean, level surface. Fully lower
the PM and what further service needs to be performed. upright, turn truck off, and engage the parking brake.
Further service consists of any repair, adjustment, If it is necessary to drive the truck to a suitable inspection
inspection, or lubrication that you discovered during the location, perform the initial braking and steering checks,
PM or any periodic service procedure that is due but not given later in this Section, as you begin to move the truck.
covered by the PM agreement).
To perform the operational checks, the truck must be
You should consult the previous PM report forms, peri- where there is sufficient clearance to raise the upright and
odic service chart, and truck hour meter to determine room to maneuver the truck at full speed without endan-
what periodic service is due. List the service due on the gering personnel, equipment, or materials.
new PM form.
PS-2-2 The Planned Maintenance Program SM 715, Mar 05

External Inspection CAUTION

Walk around the truck and take note of any obvious dam- HYDRAULIC FLUID PRESSURE. Do not
age and maintenance problems, as follows: use your hands to check for hydraulic leak-
age. Oil may be hot or under pressure. Fluid
under pressure can penetrate your skin and
Decals cause serious injury.
Check to be sure all capacity, safety, and warning plates
and decals are attached and legible. Carriage, Load Backrest, and Upright
NOTE (See Group 34 for more detailed inspection procedure.)
Do not operate a lift truck with damaged or
missing decals and nameplates. Replace them Inspect the welds on the carriage, load backrest, and
upright for cracks. Be sure that the mounting fasteners are
immediately. They contain important infor-
in place and tight.
mation. See Group 40 for decal locations.
Fittings and Fasteners

Make sure that fittings and fasteners are present, in usable
condition and fully fastened. Critical fastener torque
checks should be performed later--when making minor
adjustments and repairs.
Overhead Guard and Chassis

Be sure that the overhead guard and any other safety
devices are in place, undamaged, and attached securely.
Inspect welds and structural members for cracks or other
damage.
Lights and Safety Devices

Check safety devices, such as lights, horn, and audible
alarms, to make sure they are securely attached and have Inspect the upright assembly: rails, carriage rollers, load
on visible damage. backrest, lift chains, and lift and tilt cylinders. Look for
obvious wear and maintenance problems and damaged or
missing parts. Check for any loose parts or fittings. Check
Static Chain for leaks, any damaged or loose rollers and rail wear
(metal flaking).
Look under the truck to
make sure the static chain Carefully check the lift chains for wear, rust and corro-
contacts the floor and is not sion, cracked or broken links, and stretching. Check that
excessively worn or loose. the lift and carriage chains are correctly adjusted to have
See Group 13 for more equal tension and that the tops of the rails are within 4
information. mm (1/8 in) of each other.
Check that the lift chain anchor fasteners and locking
Leaks means are in place and tight. Be sure all safety guards and
chain retainers are in place and not damaged.
Look under the truck and on the chassis, uprights, and
Inspect the carriage stops and cylinder retainer bolts.
exposed hoses for any signs of external leakage: brake
Check all welded connections.
fluid, drive axle oil, and hydraulic fluid, and battery fluid.
Inspect all lift line hydraulic connections for leaks. Check
When you suspect hydraulic oil leaks and loose fittings, the lift cylinder rods for wear marks, grooves and
DO NOT USE BARE HANDS TO CHECK. scratches. Check the cylinder seals for leaks.

Forks Check all wheel lug nuts or bolts to be sure none are loose
or missing. Have missing bolts or lug nuts replaced and
Inspect the load forks for cracks, breaks, bending, and tightened to correct torque as explained in Group 22.
wear.
WARNING
HEEL WEAR. If the fork blade at the heel is
worn down by more than 10 percent, the
load capacity is reduced and the fork must
be replaced.
WARNING
Check tire pressure from a position facing
the tread of the tire, not the side. Use a long-
handled gauge to keep your body away. If
tires are low, the tire may require removal
and repair. Incorrect (low) tire pressure can
reduce truck stability. See Specifications in
Group 22 for proper inflation pressure.
Operational Checks
Be sure that:
Truck is parked on a level surface.
Key switch is off.
Parking brake is applied.
Directional control is in "N" (neutral).
Battery is connected.
X must be less than 25.4 mm (1 in) when measured Operators Environment

at Y height of 46 cm (18 in).
Sit in the operators seat and make sure the seat is secure and
Measure fork bending with a T-square and wood bock as that the seat adjustment mechanism operates properly.
shown above.
With the key switch off, check that travel and load han-
Inspect the fork latches to ensure that they are in good dling capability, dash display, lights, and alarms are all
condition, operate freely, and lock correctly. See Group disabled.
34 for more details on inspection procedures, including
use of fork wear gage.
Wheels and Tires

Check the condition of the drive and steer wheels and tires.
Remove objects that are embedded in the tread. Inspect the
tires for excessive wear or breaks or chunking out.

Check that the steering wheel is tight and rotates Continue this test by selecting reverse before releasing the
smoothly and adjusts for tilt properly. Check the control parking brake. The error code -79 should display and The
levers and foot pedals to make sure they are securely drive motor should be locked out.
mounted, oper-ate freely, and return to neutral when
released. Perform an additional visual inspection of the Place the direction control in neutral and release the park-
upright and overhead guard from the seated position ing brake. The numerical display should now show the
battery status (normal condition). The battery must be
Service and Parking Brake (Initial Check) recharged if the reading is less than 20 (percent). The
truck hydraulics will not function if the reading is less
Push the brake pedal down fully and hold. The brakes than 15%.
should apply before the pedal reaches the floorplate. If
Apply the parking brake
the pedal continues to creep downward, report the failure
immediately. Do not operate the truck until the brakes are See Groups 13 and 19 for detailed descriptions of all
repaired. display light functions and status error codes.
Operate the parking brake to make sure that it is securely
mounted and that it applies, catches, and releases prop-
erly.
Steering (Initial Check)
Apply the parking brake. Turn the key switch on.
Key switch is still on. Put the truck in neutral and release the
Dash Display and Safety Lock-Outs parking brake. Put the direction control in forward then turn
the steering handwheel clockwise until the steer-ing hits its
As you turn the key switch on, check the instrument dis- stop. Then turn the handwheel counterclock-wise and count
play. All indicator lights should come on for a 2-second the revolutions before the steering hits its stop. There should
lamp check. The seat belt prompt light should remain on be 5 revolutions from stop to stop. Return the steer wheels to
for 4 seconds, accompanied by the high-pitched seat-belt the straight-ahead position.
alarm. The parking brake light should remain on (if the
brake is set) and the numerical display should read -255 The steering system components should operate smoothly
to indicate that the parking brake is set. when the steering handwheel is turned.
(If any other error codes display or indicator lights iden- Hard steering, excessive play (looseness), or unusual
tify a problem, note the condition for further service sounds when turning indicates a need for detailed inspec-
action.) tion and service as described in Group 25/26.
If the truck has a steering system fault, take the truck

out of service until it is repaired.
With the parking brake set, the drive motor should not
function. Test this feature by depressing the accelerator
pedal after selecting a direction.
Place the direction control in forward and then release the
parking brake. The numerical display should now read -
79 to indicate that you have not consciously selected a
direction after parking. The drive motor and the The drive
motor should not function during this error condition.

Hydraulic System The basic adjustment procedure is described later

in this Section. Detailed upright checks and adjust-
Next you will test the hydraulic control levers and load ments are described in Group 34.
handling mechanism.
CAUTION
CAUTION
Be sure that there is adequate overhead
Check for sufficient clearance above and in
clearance before raising the upright.
front of the upright before operating the con-
trol levers. Pull back on the lift control lever and raise the car-riage
to full height. Watch the upright assembly as it rises.
Control Levers All movements of the upright, fork carriage, and lift
With the parking brake still on, check each control lever chains must be even and smooth, without binding or
in both directions to see that it works as follows: jerking or making clunking noises.
Watch for chain wobble or looseness; the chains
Lever has freeplay: You can move the lever slightly should have equal tension and move smoothly with-
without having an effect. The hydraulic pump out noticeable wobble.
motor does not start and the load handling mecha- Release the lever.
nism does not move; for instance, the carriage The basic chain adjustment procedure is described
does not lower or lift. later in this Section. Detailed chain inspection and
Lever has lag: You can move the lever slightly more adjustment procedures are in Group 34.
and the pump motor starts without causing lift, tilt,
or sideshift to occur. (Lowering occurs without the
pump motor starting.)
Lever actuates load handling function: You can
move the lever slightly more and lift, lower, tilt, or
sideshift occur slowly in the appropriate direction
Lever accelerates load handling function: You can
move the lever further to increase the speed at
which lift, lower, tilt, or sideshift occur.
If the maximum fork height cannot be reached, this

indicates there is low oil level in the hydraulic sump
or severe binding within the upright.
Push forward on the lift control lever. Watch the upright
as it lowers. If you suspect a problem with lifting or
lowering speeds, refer to Group 34 to diag-nose the
problem.
Carriage, Upright, and Sideshifter Check sideshifter action by pushing forward and
backward.
With the parking brake still on, make sure load handling
mechanism performs all functions smoothly, fully, and Horn, Lights, and Alarms
responsively:
Pull back on the tilt control lever and hold until the Test the horn and headlights and other safety devices
upright reaches the full back tilt position. Push for- before moving the truck. Check backup alarms and lights
ward on the lever to tilt it forward. Return the and all other safety equipment as you drive the truck in
upright to the vertical position and release the lever. the following steps.
Repeat these actions as you observe.
CAUTION
If there is excessive play between rails and chan-
nels, upright adjustment is required. If the service brake, parking brake, or inter-
lock is not operating properly, take the truck
If there is racking, adjustment of the cylinder rod
yokes or shims is required. (Rackingis when the out of service until it is repaired.
extension of the two tilt cylinder rods is unequal.)

Traction and Braking System on a 15% grade. Also, when travelling at full speed,
application of the parking or service brake should
Next, drive the truck to test the braking, accelerating, stop the truck in one truck-length.
turn-ing and reversing.
WARNING
Fasten your seat belt before driving the
truck.
NOTE
After you move the truck, you can check
where the truck was parked to see if there
are any leaks. Release Braking
Release Braking is the automatic slowing of the truck,
Brakes using the drive motor as a generator, when you lift your
foot from the accelerator.
Make sure that the truck is on a level surface, the travel
area is clear in front of and behind the truck, the parking Accelerate to a Medium speed. Take your foot off the
brake is released, the direction control is in neutral, and accelerator, truck should smoothly brake to a stop (dis-
the key switch is on. The numerical display should show tance depends on the RELEASE BRAKING setting).
battery condition with the parking brake off. When the truck is on a ramp and the accelerator pedal is
Move the direction control lever from neutral to for- released, the truck should brake to a stop and then con-
ward. tinue the creep down the ramp at approx. 1 MPH.
Check brakes at creep speed: Release the brake pedal and See Section 19 for adjustment procedures for the Release
depress the accelerator pedal to obtain slow forward speed. Braking function.
Apply the brake pedal to ensure that the brakes are
sufficient to stop the truck. Pedal should feel firm and Controlled Reversal
drive motor should cut off before brakes apply.
Accelerate to a slow speed and reverse the direction con-
trol without applying the foot brake. Truck should slow to
a smooth stop then accelerate normally in the opposite
direction.
Check brake pedal freeplay: Travel again and gently depress

the brake the brake pedal. The pedal should drop a very
slight distance before the brakes begin to apply.
Check brakes at full travel speed: Depress and release
the brake pedal several times while driving the truck. Repeat in both directions at various speeds.
The brakes should bring the truck to a smooth stop
without pulling, squealing, or shudder-ing. Drive Acceleration
motor should cut off before brakes apply.
After checking to see that you have a clear path, check
Check brake holding capability and adjustment: Park the
acceleration from a stand still condition. Drive the truck
truck on a grade and depress brake pedal. The brake
in a straight line at a high rate of speed. Acceleration
should hold a lift truck with rated load on a 15% grade.
should be smooth and without hesitation. Listen for
Check the function of the parking brake: Park the truck unusual drive train noise. Repeat in opposite direction.
on a grade and apply the parking brake. The parking
The accelerator pedal must move easily and smoothly
brake should hold a lift truck with rated load
throughout the acceleration stroke and return without

binding. There should be no restriction to movement on Discharging Controller Capacitors

acceleration or deceleration.
Turn off the key, put the direction control in neu-tral,
and set the parking brake.
Turning
Disconnect the battery connector.
Drive the truck in a straight line. The truck must travel Turn the key switch on.
without drifting to either side. It is necessary to discharge the capacitors before you
work on the controller.
Drive slowly (creep speed) through
a series of full right and left NOTE
turns. Check steering response Make sure that the battery has first been dis-
and smoothness of operation. connected at the battery receptacle.
The turning effort must be the
same in either direction. You To discharge the capacitors connect a 200 ohm 10 watt
should hear the power steer- resistor between the positive and negative input post of
ing pump operate over relief the controller for 10 seconds.
when in a full turn.
The drive motor control sys-tem
employs a speed differ-ential
between the left and right
motors to facilitate turn-ing. If
this system is malfunc-tioning
steering can be
difficult and wheels can make scrubbing noises.
Refer to Group 26 for steer system troubleshooting infor-
mation.
Internal Inspection
The internal inspection involves accessing the trucks
inner compartments, inspecting the various electrical and
hydraulic components, and checking fluid levels.
You can perform much of the inspection as you air clean
the truck, which is described later in this Section. General Checks
CAUTION Look for:
Remove all jewelry (watch, rings, bracelet, Pinched wires
neck chains, etc.) before working on electric Frayed or broken cables
trucks. Severe burns can result from contact
Dirty or loose electrical connections
with electrical circuits.
Loose or bent linkage pins
Proceed as follows: Signs of excessive wear or damage to linkages,
hinges, hoses, lines, clamps, and fittings
1. Park the truck on a level surface.
Leaks, (often indicated by dust or dirt built up) from
IMPORTANT pumps, steering gear, and reservoirs and plumbing
Fully lower carriage and place upright in Loose or damaged fasteners and motor mounts.
vertical position.

Fluid and Filters

IMPORTANT
Carriage must be fully lowered and upright
in vertical position before you check hydrau-
lic fluid.
Brake Fluid
Using a flshlight, check brake fluid reservoir through
inspection window. Fill to full mark, if low, with DOT 3
BRAKE FLUID. See Group 23 for procedure.
Controller Connectors
Pull connectors PL-1 through PL-8 and lubricate termi-
nals with Clark Electrical Connector Grease, part #
2819910.
Hydraulic Fuid and Filters

Remove dipstick and check hydraulic fluid level. Top off
if below full mark as described in Group 29.
Consult the periodic service chart (or service decal) to
determine if it is time to replace the sump cap filter and/
or spin-on hydraulic filter. If they are due, their replace-
ment is considered part of the PM.
L
F
F Make sure all connections are tight.

L
Battery
Inspect the battery for any damage, cracks, leaking condi-
tion, etc. If the terminals are corroded, clean and protect
them with CLARK Battery Saver (available from your
Clark dealer).
Check six cells with your hydrometer as desribed in
Group 12. A consistent reading among the six cells indi-
cates the battery is probably in good condition.
Perform the battery load test described in Group 12.
SM 715, Jun 05 The Planned Maintenance Program PS-2-9

Air Cleaning the Truck Minor Adjustments Covered by PM

You must air clean the truck as you perform the internal As you performed your inspections, you noted all needed
inspection described earlier in this Section. adjustments and repairs on the PM report form. Some of
these items may be outside the scope of the PM and
CAUTION should be reported for additional service. At this point in
Wear suitable eye protection and protective the PM, however, you should perform certain adjustment
clothing. and repairs, if needed. These include:
Switch Adjustments
CAUTION
Battery must be disconnected and capacitors If any action that is triggered or indicated by a switch
discharged before inserting air wand into does not occur at the right instant, check the switch
truck compartments. adjustment. To adjust the switch, slightly loosen the
mounting screws and slide the switch to appropriately
Use an air hose with special adapter or extension that has a
advance or retard the point at which the switch trips.
control valve and nozzle to direct the air properly. Use clean,
Retighten the screws. If switch or circuitry is defective,
dry, low-pressure compressed air. Restrict air pres-sure to 30
report this on the PM form as a further needed repair.
psi (207 kPa), maximum. (OSHA requirement).
Use air pressure to:
Parking Brake Adjustment
Blow air into all motor openings from various angles Adjust the parking brake at the caliper end. Loosen the
to remove dust. jamb nut and turn the adjusting nut to increase (or
Blow off all switches, contactors, motor controls, and decrease) the slack in the cable. Tighten the jamb nut.
all compartment walls. The brake caliper should be fully released when the park-
Air-clean the upright assembly, drive axle, steering ing brake handle is in the off position and should be fully
axle, steering cylinder. applied when the handle is fully back.
If air pressure does not remove heavy deposits of grease, oil, See Group 23 for detailed procedure.
etc., it may be necessary to use steam or liquid spray cleaner.
DO NOT clean electrical components with steam. Racking Adjustments
Racking adjustments are part of the PM. To eliminate
racking on back tilt, add or remove shims as explained in
Group 34. For forward racking adjustment, adjust rod end
mounting yokes as described in Group 34.
Chain Adjustments
With the upright fully lowered, the tops of the upright rails
should be flush with each other within 4 mm (1/8 in).
Paired chains should have equal tension. Fork heels
should rest 13 to 38 mm (0.5 to 1.5 in) off ground.
Check for chain stretch with chain ruler as described in
Group 34.
Basic chain adjustment procedure: With upright and car-
riage fully lowered, loosen jamb nut on chain anchor,
loosen adjusting nut, and turn adjusting nut to obtain cor-
rect length/tension. Tighten jamb nut.
See Group 34 for detailed procedure.
Missing or Loose Fasteners

Replace/tighten missing or loose fasteners during the PM.
This incudes bolts, cotter pins, cable ties, and so on.

Chassis Lubrication Upright and Tilt Cylinder Lubrication

Lubrication requirements are given on the trucks service Clean the fittings and lubricate the tilt cylinder rod end
decal (which is shown in Section 1 of this Group.) bushings (forward end). Clean the fittings and lubricate
the tilt cylinder base rod end bushings (rear end). Clean
At each PM, check the drive axle fluid and grease the fit- and lubricate the upright trunnion bushings.
tings at the upright pivot points and steer wheel.
Consult the service decal or periodic service chart to iden-
tify other lubrications that are due (for example, wheel
bearings) and report these on the PM form.
Be sure to clean the grease fittings before lubricating.
Remove the excess grease from all points after lubricat-
ing. Lubricate miscellaneous linkage as needed.
Drive Axle Lubrication
WARNING
To access the drive axle raise and block the
upright using safe procedures described in
Section 2, Lifting and Jacking Procedures
of Group 2, Safe Maintenance.
Check the drive axle fluid level with:

Truck on a level surface.
Oil at operating temperature. Steer Axle Lubrication
Remove the fluid level inspection/fill plug located in the Pivot the drive wheel to gain access to the grease fittings.
front surface of each drive unit housing (two places).
Grease with lubricant specification NLG # 1.
The oil level is correct (FULL) when it is within 13mm
(0.5 in) of the lower edge of the inspection plug
opening.
IMPORTANT: Add recommended fluid only, as indi-
cated on service decal. After adding oil to the drive
axle, wait several minutes until the oil has
distributed evenly throughout the unit, and check for
correct oil level. DO NOT OVERFILL.
Inspect each fill plug for damage. Replace as neces-sary.
Install and tighten the plugs. EPX Steer Axle Grease fittings.
Locate six fittings.
SM 715, Jun 05 The Planned Maintenance Program PS-2-11

Critical Fastener Torque Checks Wrapping Up the PM

For safety, maintain correct torque on all fasteners of com-
ponents that directly support, handle, or control the load Clean Up and
protect the operator.
Before closing up the truck, wipe up any spilled fluids
Check torque of critical items, including: and hand prints you may have left.
Drive axle mounting After closing up the truck, wipe off any handprints, drips,
Drive and steer wheel mounting spills, or other blemishes caused by the PM. Its a good
Counterweight mounting practice to leave the truck looking noticeably better than
when you started.
Overhead guard mounting
Tilt cylinder mounting and yokes Clean up any spills or debris you left on the floor or other
surfaces.
Upright mounting and components.
Critical fastener torque specifications are given in the
gen-eral specifications Section of Group 40. Test the Truck
Operate the truck one last time to ensure that you identi-
fied all problems and that your repairs/adjustments were
successful.
Report the PM
Finish filling out your PM form, making sure you noted
everything you checked, all the problems you found, and
all the items you adjusted or repaired.
Take the PM form to the person responsible for lift truck
maintenance, present your results, discuss any problems,
and point out where further service is needed.

Section 3
The PM Inspection Form
As an aid to service technicians performing and Use this form as a checklist, and make a record of
documenting PM inspections, Clark has prepared your inspection and truck condition. Note the spe-
an Electric Truck Planned Maintenance Report cial coding system for indicating the importance of
form. (Sample appears on the next page.) needed repairs and/ or adjustments.
SM 715, Dec 04 The PM Inspection Form PS-3-1

PS-3-2 The PM Inspection Form SM 715, Dec 04

GROUP 12 BATTERY
GROUP 12
BATTERY
Battery Service ................................................. Section 1
SM 715, Dec 04 Group 12 BATTERY,

NOTE :
Group 12 BATTERY, SM 715, Dec 04

Group 12, Battery
Section 1
Battery Service
Battery Handling .........................................................................................................................2

Battery Removal...........................................................................................................................3
Battery Maintenance....................................................................................................................4
Maximum Battery Life...................................................................................................................4
Battery Vents..................................................................................................................................4
Battery Cleaning..............................................................................................................................5
Battery Charging..............................................................................................................................5
Battery Electrolyte...........................................................................................................................5
CleanBattery Compartment.............................................................................................................5
Replacement Batteries.....................................................................................................................5
Battery Installation........................................................................................................................5
Keeping Battery Records..............................................................................................................6
Battery Tests...................................................................................................................................6
Specific Gravity Test.......................................................................................................................6
Load Test.........................................................................................................................................6
Connector, Negative Terminal, and Static Chain Installation...................................................7
SM 715, Dec 04 Battery Service 12-1-1

Group 12, Battery
Battery Handling DANGER

Explosive gas is always present around bat-
CAUTION
teries, especially when they are being
Remove all jewelry (watch, rings, bracelets, charged.
etc.) before working on electrical systems.
Severe burns can result from contact with No smoking allowed in the charging area.
electrical circuits.
Battery electrolyte must never be checked with an
open flame.
WARNING Open flame, sparks, or electric arcs must never be
Battery service must be done by trained per- allowed in the battery charging area.
sonnel. Battery acid can cause severe burns The battery contains corrosive sulfuric acid which
and injury. Do not smoke or have open can cause injury. If acid contacts your eyes or
flames around batteries. skin, flush immediately with water and get
medical assistance.
WARNING
Electric truck batteries are heavy and awk-
ward to handle. On charge, they give off
hydrogen and oxygen which, in certain con-
centrations, are explosive. Electric truck bat-
teries are also costly, so before you remove,
service, or install a truck battery, consult
BATTERY MANUFACTURER for more rec-
ommendations and instructions on handling
and charging batteries. Carefully read and
follow recommendations and instructions.
Change or service batteries only in an area designated for Persons maintaining batteries must wear protective cloth-
this purpose. Refer to page 4 for additional information. ing such as:
Be sure this area has provisions to flush and neu- Face and head shields
tralize acid spillage. Long shirt sleeves
Be certain the area has proper ventilation to venti-late Gauntlet gloves
fumes from charging batteries. Rubber apron
Check to see that there is fire protection. Fire extin-
guishers should be properly maintained and
located in designated areas.
12-1-2 Battery Service SM 715, Dec 04

Group 12, Battery
Be sure the battery service area is equipped with material DANGER

handling equipment designed for the purpose of removing
and replacing batteries, such as a conveyer or overhead Never lay tools or other metal objects on a
hoist equipped with safety hooks. battery. Metal objects contacting battery ter-
minals will cause short circuits. The shorted
IMPORTANT circuits could ignite battery fumes and cause
To prevent side forces from damaging the the battery to explode.
battery, the distance between the lifting
hooks (of the spreader bar) must be adjusted
to the same dimension as measured between
the battery lifting eyes. Make sure the lifting
hooks are the correct size to fit the lifting
eyes of the battery.
When using an overhead hoist, be sure to use an

insulated spreader bar or similar lifting device.
Be sure the hoist is equipped with a chain container to
accumulate excess lifting chain. When this is not
possible, be sure the battery is covered with a non-
conductive material, such as plywood, as shown
below. Battery Removal
If the battery does not have a cover of its own, cover it 1. Move truck to the designated battery service area.
with a non-conductive material such as plywood.
CAUTION
SAFE PARKING. Before working on truck:
Park truck on a hard, level and solid surface, such as a

concrete floor with no gaps or breaks.
Put upright in vertical position and fully lower the
forks or attachment.
Put all controls in neutral. Turn key switch OFF and
remove key.
Apply the park brake and block the wheels.
Turn key switch OFF and disconnect battery.

Group 12, Battery
Lift and latch seat deck to access battery. age andcould ignite battery fumes, causing the bat-
tery to explode.
If the battery to be handled is uncovered, cover bat-tery
with a non-conductive material (plywood, heavy Maintain good battery cable connections.
cardboard, etc.) prior to removal from truck. Check power cables and wiring for damage that can
cause premature drainage of the battery.
IMPORTANT
Do not overcharge a battery.
Do not wash battery in truck.
Do not undercharge a battery.
CAUTION Follow the instructions provided by the supplier(s) of
the battery and battery charging equipment.
An overhead hoist of sufficient lifting capac-ity
(refer to Weights in Group 40) should be Maintain accurate battery records. If battery trou-bles
used to lift battery. The safety hooks of the occur, these records will help you and your battery
insulated spreader bar should be attached to representative determine the nature of the
the lifting eyes provided in the battery casing. problem.
Be sure battery is covered. Attach lifting device. Lift and Battery Vents
remove battery.
When Charging Batteries: The vent caps must be kept
in place to avoid electrolyte spray. Care must be
Battery Maintenance taken to assure that vent caps are functioning. The
NOTE vents must be open to allow the battery to breathe.
The battery cover must be removed/ opened to
To obtain maximum performance and bat-
dissipate heat and explosive gas.
tery life, follow the instructions supplied by
your battery vendor. When Cleaning Batteries: The vent caps must be
tightly in place.
Industrial batteries are used to supply the electrical power to
operate an electric industrial truck. Their voltage depends on
the number of individual cells they contain. There are
approximately two volts for each cell in the commonly used
lead-acid type battery. Batteries normally range from 6 volts
to 72 volts. Their capacity varies depending on the
application. Only use batteries that com-ply with factory
specifications as to size and capacity.
Maximum Battery Life

Do not add acid to a battery. Only qualified battery
representatives should determine if this is neces-
sary.
When lifting a battery, use a lifting device designed
for this purpose.
Check the electrolyte level after placing a battery on
charge. The electrolyte level in a battery should be
slightly below the lower lip of the filling hole
vent. Do not overfill. Overfilling causes loss of
electrolyte.
Keep the battery clean, dry and in good condition.
Keep metal objects and tools away from the top of the
battery. Short circuits will cause battery dam-

Group 12, Battery
Battery Cleaning Clean Battery Compartment

The easiest and most satisfactory method of cleaning a . Using baking soda and water solution, clean the walls
battery is to wash it with a low-pressure cold water spray. and floor of the compartment. Rinse with clear water.
The battery top can also be washed with a baking soda
. Blow off the compartment walls and floor with an air
solution and rinsed with clear water.
hose. Allow to air-dry.
IMPORTANT
. Remove battery from truck before washing. CAUTION
Vent caps must be free of obstruction and in good Wear eye protection and protective clothing
condition. when cleaning or drying with compressed
Battery top should be clean and free of cracks or air. Reduce air pressure to 207 kPa (30 psi).
breaks. Debris removed with air pressure can cause
Battery terminals must be clean and solidly injury.
mounted.
Damaged batteries should be repaired or
replaced. Consult your battery vendor.
Check to be sure all vent caps are tight before
washing the battery.
Fill a bucket with cold water. Add a box of baking
soda to the bucket. Stir the solution until
dissolved. Keep this solution around the battery
service area at all times.
After washing battery, thoroughly rinse with clear
cold water.
Replacement Batteries
Battery Charging CAUTION
Follow the instructions supplied by the battery charger Use a battery properly sized to the dimen-sions
vendor. of the battery compartment. Batteries too small
can shift and cause damage to the truck or
injury to the operator or bystanders. Only use
Battery Electrolyte batteries that comply with factory
Check with battery manufacturers documentation recommendations as to size and capacity.
before working on battery electrolyte.
Always use a carboy tilter or siphon when handling Battery Installation
battery electrolyte.
If the battery is uncovered, cover the battery with a non-
When mixing electrolyte, always pour acid into water- conductive material (i.e., plywood, heavy cardboard, etc.)
NEVER pour water into acid. Pouring water into prior to installation.
acid will cause a dangerous chemical action or
splash. Using an overhead hoist and insulated spreader bar,
lift battery into battery compartment.
Install battery retainer, if applicable.
Remove non-conductive material from battery.
Connect battery to truck.

Group 12, Battery
Keeping Battery Records Battery Tests

Records should be maintained to get the best service out NOTE
of your battery and truck. Use both tests described here.
These records should contain:
Test Date. Each test should be dated for future ref- Specific Gravity Test
erence and comparison. Test at least six cells across battery with a temperaturecor-
Specific Gravity and Temperature Readings. Each rected hydrometer (see chart). Battery is fully charged
battery cell should be checked and recorded before when the reading falls in the 1.280 to 1.300 range. If the
and after charging. The specific gravity reading of difference between cells is more than .015, battery needs
the electrolyte, calculated using a multi-plier to maintenance.
account for the ambient temperature, should not be
less than 1.260. If below 1.250, the battery should SPECIFIC GRAVITY TEST
be recharged and tested. SPECIFIC GRAVITY STATE OF CHANGE
Variation Between Each Cell Tested. The varia-tion 1.260~1.300 100% CHARGED
in specific gravity reading between cells should
1.230~1.250 75% CHARGED
not be greater than 15 points (0.015). If readings
are greater, there are defective cells. 1.200~1.220 50% CHARGED
1.170~1.190 25% CHARGED
NOTE
1.140~1.160 VERY WEAK
The pilot cell should be changed occasionally
1.110~1.130 DISCHARGED
to distribute any electrolyte loss over the bat-
tery when taking readings.
The battery specific gravity is an indication of the bat-
Load Voltage Tests should be performed and terys state of charge. You can determine the specific
recorded indicating the condition of a battery grav-ity of the electrolyte solution in a battery with an
while it is performing work. hydrometer. If the state of charge is low, the hydrometer
will read low. If the state of charge is high, the
Actual Operating Hours of the Battery. Record the
hydrometer will read high.
actual time the battery is in use before putting it on
charger. For, example a reading from:
Charging Time. Keep an accurate record of the 1.260 to 1.300 indicates a fully-charged battery.
actual time the battery is on charger. After each
1.200 to 1.220 indicates a battery is in a discharged
charge, check to see if the battery is fully charged.
condition and cannot give satisfactory service.
Test the battery before placing it back into service.
Record these results.
Visually Inspect for loose terminal connections or Load Test
posts, a cracked case, damaged cell covers (vent
Put the main hydraulic system into tilt by-pass while
caps), or excessive corrosion. This data should be
read-ing battery volts with a voltmeter.
noted to help determine work environment and
possible trouble areas. Battery needs recharge or repair if voltage drops below
80% of the rated voltage of the battery.
Minimum acceptable readings:
36 volt battery: 28.8 volts
48 volt battery: 38.4 volts

Group 12, Battery
Connector, Negative Terminal, and Static Chain Installation
NOTE
See Group 13 for cable and wiring routing
and connection illustrations.
Static Chain: Chain must make good contact with the Batterry: Connectors must be clean, securely mounted,
floor to ensure proper grounding of the truck. Replace or tight-fitting, and show no cracking.
adjust chain as follows:
New Chain: Fasten at third link.
Worn Chain: Fasten at first link.

NOTE :
Group 12, Battery SM 715, Dec 04

GROUP 13 WIRING, SWITCHES, AND INSTRUMENTS
GROUP 13
WIRING, SWITCHES, AND INSTRUMENTS
Schematic Electric Circuit Diagrams ............. Section 1

General Electical Service Tips.......................... Section 2
Wiring and Cables ........................................... Section 3
Switches and Sensors...................................... Section 4
Instrument Panel .............................................. Section 5
SM 715, Dec 04 Group 13 WIRING, SWITCHES, AND INSTRUMENTS,

NOTE :
Group 13 WIRING, SWITCHES, AND INSTRUMENTS, SM 715, Dec 04

Group 13, Wiring, Switches, and Instruments
Section 1
Schematic Electric Circuit Diagrams
Standard Truck(TMX) ................................................................................................................ IN-28216

Accessories(TMX) ........................................................................................................................ IN-28220
Options(TMX) .............................................................................................................................. IN-28235
Standard Truck(EPX) ................................................................................................................. IN-28253
SM 715, Jun 05 Schematic Electric Circuit Diagrams 13-1-1

Standard Truck(TMX)
13-1-2 Schematic Electric Circuit Diagrams SM 715, Dec 04

SM 715, Dec 04 Schematic Electric Circuit Diagrams 13-1-3

Accessories(TMX)







Options(TMX)


Standard Truck(EPX)
SM 715, Jun 05 Schematic Electric Circuit Diagrams 13-1-13

NOTE :
Group 13, Wiring, Switches, and Instruments SM 715, Jun 05

Section 2
General Electrical Service Tips
General Electrical Service Tips Make sure battery is disconnected.

Discharging Controller Capacitors
CAUTION Always It is necessary to discharge the capacitors before you
wear safety glasses. work on the controller.
NOTE
Make sure that the battery has first been dis-
connected at the battery receptacle.
Remove all jewelry

before working on truck.
1. Move truck to service area:

. Park truck on a flat level surface.
. Fully lower upright.
. Tilt forks forward until fork tips touch the floor.
SERVICE AREA
To discharge the capacitors connect a 200 ohm 10

watt resistor between the positive and negative
input post of the controller for 10 seconds.
Disable the truck:

Turn the key switch to OFF.
Remove key.
SM 715, Mar 05 General Electrical Service Tips 13-2-1

Checking Power Cables Torquing Fasteners

Every cable and wiring harness on this truck is manufac- Improperly torqued fasteners can cause damage
tured to an exact specification. A shorter cable or harness
Use an appropriate wrench and tighten all fasteners to the
will not fit. If either a harness or cable is routed improp-
torque specified in the following inspection procedures.
erly, 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.
Pivoted
Scale Handle
Socket
Head Fo rce or Pu ll
Pointer
Cuts Typical Torque Wrench
Connecting and Mounting

Power cables having small Compo-nents
cuts may be repaired with
electrical tape.
Tape markers are used to correctly position each
wire harness and electrical cable on the truck. When
correctly installed, the tape marker will be hidden
Repairable Damage by the mounting clamp (guide). Be sure to follow
the instructions, where noted in this manual, when
installing a wire harness or electrical cables. If you
Cables having damage as shown in illustration below do not, possible shorts and equipment damage may
should be removed immediately and replaced with result.
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
Tape Marker
Damaged Casing
Clamp
(and/or Guide)
Break
Markers on Wire Harnesses and Power Cables
Broken Wires
Cable Unfit for Further Service
13-2-2 General Electrical Service Tips SM 715, Mar 05

Multiple cable and wire connections must be con- There is a moisture-resistant seal at each wireend of
nected as illustrated or electrical shorts and control the connector and between the plug and socket.
damage may result.
Check seals for damage that would make them unfit
for furtherservice (cuts, etc.). Make certain the end
Terminal Barrels seals are seated flush with the end of the connector
Must Face Opposite housing. Make certain the plug and socket
Each Other latchtightly to each other.
Firmly push plug into socket until
Assemble latch "clicks" locking the two
Back to Front components together.
Buss Bar
Barrel Latch Socket

Barrel
End seals
must be firmly Plug
seated within Seal(s)
the assembly
housing.
Multiple Connections
Seals and Latch

Connector Plugs and Receptacles are permanently
labeled with the proper PL (Plug) and SO (Socket/
Receptacle) number for easy identification. Match the
plug number with the appropriate receptacle number Retainer plates snap into place to secure the pins and
before making a connection. If you do not, electrical their sockets.
shorts and possible damage to the equipment may Check the plates and seal for damage and secure
result. i.e., Plug #PL-6 plugs into pin socket #SO-6, etc. mounting.
Pin Lock (Arrows must point in direction shown.) Retainer Plates Rubber Seal
Socket Latch
Plug
SO-6 Socket
Pin
Retainer Plates e)
Retainer Plates
PL-6 Plug Pin(s)
Example of Pin Lock Plug and Socket
SM 715, Mar 05 General Electrical Service Tips 13-2-3

NOTE :
Group 13, Wiring, Switches, and Instruments SM 715, Mar 05

Section 3
Wiring and Cables
The following illustrations depict wiring and cable routing

and connections for standard trucks and main accessory
harness.
Electrical Components(TMX) .................................................................................................... SI-46305

Main Harness(TMX) ................................................................................................................... SI-46306
Cables(TMX) ................................................................................................................................ SI-46307
Rear Accessory Harness(TMX) .................................................................................................. SI-46310
Main Accessory Harness(TMX) ................................................................................................. SI-46311
Electrical Components(EPX) ..................................................................................................... SI-46636
Main Harness(EPX) .................................................................................................................... SI-46637
Accessory Harness(EPX) ............................................................................................................ SI-46663
SM 715, Jun 05 Wiring and Cables 13-3-1

Electrical Components(TMX)
Page1of 8
SI-46305
13-3-2 Wiring and Cables SM 715, Dec 04

Page2of 8
SI-46305
SM 715, Dec 04 Wiring and Cables 13-3-3

Page3of 8
SI-46305

Page4of 8
SI-46305

Page5of 8
SI-46305

Page6of 8
SI-46305

Page7of 8
SI-46305

Page8of 8
SI-46305

Main Harness(TMX)
Page1of 10
SI-46306

Page2of 10
SI-46306

Page3of 10
SI-46306

Page4of 10
SI-46306

Page5of 10
SI-46306

Page6of 10
SI-46306

Page7of 10
SI-46306

Page8of 10
SI-46306

Page9of 10
SI-46306

Page10of 10
SI-46306

Cables(TMX)
Page1of 6
SI-46307

Page2of 6
SI-46307

Page3of 6
SI-46307

Page4of 6
SI-46307

Page5of 6
SI-46307

Page6of 6
SI-46307

Rear Accessory Harness(TMX)
Page1of 2
SI-46310

Page2of 2
SI-46310

Main Accessory Harness(TMX)
Page1of 10
SI-46311

SI-46311
Page 2 of 10

Page3of 10
SI-46311

Page4of 10
SI-46311

Page5of 10
SI-46311

Page6of 10
SI-46311

Page7of 10
SI-46311

Page8of 10
SI-46311

Page9of 10
SI-46311

Page10of 10
SI-46311

Electrical Components(EPX)
13-3-38 Wiring and Cables SM 715, Jun 05





Main Harness(EPX)






Accessory Harness(EPX)




Section 4
Switches and Sensors
Accelerator Control Switch.......................................................................................................................2

Description............................................................................................................................................2
Adjustment............................................................................................................................................2
Program Adjustment...........................................................................................................................3
Brake Switches................................................................................................................................................3
Service Brake Switch Description..................................................................................................3
Service Brake Switch Adjustment..................................................................................................3
Parking Brake Switch Description.................................................................................................4
Parking Brake Switch Adjustment.................................................................................................4
Seat Switch............................................................................................................................................4
Direction Control Switches........................................................................................................................4
Description............................................................................................................................................4
Adjustment............................................................................................................................................5
Lift and Tilt Pump Switches.....................................................................................................................5
Description............................................................................................................................................5
Switch Adjustment..............................................................................................................................5
Lift Pot Adjustment.............................................................................................................................6
Program Adjustment...........................................................................................................................6
Steer Angle Sensor.........................................................................................................................................7
Description............................................................................................................................................7
Program and Adjustment...................................................................................................................7
SM 715, Mar 05 Switches and Sensors 13-4-1

Accelerator Control Switch
Description Adjustment
The accelerator control is operated by the accelerator foot Loosen four fasteners at A and B on illustration.
pedal to send a signal for power demand to the control.
Depress pedal to floor mat and hold.
At the start, the accelerator control is stroked (by the
Position switch so that push rod is fully pushed in and
action of the accelerator pedal), and in turn sends a signal
that roller is centered on top of disc.
to the motor control, requesting it to produce longer elec-
trical pulses to the motor, which in turn will supply more Tighten fasteners as indicated on illustration.
power to the drive train.
Trouble with the accelerator control is normally investi-
An internal spring returns the control to start position. gated in conjunction with the motor control. Refer to next
The accelerator is an integral unit and is not serviceable. page for Program Adjustments.
Open-ing of the unit will void the warranty.
Accelerator
Pedal
Accelerator
Pedal
Roller Disc
Accelerator Roller Disc
A Control Switch
Torque: B Accelerator
8-10 N.m
(71-88 in-lb) Torque A Control Switch
20-25 N.m Torque:
(177-221 in-lb) 8-10 N.m B
(71-88 in-lb) Torque
20-25 N.m
(177-221 in-lb)
TMX12-25 Truck
EPX Truck
13-4-2 Switches and Sensors SM 715, Jun 05

Program Adjustment Display will show software version

Turn the key switch Off and remove the tester cord
CAUTION from the control
Before any adjustments are done, safely jack Plug the dash display harness into the "B" plug of the
up the truck, block the drive wheels off the control
floor and disconnect the battery. Lower truck to the ground and test drive truck
Use the following method to program the accelerator con-

trol to the contol panel with the handset: Brake Switches
(Detailed handset operation instructions are in Group 19.)
Service Brake Switch Description(TMX only)
Disconnect the dash display harness from the con-trol
panel The foot brake switch is on the frame under the dash
Plug handset into plug "B" of the control panel. The switch operates when it is released by the
Plug in the battery brake pedal lever during braking. Depressing or releasing
the switch operates a set of contacts that alternate from
Turn the key switch On open to closed to activate the Pedal Braking function of
Handset will go through startup and display soft-ware the con-trol. This function uses the motor to help bring
version the truck to a controlled stop.
Press the ENTER button
Display will read "MAIN MENU' "PARAMETER Service Brake Switch Adjustment(TMX only)
CHANGE".
Adjust the switch so that it clicks just before the end of
Press the ROLL UP button five times
pedal freeplay (the lag between pressing the brake and
Display will read "MAIN MENU" PROGRAM operating the master cylinder, covered in Group 23).
VACC Adjust switch as follows.
Press the "ENTER" button
Turn key switch OFF.
Display will read "VACC SETTINGS"
Make sure freeplay is properly adjusted as described in
Press the "ENTER button
Group 23.
Display will read "MIN VACC MAX"
Loosen brake switch mounting screws.
Move the directional lever to Forward position
Depress the accelerator pedal to the floor and than Rotate switch against pedal until switch trips. (A click
release slowly can be heard.) Tighten mounting screws.
Move the directional lever to the Reverse position Check operation of switch by depressing brake pedal.
Depress the accelerator pedal to the floor and than Switch should actuate just before the end of freeplay (at
release slowly which time you feel resistance in the pedal caused by
the master cylinder beginning to operate.)
Press the "ENTER" button
Press the OUT button
Display will read "ARE YOU SURE"
"YES=ENTER" "NO=OUT"
Press "ENTER" button (this stores the value for MIN
and MAX accelerator voltage)
Display will show new settings
Display will read "MAIN MENU" PROGRAM
VACC
Press "OUT button TMX truck EPX truck
SM 715, Jun 05 Switches and Sensors 13-4-3

Parking Brake Switch Description(TMX) Parking Brake Operation(EPX)

The parking brake switch is mounted to the hand brake The operator applies the parking brake by depressing a
assembly. The brake handle center pin depresses the foot pedal, which is then held down by a ratchet. The
switch when the hand lever is not applied. This depressed pedal tensions cables connected to a brake shoe
depressing of the switch closes the contacts. at each brake assembly, thereby applying the brakes.
The operator releases the parking brake by pulling up on a
When the parking brake is applied, it releases the switch,
release handle. This handle releases the ratchet, and a
allowing the contacts to return their normally open posi-
return spring returns the pedal and cable to the off posi-
tion. This open circuit signals the controller to disable the
tion. The ratchet also operates the parking brake interlock
drive motors.
switch and the parking brake indicator light switch.
IMPORTANT
The switch must cut electrical current to the
drive motor before the brakes apply. Other-
wise, excessive lining wear will result and the
drive motor will overheat.
Parking Brake Switch Adjustment(TMX)

Turn key switch OFF.
Loosen parking brake switch mounting screws.
Adjust position of switch so that there is contact with the
center pin and the switch actuates (clicks) just as the
parking brake lever is fully released.
Tighten mounting screws.
Check operation of switch before truck is returned to
service.
13-4-4 Switches and Sensors SM 715, Jun 05

Seat Switch Direction Control Switches

The TMX trucks are equipped with a seat switch that sig-
nals the control to cut the power to the drive motors when Description
it is opened.
These switches are normally open. When the directional
When the seat switch is open, a -01 fault code will be control lever is placed in the FWD or REV detent, the
dis-played on the dash display. proper switch is actuated (closed), its contacts close, and
There is a 1.5 second time delay built into the control to a signal current passes to the drive motor controller,
allow for momentary opening of the seat switch. If the which controls the rotational direction of the drive motor.
truck is operated over rough surfaces and the operator is The FWD and REV switches are located at the base of the
bounced, causing a momentary opening of the seat directional control lever. They are actuated by a cam on
switch, the truck will not shut down. the directional control lever.
Adjustment
Azdel Seat pan Turn key switch OFF.
Loosen FWD and REV switch mounting screws.
SUSPENSION SEAT
Adjust position of FWD switch so it actuates when
directional control lever is in forward detent. Adjust
REV switch so it actuates when directional control
Seat Switch
lever is in reverse detent.
Wire harness
Check operation of switches before truck is returned to
Seat Flexolater
service.
STATIC SEAT

Lift and Tilt Pump Switches Lift Pot Adjustment

Insure that the flag of the actuator is properly posi-tioned
Description on the flat of the large nut.
The pump control switches are mounted on brackets at Tighten the lock nut against the bottom of the actua-tor.
the valve spools and they are normally open. Movement Loosen the capscrews on the switch mounting bracket
of th valve spools from the neutral position trips the and adjust the Pot to the point that it just touches the
switches and closes their contacts. Current flow through actuator plate. Insure that the Pot is paral-lel with the
the con-tacts signals the pump controller to operate the lift linkage.
pump motor at the set speed for the selected function.
The lift lever activates a lift enable switch and also acti-
vates a Lift Pot. This potentiometer signals the pump con-
troller to run at an increasing speed proportional to the
rearward movement of the lever.
Switch Adjustment
Turn key switch to the OFF position.
Loosen switch mounting screws.
Adjust switch to activate after spool moves from neu-
tral.
Check operation of switch before truck is returned to
service.
Program Adjustment
! CAUTION
Before any adjustments are done, safely jack
up the truck, block the drive wheels off the
floor and disconnect the battery.
Use the following method to program the Lift Potentiome-

ter to the control panel with the handset:
Disconnect the dash display harness from the con-
trol panel
Plug handset into plug "B" of the control
Plug in the battery
Turn the key switch On
13-4-6 Switches and Sensors SM 715, Mar 05

Handset will go through startup and display soft-ware Plug the dash display harness into the "B" plug of the
version control
Press both the "ROLL UP" and "PARAM SET UP" Lower truck to the ground and test drive truck
buttons (top outside buttons) simultaneously.
Display will read "CONFIG MENU' "SET Steer Angle Sensor
MODEL"
Press "ENTER" button
Description(TMX)
Display will read "CONNECTED TO 3"
Press "PARAM SET UP" button two (2) times The steer angle sensor is mounted atop the steer axle trun-
ion assembly. This device helps the drive motor control
Display will read "CONNECTED TO 5"
generate an efficient speed differential between the two
Press "OUT" button drive motors when the truck is cornering,
The steer angle sensor is a potentiometer that translates
the angle of rotation of the steer angle into a voltage level
Press "ENTER" button (this stores the connected to read by the Dual AC control. When the steer wheel is
value) straight ahead (0 turn angle) the input signal to the con-
Display will read "CONFIG MENU" CON- trol should be at the mid point. As the vehicle turns left,
NECTED TO this input signal decreases. As the vehicle turns right, the
Press "OUT" button input signal increases.
Display will read Software Version for Pump Con-trol
Press the ENTER button Description(EPX)
Display will read "MAIN MENU' "PARAMETER The steer angle sensor is mounted under upper plate of
CHANGE". axle center. This device helps the drive motor control gen-
Press the ROLL UP button five times erate an efficient speed differential between the two drive
motors when the truck is cornering,
Display will read "MAIN MENU" PROGRAM
VACC The steer angle sensor is a a linear sensor that the moving
Press the "ENTER" button of steer axle cylinder into a voltage level read by the Dual
AC control. When the steer wheel is straight ahead (0
Display will read "VACC SETTINGS"
turn angle) the input signal to the control should be at the
Press the "ENTER button mid point. As the vehicle turns left, this input signal
Display will read "MIN VACC MAX" decreases. As the truck turns right, the input signal
Move the lift lever to full raised position increases.
Release the lift lever to the neutral position
Press the OUT button Program and Adjustment
CAUTION
Press "ENTER" button (this stores the value for MIN
up the truck, block the drive wheels off the
and MAX lift potentiometer voltage)
floor, disconnect the battery, and discharge
Display will show new settings the capacitors as described in Group SA
Display will read "MAIN MENU" PROGRAM Use the following method to adjust the steer angle sensor
VACC with the handset:
Press "OUT button (Detailed handset operation instructions are in Group 19.)
Display will show software version Disconnect the dash display harness from the con-trol
Turn the key switch Off and remove the tester cord panel
from the control Plug handset into plug "B" of the control

Plug in the battery Turn steer wheel all the way to the right
Turn the key switch On Press "ENTER" button
Handset will go through startup and display soft-ware Press "OUT button
version Display will read "ARE YOU SURE"
Press both the "ROLL UP" and "PARAM "YES=ENTER" "NO=OUT'''
SET Up" buttons (top outside buttons) simulta- Press "ENTER" button (this stores the value to be
neously. used for steering max right)
Display will read "CONFIG MENU' "SET Display will read "CONFIG MENU ADJUST-
MODEL" MENT
Press the roll down button once Press "OUT" button
Display will read "CONFIG MENU" ADJUST- Display will show software version
MENT
Turn the key switch Off and remove the tester cord
Press "ENTER" button from the control
Display will read "SET POT BRK MIN" Plug the dash display harness into the "B" plug of the
Press "ROLL UP" button (6) times control
Display will read "SET STEER O-POS" Lower truck to the ground and test drive truck
Adjust the steer wheel to where it appears to be
centered
Press "OUT button
Press "ENTER" button (this stores the value to be
used for Steering 0 position)
Display will read "CONFIG MENU" ADJUST-
MENT
Display will read "SET POT BRK MIN"
Press "ROLL UP" button (5) times
Display will read "MAX STEER LEFT"
Turn steer wheel all the way lo the left
Press "OUT button
used for steering max left)
MENT
Display will read "SET POT BRK MW
Display will read "MAX STEER RIGHT"
13-4-8 Switches and Sensors SM 715, Mar 05

Torque to 40 - 45 N-M
(30 - 33 Lbs/Ft)
Potentiometer leads
point toward front of
truck Make sure that the
potentiometer hole is
centered above the steer
(15-22 Lbs/Ft)
potentiometer drive screw
See Group 25, Section 6 for Steer Angle Sensor Removal and Replacement(TMX)
MAX 5.0
58.6
81.5
View C 163
View C
See Group 25, Section 6 for Steer Angle Sensor Removal and Replacement(EPX)

NOTE :
Group 13, Wiring, Switches, and Instruments SM 715, Dec 04

Section 5
Instrument Panel
Dash Display
SM 715, Mar 05 Instrument Panel 13-4-1

Dash Display(TMX)
The Dash Display provides the operator with an easily understandable,
visual feedback of the status of the truck and its system components..
1
2
3 6
10 9
4
7
8
Standard Display
1.Pump Motor and Pump Controller Over Temperature. 6. Numeric Display

2.Drive Motor and Drive Controller Over Temperature. 7. Hour Meter Status
3.Seat Belt Alert 8. Service Status
4.Park Brake 9. Battery Status
5.Planned Maintenance 10. Accessory Switches (Speed change switch, lights,
etc.)
13-4-2 Instrument Panel SM 715, Mar 05

Dash Display(EPX)
The Dash Display provides the operator with an easily understandable,
visual feedback of the status of the truck and its system components..
1 2 3 4 5
7
6
km/h 10
11
Park Brake
Seat Belt Alert
Drive controller & Motor overheat warning indicator lamp
Pump controller & Motor overheat warning indicator lamp
Planned Maintenance
Battery Discharging Indicator
Display Setted Speed limit
Activating Speed limit function
Hour Meter
Display Travel Speed
Service Status
SM 715, Jul 05 Instrument Panel 13-4-3

Pump Motor or Pump Motor controller Over Service Status: The following 5 codes are usu-
Temperature: The symbol is displayed to ally operator fault codes, and can be corrected
"alert" of pump motor temperature or pump by as explained in "Section 5, Operating
motor controller temperature is exceeding the Proce-dures." If you see any other codes
design limits. Do not use truck. Allow pump displayed, the truck needs to be serviced.
motor and/or controller to cool until after sym-
-01 Seat Switch Open
bol turns "OFF".
-061, -065 ,-140, -203, -207 Overheat of
Drive Motor or Drive Motor controller Over motor and controller (Restart after
Temperature: The symbol is displayed to cooling down)
"alert" of drive motor(s) temperature or drive
-66 Low Battery (truck will go into lift lock-
motor controller(s) temperature is exceeding
out when the dash display shows less
the design limits. Do not use truck. Allow
than 15%)
drive motor and/or controller to cool until after
sym-bol turns "OFF". -77 Maintenance Hours (preset hour meter
reading indicating that it is time to have
Seat Belt: At start up this symbol displays the truck serviced. Truck will reduce the
along with an audio alarm for 4 seconds. This top speed if desired)
display reminds you to fasten your seat belt.
-79 Incorrect Start Up Sequence (SRO)
-217, -245 Wrong set battery
-255 Parking Brake Switch Open
Parking Brake: The symbol is displayed and "-
255" status code appears on the numeric dis- Battery Status: If this symbol displays, the
play when parking brake is applied. Release numeric display shows the percentage of
parking brake to operate truck. usable charge remaining on the battery.
Battery discharge indicator (EPX) : This

Planned Maintenance: This symbol is dis- indicating lamp shows that the charging rate
played and "-77" status code appears on the that can be usable by the using battery
numeric display when the key switch is turned
"ON" and trucks operating hours exceed pre- One chamber will turn off when the
programmed hours for planned maintenance. charg-ing rate is reduced in 10%. Warning
The symbol is a reminder only and will turn Code:" 66:BAT LOW"
"OFF" after 4 seconds and display will return
to normal operation. The truck shall be inoper- Speed limit rate indicator (EPX)This indi-
ative while this symbol is displayed. Call Ser- cating lamp shows that the traveling speed
vice. limit rate. One chamber will turn off when
the speed limit rate is reduced in 10%.
Hour Meter: (TMX)This symbol identifies the
number displayed on numeric display as truck
operating hours. The symbol is displayed for 4 Speed limit function indicator (EPX) : This
seconds when the key switch is turned "OFF". indicating lamp shows that the traveling
speed limit. It will turn on when the traveling
EPX : This indicating lamp shows that the speed limit function of fork lift truck is
working hour is counted. It flickers in a second cycle work-ing.
when the fork lift truck is working.
Traveling speed indicator (EPX) : This indi-
cating lamp shows that the traveling speed of
fork lift truck. It will turn on when the
current traveling speed is indicated.
13-4-4 Instrument Panel SM 715, Jul 05

Using the Display Character indicator (EPX16-18)

Error code
LCD Back Light (EPX16-18) indicator (#37
LCD back light is working linked with Key error)
switch.
"- When the start key turns on, power is
applied to display. Whenever the power is
applied, LCD back light will turn on."
DISPLAY Initial Start-up(EPX16-18)

KEY ON
All the Icons and Buzzers will be ON for
1second to check the indicating conditions.
Seat belt warning mode (5seconds) after Icon
turns of for 1second: It is always indicated
regardless of communication conditions;
When this mode is working, all the indicating
data should be in normal conditions.
"(Working hour/speed, Battery discharging
rate, Speed limit rate, Parking)"
After seat belt warning mode is working, the
data supplied from controller will be indicated.
Working hour/speed indicating algorithm

(EPX16-18)
Working hour/
Hour Meter
speed will be indi-
cated at the same
portion.
Speed Meter The indicating data
is decided on the
km/h
base of traveling
speed.
If the traveling speed exceeds 0.5km/h, the
current traveling speed will be indicated
"km/h" icon turn on. When the speed gets
lower than 0.5km/h, traveling speed indicator
will be released "km/h" icon turn off.
The current working hour is indicated when the
traveling speed is lower than 0.5km/h, and the
"sandglass" icon flickers in a second cycle.
When the traveling speed is more than 0.5km/h, the
working hour indicator is released (converted to
speed indicator), and the "sandglass" icon will turn
off.
SM 715, Jul 05 Instrument Panel 13-4-5

NOTE :
Group 13, Wiring, Switches, and Instruments SM 715, Dec 04

GROUP 16 ELECTRICAL MOTORS
GROUP 16
ELECTRICAL MOTORS
Motor Specifications And Descriptions ......... Section 1

Drive Motor Overhaul ...................................... Section 2
Pump Motor Overhaul ..................................... Section 3
SM 715, Dec 04 Group 16 ELECTRICAL MOTORS,

NOTE :
Group 16 ELECTRICAL MOTORS, SM 715, Dec 04

Group 16, Electrical Motors
Section 1
Motor Specifications and Descriptions
Specifications
Drive Motors Pump Motor

Frame Size: 200 mm (7.874 in) diameter Frame Size: 170 mm (6.693 in) diameter
Weight: 45kg (99 lb) Weight: 50kg (110 lb)
Internal Bearings: Sealed and lubricated with high tem- Internal Bearings: Sealed and lubricated with high tem-
perature grease for the life of the bearing. The bearing at perature grease for the life of the bearing. The bearing at
the back end of the motor is a special encoder bearing the back end of the motor is a special encoder bearing
(sensor) that needs to be replaced every 10,000 hours, or (sensor) that needs to be replaced every 10,000 hours, or
any time the bearings are removed from the motor rotor any time the bearings are removed from the motor rotor
shaft. shaft.
Terminal Nut Torque: 15 N.m (133 in-lb) Terminal Nut Torque: 15 N.m (133 in-lb)
Rotor outside Diameter: 124 mm (4.882 in)
Rotor inside Diameter: 44 mm (1.732 in) Rotor outside Diameter: 102.2 mm (4.023 in)
Number of Slots: 48 Rotor inside Diameter: 30 mm (1.181 in)
Number of Slots: 28
Stator outside Diameter: 200 mm (7.874 in)
Stator inside Diameter: 125 mm (4.921 in) Stator outside Diameter: 170 mm (6.693 in)
Number of Slots: 36 Stator inside Diameter: 103 mm (4.055 in)
Number of Slots: 36
Nominal Air Gap: 0.5 mm (.0196 in)
Nominal Battery Voltage: 36V / 48V Nominal Air Gap: 0.4 mm (.0157 in)
Maximum Battery Voltage: 39.5V / 52.5V Nominal Battery Voltage: 36V / 48V
Nominal Speed: 945 RPM / 1335 RPM Maximum Battery Voltage: 39.5V / 52.5V
Stall Current: 275A Nominal Speed: 1310 RPM
Insulation: Class F Stall Current: 450A / 400A
Winding: Star Insulation: Class F
Encoder: 64 Pulses / Rev Winding: Delta
Encoder: 64 Pulses / Rev
SM 715, Mar 05 Motor Specifications and Descriptions 16-1-1

Description and Location The external connections are easily accessible from the
top of the motor where they are protected from external
The truck has three electric AC motors: damage.
Two identical traction motors The pump motor also has a built-in thermistor which con-
One main hydraulic/power steering pump motor. stantly monitors the winding temperature and reports this
information to the control (this sensor is not serviceable).
Should it sense that the motor is approaching the tempera-
Drive motors ture limit, the control will cutback motor current until the
The two drive motors are three-phase AC motors with temperature decreases. Since it is cutting back current and
class F insulation. These motors do not use brushes and not voltage, the top end speed will not be affected, unless
the motors are totally enclosed, minimizing the service the loads are close to capacity.
requirements. Because the motors do not use brushes and
are enclosed, sealing them from outside contamination,
there is no need to blow out the inside of the motors dur-
ing a PM. Each motor has two bearings; the drive end
bearing is a ball bearing and the bearing at the rear of the
motor is a special encoder bearing (sensor) for motor
feedback to the control. One motor drives the left traction
wheel, the other the right. The electronic control system
varies the speeds to the two motors independently to
accommodate cornering.
The external connections are easily accessible from the
top of the motor where they are protected from external
damage.
Each drive motor also has a built-in thermistor which
con-stantly monitors the winding temperature and reports
this information to the control (this sensor is not
serviceable). Should it sense that the motor is
approaching the tempera-ture limit, the control will
cutback motor current until the temperature decreases.
Since it is cutting back current and not voltage, the top
end speed will not be effected, unless on a grade.
Lift/Steer pump motor

The pump motor is a three-phase AC motor with class F
insulation with an external fan. It is also a brushless motor
and totally enclosed. The pump motor does incorporate a
fan at the rear of the motor that blows air across the out-
side of the motor frame to help control the temperature.
This fan does need to be blown out at every PM to keep it
clear of any debris. This motor has two bearings; the drive
end bearing is a ball bearing and the bearing at the rear of
the motor is a special encoder bearing (sensor) for motor
feedback to the control. An electronic control system con-
trols the speed of the motor at all times. This pump runs
for steering any time the truck is in gear, or anytime a
hydraulic function is requested.
16-1-2 Motor Specifications and Descriptions SM 715, Mar 05

Section 2
Drive Motor Overhaul
Inspection Procedure Remove the hoses from the hydraulic pump.
Before performing these service procedures: Remove the bolts securing the top, front battery plate
and remove the plate from the truck.
Park truck safely.
Remove the bolts securing the lower battery plate and
Fully lower the upright. tilt the plate back against the rear battery plate.
Apply the park brake
Remove all electrical cables from the motor. Tag cable
Turn the key switch OFF.
terminals to aid in reinstallation. Position cables out
Disconnect battery from truck receptacle. of the way of motor removal.
Discharge capacitors by connecting a 200 ohm 10 Remove bolts holding motor to axle. Have drain pan in
watt resistor between the positive and negative place to catch axle oil.
Lower motor onto floor or through the top using a
suitable chain hoist or come-a-long.
Motor Cleanliness
Reinstall in reverse order. Use new O-ring, coated with
Electric motors should be kept clean at all times to drive axle fluid.
prevent shorting, minimize wear, and optimize cooling.
Check and fill drive axle oil as described in Group 20.
Wipe off all dust, dirt, oil, water, etc., from outer
surface of motor. NOTE
Remove any debris from cooling fan air vents and When removing or installing cables to motor,
around motor frame to prevent overheating. hold the terminal's lower nut with a wrench
while turning the upper fastening nut with
Air-clean (blow off) motors using clean, dry (mois- another wrench.
ture-free) compressed air at 207 kPa (30 psi)
maxi-mum air pressure. Coat O-Ring with Transmission
Fluid Prior to Installation
The presence of any oil on or near the motor could indi-
cate either bad bearings or leaking hydraulic system. Torque to 115 - 130 N-M
(85 - 96 lb/ft)
Determine cause and repair problem before extensive
motor damage occurs.
Drive Motor Removal and Installation

