3. FOREWORD
Clark Equipment Company welcomes you to the growing group of professional
people who own, operate and maintain Clark lift trucks. This manual will familiirtze you
with service maintenance and ovefiaui information about your new truck. It has been
espedaliy prepared to help yoir maintain your Clark lift truck in an efficient and safe
operating condition.
Regular, corred maintenance and care of your Iii truck is not only important for full
and efficient truck life; it is essential for your safety. A faulty Iii tnxk is a potential
source of danger to the operator, and to other personnel working near it. The
importance of maintaining your lift truck in a safe operating condition by servicing it
regularly and, when necessary, repairing it promptly cannot be emphasized too
strongly.
To assist you in keeping your Iii truck in good operating condition, this manual
includes an outline of planned maintenance (PM) procedures that are considered
essential to the life and safe performance of your truck. Brief procedures for
inspections, operatianai checks, cleaning, lubrication, and adjustments are included
for your reference.
Clark recommends that a planned maintenance and safety inspection program (PM)
be performed by a trained and authorized mechanic on a regular basis. The PM
program provides the opportunity to make thorough inspections and checks on the
safe condition of your truck. Necessary adjustments and repairs can be done during
the PM, which will increase the life of components and reduce unscheduled
downtime. The need for major adjustments, repairs, or replacements Is found and
corrections made as required; not after failure has occurred.
4. SAFETY SIGNS AND SAFETY MESSAGES
Improper or careless techniques cause accidents. Don’t take chances with incorrect or
damaged equipment. Read and understandthe procedures for safe operation and
maintenance outlined in this manual.
STAY ALERT! Follow safety rules, regulations and procedures. Accidents can be
avoided by recognizing dangerous procedures or situations before they occur.
DRIVE AND WORK SAFELY and follow the safety signs and their messages displayed
on the truck and in this manual.
SAFETY SIGNS and MESSAGES are placed in thii manual and also on the lii truck to
provide instructbns and to identify specific areas where potential hazards exist and
special precautions should be taken. Be sure you know and understand the meaning
of these instructions, signs and messages. Damage to the truck or death or serious
injury to you or other persons may result if these messages are not followed.
NOTICE This message is used when special informatbn, instructbns or identifbation
is required relating to procedures, equipment, tools, pressures, capacities and other
special data.
IMPORTANT This message is used when special precautbns should be taken to
ensure a correct action or to avoid damage to or malfunction of the truck or a
component.
CAUTION This message is used as a reminder of safety hazards which can result in
personal injury tf proper precautions are not taken.
WARNING This message is used when a hazard exists which can result in injury or
death if proper precautions are not taken.
DANGER This message is used when an extreme hazard exists which will result in
death or serious injury if proper precautions are not taken.
5. USER SAFE MAINTENANCE PRACTICES
The following instructions have been prepared
from current industry and government safety
standards applicable to industrial truck operations
and maintenance. These recommended
procedures specify conditions, methods, and
accepted practices that aid in the safe mainte-
nance of industrial trucks. They are listed here for
the reference and safety of all workers during
maintenance operations. Carefully read and
understand these instructions and the specific
maintenance procedures before attempting to do
any repair work. When in doubt of any mainte-
nance procedure, please contact your local
CLARK dealer.
1. Powered industrial trucks can become
hazardous if maintenance is neglected.
Therefore, suitable maintenance facilities, trained
personnel, and procedures must be provided.
2. Maintenance and inspection of all powered
industrial trucks shall be done in conformance with
the manufacturer’s recommendations.
3. A scheduled planned maintenance, lubrication,
and inspection program shall be followed. ~
4. Only trained and authorized personnel shall be
permitted to maintain, repair, adjust, and inspect
industrial trucks, and in accordance with the
manufacturer’s specifications.
5. Properly ventilate work area, vent exhaust
fumes, and keep shop clean and floor dry.
6. Avoid fire hazards and have fire protection
equipment present in the work area. Do not use
an open flame to check for level, or leakage of fuel,
electrolyte, or coolant. Do not use open pans of
fuel or flammable cleaning fluids for cleaning parts.
7. Before Starting Work On Truck:
a) Raise drive wheels off of floor or disconnect
power source and use blocks or other positive
truck-positioning devices.
b) Put blocks under the load engaging means,
inner-mast(s), or chassis before working on them.
c) Disconnect battery before working on the
electrical system.