Remove the battery from the truck.
Lift the rear of the truck from the floor and block
accordinaly. (See Group SA, Section 2 for proce-
dures)
Tilt the steering column fully forward and remove the
floor plate.
Remove all electrical cables from the pump motor. Tag
cable terminals to aid in reinstallation and posi-tion
the cable out of the way.
SM 715, Mar 05 Drive Motor Overhaul 16-2-1

Non-Drive End Frame
O-Ring
Encoder Bearing
Terminal Block
Rotor
Terminal Block
Mounting Bracket
Stator
Drive End Bearing

Sleeve
O-Ring
Drive End Frame
Oil Seal
Ball Bearings Encoder Bearing

Both ball bearings are maintenance free. If it becomes The encoder bearing is used to communicate the motor
necessary to remove the bearings to repair the motor, they speed to the controller.
should be replaced. In any case the seals (shaft oil seal
NOTE
and O-ring) must be replaced.
The encoder bearing is very sensitive to
In general bearings should be replaced at approximately static electricity. If you are going to be
10,000 operating hours. working on the encoder bearing you should
have a ground strap on to insure that the
encoder bearing does not get damaged.
16-2-2 Drive Motor Overhaul SM 715, Mar 05

Replacing Encoder Bearing Insure that the encoder cables are installed cor-rectly
and do not get pinched or touch the rotor.
Install the end housing carefully onto the encoder
bearing and press it on with a steady pressure. The
lead from the bearing must located in the notch in
the housing frame.
Notch for Lead
In general the encoder bearing should be replaced every

time the motor is disassembled.
To replace the encoder bearing:

Turn key OFF.
Set park brake.
Install the rotor into the stator housing.
Disconnect battery.
Tie strap the encoder bearing lead to one of the motor
Remove the drive motor (see page 1 of this sec-tion). leads to prevent it from being pulled and
Remove motor thru bolts. contacting the rotor.
The silicone sealing the cables into the end frame will Install the drive end onto the motor making sure that
need to be loosened to allow removal of the end the terminal block mounting bracket is aligned
frame. with the slots in both end frames.
Remove the non-drive end housing from motor.
Remove rotor from motor. Terminal Block
Mounting Bracket
Use a gear puller to remove encoder bearing from the
rotor.
Press new encoder bearing on to rotor at the inner ring
with a steady pressure. The inner ring of the
bearing must to be pressed against the shaft shoul-
der.
Motor Reassembly
NOTE
Thermal Sensor Lead
The encoder bearing is very sensitive to
static electricity. If you are going to be
working on the encoder bearing you should
have a ground strap on to insure that the Install the motor through bolts and tighten.
encoder bearing does not get damaged. Fill the void around the drive motor leads with Sil-
icone # 1758629.
Reinstall the motor into the truck.
SM 715, Mar 05 Drive Motor Overhaul 16-2-3

NOTE :
Group 16, Electrical Motors SM 715, Dec 04

Section 3
Pump Motor Overhaul
Inspection Procedure IMPORTANT

The pump motor assembly weighs over 110
Before performing these service procedures: pounds. A suitable lifting device may be
Park truck safely. needed to help hold and then raise the motor
from the truck.
Fully lower the upright.
Apply the park brake Remove the 4 nuts securing the pump motor mount-ing
Turn the key switch OFF. plate to the front battery plate.
Disconnect battery from truck receptacle. Lift the motor assembly and place it on a bench for
Discharge capacitors by connecting a 200 ohm 10 service.
watt resistor between the positive and negative
Remove bolts holding motor to mounting plate.
Reinstall in reverse order.
Motor Cleanliness NOTE
When removing or installing cables to motor,
Electric motors should be kept clean at all times to
hold the terminal's lower nut with a wrench
prevent shorting, minimize wear, and optimize cooling.
while turning the upper fastening nut with
Wipe off all dust, dirt, oil, water, etc., from outer another wrench.
surface of motor.
Torque to 70 - 75 N.m
Remove any debris from cooling fan air vents and (52 - 55 Lbs.ft)
around motor frame to prevent overheating.
Air-clean (blow off) motors using clean, dry (mois- (14.75 - 18.41 Lbs.ft)
ture-free) compressed air at 207 kPa (30 psi)
maxi-mum air pressure.
The presence of any oil on or near the motor could indi-
cate either bad bearings or leaking hydraulic system.
Determine cause and repair problem before extensive TMX Truck
motor damage occurs.
Pump Motor Removal and Installation

Tilt the steering column fully forward and remove the Torque to 20 - 25 N.m
(14.75 - 18.41 Lbs.ft)
floor plate.
Disconnect battery and remove all electrical cables from
the motor. Tag cable terminals to aid in reinstal- Torque to 60 - 65 N.m
lation. Position cables out of the way of motor (44.2 - 47.9 Lbs.ft)
removal. (57.5 - 59.0 Lbs.ft)
Remove the hydraulic pump from the motor (see group EPX Truck
29 for instructions).
SM 715, Jun 05 Pump Motor Overhaul 16-3-1

Fan Housing
Fan
Non-Drive
End Frame
Wave Washer
O-Ring
Terminal Block
Encoder Bearing
Terminal Block
Mounting Bracket
Rotor
Stator
Bearing
Drive End Frame

Seal
Pump Motor Exploded View
16-3-2 Pump Motor Overhaul SM 715, Mar 05

Ball Bearings Motor Reassembly

Press new encoder bearing on to rotor at the inner ring
with a steady pressure. The inner ring of the
Both ball bearings are maintenance free. If it becomes
bearing must to be pressed against the shaft shoul-
necessary to remove the bearings to repair the motor, they
der.
should be replaced. In any case the seals (shaft oil seal
and O-ring) must be replaced. NOTE
In general bearings should be replaced at approximately The encoder bearing is very sensitive to
10,000 operating hours. static electricity. If you are going to be
working on the encoder bearing you should
have a ground strap on to insure that the
Encoder Bearing encoder bearing does not get damaged.
The encoder bearing is used to communicate the motor
Insure that the encoder cables are installed cor-rectly
speed to the controller.
and do not get pinched or touch the rotor.
NOTE Install the end housing carefully onto the encoder
The encoder bearing is very sensitive to bearing and press it on with a steady pressure. The
static electricity. If you are going to be lead from the bearing must located in the notch in
working on the encoder bearing you should the housing frame.
have a ground strap on to insure that the Install the rotor into the stator housing.
encoder bearing does not get damaged.
Tie strap the encoder bearing lead to one of the motor
leads to prevent it from being pulled and
Replacing Encoder Bearing contacting the rotor.
In general the encoder bearing should be replaced every Install the drive end onto the motor making sure that
time the motor is disassembled. the terminal block mounting bracket is aligned
with the slots in both end frames.
Install the motor through bolts and tighten.
To replace the encoder bearing:
Fill the void around the drive motor leads with Sil-
Turn key OFF. icone # 1758629.
Set park brake. Install the fan and snap ring onto the shaft.
Disconnect battery. Install the fan housing.
Remove the pump motor (see page 2 of this sec-tion). Reinstall the motor into the truck.
Remove the fan housing screws and remove the
housing.
Remove the snap ring and then pull the fan from the
rotor shaft.
Remove motor bolts.
Loosen the silicone sealer around the cables at the end
housing.
Remove the non-drive end housing from motor.
Remove rotor from motor.
Use a gear puller to remove encoder bearing from the
rotor.
SM 715, Mar 05 Pump Motor Overhaul 16-3-3

NOTE :
Group 16, Electrical Motors SM 715, Dec 04

GROUP 17 ELECTRICAL CONTACTORS
GROUP 17
ELECTRICAL CONTACTORS
Contactors Specifications and Overhaul........... Section 1
SM 715, Dec 04 Group 17 ELECTRICAL CONTACTORS,

NOTE :
Group 17 ELECTRICAL CONTACTORS, SM 715, Dec 04

Group 17, Electrical Contactors
Section 1
Contactors Specifications and Overhaul
Specifications Removal and Replacement

Standard Truck: One Drive Line Contactor, one Pump Disconnect power cables from contactors. Move power
Line Contactor. Mounting Fastener Torque: 8-10 N.m cables out of the way.
(71-88 in-lb).
Disconnect connecting bus bars from contacts.
Disconnect wiring from contactor coil terminals.
Remove mounting bolts and contactor assembly from
truck.
Reverse procedure for installation.
Drive Line Contactor

Pump Line Contactor
Torque: 8-10 N.m (71-88 in-lb)
Overhaul
WARNING
Disconnect battery before working on contactor tips.Before attempting to disassemble a con-
tactor to install a new contact set, carefully observe location and orientation of each part.
SM 715, Dec 04 Contactors Specifications and Overhaul 17-1-1

Group 17, Electrical Contactors
CONTACTOR INSPECTION AND TIP binding and that tips are in correct orienta-
tion and tips contact correct mating parts.
REPLACEMENT
Check armature and movable contacts for freedom of
movement by depressing movable arm with a screw-
driver or small rod. Check for any restrictions to
movement and for return of parts by action of spring.
Inspect contact tips. Look for any worn or eroded
surfaces. Look for evidence of tip welding.
Inspect for evidence of any contaminants on tips
(paint, dirt, paper or cloth material, etc.) which
would impair operation.
Do not use sandpaper or file tips. Any damage must
be corrected by tip replacement.
Tips must be replaced before they wear through and
damage copper base.
To remove and replace contact tips, use following
To replace tips on the contactors, loosen and remove two
cover mounting screws attaching it to coil frame.
(Observe position of positive (+) marking on cover).
Be careful not to lose return spring fitted under
cover. Remove locknut and lockwasher from contact
studs and remove contact studs from top cover.
Inspect the top cover to make sure it has not been
overheated and that the contact studs have not
melted into the plastic. Replace the studs with new.
Lift movable contact assembly off base. Remove
lock ring from armature shaft and remove moving
contact tips. Be careful not to disassemble or lose
other parts under contact tips on armature assembly.
Replace movable contacts with new and assemble
onto armature shaft. Make sure lock ring is fully
seated.
Assemble contactor by putting moving contact
assembly armature shaft into coil plunger with return
spring on top of armature shaft. Put top cover over
spring and install cover mounting screws. Be sure
return spring is in recess in top cover.
NOTE
When assembling top cover to base, make
sure it is installed with positive sign (+) mark-
ings located correctly. Use a bar or rod to
move contacts. Be sure movement is free of
17-1-2 Contactors Specifications and Overhaul SM 715, Dec 04

GROUP 19 MOTOR CONTROLS
GROUP 19
MOTOR CONTROLS
Description ....................................................... Section 1

Programming & Adjustments Using
ZAPI Handset ..................................................... Section 2

Control troubleshooting .................................. Section 3
TMX Factory Control Settings ......................... Section 4
SM 715, Dec 04 Group 19 MOTOR CONTROLS,

NOTE :
Group 19 MOTOR CONTROLS, SM 715, Dec 04

Group 19, Motor Controls
Section 1
Description
The CLARK TMX uses a Dual AC controller to control both drive motors and a single AC control-
ler to control the single motor/pump combination which supplies flow to all hydraulic functions
and steering.
Traction Control and Motors uses this information to increase motor speed in propor-
tion to the distance stroked, providing only the desired
The dual AC traction control consists of two motor con- flow rate. Tilt and aux switches mounted on the hydraulic
trols mounted to a single heat-sink plate and enclosed by valve provide unique inputs to the control. The speed of
a single cover. The left portion of the control is reference each function can be programmed independently so that
to as the "slave" control and operates the left drive motor. only the required flow rate is produced, minimizing
The right portion of the control is referred to as the "mas- power losses. When the key is in the "ON" position and a
ter" control and operates the right drive motor. The con- direc-tion is selected, the control will operate the motor at
trol receives inputs from the speed control (accelerator) a fixed rpm (roughly 500 rpm). This provides adequate
pedal, steer tire position sensor (steer pot), direction flow for the steering function. If the control receives an
switches, foot brake switch, motor encoders, motor ther- input from the lift potentiometer, tilt or aux switches, then
mistors and other miscellaneous switches. The control is it will ramp up the motor speed to match the desired
able to proportional reduce the speed of the inside tire speed. Once the request is removed the motor speed will
when the truck is in a turn, based on the steer angle input return to the fixed level. As with the traction control and
from the steer sensor. Once the steer angle exceeds a cer- motors, the lift/steer control and motor have thermistors
tain value, the inside wheel will start to reverse. The for ther-mal protection and the motor has a built-in
speed of the vehicle is controlled by the accelerator con- encoder for speed feedback.
trol pedal. For a given pedal position the control will
maintain a set speed, as determined by control parameter
settings. These settings are adjustable to meet your cus-
tomer's needs. One feature that is new to the TMX is
"release braking". This feature will apply a regenerative
braking force every time the driver lifts up off the acceler-
ator pedal. The final travel speed will be determined by
the new pedal position. The control receives motor speed
feedback from the motor encoders which allow for
precise speed regulation. Every motor also has a built-in
ther-mistor which constantly monitors the winding
tempera-ture and reports this information to the control.
Should it sense that the motor is approaching the
temperature limit, the control will cutback motor current
until the tempera-ture decreases. Since it is cutting back
current and not voltage, the top end speed will not be
effected, unless on a grade. Each control also has built-in
thermal protection that will reduce output current should
the control approach the thermal limit.
Lift/Steer Control and Motor

A single motor/pump combination is used for both
hydraulic functions and steering. The motor is controlled
by a dedicated controller. The lift lever is equipped with a
linear potentiometer that measures the distance the lever is
stroked and provides this input to the control. The control
SM 715, Dec 04 Description 19-1-1

Operational Features Brake Pedal Regen Braking

Parameter PEDAL BRAKING allows for the adjustments of
Creep Speed the amount of regen braking you receive when you apply the
service brake. The pedal braking time is adjust-able from 1
Parameters THROTTLE X POINT and THROTTLE Y second to 5.5 seconds in half-second intervals. See
POINT control how the truck reacts when you first push parameter-programming chart later in this manual.
on the accelerator. Increasing THROTTLE X POINT will
give you more pedal stroke with less speed at the begin-
ning of the stroke. Increasing THROTTLE Y POINT will Speed Limit
give more speed with less pedal stroke. See Chart below.
Parameters MAX SPEED FORWARD and MAX SPEED
SPEED f(Hz)
BACKWARD allow for the adjustment maximum speed
that the vehicle can travel in each direction. The maxi-
mum speed is adjustable from 0 Hz to 140 Hz in 1 Hz
MAX SPEED
increments. 140 Hz is the maximum allowable speed for
the TMX 12 thru 20 and 95 Hz is the maximum allowable
speed for the TMX 25.
TROTTLE Y
POINT
Example: 140 Hz = approx. 9.3 mph empty
FREQ. CREEP
74 Hz = approx. 5 mph empty
V
VACC
MIN
TROTTLE 0
ZONE
TROTTLE X
POINT
VACC
MAX
Stop on Ramp
When this feature is ON it lets the vehicle electrically hold
on an incline for up to 15 seconds. Time is adjustable with
Control acceleration AUXILIARY TIME parameter from 0 to 15 seconds.
Parameter ACCELERATION DELAY allows the adjust- When this feature is OFF the vehicle uses regen braking
ment of the time it takes to accelerate a stop to full speed. to stop on an incline. Once the vehicle has stopped it will
The time is adjustable from 1 second to 5.5 seconds in hold for 1 second then continue to creep down the incline
half-second intervals. See parameter-programming chart at approx. 1 mph. The vehicle can continue up the ramp at
later in this manual. any time without hesitation.
Regenerative braking Steering Time Delay
Parameter INVERSION BRAKING allows for the adjust- This feature uses the AUXILIARY TIME DELAY in the
ment of the amount of time that it takes to stop the pump control to delay turn off time when the directional
vehicle when changing from one direction to the other. lever is returned to neutral. This parameter is adjustable
The time is adjustable from 1 second to 5.5 seconds in from 0 to 20 seconds of delay.
half-second intervals. See parameter-programming chart
later in this manual. Static Return to Off (SRO)
This feature requires the operator to return the directional
Accelerator Pedal Position Plug braking lever to the neutral position anytime they leave the vehicle
and return. If the parking brake, seat switch or key switch is
Parameter RELEASE BRAKING allows for the adjust-
opened, the control shuts down and can not be restarted
ment of the amount of time that it takes to stop the
vehicle when you remove your foot from the accelerator. (The dash display will show a -79 fault code) until the
The time is adjustable from 1 second to 5.5 seconds in directional lever is returned to neutral. A time delay of
half-second intervals. See parameter-programming chart approximately 2 seconds is built in to allow momentary
later in this manual. opening of the parking brake or seat switch.
19-1-2 Description SM 715, Dec 04

Thermal Protector Handset

Each controller has an internal thermal protector on the This is a multifunctional tool used with the AC controls.
heat sink. The controllers will reduce the output current to The handset (Clark part #8033636) has a display and a
50% of the set current when the heat sink temperature key board for data entry.
reaches 75C. The dash will display the following codes
depending on which controller in over temperature, (Mas-
Features and functions:
ter -61 code, Slave -140 code, and Pump -203 code).
Monitor existing fault codes for both traction and
Standard Fault Codes pump controls.
Monitor hour meter readings on traction and pump
The control has over 75 fault codes assist the service controls.
tech-nicians and operators in the trouble shooting the
Monitor or adjust the control functions
vehicle. If mis-operation of the vehicle occurs, a fault
code will be displayed on the Dash Display of the Use as a tester to monitor input and output infor-
vehicle, or by plug-ging the handset into the "B: plug of mation.
the master controller and reading the fault code.
With the fault code number, follow the procedures out- NOTE
lined in Group 19, Section 03 ,"Fault Codes", section to The Handset instructions and Troubleshoot-
determine the problem and a solution. ing can be found in Group 19, Section 3 of
this manual.
Stored Fault Codes
Protection Features
This feature records the last 5 fault codes in controller.
The last 5 fault codes can be accessed through the alarm
log using a handset, or a laptop computer with the PcCon- Reverse Battery Polarity:
sole software and adapter cable. The faults are stored with
the hour meter reading when the fault first happened, the The MAIN CONTACTOR is there to protect the control-
number of time the fault has happened, and the tempera- ler against reverse battery polarity and for safety reasons.
ture the first time the fault happened.
Connection Errors:
Hour Meter Readings All inputs are protected against connection errors.
This feature will display the recorded hours of use of the
traction control to the Dash Display each time the key Thermal Protection:
switch is turned off. This hour meter reading can be
changed in the case a controller would need to be If the controller temperature exceeds 80 C, the maximum
replaced. current is reduced in proportion to the thermal increase.
The temperature can never exceed 100 C.
Battery Discharge Indication (BDI)
External Agents:
Provides accurate battery state of charge information to
the vehicle operator, Features and Functions: The controller is protected against dust and the spray of
liquid to the degree of protection meeting IP54.
Displays 100 to 0 percent charge in 5% increments.
Lift Circuit is disabled at 10% discharge
Protection Against Uncontrolled Movement:
The main contactor will not close if:
The power unit is not functioning
The controller is not functioning perfectly.

The output of the accelerator does not fall below The micro switches send a voltage signal to the micropro-
the minimum voltage value stored, with 1V cessor when a function is requested (for example: running
added request) is made.
Running microswitch is in closed position.
Accelerator Unit:
Low Battery Charge:
The accelerator unit consists of a potentiometer in 3 wire
When the battery charge is low, -66 Code, the maximum configuration.
current is reduced to half the maximum current pro-
CPOT (C21) signal.
grammed.
EN ACC (C8) is the accelerator enable. It is fed with
Protection against accidental startup: +Batt from the key switch.
NPOT (C20) is the accelerator negative supply. This out-
A precise sequence of operations is necessary before the put is feed back to the microprocessor A/D converter to
control will start (SRO). Startup cannot occur if the test the continuity of the accelerator unit circuit (test of
sequence is not followed completely. (Request for drive, pot wire disconnection). The procedure for automatic
must be made after closing the key switch). potentiometer signal acquisition is carried out using the
handset. This enables adjustment of the minimum and
Capacitor Charge: maximum useful signal level (PROGRAM VACC func-
tion), in either direction. This function is unique when it
The controllers can hold an electrical charge for several is necessary to compensate for asymmetry with the
seconds, due to the power capacitor bank. A discharge mechan-ical elements associated with the Potentiometer.
resistance is built in the controller, which ensures capaci- Espe-cially relating to minimum level. The sequence of
tor discharge to a safe voltage in about one minute, after procedure is described later in this manual.
the key is switched off. If it is necessary to work on the
controller before that time, discharge the capacitors as
described below. Analog control unit
Connection C25 (PTHERMR) and C24 (NTHERMR) are
Discharging Controller Capacitors used for the right motor thermal sensor. Connection C35
(PTHERML) and C34 (NTHERML) are used for the Left
It is necessary to discharge the capacitors before you motor thermal sensor. Sensors are analog.
work on the controller. To discharge the capacitors,
disconnect the battery at the battery receptacle, connect a
200 ohm 10 watt resistor between the positive and Speed Feedback
negative input post of the controller for 10 seconds. The traction motors control is based upon the motor speed
feed back. The speed transducer is an incremental
Communications with CLARK Dash: encoder, with two phases shifted at 90 . The encoder is
supplied with +12V from the control panel.
The traction controller communicates by serial link
(RS232) to CLARK dash. The dash shows Battery State
of charge and fault code if a fault occurs. When the key is
Steer Angle Transducer
turned off, the dash shows hour meter reading. Angular position of steered wheels in transduced to an
electric information (voltage) by means of a potentiome-
Microswitches: ter, with following characteristics:
The micro switches must have a contact resistance lower Resistance in the 2Kohm to 20Kohm range;
than 0.1ohm and a leakage current lower than 100 micro Rotation electric angle: at least 300
amps. Positive supply: 12V;
Potentiometer is installed in a way that in the zero
When full load is connected, the voltage between the key position (straight wheels), pot output volt-age
switch contacts must be lower than 0.1 volt. is in the middle of the electric range corre-

sponding to a full left-to-right transition of

steer wheels;
The potentiometer is installed in a way that, when
the truck turns right, pot voltage increases;
Use "SET STEER MIN" and "SET STEER MAX"
functions of the handset to record the extremes
(minimum and maximum) of the potentiometer
range;
Use "SET STEER 0-POS" function of the handset
to record the pot output when the steer wheels
are straight.
Steering Table
The relationship between the two motors speed changes as
a function of the steering angle.
The steering angle information comes from the transducer
(potentiometer). As the steer wheel is turned, the inside
motor will slow and than finally reverse direction to help
the truck turn sharply.

Description of Connectors - DualAC2
A1 CAN H High level CANBUS

A2 CANT H CANBUS termination output, 120 ohm internally connected toCAN_H. Connect to
CAN_L_OUT to insert termination.
A3 CAN_POS Positive of CAN circuit; to be used in case of optoisolatedCANBUS
A4 CAN_L_OUT Low level CANBUS: to be used as repetition for CAN_L lineor to be connected to CANT_H
to insert termination resistance
A5 CANT_L CANBUS termination output, 120 ohm internally connected to
CAN_L. CAN Connect to CAN_H_OUT to insert the termination.
A6 CAN_L Low level CANBUS.
A7 CAN_H_OUT High level CANBUS: to be used as repetition for CAN_H line or to be connected CANT_L to
insert termination resistance
A8 CAN_NEG Negative of CAN circuit, to be used in case of optoisolated
CANBUS
B1 PCLRRXD Positive serial reception.
B2 NCLRRXD Negative serial reception.

B3 PCLRTXD Positive serial transmission.
B4 NCLRTXD Negative serial transmission
B5 GND Negative handset power
B6 +12 Positive handset power
B7 FLASH
B8 FLASH
C1 PENC_R Positive of the right motor encoder power supply (+12V).
C2 NENC_R Negative of the right motor encoder power supply

C3 KEY Connected to +Batt through a micro switch and a 10A fuse in series
C4 CM Common of FW / REV / HB / PB / SEAT / ENABLE micro switches
C5 Seat Seat presence input; active high.
C6 FORWARD Forward direction request input; active high.
C7 REVERSE Reverse direction request input; active high.

C8 ENABLE Traction request input; active high.
C9 PB Pedal brake request input; active high.

C10 SR / HB Speed reduction or hand brake input; active low (micro switch open).
C11 PENC_L Positive of the left motor encoder power supply (+12V).
C12 NENC_L Negative of the left motor encoder power supply
C13 PHA_R Right motor encoder phase A.
C14 PHB_R Right motor encoder phase B.
C15 NPOTST Negative of steering potentiometer (-Batt)
C16 PPOTST Positive of steering potentiometer (+5V)
C17 CPOTST Steering potentiometer wiper signal.
C18 CPOTB Brake potentiometer wiper signal.
C19 NPOTB -Batt.
C20 NPOT Negative of traction accelerator (test for wire disconnection)
C21 CPOT Traction potentiometer wiper signal.
C22 PHA_L Left motor encoder phase A.
C23 PHB_L Left motor encoder phase B.
C24 NTHERM_R Negative of right traction motor temperature sensor.
C25 PTHERM_R Right traction motor temperature signal.
C26 NLC Output of main contactor coil driver (drives to -Batt)
C27 PLC Positive of main contactor coil.
C28 NBRAKE Output of electric brake coil (drives to -Batt, Maximum current 3A)
C29 PBRAKE Positive of electromechanical brake coil.
C30 PAU Xpositive of auxiliary load.
C31 NAUX Output of auxiliary load driver (drives to _Batt).
C32 -BATT
C33 PPOT Traction potentiometer positive, 5V output, use load > 1K omh.
C34 NTHERM_L Negative of left traction motor temperature sensor.
C35 PTHERM_L Left traction motor temperature sensor.
Encoder Installation
In order to control the AC motors with the ZAPI controller an incremental encoder is installed with 2 phases shifted at
90. The encoder power supply is 12V
C11/C1 +12V Positive of encoder power supply.

C12/C2 GND Negative of encoder power supply.
C22/C13 A: Phase A of the encoder
C23/C14 B: Phase B of the encoder
Connection of encoder with open collector output; +12V power supply.

The encoder power supply voltage and output electronic Description of Connections - Pump
has to be communicated to ZAPI in order to correctly set
the selection jumper in the controller.
Description of Power Connections
-B Negative of the battery

+BT Positive of the battery; if the power fuse is
not present,positive cable coming from
the Line contactor must be connected to
this power connection
A1 PCLR- Positive serial reception.
+BTF Positive of battery before power fuse,
RXD
must be connected to positive cable com-
ing from line contactor. A2 NCLR- Negative serial reception
Um: Vm; Wm Connection bars for the three phases of RXD
the right motor; follow this sequence and A3 PCL- Positive serial transmission.
the indication on the motor. RTXD
Us, Vs, Ws Connection bars for the three phases of A4 NCL- Negative serial transmission
the left motor; follow this sequence and RTXD
the indication on the motor.
A5 GND Negative console power
A6 +12 Positive console power
A7 FLAS Hmust be connected to A8 for flash
memory programming (if used).
A8 FLAS Hmust be connected to A7 for flash
memory programming (if used).
B1 -BATT -Batt
B2 MODE This input allows the customer to
select the software in case of double
version.

C1 CAN-L Low level CAN_BUS voltage I/O F3 PHYDRO Positive of the power steering contac-
C2 CAN-L- Low level CAN_BUS voltage I/O tor
OUT F4 4th Input for fourth speed request, active
SPEED HIGH
C3 CAN-H High level CAN_BUS voltage I/O
F5 SAFETY If not connected to -Batt the MC coil
power output will be disabled. Can
C4 CAN-H- High level CAN_BUS voltage I/O also be used as a general-purpose
OUT input.
F6 PTHERM Input for motor temperature.
D + Incremental ENCODER connector F7 CM Common of LIFT ENABLE / 1st
D6 SPEED / 2nd SPEED / 3rd SPEED /
4th SPEED / HYDRO / SR micro
switches.
E1 CPOT Accelerator potentiometer wiper F8 NMC This output is used to drive the main
E2 PPOT Potentiometer positive: 10V output; contactor coil (single pump configura-
keep load > 1KW. tion) or to drive an auxiliary load
E3 NPOT Negative of accelerator unit, Tested for (combi configuration)
wire disconnection diagnosis F9 NHYDRO Auxiliary output; drives the load to -
E4 CM Common of LIFT ENABLE / 1st Batt. Maximum current: 3A
SPEED / 2nd SPEED / 3rd SPEED / F10 2nd Speed Input for second speed request, active
4th SPEED / HYDRO / SR micro HIGH
switches.
F11 GND -Batt.
E5L IFT EInput for potentiometer lifting enable F12 NTHERM -Batt.
ENAL input; active HIGH
E6 1st Input for first speed request, active
SPEED HIGH
E7 3rd Input for third speed request, active
SPEED HIGH
E8 AN. IN Rotary encoder analog input
E9 PPOT Potentiometer positive: 10V output,
keep load > 1KW.
E10 -BATT -Batt
E11 -BATT -Batt
E12 HYDRO Input for power steering request, active
REQ. HIGH
E13 SR Input for speed reduction, active LOW
(switch open).
E14 DIG IN This is a digital input, free for cus-
tomer request.
F1 KEY Connected to power supply through a

micro switch (CH) with a 10A Fuse in
series
F2 PMC Positive of the auxiliary output

Pump Motor Encoder Installation Description of Pump Panel Power

AC2 controller is fit with different types of encoders. To Con-nections
control the AC motor with the ZAPI controller, it is
necessary to install an incremental encoder with 2 View of power bars:
phases shifted 90. The encoder power supply can be
+5V or +12V. It can have different electronic output.
D1 +12V Positive of encoder power supply.

D2 GND Negative of encoder power supply
D3 A Phase A of encoder
D4 A Phase A inverted (encoder with differential
output)
D3 B Phase B of encoder
D4 B Phase B inverted (encoder with differential
output)
Connection of encoder with open collector output; +12V

power supply.
-Batt Negative of battery
+Batt Positive of battery
U;V;W; Connection bars of the three motor phases;
follow the sequence and indication on the
motor

Section 2
Control Programming
Programming & Adjustments Using ZAPI Handset
Adjustments via Handset

Adjustments of parameters and changes to the controller's configuration are made using the digital Handset. The Handset
is connected to the "B: connector of the controller.
Start with the battery disconnected at the battery receptacle, key switch in the OFF position.
Disconnect the dash display harness from the Master Control and connect the handset cord into this "B" connector.
Plug in the battery and turn the key switch ON.
Description of Handset & Connections
Digital Handsets used to communicate with the AC Controllers must be fitted with EPROM CK ULTRA, minimum
"Release Number 3.05, CLARK part number 8033636.
The Handset Release Number will be displayed on the
Handset display momentarily when the key switch is first
turned ON.
SM 715, Mar 05 Control Programming 19-2-1

The Handset display will than show a screen simular to the one shown below.
As shown in this Example; the M in DA2M2BKC, indicates the the Handset is now monitoring the Master control.
The slave control is represented with a :S, and the Pump control would be indicated with a P.
The last 6 digits of the top line in the example above indicate the current software revision loaded into the Master control.
The CK indicates CLARK and the 1.05 is the software revision level.
The bottom line on the display indicates the Battery Voltage and the current level that has been set and the current
internal hour meter reading of the control.
At the bottom of the Handset there are 6 push buttons used to navigate to a different control (Master, Slave or Pump), or
to navigate through the control functions and to make changes to the paramaters.
A flow chart of the Handset functions is shown on the following page.

The Handset is used to make adjustments to the parameters, used to view test functions within the electrical system of
the truck and to view the alarms (fault codes) that are present or stored in the memory of the controls.
See Group 19, Section 4 for TMX Factory Control Settings
19-2-2 Control Programming SM 715, Mar 05

TMX Handset
Master Control Configuration
DISPLAY DUALAC2 ZAPI V0.0 DISPLAY DUALAC2 ZAPI V0.0

48V 350A 00000 48V 350A 00000
KEYBOARD KEYBOARD
HEADING
Enter
Main Menu Set Model Connected to 3 (Master), 4 (Slave), 5 (Pump)
Enter
Parameter Enter Acceleration Delay 0-9 Set Options Hour Meter Running / Key On
Change Release Braking 0-9 Battery Check On/Off
Inverse Braking 0-9 Hydraulic Key On On/Off
Pedal Braking 0-9 Stop On Ramp On/Off
Speed Limit Braking 0-9 Aux Input #1 Hydro Contactor / Brake / Exclusive Hydro
Brake Cutback 0-9 Pedal Braking Analog / Digital
Curve Braking 0-9 Roll Up Set Temperature Analog / Digital / None
Max Speed Forward Hz Steer Table Option #1 / Option #2
Max Speed Reverse Hz Extended Display On/Off
Roll Up Cutback Speed1 Hz
Cutback Speed2 Hz
Curve Cutback % Enter
Curve Cutback #1 % Adjustments Set Pot Brake Minimum ... V
Frequency Creep Hz Set Pot Brake Max ... V

Maximum Current 0-9 Set Battery Type 36/48
Adjust Battery ... V
Auxilary Time Sec
Seat Micro Switch Sec Max Steer Right ... V
ACC Smooth Sec Max Steer Left ... V
Inv Smooth Sec Set Steer 0-Position ... V
Stop Smooth Hz Set Steer Right ...
Set Steer Left ...
Throttle 0 Zone ...%
Enter Throttle Y Zone ...%
Tester Motor Voltage %
Frequency Hz Throttle X Zone ...%

Adjustment #04 C
Encoder Hz
Slip Value Hz Motor Shutdown C
Current RMS A Adjustment #02 1-9
Temperature C Adjustment #01 1-9
Temperature #1 C Adjustment #03 C
Roll Up Temperature #2 C Main Contactor Voltage ... V
Aux Output Voltage ... V
Accelerator V
Steer Angle ... Maintenance Reset On/Off
Maintenance None / Opt #1 / Opt #2
Inter Wheel Cutback %
Maintenance HRs
Forw Switch On/Off
1 X 10,000 Hours 0-6
Back Switch On/Off
1 X 1,000 Hours 0-9
Enable Switch On/Off
1 X 100 Hours 0-9
Seat Switch On/Off
1 X 10 Hours 0-9
Cutback Switch On/Off
1 X 1 Hours 0-9
Cutback Switch2 On/Off Disp Gear Ratio 0-100
Brake Switch On/Off
Save Exclusive Hydraulics On/Off
Roll Parameter Brake Pedal Pot %
Up Hand Brake On/Off
Voltage Booster %
Restore Battery Voltage V
Roll Parameter Battery Charge %
Up
Enter
Alarms Code, H, N, C
Roll
Up Enter
Program VACC Settings Min/Max

Roll VACC
Up
Enter
Motor Data Not Available
SM 715, Jun 06 Control Programming 19-2-3

Master Control - "Dualac2"
SUBMENU "SET OPTIONS"(See Group 19, Section 4 for TMX Factory Control Settings)
1. HOUR COUNTER
RUNNING: the counter registers any motor running.
SEAT: the counter registers when the "key" is closed and operator is sitting on the seat.
2. BATTERY CHECK
ON: the battery discharge level check is carried out; when the battery level reaches 10%, a fault is sig-
naled (-66 code) and the maximum current is reduced to half the programmed value.
OFF: the battery discharge level is carried out but no fault is signaled.
3. HYDRO ON
ON/OFF if this option is programmed on the controller manages the power steering function when the "key"
is switched on.
4. STOP ON RAMP
ON the stop on ramp feature (truck electrically held on a ramp) is managed for a time established by "
auxiliary time" parameter.
OFF the stop on ramp feature is not performed.
5. AUX INPUT #1
EXCLUSIVE input C10 activates power steering function, output A31 is activated.
HYDRO:
OPTION #1 input C10 is the input for the handbrake switch, active low (open switch)
OPTION #2 input C10 is input for a speed reduction switch, active low (open switch)
6. PEDAL BRAKING
ANALOG: The mechanical brake pedal has a switch and potentiometer installed. When the accelerator is
released and the pedal brake is pushed the controller performs an electrical braking whose intensity
is proportional to the brake pedal potentiometer. The minimum intensity is established by the
"Release braking" parameter, when the brake pedal is slightly pressed (brake switch closed but
brake potentiometer at minimum). The maximum intensity is established by the "Pedal Braking"
parameter, when the brake pedal is fully pressed (brake potentiometer at maximum). In the middle
positions, the electrical braking intensity is a linear function between minimum and maximum
intensity.
Digital: The truck does not have a potentiometer installed on the mechanical brake pedal, but only a micro
switch; when the accelerator is released and the brake pedal is pushed (brake switch closed), the
controller performs an electrical braking following "Pedal Braking" parameter.
7. SET TEMPERATURE
DIGITAL: A digital (ON/OFF) motor thermal sensor is connected C25 (C35) input.
ANALOG: An analog motor thermal sensor is connected to C25 (C35) (the curve can be customized on cus-
tomer request).
None No motor sensor switch connected.
8. STEER TABLE This parameter is used to set the correct steering table.

SUBMENU "ADJUSTMENTS"
1. SET POT BRK MIN: Records the minimum value of the braking pedal potentiometer when the braking pedal
(Not Used) switch is closed; the procedure is similar to the "Program VACC" function. This proce-
dure is only used if the "pedal braking" option is programmed as "Analog".
2. SET POT BRK MAX: Records the maximum value of the braking pedal potentiometer when the braking pedal
(Not Used) is fully pressed; the procedure is similar to the "Program VACC" function. This proce-
dure is only used if the "pedal braking" option is programmed as "Analog".
3. SET BATTERY TYPE: Selects nominal battery voltage.
4. ADJUST BATTERY: Fine adjustment of the battery voltage measured by the controller.
5. MAX STEER RIGHT: Records in the controller EEPROM the steer potentiometer output voltage when the
steering wheel is turned fully right (maximum of the steering potentiometer range).
6. MAX STEER LEFT: Records in the controller EEPROM the steer potentiometer output voltage when the
steering wheel is turned fully left (minimum of the steering potentiometer range).
7. SET STEER 0 POS: Records in the controller EEPROM the steer potentiometer output voltage when the
steering wheels are straight.
8. SET STEER RIGHT: Sets the max steering angle in the right direction.
9. SET STEER LEFT: Sets the max steering angle in the left direction.
10. THROTTLE 0 ZONE: Establishes a deadband in the accelerator input curve
11. THROTTLE X POINT: This parameter changes the characteristics of the accelerator input curve
12. THROTTLE Y POINT: This parameter changes the characteristics of the accelerator input curve
SPEED f(Hz)
MAX SPEED
TROTTLE Y
POINT
FREQ. CREEP
V
VACC TROTTLE 0 TROTTLE X VACC
MIN ZONE POINT MAX
VACC MIN and VACC MAX are values programmable by the "PROGRAM VACC" function.
This VACC procedure programs the actual minimun and maximum input voltages from the accelerator control.
See Group 13, Section 4 for setup procedure.

13. ADJUSTMENT #04: Determines the motor temperature level at which the "Motor Temperature" fault is
(Do Not Change) signaled. The default temperature is 130 C. Icon on dash will illuminate at this
temperature.
14. MOTOR SHUTDOWN: This parameter determines the motor temperature level at which the "Motor Shut-
(Do Not Change) down" fault is signaled. The default temperature is 145 C.
15. ADJUSTMENT #01 Adjust the upper level of the battery discharge table.(BDI display - a setting lower
than 5 will show a higher battery charge display for a longer period)
16. ADJUSTMENT #02 Adjust the lower level of the battery discharge table.( adjustment for Internal Resis-
tance Compensation of the battery - a setting lower than 5 will discharge the battery
deeper before lift lockout)
17. ADJUSTMENT #3 Adjust percentage of battery change it take to reset battery state of charge on dash
display.
18. MAIN CONT VOLTAGE: Adjusts the Line contactor coil voltage (PWM output C28).
19. AUX OUTPUT VOLTAGE: Adjusts the Electric brake coil voltage (PWM output C28).(Not Used)
20. MAINTENANCE DONE: OFF is the default Setting. When a maintenance warning occurs, the operator can
cancel the warning setting this parameter ON. When the truck is turned on again
this parameter becomes OFF.
21. MAINTENANCE:
-NONE: When truck reaches maintenance time, if this parameter is set as NONE, the con-
troller gives a maintenance warning but does not reduce performance.
OPTION #1: When truck reaches maintenance time, if this parameter is set as OPTION #1, the
controller gives a maintenance warning and reduces truck performance
OPTION # 2: When truck reaches maintenance time, if this parameter is set as OPTION #2, the
controller gives a maintenance warning and stops the truck.
22. MAINTENANCE TIME: Sets the number running truck hours before setting the maintenance fault. This is a
count down timer, it must be reset after each PM.
23. 1x 10, 000 HOURS: Sets the ten thousands units of the hour meter displayed on the dash display. This
will not change the hour meter of the controller.
24. 1x 1, 000 HOURS: Sets the thousands units of the hour meter displayed on the dash display. This will
not change the hour meter of the controller.
25. 1x 100 HOURS: Sets the hundreds units of the hour meter displayed on the dash display. This will
not change the hour meter of the controller.
26. 1x 10 HOURS: Sets the ten units of the hour meter displayed on the dash display. This will not
change the hour meter of the controller.
27. 1x 1 HOURS: Sets the units of the hour meter displayed on the dash display. This will not change
the hour meter of the controller.

Parameter Regulation
The following parameters can be modified( See Group 19, Section 4 for Clark factory recommended settings)
1. ACC DELAY: Determines the acceleration ramp
2. RELEASE BRAKING: Controls the deceleration ramp when the travel request (accelerator) is released
The higher the setting, the more aggressive the braking.
3. INVERSION BRAKING: Controls the deceleration ramp when the direction is changed (FWD to REV or
REV to FWD) during travel.
4. PEDAL BRAKING: Determines the deceleration ramp when the travel request is (accelerator) released
and the brake pedal switch is closed.
5. SPEED LIMIT BRAKING: Deceleration ramp when the pedal position is changed but not completely released
6. BRAKE CUTBACK: Determines the deceleration ramp when the speed reduction input becomes active
and the motor slows down.
7. CURVE BRAKING: Determines the rate of the decelleration ramp in a curve as the steer wheel is
(Do Not Change) turned.
8. MAX SPEED FORWARD: Determines maximum speed in forward direction.
9. MAX SPEED BACKWARD: Determines maximum speed in reverse direction.
10. CURVE CUTBACK: Speed reduction when the truck in a turn. The parameter sets the speed set point
(CLARK Special) when the truck driving wheels are running in opposite direction (3 wheel truck,
steering angle greater than roughly 67); or when the maximum steering angle is
reached (4 wheel truck, the internal wheel is stopped). In intermediate steering
angles, the speed set point will be within a range between the straight wheel speed
and the CURVE CUTBACK SPEED.
11. CURVE CUTBACK #1: Determines the speed of the inside wheel as the steering wheel is turned.
12. CUTBACK SPEED1: Speed reduction when cutback switch1 is active.
(Not Used)
13. CUTBACK SPEED2: Speed reduction when cutback switch2 is active.
(Not Used)
14. FREQUENCY CREEP: Minimum speed when the forward or reverse switch is closed, but the accelerator
(Do Not Change) is in a minimum position.
15. MAXIMUM CURRENT: Changes the maximum current of the controller
(Do Not Change)
16. AUXILIARY TIME: Determines the time that the truck will hold on a ramp if the "stop on ramp" option
(Do Not Change) is ON.
17. ACC SMOOTH ACC SMOOTH controls the acceleration rate, when the speed request is between 0
Hz and the frequency setting defined by STOP SMOOTH. When the speed request
is above the STOP SMOOTH value, then the parameter ACCELERATION
DELAY controls the acceleration rate. Adjusting this level changes the time (in
seconds) required to accelerate the truck. The lower the acceleration level the
more aggressive the acceleration is.
18. INV SMOOTH INV SMOOTH is similar to ACC SMOTH but it controls the acceleration rate after
the truck is plugged to a complete stop and starts to accelerate in the opposite
direction.
19. STOP SMOOTH Sets the frequency point where ACC SMOOTH stops and ACCELERATION
DELAY starts.

PARAMETERS PROGRAM LEVEL

Unit 0 1 2 3 4 5 6 7 8 9
Acceleration Delay (*) Sec. 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5
Release Braking (**) Sec. 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1
Inversion Braking (**) Sec. 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1
Pedal Braking (**) Sec. 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1
Speed Limit Barking (**) Sec. 8.9 8.3 7.7 7.1 6.6 6 5.5 4.9 4.4 3.8
Brake Cutback (**) Sec. 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1
Curve Braking Sec. 1.5 1.4 1.3 1.2 1.1 1 0.9 0.8 0.7 0.6
Cutback Speed 1 % 10 15 20 25 38 50 63 75 87 100
Cutback Speed 2 % 10 15 20 25 38 50 63 75 87 100
Curve Cutback % 10 15 20 25 38 50 63 75 87 100
Curve Cutback #1 % 55 60 65 70 75 80 85 90 95 100
Frequency Creep Hz 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 3
Maximum Current % IMAX 43 50 56 62 68 75 81 87 94 100
Auxiliary Time Sec. 0 0.2 0.4 0.8 1 1.5 2 3 4 5
Acc Smooth Sec. 1 1.2 1.5 1.7 2 2.2 2.5 2.7 3 3.5
Inv Smooth Sec. 1 1.2 1.5 1.7 2 2.2 2.5 2.7 3 3.5
Stop Smooth Hz 5 7 10 12 15 17 20 22 25 27
Adjustment #1 % Normal % -2.8 -2.2 -1.7 -1.1 -.06 0 0.6 1.1 1.6 2.8
Adjustment #2 % Normal % -2.8 -2.2 -1.7 -1.1 -.06 0 0.6 1.1 1.6 2.8
(*)The acceleration time shown is the time from 0 Hz to 100 Hz. This is the ideal ramp calculated by the software; the
real ramp could change as afunction of motor control parameter setting and, obviously, a function of the load.
(**)The braking feature is base on deceleration ramps. The value shown in the table is the time to decrease the speed
from 100 Hz to 0 Hz. This is the ideal ramp calculated by the software; the real ramp could change as afunction of motor
con-trol parameter setting and, obviously, a function of the load.
PARAMETERS SPEED EMPTY MPH

MPH 1 2 3 4 5 6 7 8 9 9.3
MAX SPEED FORWARD HZ 15 30 44 59 74 89 104 118 133 140
MAX SPEED REVERSE HZ 15 30 44 59 74 89 104 118 133 140
NOTE
Maximum speed for the TMX 12 through 20 can not exceed 140 Hz.
Maximum speed for the TMX 25 can not exceed 110 Hz.
Maximum speeds are adjustable from 0 Hz to 140 Hz in 1 Hz increments. Forward speed and reverse speeds can be set
independently (Forward speed can be set to 8 MPH and Reverse speed can be set at 5MPH if desired)
19-2-8 Control Programming SM 715, Jun 06

TESTER MENU
The most important input or output signals can be measured in real time using the TESTER function of the handset. The
handset acts as a multimeter able to read voltage, current and temperature. The following is a list of measurements for
different configurations.
Handset Tester: user can verify the state of the following parameters:
MASTER CONTROL
Truck Hour Meter(HRs) Accelerator (V) Brake switch (ON/OFF)

Motor voltage (%) Steer Angle () Exclusive hydro (ON/OFF)
Frequency (Hz) Int wheel cutback (%) Brake pedal poti (%)
Encoder (Hz) Forw switch (ON/OFF) Hand brake (ON/OFF)
Slip Value (Hz) Back switch (ON/OFF) Voltage booster (%)
Current RMS (A) Enable switch (ON/OFF) Battery voltage (V)
Temperature (C) Seat switch (ON/OFF) Battery charge (%)
Temperature #1 (C) Cutback switch (ON/OFF)
Temperature #2 (C) Cutback switch2 (ON/OFF)
Master Control - "Dualac2"
1) TRUCK HOUR METER: Shows truck hour meter

2) MOTOR VOLTAGE: This is the voltage supplied to the motor by the controller; it is expressed as a percent-
age of full battery voltage.
3) FREQUENCY: This is the frequency of the voltage and current supplied to the motor.
4) ENCODER: This is the speed of the motor, expressed in the same unit of the frequency; this infor-
mation comes from the speed sensor.
5) SLIP VALUE: This is the difference of speed between the rotating field and the shaft of the motor,
expressed in the same unit of the frequency.
6) CURRENT RMS: Root Mean Square value of the motor current.
7) TEMPERATURE: The temperature measured on the aluminum heat sink holding the MOSFET devices.
8) TEMPERATURE #1: This is the temperature of the right motor; if this option is programmed "None" it
shows 0.
9) TEMPERATURE #2: This is the temperature of the left motor; if this option is programmed "None" it shows
0.
10) ACCELERATOR: The voltage of the accelerator potentiometer's wiper (CPOT). The voltage level is
shown on the left-hand side of the Handset display and the value in percentage is
shown on the right-hand side.
11) STEER ANGLE: This is the indication off the angular position of the steer wheel.
12) INTERNAL WHEEL This is an indication of the speed reduction applied to the inside wheel; in other words,
CUTBACK: it shows the ratio of the two speeds.
13) FORWARD SWITCH: The level of the Forward direction digital input FW.
ON /+BV = input active, switch closed.
OFF / GND = input non-active, switch open.
14) BACKWARD SWITCH: The level of the Reverse direction digital input BW.

15) ENABLE SWITCH: The level of the Enable digital input.

16) SEAT SWITCH: The level of seat microswitch digital input.
17) CUTBACK SWITCH: The level of the Speed Reduction microswitch.
18) CUTBACK SWITCH2: The level of the Speed Reduction microswitch.
19) BRAKE SWITCH: The level of the brake microswitch.
20) EXCLUSIVE HYDRO: Status of the exclusive hydro switch.
21) BRAKE PEDAL POTI: Voltage of the brake potentiometer's wiper (CPOTB). The parameter is active only if
the "PEDAL BRAKING" parameter is set to "ANALOG".
22) HAND BRAKE: The level of the Handbrake microswitch.
OFF / GND = input non-active, switch open
23) VOLTAGE BOOSTER: This is the booster voltage supplied to the motor in load condition; It is expressed in a
percentage of the full voltage.
24) BATTERY VOLTAGE: Level of the battery voltage measured at the input of the key switch.
25) BATTERY CHARGE: The percentage charge level of the battery.

Slave Control - "Dualac2"
Submenu "Adjustments"
SET BATTERY TYPE: Selects nominal battery voltage
ADJUST BATTERY: Fine adjustment of the battery voltage measured by the controller.
AUX OUTPUT VOLTAGE: This parameter adjusts the voltage of the auxiliary output coil (power steering contactor
coil), PWM output A31.
TMX Handset
Slave Control Configuration
DISPLAY DUALAC2 ZAPI V0.0

DISPLAY DUALAC2 ZAPI V0.0
48V 350A 00000
48V 350A 00000
KEYBOARD
KEYBOARD
HEADING Enter
Set Model Connected to 4 (Slave) (3 = Master, 5 = Pump)
Enter
Main Menu Roll
Up Enter
Parameter Not Available
Change Set Options Not Available
Roll Roll
Up Enter
Up
Adjustments Set Battery Type 48/72/80/96
Enter
Tester Motor Voltage %
Adjust Battery
Frequency Hz Aux Output Voltage
Encoder Hz
Slip Value Hz
Current RMS A
Roll Temperature On/Off
Up Seat Switch
Forward Switch V
Reverse Switch V
Enable Switch On/Off
Voltage Booster %
Battery Voltage V
Save
Parameter
Roll
Up
Restore
Parameter
Roll
Up Enter
Alarms
Roll
Up Enter
Program VACC Settings Min/Max

VACC
Roll
Up Enter

TESTER MENU
SLAVE CONTROL
Motor voltage (%) Current RMS (A) Back switch (ON/OFF)
Frequency (Hz) Temperature (C) Enable switch (ON/OFF)

Encoder (Hz) Seat switch (ON/OFF) Voltage booster (%)
Slip Value (Hz) Forw switch (ON/OFF) Battery voltage (V)
Slave Control - "Dualac2"
1) MOTOR VOLTAGE: This is the voltage supplied to the motor by the controller; it is expressed as a percentage
of full battery voltage.
3) ENCODER: This is the speed of the motor, expressed in the same unit of the frequency; this informa-
tion comes from the speed sensor.
7) SEAT SWITCH: The level of seat microswitch digital input.
8) FORWARD SWITCH: The level of the Forward direction digital input FW.
9) BACKWARD SWITCH: The level of the Reverse direction digital input BW.
10) ENABLE SWITCH: The level of the Enable digital input.
11) VOLTAGE BOOSTER: This is the booster voltage supplied to the motor in load condition; It is expressed in a per-
centage of the full voltage.

PUMP CONTROL
Using the configuration menu of the programming console, the user can configure the following functions.
TMX Handset
Pump Control Configuration
DISPLAY DUALAC2 ZAPI V0.0 DISPLAY DUALAC2 ZAPI V0.0

48V 350A 00000 48V 350A 00000
KEYBOARD
HEADING
KEYBOARD
Enter
Main Menu Set Model Connected to 5 (Pump) (3 = Master, 4 = Slave)
Roll
Parameter Enter Acceleration Delay 0-9
Up Enter
Change Decelleration Delay 0-9
Acceleration Delay Tilt 0-9 Set Options Hour Meter On/Off
Deceleration Delay Tilt 0-9 Roll Battery Check Running / Key On
Roll Up Acceleration Delay Aux1 0-9 Set Temperature Analog / Digital / None
Deceleration Delay Aux1 0-9 Up Hydro Function Running/Exclusive/Hydro
Acceleration Delay Aux2 0-9 Enter Thermo Protection On/Off
Deceleration Delay Aux2 0-9 Set Battery Type 36/48
Max Speed Up Hz
Min Speed Up Hz
Adjustments
Cutback Speed % Adjust Battery
1st Speed Hz Throttle 0 Zone
2nd Speed Hz Throttle X Zone
3rd Speed Hz Throttle Y Zone
4th Speed Hz Adjustment #04
Hydro Speed Hz Motor Shutdown
Idle Speed Hz Imax Protection 1-9
Idle Time Sec Adjustment #03
Maximum Current 0-9
Auxilary Time Sec
Enter
Tester Hour Meter Truck Hrs
Motor Voltage %
Frequency Hz
Encoder Hz
Roll Up Slip Value Hz
Current RMS A
Temperature
Motor Temperature
Accelerator V
Lift Switch On/Off
1st Speed Switch On/Off
2nd Speed Switch On/Off
3rd Speed Switch On/Off
Save 4th Speed Switch On/Off
Parameter Cutback Switch On/Off
Hydro Speed Req On/Off
Roll Up Voltage Booster V
Battery Voltage V
Restore COS FI On/Off
Parameter Battery Current A
Roll Up
Enter
Alarms
Roll Up
Program Enter VACC Settings Min/Max

VACC
Roll Up
Enter

SUBMENU "SET OPTIONS"
1 HOUR METER TRUCK

ON: The pump control shares the trucks working hours with a traction control.
OFF: The pump control does not shares the trucks working hours with a traction control.
2 HOUR METER
RUNNING: The meter registers travel time only.
KEY ON: The meter registers when the "key" is closed
3 SET TEMPERATURE
DIGITAL: A digital (ON/OFF) motor thermal sensor is connected to F6 input.
ANALOG: An analog motor thermal sensor is connected to F6(the curve can be customized on customer
request).
None: No motor sensor switch connected.
4 HYDRO FUNCTION
RUNNING: Hydro request standard. Power steering function active when Forward or Reverse request is
active.
EX HYDRO: On demand steering function active. The encoder installed on steering is used to activate power
steering function.
5 THERMO PROTECTION
ON: Power reduction activated.
OFF: Power reduction function off.

SUBMENU "ADJUSTMENTS"
1. SET BATTERY TYPE: Selects nominal battery voltage.

2. ADJUST BATTERY: Fine adjustment of battery voltage measured by the controller.
3. THROTTLE 0 ZONE: Establishes a deadband in the accelerator input curve.
4. THROTTLE X POINT: This parameter changes the characteristics of the accelerator input curve.
5. THROTTLE Y POINT: This parameter changes the characteristics of the accelerator input curve.
6. ADJUSTMENT #4: To set the temperature when the warning signal of motor overheating displays. The warn-
ing temperature is 130C When the temperature rises to this point, the icon on the dash-
board will be turned on.
7. ADJUSTMENT #01: Adjusts the Lower level battery discharge table. (Not used version 1.12 + higher)
8. ADJUSTMENT #02: Adjusts the upper level of the battery discharge table.(Not used version 1.12 + higher)
9. MOTOR SHUT- To set the motor temperature when the "Motor shutdown" signal displays. The shutdown
DOWN: temperature is 145C
10. IMAX PROTEC- The value to start the current reduction when the motor temperature reaches adjustment
TION: #4 value.
11. ADJUSTMENT #03: -
SPEED f(Hz)
MAX SPEED
TROTTLE Y
POINT
FREQ. CREEP
V
VACC TROTTLE 0 TROTTLE X VACC
MIN ZONE POINT MAX
VACC MIN and VACC MAX are values programmable by the "Program VACC" function.
This VACC procedure programs the actual minimun and maximum input voltages from the lift potentiometer.
See Group 13, Section 4 for setup procedure.

Parameter Regulation: Pump Configuration

The following parameters can be modified:
1. Acceleration Delay Acceleration ramp for lift(See Tables Below).

2. Deceleration Delay Deceleration ramp for lift(See Tables Below).
3. Acceleration Delay Tilt Acceleration ramp for tilt(See Tables Below).
4. Deceleration Delay Tilt Deceleration ramp for tilt(See Tables Below).
5. Acceleration Delay Aux1 Acceleration ramp for Aux1(See Tables Below).
6. Deceleration Delay Aux1 Deceleration ramp for Aux1(See Tables Below).
7. Acceleration Delay Aux2 Acceleration ramp for Aux2(See Tables Below).
8. Deceleration Delay Aux2 Deceleration ramp for Aux2(See Tables Below).
9. Max Speed Up: Determine the maximum lifting speed with a Potentiometer control (See Tables Below).
10. Min Speed Up: Determine the minimum lifting speed with a potentiometer control when the lifting
enable switch is closed (See Tables Below).
11. Cutback Speed Speed when cutback switch is activated
12. 1st Speed Fine: First speed (Tilt Speed), fine adjustment (See Tables Below).
13. 2nd Speed Fine: Second speed, fine adjustment (See Tables Below).
14. 3rd Speed Fine: Third speed, fine adjustment (See Tables Below).
15. 4th Speed Fine: Fourth speed, fine adjustment.
16. Hyd Speed Fine: Hydro speed, fine adjustment.
17. Idle Speed: Set speed when steer on demand is active but encoder is not moving.
18. Idle Time: The set time delay before stopping the motor when steer demand is active and encoder is not moving.
19. Max Current: Maximum current of the controller (See Tables Below).
20. Auxilary Time: Time delay when power steering function request is switched off (See Tables Below).
The following tables show the different value at which the parameters can be set.
PARAMETERS PROGRAM LEVEL
UNIT 0 1 2 3 4 5 6 7 8 9
Acceleration Delay Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Deceleration Delay Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Acceleration Delay Tilt Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Deceleration Delay Tilt Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Acceleration Delay Aux1 Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Deceleration Delay Aux1 Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Acceleration Delay Aux2 Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Deceleration Delay Aux2 Sec. 0.5 0.7 1 1.4 1.9 2.5 3.2 4 4.8 5.5
Speed Fine (All) (***) Hz - - - - - - - - - -
Max Current % IMAX 47 23 58 64 70 76 82 88 94 100
Auxilary Time Sec. 0 0.2 0.4 0.8 1 1.5 2 3 4 5
The acceleration time shown is the time from 0 Hz to 100 Hz. This is the ideal ramp calculated by the software; the real
ramp could change as afunction of motor control parameter setting and, obviously, a function of the load.
The braking feature is base on deceleration ramps. The value shown in the table is the time to decrease the speed from
100 Hz to 0 Hz. This is the ideal ramp calculated by the software; the real ramp could change as afunction of
motor control parameter setting and, obviously, a function of the load.
Adjustable with a 1 Hz resolution in the 0 to 200 Hz range.

PARAMETERS MAXIMUM LIFT SPEED

UNIT TMX 12 - 20 TMX 25
MAXIMUM SPEED UP Hz 125 95
MINIMUM SPEED UP HZ 16 16
Note: maximum lift speed for TMX 12 through 20 should not exceed 125 Hz and 95 Hz for the TMX 25
PARAMETERS TILT FLOW SETTINGS

GPM 36 V Hz 48V Hz
1st SPEED FINE (TILT) 4.0 30 30
Note: Before you adjust the tilt flow settings, please insure that the flow has been adjusted at the valve first.
TILT FLOW CONTROL ADJUSTMENT

AVERAGE CLOCKWISE
TILT SPEED USEAGE TURNS OF
( / sec) L/min (gpm) ADJUSTMENT
SCREW
2.5 6.3 (1.7) UPRIGHTS AT 3937 MFH (155 ) AND ABOVE 0.5
3 8.7 (2.3 UPRIGHTS BELOW 3937 MFH (155 ) 0.75
Note: Tilt flow adjustments must be completed at the valve, before adjusting Tilt flow settings in the pump
control-ler.
PARAMETERS AUXILIARY FLOW SETTINGS

GPM 36V Hz 48V Hz
nd 2.5 20 23
2 SPEED FINE
5.5 43 51
AND
3rd SPEED FINE 7.0 55 65
10.0 79 93
Note: Before you adjust the auxiliary flow settings, please insure that the flow has been adjusted at the valve first.

AUXILIARY FLOW ADJUSTMENTS

FLOW SETTINGS L/min(gpm) CLOCKWISE TURNS OF ADJUSTMENT SCREW
6.3 (1.7) 0.50
8.7 (2.3) 0.75
12.3 (3.2) 1.00
19.0 (5.0) 1.50
23.4 (6.2) 1.75
33.5 (8.8) 2.50
39.8 (10.5) 3.00
52.9 (14.0) 4.50
Note: Auxiliary flow adjustments must be completed at the valve, before adjusting auxiliary flow settings in the
pump controller.

TESTER MENU
PUMP CONTROL
Motor voltage (%) Accelerator (V) Hydro speed req. (ON/OFF)
Frequency (Hz) Lifting switch (ON/OFF) Voltage booster (%)

Encoder (Hz) 1st speed switch (ON/OFF) Battery voltage (V)
Slip Value (Hz) 2nd speed switch (ON/OFF) Cos fi
Current RMS (A) 3rd speed switch (ON/OFF) Battery Current (A)
Temperature (C) 4th speed switch (ON/OFF) Battery charge (%)
Motor Temperature (C)
1) MOTOR VOLTAGE: This is the voltage supplied to the motor by the controller; it is expressed as a percent-
age of full battery voltage.
3) ENCODER: This is the speed of the motor, expressed in the same unit of the frequency; this infor-
mation comes from the speed sensor.
7) MOTOR TEMPERATURE: This is the temperature of the right motor; if this option is programmed "None" it
shows 0.
8) ACCELERATOR: The voltage of the accelerator potentiometer's wiper (CPOT). The voltage level is
shown on the left-hand side of the console display and the value is in percentage is
shown on the right-hand side
9) LIFTING SWITCH: Status of lifting switch.
10) 1st SPEED SWITCH: ON /+BV = input active, switch closed.

11) 2nd SPEED SWITCH: ON /+BV = input active, switch closed.

12) 3rd SPEED SWITCH: ON /+BV = input active, switch closed.

13) 4th SPEED SWITCH: ON /+BV = input active, switch closed.

14) HRYDRO SPEED REQ.: ON /+BV = input active, switch closed.

15) VOLTAGE BOOSTER: This is the booster voltage supplied to the motor in load condition; It is expressed in a
percentage of the full voltage.
17) COS FI: This is cosj (real time calculated) of the motor.
18) BATTERY CURRENT: This is the battery current (not measured but calculated.
19) BATTERY CHARGE: The percentage charge level of the battery
OTHER HANDSET FUNCTIONS
Save and Restore Function

SAVE Function allows the transfer of controller parameters to the PC memory. With this function, a copy of the control-
ler's set of parameters can be retained in a Pc and downloaded to another controller (see restore).
RESTORE Function allows you to download controller parameters from the PC memory to the controller Eeprom. Thus
a copy of the parameters stored in the Pc can be downloaded in a controller avoiding the parameter setting operation.
SETUP for INSTALLING A NEW CONTROL PANEL
Sequence for AC Traction Controller Setting

When the "Key Switch" is turned ON, if no faults are present, the Zapi Handset Display will be showing the standard
Opening Display.
If the controller is not configured to your requirements, follow the sequence detailed below. Remember to cycle the key
switch if you make any changes to the controller configuration.
Select the options required.
Select and set battery voltage.
Confirm correct installation of all wires. Use Handset's TESTER function to assist.
Perform the accelerator signal acquisition procedure using the Handset "PROGRAM VACC".(See Group 13, Sec-
tion 4 for programming procedures).
Perform the steering potentiometer signal acquisition, using the parameters in "Adjustment" menu.(See Group 13,
Section 4 for programming procedures).
Remember: when turning the wheel to the right the voltage will increase.

Set the maximum steering angles, right and left

(should be 90); use the parameters in "Adjust-
ment" menu. (See Group 13, Section 4 for pro-
gramming procedures).
Verify BATTERY VOLTAGE. Use volt meter to
determine voltage between +BT and -B on the
controller.
Verify the "MAXIMUM CURRENT"
Verify the acceleration delay requirements for the
truck. Test the parameter setting in both direc-
tions.
Verify the FREQENCY CREEP level starting from
level 0.6 Hz. The truck should just move when
the accelerator start switch is closed. Increase the
level accordingly.
Verify speed reduction.
Set Hour Meter to correct hours.

NOTE :
Group 19, Motor Controls SM 715, Dec 04

Section 3
CONTROL TROUBLESHOOTING
FAULT CODES FOR TMX
This is the list of codes that the CLARK dash display may show
Fault Fault Name Control

Code
1 "NO SEAT SWITCH" MASTER or SLAVE
8 "WATCHDOG" MASTER
13 "EEPROM KO" MASTER
17 "LOGIC FAILURE #3 MASTER
30 "VMN LOW" MASTER
31 "VMN HIGH" MASTER
37 "CONTACTOR CLOSED" MASTER
38 "CONTACTOR OPEN" MASTER
53 "STBY I HIGH" MASTER
60 "CAPACITOR CHARGE" MASTER
61 " HIGH TEMPERATURE" MASTER
65 "MOTOR TC START" MASTER or SLAVE
66 "BATTERY LOW" MASTER
71 "MOTOR SHUTDOWN" MASTER
72 "MOTOR LOCKED" MASTER
74 "DRIVER SHORTED" MASTER
75 "CONTACTOR DRIVER" MASTER
76 "COIL SHORTED" MASTER
77 "MAINTENANCE HOURS" MASTER
78 "VACC NOT OK" MASTER
79 "INCORRECT START (SRO)" MASTER
80 "FORWARD + REVERSE" MASTER
81 "TH MOTOR SENSOR KO" MASTER
82 "ENCODER ERROR" MASTER
84 "STEER SENSOR KO" MASTER
86 "PEDAL WIRE KO" SLAVE
87 "WATCHDOG" SLAVE
96 "LOGIC FAILURE #3 SLAVE
99 "TH MOTOR SENSOR KO" SLAVE
109 "VMN LOW" SLAVE
110 "VMN HIGH" SLAVE
SM 715, Mar 05 CONTROL TROUBLESHOOTING 19-3-1

Fault Fault Name Control

Code
132 "STBY I HIGH" SLAVE
139 "CAPACITOR CHARGE" SLAVE
140 " HIGH TEMPERATURE" SLAVE
148 "ENCODER ERROR" SLAVE
150 "WATCHDOG" PUMP
155 "EEPROM KO" PUMP
159 "LOGIC FAILURE #3 PUMP
171 "MOTOR SHUTDOWN" PUMP
172 "VMN LOW" PUMP
173 "VMN HIGH" PUMP
174 "TH MOTOR SENSOR KO" PUMP
182 MOTOR LOCKED PUMP
195 "STBY I HIGH" PUMP
196 "THERMIC SENSOR KO" PUMP
201 "ENCODER ERROR" PUMP
202 "CAP CHARGE" PUMP
203 " HIGH TEMPERATURE" PUMP
204 "VACC NOT OK" PUMP
205 "INCORRECT START" PUMP
206 "PEDAL WIRE KO" PUMP
207 "MOTOR TC START" PUMP
208 "BATTERY LOW " PUMP
209 "DRIVER SHORTED" PUMP
210 "CONTACTOR DRIVER" PUMP
211 "COIL SHORTED" PUMP
212 "COIL INTERUPTED" PUMP
217 "WRONG SET BATTERY" PUMP
218 "SAFETY" PUMP
222 "NO CAN MSG" PUMP
225 "AUX OUTPUT KO" PUMP
232 "MASTER KO" SLAVE
233 "NO CAN MSG 3" SLAVE
235 "THERMIC SENSOR KO" SLAVE
236 "INPUT MISMATCH" SLAVE
243 "NO CAN MSG 5" MASTER
245 "WRONG SET BATTERY" MASTER
246 "SLAVE KO" MASTER
247 "NO CAN MSG 4" MASTER
249 "THERMIC SENSOR KO"M MASTER
253 "AUX OUTPUT KO" MASTER
255 "HANDBRAKE" MASTER
Blank "DASH DISPLAY" MASTER
19-3-2 CONTROL TROUBLESHOOTING SM 715, Mar 05

Fault Code Charts
Fault Fault Name Fault Description Control Troubleshooting Action

Code Required
1 "NO SEAT No input from seat MASTER Controller detects the seat switch is open
SWITCH" switch or SLAVE during operation.
Check seat switch wiring and connec-
tions Repair seat
Check for inoperative seat switch.
switch wiring
Replace seat
switch
8 "WATCH- Watchdog circuit MASTER It is a self-diagnosing test within the logic
DOG" has been triggered between Master and Slave micro controllers.
This fault could also be caused by a CAN-
BUS malfunction, which blinds Master -Slave
communication. So , before replacing the con-
troller , check the Canbus
13 "EEPROM Warning: EEprom MASTER Fault in the area of memory in which the
KO" fault controller adjustment parameters are stored;
will use default This fault does not inhibit truck opera-
parameters tion, but the controller will use default
parameters. Replace con-
If fault persists when key is switched
OFF and ON again. troller
If the fault disappears, remember that
the parameters stored previously have
been cancelled and replaced by the
default values.
17 "LOGIC Failure in overload MASTER Fault in the hardware section of the logic Replace con-
FAILURE #3 protection hard- board that manages the hardware current troller
ware circuit protection.
18 "LOGIC Failure in U,V,W MASTER Fault in the hardware section of the logic Replace con-
FAILURE #2 voltage feedback board that manages the phase 's voltage troller
circuit feedback.


Code Required
19 "LOGIC An over voltage or MASTER This fault signals that the under voltage /
FAILURE #1 under voltage con- over voltage protection interrupt has
dition has been been triggered
detected A real under voltage / over voltage key
input (C3) happened. Voltage has been
below 16V
A real over voltage on the power capaci-
tors happened, voltage has been 63V.
Fault in the hardware section of the logic Replace con-
board that manages the over voltage pro- troller
tection.
Possible plugging in or unplugging of
battery or charger with the key switch on.
30 "VMN Wrong voltage on MASTER This test is carried out during initial diag- Replace con-
LOW" motor power out- nosis and in standby. Possible causes troller
puts; failure in the problem with motor connections or the
power section or motor power circuit; check if the 3
in the mosfet phases are correctly connected; check if
driver circuit or in there's chassis ground of the motor to
the motor truck frame.
A problem with motor connection or power
circuit.
Check if all 3 phases are correctly
connected.
Check for short between motor ter-
minal and chassis
Perform diode test
unhook battery at controller and do a
diode check between Batt + and
Batt - (should read .3 to .5 volts)
Diode test
Disconnect all power and motor leads
from control.
Select diode test on your multi meter.
Place positive meter lead on control -
Battery terminal place negative meter
lead on terminals U,V,W meter should
read .3V to .5V if not replace control.
Place negative meter lead on control +
If code presist replace control
Fault in the inverter power section.
19-3-4 CONTROL TROUBLESHOOTING SM 715, Jun 06


Code Required
31 "VMN Wrong voltage on MASTER This test is carried out during initial diag-
HIGH" motor power out- nosis and in standby. Possible causes:
puts; failure in the Problem with motor connections or the
Unhook battery at controller and do a
diode check between Batt + and Batt -
(should read .3 to .5 volts) Replace con-
Fault in the controller power section.
troller
Possible bad battery, Excessive voltage
to case of battery.
37 "CONTAC- Line contactor MASTER Before driving the line contactor coil, the
TOR power contact controller checks if the line contactor is
CLOSED" closed at power up stuck. The controller drives the bridge
for a while, trying to discharge the capac-
itor bank. If they don't dis charge, the
fault condition is entered. It is suggested
to check the contactor contact, see if it is
mechanically stuck.
38 "CONTAC- Line contactor MASTER The controller has driven the line contac-
TOR OPEN" power contact tor, but the contactor did not close.
does not pull in The wires to the coil are open or a loose
connection.
The contact does not pull in properly
53 "STBY I Wrong voltage in MASTER The microprocessors verify if the feed-
HIGH" current sensor back of current sensor device output is
feedback circuit within the zero current window. Possible
causes of the fault.
Current sensor failure.
Failure in the controller : if the fault per-
sists, replace the power unit.
60 "CAPACI- Power Capacitor When key is switched on, the controller
TOR Voltage does not tries to charge the capacitors through a
CHARGE" increase when the power resistor, and check if the capacitor
key is turned ON; is charged (1/2 battery volts) within a
failure in power timeout. If they do not charge, an fault is
section, or in signaled; the line contactor does not
Logic PCB, or in close.
driver PCB, or in The charging resistor is open
the motor MAS- The charging circuit has a failure
TER
There is a problem in the power section.
Possible Motor connection open.


Code Required
61 " HIGH Warning: Master MASTER Temperature of control is greater than
TEMPERA- or Slave or both 75C. Maximum current reduced propor-
TURE" temperature higher tionally to the temperature increase. At
that 75 degrees C 100C the maximum current of both con-
trols is reduced to zero.
65 "MOTOR Warning: Right or MASTER Right or left or both drive motors analog
TC START" left or both or SLAVE temperature sensor is greater than the
motors tempera- temperature set in ADJUSTMENT #4
ture high (over (130C) in the ADJUSTMET submenu.
Adj #4) When this fault occurs. Maximum cur- Check tempera-
rent is reduced to half and maximum ture shown on
speed is reduced to 60Hz. handset in tester
If it happens when the motor is cold, mode
Replace con-
check the wring. If all is ok, troller
66 "BATTERY Warning: Battery MASTER When battery level reaches 20% or less
LOW" charge level below or (10% on the dash display), the current
20% level for the drive motors is reduced to
50% of the programmed level and the lift
function is locked out.
71 "MOTOR Warning: Right or MASTER This fault occurs when the right or left or both
SHUT- left or both motors motor temperature switches are open (digital
DOWN" temp. are very sensor), or if the analog sensor temperature
high (over overtakes the cut off level.
MOTOR SHUT- The cut off level is adjusted with the MOTOR
DOWN param.) SHUTDOWN parameter (145C) in the
ADJUSTMENT submenu.
If this fault occurs, maximum current is
reduced to zero and the motor is stopped.
If the shutdown occurs when the motor is cold Replace con-
check the wiring. If wiring is ok troller
72 "MOTOR Drive motor MASTER After 15 seconds the motor stalled with
LOCKED" locked up maximum current, controller reduces
maximum current to 50%.
Check if Line Contactor is pulled in.
74 "DRIVER Line contactor coil MASTER When the key is turned ON, the micro-
SHORTED" driver is shorted processor checks that the line contactor
coil driver is not shorted
If it is, this fault is signaled.
Check if there is an external short or low
impedance pull-down between NLC
(C26) and -Batt.
If no external causes can be found. Replace con-
troller


Code Required
75 "CONTAC- Line contactor coil MASTER When the initial diagnosis is finished, the
TOR driver is open (not traction logic closes the line contactor
DRIVER" able to drive the and checks the voltage drain of the
coil to the correct driver.
voltage) If this is not low, the driver is unable to Replace con-
close and the fault is signaled. troller
76 "COIL Init: Line contac- When the key is turned on, the micropro-
SHORTED" tor coil driver processor checks that the line contactor coil
tection circuit is driver short circuit protection hardware If
damaged or Stby it does not react in a correct way to the
or running: short microprocessor stimulus, the fault is sig-
on line contactor naled.
MASTER When the fault occurs while the line con- Replace contac-
tactor is closed this, indicates a short cir- tor coil
cuit across the line contactor coil. check
if there is an external short circuit and if
the ohmic value (xxx Omhs) of the line
contactor coil is correct
77 "MAINTE- Displayed when MASTER This is just an indication that the vehicle
NANCE the normal hour is due for its Periodic Maintenance.
HOURS" meter exceeds the
maintenance
hours set for the
vehicle
78 "VACC NOT Warning: Accel- MASTER This fault indicates that the accelerator
OK" erator signal voltage is 1volt greater than the mini-
(CPOT) voltage mum value programmed by PROGRAM
higher than VACC function.
VACC MIN+1V The potentiometer is not correctly cali-
While the trac- brated.
tion enable The potentiometer is defective. Replace accel-
switch is open erator
Use tester mode to check for voltage
change when accelerator is depressed,
should be approx 1.5volts (0.4~1.9volts
accelerator), 2.7volts (0.4~3.1volts
accelerator) of change. If not 1.5volts
(0.4~1.9volts accelerator), 2.7volts
(0.4~3.1volts accelerator) check for wir-
ing shorts, if no shorts, replace accelera-
tor. If accelerator still doesnt change
and voltage is greater than 2.0volts
(0.4~1.9volts accelerator) & 3.2volts
(0.4~3.1volts accelerator) replace con-
trol.


Code Required
79 "INCOR- Warning: Wrong MASTER If SRO FUNCTION is active, every time Replace con-
RECT traction request work is stopped the operator must put the troller
START sequence This truck in neutral.
(SRO)" fault indicates an If forward, reverse or seat switch is
incorrect start- active when key switch is turned on.
ing sequence If forward, reverse closed without seat
switch input.
If the fault persist after checking the wir-
ing,
80 "FOR- Warning: For- MASTER Processor is continuously checking for a Replace con-
WARD + ward and reverse request for forward and reverse at the troller
REVERSE" inputs are both same time.
active Defective wiring.
Running micro switch failure.
Incorrect operation.
If defect persist
81 "TH Warning:Motor MASTER The range of the motor temperature ana-
MOTOR Master tempera- log sensor is always checked and a fault
SENSOR ture sensor is out is signaled if it's out of range
KO" of range When this fault occurs. The maximum
current is reduced to half and maximum
speed is reduced to 60 Hz.
82 "ENCODER Motor speed sen- MASTER This fault indicates that the frequency
ERROR" sor (encoder) does supplied the motor is greater that 20 Hz,
not work properly and the signal feedback from the encoder
has a jump higher than 20 Hz in less than
ten milliseconds. This condition clearly
shows a malfunctioning of the encoder
signal.
Check encoder wiring; if no fault is
found in the wiring it is necessary to
replace the encoder.
Check voltage on wire #47, should be
approx 12VDC. If not 12VDC unplug
right + left encoders, recheck wire #47
for 12VDC. If 12VDC is present now,
check encoders and encoder wiring for
shorts. If still no 12VDC replace control


Code Required
84 "STEER Steering Potenti- MASTER This fault indicates an out of range steer-
SENSOR ometer signal out ing potentiometer signal.
KO" of range The fault comes up under the following
two conditions:
The "set Steer 0 pos" (programmed
straight wheel pos) parameter is wrong
(lower than "set steer min) or higher than Replace con-
"set steer max") troller
86 "PEDAL Fault in Accelera- SLAVE Check accelerator wiring and connec- Repair wiring as
WIRE KO" tor negative tions for opens required
(NPOT) Input cir- Check accelerator input voltage using If accelerator
cuit. PcConsole handset in tester mode (volt- voltage is greater
This fault indi- age should range from 2.0 VDC to than 2.0 VDC or
cates that accelera- approx. 0.30 VDC). less than 0.30
tor wiring (NPOT
Check voltage between NPOT (pin C20) VDC replace
or PPOT) wire is
Battery Neg. (pin C12) voltage should be accelerator
open.
greater than 0.30 VDC. This voltage If voltage is not
should remain constant all the way greater than 0.3
through the pedal stroke. VDC proceed to
Check if controller input NPOT (C20) is the next step
good. Remove pins (C20, C21, C33) If it sill read 0
from connector, now connect a 4.7K ohm
resistor between PPOT (C33) and NPOT VDC the control-
(C20) now plug the connector back in, ler has a failed
this will polarize NPOT. Now check volt- input
age between (C12) -Batt and (C20) If it reads cor-
NPOT the reading should be approx. 0.6 rectly 0.6 VDC
VDC the problem is in
the accelerator or
the harness
87 "WATCH- Watchdog circuit SLAVE It is a self-diagnosing test within the
DOG" has been triggered logic between Master and Slave micro
controllers.
This fault could also be caused by a Can-
bus malfunction, which blinds Master -
Slave communication. So , before replac-
ing the controller , check the Canbus
96 "LOGIC Failure in overload SLAVE Fault in the hardware section of the con- Replace con-
FAILURE #3 protection hw cir- troller that manages the hardware current troller
cuit protection.
97 "LOGIC Failure in U,V,W SLAVE Fault in the hardware section of the con- Replace con-
FAILURE #2 voltage feedback troller that manages the phase 's voltage troller
circuit feedback.
Line contactor not closing, check param-
eter setting for main contactor.
SM 715, Jun 06 CONTROL TROUBLESHOOTING 19-3-9


Code Required
98 "LOGIC An over voltage or This fault signals that the under voltage /
FAILURE #1 under voltage con- over voltage protection interrupts been
dition has been triggered
detectedSLAVE A real under voltage / over voltage situa-
tion happened.
Verify battery setting.
Fault in the hardware section of the con-
troller that manages the over voltage pro-
tection. Replace logic Card.
99 "TH Warning:Motor SLAVE The range of the motor temperature ana-
MOTOR Slave tempera- log sensor is always checked and a fault
109 "VMN Wrong voltage on SLAVE This test is carried out during initial diag-
LOW" motor power out- nosis and in standby. Possible causes:
unhook battery at controller and do a
(should read .3 to .5 volts) Replace con-
troller
110 "VMN Wrong voltage on SLAVE This test is carried out during initial diag- Replace con-
HIGH" motor power out- nosis and in standby. Possible causes: troller
Unhook battery at controller and do a
(should read .3 to .5 volts)
132 "STBY I Wrong voltage in SLAVE The microprocessors verify if the feed- Replace con-
HIGH" current sensor back of current sensor device output is troller
causes for the fault. Replace the
Current sensor failure. power unit
Failure in the controller
If the fault persist.


Code Required
139 "CAPACI- Power Capacitor SLAVE When key is switched on, the inverter
TOR Voltage does not tries to charge the capacitors through a
CHARGE" increase when the power resistor, and check if the capacitor
failure in power timeout. If they do not charge, an fault is
the motor The charging circuit has a failure
140 " HIGH Warning: Mas- SLAVE Temperature of control is greater than
TEMPERA- ter or Slave or 75C. Maximum current reduced propor-
TURE" both tempera- tionally to the temperature increase. At
ture higher that 100C the maximum current of both con-
75 degrees C trols is reduced to zero.
148 "ENCODER Motor speed sen- This fault indicates that the frequency Replace
ERROR" sor (encoder) does supplied the motor is greater that 20 Hz, encoder
SLAVE has a jump higher than 20 Hz in less than
signal.
Check encoder wiring; if no fault is
found in the wiring.
150 "WATCH- Watchdog circuit PUMP It is a self-diagnosing test within the
DOG" has been triggered logic between Master and Slave micro
controllers. This fault could also be
caused by a CAN-BUS malfunction,
which blinds Master -Slave communica-
tion. So , before replacing the controller ,
check the CAN-BUS
155 "EEPROM Warning: PUMP Fault in the area of memory in which the
KO" Eeprom fault adjustment parameters are stored; this
controller will fault does not inhibit truck operation, but
use default the controller will use default parame-
parameters ters.
If defect persists when key is switched
OFF and ON again, replace the logic
board. If the fault disappears, remember
that the parameters stored previously
have been cancelled and replaced by the
default values.


Code Required
159 "LOGIC Failure in overload PUMP Fault in the hardware section of the con-
FAILURE #3 protection hard- troller that manages the hardware current Replace con-
ware circuit protection. troller
160 "LOGIC Failure in U,V,W PUMP Fault in the hardware section of the con- Replace con-
FAILURE #2 voltage feedback troller that manages the phase 's voltage troller
circuit feedback.
161 "LOGIC An over voltage or PUMP This fault signals that the under voltage / Replace con-
FAILURE #1 under voltage con- over voltage protection interrupt has troller
dition has been been triggered. Two possible reasons:
detected A real under voltage / over voltage situa-
tion happened.
Verify battery setting.
Fault in the hardware section of the con-
troller that manages the over voltage pro-
tection. Replace logic Card.
171 "MOTOR Warning: Pump PUMP This fault occurs when the pump motor
SHUT- motor temp. are temperature switches are open (digital
DOWN" very high (over sensor), or if the analog sensor tempera-
MOTOR SHUT- ture overtakes the cut off level.
DOWN param.) The cut off level is adjusted with the
MOTOR SHUTDOWN parameter
(145C) in the ADJUSTMENT sub-
menu.
If this fault occurs, maximum current is
reduced to 130 amps needed for steering.
If the shutdown occurs when the motor is
cold check the wiring. If wiring is ok
replace logic board.


Code Required
172 "VMN Wrong voltage on This fault signals that the under voltage /
LOW" motor power out- over voltage protection interrupt has
puts; failure in the been triggered Two possible reasons:
power section or A real under voltage / over voltage situa-
in the mosfet tion happened.
driver circuit or in Fault in the hardware section of the con-
the motorPUMP troller that manages the over voltage pro- Replace con-
tection. troller
A problem with motor connection or
power circuit.
Check if all 3 phases are correctly con-
nected.
Check for short between motor terminal
and chassis
Perform diode test
Diode test
Disconnect all power and motor leads
from control.
Select diode test on your multi meter.
Place positive meter lead on control -
Place negative meter lead on control +
If code presist replace control
173 "VMN Wrong voltage on PUMP This test is carried out during initial diag-
HIGH" motor power out- nosis and in standby. Possible causes:
unhook battery at controller and do a Replace con-
(should read .3 to .5 volts) troller
Fault in the inverter power section.
Possible bad battery, Excessive voltage
to case of battery.
174 "TH Warning:Motor PUMP The range of the motor temperature ana-
MOTOR Pump tempera- log sensor is always checked and a fault
SM 715, Jun 06 CONTROL TROUBLESHOOTING 19-3-13


Code Required
182 MOTOR Pump motor PUMP After 15 seconds of the motor being
LOCKED locked up stalled with maximum current, controller
reduces maximum current to 50%.
Check to see that the pump contactor is
pulled in
Possible bad encoder(Sensor, Bearing)
195 "STBY I Wrong voltage in PUMP The microprocessors verify if the feed-
HIGH" current sensor back of current sensor device output is
causes of the fault;
Current sensor failure.
Failure in the logic card: If the fault per-
sist, replace the power unit.
196 "THERMIC Warning: Pump PUMP The range of the temperature sensor is
SENSOR temperature sen- always checked and a warning is sig-
KO" sor is our of naled if it is out of range. This fault will
range reduce the maximum current output of
the controller to 50%.
201 "ENCODER Motor speed sen- PUMP This fault indicates that the frequency
ERROR" sor (encoder) does supplied the motor is greater that 20 Hz,
has a jump higher than 20 Hz in less than
signal. Check encoder wiring; if no fault Replace
is found in the wiring. encoder
202 "CAP Power Capacitor PUMP When key is switched on, the inverter
CHARGE" Voltage does not tries to charge the capacitors through a
increase when the power resistor, and check if the capacitor
failure in power timeout. If they do not charge, a fault is
the motor The charging circuit has a failure
203 "HIGH Warning: Pump PUMP Temperature of control is greater than
TEMPERA- Controller tem- 75C. Maximum current reduced propor-
TURE" perature higher tionally to the temperature increase. At
that 75 degrees C 100C the maximum current of both con-
trols is reduced to zero.


Code Required
204 "VACC NOT Warning: Accel- PUMP This fault indicates that the accelerator
OK" erator siganal voltage is 1volt greater than the mini-
(CPOT) voltage mum value programmed by PROGRAM
higher than VACC function.
VACC MIN+1V The potentiometer is not correctly cali-
While the trac- brated.
tion enable The potentiometer is defective.
switch is open
Tilt or sideshift switch activated at star-
tup
205 "INCOR- Warning: Wrong PUMP This fault indicates an incorrect starting
RECT traction request sequence.
START" sequence Lift or enable switch failure
Error in sequence made by operator.
Incorrect wiring.
If the fault persist after checking the wir-
ing, Replace con-
Pot partially activated at startup troller
206 "PEDAL Fault in Accelera- PUMP Check accelerator wiring and connec-
WIRE KO" tor negative tions for opens
(NPOT) Input cir- Check accelerator input voltage using
cuit. PcConsole handset in tester mode (volt-
age should range from xx VDC to
approx. xx VDC).
207 "MOTOR Warning: Pump PUMP Pump motor analog temperature sensor
TC START" motors tempera- is greater than the temperature set in
ture high ADJUSTMENT #4 (130C) in the
ADJUSTMET submenu.
When this fault occurs, current goes
down to IMX PROTECTION value and Check tempera-
motor rpm begins to decrease. Motor
current and speed decrease linearly as the ture shown on
temperature increases until MOTOR- handset in tester
SHUTDOWN is reached. mode
If it happens when the motor is cold, Replace con-
check the wring. If all is ok,, troller
208 "BATTERY Warning: Battery PUMP When battery level reaches 20% or less,
LOW " charge level the current level for the drive motors is
below 20% reduced to 50% of the programmed level
209 "DRIVER Line contactor coil PUMP When the key is turned on, the micropro-
SHORTED" driver is shorted cessor checks that the line contactor coil
driver is not shorted; If it is, this fault is
signaled. Check if there is an external
short or low impedance pull-down
between NLC (C26) and Batt- If no Replace con-
external causes can be found. troller


Code Required
210 "CONTAC- Line contactor coil PUMP When the initial diagnosis is finished, the
TOR driver is open (not controller closes the line contactor and
DRIVER" able to drive the checks the voltage drain of the driver. If
coil to the correct this is not low, the driver is unable to Replace con-
voltage) close and the fault is signaled. troller
211 "COIL Init: Line contac- PUMP When the key is turned on, the microproces-
SHORTED" tor and EB coil sor checks that the line contactor coil
driver protection driver short circuit protection hardware If
circuit is damaged it does not react in a correct way to the
or Stby or running: micro processor stimulus, the fault is sig-
short on line con- naled. When the fault that occurs while
tactor or EB coil the line contactor is closed this indicates a
short circuit across the line contactor coil.
check if there is an external short circuit
and if the ohmic value (xxx Omhs) of the
line contactor coil is correct
212 "COIL xxx PUMP xxx
INTER-
UPTED"
217 "WRONG Battery voltage PUMP This fault indicates that actual battery
SET BAT- does not corre- voltage is 20% higher or 20% lower than
TERY" spond to pro- "SET BATTERY" parameter setting.
grammed "SET Replace battery with correct battery.
BATTERY"
218 "SAFETY" Input F5 is not PUMP xxx
connected to Batt-
222 "NO CAN Pump has lost Can PUMP This Fault is present in combi Systems
MSG" communication (traction + Pump). The traction has
with Master detected a fault and has informed the
pump controller through the can-bus line.
The pump is waiting for the traction ok.
The fault must be looked for in the trac-
tion controller or can-bus circuit.
225 "AUX OUT- EB coil driver PUMP The microprocessor checks the driver of
PUT KO" shorted or open the electromechanical brake coil. If the
status of the driver output does not corre-
spond to the signal coming from the
microprocessor, the fault is signaled. It
is suggested to check for an external
short or a low impedance pull-down
between NHYDRO (F9) and -Batt.


Code Required
232 "MASTER Slave micro pro- SLAVE Slave and Master microprocessor per-
KO" cessor detects form a crosscheck in order to verify
Master processor functionality. There are two conditions
malfunctioning under which the slave enters this fault
condition:
The SLAVE microprocessor receives an
incoherent Can message from the MAS-
TER microprocessor.
The SLAVE microprocessor compares
the inputs status and the related MAS-
TER operations and finds they are not
coherent. In both cases, the SLAVE
brings the controller to a safe status
opening the power bridge and the line
contactor.
233 "NO CAN Slave has lost Can SLAVE Slave (node #4) signals that it has lost
MSG 3" communication communication with the Master (node
with Pump #3) This fault could be determined to be
a problem in the truck CAN-BUS line or
be an internal problem in the controller
logic card. First check the CAN_BUS
connection.
235 "THERMIC Warning: Slave SLAVE The range of the temperature sensor is
SENSOR temperature sen- always checked and a warning is sig-
KO" sor is our of naled if it is out of range. This fault will
236 "INPUT Slave micro pro- SLAVE Safety related inputs (Fwd direction, Rev
MIS- cessor has direction, accelerator Enable, Seat
MATCH" detected a mis- switch) are inputs to both micro proces-
match between sors by independent hardware circuit.
inputs status and The two microprocessors read these
the input status inputs and compare by exchanging
transmitted Via related status on the Canbus. If the
Canbus by master SLAVE microprocessor finds a mismatch
micro processor between its inputs and MASTER inputs,
it brings the controller to a safe status
opening the power bridge and the line
contactor.
243 "NO CAN Master has lost MASTER Master (node #3) signals that it has lost
MSG 5" Can communica- communication with the Pump (node #5)
tion with Pump This fault could be determined to be a
problem in the truck CAN-BUS line or
connections.


Code Required
245 "WRONG Battery voltage MASTER This fault indicates that actual battery
SET BAT- does not corre- voltage is 20% higher or 20% lower than
TERY" spond to pro- "SET BATTERY" parameter setting.
grammed "SET Replace battery with correct battery.
BATTERY"
246 "SLAVE Master micro pro- MASTER Slave and Master microprocessor per-
KO" cessor detects form a crosscheck in order to verify
Slave micro pro- functionality. If the MASTER detects
cessor Malfunc- SLAVE microprocessor malfunctioning,
tioning it brings the controller to a safe status
opening the power bridge and line con-
tactor.
247 "NO CAN Master has lost MASTER Master (node #3) signals that it has lost
MSG 4" Can communica- communication with the Slave (node #4)
tion with Slave This fault could be determined to be a
problem in the truck CAN-BUS line or
connections.
249 "THERMIC Warning: Mas- MASTER The range of the temperature sensor is
SENSOR ter temperature always checked and a warning is sig-
KO" sensor is our of naled if it is out of range. This fault will
253 "AUX OUT- EB coil driver MASTER The microprocessor checks the driver of
PUT KO" shorted or open the electromechanical brake coil. If the
status of the driver output does not corre-
spond to the signal coming from the
microprocessor, the fault is signaled. It
is suggested to check for an external
short or a low impedance pull-down
between NAUX (C31) and -Batt. Replace con-
If no external cause is found troller
255 "HAND- Handbrake switch MASTER Indicate that handbrake is activated Repair wiring or
BRAKE" closed Check wiring and handbrake switch. replace switch if
needed
Blank "DASH DIS- Dash Display MASTER Check 5 volt power supply for dash dis- Replace 5 V
PLAY" blank play If no 5 volts power supply
Check wiring and connector at control Replace dash
and display. If not wiring or connections display

Mar 05Group 19, Motor Controls
Section 4
TMX Factory Control Settings

Parameters in White are customer preference adjustable.
Parameters in Orange are factory preset and not adjustable.
Refer to Section 2 for Handset HYDRO KEY ON OFF

Programming Instructions STOP ON RAMP OFF
AUX INPUT #1 OPTION #1
Name Scaled Value PEDAL BRAKING DIGITAL
Master (DUALAC2) SET TEMPERATURE ANALOG
PARAMETER CHANGE 36V/48V STEER TABLE OPTION #1
ACCELER. DELAY LEVEL = 3 EXTENDED DISPLAY ON/OFF
RELEASE BRAKING LEVEL = 4 (Vers.CK1.19+Higher)
INVERS. BRAKING LEVEL = 6 SET MODEL 36V/48V
PEDAL BRAKING LEVEL = 7 CONNECTED TO 3 (Master)
SPEED LIMIT BRK. LEVEL = 0
BRAKE CUTBACK LEVEL = 5 ADJUSTMENTS 36V/48V
CURVE BRAKING LEVEL = 5 SET POT BRK MIN N/A
MAX SPEED FORW 140 Hz (TMX12-20) SET POT BRK MAX N/A
(Do Not adjust to a higher HZ) SET BATTERY TYPE 36V/48V
MAX SPEED FORW 110 Hz (TMX25) ADJUST BATTERY
(Do Not adjust to a higher HZ)
MAX STEER RIGHT 4.1 V
MAX SPEED BACK 140 Hz(TMX12-20)
MAX STEER LEFT 0.9 V
(Do Not adjust to a higher HZ)
SET STEER 0-POS. 2.5 V
MAX SPEED BACK 110 Hz (TMX25)
(Do Not adjust to a higher HZ) SET STEER RIGHT 90
CUTBACK SPEED 1 100% SET STEER LEFT 90
CUTBACK SPEED 2 100% THROTTLE 0 ZONE 1%
THROTTLE X POINT 18%
CURVE CUTBACK 20%
CURVE CUTBACK 1 100% THROTTLE Y POINT 15%
FREQUENCY CREEP 0.30 Hz ADJUSTMENT #04 130
MAXIMUM CURRENT LEVEL = 9 MOTOR SHUTDOWN 145
AUXILIARY TIME 1.5 ADJUSTMENT #02 LEVEL = 4
ADJUSTMENT #01 LEVEL = 4
ACC. SMOOTH 2.5
(Vers.CK1.21+Higher) ADJUSTMENT #03 20%
MAIN CONT. VOLT. 36 V
INV. SMOOTH 1.0
(Vers.CK1.21+Higher) AUX OUTPUT VOLT. 36 V
MAINTEN. RESET OFF
STOP SMOOTH 20Hz
(Vers.CK1.21+Higher) MAINTENANCE NONE
MAINTENANCE TIME 250
SET OPTION 36V/48V 1X10000 HOURS 0
HOUR COUNTER RUNNING 1X1000 HOURS 0
BATTERY CHECK ON 1X100 HOURS 0
SM 715, Jun 06 TMX Factory Control Settings 19-4-1

1X10 HOURS 0 AUXILIARY TIME 4

1X1 HOURS 0
DISP. GEAR RATIO 36 SET OPTION 36V/48V
(Vers.CK1.19+Higher) HOUR COUNTER RUNNING
BATTERY CHECK OFF
SLAVE (DUAL AC2) SET TEMPERATURE ANALOG
SET MODEL 36V/48V HYDRO FUNCTION RUNNING
CONNECTED TO 4 (Slave) THERM PROTECTION OFF
SET MODEL 36V/48V

ADJUSTMENTS 36V/48V CONNECTED TO 5 (PUMP)
SET BATTERY TYPE 36V/48V
ADJUST BATTERY ADJUSTMENTS 36V/48V
AUX OUTPUT VOLT. 12V SET BATTERY TYPE 36V/48V
ADJUST BATTERY
PUMP (AC2) THROTTLE 0 ZONE 5%
PARAMETER CHANGE 36V/48V THROTTLE X POINT 63%
ACCELER. DELAY LEVEL = 0 THROTTLE Y POINT 36%
DECELER. DELAY LEVEL = 0 ADJUSTMENT #04 130 C
ACCELER. DELAY TILT LEVEL = 3 MOTOR SHUTDOWN 145 C
(Software Vers.1.09+Higher) ADJUSTMENT #03 55 C
DECELER. DELAY TILT LEVEL = 0 IMAX PROTECTION 100%
(Software Vers.1.09+Higher) ADJUSTMENT #02 ** LEVEL = 4
ACCELER. DELAY AUX1 LEVEL = 0 ADJUSTMENT #01 ** LEVEL = 4
(Software Vers.1.09+Higher)
See AUX Hydraulic Settings in Section 3
DECELER. DELAY AUX1 LEVEL = 0
(Software Vers.1.09+Higher) Not used software version CK 1.12 + higher
ACCELER. DELAY AUX2 LEVEL = 0 NOTE
(Software Vers.1.09+Higher) All motors must be stopped before saving parameters.
DECELER. DELAY AUX2 LEVEL = 0 parameter may not be stored to EEPROM if motor is run-
(Software Vers.1.09+Higher) ning.
MAX SPEED UP (Do Not 125 Hz (TMX12-20)
adjust to a higher HZ)
MAX SPEED UP (Do Not 95 Hz (TMX25)
adjust to a higher HZ)
MIN SPEED UP 16.50 Hz
CUTBACK SPEED 100%
1ST SPEED FINE* 30 Hz
2ND SPEED FINE* 30 Hz
3RD SPEED FINE* 81 Hz
4TH SPEED FINE* N/A
HYD SPEED FINE 16 Hz
IDLE SPEED 12 Hz
IDLE TIME LEVEL = 5
MAXIMUM CURRENT LEVEL = 9
19-4-2 TMX Factory Control Settings SM 715, Jun 06

Group 19, Sequence of Operation
TMX 250
TMX 12-25
AC Control
GROUP 19
Sequence of Operation
SM-715, Dec 04 Sequence of Operation 19-6-1

OPERATION 1
Connect the Battery
Battery Positive will be supplied to the 5 volt converter, B+ terminal, via the #2
wire. Battery Negative is connected to the GND terminal of the 5 volt
converter completing the circuit. The converter will provide a 5 volt signal to
the dash display via the #81 wire to terminal 15.
Battery Positive will be supplied to the 12 volt converter + terminal, through the #2
wire and the #4FU fuse. Battery Negative is connected to the - terminal of the 12
volt converter completing the circuit. The converter will provide a 12 volt output
to the accessory circuit through the #5 FU fuse. The converter negative is
connected to the frame of the truck as is all 12 volt accessories completing the
negative circuit. (See page 4 & 5)
The horn is operated by pushing the horn button which will supply battery voltage to
the horn through wire #25, and to negative through wire #13.
Battery Negative is connected to the dash display at terminal 23 and to the AC

controllers at the B- terminals.
Voltages Present:
Battery volts at wire #2, 5 volts at wire #81.
Battery volts at the + terminal, 12 volts between terminal #22 and the frame of the
truck.
Battery volts at wires #12 and #25, 0 volts at wire #13 (battery Negative).
0 volts (battery Negative)
Sequence of Operation 19-6-2 SM-715, Dec 04

D
A D
C
OPERATION 1 (Continued)
Connect the Battery
A. Battery Positive will be supplied to the 12 volt converter + terminal, through the
#2 wire and the #4FU fuse.
B. Battery Negative is connected to the - terminal of the 12 volt converter completing

the circuit.
The converter will provide a 12 volt output to the accessory circuit through the #5 FU
fuse. The converter negative is connected to the frame of the truck as is all 12 volt
accessories completing the negative circuit.
Voltages Present:
Battery volts at wire #2 at the + terminal
0 volts (battery Negative)
12 volts between terminal #22 and the frame of the truck.

Accessory Diagram
A B
C
OPERATION 2
Closing the Key Switch
Closing the key switch will provide Battery Positive via the #11 wire to the
traction control at terminal TC3, and to the pump control at terminal PF1.
Battery positive is also supplied to the accelerator control. Battery Negative is
supplied to the traction and pump controls at terminal B.
Battery Positive is also supplied to the dash display at terminal 20.
The Traction Control and the Pump Control, through an internal circuit, will pre-
charge the internal capacitors.
When the traction control capacitors have charged to a preset value, the traction
control will supply battery positive voltage to the Line contactor at terminal
TC27, wire #46, and battery negative at terminal TC26, wire #45. When the
pump control capacitors have charged to a preset value, the pump control will
supply battery positive voltage to the Pump Line contactor at terminal PF8,
wire #66, and battery negative at terminal PF2, wire #65.
The Line Contactors will be energized and will close the normally open contacts
providing battery positive through the cables to the +B terminals.
The traction control will supply a 12 volt signal from terminal TB6, wire #82 to
terminal TB4, wire #80 and to the dash display, terminal 12 via wire #80.
Voltages Present:
Battery volts
Battery volts
80% Battery volts (not measurable)
Battery Positive at wires #46 and #66. Battery Negative at wires #45 and #65.
Battery Positive.
12 volts

E
E
C
A A
A
D
OPERATION 2 (Continued)
Closing the Key Switch
A. Closing the key switch will provide Battery Positive via the #11 wire to the
Cooling Fan Relay, located under the left hand dash panel, at terminal 3.
Battery Negative is connected to terminal 4 of the Cooling Fan Relay.
With Battery Positive at terminal 3 and Battery Negative at terminal 4, the electronic
relay will close the connection between terminals 1 and 2, completing the 12 volt
circuit via wire #22 through wire #59 to the cooling fans located on the control
panel. 12 volt positive will also be supplied to the strobe light, if equipped, via
wire #24.
The 12 volt circuit is completed from the fans and strobe by grounding to the frame of
the truck.
Voltages Present:
Battery positive
0 volts (Battery negative)
12 volts
0 volts (Ground)

Accessory Diagram
A B
D
OPERATION 3
System Checks
The traction control will supply a battery positive voltage at terminal TC4, wire
#42, to the directional, brake, parking brake and seat switches.
The control monitors the voltage at terminals TC5, TC6, TC7, TC9 and TC10 for
proper switch closing in performing the SRO checks.
Voltage is supplied through the normally closed contacts of the parking brake
switch, parking brake applied, through wire #33 to terminal 6 on the dash
display to illuminate the Parking Brake Icon.
The pump control will supply a battery positive voltage at terminal PE14, wire
#52, to the hydraulic valve switches.
The pump control monitors the voltage at terminals PE5, PE6, PE7, PF10 and
PE13 for switch closure.
Voltages Present:
Battery volts.
0 volts at terminals TC5, TC6, TC7 and TC9 with switches open. Battery volts at
terminal TC10 with parking brake applied.
Battery volts
Battery volts at terminals PE4 and PE13
0 volts at terminals PE5, PE6, PE7 and PF10 with the hydraulic levers in neutral
position, switches open.
SRO Explanation:
The TMX truck incorporates a seat switch for traction and pump control operation.
The seat switch must be closed before trying to travel or using any of the
hydraulic functions.
If either the forward or reverse directional control switches are closed before the seat
switch is closed or the parking brake switch is opened, the drive motors will not
operate. If the seat switch is opened or the parking brake switch is closed during
truck operation for more than 3 seconds, the control will shut down and the
directional lever will need to be cycled through neutral before restarting.

A
C
E
D
OPERATION 4
Traction System
Setting on the seat will close the seat switch. Disengaging the parking brake will
open the parking brake switch. Placing the directional lever in forward or reverse
will close the respective switch.
Depressing the accelerator slightly will close the 1 MS switch. Further depression of
the accelerator pedal will move the inductor within the accelerator decreasing the
output voltage from the accelerator to the traction control at terminal TC21.
The traction control provides a 12 volt signal from terminal TC16, via the #47 wire,
to the steer potentiometer. Battery negative is to the pot is supplied via the #48
wire to terminal TC15. When the steer wheel is centered, going straight ahead,
the output voltage from the pot on wire #49, terminal TC17 will be about 6 volts.
As the steer wheel is turned to the right, the voltage on wire #49 will increase.
When the steer wheel is turned to the left, the voltage on wire #49 will decrease.
When the traction control is signaled with the proper switch closures in the proper
order, and it receives the signal from the accelerator control, it will start turning
the transistors on and off within the control to provide an Alternating Current
(AC) to the two drive motors. As the accelerator input voltage decreases, the
pulsing of the control and the speed of the motors will increase.
The encoder bearings within the two drive motors signal the traction of the speed of
the motors and help control the pulsing.
The thermostat within the two motors will increase in resistance when they reach a
specific temperature and signal the traction control that the motors are running hot
and the control will reduce the maximum current that the motors can draw.
Voltages Present:
Battery volts when the respective switches are closed

Battery volts at terminal TC8, wire #14 with 1 MS switch closed. Approximately
4.2 volts at terminal TC21, wire 53 with accelerator in the raised position
and dropping to about 0.5 volts as the accelerator is depressed to the floor. 0
volts on terminal TC20, wire #44.
12 volts on terminal TC16, wire #47. 0 volts at terminal TC15, wire #48.
About 1 11 volts at terminal TC17, wire #49, depending on steer wheel
position.
NA
NA

D
E
F
D E
B
A
C
OPERATION 5
Pump Control System
When the traction control has received the proper switch closures in the proper order
and a directional control switch has been closed, the traction control will signal
the pump control, via the can-bus system, terminals TA1, wire #4, and terminal
TA6, wire #73, to the pump control terminals PC3 and PC1, to start pulsing the
pump motor with AC voltage to run the motor at a very slow speed.
When a hydraulic valve lever is moved it actuates a switch, closing the contacts
and providing an input voltage to the pump control at terminals PE5, PE6, PE7
and/or PF10.
If the lift lever is pulled back it will also move the transducer plunger and start to
decrease the input voltage to the pump control at terminal PE1, wire #54. With the
lift switch closed, the reduction in input voltage at terminal PE1 will signal the
control to start increasing the pulsing to the pump motor increasing the speed of
the motor. The further the lever is pulled backward, the faster the motor will run.
A circuit is available for future options to disable the increase of speed of the pump
control, other than steering speed, by placing a switch in this loop circuit.
When the pump control receives the proper switch input signals, it will start turning
the transistors on and off producing an AC voltage to the pump motor to start
running.
The encoder bearing in the pump motor signals the pump control with the speed of
the pump motor to help control the speed and current requirements of the
motor.
The thermostat within the pump motor will increase in resistance when it reaches a
specific temperature and signal the pump control that the motor is running hot
and the control will reduce the maximum current that the motor can draw.
Voltages Present:
NA
Battery volts at terminal PE13 and PE4, wire #52. Battery volts at terminal PE5,
PE6, PE7, and PF10 when corresponding switches are closed.
12 volts at terminal PE2, wire #51. Battery negative at terminal PE3, wire
#55. Around 5 volts at terminal PE1, wire #54 with lift lever in neutral
position, less than 0.5 volts with lift lever pulled fully back.
Battery volts at terminal PF5 and PF11, wire #64.
NA
NA
NA

E
C B
OPERATION 6
Accessories
When the directional lever is placed into Reverse, closing the reverse switch,
battery positive is supplied via the #18 wire to terminal 3 of the Back Up
Relay. Terminal 4 of the relay is connected to battery negative through the #13
wire.
With battery positive on terminal 3 and battery negative at terminal 4 of the
electronic relay, the relay will complete the connection between terminals 1
and 2, thus completing the 12 volt positive circuit to the back up alarm and
lights, if equipped.
The 12 volt circuit is completed from the 12 volt accessories via wire #3
connected to the frame of the truck.
Depressing the brake pedal will close the Stop Light Switch points completing the
12 volt positive circuit to the stop lights.
Closing the Head Light switch on the dash will supply 12 volts positive to the
headlights if so equipped.
Voltages Present:
Battery volts between terminals 3 & 4.

12 volts at terminal 2.
0 volts (Ground).
12 volts on wires #22 and #36.
12 volts on wires #22 and #46.

Accessory Diagram
A C
B
E
C
GROUP 20 DRIVE AXLE
GROUP 20
DRIVE AXLE
Drive Axle Specifications and Description .... Section 1

Drive Axle Troubleshooting ............................ Section 2
Drive Axle Fluid Check and Change. .............. Section 3
Drive Axle Removal and Installation .............. Section 4
Drive Axle Overhaul ......................................... Section 5
SM 715, Dec 04 Group 20 DRIVE AXLE,

NOTE :
Group 20 DRIVE AXLE, SM 715, Dec 04

Group 20, Drive Axle
Section 1
Drive Axle Specifications and Description
Specifications Description
Type: Separate housing and drive train for each drive See next page.
wheel. Each axle housing contains pinion and ring gear,
intermediate shaft, and axle shaft.
Transmission Fluid Type: Clark part no. 2776236
Fluid Capacity (each housing): 3.8 L (1 gal)
Axle-to-Frame Mounting Bolt Torque: 408-469 N.m
(300- 340 ft-lb). Use Loctitle 271.
Fill Plug Torque: 54-61 N.m (40-45 ft-lb)
SM 715, Dec 04 Drive Axle Specifications and Description 20-1-1

20- 1-2 Drive Axle Specifications and Description

Description
Each drive wheel is driven by a separate motor and drive train.
The drive axle consists of two independent housings that contain identical
com-ponents for conveying power from each (left and right) drive motor to
each drive wheel.
The two housings bolt together to form a single drive axle.
Each housing contains a pinion (A) driven by the motor output shaft, a ring gear
and ring gear shaft (C) driven by the pinion, and an output gear (D) and axle
shaft (E) driven by the teeth on the ring gear shaft.
The brake disc runs within an hydraulic caliper assembly, shown in Group 23.
Ring Gear Shaft:

Brake
Drive
Gear Disc Brake Disc
Inspection
Teeth Spline
Cover
Pinion Ring Gear
Bearing
Housing
B
C
A
D Drive Axle
Shaft Gear
Fluid Level
Check Plug
E Drain Drive Axle Components (bearing, seals, and retainers not
SM 715, Dec 04
Plug labeled). Left-hand housing shown.
Axle Shaft
Section 2
Drive Axle Troubleshooting
Proper operation of the drive axle depends on the condi- The following lists typical drive axle troubles and
tion of the other related components in the power train.. possible causes.
Therefore, to properly diagnose a suspected problem in the
drive axle, consider the drive axle fluid, drive axle assembly, Truck Wont Move in Either Direction
controls, and drive motor as a complete system.
Battery disconnected.
To identify and correct a drive axle fault, refer to the Park brake on.
description in Section 1, along with symptoms and causes
indicated in this Section. Check electrical control system. See Group 19.
Check directional control switches. See Group 13.
Inspection and overhaul of the suspect components is
described in various locations within this Group. Check contactors. See Group 17.
Check drive motor. See Group 16.
Truck Moves Only in Forward or Only in

Reverse
Check electrical control system. See Group 19.
Check directional control switchs. See Group 13.
Overheating
Low or contaminated fluid level.
Truck travel function being loaded excessively.
Worn bearings.
Check drive motor for air flow or damage. See Group
16.
Brakes Dragging. See Group 23.
Loss of Power
Low battery charge.
Drive axle bearings worn or seized.
Overheating . See Overheating above
SM 715, Dec 04 Drive Axle Troubleshooting 20-2-1

NOTE :
Group 20, Drive Axle SM 715, Dec 04

Section 3
Fluid Check and Change
WARNING
Access drive axle using safe procedures in
Group SA, Safe Maintenance.
SM 715, Dec 04 Fluid Check and Change 20-3-1

Drive Axle Fluid Level Check refer to the blocking and jacking procedure
in Group SA.
Check the drive axle fluid level with:
Truck on a level surface. NOTE
Frequently replacing lubricant is an inexpen-
Oil at operating temperature.
sive way to protect and prolong the safe oper-
Remove the fluid level inspection/fill plug located in the ating life of an essential and relatively costly
front surface of each drive unit housing (two places). major component such as the drive axle.
Extending the recommended intervals at
The oil level is correct (FULL) when it is at the lower
which drive axle fluid is changed should be
edge of the inspection plug opening.
considered only after careful evaluation of
IMPORTANT your operating conditions and/or analysis of
Use only fluid Clark part no. 2776236. Do the condition of the oil.
not overfill.
Place a low, flat drain pan beneath the drive units. The
After adding oil to the drive axle, wait several min-utes pan capacity should be more than 7.6 L (16 pints)
until the oil has distributed evenly throughout the (drive axle total capacity).
unit, and check for correct oil level. Remove drain plugs (two) from bottom of drive units,
Inspect each fill plug for damage. Replace as neces-sary. and fill plugs (two) from front of drive units.
Install and tighten the plugs. While the drive units are draining, check the breather
vents (two) to be sure they are open and not dam-
NOTE aged. Vents are located in the top front corners of the
Check the planned maintenance interval drive units.
(operating hours), or the condition of the oil
After drive units have drained, install drain plugs.
to determine if the drive axle fluid needs to
be changed. Fill each drive unit to bottom edge of fill plug open-ing
with recommended fluid.
Drive Axle Fluid Change Install fill plugs.
Drain and replace the drive axle fluid every 1000 operat- Remove drain pan. Remove blocking and lower car-
ing hours. riage.
To change oil in the drive axle: Vent
The oil should be drained when it is warmed to
operating temperature.
Put the truck in a level position.
Apply the parking brake and block the wheels to
prevent the truck from moving.
Turn key switch "OFF" and disconnect battery from
truck receptacle.
NOTE
When suitable equipment is available, the Fill Plug
truck may be raised or hoisted up and placed
in a level position on wheel cradles to allow
access under the axle. Otherwise, raise and Drain Plug
block the fork carriage only high enough to Torque:
54-61 N.m
provide access clearance to the axle. Please (40-45 ft-lb)
Drive Axle (Left Housing Only)
20-3-2 Fluid Check and Change SM 715, Dec 04

Section 4
Drive Axle Removal and Installation
! Preparation
CAUTION
To perform this service procedure, it is rec- Turn key switch "OFF".
ommended that you first: Open hood.
Park truck on a hard, level surface in correct posi-tion Disconnect battery from truck receptacle.
for using an overhead hoist, if available. Remove battery from truck as described in Group 12.
Fully lower the upright.
Remove floorboard as described in Group 38.
Return all controls to neutral and turn key switch to
the "OFF" position. Remove bolts holding front battery plate and lay back
plate to improve access.
Apply the parking brake.
7. Remove the upright as described in Group 34.
SM 715, Dec 04 Drive Axle Removal and Installation 20-4-1

Removal Raise truck frame slightly off of drive axle and move the
truck backwards away from axle assembly.
After battery and upright have been removed:
CAUTION
Drain the oil from drive units when truck is in a level
position as described Section 2 of Group 20. Truck may tip sideways. You may have to
support or guide the side of the truck or
Attach a hoist with chains of correct capacity and over-head guard to prevent tipping.
remove the drive wheels as described in Group 22.
Leave chains and hoist attached. Lower front of truck frame to the floor. Truck frame may
also be blocked up under axle mounting sur-faces.
CAUTION Block the steer wheel and be sure blocking is put
Watch truck for signs of lateral instability. It safely under the frame.
may tip sideways. You may have to support
or guide the sides of the truck or overhead Attach hoist and move drive axle assembly to the
guard to prevent tipping. overhaul disassembly area. Installation Reverse the
above procedure to replace the drive axle.
Support truck with blocks under the frame as shown in Be sure to follow safe lifting and jacking proce-dures
Group SA. Place blocks of wood under drive motors given Group SA, Safe Maintenance.
to support them, if motors were not previ-ously Apply Loctite 271 to axle mounting bolts threads and
removed. properly torque axle mounting bolts.
Disconnect power cables from drive motors. Attach tags Retighten hydraulic fittings per procedure in Group
to the motor cables for easy and correct identifi- 40.
cation at assembly. Replace the nuts on motor termi-
nals to avoid losing them.
NOTE
Alternative Procedure: It is optional to
remove drive motors before removing drive
axle from truck. Refer to GROUP 16.
Release the parking brake hand

lever to provide free-play in
the brake cable for removal
of the parking brake cable
yoke. If neces-
sary, adjust the cable to
release tension as described Coat O-ring with Trans Fluid
in Group 23, Torque to 115 - 130 N/M

(85 - 96 Lbs/Ft)
Remove the yoke of parking
brake cable from the levers
on brake caliper assembly. (Group 23.)
Disconnect hydraulic brake line from master cylin-der.
Put caps on fittings to keep clean. (Group 23.)
Inspect your truck for any other wiring leads or optional
Apply Loctite 271 after cleaning
equipment that may have to be disconnected before bolt & nut threads
axle is removed. (300 - 340 Lb/Ft)
Loosen and remove axle mounting bolts (nuts under-

neath) from axle on both sides of frame.
20-4-2 Drive Axle Removal and Installation SM 715, Dec 04

Section 5
Drive Axle Overhaul
Introduction..............................................................................................................................2
Drive Unit Disassembly.......................................................................................................... 2
Ring Gear Shaft Disassembly....................................................................................................4
Input Pinion Gear Carrier Disassembly.....................................................................................6
Drive Axle Shaft Disassembly...................................................................................................8
Ring Gear Shaft Inboard Bearing Removal...............................................................................8
Cleaning and Inspection......................................................................................................... 9
Drive Unit Reassembly........................................................................................................... 10
Drive Axle Shaft Reassembly....................................................................................................10
Input Pinion Gear Carrier Reassembly......................................................................................12
Ring Gear Shaft Reassembly.....................................................................................................14
Drive Axle Reassembly............................................................................................................ 16
Spiral Bevel and Hypoid Tooth Bearing Contact Chart.......................................................17
Special Tools Fabrication ......................................................................................................18
SM 715, Dec 04 Drive Axle Overhaul 20-5-1

Introduction Drive Unit Disassembly

Refer to Figures 1A and 1B. Remove the brake caliper as shown in Group 23.
Drive unit disassembly and overhaul procedures are grouped Remove the drive motors as shown in Group 16.
according to the following major sub-assemblies:
Remove the flange bolts and separate the two drive axle
Ring gear shaft assembly, including bearing hous- housings. as shown in the Section, Drive Axle
ing, shaft, ring gear, straight and tapered roller Removal and Replacement.
bearings, bearing cap, and oil seal.
Be sure all fluid is drained from each drive unit before
Pinion assembly, including pinion gear, bearing starting disassembly.
carrier, bearings, and bearing retainer. Remove the inspection (A) cover from top of unit.
Drive axle shaft assembly, including shaft, gear, gear (Figure 1A.)
retainer, bearings, and oil seal. Remove the brake disc (C) by sliding it off the ring gear
shaft spline. (Figure 1B.)
Figure 1A. Drive Unit Sub-Assemblies
20-5-2 Drive Axle Overhaul SM 715, Dec 04

Figure 1B. Drive Unit Sub-Assemblies

Ring Gear Shaft Disassembly Loosen and remove the mounting bolts (P) and lock-
washers (O), then remove the bearing cap (AA) and
Refer to Figure 2. oil seal assembly (Q) from housing.
Loosen and remove the ring gear bearing housing Remove the bearing preload shims (Z).
mounting combination of bolts and lockwashers (L-
M). Then, remove the housing assembly (W) from Press, or pry and pull, the old oil seal (Q) from the
the drive unit main housing. bearing cap.
Bolt Torque: 54-62 N.m (40-46 ft-lb) Remove the outer bearing cup (U) if it is loose.
Remove the ring gear bearing housing (ring gear Remove the external snap ring (I) from shaft spline at end
position) shims.(K). of outer bearing cone.
It is good practice to arrange parts in the sequence of
removal as an aid to inspection and correct reassem- Remove housing assembly from the vise. Support the
ble. bearing housing and press the shaft (F) out of the
bearing cones (H, T). This can also be done by hold-
Put the housing and shaft assembly, with the ring gear ing the housing and lightly tapping the shaft end on a
(E) up, in a vise. wooden block on the bench or floor.
NOTE Remove outer bearing cup (U), if not done previ-ously.
Use blocks of wood to protect the shaft Remove bearing cones (H, T). Remove inner
spline. bearing cup (G) from housing by pressing or using a
puller.
Carefully inspect the ring gear (E) for wear and dam-
age. Also, see inspection of pinion gear. NOTE
Also remove, clean and inspect breather vent
To remove ring gear, loosen and remove the ring gear in top side of ring gear bearing housing.
fastener bolts (D).
Replace vent, as needed.
Bolt Torque: 20-27 N.m (15-20 ft-lb)
Remove the ring gear (E) from the shaft. Arrange the parts in the sequence of removal as an aid to
inspection and correct reassembly.
Remove the housing seal (J) from groove in bearing
Refer to Page 20-5-8 for ring gear shaft inboard bearing
housing pilot flange.
removal.
Turn the housing assembly over and clamp the pinion
end in the vise. Use wood blocking to protect the
pin-ion gear teeth.

Figure 2. Ring Gear Shaft Assembly

Input Pinion Gear Carrier Disassembly Remove the pinion and bearings assembly (G-H) from
the carrier housing.
Refer to Figure 3.
Clean and inspect the pinion tapered roller bearings (F, H)
Loosen and remove the five fastener bolts (M) and for wear and other damage. Replace, as neces-
lockwashers (N) from pinion bearing carrier (I). sary. Replace worn or damaged bearing cups and
Bolt Torque: 77-88 N.m (57-65 ft-lb) cones as a set.
Tap lightly on the outer flange to loosen the carrier pilot Clean and inspect the pinion (G) gear teeth and inter-
flange from main housing. nal spline for wear and other damage. Replace, as
Remove input pinion carrier assembly (C-K) and (pinion needed.
gear position) shims from the main housing. NOTE
Remove the pinion carrier seal (J). Replace ring and pinion gears as a matched
set.
Clamp carrier (I) housing flange in a vise. Loosen and
remove the recessed hexhead pinion bearing retainer Check both input pinion bearing cups (E, H) for wear,
bolts (A), and washers (B). nicks or scratches that would render them unsuitable
Remove the outer pinion bearing retainer plate (C). for further service. Replace bearing cups and cones
as a set.
Remove the pinion bearing retainer (bearing preload)
shims (D). Arrange the parts of the input pinion gear and carrier
assembly in sequence of removal as an aid to inspec-
Remove the outer pinion bearing cup (E). Tap lightly
tion and correct reassembly.
on the back side (small end) of the pinion (G) with a
hammer and punch to move the pinion and bearings
(F) outward and drive the cup (E) from carrier.