8. Operation of the truck to check performance
must be conducted in an authorized, safe, clear
area.
9. Before Starting To Drive Truck:
a) Be in operating position.
b) Disengage clutch on manual transmissions, or
apply brake on trucks with powershift transmission
and electric trucks.
c) Put directional control in neutral.
d) Start engine or turn on power.
e) Check functioning of lift and tilt systems,
directional and speed controls, steering, brakes,
warning devices, and any load handling
attachments.
10. Before Leaving The Truck:
a) Stop truck.
b) Put directional control in neutral.
c) Apply the parking brake.
d) Stop the engine or turn off power.
e) Turn off the control or ignition circuit.
9 Put
blocks at the wheels, if truck is on an
incline.
11. Brakes, steering mechanisms, control
mechanisms, warning devices, lights, guards and
safety devices, and frame members must be
carefully and regularly inspected and maintained in
a safe operating condition.
12. Special trucks or devices designed and
approved for hazardous area operation must
receive special attention to ensure that main-
tenance preserves the original, approved safe
operating features.
13. The truck manufacturer’s capacity, operation
and maintenance instruction plates, tags, or decals
must be maintained in legible condition.
14. Batteries, motors, controllers, limit switches,
protective 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.
15. To avoid injury to personnel or damage to the
equipment, consult the manufacturer’s
procedures in replacing contacts on any battery
connection.
6. USER SAFE MAINTENANCE PRACTICES
16. Industrial trucks must be kept in a clean
condition to minimize fire hazards and help in the
detection of loose or defective parts.
17. Modifications and additions that affect
capacity and safe truck operation must not be
done without the manufacturer’s prior written
approval. Capacity, operation and maintenance
instruction plates, tags or decals must be changed
accordingly.
16. Care must be taken to assure that all
replacement parts, including tires, are
interchangeable with the original parts and of a
quality at least equal to that provided in the original
equipment. Parts, including tires, are to be
installed per the manufacturer’s procedures.
Always use genuine CLARK or CLARK-approved
parts.
19. When removing tires, follow industry safety
practices.
20. Use special care when removing heavy
components from the truck. Be sure that lifting
and handling equipment is of the correct capacity
and in good condition.
NOTICE -- You should also be familiar with
additional operating and maintenance safety
instructions contained in the following
publications:
ANSIIASME 856.1 - 1983: Safety Standard for
Low Lift and High Lift Trucks (Safety Code For
Powered Industrial Trucks). Published by: Society
of Mechanical EngLleers, United Engineering
Center, 345 E. 47th Street, New York, N.Y.
10017.
NFPA 505-1982: Fire Safety Standard for
Powered Industrial Trucks: Type Designations,
Areas of Use, Maintenance and Operation.
Available from: National Fire Protection Assoc.,
Inc., Batterymarch Park, Quincy, MA 02269.
General Industry Standards, OSHA 2206: OSHA
Safety and Health Standards (29 CFR 1910)
Subpart N-Materials Handling and Storage,
Section 1910.178 Powered Industrial Trucks. For
sale by: Supenntendent of Documents, U.S.
Government Printing Office, Washington, D.C
20402.
7. PM - PLANNED MAINTENANCE PROGRAM
A planned maintenance program of regular,
routine inspections and lubrication is important for
long life and trouble-free operation of your lift
truck. Make and keep records of your inspections.
Use these records to help establish the correct PM
intervals for your application and to indicate
maintenance required to prevent major problems
from occurring during operation.
The periodic maintenance procedures outlined in
this manual are intended to be used with the PM
report form. They are arranged in groupings of
maintenance work that are done in a logical and
efficient sequence.
A check mark or entry is made on the PM Report
Form when the PM is performed. Please note the
special coding system for indicating the
importance of needed repairs and/or adjustments.
When you have finished the PM inspections, be
sure to give a copy of the report to the designated
authority or the person responsible for lift truck
maintenance.
Do not make repairs or adjustments
unless authorized to do so.
For safety, it is good practice to:
Remove all jewelry (watch, rings, bracelets, etc.)
before working on the truck.
Always wear safety glasses when making repairs.