A
B
C
D
E
F
G
H
I
J
L
K
M
N
Figure 3. Input Gear Carrier Assembly

Drive Axle Shaft Disassembly Then, remove the axle shaft and outboard bearing cone
(C-D) assembly from the housing.
Refer to Figure 4.
Inspect the shaft, spline, seal surface, wheel mount-
The axle shaft output gear retainer (M) is held in place ing flange and holes, and bearing for wear and other
by three bolts (N) in the end of the axle shaft. The damage that would require repair or replacement.
bolts are held from loosening by bending a tab of the
fastener lock plate (M) against a flat of each bolt Inspect the outboard bearing cup (D) for wear and
head. Unbend the tabs for removal of the bolts by other damage, nicks, cracks, scratches, and signs of
failure from excessive heat.
working through the opening in the main housing
and using a hammer and a screwdriver or punch to Remove the axle shaft oil seal (B).
flatten the tabs. If axle shaft bearings need to be replaced, remove
Loosen and remove the three gear retainer bolts (N). the bearing cups (outer races) (C, D) by pulling them
from drive unit housing bores.
Remove the bolts (N), lock plate (M), gear retainer plate
(L), and shims (K). Then, reach inside the main Ring Gear Shaft Inboard Bearing Removal
housing and remove the drive axle shaft gear (J) by
sliding it off the spline of axle shaft (A). Lift the Refer to Figure 2.
gear out of the drive unit housing.
With axle shaft gear and input pinion carrier assem-bly
Arrange these parts in the sequence of removal as an aid removed, the ring gear shaft inboard bearing (S) is
to inspection and correct reassemble. Continue readily accessible. Remove the straight roller bear-
with disassembly and removal of drive axle shaft ing by pulling from the housing.
from the drive unit housing.
Look for nicks and scratches, pitting or any unusual
After moving the drive axle shaft outwards suffi-ciently wear pattern. Replace, as needed.
to loosen the bearing fit on shaft, remove the
Arrange the parts of the drive axle shaft assembly and
inboard bearing cone (I).
the ring gear inboard bearing for inspection.

N
M
L
K
J
I
H
G
E
D
C
B
A
Figure 4. Drive Axle Shaft Assembly
Cleaning and Inspection

Clean all parts with a good grade solvent and dry thor-
oughly. Do not let bearings spin dry if drying parts with
air pressure.
Inspect all parts for wear and other damage that could
cause malfunction or early failure:
Gears and splines
Bolts, nuts and washers
Housings and covers
Bearing cups and cones
Spacers and snaprings
Shafts and machined surfaces
Replace and seals and gaskets
Replace all parts that have failed, including those parts
that are worn or damaged in such a way that further ser-
viceability is questionable.
It is recommended that all bearings be replaced at each
overhaul.

Drive Unit Reassembly the outer end of axle shaft to prevent shaft
from slipping out of outboard bearing while
Apply very light coating of Permatex No. 2 to OD of
tapping the inboard bearing into place. Sug-
all oil seals and hole plugs before assembly.
gestion: Turn (rotate) housing up and sup-
Apply light coating of Crane Sealer to all pipe plugs.
port it temporarily on axle shaft outer end.
Use Crane Sealer on all capscrews and studs with thru
holes (housing end only). Install axle shaft inboard bearing (I) into correct
After assembly of parts using Permatex or Crane position.
Sealer, clean all surfaces. There must not be any
A special tool for pressing or driving the axle shaft
free or excess material that could enter the oil sys-
tem. inboard bearing cone into place may be fabricated as
shown by Diagram A on the last page of this Section.
All lead-in chamfers for oil seals and O-rings must Install axle shaft gear on spline of axle shaft (A).
be smooth and free from burrs. Inspect at assem-
bly. Install shims (K) against end of shaft, then gear retainer
Lubricate all O-rings with oil before assembly. plate (L), lock plate (M), and the three retainer bolts
(N). Do not bend tabs of lock plate until bearing
Apply a thin coating of grease between seal lips on preload has been checked.
lip-type seals prior to assembly.
Brush specified transmission fluid on all tapered and Torque gear retainer bolts (N) to:
44-49 N.m (32-36 ft-lb)
straight roller bearing cups and cones.
Rotate the axle shaft to check for correct axle shaft
Drive Axle Shaft Reassembly bearing preload setting. Add or remove shims (K) at
end of shaft under the axle shaft gear retainer plate to
Refer to Figure 5. obtain a bearing preload value of 0.68-1.13 N.m (6-
10 in-lb). This is the torque required to rotate the
Press new axle shaft outboard bearing cup (D) (outer race) shaft.
into housing bore tight. Install bearing cone(C). For rotating the axle shaft when checking axle shaft
Install new oil seal (B). Press seal into bore until outer bearing preload, it is recommended that a special
surface is flush with end of housing. adapter tool be constructed. This construction is
shown in Diagram B on the last page of this Section.
Install new axle shaft inboard bearing cup (H). Press
This tool is designed to fit into the wheel mounting
bearing cup into housing bore until tight and square
flange bolt holes of the axle shaft. Attach a torque
against snap ring (G). NOTE - The use of a 73 mm
wrench in the 3/8-inch square drive hole at the
OD piece of tubing or spacer ring as a driver is sug-
gested. center. Turn shaft slowly to measure torque required
to rotate the shaft.
Install the ring gear shaft inboard roller bearing (S on
Fig. 2). When the correct axle shaft bearing preload has been set,
be sure the bolts are tightened to the correct torque.
Then, put the axle shaft into the drive unit housing Then, bend the tabs of the lock plate against the bolt
end. heads.
IMPORTANT
Be very careful not to damage seal lips when
inserting shaft spline and bearing through
the seal.
Assemble the drive axle shaft inboard bearing cone

(I) on the end of axle shaft (A).
NOTE
Be sure to hold the axle shaft firmly in place
in the outboard bearing. Support (back up)

O
N
M
L
K
J
I
H
G
E
D
C
B
A
Figure 5. Drive Axle Shaft Assembly

Input Pinion Gear Carrier Reassembly When correct pinion bearing preload has been set, be sure
retainer bolts are tightened to the correct torque.
Refer to Figure 6.
Install new O-ring seal (J) in groove of carrier (I) pilot
Arrange the parts of the pinion gear bearing carrier for flange.
assembly.
Put pinion bearing carrier (pinion gear position) shims
Install the tapered roller bearing cones (F, G) on the (K) on the carrier mounting surface. For initial
pinion gear by pressing the inner races until firmly assembly, use same number of shims and washers
seated square and tight against shoulders on gear. Be as were removed at disassembly. Install several bolts
sure to use a pressing tool or tubing of the correct to align and hold shims in place.
diameter and press on inner race only to prevent
damage to the roller cages. Put the pinion gear and carrier assembly on drive unit
main housing.
Install the input pinion inner bearing cup (H) by pressing Be careful not to damage O-ring seal surface when
the cup into carrier bore tight and square against the installing carrier pilot flange into housing.
shoulder.
Install mounting bolts and washers and tighten. Bolt
Put the pinion gear and bearing assembly (F-H) into the Tightening Torque: 77-88 N.m (57-65 ft-lb)
carrier. Be sure it is seated correctly into inner
bearing cup. NOTE
After reassembly of the ring gear and shaft
Then, using a pressing tool or a piece of tubing of assembly (see following section), check the
correct diameter for cup, install outer bearing cup ring and pinion gears for tooth bearing pat-
(E) by pressing or driving on cup until seated lightly tern (correct position) and backlash. Add or
against outer bearing rollers. remove carrier mounting shims (noted
Install the input pinion bearing retainer (bearing pre-load above) as needed to adjust pinion gear posi-
adjustment) shims (D). For initial assembly, use tion. Be sure carrier mounting bolts are
same number of shims as were removed at disassem- tightened to correct torque after shim adjust-
bly. Be sure holes in shims are aligned with bolt ment.
holes in carrier.
Install the outer pinion bearing retainer plate (C).
Install and tighten the eight bearing retainer plate bolts
(A).
Bolt Tightening Torque: 7-10 N.m (5-7 ft-lb)
After assembly, turn (rotate) the input pinion gear in the
bearings to check for correct bearing preload set-
ting.
As an aid for rotating the pinion gear, a temporary
tool may be made using a discarded drive motor
shaft spline end with a nut welded to it.
Put the tool into gear spline and turn the pinion gear
slowly with a torque wrench to measure torque
required to rotate the pinion.
Add or remove shims at end of outer bearing cup
under retainer plate to obtain bearing preload value
of:
0.11-0.56 N.m (1-5 in-lb) torque required to rotate
pinion gear.
Available shim thicknesses: 0.003, 0.004, 0.007,
0.010, and 0.020 inch.

A
B
C
D
E
F
G
H
I
J
L
K
M
N
Figure 6. Input Gear Carrier Assembly

Ring Gear Shaft Reassembly Using a pressing tool or a piece of tubing of correct
diameter for cup, install the outer bearing cup (U)
Refer to Figure 7. into bearing housing (W) bore by pressing or driving
Arrange the parts of the ring gear shaft and bearing on cup until it is lightly seated against outer bearing
housing for assembly. rollers.
Install new inner tapered roller bearing cup (G) by Install new oil seal (Q) in ring gear housing bearing cap
pressing into bearing housing (W) until firmly seated (AA).
square and tight against shoulder in housing. Press oil seal (Q) flush with end surface of cap.
Apply a thin coating of grease between seal lips.
Next, install bearing cones on ring gear shaft (F) by first
placing bearing housing (W) with inner cup (G) Put at least two bolts (P) with lockwashers (O) in bearing
assembly over spline end of shaft. cap (AA). Then, install the bearing cap (bearing
preload) shims (Z) into bearing housing(W). For
Put shaft spline end through bearing housing (i.e., fit initial assembly, use same number of shims as were
housing over spline end of shaft). Press inner removed at disassembly.
bearing cone (T) tight and square against shoulder
on shaft. Press outer cone (H) tight and square Install bearing cap and shims on ring gear bearing
against inner cone. housing.
Install snap ring (I) into groove in shaft spline at end of Install and tighten all bearing cap fastener bolts (P) and
outer bearing cone. washers.
Bolt Tightening Torque: 44-49 N.m (32-36 ft-lb)
NOTE
After assembly of ring gear shaft and bearings into
Alternate procedure for installing bearing
bearing housing, and installation of bearing cap, turn
cones on ring gear shaft:
(rotate) the ring gear shaft in the bearings to check
Install inner bearing cup (G), both bearing
for correct bearing preload setting. Use a thin-wall
cones (T, H), and outer cup into bearing
housing. socket, or make an adapter tool from a discarded
Temporarily install the bearing cap (AA) to brake disc hub, to turn the shaft by the spline with a
clamp the bearings in place in housing. torque wrench.
Tighten bearing cap bolts to hold the bear- Turn the ring gear shaft slowly with a torque wrench to
ing cones tight and square.
measure torque required to rotate the shaft. Add or
Start the ring gear shaft (F) spline end into
the bearing cones (T, H) and, holding the remove shims under bearing cap to obtain bearing
bearing housing with shaft vertical, lightly preload value of
tap the pinion end of shaft on a wooden 0.11-0.56 N.m (1-5 in-lb)
block on the bench or floor until shaft is torque required to rotate shaft.
installed in bearings.
After correct bearing preload has been set, be sure
Remove bearing cap (AA).
bearing cap bolts are tightened to correct torque.
Install snap ring (I).
Then, install the ring gear bearing housing (ring gear
Turn the shaft and housing assembly over and clamp the position) shims (K) on drive unit housing (R). For
spline end of shaft in a vise. Use wood blocking in initial assembly, use same number of shims as were
vise to protect the spline. removed at disassembly.
Install new O-ring seal (J) in groove of bearing hous-ing Install ring gear shaft and bearing housing assembly into
(H) pilot flange. drive unit housing.
Install the ring gear (E) on mounting flange of shaft. Install and tighten the combination of bearing hous-ing
mounting bolts (L, M) and lockwashers. Tightening
Install and tighten the ring gear mounting bolts (D). Bolt
Torques:
Tightening Torque: 20-27 N.m (15-20 ft-lb
Bolts 44-49 N.m (32-36 ft-lb)
Remove assembly from vise and clamp in vise on
After installation of ring gear and shaft assembly, and input
housing flange. Use wood blocking to protect flange
pinion (earlier), check the ring and pinion gears for
surfaces.
tooth bearing pattern (correct position) and back-

lash. drive unit housing. Use a long adapter to reach the

Add or remove ring gear bearing housing shims (K) gear tooth surface inside the assembly. Backlash
as needed to adjust ring gear position and backlash. should be measured at three places around the ring
Be sure bearing housing mounting bolts are gear (rotate the gear).
tightened to correct torque after shim adjustment.
Check gear tooth bearing patterns by applying a coat-ing
Final adjustments in shim thicknesses under input pinion of gear checking compound, e.g., red lead, to the
carrier and ring gear bearing housing should be ring gear teeth. Rotate the ring and pinion through a
made based on measurement of gear mesh back-lash minimum of one revolution. Temporarily install the
with a dial indicator and on visual check of gear brake disc (shown on Figure 1) to provide a means
tooth bearing patterns. (Refer to Tooth Bearing Con- for loading the gear teeth.
tact Chart at the end of this Section.) Gear mounting
NOTE
information is etched on the ring gear.
Bearing Contact Chart is at the end of this
Ring and pinion backlash of Section. After above checks and adjustments
0.050-0.127 mm (0.002-0.005 inch) are made, continue with final assembly of
should be measured with a dial indicator. drive unit.
Put (set up) a dial indicator on the top surface of the
Figure 7. Ring Gear Shaft Assembly

Drive Axle Reassembly

1. Install new gasket on inspection cover with Permatex Inspection
(use Permatex to attach gasket to cover only). Cover
2. Install inspection cover to top of unit and tighten
bolts. Vent
3. Install brake disc by sliding on spline of ring gear
Unit
shaft. Apply a thin coating of grease to outside of Joining
brake disc hub before pushing through the seal. Be Bolt
careful not to damage seal lips when installing disc.
4. Install and tighten drain plug.
5. Fill drive unit with recommended fluid.
6. Install and tighten fill plug.
Tighten fill and drain plugs to:
54-61 N.m (40-45 ft-lb) torque Fill Plug
7. Connect the two (right and left hand) drive units
together to form the drive axle assembly. Install the
fastener bolts in drive unit flanges. Be sure drive
units are aligned with the top surfaces even and par- Drain Plug
allel with each other. Locate on the top surfaces
while tightening the flange bolts. Hold top surfaces Drive Axle (Left Housing Only)
within 1.02 mm (0.04 inch) before torquing bolts of
two units together.
Bolt Tightening Torque:
200-217 N.m (148-160 ft-lb)

Spiral Bevel and Hypoid Tooth Bearing Contact Chart
ALL CONTACT BEARINGS SHOWN BELOW ARE ON RIGHT HAND SPIRAL RING GEAR.
THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH.
TYPICAL PREFERRED BEARING ON BOTH SIDES OF

TOOTH WHILE UNDER A LIGHT LOAD
TOE BEARING ON BOTH SIDES OF TOOTH.GEAR SET

NOISY. TO MOVE BEARING TOWARD HEEL INCREASE
BACKLASH WITHIN LIMITS BY MOVING GEAR AWAY
FROM PINION.
HEEL BEARING ON BOTH SIDES OF TOOTH.GEARSET

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

CORRECT BY PULLING PINION AWAY FROM GEAR
(INCREASE MOUNTING DISTANCE).
HIGH BEARING ON GEAR AND LOW BEARING ON PINION.

CORRECT BY MOVING PINION IN TOWARD GEAR
(DECREASE MOUNTING DISTANCE).
BACKLASH SHOULD BE MEASURED WITH A DIAL INDI CATOR RIGIDLY MOUNTED WITH THE STEM
PERPENDICULAR TO THE TOOTH SURFACE AT THE EXTREME HEEL.

Special Tools Fabrication
23 mm
(0.905 in)
50-60 mm
(2.205-2.362 in)
25 mm
(0.984 in)
45 mm 5 mm
(1.77 in) (0.197 in)
Digram A. Axle Shaft Inboard Bearing Cone Driver. Construct as indicated.
Dia 12 mm (0.50) 130 mm (5.118 in)
35 mm (1.378 in)
5 mm 9.6 mm (0.377 in)
(0.196 in)
9.6 mm
(0.377 in)
25 mm (1.00 in)
76 mm (3.00 in)
152 mm (6.00 in)
Digram B. Adapter Tool for for Checking Axle Shaft Bearing Preload. Construct as indicated.

GROUP 22 WHEELS AND TIRES
GROUP 22
WHEELS AND TIRES
Wheels and Tires Specifications and Description ........ Section 1
Wheels and Tires Mounting and Maintenance .............. Section 2
SM 715, Dec 04 Group 22 WHEELS AND TIRES,

NOTE :
Group 22 WHEELS AND TIRES, SM 715, Dec 04

Group 22, Wheels and Tires
Section 1
Wheels and Tires

Specifications and Description
Cushion tires are mounted on one-piece rims. A general
Cushion description of cushion tire removal and replacement
appears in the section for cushion tires. However only
Material: Rubber except as noted. trained and experienced personnel with the proper equip-
Size: ment should attempt to change out cushion tires on the
rims. Pneumatic tires are mounted on multi-piece rims
Drive Steer
with locking rings.
TMX 12/15/15S: 18x7x12. 12 18x7x12 .12
TMX 17/20 18x8x12 .12 18x7x12 .12 WARNING
TMX 25 18x9x12 .12 18x6x12.12 (Urethane) For your safety and the safety of others,
before you do tire or rim maintenance or ser-
Mounting Nut Torques: Refter to mounting procedure in vice, read the OSHA rules regarding owner
Section 2. responsibility. Do not work on tires or rims
unless you have been trained in the correct
Pneumatic procedures. Read and understand all mainte-
nance and repair procedures on tires and
Material: Rubber rims. Serious injury or death can result if
safety messages are ignored.
Size:
Drive Steer The Occupational Safety and Health Act (OSHA) speci-
TMX 12/15 18x7x8-16PR 18x7x8-16PR fies required procedures for servicing multi-piece rim
wheels in 29 CFR Section 1910.177. It is the owners
TMX 15S 18x7x8-16PR - responsibility to comply with OSHA.
TMX 17/20 18x9x8-16PR -
In accordance with OSHA, the owner must provide a
EPX16/18 21x8x9-14PR 5.00x8-10PR
training program to train and instruct all employees who
Tire Inflation Pressure: service multi-piece rim wheels in the hazards involved
and the safety procedures to be followed. Do not let any-
Drive Steer one mount, demount, or service multi-piece rim wheels
TMX 12-25 1000 kPa (145 psi) 1000 kPa (145 psi) without correct training.
EPX16/18 1000 kPa (145 psi) 883 kPa (128 psi) The owner should obtain and maintain in the service area
current copies of the United States Department of Trans-
Mounting Nut Torques: Refter to mounting procedure in
Section 3. portation, National Highway Traffic Safety Administra-
tion publications entitled Safety Precautions for
Mounting and Demounting Tube-Type Truck/Bus
Service Intervals Tires,and Multi-Piece Rim/Wheel Matching Chart or
Wheel Mounting Bolts Check and Tightening: Every 50- other similar publications applicable to the types of multi-
250 hours of operation and each PM. piece rim wheels being serviced.
Tire Condition: Daily inspection.

Tire Pressure Check: Daily inspection.
SM 715, Jun 05 Wheels and Tires Specifications and Description 22-1-1

NOTE :
Group 22, Wheels and Tires SM 715, Dec 04

Section 2
Wheels and Tires Mounting and Maintenance
4Drive and Steer Wheels Removal and Installation.......................................................2

Cushion Tire Replacement.............................................................................................2
Pneumatic Tire Maintenance..........................................................................................3
Precautions.....................................................................................................................3
Maintenance, Inspection, and Repair..............................................................................4
Inspection and Minor Repair..........................................................................................4
Wheel Disassembly and Tire Removal..........................................................................5
Mounting of Directional Tread Tire...............................................................................7
Directional-Tread Single Drive Tires.............................................................................7
Directional-Tread Dual Tires..........................................................................................7
Filling Tires with Air......................................................................................................8
Filling Tires with Nitrogen.............................................................................................8
Checking and Adjusting Tire Pressure............................................................................9
SM 715, Dec 04 Wheels and Tires Mounting and Maintenance 22-2-1

Drive and Steer Wheels Removal and

Installation
Removal
Loosen lug nuts then use a portable jack of correct
capacity placed under the frame of truck to raise
drive wheel off floor. See Lifting, Jacking, and
Blocking in Group SA for correct, safe procedures
EPX Steer Axle
for jacking the truck. Hub
Remove lug nuts and lift the tire and wheel assembly
from drive axle hub.
Installation TMX Steer Axle

Hub
Install wheel and tire assembly on drive axle hub. Begin
tightening the lug nuts to seat the nuts in the beveled
wheel openings.
Use a crisscrossing nut-tightening sequence to pre-
torque the lug nuts 54-81 N.m (40-60 ft-lb).
Cushion Tire Replacement
CAUTION
Replacement of the original equipment tires
with tires other than those recommended by
CLARK may result in decreased operating
performance and stability.
The correct procedure for tire removal and replace-ment

requires a suitable press for pressing old tire off
wheel and pressing new tire onto wheel.
Begin the crisscrossing sequence again and torque the
lug nuts to 255-275 N.m (188-203 ft-lb). IMPORTANT
Cushion tires cannot be reused after once
IMPORTANT being pressed on and removed from the
Do not over-torque the lug nuts. Damage to wheel. The correct press fit is destroyed after
the lug nuts, wheel, or drive-axle hub may one installation and removal. Replace with
result. new tire.
4. Lower truck to floor and remove jack. Position tire on press, making sure there is adequate
clearance for the tire to be pressed off of wheel.
Use suitable tooling with the hydraulic press to cor-
rectly contact the base band of tire to press it off the
wheel.
Drive Axle Install new tire. Mount all tires with identification and
Hub type markings toward outside of wheel. Tire is to be
pressed on wheel with the outer edges flush.
22-2-2 Wheels and Tires Mounting and Maintenance SM 715, Jun 05

Pneumatic Tire Maintenance Never attempt to weld on an inflated tire/rim assem-bly.

Clean rims and repaint to stop detrimental effects of
corrosion. Be very careful to clean all dirt and rust
Precautions from the lock ring gutter. This is important to secure
The following instructions supplement the OSHA require- the lock ring in its proper position.
A filter on the air filling equipment to remove the
ments. In the event of any conflict or inconsistency between
moisture from the air line prevents a lot of corrosion.
these instructions and the OSHA requirements, the OSHA The filter should be checked periodically to make
requirements shall be controlling. sure it is working properly.
WARNING Make sure correct parts are being assembled. Ask your
distributor or the manufacturer if you have any
Before you do tire or rim maintenance, read
doubts.
the OSHA rules regarding owner
responsibil-ity. Read and understand all Do not be careless or take chances. If you are not sure
maintenance and repair procedures on tires about the proper mating of rim and wheel parts,
and rims. Do not work on tires or rims unless consult a wheel and rim expert. This may be the tire
man who is servicing your fleet, the rim and wheel
you have been trained in the correct
distributor in your area, or the CLARK dealer.
procedures. Seri-ous injury or death can
result if the safety messages are ignored. Mixing parts of one manufacturers rims with those of
another is potentially dangerous. Always ask man-
Do not let anyone mount or demount tires without ufacturer for approval.
proper training. Do not use undersized rims. Use the right rims for the
Never sit on or stand in front of a tire and rim assem-bly job.
that is being filled with air. Use a clip-on chuck and Do not overload rims. Ask your rim manufacturer if
make sure the hose is long enough to permit the special operating conditions are required.
person filling the tire with air to stand to the side of
the tire, not in front or in back of the tire assembly. Do not seat rings by hitting with a hammer while the tire
is filled with air pressure. Do not hit a filled or
Never operate a vehicle on only one tire of a dual partially-filled tire/rim assembly with a hammer.
assembly. The carrying capacity of the single tire
and rim is dangerously exceeded, and operating a Double check to make sure all the components are
vehicle in this manner can result in damage to the properly seated prior to filling tire with air.
rim and truck tip-over and driver injury. Have the tire in a safety cage when filling with air.
Do not fill a tire with air that has been run flat with-out When removing wheels, regardless of how hard or firm
first inspecting the tire, rim, and wheel assembly. the ground appears, put hardwood blocks under the
Double check the lock ring for damage. Make sure jack.
that it is secure in the gutter before filling the tire
with air. Block the tire and wheel on the other side of the vehi-cle,
before you place the jack in position. Place blocks
Always remove all air from a single tire and from both under the truck frame as near as possible to the jack
tires of a dual assembly prior to removing any rim to prevent the truck from falling if the jack should
components, or any wheel components, such as nuts fail.
and rim clamps. Always remove the valve core to
remove air from tire. Be sure all air is removed. Remove the bead seat band slowly to prevent it from
dropping off and crushing your toes. Support the
Check rim components periodically for fatigue cracks. band on your thigh and roll it slowly to the ground.
Replace all cracked, badly worn, damaged, and This will protect your back and feet.
severely rusted components.
Bead breakers and rams apply pressure to bead flanges.
Do not, under any circumstances, attempt to rework, Keep your fingers away from the bead flanges. Slant
weld, heat, or braze any rim components that are bead breaker about 10 to keep it firmly in place. If
cracked, broken, or damaged. Replace with new it slips off, it can fly with enough force to kill.
parts or parts that are not damaged, which are of the Always stand to one side when you apply hydraulic
same size, type, and make. pressure.

Maintenance, Inspection, and Repair Check all wheel lug nuts or bolts to be sure none are
loose or missing. Have missing bolts replaced and loose
Park the truck as described in Safe Parking and check
bolts tightened to the correct torque before operating the
for correct tire inflation air pressure.
truck.
Drive Tire : 1000 kPa (145 psi)-TMX, 1000
kPa (145 psi)-EPX
Steer Tire :1000 kPa (145 psi ).-TMX, 883 Inspection and Minor Repair
kPa (128 psi).-EPX
Inspect pneumatic tires and wheels carefully for:
CAUTION Low inflation pressure.
Check tire pressure from a position facing
the tread of the tire, not the side. Use a long- Damaged tires. Check tires for cuts and breaks.
handled gauge to keep your body away from Damaged wheels or loosening of the lock ring on multi-
the side. piece rims.
Wheel
Wedge
Lock
Ring
If tires are low, do not add air. Have the tire and wheel
inspected by a person trained and authorized to do
tire and wheel maintenance. The tire may require Check for loose nuts or bolts not in position.
removal and repair. Check the nuts or bolts for damage.
Incorrect (low) tire pressure can reduce the stabil-ity
of a lift truck and cause it to tip over. Check the surface of the wheels for bent flanges.
IMPORTANT Check all parts for rust or corrosion.

Check wheels and tires for damage every Mark the damaged areas with chalk so that the parts can
time you check tire pressure. Make repairs be removed from operation.
when needed. Dirt can get into cuts and
cause damage to the tire cord and tread. Remove all parts that are damaged and install new parts
Remove debris from all cuts. in the same position.
Check the condition of the drive and steer wheels and tires.
Replace parts with the correct sizes and types. See your
parts manual.
Remove objects that are imbedded in the tread. Inspect
the tires for excessive wear, cuts and breaks. Include your truck serial number when ordering
replacement parts.
22-2-4 Wheels and Tires Mounting and Maintenance SM 715, Jun 05

6. Repair tire and/or tube, as needed.

. 7. Check for cracks in the wheel.
Wheel Disassembly and Tire Removal

Remove valve core from the valve stem to be sure all air
is removed.
WARNING
Before starting disassembly, remove the air
from the tire. Failure to remove the air from
the tire can result in serious injury.
Cracks in the wheel are caused by:
2. Remove lock ring.
Deep rim tool marks.
Lock Ring Overload on wheels.
Too much air pressure in the tires.
Wheel Using the wrong size tires.
Wedge
Check for cracks in the lock ring.
Check for cracks between the stud holes in the wheel.
Cracks are caused by:
Loose wheel nuts.
Wheel not installed correctly.
Remove wheel wedge. Wrong size or type of parts used.
Remove tire from wheel. Too much torque on the wheel fasteners. If the wheel
mounting parts are too tight, the studs or bolts can
break, causing cracks in the wheel between the
stud holes.
Too little torque on the wheel fasteners. If the wheel
mounting parts are too loose, damage to parts and
tire wear will result.
Check wedge ring for wear or damage. Corrosion buildup
will cause wear and damage to the wheel wedge
ring.
Clean the wheels. Remove rust and dirt.
5. Remove the rubber inner tube protector (flap).
Clean the tire bead seat area. Remove all rust and rubber
with a wire brush or wheel.

Clean wedge and lock rings. Make sure the seating Install the tire onto the wheel rim, against the bead seat
surface and bead seat areas are clean. area.
4. Put the wheel wedge over the rim.

Apply paint to the tire rim with a brush. Or, use an
aerosol can of metal primer.
The parts must be clean and dry before you apply
the paint. Make sure to apply paint to the outside or
tire side of the rim. This is important because air is
on the metal surface of the tire side of the rim.
Apply lubricant on the tire side of the rim base. Do not
use a lubricant that has water or solvent which will
cause damage to the rubber. 5. Install the wheel wedge.
NOTE
Clark dealers can supply the correct lubri-
cant, which contains a rust inhibitor. Tire
Replacement and Wheel Reassembly
1. Put the tube into the tire.
Put the side ring over the rim and install the lock ring as
shown.
IMPORTANT
Install washer 22.123 on tube over valve stem
before flap is installed, when specified. See
sketch. Refer to Service Parts List.
Wheel Washer
Tube
2. Put the rubber tube protector (flap) over the tube.
22-2-6 Wheels and Tires Mounting and Maintenance SM 715, Dec 04

Connect air chuck and turn the tire over with the valve Mounting of Directional Tread Tire
stem down. Put 21 kPa (3 psi) of air into the tire.
All directional-tread tires are to be mounted in the correct
position with respect to the arrow cast on the side of the
tire as explained below.
Turn wheel to the other side. Check to make sure lock

ring is in correct location.
Directional-Tread Single Drive Tires

. Tire arrow to point in the direction of forward rotation.
Rotate wheel to bring arrow on tire above the wheel cen-
ter. Arrow must point toward front of truck.
Disconnect the air chuck. Use a mallet and hit the ring to
make sure the ring is fully installed. Inside
Front of truck
Directional-Tread Dual Tires

Inside dual tire arrow to point in the direction of for-
ward rotation. Rotate wheel to bring arrow on tire
above the wheel center. Arrow must point toward
10. Put the tire in an OSHA-approved safety cage. front of truck.
Inside
Front of truck
Outside dual tire arrow to point in the direction of

rearward rotation. Rotate wheel to bring arrow on
tire above the wheel center. Arrow should point
toward rear of truck.

Filling Tires with Air This will adjust the regulator pressure to a low pres-
sure near zero.
Follow these procedures when putting air into tires. All
wheel and tire assemblies must be filled in a safety cage.
The hose must have an adapter that can be connected to
the valve stem.
Attach an air hose to valve stem.
Open the control valve which will let compressed air
into the tire.
At intervals, close the control valve and check the
pressure in the tire by reading the gauge. Do not put
too much pressure into the tire.
Slowly turn the cylinder valve counterclockwise (CCW)
Continue to fill the tire to the correct air pressure. See to open position.
the Operators Manual for correct tire inflation pres-
sure.
IMPORTANT
Put equal pressure in both tires of a dual
assembly. Do not put air into a tire that is
flat without first inspecting it and the wheel
for damage.
Filling Tires with Nitrogen 4. The tank gauge will now show tank pressure.
If your air supply does not have enough pressure to fill
the tire, you can use a pressurized cylinder of commercial
nitrogen gas to get the correct tire pressure. With the tire
in a safety cage, connect the nitrogen cylinder to the
valve stem with the use of an air chuck.
WARNING
Use nitrogen only. Do not use oxygen or any
other gas to fill tires. Make sure all items of
equipment used (nitrogen cylinder, regulator,
Turn the regulator valve clockwise (CW) until the
gauges, hoses) are UL approved and in good
regulator gauge reads the correct tire pressure. Fill
condition. Use the correct regulator and hose
the tire with nitrogen.
for the pressures that are necessary.
Be sure tank valve is closed to connect hose to valve

stem. Tank valve is closed by turning handle on top
of tank clockwise to a stop.
Turn the regulator valve counterclockwise (CCW) until
you can feel no resistance from the regulator.
22-2-8 Wheels and Tires Mounting and Maintenance SM 715, Dec 04

Turn the tank valve clockwise (CW) and close the valve. Checking and Adjusting Tire Pressure
WARNING
Before you add air pressure to the tire, make
sure the lock ring is correctly positioned in
the rim and wheel wedge. The lock ring can
separate from the rim with enough force to
cause injury or death.
7. Disconnect the air chuck from the valve stem.
Attach a clip-on air chuck to valve stem. Stand by the

side of the wheel and put the correct air pressure in
the tire.
Turn the regulator valve counterclockwise (CCW) to the

off position.
If your air supply does not have enough pressure to fill

the tire, you can use a nitrogen cylinder to get the
correct pressure.
Use a tire pressure gauge to check the tire pressure. If

necessary, put more air into the tire. Do this as many
times as necessary to reach the correct tire pressure.
CAUTION Put a clip-on type air chuck on the nitrogen cylinder

Use a long-handled gauge so that your hand hose and attach it to the valve stem. Follow the pro-
does not go inside the cage, or in front of any cedures described previously for adjustment of the
component of a multi-piece wheel. nitrogen cylinder valves.
WARNING
Use nitrogen only. Do not use oxygen or any
other gas to fill tires.

NOTE :
Group 22, Wheels and Tires SM 715, Dec 04

GROUP 23 BRAKES
GROUP 23
BRAKES
Brake Specifications and Description ............................ Section 1
Brake System Fluid Check, Fill, and Bleed .................... Section 2
Brake Pedal and Master Cylinder Removal, Replacement, and

Adjustment ....................................................................... Section 3
Brake Caliper Removal and Replacement ...................... Section 4
Parking Brake Removal, Replacement, and

Adjustment ........................................................................ Section 5
Brake Overhaul ................................................................. Section 6
SM 715, Dec 04 Group 23 BRAKES,

NOTE :
Group 23 BRAKES, SM 715, Dec 04

Group 23, Brakes
Section 1
Brake Specifications and Description
Specifications Service Requirements

Service Brake: Operational checks and inspection of linkages, brake
pads, and brake lines are specified in the Periodic Service
Type: Caliper.
Chart in Group PS.
Minimum lining/pad thickness: 0.67 mm (0.06 in).
Service brake linkage adjustment and lube are not nor-
Fluid Type: SAEJ1703 (DOT-3) brake fluid only. mally required.
Fluid Capacity: 0.256 L (0.06 gal). Brake pads are self-adjusting.
Pedal Freeplay: 1-3 mm (0.039-0.118 in; measured at stop A leaking caliper or master cylinder should be overhauled
screw). or replaced.
Parking Brake: Parking brake should be adjusted if indicated by opera-
tional check.
TMX Type: Lever-type mechanically linked to brake
assembly. The following sections in this Group provide service pro-
cedures for the service and parking brake assemblies.
EPX16/18 Type: Foot-type mechanically linked to brake
assembly.
Holding Test: Rated load on 15% grade.
Description
(See illustration on the next page.)
The service brake pedal operates a master cylinder
mounted on the front cowl.
The master cylinder operates a caliper assembly centrally
mounted on the two drive axle housings.
When the caliper assembly is activated, its pads grip the
brake discs mounted on the inboard end of each drive
axle pinion shaft. Friction betwen the pads and disks
slows or stops rotation of the drive axle.
There is no power assist for the service brake.
The parking brake handle operates a ratchet and cable that
closes or releases the caliper assembly.
See Group 20,Drive Axle, for more detail.
SM 715, Jun 05 Brake Specifications and Description 23-1-1

Group 23, Brakes
TMX Parking Brake and Linkage to Brake Caliper TMX Reservoir, Pedal, Master Cylinder and Linkage
Brake Caliper and Brake Lines

Installation to Drive Axle
23-1-2 Brake Specifications and Description SM 715, Jun 05

Group 23, Brakes
EPX Reservoir, Pedal, Master Cylinder and Linkage

EPX Parking Brake and Linkage to Brake Caliper
SM 715, Jun 05 Brake Specifications and Description 23-1-3

NOTE :
Group 23, Brakes SM 715, Dec 04

Group 23, Brakes
Section 2
Fluid Check, Fill, and Bleed
Check and Fill Proceed as follows:
Inspect brake fluid level in reservoir through window in Park truck on level floor. Put direction control in neu-
left cowl cover. A flashlight may be needed. tral. Lower forks to floor, tilt forward, and apply
parking brake.
If fluid level is below full mark, remove cowl cover as
described in Group 38 and fill reservoir to full mark with Attach a clear hose to a bleed screw on the brake cal-
DOT 3 fluid. iper. Place the other end of the hose in a vessel con-
taining fluid.
Fill the brake fluid reservoir.
Open the bleed screw.
Pump the brake pedal until the fluid flowing from the
hose is free of bubbles.
Reservoir
Window
Bleeding
Continue pumping the brakes and tighten the bleed
Bleed brakes when: screw.
The brake pedal feels spongy or low. Repeat for the other caliper bleed screw.
The master cylinder, caliper, or brake lines have been Operate the brake pedal at various rates. If the pedal
leaking, repaired, or replaced. feels spongy or low, bleed the lines again.
Troubleshooting indicates that air has been intro- Refill the reservoir to the full mark.
duced into the system.
NOTE Bleed Screw
Make sure that brake pedal freeplay Clear Bleeder
is correctly set before bleeding the Hose
brakes.
Bleed Screw
SM 715, Dec 04 Fluid Check, Fill, and Bleed 23-2-1

NOTE :

Group 23, Brakes
Section 3
Pedal and Master Cylinder

Removal, Replacement, and Adjustment
Components Disassembly Pedal Height Adjustment(EPX)

Use Figures 1, 2, and 3 as guide to disassembly and See Figure 2. The brake pedal must be at the same height
adjustment. as the inching pedal. To adjust brake pedal height :
Loose the pedal stop bolt of brake and adjust pedal
Components Reassembly height to be 125 5mm from floow plate.
Replace the brake pedal components as shown in Figures Loose the pedal stop bolt of inching and adjust pedal
1 and 2 using fastener torques where shown. Also use the height to be 1255mm.
following notes: Torque the stop bolt and nut 20-25 Nm(14-18 ftlb).
Clean the reservoir and master cylinder hoses and fit-
tings. Make sure no contaminants enter the braking Freeplay Adjustment(EPX)
system.
When the brake pedal linkage is properly adjusted, brak-ing
Adjust pedal free play and micro-switch as described in
should begin only after the pedal is depressed a certain
Pedal Adjustmenton this page.
distance, This is Freeplay is Adjusted as follows :
After re-assembly and adjustment, the brake system
Loosen the jam nut on the rod brake master cylinder
must be bled; see Section 2 in this Group. After
(Figure 2).
bleeding, check all fluid connections for leaks and
test brakes completely before returning truck to ser- Depress the brake pedal 4~6mm (0.16~0.24 in).
vice.
Adjust the rod until you feel the push rod make clear-
Note orientation of pedal spring. Upper (shorter) end ance with the cylinder piston.
catches in cowl bracket. Lower (longer) end catches
on pin in link.
Pedal Adjustment(TMX)
With all components replaced and fasteners tightened to
correct torque, adjust the pedal as follows:
Adjust pedal stop screw (item F) to provide 1-3 mm
(0.04-0.12 in) of free play.
When free play is adjusted, tighten the jam nut on the
stop screw to set the distance.
Adjust micro-switch to activate just before end of pedal
free play. See Group 13 for brake switch check and
adjustments.
SM 715, Jun 05 Pedal and Master Cylinder Removal, Replacement, and Adjustment 23-3-1
Group 23, Brakes
Torque:
20-25 N.m
(177-221 in-lb)
A Hose to Master Cylinder

B Reservoir
C Brackets Welded to Cowl
D Pedal
E Pedal Spring
F Stop Screw
G Pedal Link
H Master Cylinder Link
I Master Cylinder
J Fitting to Brake Caliper Line
Torque:
40-45 N.m
(30-33 ft-lb)
Torque:
8-10 N.m
(71-88 in-lb)
Torque:
20-25 N.m
(177-221 in-lb)
(4 fasteners)
Figure 1. Reservoir, Pedal, Linkage, and Master Cylinder Assembly.(TMX Truck)
23-3-2 Pedal and Master Cylinder Removal, Replacement, and Adjustment SM 715, Jun 05
Group 23, Brakes
A Hose to Master Cylinder

B Reservoir
C Pedal
D Pedal Spring
E Stop Screw
F Master Cylinder
(To Brake Tee)
Figure 2. Reservoir, Pedal, Linkage, and Master Cylinder Assembly.(EPX Truck)
SM 715, Jun 05 Pedal and Master Cylinder Removal, Replacement, and Adjustment 23-3-3
NOTE :

Group 23, Brakes
Section 4
Brake Caliper Removal and
Replacement
Introduction Brake Replacement.

Figures 1 and 2 show: To replace rotors:
Coat splines of brake rotor with an anti-seize
The brake mounting on the drive axle.
compound before installing in truck.
The connections from the master cylinder to the Grasp rotor around the outer edge and line up with
brake. the spline.
The illustrations and accompanying text serve as a guide Push rotor onto splined shaft until it is fully engaged.
to removal and replacement. Repeat for opposite rotor. Both rotors should be free
Before beginning this service procedure: to float on the splines.
Park the truck on a level surface and lower the upright Replace brake as shown in Figure 1:
completely. Mount brake over disk.
Set mounting bolts in place and torque to 0.5-2 N.m
Raise and block the upright for better access as
(0.4-1.5 ft-lb).
described in Group SA.
Replace tube assemblies at the compression fit-tings.
Return all controls to neutral and turn key switch to Do not overtighten.
OFF position. Press brake pedal to align brake and disk.
Block the wheels. Torque mounting bolts to 60-65 N.m (44-48 ftlb).
See Section 3 for procedures to remove brake pedal and
Replace rear cover. Torque top bolts to 60-65 N.m (44-
master cylinder. See Section 6 for brake overhaul proce-
48 ft-lb); torque bottom nut to 170-190 N.m (125-
dures.
140 ft-lb).
IMPORTANT
Brake Removal
Both sides of brake must be checked and
Disconnect tube assemblies from brake at the com- fully refilled with proper lubricant. See
pression fittings shown in Figure 2. Move tubing out brake bleeding Section in this Group.
of
the way; disconnect from the tee if necessary.
Remove the cotter pin from the parking brake caliper
clevis (see Section 5).
Remove bolts and washers from brake mounting bracket.
Lift the caliper assembly from the transaxle.
To remove the brake rotors:
Slide the left-side rotor off of the splined shaft and
lift out.
Repeat for opposite rotor.
Inspect axle seals per procedures in Group Tran-
saxle. Replace if worn, leaking, or damaged.
SM 715, Dec 04 Brake Caliper Removal and Replacement 23-4-1

Group 23, Brakes
Torque:
60-65 N.m
Caliper Assembly
(44-48 ft-lb)
Front Cover
Figure 1. Brake Mounting
Brake
Disks
Drive Axle
Torque: Assembly
170-190 N.m
(125-140 ft-lb)
Tube
Assembly
Compression
Fitting
Figure 2. Brake Tubing Connections
Brake Rotors
23-4-2 Brake Caliper Removal and Replacement SM 715, Dec 04

Group 23, Brakes
Section 5
Parking Brake Removal, Replacement, and Adjustment
Removal and Replacement(TMX) Set brake handle to Off (down) position.
Remove and replace parking brake components as shown Tighten adjustment set nut until all clearance between
in the illustration. pads and disks is removed.
Loosen set nut 1/2 turn. This allows approximately 1
Adjustment(TMX) mm (0.03 in) gap between brake and pad.
Tighten jam nut.
Parking brake must be adjusted after removal and
replace-ment and at every PM. Adjust parking brake by tightening or loosening the
operators adjustor in the brake handle so that the
Install parking brake assembly and adjust cable so that
truck holds on 15% grade.
caliper lever is horizontal.
See Group 13 for parking brake switch check and
adjustment.
Hand Lever
Assembly Torque:
240-300 N.m
(177-221 ft-lb)
Parking Brake
Switch
Torque:
30-32 N.m
(22-26 ft-lb)
Caliper
Lever
Set Nut
Jam Nut
SM 715, Dec 04 Parking Brake Removal, Replacement, and Adjustment 23-5-1

Group 23, Brakes
Adjustment(EPX15-18) Adjust position of interlock and indicator switches

with pedal upstop against tab on bracket. Switch
With the pedal fully raised, upstop against tab on contacts should snap from their operated contact
bracket, adjust slack out of brake cables and tighten position to their normal position when pedal is
adjusting/locking nuts. depressed one ratchet click.
Actuate and release pedal six to eight times. Torque switch mounting nuts 0.8-1.0 Nm (7-9
lbfin). Torque bracket mounting nuts 40-45
Readjust and tighten nuts.
Nm (30-33 lbfft).
Apply a thin coat of Clark lubricant, part #1802155, to
Removal and Replacement(EPX15-18) ratchet teeth and ball end of wire rope prior to
assembly.
As shown in illustration below, with these notes:
Remove return spring for better access to bracket
mounting nuts.
Release handle
Foot pedal Upstop Ratchet
Switch
Parking Cable Return spring Switch mounting plate
Set Nut
Jam Nut
23-5-2 Parking Brake Removal, Replacement, and Adjustment SM 715, Jun 05

Group 23, Brakes
Section 6
Brake Overhaul
IMPORTANT
Brake carrier and lining assemblies must be
replaced when lining material is less than 0
.67mm (0.060 in).
Use the Disassembly and Assembly procedures to over-

haul the brake. Replace components using the correct
rebuild kit. Brake valves are not serviceable. See Group
Sections for procedures to remove, replace, adjust, and
bleed brake and components.
SM 715, Dec 04 Brake Overhaul 23-6-1

Group 23, Brakes
Disassembly Assembly
Carrier and Lining Removal Caliper Assembly
Remove parking brake jam and adjustment nuts from the Slide the brake valves in place on the brake shoe piv-ots.
adjustment bolt and washer.
Set the mounting brackets in position and install pivot
Remove the parking brake lever arm with adjustment retainer nuts; torque 115-129 N.m (85-95 ft-lb).
bolt and washer.
Remove the pad retainer nut from the sleeve and repeat Carrier and Lining Assembly
for opposite side.
Insert the outer carrier and lining assembly between the
Push brake sleeves into bushings and remove carrier and brake shoe pivots. Position the carrier against brake
lining assemblies. valve.
NOTE
Caliper Disassembly Apply a thin coat of an anti-seize compound
Remove the nuts securing the brake valves and brake to the brake sleeves before installing to car-
shoe pivots in the mounting brackets. rier and liner assemblies.
Pull the mounting brackets apart from the brake valves Install the sleeves through valve bushings and insert
and brake shoe pivots. threaded end of sleeves through the outer carrier and
lining assembly.
Parts Inspection Install pad retainer nuts to sleeves; torque 75-85 N.m
(101-115 ft-lb).
Brake carrier and lining assemblies must be replaced
when lining material is less than 0 .67mm (0.060 in). Install spacer plate between two carrier and lining
assemblies and in the center groove of the actuating
All parts must be clean and free of dust and chips before
pins.
assembly. Thoroughly clean all drilled passages, seal
grooves, and threads in the brake valves. If parts are dam- Install the inner carrier and liner assembly between the
aged or worn, replace the brake valve. outer carrier and lining assembly and the center
spacer plate.
Clean brake valves with solvent:
Check all cylinder bores for nicks, scratches, or NOTE
corrosion and blend with crocus cloth. Apply a thin coat of an anti-seize compound
Check all fluid passages and grooves and clean to the actuator pins before installing to brake
remaining dirt and fluid completely out. valves.
Inspect piston assemblies for scratches and nicks and
blend with a crocus cloth. Replace the valve if piston Install two actuator pins into brake valve on side of
is badly scratched. parking brake lever arm.
Check actuating pins for grooves. Pins with light Install adjustment bolt and washer with parking brake
grooves may be rotated so grooved portion is oppo- lever arm through brake sleeves, spacers, and carrier
site the end of the carrier and lining assemblies. and lining assemblies.
Replace deeply grooved actuating pins. Install parking brake adjustment and jam nuts, do not
Bushings should be flush with inside machined sur-face torque. See Section 5 for parking brake adjustment.
of the valve. Press bushings flush if necessary. If removed, install bleeder screws to valves (torque 4.5-11
N.m [3.3-8.3 ft-lb]). See Section 4 for procedures to
Lubricate piston seals lightly with automotive brake replace and adjust the brake.
fluid or silicon grease compatible with brake fluid.
Do not use petroleum-based oils or lubricants.
23-6-2 Brake Overhaul SM 715, Dec 04

Group 23, Brakes
Bushing
.
Pad Retainer Nut; torque 75-85 N m
(101-115 ft-lb) Bleeder Screw; torque
.
4.5-11 N m (3.3-8.3 ft-lb)
Parking Brake Adjustment and Jam Nuts
. Actuating Pin
(Jam nut torque; 31-37 N m [25-28 ft-lb])
Pivot Retainer Nut; torque 115-

. Sleeve
129 N m (85-95 ft-lb)
Spacer Fastener
Brake Carrier and

Valve Lining Operating
Assembly Cam
LH Mounting Brake
Bracket Valve
Brake Shoe Parking
Pivot
Piston RH Mounting Brake Lever
Assembly Bracket Arm
Adjustment Bolt and
Washer
SM 715, Dec 04 Brake Overhaul 23-6-3

NOTE :

GROUP 25/26 STEERING
GROUP 25/26
STEERING
Steering System Specifications

and Description. ................................................................ Section 1
Steering System Troubleshooting .................................. Section 2
Steering Column and Component
Removal and Replacement ............................................. Section 3

Steering System Relief Pressure Check
and Adjustment ................................................................ Section 4

Steering Gear Overhaul(TMX) ......................................... Section 5
Steer Axle Service (TMX) ................................................. Section 6
Steer Cylinder Overhaul (TMX) ....................................... Section 7
Steering Axle Wheel Bearing Maintenance
and Adjustment (EPX) .............................................. Section 8

Steering Axle Removal and Replacement (EPX) ............ Section 9
Steer Cylinder Removal and Replacement (EPX) ....... Section 10
Steering Gear Overhaul(EPX) ....................................... Section 11
Steer Cylinder Overhaul (EPX) ...................................... Section 12
SM 715, Jun 05 Group 25/26 STEERING,

NOTE :
Group 25/26 STEERING, SM 715, Dec 04

Group 25/26, Steering
Section 1
Steering System Specifications and Description
Steering System Type: Load sensing hydrostatic power All truck models have a hydrostatic power steering sys-
steering with variable ratio.(TMX Truck) tem, which is supplied with oil pressure from the main
hydraulic system pump. The steering handwheel operates
Steering System Type: Dynamic signal load sensing
the power steering gear (steering control valve) shown on
steering with variable ratio.(EPX Truck)
page 2, which directs oil flow to the steering cylinder on
Steering System Relief Pressure Setting: 8340-8830 kPa the steer axle. The steering cylinder operates the steering
(1210-1280 psi). linkage and steer wheel described on page 3.
Steer Cylinder Type: Double acting, piston-type. A steering system pressure relief valve, contained in the
steer gear assembly, prevents over-pressurization of the
Steer Axle: Single wheel (optional dual-wheel) mounted steering system. The pressure relief setting can be tested
on trunnion at center rear of truck.
using the gaugeinserted into the pressure line into the
steering gear.
Service Intervals
The steering gear shaft is connected to the handwheel by
Check the steering system relief pressure annually or after means of a jointed shaft. When the steering handwheel
every 2000 hours of operation. Make a visual inspection turns, it causes the steering gears spool valve to shift
of steering control unit hydraulic fittings periodically to from its closed neutral position to a turn position. This
ensure that the fittings are tight with no leakage. shift-ing of the spool directs flow to one end or other of
the steering cylinder, depending on the direction of the
turn. The amount of flow, and the sharpness of the turn,
Fastener Torques depend on how far the handwheel is rotated. The more
rapidly the handwheel turns, the more quickly the flow,
Steering Handwheel Nut: 35-40 N.m (25.5-29.5 ft-lb)
and the turn, occur.
Steering Column Cover Hex Bolts: 2-3 N.m (18-27 in.lb;
The low pressure oil from the opposite side of the steering
1.5-2.25 ft-lb)
cylinder is returned through the opposite port in the steer-
Directional Control Base Lock Nut: 0.8-1 N.m (7-9 in.lb; ing gear.
0.6-0.75 ft-lb)
As the steering handwheel stops turning, centering
Directional Control Base Flange Capscrew: 3.5-4.0 N.m springs in the valve automatically center the spool,
(2.5-2.9 ft-lb) stopping the flow of oil to the cylinder.
Ignition Switch Ring Nut: 10-14 N.m (7.3-10.3 ft-lb) Stops in the steer cylinder limit the how far the steer
wheels can be turned. It takes 5 turns of the hand wheel to
Tilt Lock Assembly Base-to-Cowl Bolts: 20-25 N.m
turn from stop to stop.
(14.8-18.5 ft-lb)
In the event of a pump failure, the steering gear acts as a
Orbitrol Bracket Bolts: 34-38 N.m (25-28 ft-lb)
limited emergency steering pump powered by manual
Lower Column Assembly Base-to-Steering Gear Bolts: rotation of the handwheel. An internal check valve auto-
34-38 N.m (25-28 ft-lb) matically closes to divert the manually-generated oil flow
to the proper port of the steer cylinder. The handwheel
Universal Joint Pinch Bolt: 25-30 N.m (18.5-22 ft-lb)
turning effort is considerably higher, however, than with
Wiring Harness Bracket Bolts: 11-13 N.m (8-9.5 ft-lb) power steering.
SM 715, Jun 05 Steering System Specifications and Description 25-1-1

The column tilt-lock mechanism allows the operator to The column cover can be removed for service to steering
adjust the steering column. The column tilt lever knob column components. The entire column can be removed
releases the adjustment setting and the column returns to for service or replacement. The steering gear, attached to
the up position by the use of springs. The tilt lock mecha- the base of the column, can be removed without
nism, the directional control lever, and the ignition switch disassem-bling the other parts of the steering column.
are protected by the steering column cover.
Horn Button
Column
Hand Wheel
Horn
Contact
Ring
Tilt Lock
Key Assembly
Switch Boot
Tilt Lock
Ignition Switch Directional

Wiring Harness Control Switch
Wiring Harness Directional Control Lever
Assembly
Steer Valve
(hydraulic lines on
page 4)
Steer Column and Steer Valve
25-1-2 Steering System Specifications and Description SM 715, Dec 04

(TMX Truck) A sensor mounted above the steer trunnion shaft, signals
The steer cylinder rod operates a drag link which pivots the position of the wheel to the electronic control, which
the steer trunnion and steer wheel mounted to it. then creates a speed differential between the two drive
motors to facilitate cornering.
Steer Angle Sensor

Assembly
Steer Trunnion
Mounting Plate
Steer Trunnion
Bearings
Steer
Cylinder
(hydraulic
lines on
page 4)
Steer Drag Link
Steer Trunnion
Steer Wheel and Bearings

Steer Linkage(TMX Truck)

Silent block
Steer Axle
Assembly
Steer Axle assembly(EPX Truck)
25-1-4 Steering System Specifications and Description SM 715, Jun 05

Steer Angle Sensor Removal and (EPX Truck)

Replacement
Removal of entire assembly. Replacement is reverse
order:
A. Potentiometer wires.
B. Fastener and washer
C. Bracket/Assembly
NOTE
Potentiometer shaft holder (G) and fastener
may remain on steer axle. NOTE Potentiome-
ter (E) wire leads should point toward front
of truck,.
H : Steering sensor
I : Fastener
Removal and replacement (reverse order) of potentiome- J : Steer Magnet
ter only. Replacement is reverse order:
Potentiometer wires. D.
Cable clamp
F. Locknut
E. Potentiometer
TMX Truck
(30 - 33 lbs-ft)
(15-22 lbs-f t)

Hydraulic Connections in Steering System(TMX)
Hydraulic Connections in Steering System(EPX)
25-1-6 Steering System Specifications and Description SM 715, Jun 05

Section 2
Steering System Troubleshooting
No steering Jerky steering

Hydraulic fluid level very low. Steering gear malfunction because of worn parts or
Air in hydraulic oil. contamination. Steering gear may require over-
haul.
Steering column sections not connected properly.
Hose broken.
Truck turns in wrong direction
Hydraulic pump contaminated or defective.
Priority valve spool stuck.(EPX) Hydraulic lines not installed correctly.
Hard steering Handwheel kickback

Hydraulic fluid level low. Check valve faulty (or not in system).
Air in hydraulic oil.
Steering gear contaminated or defective. Slow steering response
Relief valve setting too low; adjust or replace. Oil viscosity too high.
System leaking. Contaminated or defective steering gear.
Incorrect tire pressure.
Axle load too heavy. Chatter conditions
U-joint misalignment.
Loose mountings or linkage. Make certain all
Lack of lubrication.
mounting fasteners and other linkage is tight.
Defective steering gear.
Pressure relief valve set too low and is out of
Spring in priority valve broken.(EPX) adjustment; adjust or replace the relief valve.
nsufficient pump flow. Check pump for leaks and see
High number of handwheel turns Group 29, Section 3.
Steering cylinder seal leakage.

Unsatisfactory steering in either direction
Worn steering gear.
Air in system due to excessive wear in steering cyl-inder.
Steering handwheel spins freely Check for air in system. Excessive noise or foamy
condition of hydraulic fluid indicates aera-tion.
Air in system (cavitation). Check that air is not entering the system through
Low oil supply. poor threads, cracked, split, or worn hoses, bad pump
seals, bad O-rings, bad gaskets, or loose connections
Steering column detached from steering gear.
on intake side of pump. Worn cylin-ders result in
Defective steering gear. leakage past the piston. Overhaul (see Group 25,
Section 7) or replace the steer cylinder.
Incorrect system pressure due to worn pump. Replace
the relief valve or repair or replace the pump (see
Group 29).
SM 715, Dec 04 Steering System Troubleshooting 25-2-1

Noise during turns Low pressure at the pump

Worn bearing(s) in steering arm; replace bearings. Refer to the pump troubleshooting and overhaul
Worn pin in steering knuckle; replace pin. procedures in Group 29.
Worn bearings in steering knuckle; replace bear-ings.
Steering knuckle is loose; tighten castle nut. Low pressure at the steering gear
Refer to Section 5, Steering Gear Overhaul.Low
Constant noise from steering axle pressure at the steer cylinder
Seals worn out at piston rod end of steer cylinder;
Loose or worn hub bearing cones. Adjust or replace
replace seals.(TMX)
hub bearing cones. Replace bearing cones and
bearing cups as a set.
Steer cylinder rod binding or sticking
Fluctuating pressure Binding of linkage. With hydraulic flow shut off from
the cylinder and the rod end uncoupled, the rod
Faulty operation of relief valve. Fluctuating pres-sure should slide freely in or out by hand. If the pis-ton is
or loss of pressure in the system is usually caused
binding, overhaul or replace the cylinder.
by scales, chips, sludge, or filings that have lodged
between the relief valve and seat. A dam-aged
spring or worn valve may also be the cause of the
trouble. Flush and refill the system and replace the
hydraulic return line filter element. If condition
still exists, replace the relief valve.
25-2-2 Steering System Troubleshooting SM 715, Dec 04

Group 25, Steering
Section 3
Steering Column and Component Removal and Replacement
Steering Column and Component Removal..........................................................2

Key Switch Removal.....................................................................................................2
Hand Wheel, Horn Contact Ring, and Directional Control Assembly Removal .2
Column Tilt Lock Assembly Removal........................................................................4
Steering Gear and Lower Steering Column Removal..............................................4
Steering Column and Component Replacement..................................................6
Steering Gear and Lower Steering Column Replacement.......................................6
Column Tilt Lock Assembly Replacement................................................................7
Directional Control Assembly Reassembly................................................................7
Directional Control Assembly and Key Switch Replacement.................................8
Steering Hand Wheel Replacement.............................................................................9
IMPORTANT
Before removing any component for overhaul, make sure
the correct repair parts, seals, and gasket sets are available.
Key Switch
Lock Nut
Horn contact Ring
Column Lower Cover
Direction Control Assembly Turn Signal Assy(EPG ONLY)
Tilt Lock Assembly Boot
Wire Harness
Key Switch &Turn Signal SW
Wire Harness
Directional Control SW
Tilt Lock Assembly
Direction Control & Turn Signal Assy

Typical Steering Column Assembly
SM 715, Jun 05 Steering Column and Component Removal and Replacement 25-3-1
Group 25, Steering
CAUTION Remove the lock ring nut securing the key switch to the
lower cover. Label all wires and terminals for cor-
SAFE PARKING. Before working on truck: rect reconnection when reassembling.
Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
Put upright in vertical position and fully
lower the forks or attachment.
Put all controls in neutral. Turn key switch
OFF and remove key.
Apply the parking brake and block the
wheels.
Steering Column and Component

Removal
Use the following steps to disassemble the steering col-
umn for service to the: Hand Wheel, Horn Contact Ring, and
Key Switch Directional Control Assembly Removal
Horn Button Disconnect the battery.
Directional Control Lever Assembly
Column Tilt Lock Assembly Gently pry the horn button from the steering hand wheel
Upper and Lower Steer Column hub using a small, flat-bladed screw driver.
Steering Gear.
Determine which component requires service and check
the procedure for removing that component. Read the
pro-cedure completely before beginning disassembly.
Key Switch Removal

Disconnect the battery.
Remove the four socket head bolts holding the two
halves of the column cover together. The directional
control assembly and the key switch are exposed.
3. Disconnect the horn wire from the steer column and

unplug the horn contact wires from the terminal on
the bottom of the horn button.
4. Remove the nut holding the hand wheel to the steer-
ing column.
5. Use a wheel puller to remove the hand wheel from
the steering column. Hand wheel has two M8X1.25
threaded inserts in the hub for this purpose.
25-3-2 Steering Column and Component Removal and Replacement SM 715, Jun 05
Group 25, Steering
Unplug the horn contact ring wire from the terminal on Lift the directional control lever and boot off the diecast
the bottom of the handwheel. base.
Using a 2.5 mm allen wrench, remove the four socket Unplug wires from directional switches. Label all wires
head bolts holding the two halves of the column and terminals for correct connection when
cover together. Remove the top cover. Gently pull reassembling. Remove the direction control switches
the bottom cover away. by removing the mounting screws on the base.
Directional Control Lever Detent Spring Removal

If not already disassembled, remove the four socket bolts
NOTE holding the two sides of the column cover together.
Remove the top cover.
Use care when removing the bottom cover as
the ignition switch wiring is attached. Pry the two retainer clips from the posts on the direc-
tional control base securing the detent spring. Lift
Remove the horn contact ring. Unplug the wire from the spring off posts.
terminal on the bottom of the ring.
SM 715, Dec 04 Steering Column and Component Removal and Replacement 25-3-3
Group 25, Steering
Column Tilt Lock Assembly Removal (TMX) Steering Gear and Lower Steering
NOTE
Column Removal(TMX)
The tilt lock assembly is not serviceable; only NOTE
the return springs are serviceable. The tilt Lower steer column is not serviceable. It
lock assembly should be removed only for should be removed only for replacement as a
replacement as a complete assembly. new assembly.
SeeHand Wheel, Horn ContactRing, and Direc-tional Put a pan under the truck to catch hydraulic fluid which
Control Assembly Removal to remove the steering will drip when fittings are loosened. Label the four
hand wheel, horn ring, and directional con-trol hose fittings of the steering gear to make sure they
assembly. are reassembled correctly. Loosen and remove the
Unplug thekey switch anddirectional control switches. hydraulic fittings at the steering gear. Cap the ends to
Label all wires for correct reassembly. Dis-connect the prevent fluid leaks. Cap the steering gear ports to
key and directional control wiring har-ness from the prevent dust and debris from getting into the steering
main harness at lower right of cowl. gear. Keep hydraulic ports and hoses clean.
Loosen the pinch bolt of the lower universal joint

connection.
If upper portion of the steering column has not been

removed, loosen the pinch bolt of the lower
universal joint connection.
Remove the two bolts and spacers securing the lower
Remove the four bolts holding the base of the tilt lock column shaft and steering gear to the bracket on the
assembly to the cowl. lower cowl.
Group 25, Steering
Remove the bolts to detach the steering gear from the Loosen the pinch bolt of the lower universal joint
lower steering column. connection.
Upper steering column
Tilt lock assembly
Lower steering column
Slip the boot off the tilt lock assembly.

Remove the dash panel and instrument pod :
Remove the lower shaft and steering gear assembly from Remove the three screws securing the instrument
the truck. pod to the dash.
Column Tilt Lock Assembly Removal (EPX) Instrument pod
NOTE
Wiring harness
The tilt lock assembly is not serviceable; only connector
the return springs are serviceable. The tilt
lock assembly should be removed only for
replacement as a complete assembly.
Raise the operators seat deck and lift out the floor plate.
Remove the left, right, and center cowl covers from
under the dash. See removal and replacement proce-
dures in Group 38.
See Hand Wheel, Horn Contact Ring, and Direc-tional
Control Assembly Removal to remove the steering
hand wheel, horn ring, and directional con-trol
assembly. Gently lift the instrument pod up exposing the
Unplug the ignition switch and directional control switches. harness connector. Unscrew jack screw in con-
Label all wires for correct reassembly. Dis-connect the nector and unplug the connector from the instru-
ignition and directional control wiring harness from the ment pod.
main harness at lower right of cowl.
SM 715, Dec 04 Steering Column and Component Removal and Replacement 25-3-5
Group 25, Steering
Remove the screws securing the dash panel to the Steer Column and Component
cowl.
Replacement
Dash panel
These steps cover the procedures for reinstallation of the
steering column including the steering gear, the tilt lock
assembly, directional control assembly, ignition switch,
and steering hand wheel and horn.
IMPORTANT
Make sure all parts are clean and dry before
Cowl reassembling.
It may be necessary to assemble the steering
column in place and hand tighten fittings so
that the correct alignment of the entire col-
umn and parts can be checked.
Once you have the correct alignment, torque
all fittings to their correct specifications.
Steering Gear and Lower Steering

Column Replacement
NOTE
If the upper steering column has not been
Remove the hydraulic control lever cover panel and removed, the lower steering column must be
dash. left loose at the universal joint pinch connec-
Remove the two bolts from the wiring harness tion to allow some play in the column for
bracket located under the cowl. positioning the steering gear.
Remove the four bolts holding the base of the tilt
lock assembly to the cowl. Attach the steering gear to the lower column base.
Torque the two bolts to 34-38 N.m (25-28 ft-lb).
Set the column into position with the lower column
assembly aligned through the bracket mounted on
the lower frame cowl.
25-3-6 Steering Column and Component Removal and Replacement SM 715, Dec 04
Group 25, Steering
Coat the splines of the lower assembly with alight coat Directional Control Assembly Reassembly
of anti-seize lubricant and insert into the univer-sal
joint pinch connector of the upper assembly. Slip the lever boot onto the lever if it has been removed.
Match the skip tooth on the spline with spline on
uni-versal joint. Torque the pinch bolt to 25-30 Nm
(18.5-22.25 ft-lb).
Reconnect the clean hydraulic fluid lines to the clean
steering gear. Make sure the hoses are reconnected
to the correct ports. Torque the fittings per Group 40,
Hydraulic Fitting Tightening Procedure.
Make sure the flange capscrew and clamp are on the

directional control base.
Install the detent spring on the posts of the base and
secure with the retainer clips.
Column Tilt Lock Assembly Replacement

EPX)
Set the tilt lock assembly onto the cowl. Replace the four
bolts and torque to 20-25 Nm (14.8-18.5 ft-lb).
4. Reset the forward or reverse switch onto the base and

secure with screws.
Group 25, Steering
Apply a thin coat of grease in the bore of the direc-tional mounted on the steering column, connect the
control lever. Slip the lever onto the directional con-tinuity meter from the Normally Open
control base. terminal to vehicle ground.
Rotate the directional control lever in the forward
direction (push lever up) until a #8 (or 4 mm)
screw can be inserted into the middle detent on
the lever.
Loosen the mounting screw on the forward switch
and adjust the switch box to achieve conti-nuity
through the switch.
Remove #8 (4 mm) screw and return lever to neu-
tral detent. Switch must break continuity, If
switch does not break continuity, it must be read-
justed using the above steps.
When adjustment is correct, torque switch box
mounting screws to 0.8-1.0 Nm (7-9 in-lb; 0.6-
0.73 ft-lb).
Repeat procedure for Reverse switch.
Tighten the capscrew/clamp of the directional control
lever assembly to 3.5-4 Nm (2.5-2.9 ft-lb).
Directional Control Assembly and Key
Clean the capscrew and apply Loctite 262 before
applying torque. Switch Replacement
Adjust the directional control using the following
illustration: Slip the directional control assembly onto the steer-ing
column shaft.
Clean the capscrew, apply Loctite 262, and tighten the

clamp bolt of the assembly to 3.5-4 Nm (2.5-2.9 ft-
lb).
Check the assembly for smooth operation and make
necessary adjustments before proceeding.
Connect the wiring to the directional control switches
according to the labels you made during
disassembly.
Loosen mounting screws and set the directional
switch boxes to approximately the middle of the
mounting slot on the assembly base.
Connect a continuity meter on the forward switch from
the Common terminal to the Normally Open
terminal. If the adjustment procedure is being
performed with the directional control assembly
25-3-8 Steering Column and Component Removal and Replacement SM 715, Dec 04
Group 25, Steering
Set the key switch into the mounting hole on the lower Steering Hand Wheel Replacement
half of the column cover. Tighten the lock ring nut to
lo-14 Nm (7.5-10.3 ft-lb). Reconnect the horn contact ring wire from the base of
the handwheel to the bottom of the horn button.
Reconnect the horn contact ring wires to the horn

contact ring.
Apply a coat of insulating paste (Clark part no. 2802205)
to horn contact ring, then set the hand-wheel into
position and tap with a rubber or plastic mallet to
seat it on the column.
Tighten the nut onto the column to a torque of 35-40
Nm (25.5-29.5 ft-lb).
Screw the horn wire into the column and plug it into its
connection on the bottom of the horn button.
Slip the horn contact ring onto the steering column. The
groove in the ring should be on the lower portion of
Horn
the ring when it is replaced on the column. The
Wire
terminal should be on the right-hand side of the
muck.
Join both halves of the cover over the upper column. The
parting line of the boot must be aligned with the parting
line of the two cover halves. Set the direc-tional control
lever boot into the correct position. The horn ring
contact should be positioned so that the two
cover halves fit the groove in the ring. Tighten the
four socket bolts to 2-3 Nm (1.5-2.25 ft-lb).
Set the horn button into place and pop it into position
carefully. The horn symbol should be parallel to the
CLARK lettering on the hand wheel.
Reconnect the battery.
Replace the center cowl cover over the steering col-
umn. See Group 38 for instructions to replace the
cowl covers. Torque the screws to 8-10 Nm (5.5-7.5
ft-lb).
Group 25, Steering
IMPORTANT
If you set the column loosely into place to
assure correct alignment, recheck that all
mounting brackets, the universal pinch joint,
and all fasteners are torqued to their correct
limits. See the individual steps in the reas-
sembly procedures to find torque limits.
Turn the key switch ON to check its function. Make sure

no fluid leaks are evident in the steering control valve
hydraulic fittings. Remove the wheel chocks to check all
functions of the steering column, including directional
controls, tilt lock mechanism, and steering gear for correct
operation before returning the truck to service.
Group 25, Steering
Section 4
Steering System Relief Pressure Check and Adjustment
CAUTION gically removed within a few hours by a doc-

tor familiar with this type of injury or
SAFE PARKING. Before working on truck: gangrene may result.
Park truck on a hard, level, - and solid sur-
face, such as a concrete floor with no gaps or
breaks. Steering System Relief Pressure Setting
Put upright in vertical position and fully Check and Adjustment
Put all controls in neutral. Turn key switch This procedure requires installation of a pressure gauge in
OFF and remove key. the pressure line from the priority valve on the hydraulic
Apply the parking brake and block the pump to the steering gear assembly. The pressure is mea-
wheels. sured while the steering handwheel is turned fully in one
direction to put the steering system in bypass. Steering
system relief pressure setting may be checked using a
Description and Operation Mica Quadrigage (Clark Part No. 1800106) or with a con-
Steering system relief pressure settings above the speci- ventional pressure gauge, 0-20,700 kPa (0-3000 psi).
fied values can cause failure of the steer lines, damage to Tilt the steering column fully forward and raise the seat
seals in the steering gear, and steering linkage breakage deck.
on the steer axle. The steering system's pressure relief
valve is part of the steering gear assembly. Steering sys- Remove floor plate to access steering gear.
tem relief pressure is adjustable and should be checked if
indicated by troubleshooting. A pressure gauge will need
to be plumbed into the pressure line from the priority
valve on the hydraulic pump to the steering gear assembly
to check steering relief pressure.
Steering system relief pressure setting should be 8340-
8830kPa (1210~1280psi).
NOTE
If relief pressure is not correct, the problem
may be caused by dirt in the valve or relief
valve on the steer pump or worn parts in the
steering control valve or steer pump.
WARNING
Do not use your hands to check for hydraulic
leakage. Use a piece of cardboard or paper to
search for leaks. Escaping fluid under pres-
sure can penetrate the skin causing serious
injury. Relieve pressure before disconnecting
hydraulic or other lines. Tighten all connec-
tions before applying pressure. Keep hands
and body away from pinholes and nozzles
which eject fluids under high pressure. If any
fluid is injected into the skin, it must be sur-
SM 715, Dec 04 Steering System Relief Pressure Check and Adjustment 25-4-1
Group 25, Steering
3. Install Quadrigage in the pressure line to the steering a. Remove plug.

gear. L-Wrench Size: 8 mm
or
Adjust the pressure.

Specification: 8340-8830kPa (1210~1280psi)
To increase: turn clockwise
To decrease: turn counter-clockwise
TMX Truck
L-Wrench Size: 6mm
To increase
To decrease
Repeat check and adjustment procedure until correct

relief pressure is set.
If the correct relief pressure cannot be gained, con-
sider overhauling the hydraulic pump or replacing
(EPX Truck) the pressure relief valve.
Put the key in the key switch and turn it On. Disconnect the tee and pressure gauge, reconnect lines,
and reinstall the adjustment port plug.
Turn the steering handwheel in one direction until
steering cylinder reaches its stop (relief bypass). Test drive the truck and insure that the steering is
Hold steering handwheel in relief position until pres- performing satisfactory.
sure reading is taken, and then release. Turn key
switch Off. Pressure should read 8340-8830kPa
(1210~1280psi).
To adjust the steering pressure relief to 8340-8830kPa
(1210~1280psi):
25-4-2 Steering System Relief Pressure Check and Adjustment SM 715, Jun 05
Group 25, Steering
Section 5
Steering Gear Overhaul (TMX)

Steering unit..........................................................................................................................................2
Disassembly..........................................................................................................................................2
Assembly...............................................................................................................................................5
Assembly Pattern for Standard Bearings..............................................................................................7
IMPOTANT
Before removing any component for overhaul, make sure the correct repair parts, seals, and gasket sets
are available.
NOTE
The following material does not show the load sensing port on the steering gear (steering control unit).
The port is located in the center of the other four ports. The load sensing port requires no special over-
haul procedures.
SM 715, Dec 04 Steering Gear Overhaul (TMX) 25-5-1

Group 25, Steering
Steering Unit Torque wrench 0~7 kgf.m(0~50 lbf ft)

13mm socket(12 point)
6, 8 and 12mm hexagon sockets
Tools 12mm screwdriver
2mm screwdriver
Holding tool
13mm ring spanner
6, 8 and 12mm hexagon L wrench
Plastic hammer
Tweezers
Assembly tool for O-ring and kin-ring.
The tools listed above are not available from CLARK.
Disassembly
In repair keep all parts clean. Be sure the steering unit is
thoroughly cleaned and free of dirt and debris prior to dis-
assembly.
Place the steering unit in the holding tool and remove the
Assembly tool for cardan shaft
screws in the end cover (6-plus one special screw).
Assembly tool for dust seal

Remove the end cover, sideways.
25-5-2 Steering Gear Overhaul (TMX) SM 715, Dec 04

Group 25, Steering
Lift the gerotor set(with spacer if fitted) off the unit. Take Remove O-ring.
out the two O-rings.
Remove cardan shaft. Shake out the check valve ball( 8 mm)
Shake out the two anticavitation check valve balls.(if
equipped)
Remove distributor plate.
Take care to keep the cross pin in the sleeve and spool
horizontal.
The pin can be seen through the open end of the spool.
Press the spool inwards and the sleeve, ring, bearing races
and needle bearing will be pushed out of the housing
together.
Screw out the threaded bushing over the check valve.

Group 25, Steering
Take the ring, bearing races and needle bearing from Carefully press the spool out of the sleeve.
sleeve and spool. The outer(thin) bearing race can some-
times "stick" in the housing, therefore check that it has
come out.
Press the neutral position springs out of their slots in the

spool.
Press out the cross pin. Use the special screw from the
end cover.
Remove dust seal and O-ring / kin-ring.
A small mark has been made with a pumice stone on both

the spool and sleeve close to one of the slots for the neu-
tral position springs (see drawing) If the mark is not visi-
ble, remember to leave a mark of your own on the sleeve
and spool before the neutral position springs are disas-
sembled.

Group 25, Steering
Screw out the plug using and 6 mm hexagon L wrench. The pressure relief valve is now disassembled.
Remove seal washers.
Unscrew the relief set screw using and 6 mm hexagon L Assembly

wrench.
Before assembly clean all parts very carefully, replace all
seals and O-rings, and lubricate all parts with hydraulic
oil.
Assemble Spool And Sleeve

When assembling spool and sleeve only one of two possi-
ble ways of positioning the spring slots is correct. There
are three slots in the spool and three holes in the sleeve in
the end of the spool/sleeve opposite to the end with spring
slots. Place the slots and holes opposite each other so that
parts of the holes in the sleeve are visible through the
Shake out the spring and piston. The valve seat is boned slots in the spool.
into the housing and cannot be removed.
Place the two flat neutral position springs in the slot.
Place the curved springs between the flat ones and press
them into place.

Group 25, Steering
Line up the spring set. Guide the ring down over the sleeve.
WARNING
The ring should be able to rotate free of the
springs.
Guide the spool into the sleeve.

Make sure that spool and sleeve are placed correctly in
relation to each other.
Fit the cross pin into the spool/sleeve.
Press the spring together and push the neutral position

Fit bearing races and needle bearing as illustrated.
springs into place in the sleeve.
Line up the springs and center them.

Group 25, Steering
Assemble Pattern For Standard Bearings Press and turn the O-ring / kin-ring into position in the
1 housing.
2
1. Outer bearing race
4 2. Needle bearing
3. Inner bearing race *(thicker)

5 4. Spool
Turn the steering unit until the bore is horizontal. Guide

the outer part of the assembly tool into the bore for the Draw the inner and outer parts of the assembly tool out of
spool/ sleeve. the steering unit bore, leaving the guide from the inner
part in the bore.
Grease O-ring and kin-ring with hydraulic oil and place

them on the tool.
With a light turning movement, guide the spool and
sleeve into the bore.
WARNING
Fit the spool set holding the cross pin hori-
zontal.
Hold the outer part of the assembly tool in the bottom of

the steering unit housing and guide the inner part of the
tool completely to the bottom.

Group 25, Steering
The spool set will push out the assembly tool guide. The Place the distributor plate so that the channel holes match
Oring and kin-ring are now in position. the holes in the housing.
Turn the steering unit until the bore is vertical again. Put
Guide the cardan shaft down into the bore so that the slot
the check valve ball into the hole indicated by the arrow.
is parallel with the connection flange.
Screw the threaded bushing lightly into the check valve

bore. The top of the bush must lie just below the surface
of the housing. Place the cardan shaft as shown so that it is held in posi-
tion by the mounting fork.
Grease the O-ring with mineral oil approx. viscosity 500

cSt at 20C.
Grease the two O-ring with mineral oil approx. viscosity
500 cSt 20C and place them in the two grooves in
gerotor assy.

Group 25, Steering
Fit the gerotor assembly on the cardan shaft. Place the end cover in position.
Fit the special screw with washer and place it in the hole
WARNING shown.
Fit the rotor and cardan shaft so that a tooth
base in the rotor is positioned in relation to
the shaft slot as shown. Turn the stator so
that the seven through holes match the hous-
ing.
Fit the six screws with washers and insert them.

Crosstighten all the screws in several stages. 3.0 0.3
kgf.m(22 2 lbf.ft)
Fit the spacer, if any.

Group 25, Steering
Place the dust seal ring in the housing. Ther dust seal ring Fit the piston.
must be placed only after the pressure relief valve has
been fitted.
Fit the spring.
Fit the dust seal ring in the housing using special tool and
a plastic hammer.
Screw in the relief screw with an 8 mm hexagon L

wrench.
Adjust the pressure setting on a test bench or in the vehi-
cle.
Press the plastic plugs into the connection ports. Do NOT

use a hammer.
Install the plug with dust seal into the housing using an 8
mm hexagon L wrench.
5.1 1 kgf.m(37 7 lbf.ft)

Group 25, Steering
Priority Valve Pull out the plug with seal ring (alu.) and spring.
Tools
Torque wrench
Hexagon (Allen) socket 8 mm
Hexagon socket(12 point) 22 mm
Open-end spanner 22 mm
Nylon pin
Allen wrench 8 mm
These tools are not available from CLARK. Press out the spool using the nylon pin.
Disassembly Cleaning
Screw out the PP plug using the 8 mm hexagon Allen Clean all parts carefully in cleaning solvent.
Wrench. Remove the seal ring (alu.)
Inspection and Replacement
Check all parts carefully and make any replacements nec-
essary. All seal rings must be replaced.
Lubrication
Before assembly, lubricate all parts with hydraulic oil.
Assembly
Loosen the LS plug using the 22 mm open-end spanner. Guide the spool into the bore. Use the nylon pin to center
the spool in the bore.

Group 25, Steering
Put in the PP plug. Remember seal ring. Tighten the LS plug with a torque wrench using a 22 mm
hexagon socket.
5 1 kgf.m (36 7 lbf.ft)
Guide the spring and LS plug into the bore. Remember

seal ring.
Tighten the PP plug with a torque wrench using a 8 mm
hexagon Allen socket.
5 1 kgf.m(36 7 lbf.ft)

Group 25, Steering
Section 6
Steer Axle Service (TMX)

Steer Axle Trunnion Bearings Check....................................................................................................2
Steer Trunnion Bearing Adjustment......................................................................................................2
Steer Wheel Bearing Maintenance........................................................................................................3
Steer Wheel Bearing Adjustment..........................................................................................................3
Steer Wheel Bearing Lubrication and Replacement.............................................................................4
Steer Angle Sensor Removal and Replacement....................................................................................5
Steer Cylinder Removal and Replacement.......................................................................................... 7
Trunnion Removal and Replacement....................................................................................................7
Steer Axle Linkage Removal and Replacement....................................................................................8
Trunnion Bearings Removal and Replacement.....................................................................................8
NOTE
DUAL-WHEEL and SINGLE-WHEEL STEER AXLES.
This Section shows overhaul procedures for a single-wheel steer axle.
However, the procedures and torque specifications can be applied to the
dual-wheel steer axle as well.
Single-Wheel Steer Axle Dual-Wheel Steer Axle
SM 715, Dec 04 Steer Axle Service (TMX) 25-6-1

Group 25, Steering
CAUTION Disconnect the rod end of the steer cylinder as shown

below. This will allow the steer axle to be moved
SAFE PARKING. Before working on truck: (rotated) freely while adjusting the trunnion bearings.
Park truck on a hard, level, and solid sur-
face, such as a concrete floor with no gaps Bend lock washer tab clear of slot in locknut. Loosen
or breaks. locknut several turns, but do not remove.
Put upright in vertical position and fully
Loosen the bearings by rotating the trunnion shaft and/or
shaking the steer wheel from right to left.
Put all controls in neutral. Turn key switch
OFF and remove key. Tighten the retaining nut to 271 N.m (220 ft-lb) to seat
Apply the parking brake and block the the bearings. Then loosen the retaining nut and
wheels. retighten to 20-27 N.m (14.8-20.0 ft-lb).
Steer Axle Trunnion Bearings Check Locknut
Be sure that truck is parked and blocked up correctly to Lockwasher

raise the steer wheel off the floor.
Inspect the steer axle and trunnion for damage and wear.
Check the steer axle trunnion bearings for excessive
free-play or looseness. Hold the steer wheel with
both hands and try to move the entire steer axle in
the trunnion bearings. Be sure that any movement Bend a lock washer tab back into a slot in the lock-nut.
that you feel is not due to wheel bearing clearance
Check for free movement of the trunnion shaft and bearings
free-play. If the trunnion bearings have excessive
by turning the steer axle to the right and left.
loose-ness, the bearings require adjustment.
Check trunnion bearing preload.
Put a torque wrench on the locknut. It should require
Steer Trunnion Bearing Adjustment
2.0-2.7 N.m (1.5-2.0 ft-lb) rolling torque to rotate the
Remove battery from truck, for best access to top of steer axle in the trunnion bearings. Tighten or loosen
steer axle trunnion. Refer to Group 12 for battery the retaining nut to obtain correct preload torque.
removal procedure. Install steer cylinder rod end, steer angle sensor assembly,
It is not necessary to remove the hood and counter- and battery.
weight. However, access to the steer trunnion bear- Installation of steer angle assembly is described later
ings is much easier when the counterweight is in this Section. Adjustment is described in Group 13.
removed.
Remove the drive motor steer angle sensor assembly
that is mounted atop the steer trunnion. The proce-
dure is shown later in this Section.
Trunnion Shaft
Nut and
Cotter Pin
Torque
65-75 ft-lb
(89-103 N-m).
Rod End
Ball Stud
25-6-2 Steer Axle Service (TMX) SM 715, Dec 04

Group 25, Steering
Steer Wheel Bearing Maintenance Steer Wheel Bearing Adjustment

Be sure that truck is parked and blocked up correctly to The steer wheel bearings are retained and adjusted by a
raise the steer wheel off the floor. self-locking bearing nut. With truck properly blocked:
NOTE Remove hubcap by tapping lightly on the outer edge of
It is optional to raise and block up entire hubcap.
truck. Loosen spindle (bearing adjusting) nut and bearings:
After spindle nut is loosened, hit the top of wheel to
To check the steer wheel bearings for excessive free play loosen the bearings.
or looseness, hold the wheel with both hands and try
to rock it from side to side. Also, try to pull it in and IMPORTANT
out along the wheel spindle. There should be a small SPINDLE NUT SHOULD BE REPLACED
amount of free movement. (The maximum allowable WITH A NEW ONE each time it is removed
bearing end play is 0.08 mm [0.003 in]). If the wheel because holding torque capability is partially
has excessive end play, the bearings require destroyed with each removal.
additional service and/or adjustment.
Tighten spindle nut to the correct tightening torque while
rotating the wheel by hand: 230-244 N.m (170-180
ft-lb).
NOTE
Set the steer wheel bearing adjustment by
torquing the self-locking spindle nut to the
specified value. Overtightening causes drag
and results in lower travel speed and higher
power use. Some additional adjustment may
be required however. See next step.
Check for correct bearing adjustment by rotating the

wheel by hand. Wheel should rotate freely or with
only slight drag. Readjust bearings as necessary.
Install the hub cap by tapping it into place with a rub-ber
or plastic-faced hammer.
Spindle Nut
Hub Cap

Group 25, Steering
Steer Wheel Bearing Lubrication Clean and inspect the bearing cups and cones for wear
and other damage. Replace if necessary.
and Replacement
NOTE
To clean, repack and adjust bearings:
Always replace damaged bearing cups and
Be sure that truck is parked and blocked up correctly to cones as a set.
raise the steer wheel off the floor.
If bearings require replacement, remove the grease seal
Remove the wheel and tire assembly. (Place a block of
and the inner bearing cone using a brass drift pin or
wood under the tire to prevent rotation of the wheel
rod to drive the bearing and seal out of the hub.
when loosening the lug bolts. Use a pry bar under
Grease seal may be first removed by using a puller
the tire to help move the wheel on and off the wheel
or prying out of the bore in hub (damage is unimpor-
hub.)
tant; install new seal at assembly). Use a standard
IMPORTANT puller to remove the bearing cups.
It is recommended that you first remove the Install new bearing cups by pressing into wheel hub. Be
wheel when servicing the bearings. The sure cups are fully seated in bearing bore.
heavy weight of the wheel and tire can cause
damage to the grease seal when the wheel Pack the bearings with grease and install the inner bearing
hub is moved on the spindle. It also makes in the hub.
the work simpler and easier. Recommended greasing procedure:
Use MP grease NLG # 2.
Remove hub cap from wheel hub. Pack bearings with grease before assembly.
Clean the excess grease from around the spindle nut. Pack cavity in hub between bearings one-half full
with grease at assembly.
Loosen and remove the spindle nut.
Put the hub on the spindle. Be careful not to damage seal
Remove the outer bearing cone. lip when moving the hub over the end of spindle and
Pull the wheel hub off the spindle. Hold the hub firmly threads.
to avoid dragging the grease seal at the back side Install the outer wheel bearing after it has been packed
across the threads on spindle end. with grease.
Clean the old grease out of center of wheel hub. Install NEW spindle nut. Adjust spindle nut and bearing
as explained on page 3.
Replace hub cap and remove truck from blocks.
Cup, Outer
Hub Cap
Spindle Nut
Cone, Outer
Torque
230-244 N-m
(170-180 ft-lb)
but follow full
adjustment proce-
dure on page 3.
Hub
Cup, Inner
Cone, Inner
Seal

Group 25, Steering
Steer Angle Sensor Removal and Display will read "SET STEER O-POS"
Replacement Press "ENTER" button
Adjust the steer wheel to where it appears to be
centered
Description
The steer angle sensor is mounted atop the steer axle trun- Press "OUT button
ion assembly. This device helps the drive motor control
generate an efficient speed differential between the two
drive motors when the truck is cornering,
The steer angle sensor is a potentiometer that translates used for Steering 0 position)
the angle of rotation of the steer angle into a voltage level
read by the Dual AC control. When the steer wheel is
MENT
straight ahead (0 turn angle) the input signal to the con-
trol should be at the mid point. As the vehicle turns left, Press "ENTER" button
this input signal decreases. As the vehicle turns right, the Display will read "SET POT BRK MIN"
input signal increases. Press "ROLL UP" button (5) times
Display will read "MAX STEER LEFT"
Check and Adjustment Turn steer wheel all the way lo the left
CAUTION
Press "OUT button
up the truck, block the drive wheels off the Display will read "ARE YOU SURE"
floor, disconnect the battery, and discharge "YES=ENTER" "NO=OUT"
the capacitors as described in Group SA Press "ENTER" button (this stores the value to be
used for steering max left)
Use the following method to adjust the steer angle sensor
with the handset:
MENT
Disconnect the dash display harness from the con-trol
Display will read "SET POT BRK MW
panel
Plug handset into plug "B" of the control
Display will read "MAX STEER RIGHT"
Plug in the battery
Turn steer wheel all the way to the right
Turn the key switch On
Handset will go through startup and display soft-ware
version Press "OUT button
Press both the "ROLL UP" and "PARAM Display will read "ARE YOU SURE"
SET Up" buttons (top outside buttons) simulta- "YES=ENTER" "NO=OUT'''
neously. Press "ENTER" button (this stores the value to be
Display will read "CONFIG MENU' "SET used for steering max right)
MODEL" Display will read "CONFIG MENU ADJUST-
Press the roll down button once MENT
Display will read "CONFIG MENU" ADJUST- Press "OUT" button
MENT Display will show software version
Press "ENTER" button Turn the key switch Off and remove the tester cord
Display will read "SET POT BRK MIN" from the control
Press "ROLL UP" button (6) times Plug the dash display harness into the "B" plug of the
control

Group 25, Steering
Lower truck to the ground and test drive truck
(30 - 33 Lbs/Ft)
Potentiometer leads
point toward front of
truck Make sure that the
potentiometer hole is
centered above the steer
(15-22 Lbs/Ft)
potentiometer drive screw
EPX16-18 Steer Angle Sensor.

EPX16-18
25-6-6 Steer Axle Service (TMX) SM 715, Jun 05

Group 25, Steering
Steer Cylinder Removal and Trunnion Removal and Replacement

Replace-ment Support trunnion with a sling and hoist of adequate
Disconnect battery and remove it from the truck. capac-ity.
For best access, remove counterweight as described in Removal and Replacement. Replacement is reverse order:
Group 38. C. Remove and replace steer cylinder as described
Raise and block rear of truck. previously.
Trunnion mounting bolts.
Remove wheel as described in Group 22. Trunnion assembly.
Removal and Replacement. Replacement is reverse Replacement Note: If necessary, replace trunnion
order: bearings and linkage as described in on following pages
Hydraulic fittings. before replacing trunnion assembly.
Replacement note: Clean fittings. See Group 40,
Hydraulic Fitting Tightening Procedure.
Cotter pin and nut.
Steer cylinder.
Torque
89-103 N.m
(65-75 ft-lb)
B
Torque
339-381 N.m D
(251-280 ft-lb)
C B
Torque
A 89-103 N.m
(65-75 ft-lb)

Group 25, Steering
Steer Axle Linkage Removal and Trunnion Bearings Removal and

Replacement Replacement
Removal: Remove trunnion assembly as described on Removal: Separate upper trunnion casting from axle and
pre-vious page. linkage as shown in previous sections.
Removal and Replacement.Replacement is reverse order: Removal and Replacement. Replacement is reverse order:
Locknut and lockwasher. Seal
Replacement Note: Adjust locknut as explained
Seal
under Steer Trunnion Bearing Adjustment pre-
viously in this Section. Cone
Replacement Note: Pack cones with grease meet-
Fastener and bushing
ing spec MS9C. Clark part no. 3762514
Steering arm
Cone
Fastener
Cup
Fastener
Cup.
Drag link.
Replacement Note: Replace trunnion bearings as
shown in next column before reassembling link-
age.
B
A Torque
.
240-270 N m
(177-199 ft-lb)
D
Torque F
.
20-25 N m
(14-18 ft-lb)
E
Torque
.
20-25 N m
(14-18 ft-lb)

Group 25, Steering
Section 7
Steer Cylinder Overhaul(TMX)
IMPOTANT
Before removing any component for overhaul, make sure the correct
repair parts, seals, and gasket sets are available.
SM 715, Dec 04 Steer Cylinder Overhaul(TMX) 25-7-1

Group 25, Steering
Preparation For Disassembly 6. Remove and discard the tube seal, rod U-cup seal,
and rod wiper from the gland.
IMPORTANT
Overhaul tilt cylinders only in a clean, dust-
free location, using clean tools and equip-
Cylinder Inspection
ment. Dirt or grit will damage the Carefully clean all parts in an approved solvent and
highlymachined surfaces and will result in place on a clean surface.
leakage or premature failure of components.
Cleanliness of the hydraulic circuit is Check the piston and rod for damage. Look for gouges,
extremely important to the proper operation scratches, corrosion, or evidence of unusual wear.
and maintenance of the system. Be sure the Minor surface damage may be repaired by use of
work area is clean. fine abrasion cloth or stoning. Deeper damage will
require replacement of piston rod assembly. Be sure
Before disassembly, the exterior of the tilt cylinder the threads on the rod are undamaged.
should be carefully cleaned to remove all dirt and Inspect the cylinder tube internal bore for wear,
grease accumulation. scratches or other damage. Deep gouges or pitted
surfaces require replacement of parts. Check the out-
Be sure all hydraulic oil has been removed from the side of the entire cylinder for damage. Inspect all
cylinder. Stroking the piston rod will help force the welds for cracks. Inspect the ports to be sure they are
oil out. free of contamination and that the threads are clean
Before starting disassembly, the tilt cylinder should be and not damaged.
carefully examined to determine if there is any Put a light coating of hydraulic fluid on all parts. If parts
evidence of external damage. are to be left disassembled for awhile, they should be
covered with a clean cloth.
Cylinder Disassembly
The tilt cylinder can be held by clamping the base end or
Cylinder Reassembly
the tube in a vise while disassembling. Install piston rod wiper and rod U-cup, and tube seal in the
gland. Make sure U-cup and wiper are installed in
IMPORTANT
proper orientation as shown in the illustration.
Do not use excessive force when clamping on
the tube. Install tube seal, shear ring, tube end back up seal, and
tube end seal on gland.
Remove the external retaining ring from the gland.
Replace the piston packing and expand ring..
Push the gland assembly into the cylinder tube until the
tube end seal ring and backup ring come off the Install gland on piston rod. Use gentle pressure and
gland and the shear ring becomes accessible. careful movements to avoid damage to the U-cup
seal and rod wiper when these parts are moved over
Pry under the rins outer edge with a soft metal pick and the piston rod end.
pull the ring from its groove and out of the tube.
NOTE
Carefully pull the rod and piston assembly and gland
from the cylinder tube. Remove gland from rod. Reassemble cylinder carefully to prevent
damage to seals.
WARNING
Install piston and rod assembly. Be careful not to
The use of compressed air to blow the piston
damage the piston seals when installing the piston
out of the barrel is not recommended. High-
into end of cylinder tube.
pressure air can result in piston and rod
being ejected at high velocity (explosively), Insert gland assembly over rod and into cylinder tube,
causing severe injury to personnel and prop- compressing the shear ring to fit into the tube. Push
erty damage. gland inward until shear ring snaps into its groove in
the tube.
Remove and discard the piston packing and expand ring
Install external retainer ring.
from the piston.
Check the assembly by making sure the piston slides
freely within the cylinder.
25-7-2 Steer Cylinder Overhaul(TMX) SM 715, Dec 04

Group 25, Steering
Grease Fitting
Dust Cover
Ball Stud
Ball Stud
Retainer
Cap
Piston
Piston Packing
Expand Ring
Gland
Tube Seal
Shear Ring
Tube End Seal Back-Up Seal
Tube End Seal
Retaining Ring Dust Cover

Ball Stud
U-Cup
Roll Pin
Wiper
Rod
Grease Fitting
Ball Stud Housing
Mounting Ends Overhaul

The cylinder base and rod ends mount to the frame and
axle via bull stud joints. The dust covers, housings, and
ball studs can be replaced if damaged.
To remove the rod end mounting, first remove the roll pin
with a drift punch. Then unscrew housing from rod.
To remove ball studs from either joint, remove caps and
retainers first.
Inspect the ball stud and housing races for damage.
Replace damaged parts and reassemble joint reversing
above procedure. Grease joints with multi-purpose grease
NLG#2.
SM 715, Dec 04 Steer Cylinder Overhaul(TMX) 25-7-3

NOTE :
Group 25, Steering SM 715, Dec 04

Group 25, Steering
Section 8
Steering Axle Wheel Bearing Maintenance and Adjustment
(EPX)
Wheel Bearing Check.........................................................................................................................1
Wheel Bearing Lubrication................................................................................................................1
Bearing Disassembly.............................................................................................................................2
Bearing Reassembly..............................................................................................................................3
Wheel Bearing Adjustment................................................................................................................4
IMPOTANT
are available.
WARNING Wheel Bearing Lubrication

SAFE PARKING. Before working on truck: These procedures cover bearing lubrication for the steer-
ing axle. Use the procedures to clean, repack and adjust
Park truck on a hard, level, and solid surface, such as bearing.
a concrete floor with no gaps or breaks.
Wheel mountion Hub
Put all controls in neutral. Turn key switch OFF and
remove key.
Apply the parking brake and block the wheels.
Remove Battery Connector.
Wheel Bearing Check

Wheel bearings check should be performed every PM.
Wheel bearings need adjustment only after 2000 hours or
as needed. It is recommended that you clean and repack
the bearings before adjustment. Check hourmeter total
hours and refer to the truckis PM schedule. See steer Steer Axle Knuckle
wheel bearing lubrication procedure below.
To check the steer wheel bearings for excessive free play
or looseness:
Grasp the wheel with both hands and try to move it by a
rocking motion top-to-bottom.
Try to pull it in and out along the wheel spindle. Watch
for excessive free movement in wheel bear-ings or
steering knuckle bearings. There should be a small
amount of free movement. If the wheel has
excessive free movement, the bearings require addi-
tional service and/or adjustment.
SM 715, Jun 05 Steering Axle Wheel Bearing Maintenance and Adjustment (EPX) 25-8-1
Group 25, Steering
Bearing Disassembly Refer to the exploded view illustration of the wheel

bearing assembly. Loosen and remove the hubcap
Be sure truck is parked and blocked up correctly and safely from hub.
to raise steer wheels off the floor. Refer to Lifting,
Jacking, and Blocking, in the Group SA. Clean the excess grease from around the wheel nut.
NOTE Remove cotter pin, loosen and remove wheel nut.

Because of the heavy weight of the wheel and Remove outer bearing by pulling out on the hub slightly
tire, it is suggested to first remove the wheel to loosen bearings.
and tire assembly from spindle when servic-
ing the bearings to avoid damage to the
grease seal when the wheel hub is moved off
or on the spindle. It also makes the work
sim-pler and easier.
Knuckle
Grease Seal
Hub
Bearing Bearing
Washer
Nut
Hub cab
Cotter Pin
25-8-2 Steering Axle Wheel Bearing Maintenance and Adjustment (EPX) SM 715, Jun 05
Group 25, Steering
Pull the hub off the knuckle. Support the hub to avoid Wheel Bearing Adjustment
dragging the grease seal at the back side across the
thread on knuckle end. The steer wheel bearings are retained and adjusted by the
wheel nut.
Clean the old grease out of center of the hub.
NOTE
Remove the inner bearing cone and grease seal.
You should clean and repack the wheel bear-
Clean and inspect the bearing cups and cones for wear or ings before performing a wheel bearing
other damage. Replace, as necessary. adjustment. See Wheel Bearing Lubricationi
in this Section for the complete procedure.
IMPORTANT
Keep serviceable bearing cups and cones
matched together. Always replace bearing WARNING
cups and cones as a set. SAFE PARKING. REFER TO PAGE 1.
Inspect grease seal for wear and damage. Replace as Make sure the truck is parked on a level, hard sur-face,
necessary. It is recommended to install a new grease the upright is fully lowered, the drive wheels are
seal whenever old ones are removed. chocked, and the steer wheels are jacked and
blocked securely. Refer to Lifting, Jacking, and
Blocking for safe procedures.
Bearing Reassembly
Remove hubcap.
NOTE
Remove and discard cotter pin.
Use Grade No. 2 EP multi-purpose grease,
Clark MS-107C. Loosen wheel nut.
Install grease seal a the knuckle. After wheel nut is loosened, hit the top of wheel to
loosen the bearings. This moves the bearings free of
Pack the bearings with grease and install the inner their seated, running position.
bearing on the kunckle.
Rotate hub or wheel counter clockwise and torque wheel
Install the hub on the knuckle. nut to 27.5-29.4 N.m (20.3-21.7 ft-lb).
Pack the bearing with grease and install on the knuckle Back wheel nut up until it is loose.
Assemble washer and castle and nut. While turning the hub or wheel counter clockwise,
torque the wheel nut to 6.9-9.8 N.m (5.1-7.2 ft-lb).
Loosen castle nut in 1/4~1/2 round after tightening
knuckle nut in 27.5~29.4 N.m (20.3~21.7 ft.lb) rotat- Back up wheel nut to nearest castellation slot and install
ing hub. new cotter pin.
Install a split pin in the first groove of a castle nut in the 10. Recheck for correct bearing adjustment by rotat-ing
loosing directing after tightening in 6.9~9.8 N.m the wheel by hand. Wheel should rotate freely or
(5.1~7.2 ft.lb) with only slight drag. Readjust bearings by adjust-
ing wheel nut as necessary to avoid binding in bear-
Install hub cap.
ings.
Bend cotter pin tabs over.
Pack the area around wheel nut with grease.
SM 715, Jun 05 Steering Axle Wheel Bearing Maintenance and Adjustment (EPX) 25-8-3
NOTE :
Group 25, Steering SM 715, Jun 05

Group 25, Steering
Section 9
Steering Axle Removal and Replacement (EPX)
Steer Axle Removal.............................................................................................................................1

Steer Axle Replacement......................................................................................................................2
CAUTION ing, Jacking, and Blocking in Group SA for safe

procedures to jack the truck.
CAUTION
Park truck on a hard, level, and solid surface, such as
Make sure truck is correctly raised and
a concrete floor with no gaps or breaks.
safely blocked using hardwood blocks under
Put upright in vertical position and fully lower the the frame. Be sure the blocking will permit
forks or attachment. installation of the axle without disturbing the
Put all controls in neutral. Turn key switch OFF and blocking.
remove key.
Apply the parking brake and block the wheels. Loosenandremove hydraulic steering lines from steering
cylinder. Plug fittings and cap open ends of lines.
Keep all hydraulic fittings and openings clean.
Steer Axle Removal
CAUTION
Remove the counterweight before removing the steer
axle. Refer to Group 38, Section 2, Counterweight Axle must be supported before any attaching
Removal and Replacement. (It is possible to fasteners are removed.
remove the steer axle without removing the
counterweight but much easier if it is removed). If another lift truck is used to temporarily support axle
while removing, put forks in center of carriage about
WARNING 305 mm (12 in) apart. Move forks under axle and
raise itjust toremoveits weight from mounting-bolts.
Do not remove the counterweight unless you
Or use a portable floor jack to carefully support the
have training and are familiar with the cor-
axle at its center section.
rect procedures. Counterweights can fall if
not handled correctly and cause severe Loosen and remove mounting bolts.
injury or death.
Carefully withdraw the axle from beneath the truck and
move to safe storage.
WARNING
Do not raise truck by hoisting on overhead
guard or by jacking or lifting on counter-
weight.
Block the drive wheels of the truck and raise and block
the rear end. Remove steer wheels. See Lift-
SM 715, Jun 05 Steering Axle Removal and Replacement (EPX) 25-9-1

Group 25, Steering
Install bolts and tighten to 104.9-126.5 Nfim (77.5-93.5

Silent Block ft-lb).
Remove temporary axle support from under truck.
Connect the hydraulic lines to steering cylinder.
Steer Axle
IMPORTANT
Make sure all fittings and openings on the
hydraulic lines are clean.
Carefully raise the truck off the blocking as described in

Lifting, Jacking and Blocking. Remove the
blocking and lower the truck to the floor.
If removed, reinstall countenveight; refer to Group 38,
Section 2, Counterweight Removal and
Replacement.
Steer Axle Replacement Check the axle and steering system for proper opera-tion.
Operate the steering gear to move the steer wheels to
Replacement is the reverse of removal. maximum travel in both directions. Note any unusual
motion or noise. If the system appears to be
CAUTION
operating correctly, drive the truck slowly. Fully
Make sure truck is correctly raised and steer the vehicle in each direction and check
safely blocked using hardwood blocks under response.
the frame. Be sure the blocking will permit
installation of the axle without disturbing the Check steering cylinder hose line connections and
blocking. cylinder rod seals for any evidence of oil leakage
before returning the truck to service.
If silent blocks have been removed from axle, install
new silent block assemblies. Use a rubber or plastic
mallet to seat the silent mounts onto theaxle trun-
nions.
Make sure that the silent blocks are positioned cor-rectly
on the rear frame.
Use a fork lift truck or mobile floor jack to tempo-rarily
support and raise the axle into place under the truck.
If another lift truck is used to handle axle, cen-ter
the forks with about 305 mm (12 in) spreadbe-tween
them. Place steer axle assembly in secure position
on fork tips. If hydraulic jack is used, be sure axle is
securely supported on jack pad.
WARNING
Heavy components can fall and cause severe
injury. Keep your body clear at all times.
Install axle assembly into frame by slowly raising it up.

Reset the two mounting plates under the silent blocks of
the axle.
25-9-2 Steering Axle Removal and Replacement (EPX) SM 715, Jun 05

Group 25, Steering
Section 10
Steering Cylinder Removal and Replacement (EPX)
Steer Cylinder Removal......................................................................................................................1

Parts Inspection.....................................................................................................................................2
Steer Cylinder Replacement...............................................................................................................2
WARNING Remove the cotter pin from the bottom of the steer-ing
link pin. Steering link pin attaches steer cylinder rod
SAFE PARKING. Before working on truck: end to steering link.
Park truck on a hard, level, and solid. Link Pin
surface, such as a concrete floor with no gaps or
breaks. Bearing
Put all controls in neutral. Turn key switch OFF and Steering Link
remove key.
Washer
Cotter Pin
Steer Cylinder Removal
NOTE
The steer cylinder can be removed from the steer axle for
Mark left-side and right-side parts for cor-
overhaul or replacement without removing the steer axle
rect reassembly.
from the truck. The cylinder should be overhauled or
replaced if steering problems or troubleshooting informa- Tap steer link pin upward until it clears the steering link
tion indicate the cylinder is malfunctioning. See Group bearing and remove the pin.
25, Section 2, Steering System Troubleshooting, for Rotate the steering link away from the cylinder rod end.
steering problem diagnoses. See Section 12 in this Group
Remove steer link bearing from steering link.
for steer cylinder overhaul procedures.
Repeat steps 1 through 5 for the opposite side of the
Place a drain pan under the steer cylinder and remove steer cylinder.
the hydraulic lines from the cylinder fittings. Cap fit- Remove the four steer cylinder mounting bolts and
tings and lines to prevent fluid from leaking and to washers from the steer axle.
protect the components and hydraulic system from Cylinder is now ready to be removed from the steer axle
dust and dirt. Label hoses and fittings for correct body. Cylinder must be lifted off dowel pins positioning
reassembly. cylinder to axle body.
Mounting Bolt
Remove Fitting
Dowel Pin
SM 715, Jun 05 Steering Cylinder Removal and Replacement (EPX) 25-10-1

Group 25, Steering
WARNING Position the steering link with the cylinder rod end.
Reuse steer link bearing if still serviceable. Install
Cylinder is somewhat heavy and bulky. new bearings if scoring or wear marks are evident or
When removing cylinder from mounting be if the bearings do not operate smoothly.
prepared to lift and move the full weight of
the cylinder.
Link Pin
Parts Inspection Bearing
Completely inspect all parts:

Clean all bearings, cups, seals, pins, and other parts in an Steering Lin
approved cleaning fluid.
Inspect all parts for scratches, chips, scoring, and uneven
or heavy wear. Check steering links to be sure they Washer
are not bent or twisted. Check all threaded parts for Cotter Pin
damage.
Replace all parts showing excessive wear or signs of Rotate steering link into cylinder rod end and align
damage. bearing hole with rod end.
If parts are to be left exposed, coat all mating sur-faces
of parts with a light layer of engine oil. Keep all Tap pin through steer link bearing hole with cotter pin
parts clean and covered. hole on lower end.
Remove and clean all grease fittings before reassem- IMPORTANT
bling cylinder components. Make sure bearing is properly aligned with
Refer to Section 5, Steer Cylinder Overhaul, if pressure pin in the hole.
check or troubleshooting tips indicate a problem with
steer cylinder performance. Install the cotter pin to the steering link hole.
Repeat steps 1 to 5 for opposite side.
Steer Cylinder Replacement Clean and replace hydraulic hoses on correct, clean,
Remount the steer cylinder onto the steer axle dowel cylinder fittings. See Group 40, Hydraulic Fitting
pins; set bolts and washers in place and torque Tightening Procedure for replacement procedures.
mounting bolts to 100-110 N.m (74-81 ft-lb).
Mounting Bolt
Remove Fitting
Dowel Pin
Check to be sure all lube fittings are installed. Fill all
WARNING lubrication points with correct lubricant. See recom-
Cylinder is somewhat heavy and bulky. mended greasing procedure above.
When remounting cylinder to steer axle
Test function of steer cylinder before returning the truck
body, be prepared to lift and maneuver the
to service.
full weight of the cylinder as you set it into
position.
25-10-2 Steering Cylinder Removal and Replacement (EPX) SM 715, Jun 05

Group 25, Steering
Section 11
Steering Gear Overhaul(EPX)
IMPORTANT
Before removing any component for overhaul, make sure
the correct repair parts, seals, and gasket sets are available.
NOTE
The following material does not show the load sensing port
on the steering gear (steering control unit). The port is
located in the center of the other four ports. The load
sensing port requires no special overhaul procedures.
SM 715, Jun 05 Steering Gear Overhaul(EPX) 25-11-1

Group 25, Steering
Disassembly Remove meter (gerotor). Be careful not to drop star

(rotor).
Cleanliness is extremely important when repairing a
steer-ing gear. Work in a clean area. Before disconnecting
lines, clean port area of unit thoroughly. Use a wire brush
to remove foreign material and debris from around
exterior joints of the unit.
NOTE
Although not all illustrations show the unit
in a vise, it is recommended to keep the unit
in the vise during disassembly. Follow the
clamping procedures explained throughout
the text.
Remove seal from meter.

Meter (Gerotor) End
Remove drive spacer(s).
Clamp unit in vise, meter end up. Clamp lightly on
edges of mounting area, as shown. Use protective Remove drive.
material on vise jaws. Do not overtighten jaws.
9. Remove spacer plate.

2. Remove capscrews.
10. 10.Remove seal from housing.
Control End
11. Remove housing from vise and place on a clean soft
cloth to protect surface finish. Use a thin-bladed
screwdriver to pry retaining ring from housing.
Remove end cap.

Remove seal from end cap.
25-11-2 Steering Gear Overhaul(EPX) SM 715, Jun 05

Group 25, Steering
Place assembly so shaft is horizontal. Rotate spool and IMPORTANT

sleeve until pin is horizontal. Push spool and sleeve Do not bind spool and sleeve in housing.
assembly forward with your thumbs just far enough Rotate spool and sleeve assembly slowly
to free seal gland bushing from housing. Remove when removing from housing.
bushing.
Push pin from spool and sleeve assembly.
Push spool partially from control end of sleeve, then
remove six centering springs from spool carefully by
hand. Note their position in the unit before they are
removed.
13. Remove quad ring seal from seal gland bushing.
Use a thin-bladed screwdriver to pry dust seal from seal

gland bushing. Do not damage bushing.
Remove two bearing races and the needle thrust bear-ing
from spool and sleeve assembly. Push spool back through and out of sleeve. Rotate spool
slowly when removing from sleeve.
Remove seal from housing.
Remove spool and sleeve assembly from cap (14-hole)

end of housing.
Remove set screw from housing.

Screw a 1/8-inch-24 NC machine screw into end of check
ball seat. Then pull on screw with pliers to lift seat
out of housing.
Remove two seals from check valve seat.
Tip housing to remove check ball and check ball retainer.

Group 25, Steering
Parts Inspection Lubricate check ball seat and seals thoroughly before
installing seat in housing. When installing seat do
Inspect all parts for damage, cracks, broken parts, dam- not twist or damage seals. Install check ball seat in
aged threads, corrosion or erosion of surfaces, worn hous-ing; insert open end of seat first. Push check
spots, nicks or scratches. ball seat to bottom of hole.
Check all mating surfaces. Replace any parts that have Install set screw. Use a 5/16-inch Allen wrench to torque
scratches or burrs that could cause leakage. Discard all set screw to 11 Nm (100 in-lb; 8.3 ftlb). To prevent
old seals and replace with new ones. interference of parts, make sure top of set screw is
slightly below housing mounting surface.
Clean all metal parts in clean solvent. Blow dry with air.
Do not wipe dry with cloth or paper towel because lint or Assemble spool and sleeve carefully so that the spring
other matter can get into the hydraulic system and cause slots line up at the same end. Rotate spool while
damage. Do not use a coarse grit or try to file or grind sliding parts together. Some spool and sleeve sets
these parts. have identification marks ; align these marks. Test
If parts are left exposed, cover them with a clean cover to for free rotation. Spool should rotate smoothly in
prevent airborne dust from collecting on them. sleeve with finger tip force applied at splined end.
Reassembly
Refer to Service Parts Book when ordering replacement
parts. A good service policy is to replace all old seals
with new seals at overhaul.
NOTE
Lubricate all seals (with exception of new
quad ring seal) with clean petroleum jelly
such as Vaseline. Bring spring slots of both parts in line and stand parts on
Do not use excessive lubricant on seals for end of bench. Insert spring installation tool (avail-
meter (gerotor) section. able as Part No. 6000057) through spring slots of
Make sure all parts are clean and free of both parts. Position three pairs of centering springs
dust. Before assembly, lightly coat all (or two sets of 3 each) on bench so that extended
internal metal parts with oil. edge is down and arched center section is together.
In this position, insert one end of entire spring set
into spring installation tool, as shown.
Control End
Use a needle-nosed pliers to lower check ball retainer
into check valve hole of housing. Make sure retainer
is straight (not tilted on edge) in housing.
On those units which use the low torque centering

springs, there are two pairs of centering springs (or
two sets of each) and one pair (two) spring spacers.
The spring spacers are installed together between the
two sets of centering springs. The installation proce-
dure is the same as that used on the standard (three
Install check ball in housing.
pairs of centering springs) units.
Lubricate 5/8-inch diameter seal and 7/16-inch diam-eter
seal. Install seals on check ball seat, as above.

Group 25, Steering
Compress extended end of centering spring set and push Install two bearing races and the needle thrust bear-ing in
into spool sleeve assembly withdrawing instal-lation the order shown.
tool at the same time.
Center the spring set in the parts so that they push down
evenly and flush with the upper surface of the spool
and sleeve.
Install pin through spool and sleeve assembly until pin
becomes flush at both sides of sleeve.
Install 1-1/4-inch diameter dust seal in seal gland

bushing; flat or smooth side of dust seal must face
Position the spool and sleeve assembly so that the splined down towards bushing.
end of the spool enters the 14-hole end of housing Install dry quad ring seal in seal gland bushing. Smooth
first. seal in place with your finger. Do not use any seal
that falls freely into pocket of bushing. Seal should
not fall into place but should require light force to
seat.
IMPORTANT
Be extremely careful that the parts do not tilt
out of position while being installed. Push
parts gently into place with slight rotating
action; keep pin nearly horizontal. Push the
spool assembly entirely within the housing
bore until the parts are flush at the meter end
or 14-hole end of housing. Do not push the
spool assembly beyond this point to prevent
the cross pin from dropping into the dis-
charge groove of the housing. With the spool
assembly in this flush position, check for free
rotation within the housing by turning with
light finger tip force at the splined end.
Place housing on clean, lint free cloth. Install 2-1/8-inch

diameter seal in housing.

Group 25, Steering
Install seal gland bushing over the spool end with a Meter (Gerotor) End
twisting motion. Tap the bushing in place with a rub-
ber hammer. Make sure the bushing is flush against Clamp housing in vise, as shown. Clamp lightly on edges
the bearing race. of mounting area. Do not overtighten jaws.
On those units which use the Teflon seal, install the
Teflon back-up ring into the recess cut into the seal
gland bushing. Install the Teflon seal over the spool
end, then carefully install the seal gland bushing
over the spool end using a rotary motion.
NOTE
The seal gland bushing which is used with
the Teflon seal is not the same as the seal
gland bushing used with the standard quad-
ring seal. The seal gland bushing with the
Teflon seal has an identification groove cut
into the outer diameter of the bushing. The
grooved bushings can only be used with the NOTICE
Teflon seals and the non-grooved bushings Check to ensure that the spool and sleeve are
used only with the quad-ring seals. flush or slightly below the surface of the
housing.
IMPORTANT
Clean the upper surface of the housing by
wiping with the palm of clean hand. Clean
each of the flat surfaces of the meter section
parts in a similar way when ready for reas-
sembly. Do not use cloth or paper to clean
surfaces.
19. Install 3-inch diameter seal in housing.
Install retaining ring in housing. After installing ring, tap on

ring or pry with screwdriver around entire cir-
cumference of ring to properly seat ring in groove.
Install spacer plate. Align bolt holes in spacer plate with

tapped holes in housing.

Group 25, Steering
21. Rotate spool and sleeve assembly until pin is parallel 24. Install drive spacer(s) when used, in meter.
with port face. Install drive, making sure you engage

drive with pin.
IMPORTANT
Failure to properly install drive and pin may
cause unit to self steer.
NOTE
To assure proper alignment, mark spline end
of drive shaft with a line parallel to slot on
other end, before installing.
22. Install 3-inch diameter seal in meter (gerotor). Install 3-inch diameter seal in end cap.
Install end cap on gerotor, and align holes.
Install 7 dry cap screws in end cap. Pretighten screws to
initial torque of 17 Nm (150 inlb), then torque
screws to final torque of 31 Nm (275 inlb) in the
sequence shown.
With seal side of meter toward spacer plate, align star

valleys on drive. Note the parallel relationship of ref-
erence lines A, B, C, and D in figure. Align bolt
holes without disengaging meter from drive. Be sure
star has engaged drive spline in position shown.
Inspect the assembly to be sure all parts have been

installed and fasteners correctly installed and tight-
ened.
(Reprint courtesy of EATON Corporation)

NOTE :
Group 25, Steering Column and Gear SM 715, Jun 05

Group 25, Steering
Section 12
Steering Cylinder Overhaul(EPX)

Preparation for Steer Cylinder Disassembly and Overhaul.............................................2
Steer Cylinder Disassembly............................................................................................2
Parts Inspection...............................................................................................................2
Steer Cylinder Reassembly..............................................................................................2
Operational Pressure Test................................................................................................3
IMP ORTANT
are available.
Piston
Rod
Piston Seal
Tie Rod
Nut
O-Ring
Dry Bearing Retaining Ring

Gland
Rod Seal
Dust Wiper
SM 715, Jun 05 Steering Cylinder Overhaul(EPX) 25-12-1

Group 25, Steering
Preparation for Steer Cylinder seating for correct reassembly. Replace with new
seals and wipers at assembly.
Disas-sembly and Over haul
Refer to Section 5 for removal of steer cylinder from the Parts Inspection
steer axle body.
Carefully clean all parts in an approved solvent and
IMPORTANT
place on a clean surface.
Cleanliness is of extreme importance in the
repair and overhaul of this assembly. Check the piston for chips, cracks, and looseness on the
rod. If loose, replace rod and piston assembly.
Overhaul steer cylinder only in a clean, dust-free location, Be sure the piston-seal groove in the piston is smooth,
using clean tools and equipment. Dirt or grit will true, and undamaged.
damage the highly-machined surfaces and will result in
leakage or premature failure of components. Check the piston rod for damage. Look for scratches,
Cleanliness of the hydraulic circuit is extremely grooves, gouges, pitting, corrosion or other evidence
important to the proper operation and maintenance of of unusual wear. Minor surface damage may be
the system. Be sure the work area is clean. repaired by use of fine abrasion cloth or stoning.
Deeper damage will require replacement of piston
Before disassembly, the exterior of the steer cylinder rod assembly.
should be carefully cleaned to remove all dirt and
grease accumulation. Carefully inspect the cylinder internal bore for wear,
scratches, corrosion or other damage. Check the out-
Be sure all hydraulic fluid has been removed from the side for damage. Inspect all welds for cracks.
cylinder. Stroking the piston rod will help force the
fluid out. Inspect the cylinder ports and threads to be sure they are
free of contamination and that the threads are clean
Before starting disassembly, the steer cylinder should be and not damaged.
carefully examined to determine if there is any
external damage. Check the gland for cracks or damage that could cause
failure.
Steer Cylinder Disassembly Deep gouges or pitted surfaces require replacement of

parts.
Clamp the steer cylinder assembly in a vise. Wrap the
cylinder in a course cloth to prevent slipping and Put a light coating of hydraulic fluid on all parts. If parts
scratching. Use extreme caution when tightening are to be left disassembled for a period of time, such
vise and do not overtighten; cylinder can be bent, as overnight, they should be covered with a clean
dis-torted, and potentially destroyed. cloth.
Loosen nuts and remove the rod from cylinder assembly.