Be sure to:
Make a record of all maintenance and operating
problems you find.
Write the hour meter reading on the PM report
form.
HOW TO PERFORM THE PM
PERfODlC INSPECTIONS AND
MAINTENANCE
VISUAL INSPECTION
First, perform a visual inspection of the lift truck and
its components. Walk around the truck and take
note of any obvious damage and maintenance
problems. Check for loose fasteners and fittings.
NAMEPLATES AND DECALS
Check to be sure all capacity, safety, and warning
plates or decals are attached and legible.
Do not operate or allow a lift truck with damaged or
missing decals and name plates to be operated.
They contain important information. Replace them
immediately.
Be sure that safety devices are in place,
undamaged, and attached securely.
WHEELS AND TIRES
Check the condition of the drive wheel and rear
wheels and tires. Remove objects that are
embedded in the tread. Inspect the tires for
excessive wear and breaks or “chunking out”, and
bond failure between the tire and rim.
Check all wheels for proper tightness. Adjust if
necessary.
FUNCTIONAL TESTS
To be sure that all controls and systems
are functioning correctly.
Test horn and all other safety equipment and
accessories. Be sure they are properly mounted
and working correctly.
Press the horn button to check horn function. If
the horn or any other part does not operate, report
the failure and have3 repaired before the truck is
put back into operation.
Operate service and parking brakes, directional
controls, and steering system. Be sure all controls
operate freely and return to neutral properly.
SM545 PM -1
8. PM - PLANNED MAINTENANCE PROGRAM
TEST DRIVE THE TRUCK
Check all around to be sure that your intended
path of travel is clear of obstructions and
pedestrians.
Test the truck for:
general correct operation
drive train function
steering performance
brake performance
by driving the truck in both the forward and reverse
directions, first in a straight line and then, slowly,
through a series of full right and left turns.
Listen for any unusual drivetrain or other running
noises, such as wheel beating noise, vibration,
etc. Note any lack of smoothness in steering.
When you have completed the
operational tests, park and leave truck
according to standard shutdown
procedures.
BRAKES
Check the service / parking brake system. Push
the brake pedal all the way down and hold. The
brakes should be fully released at this pedal
position.
To check parking brake holding capability and
adjustment, drive the truck onto a grade and
release the pedal. The parking brake should hold
the truck on the grade that the truck can climb with
a capacity bad or a 10 % grade whichever is the
lesser.
CAUTION - Do not operate a truck if the
setvlce or parking brakes are not
operating properly.
STEERING SYSTEM
Check the steering system for abnormal looseness
and damage. Check for any changes in steering
action. Hard steering or looseness, unusual
sounds when turning or maneuvering indicates a
need for inspection and servicing.
Never operate a truck which has a
steering system fault.
BATTERY
Inspect the battery retainment and replace any
damaged or missing parts.
Inspect the battery for any damage, cracks, leaking
condition. If your battery has removable vent caps,
check to be sure the cells are all filled. If possible,
refill with distilled water to bottom of vent cap
opening.
MECHANISM
Finally, inspect all control pedals, levers, and
linkages for wear and smoothness of operation.
AIR CLEANING
Always maintain a lift truck in a clean condition. Do
not allow dirt, dust, lint, or other contaminants to
accumulate on the truck. Keep the truck free from
leaking oil and grease. Wipe up all oil spills. Keep
the controls and floorboards clean, dry, and safe.
A clean truck makes it easier to see leakage, loose,
missing or damaged parts, and will help prevent
fires. A clean truck will run cooler.
The environment in which a lift truck operates will
determine how often and to what extent cleaning
is necessary. For example, trucks operating in
manufacturing plants which have a high level of dirt
or lint (e.g., cotton fibers, paper dust, etc.) in the air
or on the floor, will require more frequent cleaning.
Lift trucks should be air cleaned at every
PM Interval, and otherwise as often as
required.
Air cleaning should be done using an air hose with
special adapter or extension having a control valve
and nozzle to direct the air properly. Use clean,
dry, low-pressure compressed air: restrict air
pressure to 1207kPa] 30 psi, maximum.
CAUTION - Wear suitable eye protection
and protective clothing.
CRITICAL FASTENER TORQUE
CHECKS
Check torque of critical items, including:
Drive unit mounting
Drive and rearwheel mounting
components.