Steer Cylinder Reassembly
Remove one gland by pulling it from cylinder barrel and
pulling it off the piston rod. Check to make sure the overhaul kit you have is correct
and that all parts are included.
Remove the piston and rod assembly from the Cylin-der.
IMPORTANT
Remove gland from opposite end of steer cylinder.
Be sure inside of cylinder and all parts are
Remove the seal and O-ring set from the piston. Dis-card clean before starting reassembly. Assemble
seals. Replace with new seal set at assembly. cylinder carefully to prevent damage to seal
lips and Orings. Seals should be lubricated
Remove (inner) gland packing (O-ring) seal. Replace with hydraulic oil to assist assembly into cyl-
with new seals at assembly.
inder barrel and gland. Heating seal rings in
Remove the rod (U-cup) seal and dust wiper from gland boiling water before starting assembly will
and discard. Note direction of seal and wiper aid in assembly.
1. Install new piston seal on the piston.
25-12-2 Steering Cylinder Overhaul(EPX) SM 715, Jun 05

Group 25, Steering
Install new gland packing (O-ring) seal and dry bear-ing

on inner end of gland.
Install new dust wiper and rod (U-cup) seal in outer end
of gland and install retainer ring.
IMPORTANT
Be sure the rod wiper and dust (U-cup) seal
are installed in the correct directions.
Lightly lubricate the cylinder and gland mating sur-faces

with hydraulic oil before assembly.
Install the gland onto the cylinder bore rim, making sure
gland is fully seated on cylinder.
Install piston and rod assembly into the cylinder.
NOTE
A special part is included in the parts kit to
allow you to slip the gland over the rod end
without damaging the gland seals.
Repeat above procedure for installation of opposite

gland.
Install the tie rods and nuts.
Operational Pressure Test

Once cylinder is remounted on axle (see Section 4), con-
nect pressure source in turn at each port. Extend piston
rod at each side and test with internal pressure of 13790
kPa (2000 psi). At this pressure no leakage must occur.
Typical operating pressure is 8620kPa (1250psi).
SM 715, Jun 05 Steering Cylinder Overhaul(EPX) 25-12-3

NOTE :
Group 25, Steering Column and Gear SM 715, Jun 05

GROUP 29 MAIN HYDRAULIC SYSTEM
GROUP 29
MAIN HYDRAULIC SYSTEM
Main Hydraulic System

Specifications and Description ............................... Section 1
Fluids and Filters ............................................................. Section 2
Hydraulic System Troubleshooting ................................ Section 3
Hydraulic System Pressure Check and Adjustments ... Section 4
Main Hydraulic Pump Overhaul ...................................... Section 5
SM 715, Dec 04 Group 29 Main Hydraulic System,

NOTE :
Group 29 Main Hydraulic System, SM 715, Dec 04

Group 29, Main Hydraulic System
Section 1
Main Hydraulic System

Specifications and Description
Specifications............................................................................................................................2
Serviceable Items.....................................................................................................................3
Service Intervals.......................................................................................................................3
Description................................................................................................................................3
Pump Motor Mounting Illustration............................................................................................4
Main Hydraulic Lines Illustration..............................................................................................5
Steer Lines Illustration...............................................................................................................6
Main Hydraulic Valve Inlet Lines Illustration...........................................................................7
SM 715, Dec 04 Main Hydraulic System Specifications and Description 29-1-1

Specifications Flow Control Adjustments: Adjustable from 4 to 38 L/min

(1 to 10 gpm). Before adjusting, turn fully counter-clock-
Hydraulic Fluid Type: Clark specification MS-68 (Clark wise to stop. Each clockwise turns of the adjustment
part #I802155 and#1800236) increases flow by 3 L/min (.75 gpm).
Hydraulic Pump Type: Integral gear-type pump and
motor assembly. Auxiliary Flow Adjustments
Sump Capacity: Usable oil = 19 Liters (5.0 Gal) Flow Settings Clockwise Turns of
Filter Type: Disposable, 25 micron, fill flow return line L/min (gpm) Adjustment Screw
oil filter and a 10 micron filter cap/breather filter. 6.3(1.7) 0.50
Main Relief Valve Setting: 18,000 to 18,700 kPa (2600 to
8.7(2.3) 0.75
2700 psi) at rated flow.
Auxiliary Relief Valve Setting: 13,300 to 14,300 kPa 12.3 (3.2) 1.0
(1925 to 2075 psi) at rated flow. 19.0 (5.0) 1.50
Rated Flow: 23.4 (6.2) 1.75
Lift spool (spool #l): 76 L/min (20 33.5 (8.8) 2.5
Tilt spool (spool #2): 38 L/min (10 gpm). 39.8(10.5) 3.00
Auxiliary spool (spool #3): 38 L/min (10 gpm). 52.9 (14) 4.50
Auxiliary spool (spool #4): 38 L/min (10 gpm).
Integral Pressure Compensated Flow Control Settings:
Tilt spool (spool #2): 12.3 L/min (3.2 gpm).
Afier adjusting the flow control valve settings it will be
Auxiliary spool (spool #3): 6.7 L/min (1.7 gpm). necessary to also adjust the pump control panel parame-
Auxiliary spool (spool #4): 38 L/min (10 gpm). ters to coincide with the settings you have made. See
Tilt Flow Settings: Group 19 for the proper Handset usage.
Tilt Flow Control Adjustments Pump Control Panel Settings (Using the Handset)
Average Tilt Speed Usage Clockwise Turns of Parameters Auxiliary Flow Settings
Adjustment Screw
/Sec Lpm (gpm)
GPM 36V Hz 48V Hz
2.5 6.3 (1.7) 3937 (155") 0.5
2nd Speed Fine 2.5 20 33
MFH & Above
and 3rd Speed
5.5 43 51
3 8.7 (2.3) Up to 3937 0.75 Fine
(155") MFH 7.0 55 65
10.0 79 93
Maximum Pressure Drop at Rated Flow:
Inlet to outlet: 689 1cPa (100 psi).
Lift spool (spool #I):
Inlet to cylinder port: 689 kPa (1 00 psi)
Cylinder port to outlet: 550 kPa (80 psi)
Tilt spool (spool #2):
Inlet to cylinder port: 689 kPa (100 psi)
Cylinder port to outlet: 550 kPa (80 psi).
Auxiliary spools (spools #3 and #4):
Cylinder port to outlet: 207 kPa (30 psi).
29-1-2 Main Hydraulic System Specifications and Description SM 715, Dec 04

Serviceable Items Description

The following description focuses on hydraulic circuitry
up to the main hydraulic control valve, that is, the lift/tilt/
Serviceable items are the pump, motor, priority valve,
aux circuit.
return line filter, main control valve, and cylinders. Other
components, such as hoses, fittings, and clamps, and the The TMX truck uses one hydraulic pump and motor
load-lowering flow valve are non-serviceable and should assembly to supply oil for all hydraulic functions, includ-
be replaced if worn or damaged. ing the power steering system. The speed of the pump and
motor assembly is controlled by the AC Pump control and
the pump will only turn fast enough to provide the needed
Service Intervals oil flow for the function that is being used. Switches and
Hydraulic Fluid Level Checks: Every 8-10 hours or daily. transducers are used on the hydraulic control valve levers
to supply the inputs to the AC control panel for the differ-
Hydraulic Fluid Change (Drain and Refill): Every 2000 ent functions.
hours of operation or every year.
A Priority valve is incorporated in the hydraulic system,
Hydraulic Fluid Filter Replacement: After the first 50 mounted on the side of the pump, to provide a measured
hours of operation, then every year or 2000 hours of oper- flow of oil to the steer system at all time the truck is run-
ation. ning. The remaining oil flow is diverted to the main
Hydraulic System Relief Pressure Check: Every year or hydraulic valve for the other hydraulic functions.
every 2000 hours of operation. The hydraulic oil is constantly being filtered by passing all
of the steer gear return oil through the spin-on oil filter.
The pump and motor assembly is located under the floor
plate and is mounted to the front battery plate. See Group
16 of this manual for removal and replacement of the
pump and motor assembly.
SM 715, Dec 04 Main Hydraulic System Specifications and Description 29-1-3

Pump Inlet
Elbow
Pump Motor Mounting(TMX)
Pump Motor Mounting(EPX)
29-1-4 Main Hydraulic System Specifications and Description SM 715, Jun 05

Filter Return Line
Main Valve
Return Lines
Pump Sunction Line

Sump Tank
W/O Seat
Brake With Seat
Brake
Main Hydraulic Lines(TMX)

Filter Return Line
Sump Tank
Main Valve
Return Lines
Pump Sunction Line

Main Hydraulic Lines(EPX)
SM 715, Jun 05 Main Hydraulic System Specifications and Description 29-1-5

Steer Gear
Return Line
Steer Gear Pressure Line
Priority Valve
Steer Cylinder Lines
Steer Lines(TMX)
Steer Cylinder Lines
Steer Lines(EPX)
29-1-6 Main Hydraulic System Specifications and Description SM 715, Jun 05

Main Valve Pressure Line
Priority Valve
Main Hydraulic Valve Inlet Line(TMX)
SM 715, Jun 05 Main Hydraulic System Specifications and Description 29-1-7

NOTE :
Group 29, Main Hydraulic System SM 715, Dec 04

Section 2
Fluids and Filters
Hydraulic Sump Tank Fluid Level Check.............................................................................2

Hydraulic Fluid and Filters Change......................................................................................2
Filter Change..............................................................................................................................2
Breather Maintenance................................................................................................................3
Fluid Change..............................................................................................................................3
SM 715, Dec 04 Fluids and Filters 29-2-1

Hydraulic Sump Tank Fluid Level Hydraulic Fluid and Filters Change
Check Drain and replace the hydraulic system fluid every
Check the hydraulic sump tank oil level with: 2000 operating hours, or once a year.
Truck on a level surface. Replace the hydraulic oil filter at every oil change.
Upright in the vertical position. Replace the sump tank breather every 1000 operat-ing
hours.
Fork carriage fully down.
Oil at operating temperature.
Filter Change
Pull the dipstick out, wipe it with a clean wiper, and
push it back into the dipstick tube. Remove the dip- Remove and replace the hydraulic system filter per
stick again and check the oil level indication. recommended planned maintenance schedule, or as
may be required by truck operating conditions and
Check the condition of the hydraulic fluid (age, color or usage.
clarity, contamination), to determine if it should be
replaced. Install a new oil filter. Be sure to follow the installa-tion
Refer to PM records for operating time since last oil instructions printed on the filter.
change. Check for leaks after installation of the filter. Also, check
Refer to next page if fluid needs to be changed. that the hydraulic line connections at the filter
adapter are tightened correctly.
The hydraulic system oil level should be between the oil
level markings on dipstick. NOTE
In the event of failure of a major hydraulic
system component, such as the main pump, or
the possibility of severe contamination of the
fluid, samples of hydraulic oil should be
F submitted to an independent commercial lab-
L
F oratory for analysis of the contaminant level.
NOTE
Approximately 2.8 L (0.75 gal) of hydraulic
oil is required to fill the hydraulic tank from
the "L" (LOW) mark to the "F" (FULL)
mark. DO NOT OVERFILL. Use MS-68
fluid.
5. Add recommended fluid only, as required.

NOTE
Remove or pull dipstick part way out to vent
air from tank while filling. When adding
fluid, check the fluid level again with the dip-
stick after operation of the truck including
operation of the upright through several lift
cycles.
29-2-2 Fluids and Filters SM 715, Dec 04

Breather Maintenance Fluid Change

Remove the hydraulic sump tank fill cap/ breather and WARNING
inspect for contamination and damage.
Clean or replace the fill cap/breather, per recom-mended
1.Park truck on a hard, level, and solid surface,
planned maintenance schedule, or as required by
operating conditions. such as a concrete floor with no gaps or breaks.
2.Put upright in vertical position and fully lower
the forks or attachment.
3.Put all controls in neutral. Turn key switch OFF
and remove key.
4.Apply the parking brake and block the wheels.
There is no drain plug in the hydraulic sump tank. Unless

the sump tank is to be removed for other repair or mainte-
nance, the hydraulic fluid can be changed by one of the
following methods:
Remove of the sump breather/filler cap and strainer
and draw the fluid out with a separate pump and
hose.
Pump the fluid out by using the trucks hydraulic
system. This method, described below, may be
used most easily and satisfactorily for routine
changing of the fluid.
Breather Cap
Dipstick
Breather Cap
Dipstick
Filter
(TMX Truck)
Filter
(EPX Truck)
SM 715, Jun 05 Fluids and Filters 29-2-3

Remove the snap-on cap and connect a suitable drain Move tilt control lever to the back tilt position to start
hose to the diagnostic check port fitting. the lift pump. A steady stream of used oil should
flow from the drain line. Hold tilt lever in this posi-
NOTE
tion until sump tank is empty. Release the tilt lever
Use quick-disconnect adapter fitting. immediately when flow becomes unsteady .
Turn the key switch OFF.
Disconnect drain line from truck and replace cap.
Remove and discard old oil filter and install new fil-ter
as described previously.
Remove and replace the sump breather cap as described
previously.
Refill the sump tank with Clark MS-68 Hydraulic Fluid.
Check truck operation. Turn key switch ON. Operate the
You will need a drain pan of 19 L (5 gal) minimum hydraulic system. Cycle the lift system several times:
capacity. Be sure the outlet end of the drain line is Raise the lift carriage to full height and lower fully
directed into the drain pan and held from moving down. Check for leaks. Recheck sump tank fluid
when pressurized. level.
Turn key switch ON.
CAUTION
IMPORTANT Be sure there is adequate overhead clearance
EMPTYING SUMP. Continue the next step before raising upright.
until the sump is empty. At that point, the
pump speed increases noticeably and a whin- 11. Turn the key switch OFF.
ing sound is heard. Release the tilt lever
immediately when this occurs. Adaptor Fit-
ting Cap
29-2-4 Fluids and Filters SM 715, Dec 04

Section 3
Hydraulic System Troubleshooting
Noisy Pump................................................................................................................................2
Pump Not Delivering Hydraulic Fluid.......................................................................................2
Failure to Build Pressure............................................................................................................2
Pump Not Developing Sufficient Pressure................................................................................2
Pump Output Low......................................................................................................................2
Foaming Fluid............................................................................................................................2
Overheated Pump and/or Fluid..................................................................................................2
External Leakage.......................................................................................................................2
Shaft Seal Leakage.....................................................................................................................3
No lift, tilt, or auxiliary function................................................................................................3
No motion, slow or jerky action of hydraulic system................................................................3
Foaming hydraulic fluid.............................................................................................................3
Overheated hydraulic fluid....................................................................................................... 3
Load cannot be lifted to maximum height.................................................................................3
Oil leaks at top of lift (secondary) cylinder(s)...........................................................................3
Oil leak at tilt or auxiliary function cylinder.............................................................................3
Load will not hold......................................................................................................................3
Oil leaks at either end of main hydraulic valve spool................................................................4
Spring-centered spools do not return to neutral.........................................................................4
No relief valve action (high pressure)........................................................................................4
Load drops when spool is moved from neutral to lift position..................................................4
SM 715, Dec 04 Hydraulic System Troubleshooting 29-3-1

Noisy Pump Pump Output Low

Hydraulic fluid level low; measure and correct fluid Cavitating pump; see Noisy Pump.
level. Air in fluid or wrong fluid; drain and fill with cor-rect
Fluid viscosity too high; change to specified fluid. fluid.
Air leak at pump inlet line; check plumbing tight-ness. System relief valve set too low or too high, stuck or
Inlet line restriction; check for foreign material or line leaking; correct relief valve, pump may be OK.
kinks, check and clean sump suction screen. Overheated fluid; see Overheated Pump and/or
Air leak at pump shaft packing; replace packing. Fluid.
Defective hydraulic pump; continue other trouble- Contaminated fluid; eliminate contamination source
shooting items, then consider servicing or replac- and replace fluid.
ing pump. Gear face, body or cover nicked; repair or replace
pump.
Pump Not Delivering Hydraulic Fluid Excessive side loading, wear plate tight in body bore,
pinched thrust plate; inspect and service pump.
Hydraulic fluid level low; check and correct fluid
level.
Overheated Pump and/or Fluid
Inlet line restriction; check for foreign material or line
kinks, check and clean sump suction screen. Low viscosity fluid; drain and fill with correct fluid.
Air leak in suction line; check plumbing tightness. Contaminated fluid; drain fluid, replace filter, and fill
Fluid viscosity too high; check fluid viscosity and sump.
change to specified fluid. Cavitating pump; see Noisy Pump.
Defective hydraulic pump; continue other trouble- Pump drive shaft misaligned; check mounting and
shooting items, then consider servicing or replac- alignment.
ing pump. Axial loading on drive shaft; check shaft end clear-
ance and shaft alignment; check for worn key/
Failure to Build Pressure spline.
Relief valve usually in bypass; check relief setting.
Hydraulic fluid level low; measure and correct fluid
level.
External Leakage
Defective relief valve or pump; perform pressure
check to test valve and pump. Excessive system pressure; replace pressure con-trol
valve on main hydraulic valve.
Pump Not Developing Sufficient Pressure Faulty or distorted pump seal gasket; replace seal
gasket.
Leak in hydraulic control system; check system for
and correct leaks. Damaged surfaces on pump body or cover; correct
and replace as required.
Inlet line restriction; check for foreign material or line
kinks.
Shaft Seal Leakage
Defective hydraulic pump; continue other trouble-
shooting items, then consider servicing or replac- Damaged or worn seal; replace.
ing pump.
Shaft scratched or worn or seal nicked; repair (pol-
ish) or replace and add new seal.
Front cover bearing out of position; replace front
cover assembly.
29-3-2 Hydraulic System Troubleshooting SM 715, Dec 04

Shaft seal housing bore scratched; replace front cover Overheated hydraulic fluid
assembly.
Thin fluid; drain and fill with correct fluid.
Improper fit of shaft; replace front cover assembly.
Contamination; inspect and service pump. Fluid contaminated; drain sump, replace filter, and
refill.
Pump operated in wrong rotation; replace shaft and
pressure loading seals. Cavitating pump; check hydraulic plumbing for
airtight hoses and connections.
Seal installed backwards; inspect and service seal.
Pump driveshaft misaligned; check mounting and
alignment.
No lift, tilt, or auxiliary function Axial loading on drive shaft; check shaft end clear-
Hydraulic fluid very low; check and fill to correct ance and shaft alignment; check for worn key/
level. spline.
Hose or fittings broken; replace component. Relief valve in bypass; check relief setting.
Defective main lift valve; check other Trouble-
shooting items for possible cause, then consider Load cannot be lifted to maximum height
rebuilding or replacing main lift valve.
Hydraulic fluid low; check and fill to correct level.
Hydraulic pump defective; check other Trouble-
shooting items for possible cause, then consider Hydraulic pump defective; check other Trouble-
rebuilding or replacing pump. shooting items for possible cause, then consider
rebuilding or replacing pump.
No motion, slow or jerky action of Oil leaks at top of lift (secondary) cylinder(s)
hydraulic system
Plugged vent line; check and clear line.
Spool not moved to full stroke; check travel and
Worn or damaged piston seal; rebuild cylinder.
linkage adjustment.
Scored cylinder wall; replace cylinder.
Relief valve not properly set, stuck in place, and/or
worn; check and clean valve, replace if necessary.
Dirt or foreign particles lodged between relief valve Oil leak at tilt or auxiliary function cylinder
control poppet and seat; check valve and clean.
Worn or damaged seal; rebuild cylinder.
Valve body cracked inside; check and replace entire Scored piston rod; repair or replace rod.
valve.
See Group 34, Cylinder Removal, Overhaul, and
Replacement.
Foaming hydraulic fluid Load will not hold

Low oil level; check and fill to correct level.
Oil bypassing between lift spool and valve body;
Wrong fluid; drain and refill with correct oil. overhaul valve and spool.
Oil too heavy; change to correct viscosity. Spool not centered; see spool remedies for correct-ing
Pump inlet line restriction or line kinked; clean line or problems when spools do not return to neutral.
repair kinked hose. Oil bypassing piston in cylinder; repair or replace
Hydraulic pump cavitating (pumping air with fluid); cylinder.
check hydraulic plumbing for airtight hoses and
connections on inlet side of pump. Oil leaks at either end of main hydraulic
valve spool
Defective O-ring seals; rebuild valve.
SM 715, Dec 04 Hydraulic System Troubleshooting 29-3-3

Spring-centered spools do not return to neu-

tral
Broken springs; rebuild valve. Entrapped foreign
particles; check and clean system and valve.
Bent spool; replace with new valve section.
Misalignment or binding of linkage; check and align/
adjust linkage.
No relief valve action (high pressure)

Small particles of dirt in relief valve subassembly;
check, clean, and/or replace relief valve, clean
hole.
Relief valve subassembly installed backwards;
reinstall correctly.
Load drops when spool is moved from neu-

tral to lift position
Dirt or foreign particles lodged between check valve
ball and seat; check and clean.
Sticking or scored check valve; clean if sticking,
replace if scored, replace poppet.
29-3-4 Hydraulic System Troubleshooting SM 715, Dec 04

Section 4
Hydraulic System Pressure Checks and Adjustments
Relief Pressure Checks..............................................................................................................2

Main Pressure Relief Adjustment..............................................................................................3
Auxiliary Pressure Relief Adjustment.......................................................................................3
Flow Control Adjustments........................................................................................................ 4
CAUTION
1.Park truck on a hard, level, and solid surface, such as a
2.Put upright in vertical position and fully lower the forks or
attachment.
3.Put all controls in neutral. Turn key switch OFF and
remove key.
SM 715, Dec 04 Hydraulic System Pressure Checks and Adjustments 29-4-1

Relief Pressure Checks NOTE

Use quick-disconnect adapter fitting, Clark
Following is the procedure for checking main hydraulic Part #913125.
valve lift pressure and auxiliary relief pressure (if the
truck is equipped with an auxiliary component). Check main relief pressure: Turn key switch on, move
Hydraulic system relief pressure setting may be checked the tilt control lever to full back (or forward) tilt
using a Mico Quadrigage (Clark Part No. 923770) or relief position. Hold tilt control in relief position
with a conventional pressure gauge with suitable pressure until pressure reading is obtained, and then release.
range calibration. To cover all models of the truck, a Gauge should read 20,000 to 21,000 kPa (2900 to
gauge with capacity range of 0 to 34,475 kPa minimum 3000 psi).
(0 to 5000 psi) is recommended. IMPORTANT
WARNING Do not operate system in relief any longer
than required to read the pressure gauge.
HYDRAULIC FLUID SAFETY. Keep all
hydraulic ports and components clean. Wipe
Check auxiliary relief pressure: (Truck must have
the area on the pump around the diagnostic
auxiliary component and auxiliary section added to
check port completely clean to prevent any
main hydraulic valve.) Move the auxiliary control
contamination from entering the hydraulic
lever to full back or forward relief position. Hold
system.
auxiliary control in relief position until pressure
When checking the hydraulic system, do not reading is obtained, and then release. Gauge should
use your hands to check for leakage. Use a read 13,300 to 14,300 kPa (1925 to 2075 psi).
piece of cardboard or paper to search for
leaks. Escaping fluid under pressure can
pen-etrate the skin causing serious injury.
Relieve pressure before disconnecting
hydraulic or other lines.
Tighten all connections before applying pres-
sure. Keep hands and body away from pin-
holes and nozzles which eject fluids under
high pressure.
Remove the covers enclosing the main hydraulic valve

to access the hydraulic system pressure diag-nostic
check port.
Remove the cap from the gauge port on the valve and
connect pressure gauge to the fitting.
29-4-2 Hydraulic System Pressure Checks and Adjustments SM 715, Dec 04

Main Pressure Relief Adjustment Replace the hydrostat in the same position with the new
unit.
IMPORTANT
Recap the pressure relief valve and replace in the valve
Main pressure relief setting is set at the fac-
body.
tory and should not be adjusted. If the relief
pressure does not measure within the setting Replace the spring, O-ring, and plug.
range, a hydrostat in the pressure relief valve
must be replaced. If you attempt to adjust
the hydrostat in the relief valve, your
Auxiliary Pressure Relief Adjustment
warranty on the equipment may be voided. IMPORTANT
The auxiliary relief setting only applies to a
To replace the hydraulic system main pressure relief hydraulic valve that has auxiliary sections
valve: added.
Remove the plug, O-ring, and spring from hydraulic
valve port shown in the following illustration. To adjust the hydraulic system auxiliary pressure relief
valve:
Loosen the jam nut on the auxiliary relief valve
adjustment screw.
Jam Nut and Adjustment Screw
Auxiliary Pressure Relief Valve

TMX Truck TMX Truck
Jam Nut and Adjustment Screw
Auxiliary Pressure Relief Valve
Main Pressure Relief Valve

EPX Truck
EPX Truck Turn the adjustment screw to set the auxiliary pres-sure
relief setting to the normal range.
Remove the main pressure relief valve.
Reset the jam nut on the auxiliary relief valve adjust-
Screw open the main pressure relief valve and remove ment screw.
the hydrostat in the valve.
SM 715, Jun 05 Hydraulic System Pressure Checks and Adjustments 29-4-3

Flow Control Adjustments

Flow control can be adjusted to meet the specifications
given in Section 1.
To make the following adjustments, position the tilt cylin-
ders mid-way in their stroke (upright vertical).
Remove the nut from the main hydraulic valve tiebolt
stud.
Remove nut
and tie-bolt.
Adjust flow here.
Bottom View of Typical Valve (no auxiliary attachments).

Remove the stud from the valve.
Turn the flow control adjuster fully counterclockwise to
the stop. Do not tighten against stop, or you can
damage valve seat.
Turn adjuster clockwise per flow control specifica-tions
in Section 1.
Repeat steps 3 and 4 for each flow control change
required.
Reinstall the tie bolt stud in the valve. Torque the stud to
38-43 N.m (28-32 ft-lb).
Reinstall the nut on the tie bolt and torque to 38-43 N.m
(28-32 ft-lb).
29-4-4 Hydraulic System Pressure Checks and Adjustments SM 715, Dec 04

Section 5
Main Hydraulic Pump Overhaul
Removal and Installation........................................................................................................2

Routine Maintenance............................................................................................................. 3
SM 715, Dec 04 Main Hydraulic Pump Overhaul 29-5-1

Removal and Installation Te remove or replace pump and leave motor installed,
pro-ceed as follows (replacement is reverse order):
WARNING Loosen/tighten bracket clamp screw (A) and shift
SAFE PARKING. Before working on truck: motor/pump assembly as ncessary for punp
access or mounting.
Park truck on a hard, level and solid surface, Hydraulic fittings.
such as a concrete floor with no gaps or breaks. Keep lines elevated to prevent dripping of fluid.
Tighten per hydraulic fitting tightening procedure
Put upright in vertical position and fully lower
in Group 40.
the forks or attachment.
Mounting bolts.
Put all controls in neutral. Turn key switch OFF Ground lead.
and remove key. Main pump.
Apply the park brake and block the wheels.
After installation:
NOTE Check operation of hydraulic system and fluid level of

sump. Add MS-68 hydraulic fluid as necessary.
To remove motor and pump as an assembly,
refer to motor removal procedure in Group
16.
Priority
Pump Inlet Valve
Elbow Pump Inlet
Elbow
Suction Hose
Pump Mounting Bolts
(TMX Truck)
Pump Mounting Bolts
(EPX Truck)
29-5-2 Main Hydraulic Pump Overhaul SM 715, Jun 05

Routine Maintenance
No maintenance is necessary other than periodic
checks for tightness of the mounting bolts and port
fittings plus visual examination for oil leaks. The
unit should be kept externally clean, especially in
the area of the shaft seal as dirt can accelerate seal
wear and cause leakage.
The unit must be operated on clean hydraulic fluid.
Directions for filter service in this Group must be
adhered to. A fluid cleanliness level of ISO4406
17/14 or better is recommended to give maximum
life.
SM 715, Dec 04 Main Hydraulic Pump Overhaul 29-5-3

NOTE :

GROUP 30 MAIN HYDRAULIC SYSTEM
GROUP 30
MAIN HYDRAULIC SYSTEM
Hydraulic System Schematic ........................................... Section 1
Main Hydraulic Control Valve

Removal and Overhaul ............................................ Section 2
SM 715, Dec 04 Group 30 Main Hydraulic System,

NOTE :
Group 30 Main Hydraulic System, SM 715, Dec 04

Section 1
Hydraulic System Schematic
Description................................................................................................................................2
SM 715, Dec 04 Hydraulic System Schematic 30-1-1

Description When all the control valve spools are in neutral, the micro
switch opens and signals the Pump Control Panel to slow
The following description focuses on hydraulic circuitry to the preset speed to provide enough oil flow for the
controlled by the main hydraulic control valve, that is, the steering system. When a spool is partially shifted and the
lift/tilt/aux circuit. Various other hydraulic systems come associated cylinder or other actuator has not reached its
into play, however, and are mentioned. The entire hydrau- end-of-travel, some of the fluid flows to the cylinder (or
lic system is depicted in the schematics at the end of this other actuator) and the rest flows to the sump line. In both
Section. cases, the pressure in the system should be less than the
Descriptions of the braking and steering circuits are given amount required to open the relief valves. The main relief
in Groups 23 and 25. valve vents flow to the sump when one of the following
conditions is present:
The hydraulic sump is equipped with a full-flow return
line filter, and filter cap/breather. The operator continues to hold the lift control in the
lift position after the lift mechanism reaches its
The main hydraulic pump is driven by an electric motor and end of- travel.
draws fluid from the sump. From the main control valve, the
Too heavy a load is being lifted.
oil is directed to the lift cylinders, tilt cylinders, auxiliary
function and back to the sump. From the steering valve, oil The operator continues to hold the tilt control in the
is directed to the steering cylinder as described in Group tilt position after the tilt mechanism has reached
25/26 and to the sump via the return line filter. its end-of-travel (This is called "tilt bypass.")
Auxiliary relief fails to operate.
The main hydraulic control valve features an open-center,
The auxiliary relief valve vents flow to the sump when
parallel-circuit type modular design. It has the main (lift/
the operator continues to hold the attachment control in
tilt) pressure relief valve (steering pressure relief valve is
the operated position after the attachment reaches its end-
on steer gear), a secondary pressure relief valve for
of-travel. Main and auxiliary relief pressure settings can
optional auxiliary components, a lift spool, a tilt spool
be checked through a gauge port on the valve. A tilt-lock
with an integral counterbalance valve, optional auxiliary
valve built into the main control valve assembly locks the
spools, and adjustable pressure compensated flow con-
upright into its current tilt position when the truck is
trols. All spools are low leakage design.
turned off. A load lowering flow valve mounted on the
The main valve has from two to four valve sections. Each upright limits the speed at which the operator can lower a
section performs a separate function; standard two spool load, decreasing the speed for heavier loads. A velocity
assemblies have an inlet/lift section (with fluid inlet port), a fuse built into at least one of the lift cylinder ports pre-
tilt section, and an outlet section. A third and fourth sec-tion vents the upright from falling rapidly should a hydraulic
may be added to control auxiliary components. When lift line rupture or be disconnected.
attachments are used, an auxiliary section may be added to
the outer (RH) side of the standard (lift/tilt only) main valve.
The optional auxiliary sections also have an adjustable relief
valve and can be assembled with optional flow control
levels. The valve spools are arranged in stan-dard sequence
(from the operator's position) to first pro-vide lift control,
then tilt, and finally auxiliary control. The control levers are
spring loaded (by the valve spool centering springs) to return
them to neutral when released. Oil flow is controlled by how
fast and how far the control handles are moved. Excess oil
flow is returned to the sump. A check valve prevents reverse
flow.
30-1-2 Hydraulic System Schematic SM 715, Dec 04

SM 715, Dec 04 Hydraulic System Schematic 30-1-3

30-1-4 Hydraulic System Schematic SM 715, Dec 04

STANDARD (EPX Truck)
SM 715, Jun 05 Hydraulic System Schematic 30-1-5

NOTE :

Section 2
Hydraulic Control Valve Removal

and Overhaul
Hydraulic Control Valve Removal ....................................................................................... 2

Preparation for Valve Removal ................................................................................................ 2
Control Valve Linkage Disassembly ........................................................................................ 2
Valve Removal .......................................................................................................................... 2
Hydraulic Control Valve Replacement . ............................................................................... 3

Valve Replacement ................................................................................................................... 3
Control Valve Linkage Reassembly ......................................................................................... 3
Reinstall Valve ......................................................................................................................... 4
Lift and Tilt Pump Switches Adjustment.................................................................................. 4
Operational Checks .................................................................................................................. 4
Preparation for Disassembly . ................................................................................................... 5
Hydraulic Control Valve Overhaul ......................................................................................
5
Disassembly ................................................................................................................... .......... 6
Cleaning, Inspection, and Repair .............................................................................................. 7
Reassembly .................................................................................................................... .......... 8
Relief Valve Settings.......................................................................................................... ....... 8
CAUTION
!

attachment.
remove key.
5. Disconnect the battery.
SM 715, Dec 04 Hydraulic Control Valve Removal and Overhaul 30-2-1

Hydraulic Control Valve Removal Control Valve Linkage Disassembly

IMPORTANT Remove the cotter rings and clevis pins connecting the lift
Keep all hydraulic ports, components, and and tilt (and auxiliary, as applicable) lever rods from the
fittings completely clean during valve hydraulic valve spools. Back off the lower jam nut at the
removal and replacement to prevent any turn buckle to allow the valve spool to be rotated before
con-tamination from entering the hydraulic removing the clevis pins.
sys-tem.
Preparation for Valve Removal

Park truck in a safe position and fully lower the upright. Clevis
Return all controls to neutral, apply the parking brake, Pin
turn the key switch OFF, and disconnect the battery. Cotter
Ring
Move all hydraulic control levers to all working posi-
tions and return them to neutral. Be sure there is no
hydraulic pressure applied to the system by attach- Turnbuckle
ments.
Lower Jam
Remove floor plate. Nut
Remove the right cowl cover from under the dash in the
operators compartment. See removal and Valve Spool
replacement procedures in Group 38.
Air clean the hydraulic valve and fittings. Valve Removal
Place a drain pan under the truck and loosen and remove Remove the three hex capscrews mounting the hydrau-lic
all hydraulic lines from the valve. Plug the valve valve to the hydraulic assembly bracket. Two of the
ports. Mark or tag each line as removed to assure capscrews thread into the valve itself; the third is secured
correct position of line at assembly. with a flange nut.
To Hydraulic Assembly
Upright Bracket ( Cowl)
Return Line
to Sump
Feed Line
Remove valve assembly from truck. See Section 6 for
from Pump Tilt Cylinder valve overhaul instructions.
Lines
NOTE
Be sure to clean up any oil spills and dry the
8. Cap ends of lines to keep them clean. Tie ends of floor to prevent accidents.
lines to truck to prevent loose ends dropping and
leaking oil onto floor.
30-2-2 Hydraulic Control Valve Removal and Overhaul SM 715, Dec 04

Hydraulic Control Valve Replacement Control Valve Linkage Reassembly

Insert the clevis pins through the rod-end clevises and
Valve Replacement valve spools of the lift and tilt spools (and auxil-iary
lever rods and spools where applicable) and secure
Position the main valve on the hydraulic assembly with the cotter rings. Rotation of the valve spools is
bracket (lower cowl). Install valve mounting fasten- required to allow insertion of the clevis pins. Rotate
ers and tighten hand tight so that valve mounting can spools back so all pins are in line.
be adjusted for alignment with the lever connecting
rods.
Hydraulic Assembly
Bracket (Lower Cowl)
Clevis Pin
Cotter
Ring
Turnbuckle
Lower Jam
Install the hydraulic lines on the proper ports. Make sure Nut
all lines are clean, are routed correctly in the truck,
and are not kinked. Torque fittings according to
Hydraulic Fitting Tightening Procedure in Group Valve Spool
40.
NOTE
The illustration above and system specifica-tion
To Upright
torques also apply for auxiliary hydrau-lic
functions, such as a side-shifter or rotator.
When alignment between the lever rods and the valve is

set and levers are inline and level with one another,
tighten the valve mounting capscrews and flange
nuts to 40-50 N.m (30-33 ft-lb).
Return Line
to Sump
Feed Line Tilt Cylinder

from Pump Lines
Adjust the valve to align with the lever connecting rods.

Lift and Tilt Pump Switches Adjustment Operational Checks

Turn key switch to the OFF position. Operate the truck and hydraulic system. Check the
system for leaks.
Loosen switch mounting screws.
Adjust switch to activate after 2 mm (0.08 in) of spool WARNING
travel from neutral. Do not use your hands to check for hydraulic
leakage. Use a piece of cardboard or paper to
Tighten mounting screws. search for leaks. Escaping fluid under pres-sure
Micro Switch can penetrate the skin causing serious injury.
Relieve pressure before disconnecting
Switch
hydraulic or other lines. Tighten all connec-
Mounting tions before applying pressure. Keep hands and
Bracket body away from pinholes and nozzles which
Switch eject fluids under high pressure.
If any fluid is injected into the skin, it must
be surgically removed within a few hours by
a doctor familiar with this type injury or
gangrene may result.
shown Check the operation of the valve and hydraulic sys-tem

mounted by moving the valve control levers to the various
positions. The levers must operate smoothly with no
binding. When released from any working position,
the levers must return sharply to their neutral posi-
tions.
If valve spools do not move or return to correct posi-
tion for full function of lift, tilt, or auxiliary cylin-
ders:
Loosen jam nuts on adjustment turnbuckles of lever
rods.
Adjust turnbuckle to increase or decrease spool

movement to correct measure.
Retighten turnbuckle jam nuts to 39-44 N.m (28.5-
32.5 ft-lb).
If valve was disassembled or overhauled. Check relief
pressur as described in the hydraulic system pressure
check Section of this Group.
Replace the cowl cover under the operators compart-
ment dash. See removal and replacement procedures
in Group 38.

Hydraulic Control Valve Overhaul IMPORTANT

CLEANLINESS. Overhaul valve only in a
The following overhaul instructions describe a two spool clean, dust-free location, using clean tools
assembly with the inlet/lift section, a tilt (or auxiliary) and equipment. Dirt or grit will damage the
section, and outlet section (outlet section contains no highly-machined surfaces and will result in
spool). leakage or premature failure of components.
Preparation for Disassembly Cleanliness of the hydraulic circuit is
extremely important to the proper operation
IMPORTANT and maintenance of the system. Be sure the
PARTS. Before removing any component for work area is clean.
overhaul, make sure the correct repair parts,
seals, and gasket sets are available. Clean outside of valve with a good grade of solvent
and dry thoroughly.
Before starting disassembly, the valve should be
carefully examined to determine if there is any
evi-dence of external damage.
Inlet/Lift Section.
See Figure 1 for
close-up view.
Outlet/Aux Section.
See Figure 3 for
close-up view.
Tilt/Aux Section.
See Figure 2 for
close-up view.
Main Hydraulic Valve Exploded View.

Disassembly Remove and label all parts between the sections for
correct reassembly. These include:
During disassembly, pay particular attention to identifica- Retainers and seals which are included in the
tion of parts for reassembly. Spools are selectively fitted to replacement seal kit.
valve bodies and you must return each spool to the same O-rings, springs, and ball which are replaced sep-
body from which it was removed. You must also be sure to arately.
reassemble the valve sections in the original order.
NOTE
NOTE Keep parts in order as removed and avoid
Valve sections may or may not require sepa- mixing the sections and parts.
ration for overhaul.
Disassemble each valve spool, one at a time, from
If only valve spools are being overhauled, you do not have bottom of valve as shown in the illustration.
to separate the sections. For a complete overhaul, includ-ing
replacement of the seals, retainers, O-rings, springs, and Remove the valve spools by tapping lightly on the top
balls used between the sections, follow steps 1 and 2. To end with a soft-faced hammer to drive them out of
overhaul only the valve spools, begin with step 3. the valve body.
Remove the nuts and studs connecting the valve sec- Arrange the parts in the sequence of removal.
tions.
Plug O-ring
AUXILIARY PRESSURE Spring

RELIEF VALVE (adjustable)
Set Screw Hydrostat spool

Nut
Plug
Relief Plug
O-ring
O-ring
O-ring (4 required)
Ball
Inlet/Lift Body
Seal
MAIN
RELIEF VALVE
Retainer
Lift Spool Assembly

O-ring
(Construction shown in
Figure 2.) Seal
O-ring
Figure 1. Inlet/Lift Body, Main Pressure Relief Valve, and Auxiliary Pressure Relief Valve.
See Figures 2 and 3 for remainder of valve.

Cleaning, Inspection, and Repair Inspect the main pressure relief valve for damage. Relief
valve must be free from contamination, burrs, and
Discard all old seals. Wash all parts in a clean min-eral scoring. Plug, spring, and O-ring should be cleaned
oil solvent and place them on a clean surface for and inspected for damage.
inspection.
NOTE
Carefully remove any burrs by light stoning or lap-ping. Entire relief valve assembly must be replaced
Be sure there is no paint or burrs on mating sur-faces if damaged. Relief valve pressure is con-
of valve bodies. trolled by a hydrostat in the valve relief valve
Inspect valve spools and bores for burrs and scoring. If assembly and is set at the factory. No adjust-
scoring is not deep enough to cause leakage, the ments are recommended; if pressure relief
surfaces can be stoned or polished with crocus cloth. setting is not in recommended range,
If scoring is excessive, valve body and spool must be hydrostat must be replaced.
replaced. Check each valve spool for free movement
in its bore.
Tilt or Auxiliary
Spring Body
Quad Ring
O-ring
Quad Ring
Sleeve
Retainer
Dust Cover
Springs
Spool
"C" Washers
Screw (2 required)
Ball (Used only in lift section.)

O-Ring
Spool Flow Control Poppet (Used
Plug only in tilt & auxiliary sections.)
Spring
O-Ring Spring
Ball Adjustable Flow
Control Nut
COUNTERBALANCE
O-ring
VALVE Retainer
(Tilt & auxiliary Flow Back-up
sections only.) Ring Ring
Adjuster
FLOW CONTROL
Figure 2. Valve Spool and Tilt (or Auxiliary) Body . Differences in lift (or tilt) and auxiliary components noted.
See Figures 1 and 3 for remainder of valve.

Inspect the lift and tilt relief valves for damage. Check Install seal rings and the seal ring retainer in the grooves
the relief valve for smooth free movement in its in body of each inlet and center section. Use
bore. The valve poppet should move easily from petroleum jelly to hold the seals in place. Carefully
only the force of its own weight. place the sections together in the same order in
which they were removed.
Inspect the valve body to make sure it has not been
physically damaged. Examine all threads to be sure Torque dust-cover screws to 10.8-13.5 N.m (8-10 ftlb).
they are clean and not damaged or burred. Inspect
Reinsert studs between valve sections and torque nuts to
all bores and poppet seats. Poppet seat must be even
27-34 N.m (20-25 ft-lb).
all around its circumference with no nicks, burrs, or
indentations in any of the seat face.
Relief Valve Settings
All springs should be free of corrosion and not bro-ken
or bent. After overhaul and reinstallation of the main hydraulic
If parts must be left unassembled for a period of time or valve, the hydraulic system relief pressure and auxiliary
overnight, cover with a lint-free clean material. valve relief pressure settings (if truck and valve are
equipped with an auxiliary component and section) must
be checked. See the hydraulic system checks and adjust-
Reassembly ments Section of this Group (30) for procedures.
Use the exploded view illustratiosn of the valve section, If the truck is not equipped with any auxiliary equipment,
spools, and relief valves for reassembly. no adjustments are necessary. If an auxiliary section has
been added to the hydraulic valve and auxiliary compo-
Assemble valve in reverse order of disassembly.
nents have been installed on the truck, check the relief
Coat all parts with clean hydraulic oil to facilitate pressure. See the hydraulic system checks and adjust-
assembly and provide initial lubrication. Petroleum ments Section of this Group (30) for procedures.
jelly can be used to hold seal rings in place during
assembly.
Use new O-rings and seals for all parts.
Outlet body
Tie-Bolt
Torque:
37.8-43.2 N.m
(28-32 ft-lb)
Figure 3. Outlet Body/Aux Section. See Figures 1 and 2 for remainder of valve.

GROUP 32 TILT CYLINDERS
GROUP 32
TILT CYLINDERS
Tilt Cylinder Specifications and Description ................. Section 1

Checks and Adjustments ................................................ Section 2
Tilt Cylinder Removal and Installation ............................ Section 3
Tilt Cylinder Overhaul ...................................................... Section 4
IMPORTANT
Other hydraulic-related components and curcuits are described and
Illustrated in Group 25/26, "Steering," Group 29/30, "Hydraulic
System", and Group 34, "Uprights." Refer to these other groups for
hydraulic components not covered in this group.
SM 715, Dec 04 Group 32 TILT CYLINDERS,

NOTE :
Group 32 TILT CYLINDERS, SM 715, Dec 04

Group 32, Tilt Cylinders
Section 1
Tilt Cylinder Specifications and Description
See Group 29 for hydraulic system specifications. The tilt cylinders provide backward and forward tilt of the
Tilt Cylinder Type: Double-acting upright. The forward and back tilt angles are governed by
the cylinder stroke and by use of spacersand differ-
Maximum Operating Pressure: 21,000 kPa (3,000 psi) entlength rod ends. The tilt cylinders are pin-mounted to
Tilt Ranges: (188 Triple Stage Upright): 3o back tilt and the truck frame and upright using yokes, clevises, and
5o forward tilt pins. Pins are held in place by a lock plate and fastener to
prevent the pins from working their way out.
Fastener Torques The tilt cylinders are serviced by removing them from the
truck and disassembling them for complete overhaul,
Rod-End Yoke Bolts: 170-190 N.m (125-140 ft-lb) including installation of new seals and or other cylinder
components.
Service Intervals The tilt lock valve is integrated into the tilt section of the
main hydraulic control valve. The tilt lock valve prevents
Tilt Cylinder Drift Test: Every 50-250 hours or each PM.
the upright from tilting forward when the truck is not run
Tilt Cylinder Check and Adjustment: Every 50-250 hours ning. The tilt lock valve is not serviceable and must be
or each PM. replaced as a valve section if defective.
Tilt Cylinder Rod Seal Condition Check: Every 50-250
hours or each PM.
Tilt Cylinder Mounting Check and Tightening: Every 50-
250 hours or each PM.
Tilt Cylinder Rod-End Check and Tightening: Every 50-
250 hours or each PM.
Tilt Cylinder Rod-End Lubrication: Every 50-250 hours
or each PM.
Tilt Cylinders
SM 715, Dec 04 Tilt Cylinder Specifications and Description 32-1-1

NOTE :
Group 34, Upright SM 715, Dec 04

Section 2
Tilt Cylinder Checks and Adjustments

Tilt Cylinder Drift Test............................................................................................................1
Drift Causes and Remedies...................................................................................................... 2
Tilt Cylinder Racking Check..................................................................................................2
Forward Adjustment...................................................................................................................2
Backward Adjustment................................................................................................................3
Tilt Flow Control Adjustments...............................................................................................3
CAUTION Raise the capacity load 2500 mm (98.5 in) off the ground
and tilt the upright vertical. Shut off the truck.
1.Park truck on a hard, level, and solid sur-
face, such as a concrete floor with no gaps
or breaks.
2.Put upright in vertical position and fully
3.Put all controls in neutral. Turn key switch
OFF and remove key.
4.Apply the parking brake and block the
wheels.
2500mm(98.5in)
Tilt Cylinder Drift Check
To check tilt cylinder drift, a rated capacity load is placed
on the forks, lifted up and held to determine if the tilt cyl-
inder rods moves (drifts) in a specified length of time.
It is recommended that a test load, made up of a fullcapac-ity
load equally distributed on a 1220 x 1220 mm (48 x 48 in)
pallet, be used. The material used to make up the test load Measure and write down the distance between the
must be stacked to provide load stability and must not extend cylinder-spacer face and the rod-end yoke.
beyond the pallet. It must be secured on the pallet. Refer to
the truck data plate for capacity rating. Measure rod
distance here
Adjust fork width as wide as possible to distribute the load.
Refer to truck nameplate for capacity rating.
CAUTION
Test load must be stacked stably, not extend
beyond the pallet, and be secured on the pal-
let.
Drive the forks into the load pallet until the test load and Wait five minutes and measure and write down dis-tance
pallet rest against the load backrest. Apply the between rod end and spacer.
parking brake and chock the wheels.
The measurement must not exceed the following
measures:
SM 715, Dec 04 Tilt Cylinder Checks and Adjustments 32-2-1

Temperature Drift
0.5, 3.1mm @ 1 min

50 C (122 F)
5, 31.1mm @ 10 min
Drift Causes and Remedies

Tilt cylinder drift indicates the following possible prob-
lems:
Tilt cylinder hydraulic circuit hoses or fittings are
leaking. Check the circuit components and repair
as necessary.
Cylinder piston seals are worn, damaged, or defec-tive
allowing fluid past the piston and causing the rod to Forward Adjustment
drift. Consider rebuilding the cylinders if the other
Slowly tilt upright fully forward to the end of the tilt
remedies in this list are not successful. See Section 3
cylinder stroke.
for cylinder removal and replacement and Section 4
for cylinder repair, if necessary. As the cylinders approach the end of the stroke, watch
The main hydraulic tilt valve is misadjusted, worn, or both piston rods for equal movement and upright for
defective. Fluid is leaking past the valve and twisting. Note if upright racks (is twisted at the
causing the tilt cylinders to drift. See Group 30 for end of its movement by unequal stroke of tilt
hydraulic valve troubleshooting. cylinders).
NOTE
Tilt Cylinder Racking Check Correct the twisting effect by shortening the
cylinder that is the longest length. Forward
Upright racking occurs when tilt cylinder strokes are twisting must be adjusted before backward
unequal. Cylinders should be checked regularly during twisting. If forward adjustment is not
operation to determine if cylinder strokes are the same. needed, continue with backward adjustment.
To check for racking:
Make sure truck is parked on level surface with To adjust, loosen rod-end yoke capscrew on the tilt
parking brake applied and wheels chocked. cylinder that extends the farthest, and turn piston rod
into rod-end yoke to shorten.
Check condition of the tilt cylinder, rod-end yoke,
mounting pins, piston rod, rod wiper, cylinder
gland, etc., for excessive wear or damage. Make Loosen
repairs before making twisting adjustment. capscrew.
Use a capacity load (see truck nameplate) centered on Turn to adjust.

the forks.
CAUTION
Be sure to secure the load to the fork
carriage to keep it from falling off when
tilted for-ward.
Raise the upright only to the height that will
allow the fork tips to clear the floor when
tilted fully forward.
Forward Adjustment: Pneumatic-tire truck rod-end

yoke orientation shown.
32-2-2 Tilt Cylinder Checks and Adjustments SM 715, Dec 04

NOTE Use rod shims to fill in the space between the rod-end
Use wrench flat on rod under spacer (if yoke and spacer. Screw rod back into yoke the same
installed). Move spacer for access. number of turns needed to remove.
Continue to turn rod into rod end until tilt cylinder

strokes are equal. Rod Shim
IMPORTANT Rod-End
Cylinder Rod Yoke
The rod must be threaded onto the rod-end
yoke a distance at least as great as the diame- Wrench Flat
ter of the rod plus 6.5 mm (0.25 in).
Add 6.5
mm (.25
in) to
Spacer
diameter
of rod.
Thread rod into rod-
end yoke the rod
diameter plus 6.5 mm
(0.25in). Tighten capscrew of the rod-end yoke to 166-193 N.m
(122-142 ft-lb), and repeat the racking test.
Repeat steps 1-5 for fine corrections if any racking
Tighten capscrew of the rod-end yoke to 166-193 N.m remains evident.
(122-142 ft-lb), and repeat the racking test.
When no racking occurs, retighten yoke capscrew to
Repeat steps 1-5 for fine corrections if any racking 166-193 N.m (122-142 ft-lb).
remains evident.
Check all tilt functions before returning the truck to
When no racking occurs, retighten capscrew of the rod- service.
end yoke to 166-193 N.m (122-142 ft-lb).
Check all tilt functions before returning the truck to Tilt Flow Control Adjustments
service.
See checks and adjustments Section of Group 29/30 for
adjustment procedure.
Backward Adjustment
Perform forward check and adjustment first. Then:
Slowly tilt upright fully backwards while watching
piston rods. They should both bottom out at the same
time. If they dont, adjust backward tilt using the fol-
lowing steps.
Stop the upright when the first tilt cylinder bottoms out
against its rod spacer.
Go to the opposite cylinder and remove the capscrew on
the rod-end yoke and screw rod out of yoke. Count
the number of turns required to remove the rod from
the yoke.
SM 715, Dec 04 Tilt Cylinder Checks and Adjustments 32-2-3

NOTE :

Section 3
Tilt Cylinder Removal and Replacement
SM 715, Dec 04 Tilt Cylinder Removal and Replacement 32-3-1

CAUTION Tilt Cylinder Removal and Replace-

!
SAFE PARKING. Before working on truck: ment
1.Park truck on a hard, level, and solid sur- Move tilt lever back and forth several times to relieve
face, such as a concrete floor with no gaps any pressure.
or breaks. Use an adequate chain and hoist to support the upright so
2.Put upright in vertical position and fully that it cannot fall when tilt cylinder pins are
lower the forks or attachment. removed.
OFF and remove key.
! WARNING
4.Apply the parking brake and block the The upright assembly is heavy. Use only hoists
wheels. with enough capacity to lift the entire assembly.
Keep hands and feet away from the assembly.
Use prybars to move the assembly into position
for tilt cylinder replacement.
Also support cylinder with a sling to prevent
the cylinder from dropping when pins are
removed.
Removal Sequence. (Replacement is reverse order). See

page 3.
Hydraulic lines.
Removal note: Put a drain pan under the truck at
each tilt cylinder position before removing the
hydraulic lines. Cap lines.
Mounting bolt.
Washer.
Locking pin.
Mounting pin.
Installation note: Make sure the spherical bearing
is aligned so that pin fits smoothly in yoke.
Cylinder assembly.
Spherical bearing.
Parts Inspection Spherical bearing.
Clean all bearings, pins, and other components in an NOTE
approved cleaning fluid. If the rod-end yoke has been removed from
Inspect all parts for scratches, nicks, dents, and wear. the rod or loosened for adjustment, reinstall
Check the cylinder rods to be sure they are smooth the clamp bolts to a torque of 166-193 N.m
with no scratches. Check all threaded parts for dam- (122-142 ft-lb). Nuts must be on inside of
age. upright rails
Replace all parts which show damage. See Section 2 for tilt cylinder adjustment procedures.
If parts are to be left exposed, coat all mating sur-faces When adjustments are made, check all upright com-
of parts with a light layer of engine oil. ponents under load before returning the truck to ser-
vice.
32-3-2 Tilt Cylinder Removal and Replacement SM 715, Dec 04

A
See Group 40
for hydraulic
fitting tighten-
ing procedure.
H
Upright must be supported with D
adequate capacity hoist.
G
E
Cylinder must be
supported with sling.
F
Torque: 20-22 N.m

(177-221 in-lb)
Tilt Cylinder Removal Replacement Steps (ref. page 2)
SM 715, Dec 04 Tilt Cylinder Removal and Replacement 32-3-3

NOTE :

Section 4
Tilt Cylinder Overhaul
IMPOTANT
Before removing any component for overhaul, make sure the correct repair parts, seals, and gasket
sets are available.
SM 715, Dec 04 Tilt Cylinder Overhaul 32-4-1

Preparation For Disassembly Remove and discard the piston seal and O- ring from the
piston.
IMPORTANT
Overhaul tilt cylinders only in a clean, dust-
free location, using clean tools and equip-
ment. Dirt or grit will damage the
highlymachined surfaces and will result in
leakage or premature failure of components.
Cleanliness of the hydraulic circuit is
extremely important to the proper operation
and maintenance of the system. Be sure the
work area is clean.
Before disassembly, the exterior of the tilt cylinder Remove and discard the rod U-cup seal, static seal, and
should be carefully cleaned to remove all dirt and piston rod wiper from the gland.
grease accumulation.
Be sure all hydraulic oil has been removed from the Inspection
cylinder. Stroking the piston rod will help force the
oil out. Carefully clean all parts in an approved solvent and
place on a clean surface.
Before starting disassembly, the tilt cylinder should be
carefully examined to determine if there is any Check the piston and rod for damage. Look for
evidence of external damage. gouges,scratches, corrosion, or evidence of unusual
wear. Minor surface damage may be repaired by use
of fine abrasion cloth or stoning. Deeper damage
Disassembly will require replacement of piston rod assembly. Be
sure the threads on the rod are undamaged.
The tilt cylinder can be held by clamping the base end or
the barrel in a vise while disassembling. Inspect the tilt cylinder barrel internal bore for wear,
scratches or other damage. Deep gouges or pitted
IMPORTANT
surfaces require replacement of parts. Check the out-
Do not use excessive force when clamping on side of the entire cylinder for damage. Inspect all
the barrel. welds for cracks. Inspect the ports to be sure they are
free of contamination and that the threads are clean
Remove the retaining ring on the gland with snap ring and not damaged.
pliers.
Put a light coating of hydraulic fluid on all parts. If parts
Push the gland assembly into the cylinder barrel to
provide access to the shear ring. are to be left disassembled for awhile, they should be
covered with a clean cloth.
With a brass punch, drive the shear ring inward to
compress it and provide access to its outer edge.
Then pry under the rings outer edge with a soft Reassembly
metal pick to compress the ring some more. This
allows you to pull the ring over the shoulder in the Install piston rod wiper, rod U-cup, and static seal on the
barrel and extract the ring. gland. Make sure U-cup and wiper are installed in
proper orientation as shown in the illustration.
Carefully pull the rod and piston assembly, and gland from
the cylinder barrel. Remove gland from rod. Replace the piston O-ring and piston seal.
WARNING Install gland on piston rod. Use gentle pressure and

careful movements to avoid damage to the U-cup
The use of compressed air to blow the piston
seal and rod wiper when these parts are moved over
out of the barrel is not recommended. High-
pressure air can result in piston and rod the piston rod end.
being ejected at high velocity (explosively), NOTE
causing severe injury to personnel and prop-
Reassemble cylinder carefully to prevent
erty damage.
damage to seal lips and O-rings.
32-4-2 Tilt Cylinder Overhaul SM 715, Dec 04

Install piston and rod assembly into cylinder barrel. Be Install the shear ring: Slip it over the rod and, with a
careful not to damage the piston seals when brass punch, drive it in until it travels past the shoul-
installing the piston into end of cylinder. der and snaps against the barrel wall. The pull the
gland and piston assembly forward to make the snap
Insert gland over rod and into cylinder until the entire gland
ring seat against the shoulder in the barrel wall.
is below the shoulder the shear ring seats against. Be
careful not to damage gland static seal. Check the assembly by making sure the piston slides
freely in and out of the cylinder.
See Section 3 for replacement procedures; see Section 2
for checks and adjustments before returning the truck to
service.
Shear Ring
Spacer
Gland Static Seal Cylinder Barrel
Retaining Ring
Gland
Rod
Wrench Flat
Rod Wiper
Rod U-Cup Seal Piston
Piston Seal and Dust Seal
O-Ring
Cut-Away View of Tilt Cylinder
SM 715, Dec 04 Tilt Cylinder Overhaul 32-4-3

NOTE :

GROUP 34 UPRIGHTS
GROUP 34
UPRIGHTS
Upright Specifications and Description ......................... Section 1

Troubleshooting ............................................................... Section 2
Upringht Inspection .......................................................... Section 3
Carriage and Upright Roller Clearance
Checks and Shim Adjustments ...................................... Section 4

Cylinder Removal, Shimming,
Overhaul, and Replacement ............................................. Section 5

Upright Chain Inspection, Adjustment,
and Replacement ............................................................. Section 6

Fork and Carriage Removal and
Replacement ..................................................................... Section 7

Upright Removal and Replacement ................................ Section 8
SM 715, Dec 04 Group 34 UPRIGHTS,

NOTE :
Group 34 UPRIGHTS, SM 715, Dec 04

Group 34, Uprights
Section 1
Upright Specifications and Description
General Specifications stamped on the upright of the truck to determine the type
of cylinder, piston or ram, used on the upright.
Upright Weight: Approximately 330 kg (730 lb) to
approximately 700 kg (1550 lb) without carriage.
Carriage Weight: Approximately 80 kg (180 lb) to 100 kg Upright Upright Cylinder Type
(220 lb) with a 37 inch carriage. Type Number
Fork Weight: Approximately 40-65 kg each (90-145 lb) StandardV1204 Piston-Type Lift Cylinder
T TSU M1203 Piston-Type Secondary Cylinder
IMPORTANT
M M1204 Piston-Type Secondary Cylinder
Before hoisting, the weights of upright, car- X HiLO H1205 Ram-Type Secondary Cylinder
riage, forks and attachments being lifted
H1206 Ram-Type Secondary Cylinder
must be combined to determine what lifting
capacity is required of the hoisting equip- E Standard V1218 Piston-Type Lift Cylinder
ment. P TSU M1218 Piston-Type Secondary Cylinder
X HiLO H1218 Ram-Type Secondary Cylinder
Capacities and Lift Heights: Upright, carriage, and fork
capacity and upright lift heights are listed on the truck is Drift:
data plate.
Lubricants: Upright should not drift (fall) 100 mm (4 in) in ten min-
utes under a capacity load. If drift over 100 mm (4 in) in
All Purpose Grease (MS-9) ten minutes is evident, cylinder should be checked for
Innerslide Lubricant (Clark P/N 886396) internal leakage. See Section 3 for drift test procedures.
Chain and Cable Lube (Clark P/N 886399)
Fastener and Fitting Torque Specifications
Cylinder Types Load Back Rest: 170-190 N.m (125-140 ft-lb)
Standard uprights use two lift cylinders. Triple stage and Chain Anchor Bolt Jam Nut: 80-150 N.m (59-110 lbf-in)
Hi-Lo uprights use three cylinders, a primary (center-
mounted) cylinder, and two secondary cylinders. All pri- Carriage Side-Thrust Roller Bolts: 34-40 N.m (26-30 lbf-
mary cylinders used on triple-stage uprights (TSUs) & in)
Hi-Lo are piston cylinders. Hose Fittings: See Group 40, Hydraulic Fitting Tighten-
ing Procedure.
The Secondary cylinders used on Hi-Lo uprights are ram
cylinders. Rod End Bolts: 164-190 N.m (122-142 ft-lb)
IMPORTANT Tilt Cylinder Rod-End Mounting bolt: 25-30N.m (221-
Before removing any component for over- 266 lbf-in).
haul, make sure the correct repair parts,
seals, and gasket sets are available.
The types of cylinders used on the truck are listed below.

Check the first five characters of the upright number
SM 715, Jun 05 Upright Specifications and Description 34-1-1

Group 34, Uprights
Service Intervals roller bearing surface can be reduced by the use of over-
size rollers on a one-time basis.
All upright components should be visually checked
every day during the Operators Daily Inspection. Forks use a hanger design for mounting on the carriage.
Auxiliary attachments may be added to the upright for
A thorough visual inspection should be performed by specialized handling operations. The hydraulic circuit is
a trained service professional every 50-250 hours.
modified with a hose adapter kit and an auxiliary section
Lift chains should be inspected and lubricated every is added to the main hydraulic valve to operate the attach-
50-250 hours or monthly. ment.
Lift chain tension should be checked every 50-250 The lift and secondary cylinders on standard uprights, Hi-
hours or monthly. Lo uprights and triple-stage uprights (TSUs) may be
Upright and carriage roller checks should be per- either piston-or ram-type cylinders. The primary cylinder
formed every 50-250 hours or monthly. on TSUs and Hi-Lo uprights are piston-type cylinder. See
Roller patterns should be checked every 6 months or the chart under Specifications to determine the type of
after 1000 hours of service. cylinder used on the upright you are servicing.
Racking and drift tests should be performed every 6 Piston-type cylinders contain a by-pass check valve in the
months or after 1000 hours of service. piston that allows air and fluid that have accumulated in
The complete extended inspection should be per- the rod end of the cylinder to return to the system. The
formed at least every year or 2000 hours of opera- check valve can be removed and cleaned if indicated by
tion. troubleshooting. A non-serviceable check-ball-type cush-
ioning function is built into ram and piston cylinders for
smooth staging during the lowering cycle. The primary
Description cylinder on TSUs incorporates cushioning on the lift
cycle. A flow control valve in the hydraulic port of the lift
The upright assembly includes the lift chains, lift cylin-
cylinders (secondary cylinders on TSUs) prevents the
ders, carriage, forks, and mast or rail sets. Each of the
components can be serviced using the tests, checks, mast from falling rapidly in case of sudden fluid pressure
adjustments, and removal and replacement procedures in loss due to line breaks or other malfunction of the hydrau-
the following Sections. lic circuit.
The upright uses the hydraulic cylinders and chain sets to As explained in more detail in Group 30, the main pump
lift the carriage and rail sets. On standard, two-stage sends fluid to the main hydraulic control valve, which
uprights, the lift cylinders lift the carriage with chains and contains spools that route fluid to the lift cylinders and tilt
directly lift the inner rail set. On triple-stage uprights, the cylinders. The valve assembly also contains a counterbal-
primary (free-lift) cylinder lifts the carriage by chains. ance valve that prevents upright tilt when the truck is not
When the primary cylinder reaches its maximum exten- operating.
sion, fluid is diverted to the secondary lift cylinders, Fluid flow rates for lift functions are factory set and not
which lift the inner rails using a second set of chains and adjustable. Flow rates for tilt and auxiliary functions are
lift the intermediate rails by direct lift. controlled by adjustments on the main hydraulic valve. A
On Hi-Lo uprights, the primary (free-lift) cylinder lifts non-adjustable load-lowering flow valve mounted on
the carriage by chains. The secondary cylinders directly the upright limits upright lowering speed.
lift the inner rail set by rod. Groups 29 and 30 contain general hydraulic information
Hi-Lo uprights not used second set of chain for secondary including upright hydraulic functions. Other hydraulic
cylinder. checks for the upright appear in Troubleshooting, Sec-
tion 2.
Friction and play between the nesting rails is controlled by
roller sets mounted on the rails and carriage. When rails or
rollers become worn, the gap between the rollers and rails
becomes larger, creating more play in lifting and lowering
operations. The rail web to roller side clearances can be
reduced by shimming the rollers to close the gap between the
roller and rails. The gap between the rail flange and
34-1-2 Upright Specifications and Description SM 715, Dec 04

Group 34, Uprights
Upper Roller
Lift Cylinder
Chain Sheave
TMX Truck
Chain Anchor
Outer Rail Set
EPX Truck
Lift Chain
Load Lowering
Flow Valve
Typical Standard Upright Assembly
Lower Roller
Inner Rail Set
Carriage
Upper Roller
Secondary
Load Lowering Cylinder
Flow Valve Hose Inner Rail Set
Chain Sheave
Primary Cylinder/
Carriage Chain
Chain
Anchor
Outer Rail Set
Primary
Cylinder
Lower Roller
Carriage
Typical Hi-lo Upright Assembly
SM 715, Jun 05 Upright Specifications and Description 34-1-3

Group 34, Uprights
Hose Sheave
Outer Rail Set
Upper Roller
Secondary Cylinder
Upper Roller
Chain Anchor
TMX Truck
Primary Cylinder
Chain Sheave
Load Lowering
Flow Valve
Primary
EPX Truck Cylinder/
Carriage
Chain
Intermediate
Rail Set
Lower Roller
Inner Rail Set
Lower Roller
Typical Triple-Stage Upright Assembly
34-1-4 Upright Specifications and Description SM 715, Jun 05

Group 34, Uprights
Typical Triple Stage Upringht-Overhead View
Roller Adjustment shims Carriage

External thrust roller
Carriages and Roller Sets
SM 715, Dec 04 Upright Specifications and Description 34-1-5

Group 34, Uprights
TMX Truck
EPX Truck
wo-Hose Adaptation for the Triple Uprigt (TMX)
TMX Truck
EPX Truck
Two-Hose Adaptation for the Standard Uprigt (TMX) Two-Hose Adaptation for the Hi-Lo Uprigt (TMX)
34-1-6 Upright Specifications and Description SM 715, Jun 05

Group 34, Uprights
Section 2
Troubleshooting
The visual inspection and the operational checks pre- Dry hose sheave or rollers; check condition of all
sented in Section 3 should be used to determine problems sheaves and rollers and lubricate as necessary.
with the upright. Possible problems, causes, and remedies Damaged chain sheaves; check condition of chain
are listed below. sheaves and repair or replace.
Other troubleshooting information about the hydraulic Excessive fork hanger or carriage fork bar wear;
cir-cuit and components appears in the troubleshooting inspect and replace as necessary.
Sec-tions of Groups 29 and 30. Use these other Seals dry; lubricate rod.
troubleshooting Sections for more detailed problem isola- Seals dry - all primary cylinders; remove gland and
tion with Upright hydraulic functions. add 100 ml (3.4 oz) of hydraulic oil to rod side of
piston, see Cylinder Removal, Shimming, Over-
WARNING haul, and Replacement.
The procedures for troubleshooting uprights,
carriages, and forks involve movement of the
No lift, tilt, or auxiliary function
components. Failure to follow these warnings
can result in serious injury. Hydraulic fluid level low; check level and fill.
Make sure overhead clearances are adequate Broken hoses or fittings; check and repair.
before raising the upright to full lift height.
Do not walk or stand under raised forks. Damaged or blocked sump strainer; check and clean.
Block carriage and upright whenever Hydraulic pump defective; see Group 29 for pump
making checks with the upright elevated. troubleshooting.
Keep clear of load and carriage when Defective main hydraulic control valve; see Group 30
making any check or adjustment. for valve troubleshooting.
Keep your arms and fingers away from mov- Defective upright load-lowering flow valve; disas-
ing parts of the upright. semble valve, check and clean or replace.
Do not reach through open areas of the
upright.
No lift function but tilt operates
Upright noise Broken hoses or fittings; check and repair.
Cylinder is damaged; inspect and repair.
Bent or broken components; inspect upright thor-
oughly and repair or replace components as Main hydraulic control valve, lift section defective;
required. see Group 30 for valve troubleshooting and
service information.
Damaged upright roller; check condition of rollers and
replace defective rollers. Upright load-lowering flow valve damaged; disas-
semble valve, check and clean or replace.
Roller scuffing rails; clean and lubricate rails.
Roller (carriage or upright) shimming needs
adjustment; check and adjust as required.
Fit between roller edge and rail flange excessively
loose in rails; replace with oversized, Select-Fit
rollers. SeeUpright Roller Clearance Check and
Shim Adjustment.
Dry lift chain; lubricate chain.
SM 715, Dec 04 Troubleshooting 34-2-1

Group 34, Uprights
Load cannot be lifted to maximum height Defective priority valve; see Group 30 for valve
troubleshooting information.
Hydraulic fluid level low, check level and fill. Defective upright load-lowering flow valve remove
Debris in upright; check and clean. valve clean, inspect, and replace if neces-sary.
Hydraulic hose fittings loose or damaged; check and
torque correctly (see Group 40 for specifica-tions) Lowering speed sluggish
or replace.
Check cylinder for external leakage; replace cylin-der Damaged or binding upright roller; check condi-tion
if cracked. of roller and replace if necessary.
Cylinder shimming is incorrect; check and adjust Damaged or kinked hydraulic hose or tube; check
shimming. condition of hose and tube, repair or replace as
Internal leakage on lift or secondary piston cylin-ders; necessary.
remove rod and piston and clean check valves; Defective upright load-lowering flow valve; check,
also clean and inspect/replace piston seals. See clean and replace valve if necessary.
Section 5. Defective velocity fuse; remove fuse from cylinder
Cylinder check valve on lift or secondary piston hydraulic port, clean and recheck for proper opera-
cylinders not functioning properly; remove rod and tion.
piston and clean check valves; also clean and
inspect/ replace piston seals. See Section 5. Load bounces excessively when lowering
Hydraulic pump defective; see Group 29 for pump
troubleshooting information. Air in hydraulic system, TSU and Hi-Lo ram-type
Upright rails binding: cylinders; set capacity load on upright and lift from
Perform a visual inspection and check for worn, or fully collapsed to full lift height for 10-15 cycles.
distorted parts, broken or cracked rails or tie- Defective upright load-lowering flow valve; check,
bars, correct chain and hosing placement and clean and replace valve if necessary.
operation Defective main lift valve; see Group 30 for valve
Check rollers for contamination and proper oper- troubleshooting and service information.
ation, perform roller clearance check and adjust- Defective velocity fuse; remove fuse from cylinder
ment. hydraulic port, clean and recheck for proper opera-
tion.
Lift speed sluggish
Upright mis-staging (TSU & Hi-Lo lifting)
Hydraulic fluid level low; check level and fill.
Broken hoses or fittings; check and repair. Debris in upright roller area of carriage; check and
Pump inlet line restricted; remove from pump and clean.
clean. Interference between carriage and inner rail or cyl-
Damaged or binding upright roller; check condi-tion inder; check staging alignment and adjust or repair
of roller and replace if necessary. as necessary.
Internal leakage on piston-type lift and secondary Bent or broken carriage or inner rail; replace part - do
cylinders (with load); perform cylinder checks not try to repair by welding.
listed under iLoad cannot be lifted to maximum Damaged or binding carriage roller; check condi-tion
height.i of roller and replace if necessary.
Hydraulic pump defective; see Group 29 for pump Carriage roller shimming or thrust roller out of
troubleshooting information. adjustment; perform roller checks on carriage and
Defective main lift valve; see Group 30 for valve make adjustments as necessary.
troubleshooting and service information. Damaged or kinked primary cylinder hose; check
Defective velocity fuse; remove fuse from cylinder condition of hose, repair or replace as necessary.
hydraulic port, clean and recheck for proper opera- Primary cylinder chain or chain sheave binding or
tion. damaged; inspect and repair.
34-2-2 Troubleshooting SM 715, Dec 04

Group 34, Uprights
Internal leakage in primary lift cylinder; perform Carriage and upright roller shimming or thrust roller
cylinder checks listed under Load cannot be out of adjustment; perform roller checks on
lifted to maximum height. upright and/or carriage and make adjustments as
Damaged primary lift cylinder causing binding in the necessary.
cylinder; inspect and repair or replace cylinder. Defective velocity fuse; remove fuse from cylinder
Defective velocity fuse; remove fuse from cylinder hydraulic port, clean and recheck for proper opera-
hydraulic port, clean and recheck for proper operation.
tion.
External leakage on primary cylinder
Upright mis-staging (TSU lowering)
Gland loose; check and tighten primary cylinder gland
Debris in upright roller area or tie bar area; check and to 135 N.m (100 ft-lb) and glands on lift
clean. (secondary) cylinders to 100 N.m (73 ft-lb).
Bent or broken carriage or inner rail; replace part - do Cracked cylinder tube; replace tube.
not try to repair by welding. Rod seal damage; replace seals and check for:
Damaged or binding roller on upright; check con- Damaged rod seal groove in gland; check for
dition of roller and replace if necessary. damage to groove and replace seal or gland if
necessary
Carriage and upright roller shimming or thrust roller
out of adjustment; perform roller checks on Scored cylinder wall; repair or replace cylinder
upright and/or carriage and make adjustments as tube if necessary
necessary. Leaking check valve; clean and replace if nec-
essary
Damaged or kinked lift cylinder hose; check condi-
tion of hose, repair or replace as necessary. Leaking O-ring seal on check valve; replace check
valve.
Lift cylinder chain or chain sheave binding or dam-
aged; inspect and repair. Gland static seals (O-rings and back-up ring) dam-
aged; replace back-up ring.
Bent cylinder rod; inspect and replace rod and/or
cylinder as necessary. Gland static seals sealing surface damaged; check groove
and bore and repair or replace as necessary.
Internal leakage in piston-type cylinders; perform
cylinder checks listed under Load cannot be
lifted to maximum height. External leakage on lift (Standard) and
Damaged lift cylinder causing binding in the cylin- sec-ondary cylinder (TSU & Hi-Lo)
der; inspect and repair or replace cylinder.
Gland loose; check and tighten gland on cylinders to
Defective velocity fuse; remove fuse from cylinder
100 N.m (73 ft-lb).
hydraulic port, clean and recheck for proper opera-
tion. Cracked cylinder tube; inspect and replace tube.
Seal damage in piston-type cylinders; replace pis-ton
seals and rod seals.
Upright mis-staging (Standard and Hi-Lo
Damaged seal groove, piston-type cylinders; check for
upright lowering) scratches, nicks, or burrs and repair or replace rod
Damaged or binding roller on upright; check con- and piston.
dition of roller and replace if necessary. Scored cylinder wall, TSU piston-type cylinders;
Top carriage roller retaining cap screw loose; check replace tube and all seals.
and replace cap screw. Scored or damaged rod; replace rod and all seals.
Lift cylinder chain or chain sheave binding or dam- Damaged gland back-up seal; inspect and replace seal.
aged; inspect and repair. Gland static seals sealing surface damaged; check
Debris in upright roller area or tie bar area; check and grooves and bore.
clean.
Bent or broken carriage or inner rail; replace part - do
not try to repair by welding.
SM 715, Dec 04 Troubleshooting 34-2-3

Group 34, Uprights
Oil leak at top of lift cylinder

Scored cylinder wall; see Section 5.
Worn or damaged gland rod-seal; see procedures for
piston-type cylinders under Cylinder leaking
internally.
Unsatisfactory lift or tilt cylinder drift test

results
Cylinder leaking internally; remove cylinder gland
and check:
Primary cylinder should have only 3.4 ounces (100
ml) on rod side of the piston
Piston-type lift and secondary cylinders should be
dry on rod side of piston.
If fluid is leaking past piston:
On piston-type cylinders, remove rod and piston,
clean check valves and clean and inspect/replace
piston seals
On ram-type cylinders, inspect/replace rod and
piston.
See Section 5.
Cylinder hydraulic fittings loose or worn; check fitting
O-rings, tighten fittings according to Group
40,Hydraulic Fitting Tightening Procedure.
Check valve worn or damaged; remove rod and
piston, clean check valve and replace if necessary.
Control valve spool linkage malfunctioning, dam-
aged, or worn; see Group 30, Section 5 for linkage
adjustment and/or replacement.
Counterbalance function in main hydraulic control
valve malfunctioning, damaged, or worn; inspect
and clean or replace if necessary.
34-2-4 Troubleshooting SM 715, Dec 04

Group 34, Uprights
Section 3
Upright Inspection
Basic Visual Inspection.....................................................................................................................................2

Extended Inspection..........................................................................................................................................3
Forks.................................................................................................................................................................3
Lift Chains........................................................................................................................................................4
Carriage and Upright Weldments.....................................................................................................................5
Carriage and Upright Rollers............................................................................................................................6
Cylinders...........................................................................................................................................................7
Hydraulic Plumbing..........................................................................................................................................9
Upright Drift.....................................................................................................................................................9
CAUTION
Park truck on a hard, level, and solid surface, such as a concrete floor
with no gaps or breaks.
Put upright in vertical position and fully lower the forks or attachment.
Put all controls in neutral. turn key switch OFF and remove key.
Upright
Load
Backrest
Carriage
Forks
SM 715, Dec 04 Upright Inspection 34-3-1

Group 34, Uprights
Basic Visual Inspection Proper lubrication. The links should have a coat of oil
on all surfaces. Lubrication oil should penetrate
Use the following steps to conduct an initial visual inspec- completely into chain joints.
tion of the upright. This is the same type of inspection Good condition of the chain links and pins. No rust,
operators should be conducting on a daily basis. corrosion, stiffness, or cracking should be evi-
If you note problems with any component during the dent. Pins should not be turned or protruding.
basic visual inspection, continue with iExtended Excessive side wear or edge wear on the chain plates.
Inspectioni for checks and service. Correct, equal tension on chain sets.
Secure anchor bolt, adjustment nut, and jam nut
WARNING
mounting.
The procedures for checking, maintaining,
Correct alignment of the chain anchors to the chain and
and adjusting uprights, carriages, and forks chain sheaves. Adjust turned chain anchors.
involve movement of the components.
Failure to follow these warnings can result in Loose, broken, or damaged anchor bolt pins and cotter
pins. Replace defective pins and cotter pins.
serious injury. Always use extreme caution.
Do not walk or stand under raised forks.
Keep clear of load and carriage when Rollers
making any check or adjustment.
Keep your arms and fingers away from mov- Inspect the upright and carriage rollers for:
ing parts of the upright. Broken or loose rollers.
Do not reach through open areas of the Loose, broken, or misadjusted thrust roller on the
upright. carriage.
Obvious signs of failed bearing seals.
General
NOTE
Check to make sure all fasteners are secure.
Some grease will purge from the bearings in
Check to make sure the upright lifts and lowers the first 100-200 hours of operation.
smoothly with and without a capacity load.
Check for visible damage to components. Excessive looseness in carriage or upright roller
shimming.
Forks
Upright and Carriage Weldments
Check function and security of the fork latch.
Inspect the forks for cracks, especially the hanger and Inspect the upright and carriage for:
heel areas. Debris or foreign objects on the components.
Check for wear in the fork heel. If heel wear is evi- Bent, cracked, or broken components.
dent, perform the extended inspection.
Undesirable wear on or contact between compo-nents.
Inspect the fork hanger and carriage fork bar for
excessive wear. Irregular roller patterns and signs of excessive wear or
scraping on the rails.
Inspect for bent forks.
Load Backrest Hydraulic System

Inspect load backrest for damage such as cracks or Inspect the upright hydraulic system components for:
bending.
Check for tight mounting fasteners. Damage or wear on all hoses and hydraulic tubes.
Leaks on hoses, fittings, or valves.
Lift Chains Leakage on the cylinders.
Excessive drift in lift or tilt operations.
Inspect the chains for:
34-3-2 Upright Inspection SM 715, Dec 04

Group 34, Uprights
Extended Inspection
The extended inspection should be performed whenever
the basic visual inspection indicates upright problems, as
specified for PMs, or at least every 2000 hours.
Forks
Forks have a limited service life because of wear and
fatigue. Forks should be tested every 50-250 hours using
a visual inspection, a fork thickness check, a fork bending
check, and a fork gap check. If replacement is necessary,
Fork Bending Check
always replace the pair to ensure fork integrity.
Fork Alignment Set a carpenters square on the block against the fork
shank
Park the truck on a flat, even surface, tilt upright to
vertical position, and set forks 25-50 mm (1-2 in) Check the fork 508 mm (20 in) above the blade to make
sure it is not bent more than 14.5 mm (0.6 in) at the
above the ground.
maximum.
Compare fork arms to be sure they are straight, on the
same plane (level), and the same length. If blades are bent over the 14.5 mm (0.6 in) allow-ance
they should be replaced as a set. See Section 7,
Measure the distance from the fork tips to the ground. Fork and Carriage Removal and Replacement, for
The height difference between the forks tips should procedures to remove and replace the forks.
be no more than 6mm(0.25in).
Fork Fatigue
Fatigue cracks normally start in the heel area or on the
underside of the top hanger. If cracks are found, the fork
should be replaced. Dye penetrants or magnaflux can be
used for a more accurate inspection.
Fork Wear and Heel Wear
Industrial Truck Association (ITA) standards require that
a fork be removed from service when the blade or heel
thickness is reduced by 10% over its original thickness. If
Fork Arm Height the heel is 10% smaller than the arm, the load capacity
could be reduced by 20%. A 5,000-pound (2272 kg)
If the fork tips are not aligned within the specified capacity fork with 10% wear can only safely handle
6mm(0.25in) difference, the cause of the problem 4,000 pounds (1818 kg).
must be determined and corrected before returning
the truck to service. If replacement is necessary, Use of fork wear calipers are recommended (Clark part
always replace the forks in a set. number 1803641) to gauge fork wear as follows:
Fork Bending Use the outside jaws of the caliper to measure fork
thickness in the shank area of the fork.
Overloading, glancing blows against solid objects, or
picking up loads unevenly can bend or twist a fork. Use
the following procedure to check for fork bending.
Place a 50 x 100 x 610 mm (2 x 4 x 24 in) wood block
flat on the fork. Make sure the block is not rest-ing
on the heel radius.

Group 34, Uprights
NOTE
NOTE
Hold the caliper square and use light pres- A small amount of lubricant can be applied
sure to squeeze the outer jaw tips against the to the fork latch. Do not over lubricate and
fork shank. Take care not to accidentally allow lubricant to run down on carriage fork
alter the reading of the calipers. bar.
Check the fork blade area to the inside jaws of the Check fork stops for widening of notches or round-ing of
caliper. top edge. Replace the carriage if fork stops are
excessively worn.
If the inside jaws fit over the fork in the blade area, wear
exceeds allowable 10% wear and a new set of forks
should be installed. Lift Chains
Fork Hanger Wear and Carriage Fork Bar Wear The following checks should be performed every 50-250
hours to ensure correct chain performance See Section 6
Inspect the fork hangers and carriage fork bar. Excessive
for more complete chain inspection and maintenance pro-
wear can cause the fork to disengage the fork bars or
cedures.
reduce fork hanger life.
Chain Wear (Stretch) - All Lift Chains
Lift chain stretch due to wear in the joints can be mea-
sured using a measuring tape or Clarkis chain check ruler.
If fork hangers are excessively worn, replace the forks

as a set.
If carriage fork bar is excessively worn, replace the
Chain Check Ruler - Clark Part Number 59-960-9908
carriage.
When any section of the chain has worn and increased its
IMPORTANT
original length by 3% or more, the chain must be replaced.
Welding is not recommended for repairing
forks or carriage. Replace the worn parts When checking chain wear, always measure a segment of
with new parts. the chain that rolls over a sheave.
Fork Latch and Carriage Fork Stops

Check fork latches for proper operation. Latches should
operate smoothly. The spring should be in good
condition and securely lock the fork into posi-tion.
Replace the fork latch if it does not operate properly.

Group 34, Uprights
IMPORTANT If one chains moves more than the other;

Never replace a single chain in a set. Always Lower the forks to ease tension on the chains.
replace the two chains in a set for consistent Adjust chain adjustment nuts for equal tension on
lift operation. Always replace anchor pins both chains. See Section 6 for chain adjustment
when replacing chains. procedures
For example, measure a 305 mm (12 in) segment of the 4. Repeat the tension test and make adjustments until the
chain that does not roll over a sheave and count the tension is equal on both chains when the carriage
number of links in the segment. and upright are raised.
Find an area of the chain that normally runs over the
sheave. This can usually be identified by wear on the Carriage and Upright Weldments
plate edges that roll over the sheave.
If the same number of links measures over 315 mm The carriage and upright should be checked for fatigue
(12.36 in) the chain must be replaced. cracks and bent components every 2000 hours or every
If using a chain check ruler, see instructions on the ruler. year..Fatigue cracks start in areas of stress after a high
Chain replacement procedures appear in Section 6. number of load cycles. Stress concentrations typically
exist in welded joints, in the area around a welded joint,
Chain Length or in the corners of parts. Dye penetrant, magnaflux, or
IMPORTANT other crack detection methods can be used to find or trace
cracks. If cracks are found in any structural weldment, the
Perform a chain length check and adjust-
component should be replaced before returning the truck
ment every 50-250 hours. Checks and adjust-
to service.
ments should also be performed to adjust for
chain stretch and tire wear. Bent components indicate excessive loading or high
impacts to the weldments. Bent components are
Chain length must be adjusted if: usually structurally damaged and should be
The fork-to-ground clearance is less than 5 mm (.20 replaced.
in) or more than 25 mm (1.0 in) when the upright Inspect roller contact patterns on the rail sections.
is vertical. Roller contact patterns should be smooth and regu-
The center of the bottom carriage roller comes within lar.
20 mm (0.80 in) of the bottom edge of the inner In some applications, it may take up to 500 hours
rail. of operation to develop a roller contact pattern
on the flange of the rail.
The carriage safety stop hits the inner rail stop at full In applications where heavy loads are common, a
lift height. rail lubricant may be required to allow proper
On TSU and Hi-Lo, the difference between the wear-in on the roller.
bottom of the inner rail and the outer rail is greater Check rails and carriage for wear due to undesir-able
than 10 mm (0.40 in). contact between components. Such contact can be
See Section 6 for chain length adjustment procedures. an indication of broken rollers, loose com-ponents,
Chain Tension foreign objects or debris on the upright, or a
broken weldment.
IMPORTANT If contact or rubbing exists, the condition must be
Center any auxiliary attachments before corrected immediately.
beginning tension check Rail and carriage weldments with damage should
be replaced.
Raise the upright enough to put tension on the chains to Tie bar areas should be free of foreign objects and
be checked. debris. The roller area of the rail should be cleaned
Push the chains forward and pull them backward; the every 500-1000 hours in a normal application.
amount of tension should be equal on both sides. In applications where excessive amounts of
contaminants settle in the rail channels, clean-
WARNING ing may be required on 50-250 hour intervals.
Do not reach through the upright to push If excessive contamination exists, the rollers
chains for tension check. should be exposed and the bearing seal areas
cleaned thoroughly.

Group 34, Uprights
See Section 4 for carriage roller and upright

roller removal and installation. Shoulder
Roller shaft
Carriage and Upright Rollers
shims
Carriage Thrust Rollers Bearing outer race
The external thrust roller runs along the outside flange

of the inner rail to control lateral load on the
carriage.
External thrust rollers are found on all uprights.
External thrust roller
Indications of broken or damaged rollers include:
Part of all of roller bearing missing
Bearing outer race loose
Scraping noise from the upright
Scraping of carriage fork bar on inner rail (carriage
rollers)
Upright rail sections scraping together (upright
The extenal thrust roller should be checked for smooth rollers)
rotation, seal integrity, radial bearing tightness, and a tight Upright mis-staging
cap screw. A roller should turn smoothly without sticking Excessive looseness of the rail section or carriage
and be grit free. Replace the roller if any defect is found. demonstrated by the following load test.
External thrust roller cap screws have a locking patch to NOTE
prevent the cap screw from backing out. Repeated
Some grease will purge from the bearings in
removal will deteriorate the ability of the patch to hold
the first 100-200 hours of operation. This is
the cap screw. If the cap screw is backing out without
not necessarily a sign of a failed roller bear-
holding, a new cap screw is recommended. The cap
ing seal.
screw can also be cleaned and set using thread locking
compound Loctite 271 (Clark Part 1802302).
Load Test
NOTE
A load test helps you to determine the amount of clear-
Some grease will purge from the bearings in ance between the moving upright parts. The upright
the first 100-200 hours of operation. This is requires some lateral movement between the interlocking
not necessarily a sign of a failed roller bear- rails and the carriage. But, too much or too little clearance
ing seal. can be the cause of binding and uneven operation.
The external thrust rollers are not adjustable. WARNING

Carriage and Upright Main Load Rollers An upright or carriage can move unexpect-
edly during service procedures causing
Inspect the carriage and upright main load rollers for bro- severe injury:
ken, loose, or rough bearings. Defective rollers should be Do not walk or stand under raised forks.
replaced. Keep clear of load and carriage when
making any check or adjustment.
Keep your arms and fingers away from mov-
ing parts of the upright.
upright.
Failure to follow these warnings can result in
serious injury.

Group 34, Uprights
Place a capacity load on the forks and secure it to the Excessive lateral shift in the upright at, or near, full
carriage. maximum fork height (MFH)
CAUTION Irregular roller patterns on the rail.
Test load must be stacked stably, not extend Signs of over shimming include:
let. Operate the truck only from within the Mis-staging or hanging up of the upright
operatoris compartment. Excessive wear in the rail web
Premature bearing failure.
Tilt the upright back slightly and raise the upright to its
maximum extension several times. Note the Perform the following roll pattern check and the load test
smoothness of operation, the carriage play, and play if the need for roller shimming is suspected. See Section 4
for detailed clearance measurement procedures.
between the rails.
Roll Patterns
Move the load 100 mm (4 in) off center on the forks and
resecure it to the carriage. Impressions made by rollers on upright rails are called
roll patterns. Roll patterns can provide indication of the
Raise the upright to its maximum extension and lower need for upright or carriage adjustment.
the load to the floor several times.
WARNING
Repeat the step, moving the load 100 mm (4 in) off
center to the other side. Keep clear of load and carriage when
making any checks or adjustments.
Raise the upright to its maximum extension and lower
the load to the floor several times. Elevate the carriage about 1.3 m (4 feet).
Carefully observe the smoothness of operation, particu- Apply a light, thin layer of grease to the roller con-tact
larly in carriage play, and play between the rails. If any area.
unusual movement, staging, or noise occurs during the Lower the forks and pick up a capacity load. Raise and
test, correct the problem before returning the truck to ser- lower the upright several times.
vice. Continue with the following roller shimming checks Back out from the load and raise the carriage.
if too much play is evident in the carriage and rails in the
load test. The troubleshooting guide may also help to Compare the impressions of the rollers on each side of the
upright rails. The impressions should look the same on
identify specific problems with upright operation.
both sides. Look for signs of metal scoring or gouging
Roller Side-Clearance which can indicate excessive pressure caused by damaged
or misadjusted rollers.
The carriage and upright rollers are shimmed between the
inner race and the roller shaft shoulder to maintain mini- Carriage rollers, including side-thrust rollers, and all
mal clearance between the side of the roller and the web upright rollers can be checked by examining roll patterns.
If irregular impressions result from the checks, perform
of the adjacent rail. Shim adjustments help accommodate
the Lift Cylinder Shimming Check and the Load Test
manufacturing tolerances and wear in the upright rail sec- to further diagnose problems.
tions.
Side Clearance See Section 4 for procedures to measure clearances and
Roller adjust carriage or upright rollers.
Roller Shaft
and shoulder
Cylinders
Rail Web
Use the Drift Test, presented under Hydraulic Checks
below, for additional diagnosis of cylinder condition. See
Section 5 for cylinder repair.
External Leakage (All Cylinders)
Signs of loose shimming include: To check for external leakage on the primary cylinder:
Excessive lateral (side-to-side) movement in the upright
rail sections

Group 34, Uprights
Clean the top of the gland and rod to remove any Cycle the upright 5-10 times through the first 2/3 length
buildup of debris. of the primary stroke and lower forks com-pletely.
Check rod surface for defects or unusual wear. Slowly lift the carriage 305-610 mm (1-2 ft) into the
Nicks, burrs, or other sharp defects can cause dam-age secondary lift stage then lift to full extension.
to the seal and will lead to leaks. The rod should If the carriage does not lift to full height, the problem is
be repaired or replaced. likely an internal leak and the cylinder should be
For piston-type cylinders, small blunt defects in the overhauled.
top and midsection of the rod can be tolerated in
this cylinder design. The high pressure sealing is If the carriage does lift to full height, but you still
over the last several inches of stroke. This type of suspect an internal leak, repeat the procedure with a
defect is acceptable if leakage is not evident. 40-70% capacity load.
Check for external leakage from the cylinder barrel, NOTE

gland O-rings and backup ring, and the rod seal. The primary cylinder normally has approxi-
mately 100 ml (3.4 oz) of hydraulic fluid on
the rod side of the piston as a precharge.
Use the Drift Test, presented under Hydraulic Checks

below, for additional diagnosis of cylinder condition. See
Section 5 for cylinder repair.
Internal Leakage on Piston-Type Lift and Secondary
Cylinders
To check for internal leakage in Standard lift and TSU
secondary cylinders:
Lift the upright to MFH then lower forks completely.
Cycle the upright 5-10 times through the first 2/3 length
of the lift cylinder stroke and lower forks com-
pletely.
The gland O-rings and backup ring are near-zero
Lift the upright to full MFH.
leakage seals. If, after cleaning the gland and tube,
oil accumulates to form a run, the O-rings and Watch for the lift cylinder to increase lift speed. If you see
backup ring should be replaced (see Section 5). an increase in lift speed, one or both of the lift cylinders
External leakage from the barrel requires replace- have an internal leak and requires overhaul.
ment of the barrel. If the upright does not increase lifting speed, but you still
NOTE suspect an internal leak, repeat the procedure with a
capacity load. If the upright does not extend to full MFH,
The seals are installed with lubricant and a the problem is likely an internal leak and the cylinder
trace amount will be in the gland/tube inter- should be overhauled.
face area.
Lift Cylinder Shimming
After cleaning the top of the gland and the barrel, cycle The lift cylinders on standard, TSU and Hi-Lo uprights
the upright 5-10 times. If a ring of oil forms to run 3 bottom out at the end of the stroke to limit upright exten-
mm (0.125 in) down the rod, the cylinder must be sion.
overhauled or replaced.
The upright has dual lift cylinders and the cylinders
Internal Leakage on Primary Cylinder exten-sion length must be equal. If not, racking or side-
toside shifting, results. Rod extension length is made
To check for internal leakage on the primary cylinder:
equal by using shims under the rod end of the cylinder. To
Lift the upright to maximum height then lower forks deter-mine if shimming of the cylinders is required to
completely. prevent racking, perform the following operational check:

Group 34, Uprights
CAUTION Upright Drift

Make sure truck is parked on level surface Drift tests check cylinder, main valve, and hydraulic cir-
with parking brake applied and wheels cuit integrity under load pressures. A load is held elevated
chocked; make sure overhead clearance is for an extended period to determine how much the
adequate to extend upright to its full height. upright drifts (moves) over a specified time period. A
tilt cylin-der drift test appears in Group 32, Section 2,
Center the forks or attachments on the upright. Tilt Cylin-der Checks and Adjustments.
Check for equal chain tension.
WARNING
Raise the upright from the retracted position to full lift An upright or carriage can move unexpect-
height. Note the point when the lift cylinders reach edly during service procedures causing
the end of their stroke. severe injury:
If the upright shifts right or left noticeably, shim-ming Do not walk or stand under raised forks.
is required. Keep clear of load and carriage when
Repeat the check three times before adding shims. making any check or adjustment.
Keep your arms and fingers away from mov-
NOTE ing parts of the upright.
Offset or unbalanced loads and off-center Do not reach through open areas of the
attachments can cause the upright to shift upright.
even with proper lift cylinder shimming. Failure to follow these warnings can result in
serious injury.
See Section 5 for lift cylinder shimming procedure. Rack-
ing adjustments for tilt cylinders appear in Group 32, Sec- Raise the empty upright and carriage to its full exten-
tion 2, Tilt Cylinder Checks and Adjustments. sion and lower to a point halfway down from full
extension.
Hydraulic Plumbing Shut off the truck. Apply the parking brake and chock
the wheels.
Use the Lift Cylinder Shimming Check, the Load Test,
and the following Drift Test to check the performance of With a pencil or chalk, make a mark across the rails on
the hydraulic system. one side of the upright.
Check all fittings for leakage. Disassemble fittings and WARNING
inspect the seals. Replace seals as required. See
Group 40 for hydraulic fitting tightening procedures. Keep clear of load and carriage when making
any checks or adjustments. Do not use the
Check all hoses and tubes for wear and damage. upright to climb; use an approved platform.
Hoses or tubes with scrapes or kinks should be
replaced.
Hoses with outer cover wear exposing the rein-
forcement braiding should be replaced.
Mark upright
rails here

Group 34, Uprights
Wait five minutes and recheck the mark. Measure and

write down the distance the marks on the inner and
intermediate rails have drifted from the mark on the
outer rail.
If upright rails drift 50 mm (2 in) or more in the ten
minutes, read and follow the procedures presented in
Drift Causes and Remedies.
If no drift does not exceed 50mm (2 in) in the ten
minutes, retest the upright with a 50% load. Adjust
fork width as wide as possible to lift the half-load
equally distributed on a 1220 x 1220 mm (48 x 48
in). Refer to truck nameplate for capacity rating.
CAUTION
Test load must be stacked stably, not extend
let.
Drift Causes and Remedies

If drift of 50 mm (2 in) or more is evident under a half-
load, consider the following causes and remedies:
The main hydraulic valve is misadjusted, worn, or
defective. Fluid is leaking past the valve and caus-
ing the upright cylinders to drift. See Group 30 for
hydraulic valve troubleshooting and service.
Upright hydraulic circuit hoses or fittings are leak-ing.
Check the circuit components and repair as
necessary.
Cylinder piston seals are worn, damaged, or defec-
tive allowing fluid past the piston causing drift.
Primary cylinder or piston-type lift or secondary
cylinders have a check valve that allows oil to flow
back to the rod side of the cylinder. This check valve
may be clogged or defective. Inspect the
check valve for proper sealing and operation.
Consider rebuilding the cylinders if the first two remedies
in this list are not successful. See Section 5 for removal,
overhaul, and replacement procedures for primary and
secondary cylinders.

Group 34, Uprights
Section 4
Carriage and Upright Roller Clearance Checks

and Shim Adjustment
Introduction..............................................................................................................................1
Roller Side Clearance Checks.................................................................................................3
General Roller Side Clearance Checking Procedure.................................................................3
Directions for Checking Specific Rollers..................................................................................4
Carriage Rollers..............................................................................................................4
Upright Rollers...............................................................................................................5
Oversize Rollers.......................................................................................................................5
Lift Roller Shimming...............................................................................................................5
Carriage Roller Shimming........................................................................................................ 5
Upright Roller Shimming......................................................................................................... 6
Upright Disassembly......................................................................................................6
Roller Removal, Shimming, and Replacement...............................................................7
Upright Reassembly........................................................................................................8
Overshimming............................................................................................................................9
IMPORTANT WARNING
Before removing any component for over- Use an approved safety platform to reach the
haul, make sure the correct repair parts and/ upper areas of the upright. Never use the
or kits are available. upright as a ladder.
WARNING
An upright or carriage can move unexpect- Introduction
edly:
Standard and Hi-Lo upright assemblies have two lift
Do not walk or stand under raised forks roller sets mounted on the rails, three lift roller sets
Kee clear of load and carriage when making any mounted on the carriage, and on external thrust roller set
check or adjustment mounted on the carriage.
Keep your arms and fingers away from moving The triple-stage upright assemblies have four lift roller
parts of the upright. sets mounted on the rails, three lift roller sets mounted on
Block the carriage or upright when working with the carriage, and one thrust roller sets (external)
the components in a raised position. mounted on the carriage. (see the Roller Side Clearance
Do not reach through open areas of the upright. Chart on next page.)
Never attempt to move or align the rails by hand. Each carriage and upright lift roller is nested within its
Use a prybar. adjacent rail set. The front face of the lift roller handles
Failure to follow these warnings can result in seri- front-to-back friction and play between the nesting seg-
ous injury. ments of the upright assembly, the side face of the
roller radius handles side-to-side friction and play. The
rollers are canted (tilted) to allow the side face to bear
properly on the web.
SM 715, Dec 04 Carriage and Upright Roller Clearance Checks and Shim Adjustment 34-4-1
Group 34, Uprights
Rail flange wear can cause excess play between the lift
rollers and the rail flange. The only way to correct this is Gap
to install oversize rollers-only one size of which is avail- Lift Roller
able. If oversize rollers were fitted previously, the only Shoulder Side Face
remedy for excessive front-to-back play is to replace the Of Clearance
rail set. (carriage middle rollers are always standard-size Rail Web
rollers; see Oversize Rollers later in this Section for
Rail Flange
details on roller replacement.)
The gap between the roller side and the web of
adjacent rail set affects the side-to-side motion of the
upright-which should be as small as possible without
causing the sliding segments to bind.
Roller Side Clearance Chart
Web Area Gap at Mimimumm Span of Rail Set Gap at Maximum Span of Rail Set
Roller Set# Forming Gap a b a b
Target Allowed Target Allowed
(mm) (in) (mm) (in) (mm) (in) (mm) (in)
#1 Front, Inner rail 0.5-1.5 0.02-0.06 0.5-1.25 0.02-0.05 d d 2.25 0-0.09
#2 Front, Inner rail 0-0.75 0-0.03 e 0-0.06 d d 2.25 0-0.09
0-1.5
#3 Back, Inner rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#4 Back, Inner rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#5 Back, Intermd rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#6 Back, Intermd rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#7 Back, Outer rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
a. Target is the desired gap after reshimming the roller set.

b. Allowed is the acceptable gap when checking roller set.
d. Ideal is same as final measured gap at minimum width point of rail set.
e. Measured at top of inner rail.
34-4-2 Carriage and Upright Roller Clearance Checks and Shim Adjustment SM 715, Dec 04
Group 34, Uprights
You check the performance effect of the lift roller side Position the carriage or rails so that the roller set you
clearance by means of the load test described in Section want to check is at the mark for the narrowest span
3. To evaluate with certainty that the clearance is on the adjacent nesting rail set.
excessive, you perform the checks given below.
To correct excessive lift roller side clearance, you add
shims as described later in this Section. Narrowest
span
Roller Side Clearance Checks

The same basic procedure is used for checking all the lift
rollers. That general procedure is given in the subsection Widest
span
directly below. Special instructions for specific rollers
fol-low that subsection. Follow those directions (in the
sub-section called Directions for Checking Specific
Rollers) and you will be directed to general and specific Example of Aligning Roller Set with Widest and
informa-tion you need. Narrow-est Spans Marked on Adjacent Rail Set. Rail sets
are shown separated for clarity.
General Roller Side Clearance Checking Clamp the rails together opposite the roller you intend to
Pro-cedure check. Use wooden shim blocks to protect the rails.
Place clamp as close to roller as possible. Torque
For each roller set, you need to measure the gap between clamp to 25 N.m (20 ft-lb).
the outside face of a roller and its adjacent nesting rail. In
general, the lift roller side clearance check procedure is as
follows:
With the spanner tool, find and mark the narrowest and
widest spans in each rail set at the roller-contact
areas in the rail webs:
Inner Rail Set-Mark narrowest and widest spans for
both the front and back web areas.
Outer and Intermediate Rail Sets-Mark narrowest and
widest spans for the back web area only. Measure the gap with a feeler gauge. Make sure roller is
tight against its shoulder. Write down the result.
Web Areas on Typical Rail Set

Repeats steps 2 through 4 for the widest span marked on
the rail set.
Group 34, Uprights
6. If the clearance at the widest rail set span is more Top Carriage
than 2.25 mm (0.09 in), the roller set needs shim-
ming.
If the clearance at the narrowest rail set span is more
than 1.0 mm (0.04 in), the roller set should be
shimmed; however, it is OK for the middle carriage
roller gap to be up to 1.5 mm (0.06 in).
7. Repeat entire procedure for each roller set, following Rollers
the instructions in Directions for Checking Specific
Rollers below.
Directions for Checking Specific Rollers

1. Move the top carriage lift roller to the narrowest span
Use these directions to supplement the general on the inner rails set.
procedures given above.
2. Clamp rail to one side as in general procedures. Check
Carriage Rollers clearance of lift roller on clamped side.
Bottom Carriage Rollers
Follow the general procedure above.
Middle Carriage Rollers
The middle rollers are difficult to access and require the
following special procedures.
Raise the carriage until the middle rollers are at the top
of the inner rails.
Measure roller side clearance at the top of the inner rails.
Note measurement here:
_____________________.
If gap is less than 1.5 mm (0.06 in), shimming is not The lift roller to stand off from the web by .01 to 1
required. mm (0.001-0.03 in).
If gap is more than 1.5 mm (0.06 in), check
clearance at narrowest span by comparison with the Check clearance on lift roller opposite clamped side as in
top of the rail set as follows: the general procedures. If clearance is greater than
With spanner tool, measure span of inner rail set at 1.25 mm (0.05 in), the roller set should be shimmed.
top of the front web area. Note measurement Move clamp to opposite side and check clearance on
here: _____________________. clamped side as in step 2 directly above. Gap should
With spanner tool, measure span of inner rail set at be 0.01-1.0 mm (0.001-0.03 in).
narrowest span of front web area. Note mea-
surement here: _____________________. Move the top carriage lift roller to the widest span on the
Subtract measurement in step b from measure-ment inner rail set and check clearance as in general
in step a, Write result here: procedures.
b-a= _____________________.
If the calculated gap is less than or equal to the
gap measured in step 2, the roller set does not
require shimming. Otherwise, the roller set
should be shimmed.
34-4-4 Carriage and Upright Roller Clearance Checks and Shim Adjustment SM 715, Dec 04
Group 34, Uprights
Upright Rollers Oversize Rollers

Remove the carriage as described in Section 7 of this At the time of roller shimming,
Group. you may want to replace the lift
Fully extend the upright making sure carriage hoses and rollers with oversize rollers to
chains are secured out of the way to prevent damage. counter rail flange wear as
detected by inspection and the
WARNING load test. Because there is only
An upright or carriage can move unexpect- one size of oversize rollers, you
edly: can install them only if they
were not installed previously.
Do not walk or stand under raised forks
Keep clear of load and carriage when mak- Identify oversize rollers as fol-
ing any check or adjustment lows: If a roller is oversize, it
has an indented radius in the
Keep your arms and fingers away from
outer edge of its mounting side,
moving parts of the upright.
as shown below.
upright.
Never attempt to move or align the rails by Lift Roller Shimming
hand. Use a prybar. You need to shim lift rollers if the roller side clearance
Use an approved safety platform to reach the checks indicated that clearance was excessive at either the
upper areas of the upright. Never use narrowest or widest span of the roller sets adjacent rail
the upright as a ladder. set. Your objective in shimming is to add only enough
Failure to follow these warnings can result in shims to bring the clearances at both the widest and nar-
serious injury. rowest spans into tolerances. In practice, you achieve this
Follow the General Roller Side Clearance Checking by shimming to obtain the smallest possible clearance at
Procedure given earlier in this Section. the narrowest span of the rail set.
The clamping procedure is as illustrated below.
Carriage Roller Shimming
Using the measurement you recorded in previously in the
Roller Side Clearance Checks, determine the number of
shims required to reduce the carriage roller clearance at
the narrowest span on the inner rail to 0-0.75 mm (0-0.03
in):
Remove the carriage as described in Section 8, Fork

and Carriage Removal and Replacement.
Remove the rollers (note the number of shims already on
the roller shafts, if any).
Clean and inspect roller bearings, shims, and shafts.
Replace any defective parts.
Group 34, Uprights
Add shims to the top and bottom rollers as deter-mined Upright Roller Removal
in the previous steps.
After the carriage has been removed, lower the upright
Install shims with the same number on each side. rails until both of the secondary (final) lift cylinders
When an odd number of shims is required, always are completely collapsed.
place the odd shim on the same side on all roller
sets. Jack the truck and block under the frame so that the
bottom of the upright is approximately 254 mm (10
Use a straight bar to determine the number of shims to in) off the floor. See Lifting, Jacking, and
add to the middle roller shaft as shown in the fol- Blocking in Group SA for safe procedures.
lowing illustration. This shimming may be asymmet-
ric, meaning the numbers of shims do not have to Set the parking brake and block the steer wheels.
match those of the top and bottom rollers. Tilt the upright to as near vertical as possible.
Using a hoist and lifting strap of adequate capacities,
connect the lifting strap to the inner rail on standard &
Hi-Lo uprights or intermediate rails on triple-stage
uprights. Lift hoist to remove slack from the strap.
Reinstall all bearings; torque top roller fasteners to 40-

45 N.m (30-33 in-lb). Disconnect the flow control valve manifold from the
upright bracket.
Upright Roller Shimming

Use the following procedures to remove, shim, and
replace rollers. Use the preceding checks to determine the
number of shims required to reduce the roller clearances
to 0.75 mm (0.03 in) or less.
WARNING
Use an approved safety platform. Never use
the upright as a ladder. TMX Truck EPX Truck
CAUTION Disconnect the cylinder guide bolts. In Hi-Lo upright,

disconnect the secondary cylinder hose.
The carriage should be removed for shim-
ming or when any service is performed on
the upright. See Section 8, for removal and
replacement procedures.
34-4-6 Carriage and Upright Roller Clearance Checks and Shim Adjustment SM 715, Jun 05
Group 34, Uprights
Secure the cylinder to prevent its falling and discon-nect Roller Removal, Shimming, and Replacement
the cylinder rod retaining bolts.
To add shims to, or replace the rollers:
Use a puller to remove the rollers from the posts. Or, gently
pry the rollers off the posts. Pry at different points
around the bearing to work it off. Do not dam-age the
bearing seals on the backside of the roller.
Inspect all roller components when removed:
Clean and inspect the rollers, shims, and roller
shafts.
Bearings should be in good condition and allow the
roller to spin smoothly with a true rotation.
Clean rail sections and add lubricant if necessary.
Replace any worn or damaged component.
NOTE
For 4-hose adapters, you must disconnect the If the clearance check indicated an even number of
hose sheave and bracket. This is not neces- shims needed, split the number evenly between the
sary for 2-hose adapters. rollers on either side of the upright.
If the clearance check indicated an odd number of shims
Move the sheave with the hoses and any other con- needed, keep the odd number to the same side on all
nected components out of the way. rails of the upright. If three shims are needed, for
Disconnect the rail cylinders by raising the rails to free example, add one to the rollers on the left side. Add
the cylinder rod ends from the tie bar. Tilt the the other two on the rollers on the right side.
cylinders inward and secure out of the way of the tie Reposition the rollers onto the roller shaft and use a
bars. plastic or hard-rubber mallet to gently tap the roller.
Lower the assembly completely to expose the rollers. Seat the roller evenly by continuing to tap gently
until it is fully seated and snug against the added
The lower roller set of the inner rail and upper roller set shims.
of the outer rail on standard and triple-stage uprights are
now exposed for shim adjustment.
Group 34, Uprights
Upright Reassembly Reconnect the cylinder guide bolts. Do not tighten until
inner and/or intermediate rails are in the fully
The following steps detail the procedures for reassem-
lowered position. Torque guide bolts nuts to 20-25
bling the upright.
N.m (14.8-18.5 ft-lb).
WARNING
The upright can move unexpectedly:
upright.
Never attempt to move or align the rails by
hand. Use a prybar.
Failure to follow these warnings can result in Reconnect the cylinder rod bolts. Torque rod bolts to 20-
serious injury. 25 N.m (14.8-18.5 ft-lb). In Hi-Lo upright,
Reconnect the secondary cylinder hose.
Connect the lifting strap to the inner rail on standard &
Hi-Lo uprights or intermediate rails on triple-stage
uprights and raise the rails just high enough to clear
the lift cylinders. Use a prybar to guide the rails and
allow the rollers to reenter the rail channel.
Replace the 4-hose sheave and bracket assembly onto

the upright. Torque nuts to 20-25 N.m (14.8-18.5
ftlb).
Reconnect the load lowering flow valve to the upright
bracket. Torque nuts to 20-25 N.m (14.8-18.5 ft-lb).
Reposition the rail cylinders and slowly and carefully lower

the rails to seat the rod end into the mounting.
TMX Truck EPX Truck
7. Jack up the truck only enough to remove the blocking

and slowly lower the truck so that its full weight is on
the floor.
8. Replace the carriage and forks.
34-4-8 Carriage and Upright Roller Clearance Checks and Shim Adjustment SM 715, Jun 05
Group 34, Uprights
Test the upright lift and tilt functions; make sure all Overshimming
upright components work correctly and smoothly.
Check for overshimming as described in the next Use these steps to check for overshimming:
subsection. Repeat the load test to make sure the With the forks removed, lift the upright to maximum
upright works correctly under load. When you are fork height.
sure all components are operating correctly, perform
the chain adjustment checks in Section 3 before Slowly lower the upright.
returning the truck to service. The carriage should not bind or hang up at any point
along the rails.
If the carriage binds or hangs up, and the rails are not
clogged with grease or debris, the carriage
requires reshimming. See Troubleshooting for
other mis-staging problems.
NOTE :

Group 34, Uprights
Section 5
Cylinder Removal, Shimming, Overhaul,

and Replacement
Cylinder Types..........................................................................................................................1
Lift Cylinder Shimming Procedure........................................................................................1
Primary Cylinder Removal and Replacement (TSU Only).................................................2
Lift and Secondary Cylinder Removal and Replacement....................................................3
Cylinder Overhaul...................................................................................................................4
Cylinder Disassembly................................................................................................................4
Parts Inspection and Service......................................................................................................5
Cylinder Reassembly.................................................................................................................5
Cylinder Types CAUTION

Standard uprights use two lift cylinders. Hi-Lo and Triple To remove, or partially remove, the cylinders
stage uprights use three cylinders, a primary (center- from the upright for shimming or overhaul,
mounted) cylinder, and two secondary cylinders. All pri- start with the truck in a safe position:
mary cylinders used on Hi-Lo and triple-stage uprights Turn key switch to OFF and remove key
(TSUs) are piston cylinders. The secondary cylinder used Parking brake applied
on Hi-Lo uprights are ram cylinders.
Directional lever in neutral
IMPORTANT Forks lowered completely
Before removing any component for over- Wheels blocked.
haul, make sure the correct repair parts,
seals, and gasket sets are available.
Lift Cylinder Shimming Procedure
Upright Upright To shim the lift cylinders to correct unequal cylinder
Type Num- Cylinder Type
ber stroke:
Standard V1204 Piston-Type Lift Cylinder 1. Fully lower upright until both lift cylinders are col-
T TSU M1203 Piston-Type Secondary Cylinder lapsed.
M M1204 Piston-Type Secondary Cylinder 2. Attach a hoisting strap to the tie bar of the inner rail
X Hi-Lo H1205 Ram-Type Secondary Cylinder or intermediate rail tie bar of TSUs.
H1206 Ram-Type Secondary Cylinder
E Standard V1218 Piston-Type Lift Cylinder
P TSU M1218 Piston-Type Secondary Cylinder
X Hi-Lo H1218 Ram-Type Secondary Cylinder
SM 715, Jun 05 Cylinder Removal, Shimming, Overhaul, and Replacement 34-5-1

Group 34, Uprights
CAUTION Make sure the cylinder is completely collapsed and

pressure is released.
Make sure hoisting equipment is of adequate
capacity and in good working order. Disconnect and cap the hydraulic line at the base of the
cylinder.
Remove the cylinder rod retaining bolt. In Hi-Lo
Remove and discard cotter pins from chain anchor bolt
upright, Remove the cylinder hoses.
pins on the cylinder.
Load Lowering
Flow Valve
Slowly lift the inner (or intermediate) rails off the top of Remove the pins, draw the chain through the sheave, and
the cylinder to expose the cylinder rod top. drape the chain over the carriage.
CAUTION
Block rail in up position.
Insert shim(s) over rod end of cylinder with the shorter

stroke to compensate for unequal stroke length.
Slowly lower the inner or intermediate rail back onto the
rod ends.
CAUTION Remove the snap ring holding the chain sheave (and
Do not try to maneuver the cylinder or rails hose bracket, if equipped) on the rod end and move
with your hands. Use a prybar. assembly off top of rod.
Replace cylinder rod retaining bolt to secure rod end

into inner or intermediate rail mounting hole. Torque
the cylinder rod retaining bolts to 20-25 N.m (14.8-
18.5 ft-lb).
Repeat the racking test and adjustment until no rack-ing
is evident during upright lift extension.
Check all upright functions before returning the truck to
service.
Primary Cylinder Removal and

Replacement (TSU & Hi-Lo)
Remove the primary cylinder for replacement only.
Cylin-der can be overhauled without removing it from
the upright. See Cylinder Overhaul for procedures.
34-5-2 Cylinder Removal, Shimming, Overhaul, and Replacement SM 715, Dec 04

Group 34, Uprights
Disconnect cylinder mounting bolts and cylinder base Disconnect and cap the hydraulic line from the base of
mounting bolts.) each cylinder. Remove the mounting bolts from the
manifold block.
Use these steps in reverse to replace the cylinder. Check

Group 40 for hydraulic fitting tightening procedures. If
complete cylinder was torque hydraulic line bracket to 40-
N.m (30-33 ft-lb);torque cylinder mounting coller bolt Lower the carriage
nuts to 70-80 N.m (52-59 ft-lb Using a hoist and lifting strap of adequate capacities,
connect the lifting strap to the inner rail on standard
Lift and Secondary Cylinder uprights and inner and intermediate rails on triple-
stage uprights.
Removal and Replacement
Only piston-type lift and secondary cylinders must be
removed from the upright for overhaul. The cylinder
gland and rod can be removed for overhaul while leaving
the cylinder tube mounted on the truck.
Make sure the cylinders are completely collapsed and
pressure is released.
Tilt the upright to as near vertical as possible.
Using a hoist and lifting strap of adequate capacities, lift
the carriage to access the hydraulic lines at the base
of the cylinders.
CAUTION
Make sure hoisting equipment is of adequate
capacity and in good working order.
7. Disconnect the cylinder guide bolts.
SM 715, Dec 04 Cylinder Removal, Shimming, Overhaul, and Replacement 34-5-3

Group 34, Uprights
8. Disconnect the cylinder rod retaining bolts. Clean the rod-end and gland thoroughly to prevent
contamination from falling into the cylinder during
disassembly.
With a blunt punch or chisel, bend the lock ring out of
the locking grooves of the gland.
Use a spanner wrench to remove the gland. Reuse the
lock ring if undamaged.
Carefully lift the rod out of the cylinder and place in a
clean area.
Remove the cylinders by raising the inner rail (and Inspect the tube and tube end for damage and cover the
intermediate rail on the triple stage upright) to free cylinder tube end to prevent contamination.
the cylinder rod ends from the tie bar.
Remove any shims and note number and location. Remove all rings and seals from the piston and the
gland.
Lift the cylinders off the base mount.
Rod Wiper
Use these steps in reverse to replace the cylinders. Torque Rod Seal
the cylinder rod retaining bolts to 20-25 N.m (14.8-18.5 O-Ring
Back-Up Ring
ftlb). Torque the cylinder guide bolt nuts to 30-35 N.m Gland
(22.2-25.6 ft-lb). Check Group 40 for hydraulic fitting O-Ring
tightening procedures. Tube
Rod
Spacer
Cylinder Overhaul
Use these steps to overhaul the primary and lift and sec- Retaining Ring
ondary cylinders. Check Valve
Piston
NOTE
Cylinder Seal
During overhaul, set rod or cylinder on a
Snap Ring Pin
work bench with adequate support for safe
Wear Ring
and convenient disassembly. Two sets of 4x4
in (100x100 mm) V-notched blocks are
helpful; one set for the cylinder barrel and
one set for the piston rod. The blocks prevent
nicks and scratches from harming the piston
or rod.
For piston-type cylinders:
Remove the check valve from the piston for
Cylinder Disassembly
inspection and cleaning by removing the snap
To overhaul the primary cylinder, it is not neces-sary ring from the piston bore.
to remove the cylinder from the upright. Instead,
free the rod end of the cylinder as explained in
Cylinder Removal.
To overhaul piston-type cylinders, you should remove
the cylinders from the upright as explained in
Cylinder Removal. The cylinders have seals on
the piston, and the rods must be removed for seal Check Valve. Arrow shows direction of flow
replacement.
b. Use a blunt hook to pop the check valve out.
The ram-type lift cylinders are sealed on the rod only.
The only serviceable seals are inside the gland. It IMPORTANT
is not necessary to remove these cylinders from Use extreme care that you do not make nicks
the upright for overhaul. Instead, free the rod end and burrs on the interior surface area of the
of the cylinder as explained in Cylinder
cap or cylinder or the piston.
Removal.

Group 34, Uprights
Parts Inspection and Service Replace the piston seals:

Primary cylinder pistons require a piston seal and
Clean all parts completely in a suitable solvent. Dry all wear ring. Install the piston seal from the top of
parts with a soft clean cloth. the rod. Use a ring compressor to compress the
Inspect cylinder barrel and bore for cracks, pining, piston seal. This prevents damage to the seal dur-
scoring, or other irregularities that may require ing reassembly.
replacement of the barrel.
Inspect the piston and rod for nicks, scratches, scor-ing,
or other defects that may demand new parts.
Check all gland and piston seal grooves for nicks, burrs,
and scratches that can damage seals during
reinstallation. Piston-type lift and secondary cylinder require a
cylinder seal, a back-up ring, and a wear ring on
Inspect and clean the check valves.
the piston. Install the cylinder seal from the top
Inspect all seals, including the check valve O-ring. of the rod.
NOTE
Minute imperfections inside the cylinder
bar-rel or on the piston or rod may be
improved for acceptable use by careful
honing. How-ever, removal of material that
produces a notch, groove, or out-ofroundness Ram-type lift (secondary) cylinder piston require-
may cause excessive leakage during seals.
operation and a shortened life.
For protection against corrosion, lubricate spacers
(where used) with petroleum-based hydraulic fluid.
Use new parts as necessary. Always use the Packing Kit
Slide the spacer onto the rod.
listed in the parts manual. New kits include all the
seals, wiper rings, wear rings and O-rings neces-sary Insert the piston and rod into the cylinder. Be careful not
for the particular cylinder. to scratch or damage the cylinder gland nut threads.
For primary cylinders, add 3.4 oz (100 ml) of hydrau-lic oil
Cylinder Reassembly into the cylinder on the rod side of the piston.
Take care when installing these parts to make sure that no Install the lock ring onto the gland. Lubricate cylin-der
parts are damaged. threads and screw gland onto cylinder. Be careful not
to damage gland seal. Make sure the gland is fully
Coat all packing, seals and rings in clean, hydraulic oil seated on the cylinder barrel. Deform the lock ring
(Clark part number 1800236 qt., 1802155 gal.) prior into slots in the tube and the gland.
to reassembly. Coat the inside of the gland nut bore
with hydraulic oil. Check the assembly by making sure the piston slides
freely in and out of the cylinder.
Replace the U-cup seal (groove toward bottom of
cylinder), rod wiper, and O-ring and back-up seals Tighten the gland nut:
on the gland. On primary cylinders, tighten the gland nut to 100
N.m (75 ft-lb).
On lift and secondary cylinders, tighten the gland nut
to 100 N.m (75 ft-lb).
This competes the cylinder repair procedure. Replace the
cylinders as described in Cylinder Removal and Replace-
ment. Complete the chain length adjustment in Section 3
NOTE for correct carriage and rail position. When all adjust-
O-rings should be carefully installed to elimi- ments are completed, return the truck to service.
nate cuts or twisting.
SM 715, Dec 04 Cylinder Removal, Shimming, Overhaul, and Replacement 34-5-5

Group 34, Uprights

Group 34, Uprights
Section 6
Upright Chain Inspection, Adjustment,

and Replacement
Periodic Inspections.................................................................................................................3
Chain Length Adjustments.....................................................................................................4
Standard Upright Chain Length Adjustment..............................................................................5
Triple-Stage Upright (TSU) Chain Length Adjustments...........................................................5
Chain Lubrication....................................................................................................................7
Chain Removal and Replacement..........................................................................................7
General Guidelines.....................................................................................................................7
Lift Chains (Standard and TSUs................................................................................................7
Primary Cylinder/Carriage Chains (TSUs)................................................................................8
Other Chain Service Notes......................................................................................................8
TMX Truck
EPX Truck
Chain Configuration - Standard Upright Chain Configuration - Hi-Lo Upright
SM 715, Jun 05 Upright Chain Inspection, Adjustment, and Replacement 34-6-1

Group 34, Uprights
TMX Truck
EPX Truck
Chain Configurations - Triple Stage Uprights
34-6-2 Upright Chain Inspection, Adjustment, and Replacement SM 715, Jun 05

Group 34, Uprights
Periodic Inspections Chain with rotated/displaced heads or abnormal pin pro-

trusion should be replaced immediately. Do not attempt to
Each 50-250 hours of operation (more frequently in severe repair the chain by welding or driving the pin(s) back into
or extreme environments), chains should be inspected and the chain. Once the press fit integrity between outside
lubricated. Inspection should focus on the following: plates and pins has been altered, it cannot be restored.
Any wear pattern on the pin heads or the sides of the link
Elongation plates indicates misalignment in the system. This
condition dam-ages the chain and increases frictional
When a length of 12.00 inches (305 mm) of new chain has loading, and should be corrected.
elongated to a length of 12.360 inches (315 mm), it should
be discarded and replaced. It is important to measure the
chain in the section that moves over the sheaves because it
receives the most frequent articulation. 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% or Cracked Plates

when 12 inches (305 mm) of chain is stretched 3/8 inch
(10 mm). The chains should periodically be inspected very care-
fully, front and back as well as side to side, for any evi-
dence of cracked plates. If any one crack is discovered,
Edge Wear the chain(s) should be replaced. It is important, however,
to determine the causes of the crack before installing new
Check the chain for wear on the link plate edges caused
chain so the condition does not repeat itself.
by running back and forth over the sheave. The maximum
reduction of material should not exceed 5%. This can be Fatigue Cracking - Fatigue cracks are a result of
compared to a normal link plate height by measuring a repeated cyclic loading beyond the chains endur-
portion of chain that does not run over the sheave. Dis- ance limit. The magnitude of the load and fre-
torted or battered plates on leaf chain can cause tight quency of its occurrence are factors which
joints and prevent flexing. determine when fatigue failure will occur. The
loading can be continuous or intermittent (impulse
load).
Worn contours and worn surfaces on the outside links or

pin heads should not exceed 5% of new link height.
Fatigue cracks generally run from the pin hole toward

Turning or Protruding Pins the edge of the link plate approximately 90 from the line
Highly loaded chain operating with inadequate of pull.
lubrication can generate abnormal frictional forces Fatigue cracks almost always start at the link plate
between pin and link plates. In extreme instances, the pin hole (point of highest stress) and are
torque could surpass the press fit force between the pins perpendic-ular to the chain pitch line. They are
and the outside plates, resulting in pin rotation. When often micro-scopic in their early stage. Unlike a
chain is allowed to operate in this condition, a pin, or pure tensile failure, there is no noticeable yielding
series of pins, can begin to twist out of a chain resulting (stretch) of the material.
in failure. The pin head rivets should be examined to
determine if the VEE flats are still in correct alignment.
SM 715, Dec 04 Upright Chain Inspection, Adjustment, and Replacement 34-6-3

Group 34, Uprights
Stress - Corrosion Cracking - The outside link plates, Tight Joints

which are heavily press fitted to the pins, are
particularly susceptible to stress corrosion All joints in leaf chain should flex freely. Tight joints
cracking. Like fatigue cracks, these initiate at the resist flexure and increase internal friction, thus
point of highest stress (pin hole) but tend to extend increasing chain tension required to lift a given load.
in an arc-like path between the holes in the pin Increased ten-sion accelerates wear and fatigue problems.
plate.
Arc-like cracks in plates are a sign of stress corrosion.