Replace missing bolts and tightened loose bolts to
the correct torque before operating the truck.
Fasteners in highly loaded (critical) components
can quickly fail if they become loosened; also,
loose fasteners can cause damage or failure of the
component. For safety, it is important that the
correct torque be maintained on all critical
fasteners of components which directly support,
handle or control the load, and protect the
operator.
SMS45 PM-2
9. PLANNED MAINTENANCE PROGRAM
SAFETY AND OPERATIONAL CHECKS
PM Interval:
A = 8 - 10 hours, or daily
B = 50 - 250 hours, or every month
C = 450 - 500 hours, or every 3 months
D = 900 - 1000 hours, or every 6 months
E = 2000 hours, or every year
SM 545 PM-3
10. PLANNED MAINTENANCE PROGRAM
RECOMMENDED MAINTENANCE
AND LUBRICATION SCHEDULE
Notes:
*Replace As Required
PM Interval:
A = 8 - 10 hours, or daily
B = 50 - 250 hours, or every month
C = 450 - 500 hours, or every 3 months
D = 900 - 1000 hours, or every 6 months
E = 2000 hours, or every year
Nominal
Maintenance Interval
MAINTENANCE AND LUBRICATION A B C D E
Test wound .
Clean drive unit air vent
Check drive axle unit level
Drain and replace drive unit fluid
Check brake condition and wear
SM 545 PM-4
11. 1.0
2.0
4.0
Rleotriaal
1.1 Travel amp draw unloaded
1.2 Travel amp draw loaded
Speeds
2.1 Travel unloaded
2.2 Travel loaded
Tire & wheel
4.11 Drive tire aire 10.5 x 5 x 6.5
4.12 Standard rubber part number 20071-01
4.13 Optional urethane
4.2 Drive tire eompound
4.21 Rubber Shore A, 60-70 durometer
4.22 Urethane Shore A, 80-90 durometer
4.3 Load uheel .
4.31
4.32
4.33
Size
Standard rubber
Optional urethane
4.4 Load wheel ampound
4.41 Rubber Shore A 70 durometer
*4.42 Urethane Shore A 90 durome
ter
5.0 Fluids and Lubricant8
SPECIFICATIONS
PT a PTT-5
E!
PT a PlT-5 Pi & PlT-7
5.0 mph 7.0 mph
3.0 mph 5.0 mph
PT & PIT-7
;:
PTT-7 wl4th Speed
8.0 mph
6.0 mph
part number 20262.01
8 x 4.5 x 4.5
part number 24268-00
part number 24269-00
5.1 Transmission
5.11 Type of fluid Aft Dexron II ATFDexron II
5.12 capaelty l quart 1 quart
PT 6 P-l-r-5
22:l
PT a PI-r-7
14:l
13. DATE
PLANNEDMAINTENANCE
SCHEDULE
Year SerialNo.
2.0 100Houror MonthlyPM
Jar Feb Mar Apr May Jur Jul Aug Sep Ott Nov Ded
1. Cheokcondition
of batteryCharge
2. Visually
inspect
for leaks,loose,missing,or damagedparts
3
4:
Cheokall operating
ufunctions
and adjustments
Checktransmission
oil level
5. Lubricate
all greasefitti
6. Inspeot
powercablesand controlwiring
::
Cleanwithoompressed
air
Inspeot
contactor
tips for pitting
3.0 500 Houror Semi-Annual
PH
1. Cleanbattery
and machine
4.0 1000Houror AnnualPM
I I
I
1
I I I
I
1. Drain,flush,and refill transmission
gear case I
2. Inspect
motorbrushes
Lubrication
Grease,
lubepointsand battery
rollers
- TexasRef.C&C 1880
Transmission
-
Speoifiaation
ATR DexronII
14. _’
PT.5 & PT-7 LUBRICATION CHART
1 Gear case transmission Drain,flushAd refill AFT Dexron
2 Loadwheelaxle
,3 Handlebearing
4 Framecasters
Use Lub. Gun & Adapterfor
flushtipyfittinKs
Cleanand oil
Use standard
lub gun
Tex. Ref. C&C 5880
Motoroil
Tex.Ref. C&C 1880
i
15. PTT-5 & PTT-7 LUBRICATION CHART
1 Gearca8e transmission Drain,flushand refill AFT Dexron
2 Loadwheelaxle Use Lub.Gun & Adapterfor
flushtipyfittings Tex. Ref. C&C #880
3 Handlebearing Use standard
lub gun
4 Frame casters Use standard
lub gun
Tx. Ref. C&C f880
Tex. Ref. C&C X880
i
3
16. 1.0 Mechanical Brake - PT-5 & PT-7
Proper adjustment of the meohanioal
operation of the truck.
The brake action of the tranmission is achieved by a pair of springs that
brake is important for satisfactory
press against a brake actuating lever which in turn grabs a brake disk.
The brake is always applied in the static (brake on) position.
To release the brake, the actuating lever must be pushed away from the
-- --- --
brake disc. There are two (2) adjustments provided to permit tailoring the
brake for different operating conditions. The first adjustment is the
brake release.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Loosen the two (2) screws that hold the
slide as far left as possible.
On the front cover of the transmission,
Loosen the jam nut.
brake interlock switch and
back out the brake pressure
Lower the handle all the way to engage the brake.
Turn the adjusting cam screw in l/3 of a revolution increments. Adjust
inward towards the brake actuating lever for less brake and outward
for more brake.
After each attempt at adjusting, move the actuating lever to the opera-
tion position. Get the truck moving and release the handle to test the
brake.
When correctly adjust’with handle down, test with handle up.
If braking is uneven between handle up and handle down, need to center
cam lobes on the brake actuation rod and adjustment nut, to center turn
adjusting nut using l/16 turn increments, until braking is even at
handle up and handle down.
Tighten the jam nut.
Recheck the brake if the brake release is properly adjusted. No brake
drag in the operation should occur.
Readjust the interlock switch.
The second brake adjustment controls the aggressiveness of the brake. To make
this adjustment:
1. Lower the handle to release the brake.
2. Turn each of the brake pressure adjusting screws (located in the front
cover of the transmission) inward until resistance is felt, then turn
in & turn further. This creates more spring pressure against the brake
actuator lever causing it to grasp the brake disk more positively.
-6-
17. 1.0 Mechanical Brake - PIT-5 & PIT-7
Proper adjustment of the mechanical brake is important for satisfactory
operation of the truck.
The brake action of the tranmission is achieved by a pair of springs that
press against a brake actuating lever which in turn grabs a brake disk.
The brake is always applied in the static (brake on) position.
To release the brake, the actuating lever must be pushed away from the
---
brake disc
--
p-0 There areTo (2) adjustments provided to permit tailoring the
brake for different operating conditions. The first adjustment is the
brake release.
1. Loosen the four (4) cap screws that hold the brake interlock switch and
slide as far left as possible.
2. On the front cover of the transmission, back out the brake pressure
adjusting screws. These screws control the unount of spring pressure
needed by the brake actuating lever to grab the brake disks.
3. Loosen the jam nut.
4. De-energize the brake solenoid to engage the brake.
5. Turn the adjusting cam screw in l/3 of a revolution increments. Adjust
inward towards the brake actuating lever for less brake and outward
for more brake.
6. After each attempt at adjusting, move the energize the brake solenoid
to the operating posiXon. Get the truck moving and de-energize the
brake solenoid to test the brake.
7. Whencorrectly adjusted tighten the jam nut.
8.’ Recheck the brake if the brake release is properly adjusted. No brake
drag in the operation should occur.
9. Readjust the interlcck switch.
The second brake adjustment controls the aggressiveness of the brake. To make
this adjustment:
1. Lower the handle to release the brake.
2. Turn each of the brake pressure adjusting screws (located in the front
cover of the transmission) inward until resistance is felt, then turn
in f turn further. This creates more spring pressure against the brake
actuator lever causing it to grasp the brake disk more positively.
-7-
18. 3. Operatethe truck
stopping range is
and readjust
if necessary
untilthe satisfaotory
achieved.
Note: Overadjustment
of the brakepressurescrewsmay causeexcessive
brakewear.
2.0 Brake Solenoid
The brake on the PTT-5 & PTT-7 Is released by an electric solenoid. The sole-
noid must be properly adjusted for the brake to release.
1. Adjustthe plungerso thereis 1" of it exposedbelowthe plunger
barrel. This is acoomplished
by adjusting
the nut at the top of the
solenoid.
2. With the brakesolenoid
de-energized,
adjustthe clevisthatis on the
plungeruntilthe pin will slidethruthe clevisand brakeoperating
level.
3. Adjustthe repairspringso thatthereis no tensionon it when the
brakeis released.
3.0 Interlock
Switch
The interlock
switchis locatedinsidethe motorshieldand is controlled
by the
brakeoperating
linkage. As the brakeis applied,
the brakeoperating
lever
oomesoff the highpointof the adjusting
screw. As it fallsto a low point,
the shaftmovesleftand activates
the interlock.Thus,when properly
adjusted,
the drivemotorturnsoff when the brakeis applied. Any requiredbrakeadjust-
mentsshouldbe performed
priorto an adjustment
of the interlock.Adjusting
procedure:
1. PT & PTT-5 Loosen
shield.
PT & PIT-7 Loosen
2. Slideswitchleft
th$ fourscrewsholdingthe interlock
switchto the motor
screwsholdingthe interlock
switchto the bracket.
away fromthe brakeleveras far as possible.
3. Adjustbrake,if necessary,
according
to
4. Placebrakein "braked"
position.
5. Slideswitchassembly
to the rightuntil
instructions.
the switchsnaps.
6. Move an additional
l/32"and tightenscrews.
7. Checkthat the actuating
rod makessolidcontactwith the switchlever.
8. Checkthat the switchsnapsnear the middleof actuating
rod movement.
-8-
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your reading. Please Click
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20. 7.0
10.0
12.0
Transmission
Rollers
The fourrollerscontaining
the transmission
will occasionally
require
adjustment.When theydo, the procedure
is as follows:
1.
2.
3*
4.
5.
. .
Loosenthe locknutand boltholdingbearingassembly..
Wedgethe transmission
firmlyagainstthe non-adjustable
rollers.
Turn the eccentric
adjusters
so the two adjustable
rollersare firmand
evenwith eachother.
Retighten
the boltsand locknuts.
Rotatetransmission
makingsureit rotatesfreely.
Caster
The stabilizer
castershouldbe adjusted
so thereis l/8"preloadon the
castersprings. The procedure
for thisadjustment
is as follows:
1. Placel/8” shimunderthe drivetire.
2. R move casterfromcarrierframe.
3* Installshimsbetweencarrierframeand caster,so thatcasterjust
touchesthe floor.
See Section7.4 of thismanualfor SCR cardAdjustment.
-9-
21. DRIVETIREREPLACEMENT
To replace the drive wheel, the following steps should be taken.
1.
2.
3.
4.
5.
6.
Disconnect
the battery.
Hoistthe truck approximately one foot and block truck.
Remove the five (5) bolts holding the wheel.
Tap the drive wheel off the shoulder and remove the tire and wheel.
Press on new tire, make sure tire is flush with the lug bolts side of
the wheel.
Install wheel and lug bolts. Torque bolts to 125 ft/lbs. on BT and 80
ft/lbs. on, PE.
LOADWHEELPLACEMENT
1.
2.
3.
4.
I 5.
6.
7.
8.
9.
Park machine on level surface and disconnect battery.
Hoist oi- jack machine just high enough so that the particular load
wheel barely clears the floor. Block machine securely.
Remove hub cap. Bend back locking ring tabs and remove retaining nut,
locking ring, locating washer and outer bearing. At this time the
wheel can be removed.
Remove inner seal anh bearing.
If the new wheelis beingpressed,
make sure that the tire ring is
flush on the outer edge of the wheel.
Clean and inpsect wheel bearings and replace if necessary. Repack
bearings
and installinnerbearingand seal.
Slidewheelon axle shaft,installouterbearing,
locating
washer,
lockingringand retaining
nut.
Tightenretaining
nut to 25 ft. lbs.whilespinning
wheel. Loosenwheel
and retroqueto 2-6 in. lbs.or untilall freeplay is removedfrom
bearing.
Bend lockingtabsin placearoundretaining
nut and installhub cap.
Greasewith standard
adapter. Lowermachineand checkoperation.
-lO-