More than one crack can often appear on a link If lubrication does not loosen a tight joint, the chain may
plate. In addition to rusting, this condition can be have corrosion and rust problems or bent pins and must
caused by exposure to an acidic or caustic medium be replaced.
or atmosphere.
Stress corrosion is an environmentally assisted fail- See Section 3 for detailed chain stretch, length, and ten-
ure. Two conditions must be present: a corrosive sions checks.
agent and static stress. In the chain, static stress is
present at the pin hole due to the press fit pin. No Chain Length Adjustments
cyclic motion is required, and the plates can crack
during idle periods. The reactions of many chemi-cal
agents (such as battery acid fumes) with hard-ened
WARNING
steel can liberate hydrogen which attacks and An upright or carriage can move unexpect-
weakens the steel grain structure. edly:
For this same reason, never attempt to electroplate Do not walk or stand under raised forks
a leaf chain or its components. The plating process
liberates hydrogen, and hydrogen embrittlement Keep clear of load and carriage when mak-
cracks will appear. These are similar in appearance ing any check or adjustment
to stress corrosion cracks. Keep your arms and fingers away from
If a plated chain is required, consult Clark. Plated moving parts of the upright.
chains are assembled from modified, individually Block the carriage or upright when work-ing
plated components which may reduce the chain
with the components in a raised posi-tion.
rating.
Corrosion Fatigue - Corrosion fatigue cracks are very
similar (in many cases identical) to normal fatigue upright.
cracks in appearance. They generally begin at the Never attempt to move or align the rails by
pin hole and move perpendicular (90) to the chain hand. Use a prybar.
pitch line. Failure to follow these warnings can result in
Corrosion fatigue is not the same as stress corro- serious injury.
sion. Corrosion fatigue is the combined action of
an aggressive environment and a cyclic stress (not
a static stress alone, as in stress corrosion).
Ultimate Strength Failure

This type of failure is caused by overloads far in excess
of the design load.
Broken plate caused by overload.
34-6-4 Upright Chain Inspection, Adjustment, and Replacement SM 715, Dec 04

Group 34, Uprights
Standard Upright Chain Length Adjustment Raise carriage about 1 m (3.2 ft) and measure the
distance from where the center of the bottom car-
To adjust chain length on the standard upright use the fol- riage roller stopped to the bottom edge of the inner
lowing illustration and procedures: rail. Distance should not be less than 20 mm (0.80
in) or chain length adjustment is required.
Carriage stop-to-upright:
Lift upright to its full height and check for clear-ance
on the carriage safety stop.
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
Adjust chain The carriage stop must not be allowed to
length here
con-tact the upright stop under any
To carriage circumstance during normal operations.
Fork-to-ground clearance: If all three chain length requirements listed above cannot
a. Set the upright to vertical position. be met, the tire diameter may be out of the design range
allowance. Also, excessive tire wear will decrease
carriage stop clearance.
Oversized tires will reduce the bottom carriage roller
engagement on the inner rail when the carriage is in the
lowered position. The fork-to-ground clearance can devi-
ate from the 10-20 mm (0.40-0.80 in) allowance by a
small amount if necessary to maintain the safe 20 mm
(0.80 in) clearance of the bottom carriage roller to the
lower edge of the inner rail.
Break the jam nuts loose on the chain anchors.

Triple-Stage Upright (TSU) and Hi-Lo
Turn the chain adjustment nuts until clearance Chain Length Adjustments
between forks and ground is 10-20 mm (0.40-
0.80 in). Triple-stage uprights use two chain sets; one set for car-
riage lift and one set for rail lift. Adjustment anchors for
IMPORTANT the lift cylinder stage are located at the back of the outer
For all chain anchor adjustments: rail. Adjustment anchors for the primary lift stage are
Threaded chain anchors must be left free to behind the primary cylinder. Carriage chain anchors are
pivot in mounting hole. not intended for adjustment.
Anchor cotter pin heads must be to the For TSU inner rail lift chains, chain length must be
inside of the upright. adjusted if the difference between the bottom of the inner
Torque jam nuts to adjustment nuts to 80- rail and the outer rail is greater than 10 mm (0.40 in).
150 N.m (59-110 ft-lb) For the TSU and Hi-Lo primary cylinder lift chain, the
Make sure chain anchors are secured so that chain length must be adjusted if:
no twist is evident in the chains.
The fork-to-ground clearance is less than 5 mm (0.20
Carriage roller position: in) or more than 25 mm (1.0 in) when the upright
is vertical.
Raise carriage about 1 m (3.2 ft) and smear a bead of
grease on the bottom 75 mm (3 in) inner rail in The center of the bottom carriage roller comes within
the area of the roller pattern. 20 mm (.80 in) of the bottom edge of the inner
Tilt upright fully back and completely lower. rail.

Group 34, Uprights
The carriage safety stop hits the inner rail stop at IMPORTANT
full lift height. For all chain anchor adjustments:
To adjust the cylinder lift chains on a TSU use the
Threaded chain anchors must be left free to
follow-ing illustration and procedures:
pivot in mounting hole.
Anchor cotter pin heads must be to the inside
of the upright.
Torque jam nuts to adjustment nuts to 80-
150 N.m (59-110 ft-lb).
Make sure chain anchors are secured so that
no twist is evident in the chains.
Carriage roller position:

Raise carriage about 1 m (3.2 ft) and smear a bead of
Adjust chain grease on the bottom 75 mm (3 in) of the inner
length here
rail in the area of the roller pattern.
To inner rail Tilt upright fully back and completely lower.
Raise carriage again about 1 m (3.2 ft) and mea-sure
Set the upright in the vertical position. the distance from where the center of the bottom
carriage roller stopped to the bottom edge of the
Break the jam nuts loose on the chain anchors. inner rail. Distance should not be less than 20
Adjust the chain anchor adjustment nuts until the bottom mm (0.80 in) or chain length adjustment is
of the inner rail is within 2.5 mm (0.10 in) of the required.
bottom of the outer rail. Carriage stop-to-upright:
To adjust the primary cylinder lift chain on TSU and Hi- Lift upright to its full height and check for clear-ance
Lo use the following illustration and procedures: on the carriage safety stop.
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
con-tact the upright stop under any
circumstance during normal operations.
Adjust chain If all three chain length requirements listed above cannot
length here To carriage be met, the tire diameter may be out of the design range
allowance. Also, excessive tire wear will decrease
Fork-to-ground clearance: carriage stop clearance.
Set the upright to vertical position.
Break the jam nuts loose on the chain anchors. Oversized tires will reduce the bottom carriage roller
engagement on the inner rail when the carriage is in the
Turn the chain adjustment nuts until clearance
lowered position. The fork-to-ground clearance can devi-
between forks and ground is 10-20 mm (0.40-
ate from the 10-20 mm (0.40-0.80 in) allowance by a
0.80 in).
small amount if necessary to maintain the safe 20 mm
(0.80 in) clearance of the bottom carriage roller to the
lower edge of the inner rail.

Group 34, Uprights
Chain Lubrication General Guidelines

Like all bearing surfaces, the precision-manufactured, Chain Movement - Make sure that the chain oper-
hardened-steel, joint-wearing surfaces of leaf chain ating path is clear and that the chain articulates
require a film of oil between all mating parts to prevent freely through its full range of operation.
accelerated wear. Lubrication - Assure that the chain is well lubri-cated
Maintaining a lubricant film on all chain surfaces will: with the heaviest oil that will penetrate the void
between the link plate apertures and the pins.
Minimize joint wear. Paint - Make sure the chain does not get painted over
Improve corrosion resistance. at any time.
Reduce the possibility of pin turning. Protection - Where necessary, as a protection from
Minimize tight joints. atmosphere or sliding wear, the chain may be cov-
ered with a layer of grease. It should be noted,
Promote smooth, quiet chain action.
however, that the grease will have to be removed at a
Lower chain tension by reducing internal friction in later date for chain inspection and relubrication.
the chain system.
Chain Mountings - Double check to be sure all chain
Laboratory wear tests show #40 oil to have greater ability fastening devices are secured and all adjust-ments
to prevent wear than #10 oil. Generally, the heaviest have been made to assure uniform loading of
(highest viscosity) oil that will penetrate the joint is best. multiple chain applications. Check chain anchors
and pins for wear, breakage, and misalign-ment.
Whatever method is used, the oil must penetrate the chain
Damaged anchors and pins should be replaced.
joint to prevent wear. Applying oil to external surfaces
will prevent rust, but oil must flow into the live bearing Sheaves - Sheaves with badly worn flanges and
surfaces for maximum wear life. outside diameter should be replaced. This wear
may be due to chain misalignment or frozen bear-
To prepare the chain for oiling, the leaf chain plates ings.
should be brushed with a stiff brush or wire brush to clear
the space between the plates so that oil may penetrate the
live bearing area.
Lift Chains (Standard and TSUs)
Oil may be applied with a narrow paint brush or directly To remove and replace the lift cylinder and/or carriage
poured on. Chain should be well flooded to be sure the oil chain set on standard and triple-stage uprights (TSU):
penetrates the joint. Attach a hoist strap on the carriage of the standard
In locations difficult to reach, it may be necessary to use a upright or inner rail of the TSU.
good quality oil under pressure such as an aerosol can or Lift the carriage or inner rail slightly to create slack in
pump pressure spray. the chains. Block the carriage or inner rail up for
safety.
Chain Removal and Replacement Remove the chain anchor pins on the outer rail and pull
the chains off of the sheaves on the inner or
WARNING intermediate rails.
The procedures for removing and replacing
chain sets involve hoisting and blocking com-
ponents.
upright.
Failure to follow these warnings can result in
serious injury. See iLifting, Jacking, and
Blockingi for safe blocking procedures.

Group 34, Uprights
Remove the chain anchor pins from the carriage on the

standard upright or the inner rail on the TSU. On the
TSU, the inner rails must be lowered to the floor to
access the chain anchor pins.
Remove the chain anchor pins from the back of the

Lift Chain Removal from Carriage (standard upright) carriage.
Use these steps in reverse to replace the primary cyl-

inder/carriage chain.
Triple-Stage Upright Lift Chain Removal from Inner Rail
Perform the chain length adjustment and chain tension
NOTE check before returning the truck to service.
If a hose adapter assembly is used, the chain
sheaves must be loosened and removed to Other Chain Service Notes
prevent the hoses from stretching when the
inner rails of the TSU are lowered to access Use lengths of factory assembled chain. Do not build
the chain anchor pins. lengths from individual components.
Do not attempt to rework damaged chains by
Use the steps in reverse order to replace the lift chain replacing only the components obviously faulty.
set. The entire chain may be compromised and should
be discarded.
Primary Cylinder/Carriage Chains (TSU Never electroplate assembled leaf chain or its com-
ponents. Plating will result in failure from hydro-gen
& Hi-LO) embrittlement. Plated chains are assembled from
modified, individually plated components.
Tilt the upright forward, lower it, and completely col-
lapse the primary cylinder to create slack in the Welding should not be performed on any chain or
chains. The carriage may also be lifted and blocked component. Welding spatter should never be
in position and the primary cylinder completely col- allowed to come in contact with chain or compo-
lapsed to create slack in the chains. nents.
Leaf chains are manufactured exclusively from heat
Remove the chain anchor pins from the back of the treated steels and therefore must not be annealed.
primary cylinder. Pull the chains through the chain If heating a chain with a cutting torch is absolutely
sheave and lay over the carriage load backrest. necessary for removal, the chain should not be
reused.

Group 34, Uprights
Section 7
Fork and Carriage Removal and Replacement
CAUTION Lift tip of each fork and put a 100 x 100 mm (4 x 4 in)
block under the fork arm near the heel.
1.Park truck on a hard, level, and solid sur- CAUTION
face, such as a concrete floor with no gaps Forks weigh 40-65 kg (90-145 lbs) each. Take
or breaks. care when lifting.
OFF and remove key.
wheels.
Fork Removal
Forks do not need to be removed to remove the carriage.
Blocking the Fork
1. Release the fork latches.
Push down on tips of the forks to disengage the fork
hooks from the carriage fork bar.
Lift fork heel and remove block.
CAUTION
Forks are not stable sitting free in upright
position. Use care when working around the
forks.
Latch Operation
Move each fork to the notch on the bottom of the lower 6. Back the truck away from the forks.
carriage cross bar.
Fork Replacement
1. Carefully drive truck up close to forks.
! CAUTION
Forks are not stable sitting free in upright
position. Use care when working around the
forks.
2. Drag forks into position close to carriage and to line

up with the notche on the lower carriage cross bar.
3. Lift fork heel and place block under arm near the
heel.
SM 715, Dec 04 Fork and Carriage Removal and Replacement 34-7-1

Group 34, Uprights
Lift tips of forks to engage the fork hooks on the upper Once the carriage is fully lowered, clamp the front of
carriage fork bar. one fork to the pallet to prevent the carriage from
Remove blocks from under fork. falling over backwards when removed.
Check fork latches when repositioning forks to upper

carriage fork notches.
Carriage Removal
The carriage should be removed for shimming or when
any service procedure is performed on the upright.
WARNING
The procedures for checking, maintaining,
and adjusting uprights, carriages, and forks
involve movement of the components.
Keep clear of load and carriage when mak-
ing any check or adjustment.
upright. For carriage auxiliary components, the hose sheave
Always use a prybar to move the upright or bracket must be unbolted from the primary cylinder
carriage. chain sheave bracket. Move the hose bracket off the
Failure to follow these warnings can result in chain bracket.
serious injury.
Set upright tilt to 0 degrees (vertical). Raise the car-riage

about 12 in (305 mm).
Place a heavy pallet under the forks. Turn the key off.
Lower the carriage onto the pallet and keep lowering
(until the primary cylinder is all the way down on
TSUs). Before proceeding with the next step read
the following warning.
WARNING
You may need to pull on the hoses/cables and
chains while lowering the primary cylinder
to get it all the way down. This is done to
create slack in hoses/cables and chains and to
dis-place as much oil as possible, which will
reduce oil loss when disconnecting hydraulic
lines for auxiliary components.
You may need a helper to hold the control
handle in the lowering position while you
pull on the carriage chains to fully collapse
the primary cylinder (on TSU & Hi-Lo).
When pulling on the chains to lower the
primary cylinder (on TSU & Hi-Lo), the
ignition must be off.
34-7-2 Fork and Carriage Removal and Replacement SM 715, Dec 04

Group 34, Uprights
Disconnect the carriage chains at the base of the car-

riage. Pull chains back off primary cylinder sheave.
For carriage auxiliary components, disconnect hoses (2-

or 4-hose assemblies) from carriage. Remove the
bolts and strap fixture also.
Lower the upright rails until both of the secondary
cylinders are completely collapsed.
Carriage Replacement
To replace the carriage:
First check to be sure the carriage is securely clamped to
the pallet.
Move the truck up to the carriage assembly with the
inner rail centered on the carriage.
Raise the upright until the inner rail is high enough to
clear the upper carriage rollers.
Cap all lines to prevent leaks. Tilt the upright until it is at the same angle as the car-
Label all lines and fittings for correct reassembly. riage assembly.
Elevate the primary cylinder to its maximum height. Be Now slowly move the truck forward until the inner rail is
sure all hoses and loose parts are secured out of the centered over the carriage rollers.
way to prevent damage.
Continue elevating the upright until the inner rail clears
the carriage.
Remove steer wheel blocks. Release the parking brake
and slowly back the truck away from the car-riage.
SM 715, Dec 04 Fork and Carriage Removal and Replacement 34-7-3

Group 34, Uprights
WARNING If the carriage is equipped with a carriage auxiliary

component, reconnect the hose sheave bracket to the
Never attempt to move or align the carriage top of the primary cylinder chain sheave barcket.
or bearings by hand. Use a pry bar.
Lower the upright until the inner rail clears all of the
carriage rollers.
NOTE
If the rail or bearings bind, raise the upright,
back away from the carriage and check to be
sure the carriage rollers are installed prop-
erly.
When the inner rail has cleared the carriage rollers,

continue to lower the upright until the lift cylinders
are lowered completely.
Reconnect the hoses and mounting strap to the car-riage
Reset the truck in a safe position: auxiliary component if the carriage is so equipped.
Ignition off
Parking brake applied
Directional lever in neutral
Forks completely lowered
Block steer wheels.
Reinstall the carriage lift chains to the base of the
carriage.
Lubricate all O-rings with a light coating of system

hydraulic fluid or a compatible oil.
Use two wrenches to tighten hose fittings to pre-vent
hoses from twisting.
See Group 40 for hydraulic fitting tightening pro-
Set anchor bolts so that no twist develops in the cedures.
chains.
Adjust carriage height according to Section 6 and chain
Anchor pin heads must be pointing to the inside of the
upright. tension according to Section 3.
Use new cotter pins. Remove the C clamp from the pallet and check the
operation of the carriage and the upright. Carefully
IMPORTANT check for oil leaks. Make sure the carriage and
Always use new anchor pins when replacing upright work smoothly and correctly before
chain sets. returning the truck to service.
34-7-4 Fork and Carriage Removal and Replacement SM 715, Dec 04

Group 34, Uprights
Section 8
Upright Removal and Replacement
This Section describes how to remove the entire upright

assembly from the truck. The carriage and forks must be
! CAUTION
removed from the upright assembly before the upright is SAFE PARKING. Before working on truck:
removed. (For uprights with an auxiliary component, a 1.Park truck on a hard, level, and solid sur-
side-shifter for example, the two hydraulic hoses power-
ing the auxiliary component must be removed before the face, such as a concrete floor with no gaps
carriage is removed.) See Section 7, Fork and Carriage or breaks.
Removal and Replacement, for procedures to remove the 2.Put upright in vertical position and fully
carriage and fork assembly from the upright. lower the forks or attachment.
OFF and remove key.
wheels.
Tilt Cylinder
Mounting Stoper
Tilt Cylinder
Mounting Bolt
Cylinder Rod End
Grease Nipple
Spacer
Upright Mounting Pin
Outer Rail Set
Washer
Upright Mounting Bolt
Typical Upright Installation
SM 715, Dec 04 Upright Removal and Replacement 34-8-1

Group 34, Uprights
Upright Removal Disconnect and cap hydraulic line at the load-lower-ing

flow valve. Secure the hose out of the way of the
The following procedures are for uprights with carriage upright.
and forks, or auxiliary components removed. See Section
7, Fork and Carriage Removal and Replacement,for
instructions on removing the forks and carriage.
WARNING
The upright assembly is heavy. Use only
hoists with enough capacity to lift the entire
assembly. Keep clear of the assembly as it is
being hoisted and set down. Keep hands and
feet away from the assembly. Use prybars to
move the assembly into position for reattach-
ment.
Attach a hoist and strap of adequate capacity to the

upright as shown below. Tension the hoist so that the EPX Truck
upright cannot fall when upright mounting pins and TMX Truck Disconnect
tilt cylinder pins are removed. and cap line from
main hydraulic
control valve.
NOTE
For two-hose adapter assemblies, the

hydraulic lines to the upright must also be
disconnected and capped.
Disconnect
lines here.
TMX Truck
Disconnect
EPX Truck lines here.
34-8-2 Upright Removal and Replacement SM 715, Dec 04

Group 34, Uprights
Remove tilt cylinder rod-end, rod-end mounting bolt and Upright Replacement
stopper from upright.
Use an overhead chain hoist of adequate capacity and an
approved lift chain to lift upright into position.
Tilt Cylinder
Rod End
Tilt Cylinder
Mounting Stoper
Tilt Cylinder
Mounting Bolt
Remove upright mounting pin bolt and lift upright off WARNING
frame. See illustration on page 1. Use prybars to move the assembly into posi-
Slowly set upright down on the floor, 100 x 100 mm (4 x tion for reattachment.
4 in) blocking, or sturdy pallets set end-to-end.
Install upright mounting pin and bolt. Torque to 25-
30N.m (221~266 lbf-in)
Spacer
Washer
Upright Mounting Pin

Upright Mounting Bolt
SM 715, Dec 04 Upright Removal and Replacement 34-8-3

Group 34, Uprights
Install rod end pins, lock plates, and fasteners. Tighten NOTE
lock plate fasteners to a torque of 121-136 in-lb Reconnect two-hose adapter assembly
(19.3- 21.5 N.m). hydraulic lines to the upright-mounted
bracket.
Tilt Cylinder
Rod End
Tilt Cylinder
Mounting Stoper
Tilt Cylinder
Mounting Bolt
TMX Truck
Attach hydraulic lines to the upright flow control valve:
EPX Truck
Remove the lift chain between the upright and hoist.

Completely check all upright and hydraulic compo-nents
under load before returning the truck to service.
See Section 8, Fork and Carriage Removal and
Replacement, for steps to replace the carriage and
EPX Truck fork assembly.
TMX Truck
Lubricate all O-rings with a light coating of system

hydraulic fluid or a compatible oil.
Use two wrenches to tighten hose fittings to pre-vent
twisting lines.
See Group 40 for hydraulic fitting tightening pro-
cedures.
34-8-4 Upright Removal and Replacement SM 715, Jun 05

GROUP 38
GROUP 38
COUNTERWEIGHT AND CHASSIS
Counterweight Specifications and Description ............ Section 1

Counterweight Removal and Installation........................ Section 2
Overhead Guard Removal and Installation .................... Section 3
Floor Plate, Seat, and Seat Deck Removal
and Installation ........................................................ Section 4
SM 715, Dec 04 Group 38, COUNTERWEIGHT AND CHASSIS

NOTE :
Group 38, COUNTERWEIGHT AND CHASSIS SM 715, Dec 04

Group 38, Counterweight and Chassis
Section 1
Counterweight Specifications and Description
Specifications Maintenance Requirements

Counterweight Mounting Bolts Torque: 339-381 N.m WARNING
(251.280 ft-lb) Counterweight Weight: Different counter-
weights are used based on truck capacity and battery THE COUNTERWEIGHT IS
com-partment length, as follows: EXTREMELY HEAVY. Do not remove the
TMX Truck counterweight unless you have training and
Battery Compartment are familiar with the correct procedures.
Truck Capacity Length Counterweight Counterweights can fall if not handled cor-
2500 lb (1250 kg) 13.75 1262 lb (573 kg) rectly and can cause severe injury or death.
3000 lb (1500 kg) 13.75 1836 lb (834 kg) Keep your hands, feet, and body clear of the
3000 lb (1500 kg) 20.5 914 lb (415 kg) counterweight at all times.
3500 lb (1750 kg) 20.5 1262 lb (573 kg) HOISTING EQUIPMENT must be capable
4000 lb (1815 kg) 20.5 1836 lb (834 kg) of handling the weight of the counterweight
4000 lb (2000 kg) 20.5 2094 lb (950 kg) when removing or replacing. Make sure your
lifting equipment is of adequate capacity to
5000 lb (2270 kg) 20.5 2894 lb (1314 kg)
handle the weight.
EPX Truck
Battery Compartment The counterweight must be maintained in good condition
Truck Capacity Length Counterweight and securely attached to the lift truck. Because of its
3500 lb (1600 kg) 29 1080 lb (490 kg) heavy weight and bulky mass, the counterweight must be
4000 lb (1800 kg) 29 1300 lb (590 kg) carefully supported and handled. When removed from the
truck, store at floor level as shown below to be sure it will
Description not fall or tip, causing damage or injury.
The counterweight is a solid, cast-iron piece mounted to

the back of the lift truck. It is used to counterbalance the
loads placed on the upright at the front of the truck. The
weight must be great enough to counteract forward tip-
ping when lifting or stopping with a capacity load. The
battery provides much of the counterweight on an electric
truck.
WARNING
BATTERY WEIGHT. The minimum battery
weight for your truck is stamped on the
nameplate. Never operate the truck with a
Generic Illustration
battery that weighs less.
Large, hardened steel bolts hold the counterweight to the

frame.
SM 715, Jun 05 Counterweight Specifications and Description 38-1-1

NOTE :
Group 38, Counterweight and Chassis SM 715, Dec 04

Section 2
Counterweight Removal and Installation
CAUTION appropriately- sized eye bolt installed

through the top lifting hole.
SAFE PARKING. Before working on truck: Use only overhead lifting equipment having
1.Park truck on a hard, level and solid sur- a safe lifting capacity in excess of that of the
face, such as a concrete floor with no gaps counterweight.
or breaks.
Counterweight hooks
OFF and remove key.
4.Apply the park brake and block the wheels.
Remove the battery as described in Group 12.

TMX
Install eye bolt into the counterweight. Eyebolt must be
able to lift up to 2894 lb (1314 kg), depending on the
Counterweight hooks
truck model. (See weight specifications in Sec-tion
1.)
Using an overhead hoist with sufficient lifting capac-ity,
attach hoist chain to eyebolt. Slowly lift hoist until
slack is removed from chain.
Remove the counterweight mounting bolts from inside
the battery compartment. Stand clear of the
counterweight as it is being hoisted, moved, or
mounted. EPX
Slowly lift the counterweight from the truck frame until

it is free from the counterweight hooks on the frame
and can be moved back to clear the electronic
controls. Take care not to damage the controls.
Slowly lower the counterweight onto a sturdy pallet. Set
the counterweight on its flat side if possible.
WARNING
Observe proper, safe lifting practices when
lifting counterweight on or off truck. Generic Illustration
Counterweight should only be lifted by
SM 715, Jun 05 Counterweight Removal and Installation 38-2-1

Counterweight Installation
WARNING
Stand clear of the counterweight as it is being
hoisted, moved, or mounted.
During mounting, always use prybars for
location adjustments. Do not place any part
of your body between the counterweight and
truck.
Inspect the counterweight mounting bolts and nuts to

make sure they are in good condition before install-
ing. Make sure the mounting nuts are in place in the
counterweight.
Slowly raise the counterweight high enough to clear the
counterweight hooks on the frame. Take care not to
damage the electronic controls. Slowly lower the
counterweight onto the frame hooks.
Make sure that the bolt holes in the counterweight align
properly with the mating holes in the frame.
Torque the mounting bolts 340-380 N.m (251.280 ft-lb)
Remove the hoist and eyebolts.
IMPORTANT
Never allow a truck to be put into service
without the counterweight mounting bolts in
place. Check the bolts and torque regularly.
Counterweight Hooks
Torque :
Mounter nut
TMX
Counterweight Hooks
Torque :
EPX
38-2-2 Counterweight Removal and Installation SM 715, Jun 05

Section 3
Overhead Guard Removal and Installation
CAUTION WARNING
SAFE PARKING. Before working on truck: Overhead guard must be in place to protect
operator from falling objects.
1.Park truck on a hard, level and solid sur-
face, such as a concrete floor with no gaps
or breaks.
OFF and remove key.
4.Apply the park brake and block the wheels.
It is not necessary to remove the overhead guard for nor-

mal service or repair of the truck. If the overhead guard
must be rplaced or repaired, remove it as follows:
Remove the electric part all
Remove the seat deck from the truck
(TMX Truck)
Support the cowl assembly with an overhead lifting
device and remove fasteners holding the front cowl
assembly to the overhead guard.
Cowl
Assembly
Torque:
40-45 N.m (EPX Truck)
(30-33 ft-lb)
4. Remove the overhead guard mounting bolts.

5. Lift the overhead guard from the truck. Torque overhead guard mounting bolts: 88-95 N.m (65-70
6. Reverse procedure for installation. lb-ft)

SM 715, Jun 05 Overhead Guard Removal and Installation 38-3-1
NOTE :
Group 38, Counterweight and Chassis SM 715, Dec 04

Section 4
Floor Plate, Seat, and Seat Deck

Removal and Installation
CAUTION

attachment.
remove key.
Floor Plate Removal and Installation To replace the floor plate, position the front of floor
plate first, then unfold it into position.
Tilt the steering column fully forward.
IMPORTANT
Fold the floor plate on its hinge and lift out the oper- Make sure the accelerator pedal has a full
ators compartment. Rubber mat lifts out with floor stroke and does not bind.
plate. Floor plate is not fastened to the truck. Refer to Group 13 for accelerator pedal and
control information.
SM 715, Dec 04 Floor Plate, Seat, and Seat Deck Removal and Installation 38-4-1
Seat Removal and Installation

Overhead Guard
Use the following illustrations as a guide to removing
Storage Console
installing the seat and seat deck components. Torque:
70-80 N.m
(52-59 ft-lb)
Torque:
6-13 N.m
(60-120 in-lb)
Torque: Torque:
40-45 N.m 8-10 N.m
(30-33 ft-lb) (71-88 in-lb)
(EPX Truck)
Seat Deck
Gas Spring
Torque:
23-25 N.m
(203-221 in-lb)
Torque:
20-25 N.m
(176-221 in-lb)
Overhead Guard
Torque:
100-110 N.m
(73-81 ft-lb)
Torque:
40-45 N.m
(30-33 ft-lb)
(TMX Truck)
Seat Deck
Leveler
Torque:
20-25 N.m
(176-221 in-lb)
38-4-2 Floor Plate, Seat, and Seat Deck Removal and Installation SM 715, Jun 05
GROUP 40
GROUP 40
SPECIFICATIONS
Nameplates and Decals .................................................... Section 1

General Specifications .................................................... Section 2
Hydraulic Fitting Tightening Procedures ....................... Section 3
SM 715, Dec 04 Group 40, SPECIFICATIONS

NOTE :
Group 40, SPECIFICATIONS SM 715, Dec 04

Group 40, Specifications
Section 1
Nameplate and Decals
Nameplate and Decal Locations (TMX)....................................................................................2

Nameplate and Decal Locations (EPX).....................................................................................3
Nameplate and Decals................................................................................................................4

Truck Data and Capacity Plate.............................................................................................4
Warning Decal......................................................................................................................5
Operator Safety Decal..........................................................................................................5
Hand Safety Warning Decal.................................................................................................6
Keep Away from Forks Decal..............................................................................................6
Battery Connector Warning Decal........................................................................................6
Polarity Warning Decal........................................................................................................6
Electric Truck Wirning Decal...............................................................................................7
SM 715, Jun 05 Nameplate and Decals 40-1-1

Nameplate and Decal Locations
(TMX)
TMG Service Chart
WARNING
BEFORE OPERATING lift truck, operator must:
Be trained and authorized.
Read and understand operator's
manual.
Not operate a faulty lift truck.
Not repair lift truck unless trained and authorized.
Have the overhead guard and load
* backrest extension in place.
* DURING OPERATION, lift truck operator must:

Wear a seat belt.
Keep entire body inside truck cab.
Never carry passengers or lift people.
Keep truck away from people and obstructions.
* Travel with lift mechanism as low as possible.
and tilted back.

c
* TO PARK lift truck, operator must:
Completely lower forks or attachments.
Shift into neutral.
Turn off key.
Set parking brake.
Clark Material Handling Co. Sit Down Rider 2798233
IMPORTANT
--------------------
-------------------
-----------.
--------------------
------------.
WARNING
Disconnect battery before handling
electrical components.
Connect positine to positive, negative

to negative to prevent damage. 2811139
WARNING
TRUCK CAN MOVE UNEXPECTEDLY!
BEFORE WORKING ON THIS TRUCK.
BREAKING THESE RULES MAY CAUSE

SERIOUS OR FATAL INJURY TO
YOURSELF AND OTHERS.
Hydraulics Diagram
CAUTION
Wiring Schematic TMG Service Chart
WARNING
BEFORE OPERATING lift truck, operator must:
DOT3 only Be trained and authorized.
manual.
to prevent failure Not operate a faulty lift truck.
*
of braking system
Have the overhead guard and load backrest
extension in place.
DURING OPERATION, lift truck operator must: *
2825871
Wear a seat belt.
WARNING Never carry passengers or lift people.
Travel with lift mechanism as low as possible.
*
Disconnect battery before handling and tilted back.
TO PARK lift truck, operator must:
Completely lower forks or attachments. *
Shift into neutral.
Connect positine to positive, negative Turn off key.
Set parking brake. Wiring Diagram
to negative to prevent damage. 2811139 Clark Material Handling Co. Sit Down Rider 2798233
40-1-2 Nameplate and Decals SM 715, Mar 05

Nameplate and Decal Locations

(EPX)
WARNING * Hydraulics Diagram
Read the *
manual
Buckle up! *
CAUTION
Apply brake *
DOT3 only
when leaving
truck
to prevent failure
Watch Out
of braking system
For Other 2825871
People
Most lift truck

INJURIES
are to other
people near
the lift truck.
Prevent
Overturns!
AVOID :
slippery,
sloping, or
uneven
surfaces
loads over
capacity on
nameplate
unstable or
high loads
low tire
pressure
poorly
maintained
lift truck
fast or sharp
turns
In Case of
Tip-Over:
Don't
jump
Hold on
tight
Brace feet
Lean
away
INSIDE OF COVER
CTWT
WARNING
.
--------------------------------------------------------------------
.
WARNING
--------------------------------------------------------------------
---------------------------------------------
--------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------- --------------------------------------------------------------------
. .
TIRE PRESSURE
WARNING
IMPORTANT Disconnect battery before handling . . (bar)
--------------------
------------------- BEFORE OPERATING lift truck, operator must:
electrical components. . FRONT TIRE Be trained and authorized.
-----------. -----------------------------------------------------------------------------------------------------------------------
. REAR TIRE
Read and understand
-------------------- . A B operator's manual.
------------. Connect positine to positive, negative
.
. P/NO
to negative to prevent damage. 2811139 -------------------------------------------------------------- . Have the overhead guard and load
backrest extension in place.
DURING OPERATION, lift truck operator must:
Wear a seat belt.
Never carry passengers or lift people.
and tilted back.

c
Shift into neutral.
Turn off key.
Set parking brake.
SM 715, Jun 05 Nameplate and Decals 40-1-3

Nameplate and Decals can occur if these capacities are exceeded. Do not
exceed the maximum capacity specified.
This section shows the nameplate (data and capacity
plate) and decals required to be on all operating Clark Truck weight . The approximate weight of the truck
industrial trucks. The nameplate lists the data on the truck without a load on the forks. The truck weight plus
. type and serial number . and the capacities of the truck. the weight of the load must be considered when
Decals depict or explain the hazards the operator must operat-ing on elevators, elevated floors, etc., to be
avoid when operating the truck. The nameplate and sure it is safe.
decals are placed in specific locations on the truck and
CAUTION
are intended to warn others working around the truck of
its hazards as well. The nameplate and decals MUST BE Before attachments are added, or if the truck
IN PLACE on all trucks. is modified after leaving the factory, you
must contact your authorized Clark dealer
If any decals or the nameplate are missing from the truck, for authorization and a new nameplate as
check with your local Clark dealer for replacements. This capacity will new affected. This is required
is required by OSHA. by OSHA.
IMPORTANT
Do not allow a lift truck with damaged or From the factory this truck
meets Part II ANSI B56.1
missing decals or data plate to be placed in Model Type
service. Replace them immediately. They Serial No.
Attachments
contain important information as described in
A
on the following pages. This is required by
OSHA. The location of all decals is also B mm
in lb
shown on the following pages. mm kg
in lb
mm kg
Truck Data and Capacity Plate in lb
mm kg
Load C in
The truck data and capacity plate provides essential infor- mm
mation about the truck. This information is important for C. G. C
Capacities are for
both operators and service personnel. Operators can see centered loads only.
B
what the trucks capacities and load ratings are. Service A Capacities are with
attachment or forks with
personnel must identify the truck model, type, and serial upright in vertical position.
number when ordering parts. Refer to numbers on exam- Truck Weight lb or kg
ple data plate illustration. w / Max Battery lb or kg
Max Battery lb or kg
1. Truck model number or registered name. Min Battery lb or kg
2. Truck serial number--An identification number Max Amp Hrs. Volts No.
2811000
For other capacities consult Clark Material Handling Co., Lexington, KY
assigned to this particular truck and should be used
when requesting information or ordering service
parts for this truck from your authorized CLARK
dealer. The serial number is also stamped on the
frame.
1
2
3. Attachment description (if any installed)--The user
3
must see that the truck is marked to identify the
attachment(s), including weight of the truck/attach-
ment combination and truck capacity with the attach- 4
ment.
4. Capacity rating, load center, and lifting height data-- 5
Shows the maximum load capacity of this truck with
relation to load centers and fork heights (see diagram
on plate). Personal injury and damage to the truck

Warning Decal Operator Safety Decal

The Operator Safety Warning Decal describes basic safe The Operator Safety Decal depicts impor-
operating procedures that should be used when operating tant points about truck operation and warns WARNING
the truck. This decal depicts important points about truck operators about truck safety haz-ards. The Read the
manual
operation and warns operators about truck safety hazards. Operator Safety Decal is meant as a
This decal is meant as a reminder for operators. It is reminder for operators and is placed where
placed where operators can review the points daily as operators can review the points daily as
Buckle up!
they conduct a visual inspection and prepare the truck for they conduct a visual inspection and
work. prepare the truck for work.
WARNING
Apply brake
when leaving
truck
BEFORE OPERATING lift truck, operator must: Watch Out

For Other
Be trained and authorized.
People
manual.
Have the overhead guard and load backrest
Most lift truck
extension in place. INJURIES
are to other
DURING OPERATION, lift truck operator must: people near
Wear a seat belt. the lift truck.

Never carry passengers or lift people. Prevent
Keep truck away from people and obstructions. Overturns!
and tilted back.
Shift into neutral.
Turn off key.
P P
AVOID :
slippery,
sloping,
Set parking brake. or uneven
Clark Material Handling Co. Sit Down Rider 2798233
surfaces
loads over
IMPORTANT capacity on
nameplate
Safety and warning decals are placed in con- unstable
spicuous locations on the truck to remind or high
operators of essential procedures or to pre- loads
vent them from making an error that could low tire
pressure
damage the truck or cause personal injury.
poorly
Safety and warning decals should be
maintained
replaced immediately if missing, damaged or lift truck
illegible. This is required by OSHA. fast or
sharp turns
Lift trucks can be tipped over if operated improperly.
In Case of
Experience with lift truck accidents has shown that the Tip-Over:
driver cannot react quickly enough to jump clear of the Don't
jump
truck and overhead guard as the truck tips. To protect
operators from severe injury or death in the event of a tip-
over, make sure this decal is in place to remind them to
always use their seat belts. Hold on
tight
Brace feet
Lean
away
2798235
SM 715, Mar 05 Nameplate and Decals 40-1-5
Hand Safety Warning Decal Battery Disconnect Warning Decal

This safety decal is placed on the upright to warn of the This warning decal is located on the front of the seat deck. It
danger of injury from movement between rails, chains, warns of the danger of truck movement when removing or
sheaves, fork carriage, and other parts of the upright inserting the battery connector by calling for turning the key
assembly. Operators and others should never climb on or switch to OFF and setting the parking brake.
reach into the upright. Personal injury will result if any
WARNING
body part is put between moving parts of the upright.
Turn key switch off

and set parking
brake before
removing
2791862 or inserting battery
connector.
Keep Away from Forks Decal Truck may start in

This safety decal is placed on the upright to warn of the motion if you do not.
danger of injury from forks when they are in the raised
2743642
position. Operators and others should never ride on or
stand under forks or attachments. The forks can fall and
cause injury or death.
Polarity Warning Decal
This warning decal is located on the front of the seat
deck, adjacent to the Battery Disconnect Warning Decal.
It notes the need to disconnect the battery before handling
electrical components and to always make electrical con-
nections positive to positive and negative to negative to
prevent damage.
! WARNING
Disconnect battery before handling
Connect positive to positive, negative

to negative to prevent damage.

Electric Truck Warning Decal

This warning decal is located on the inside of the electri-
cal contactor compartment door. It warns that to prevent
unexpected movement of the truck when working on it, to
raise the drive wheels, disconnect the battery, discharge
the capacitors and refer to maintenance procedures.
WARNING
TRUCK CAN MOVE UNEXPECTEDLY!
BEFORE WORKING ON THIS TRUCK.
Raise drive wheels clear of operating surface.
Disconnect battery.
Discharge capacitor(s).
Refer to maintenance procedures.
BREAKING THESE RULES MAY CAUSE

SERIOUS OR FATAL INJURY TO
YOURSELF AND OTHERS.
2770314
SM 715, Mar 05 Nameplate and Decals 40-1-7

NOTE :
Group 40, Specifications SM 715, Dec 04

Section 2
General Specifications
Weights and Performance Specifications......................................................................2

Capacities.................................................................................................................................2
Truck Weights and Axle Weights..........................................................................................2
Parking Brake Test..................................................................................................................2
Travel Speeds..........................................................................................................................2
Turning Radius (outside)........................................................................................................3
Drift, Lift and Tilt Cylinders.....................................................................................................3
Lift Speeds, Upright................................................................................................................3
Critical Fastener Torque Specifications..........................................................................3
Group Specifications...........................................................................................................4
Group 16, Motors Specifications...........................................................................................4
Group 17, Contactors Specifications...................................................................................4
Group 19, Motor Controls Specifications.............................................................................5
Group 20, Drive Axle Specifications.....................................................................................5
Group 22, Wheels and Tires Specifications........................................................................5
Group 23, Brake System Specifications..............................................................................5
Group 25/26, Steer System Specifications.........................................................................5
Group 29/30, Hydraulic Sytem Specifications....................................................................5
Group 32, Tilt Cylinder Specifications..................................................................................6
Group 34, Uprights Specifications........................................................................................6
Group 38, Counterweight Specifications.............................................................................6
SM 715, Mar 05 General Specifications 40-2-1

Weights and Performance Specifications
Capacities
For standard transaxle trucks and hydrostatic transmission trucks.
Models At 500 mm (24 in) Load Center
TMX 12 1250 kg 2500 lbs
TMX 13 1250 kg 2500 lbs
TMX 15s 1500 kg 3000 lbs
TMX 15 1500 kg 3000 lbs
TMX 17 1750 kg 3500 lbs
TMX 18 1800 kg 4000 lbs
TMX 20 1815 kg 4000 lbs
TMX 20x 2000 kg 4000 lbs
TMX 25 2270 kg 5000 lbs
EPX16 1600 kg 3500 lbs
EPX18 1800 kg 4000 lbs
Note: Rated capacity applies when using uprights with maximum fork height up to and including TMX 12-25, EPX16-
18 3861 mm (152 in).
Truck Weights and Axle Weights

Approximate weights for trucks with triple stage upright and minimum battery weight.
Empty Vehicle Empty Drive Loaded Drive Empty Steer Loaded Steer
Weight) Axle Weight Axle Weight Axle Weight
Axle Weight
(kg/lbs)* (kg/lbs) (kg/lbs) (kg/lbs)
(For U.S market)
TMX 12 3288/7249 1866/4114 3947/8701 1422/3135 475/1048
TMX 15S 3587/7908 1855/4090 4352/9594 1731/3818 596/1314
TMX 15 3593/7921 2091/4610 4443/9796 1501/3311 510/1125
TMX 17 3767/8305 2163/4769 4907/10819 1603/3536 447/986
TMX 20 4066/8965 2167/4777 5303/11692 1900/4187 577/1272
TMX 25 4578/10093 2158/4758 6078/13401 2420/5335 767/1692
(For Other markets)
TMX 13 3223/7105 1844/4065 4034/8893 1379/3040 439/967
TMX 15S 3483/7678 1834/4043 4337/9561 1649/3635 646/1424
TMX 15 3369/7427 1812/3994 4169/9191 1557/3432 700/1543
TMX 18 3773/8318 1807/3983 4951/10915 1966/4334 622/1371
TMX 20x 3888/8571 1807/3983 4951/10915 2081/4587 937/2065
EPX16 3095/6823 1301/2868 4021/8865 1794/3955 674/1486
EPX18 3240/7142 1278/2817 4338/9564 1962/4325 702/1548
Note: Refer to the truck data plate for exact service and axle weights.
Parking Brake Test

The brake must be capable of holding the truck with a full rated-capacity load on a 15 % grade.
40-2-2 General Specifications SM 715, Jun 05

Travel Speeds
Maximum speeds with triple stage upright.
(For U.S markets)
TMX 12 TMX 15S TMX 15 TMX 17 TMX 20 TMX 25
MPH(kph) MPH(kph) MPH(kph) MPH(kph) MPH(kph) MPH(kph)
36 Volt 48 Volt 36 Volt 48 Volt 36 Volt 48 Volt 36 Volt 48 Volt 36 Volt 48 Volt 36 Volt 48 Volt
Empty 9.3(15) 9.3(15) 9.3(15) 9.3(15) 9.3(15) 9.3(15) 9.3(15) 9.3(15) 9.3(15) 9.3(15) 7.5(12) 7.5(12)
Loaded 9.3(15) 9.3(15) 9.3(15) 9.3(15) 9.3(15) 9.3(15) 9.3(15) 9.3(15) 9.3(15) 9.3(15) 7.5(12) 7.5(12)
(For Other markets)

TMX 13 TMX 15S TMX 15 TMX 18 TMX 20X
MPH(kph) MPH(kph) MPH(kph) MPH(kph) MPH(kph)
48 Volt 48 Volt 48 Volt 48 Volt 48 Volt
Empty 9.3(15) 9.3(15) 9.3(15) 9.3(15) 7.5(12)
Loaded 9.3(15) 9.3(15) 9.3(15) 9.3(15) 7.5(12)
Maximum speeds with two stage upright
(For Other markets)

EPX 16 EPX 18
MPH(kph) MPH(kph)
48 Volt 48 Volt
Empty 10.6(17) 10.6(17)
Loaded 10.6(17) 10.6(17)
Turning Radius (outside)
mm in
TMX 12 1356 53.4
TMX 13 1356 53.4
TMX 15S 1356 53.4
TMX 15 1519 59.8
TMX 17 1519 59.8
TMX 18 1519 59.8
TMX 20 1519 59.8
TMX 20x 1530 60.2
TMX 25 1565 61.6
EPX 16 1805 71.0
EPX 18 1835 72.2
Drift, Lift and Tilt Cylinders

Upright Fork Downdrift: Should not exceed 100 mm (4 in) in a 10-minute period.
Tilt Cylinder Drift: Should not exceed 5 in a 10-minute period.
Determined by marking and measuring carriage descent and upright forward tilt from raised, non-tilted position with
hydraulic fluid at operating temperature; and a capacity load held evenly distributed on lift forks. (If a pallet is used, load
should not extend beyond pallet; load should be stacked to provide maximum stability.) Fork completely engaging load
and adjusted as wide as possible to provide even distribution of weight.
SM 715, Jun 05 General Specifications 40-2-3

Lift Speeds, Upright

(For U.S markets)
Lowering
Lift Speeds - fpm(m/s) Speed
fpm (m/s)
TMX 12 TMX 15S TMX 15 TMX 17 TMX 20 TMX 25 TMX12-25
36 48 36 48 36 48 36 48 36 48 36 48
Volt Volt Volt Volt Volt Volt Volt Volt Volt Volt Volt Volt
STD Empty 118(0.60) 120(0.61) 118(0.60) 120(0.61) 118(0.60) 120(0.61) 118(0.60) 120(0.61) 118(0.60) 120(0.61) 94(0.48) 96(0.49) 82(0.41)
Loaded 74(0.38) 85(0.43) 71(0.36) 83(0.42) 71(0.36) 83(0.42) 63(0.32) 79(0.40) 55(0.28) 59(0.30) 47(0.24) 55(0.28) 89(0.45)
TSU Empty 104(0.53) 118(0.60) 104(0.53) 118(0.60) 104(0.53) 118(0.60) 104(0.53) 118(0.60) 104(0.53) 118(0.60) 89(0.45) 94(0.48) 77(0.39)
Loaded 73(0.37) 83(0.42) 69(0.35) 82(0.41) 69(0.35) 82(0.41) 65(0.31) 75(0.39) 61(0.31) 75(0.38) 45(0.23) 53(0.27) 86(0.43)
(For Other markets)

Lift Speeds - fpm(m/s) Lowering Speed fpm (m/s)
TMX 13 TMX 15S TMX 15 TMX 18 TMX 20X
48 Volt 48 Volt 48 Volt 48 Volt 48 Volt 48 Volt
STD Empty 120(0.61) 120(0.61) 120(0.61) 120(0.61) 96(0.49) 82(0.41)
Loaded 85(0.43) 83(0.42) 83(0.42) 79(0.40) 55(028) 89(0.45)
TSU Empty 118(0.60) 118(0.60) 118(0.60) 118(0.60) 94(0.48) 77(0.39)
Loaded 83(0.42) 82(0.41) 82(0.41) 77(0.39) 53(0.27) 86(0.43)
(For Other markets)

Lift Speeds - fpm(m/s) Lowering Speed fpm (m/s)
EPX 16 EPX 18
48 Volt 48 Volt 48 Volt
STD Empty 118(0.60) 118(0.60) 89(0.45)
Loaded 89(0.45) 85(0.43) 98(0.50)
Critical Fastener Torque Specifications
Tightening Torque, Dry

N.m ft-lb
Drive Axle-to-Frame Mounting Bolts: 408-469 300-340
Drive Wheel Lug Bolts 255-275 188-203
Steer Wheel Lug Nuts(TMX) 255-275 188-203
Steer Wheel Lug Nuts(EPX) 157-193 116-142
Steer Trunnion Mounting Bolts 339-381 251-280
Steering Handwheel Retaining Nut 35-40 25.5-29.5
Tilt Cylinder Yoke Clamp Bolts 166-193 122-142
Tilt Cylinder Pin Retainer Bolts 20-22 177-221
Counterweight Mounting Bolts (Bottom) 339-381 251-280

Group Specifications
Group 16, Motors Specifications Group 19, Motor Controls

Specifica-tions
Drive Motors
General Drive Motor Control
Type: AC Type: AC Dual Motor Control
Voltage: Dual Voltage 36 or 48 volts
Frame Size: 200 mm (7.874 in) diameter
Weight (Approx.): 45 kg (99 lb) Lift Pump Motor Control
Internal Bearings: Bearings are sealed and lubricated with
Type: AC
hightemperature grease for the life of the bearing
Voltage: Two unique controls, one for 36 volt and
(Approx service life = 10,000 hours). The bearing at
another for 48 volt
the non-drive end of the motor is a special encoder
bearing (sen-sor).
Rotation: Reversible; CW for forward travel; CCW for
Group 20, Drive Axle Specifications
reverse travel when viewed from drive end. Terminal Nut Type: Separate housing and drive train for each drive
Torque: 15 N.m (133 in-lb) wheel. Each axle housing contains pinion and ring gear,
Rotor intermediate shaft, and axle shaft.
Transmission Fluid Type: Clark part no. 2794022
Outside Diameter: 124 mm (4.882 in) Fluid Capacity (each housing): 3.8 L (1 gal) Axle-to-
Number of slots: 48 Frame Mounting Bolt Torque: 408-469 N.m (300-340
Stator ftlb). Use Loctitle 271.
Fill Plug Torque: 54-61 N.m (40-45 ft-lb)
Outside Diameter: 200 mm (7.874 in)
Number of slots: 36
Insulation: Class F Group 22, Wheels and Tires
Specifica-tions
Lift Pump Motor
Cushion
General
Material: Rubber except as noted.
Type: AC Dual Voltage 36 and 48 volt
Size:
Frame Size: 170 mm (6.693 in) diameter
Drive Steer
Weight (Approx.): 50 kg (110 lb) TMX 12/13/15/15S 18x7x12.1 18x7x12.1
Internal Bearings on Pump End, Special Encoder Bearing TMX 17/18/20 18x8x12.1 18x7x12.1
on Commutator End: Bearings are double sealed and TMX 20x/25 18x9x12.1 18x6x12.1 (urethane)
lubricated with hightemperature grease for the life of the Mounting Nut Torques: Refter to mounting procedure in
bearing(Approx service life = 10,000 hours). Section 2.
Rotation: Unreversible; CCW, viewed from drive end
Terminal Nut Torque: 15 N.m (133 in-lb)
Insulation: Class F
Group 17, Contactors Specifications

One drive line contactor, one pump line contactor Mount-
ing Fastener Torque: 8-10 N.m (71-88 in-lb)
SM 715, Mar 05 General Specifications 40-2-5

Pneumatic Group 29/30, Hydraulic Sytem

Material: Rubber Specifi-cations
Hydraulic Fluid Type: Clark specification MS-68 (Clark
Size:
part #1802155 and #1800236)
Drive Steer
Hydraulic Pump Type: Integral gear-type pump and motor
(For U.S. Market) assembly.
TMX 12/15 18x7x8-16 PR 18x7x8-16 PR Sump Capacity: Usable oil = 19 Litres (5.0 Gal)
TMX 15S 18x7x8-16 PR 18x7 (Solid Filter Type: Disposable, 25 micron, full flow return line
Only) oil filter and a 10 micron filter cap/breather filter.
TMX 17 18x9x16PR - Main Relief Valve Setting: 20,000 to 21,000 kPa (2800 to
(For Other Markets) 3000 psi) at rated flow.
TMX 13/15S/15/18 18x9x8 18x7x8 Auxiliary Relief Valve Setting: 13,300 to 14,300 kPa
(1925 to 2075 psi) at rated flow.
TMX 13/15S/15/18/ - 15x4 1/2x8
20x Rated Flow:
EPX 16/18 21x8x9-14PR 5.00x8-10PR Lift spool (spool #1): 76 L/min (20 gpm).
Tilt spool (spool #2): 38 L/min (10 gpm).
Group 23, Brake System Specifica-
Integral Pressure Compensated Flow Control Settings:
tions Tilt spool (spool #2): 15 L/min (4.0 gpm).
Auxiliary spool (spool #3): 6.7 L/min (1.7 gpm).
Service Brake Auxiliary spool (spool #4): 38 L/min (10 gpm).
Tilt Flow Control Adjustments
Type: Caliper
Average Tilt Clockwise Turns
Minimum lining/pad thickness: 0.67 mm (0.06 in).
(/sec) Lpm Usage of Adjustment
Fluid Type: SAEJ1703 (DOT-3) brake fluid only
(gpm) Screw
Fluid Capacity: 0.256 L (0.06 gal).
Pedal Freeplay: 1-3 mm (0.039-0.118 in; measured at 2.5 6.3(1.7) 3937 (155in). 0.5
stop screw). MFH & Above
3.0 8.7(2.3) Up to 3937 0.75
(155in). MFH
Parking Brake
Maximum Pressure Drop at Rated Flow:
Type(TMX): Lever-type mechanically linked to brake
Inlet to outlet: 689 kPa (100 psi)
assembly.
Lift spool (spool #1):
Type(EPX): Foot-type mechanically linked to brake
assembly. Inlet to cylinder port: 689 kPa (100 psi)
Cylinder port to outlet: 550 kPa (80 psi)
Holding Test: Rated load on 15% grade
Tilt spool (spool #2):
Group 25/26, Steer System Cylinder port to outlet: 550 kPa (80 psi)
Specifica-tions Auxiliary spools (spools #3 and #4):
Steering System Type: Load sensing hydrostatic Inlet to cylinder port: 345 kPa (50 psi)
power steering with variable ratio. Cylinder port to outlet: 207 kPa (30 psi)
Steering System Relief Pressure Setting: 8274-8825 Flow Control Adjustments: Adjustable from 4 to 38 L/min
kPa (1200-1280 psi). (1 to 10 gpm). Before adjusting, turn fully counter-clock-
Steer Cylinder Type: Double acting, piston-type. wise to stop. Each 1/4 clockwise turn of the adjustment
Steer Axle: Single wheel (optional dual-wheel) mounted increases flow by 3 L/min (0.75 gpm).
on trunnion at center rear of truck.

Group 34, Uprights Specifications

Auxiliary Flow Adjustments Upright Weight: approximately 363 kg (800 lb) to
Flow Settings Clockwise Turns of approx-imately 1000 kg (2200 lb)
L/min (gpm) Adjustment Screw Carriage Weight: approximately 109 kg (240 lb)~120kg
(265 lb)
6.3 (1.7) 0.50
Fork Weight: approximately 50-71 kg each (110-156 lb)
8.7 (2.3) 0.75
12.3 (3.2) 1.00 IMPORTANT
19.0 (5.0) 1.50 Before hoisting, the weights of upright, car-
riage, and forks must be combined to deter-
23.4 (6.2) 1.75
mine what lifting capacity is required of the
33.5 (8.8) 2.50 hoisting equipment.
39.8 (10.5) 3.00
52.9 (14) 4.50 Capacities and Lift Heights: Upright, carriage, and fork
capacity and upright lift heights are listed on the truck's
After adjusting the flow control valve settings it will be data plate.
necessary to also adjust the pump control panel parame- Lubricants:
ters to coincide with the settings you have made. See All Purpose Grease (Clark specification MS-9)
Group 19 for the proper Handset usage. Inncrslidc Lubricant (Clark part #886396)
Chain and Cable Lube (Clark part #886399)
Pump Control Panel Settings
(Using the Handset)
Parameters Auxiliary Flow Settings
Group 38, Counterweight
GPM 36V Hz 48V Hz Specifica-tions
2.5 20 33 Counterweight Mounting Bolts Torque: 339-381 N.m
2nd Speed Fine and 5.5 43 51 (251-280 ft-lb)
3rd Speed Fine 7 55 65 Counterweight Weight: Different counterweights are used
10 79 93 based on truck capacity and battery compartment length,
as follows:
Group 32, Tilt Cylinder Specifications Battery Compartment

See Group 29 for hydraulic system specifications. (For U.S market)
Model Truck Capacity Length Counterweight
Tilt Cylinder Type: Double-acting.
TMX12 2500 lb (1250 kg) 13.75 1262 lb (573 kg)
Maximum Operating Pressure: 21,000 kPa (3,000 psi). TMX15s 3000 lb (1500 kg) 13.75" 1836 lb (834 kg)
Tilt Ranges: TMX15 3000 lb (1500 kg) 20.5" 914 lb (415 kg)
TMX17 3500 lb (1750 kg) 20.5" 1262 lb (573 kg)
Upright MFH (in / mm) Tilt TMX20 4000 lb (1815 kg) 20.5" 1836 lb (834 kg)
B F TMX25 5000 lb (2270 kg) 20.5" 2894 lb (1314 kg)
thru 151 (3835mm) 8 6 (For Other markets)
152 (3860mm) thru 240.5 (6109mm) 5 3 TMX13 2500 lb (1250 kg) 13.75 1262 lb (573 kg)
241 (6121mm) and over 3 0 TMX15s 3000 lb (1500 kg) 13.75" 1836 lb (834 kg)
TMX15 3000 lb (1500 kg) 20.5" 914 lb (415 kg)
TMX18 4000 lb (1800 kg) 20.5" 1836 lb (834 kg)
TMX20x 4000 lb (2000 kg) 20.5" 2098 lb (952 kg)
EPX16 3500 lb (1600 kg) 29" 1080 lb (490 kg)
EPX18 4000 lb 1800 kg) 29" 1300 lb (590 kg)
SM 715, Jun 05 General Specifications 40-2-7

NOTE :

Section 3
Hydraulic Fitting Tightening Procedure
Tighten fitting finger tight until it stops turning, while Using finger tips only, lightly snug fitting with a wrench
moving the fitting lightly side to side to pre-vent until it bottoms out on the seat or port. Do not
cocking or thread damage. overtighten.
SM 715, Dec 04 Hydraulic Fitting Tightening Procedure 40-3-1

NOTE :

Technical
Publications
700 Enterprise Dr.
Lexington, KY 40510
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When new or revised information is published to update Jul. 2005

SM 715, Jul 06 REVISION HISTORY - 1

2 - REVISION HISTORY SM 715, Jul 06

SM 715, Jul 05 REVISION HISTORY - 3

REVISION HISTORY SM 715, Dec 04

Arrangement and Use of this Manual

Contents by Group and Section

SA SAFE MAINTENANCE 5. Parking Brake Removal, Replacement,

22 WHEELS AND TIRES 34 UPRIGHTS

SM 715, Jun '05 CONTENTS -1

8. Upright Removal and Replacement

0 COUNTERWEIGHT AND CHASSIS

CONTENTS -2 SM 715, Jun '05

Alphabetical Listing of Topics

SM 715, Jun '05 CONTENTS -3

Alphabetical Listing of Topics SM 715, Dec '04

Safety ................................................................. Section 1

Towing ............................................................... Section 3

SM 715, Dec 04 Group SA SAFE MAINTENANCE,

Group SA SAFE MAINTENANCE, SM 715, Dec 04

Safety Signs and Messages Safe Maintenance Practices

SM 715, Dec 04 Safety SA-1-1

SA-1-2 Safety SM 715, Dec 04

Lifting, Jacking, and Blocking

Raising Drive Wheels.........................................................................2

SM 715, Dec 04 Lifting, Jacking, and Blocking SA-2-1

0 CAUTION 23Lower the drive wheels to the floor by reversing this

5. Reverse the procedure to remove the chains.

SA-2-2 Lifting, Jacking, and Blocking SM 715, Dec 04

23Park truck safely.

23Jack up one side of the truck about 50 mm (2 in) and

SM 715, Dec 04 Lifting, Jacking, and Blocking SA-2-3

Raising Entire Truck ! CAUTION

23 Carefully raise the truck one side at a time, only as

SA-2-4 Lifting, Jacking, and Blocking SM 715, Dec 04

SM 715, Dec 04 Towing SA-3-1

Group SA, Safe Maintenance SM 715, Dec 04

Maintenance Schedule .................................... Section 1

The PM Inspection Form ................................. Section 3

SM 715, Dec 04 Group PS PERIODIC SERVICE,

Group PS PERIODIC SERVICE, SM 715, Dec 04

Periodic Service and Planned Maintenance..............................2

SM 715, Mar 05 Maintenance Schedule PS-1-1

Periodic Service and Planned Determining Maintenance Intervals

Service Chart/Lubrication Points

PS-1-2 Maintenance Schedule SM 715, Mar 05

TMX Service Chart/Lubrication Points

SM 715, Mar 05 Maintenance Schedule PS-1-3

EPX Service Chart/Lubrication Points

PS-1-4 Maintenance Schedule SM 715, Jun 05

Recommended Periodic Service Schedule

Every Every Every

SM 715, Mar 05 Maintenance Schedule PS-1-5

TASKS Every Every Every

PS-1-6 Maintenance Schedule SM 715, Mar 05

Introduction to Planned Maintenance..........................................................................................2

SM 715, Mar 05 The Planned Maintenance Program PS-2-1

Introduction to Planned Maintenance The PM procedure, in outline form, is as follows: