Clark wp 40 service repair manual

FOREWORD
This service publication provides information covering normal service,
maintenance and repair of the Clark industrial trucks noted on the cover. It has
been specifically prepared to help owners and service personnel maintain these
trucks in efficient and safe operating condition.
Regular, correct maintenance and care of industrial trucks is not only important
for long and efficient truck life; it is essential for safe operation. The importance
of proper maintenance through planned service, inspection and qualified repairs
cannot be emphasized too strongly.
To assist in keeping industrial trucks in good operating condition, this manual
includes preventive maintenance procedures to be performed at regular intervals.
These are essential to the service life and safe operation of all industrial trucks.
Instructions for safety inspections, operational checks, cleaning, and lubrication
are provided for reference in setting-up and conducting a recommended periodic
Planned Maintenance (PM) program.
Refer to the Operator’s Manual, located on the truck, for additional information
on the operation, care and maintenance of your truck.
Genuine Clark replacement parts should be used for all service and repair
requirements. Substitute parts from othersources may be different than original
parts and may not meet OSHA or other safety requirements.
Any reference to brand names other than Clark in this manual is made simply as
an example of the type of tools and materials recommended for use and, as such,
should not be considered as an endorsement. Equivalents, if available, may be
used.
For more information on maintenance and repair of these trucks, contact your
authorized Clark dealer.
NOTICE
The descriptions and specifications included in this manual
were in effect at the time of printing. Clark Equipment
Company reserves the right to discontinue modelsatany time,
or make improvements and changes in specifications or
design without notice and without incurring obligation.
Spectjications, torques, pressures, measurements, adjustments,
illustrations and other items may change at any time. Contact
your authorized CLARK dealer for information on possible
updates or revisions.
0 1996 Clark Material Handling Company
SM611 Aug 96

Safety Notice
IMPORTANT SAFETY NOTICE
Read and understand all safety precautions and
warnings before performing repairs on lift trucks.
Appropriate service methods and proper repair procedures are essential to the safe, reliable operation of industrial
trucks as well as the personal safety of the individual doing the work. This Service Manual provides general
directions for accomplishing service and repair work with tested, effective techniques. Following them will help
assure successful repair and reliable truck operation.
There are numerous variations in procedures, techniques, tools, and parts for servicing industrial trucks, as well
as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and
provide advice or precautions as to each. Accordingly, anyone departing from the instructions provided in this
manual through procedures used or choice of tools, materials, and parts may jeopardize his or her personal safety
and/or the safety of the vehicle user.
Improper or careless techniques cause accidents. Don’t take chances with incorrect or damaged
equipment. Read and understand the 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.
General Precautions
The following list contains general precautions that should be followed when working on a lift truck:
Always wear safety glasses for eye protection.
Remove rings, watches, loose jewelry and open clothing before working on a vehicle, to avoid
serious injury.
Do not smoke while working on a vehicle.
Put ignition switch in the OFF position, unless otherwise required by the procedure.
Set the parking brake. Place wheel chocks or wood blocks of 4” x 4” size or larger to the front and
rear surfaces of the tires to provide further restraint from inadvertent vehicle movement.
Use safety stands or blocks whenever a procedure requires you to be under the vehicle.
Service Electric Truck Batteries in a well-ventilated area to avoid the danger of igniting explosive
gases.
Always Discharge the Capacitors prior to working on or around electrical components.
Avoid contact with Battery Acid. The battery contains corrosive acid which can cause injury.
SM611 Aug 96

TABLE OF CONTENTS
Section 0 Maintenance
0.1 Truck Identification
0.2 System Operation
0.3 Specifications
0.4 Maintenance and Adjustments
0.5 Troubleshooting
0.6 Component Removal and Installation
0.7 Component Repair
Section 1 Transmission
1.1 Component Identification
1.3 Specifications
1.5 Troubleshooting
1.6 Component Removal and Installation
1.7 Component Repair
Section 2 Electrical
2.1 Component Identification 2-2
2.2 System Operation 2-15
2.3 Specifications 2-28
2.4 Maintenance and Adjustments 2-29
2.5 Troubleshooting 2-36
2.6 Component Removal and Installation 2-72
2.7 Component Repair 2-76
Section 3 Hydraulic
O-l
o-2
o-3
o-15
o-22
o-22
o-22
l-2
l-4
l-4
l-4
l-5
l-5
l-9
i

Section 4 Frame
ii

0.1 Truck Identification
This repair manual covers the following Clark Products: WP-40 Low Lift Pallet
Trucks from serial number WP40- l-8 163 and above.
Clark reserves the right to change the information and specifications contained
within this manual at any time without incurring any obligation relating to such
changes.
o-1

Federal and State laws require that operators be completely trained in the safe
operation of lift trucks.
An Operator’s Manual is attached to every Clark lift truck when it is
manufactured. If the Operator’s Manual is missing from the truck a new manual
may be obtained by contacting Clark Technical Publication by Fax at 414 79%
8757.
This manual is not a training manual. The information contained in this service
manual is intended as a guide to help the authorized technician safely repair the
truck.
o-2

0.3
I.
Specifications
Specifications
A. Electrical - Maximum AMP Draw
1. Drive Motor Armature - Cable A2 12 volt
2.
a) In Top Variable Speed
Lift Pump Motor - Cable Al
a) Against Pressure Relief
B.
C.
F.
Hydraulic System
1. Type of Fluid
2. Capacity
Tires and Wheels
1. Drive Tire
2. Load Wheels
Fluids and Lubricants
1. Hydraulic Fluid
a) Standard
b) Freezer application
2. Lubricating Grease
3. Transmission Oil
71A
24 volt
45A
200A 115A
Hydo 32 (standard)
Texaco 15 (Freezer only)
Approx. 1 quart
10.5 x 5 x 6.5 inches
3.25 x 5 inches
HYDO 32
Texaco 15
Texas Refineries C & C #880
85W 90 API GL5
o-3

INCH (SAE) AND
METRIC
FASTENERS
O-5

INTRODUCTION
Threaded fasteners like bolts, nuts, capscrews and studs are made to specifications that
describe the mechanical strength and hardness of the fastener. A fastener used in a
&sign application is selected according to its specifications. Clark buyspartsfrom many
countries. There are several standards used by these countries in the manufacture of
threaded fasteners. Many of these fasteners are similar, but cannot be used as direct
replacement.
Service persons must use replacement fasteners that have the same specifications. Fasteners
made to each specification have identification marks for that specification. This specification
is commonly called “Grade” for SAE standards and “property” for metric standards. This
section describes the identification of some common fasteners.
The metric system used by Clark is described as SI (International System of Units, also
called SI in all languages). The SI system of measurement is described in IS0 Standard
looo, 1973.
NOMENCLATURE, THREADS
The thread design is specified by a series of numbers and letters for inch and metric
fasteners. (See Figure 1). The diameter of the shank of the fastener is shown first in the
series [M12= 12mm, M20=20mm (l/2= l/2 inch, 3/4=3/4 inch)].
The number of threads per inch is normally not shown for inch nomenclature and only the
UNC (Unified National Coarse) or UNF (Unified National Fine) is shown. This number of
threads per inch is not shown because a UNC or UNF fastener has a standard number of
threads per inch for a specific diameter.
The length of a shank is often indicated as part of the description of a fastener. This length is
shown in inches for inch fasteners and in millimeters for metric fasteners.
A capscrew will have the following description:
A = SHANK DIAMETER
B = NUMBER OF THREADS PER B = PITCH
UNIT OF LENGTH C = LENGTH
C = TYPE OF THREAD
FIGURE 1 - THREAD DESIGN
Hx 13UNC THREAD
(DILL x NO OF THREADS PER INCH)
u.s
--- -_-----
METRIC
Ml 2 I 1.75 mm _THREAD
(mm DIA. I THREAD PITCH mm)
O-6

STRENGTH IDENTIFICATION
The most common property classes for metric fasteners are 8.8 and 10.9. The property class
is marked with a number on the head of the capscrew or on a nut. Property classes less then
8.8 are often not marked. Grades for inch bolts go from 2 to 8. Grade 2 fasteners normally
do not have marks. The following tables show the marks that identify the grades and
property classes for different fasteners.
ALWARNINGWhen fasteners must be replaced, the new fasteners must be of the same
strength or greater then the original fasteners. The new fasteners must also
be the correct size.
NOTE: IDENTIFICATION MARKS ARE ACCORDING TO BOLT STRENGTH.
THE HIGHER THE NUMBER OR THE INCREASE IN THE NUMBER OF MARKS
INDICATES INCREASED BOLT STRENGTH.
TABLE 1 - BOLTS AND SCREWS
TYPE OF
FASTENER
I
INCH FASTENERS.
SIILt4GTHLLYELI’ ,AI C”..DLS
+ MARKINGS NOT REOUIRED
HEX HEAD BOLTS
& CAPSCREWS
I
FLANGE SCREWS
I 2.POINT
FLANGE SCREWS 1
HEX SOCKET HEAD
CAPSCREWS
MARKINGS NOT REOUIRED
5.1
METRIC FASTENERS.
sT”LWG,” LfWL) rROPLRlr CL.ssES
*’ MARKINGS NOT REQUIRED
9.6 109 12 9
MARKINGS
SAME AS ABOVE
8.6 12 9
fJ 112.0
4e.* 9.8
@@
o-7

TABLE 2 - STUDS AND NUTS
TYPE OF INCH FASTENERS. METRIC FASTENERS.
STRLNGfn LEVELS. SAE GRADES
FASTENER
STREI(QlHLEVELS PROPERTY CLASSES
ilc MARKINGS NOT REQUIRED +k MARKINGS NOT REQUIRED
4.e*
66 @&jQ
9.8 10.9 12.9
-
STUDS
6 0 Q @ @ iz!iF
LARGER
‘I.
OR@@@@
OPTIONAL GEOMETRIC SYMBOLS FOR
SIZES M5 THRU Ml 1 ONLY.
5 8 9
MARKINGS NOT REQUIRED
iEX SLOlTED NUTS
HEX FL4NGE NUTS
O-8

TABLE 3 - TORQUE NUTS
TYPE OF
FASTENER
INCH FASTENERS. METRIC FASTENERS.
STIIENGTWLEVELS.s*E tm*ms CTlLnGTHLLYLLI’CnowiRTVCLASSES
m
&f=jg&
&J&J&
ALL METAL PRE-
VAILING-TOROUE
NUTS
f G
OR
m
M'.@ (-@
OR
ALL METAL PRE-
VAILING-TORQUE B3B
FLANGE NUTS
o-9

TABLE 4 - TORQUE NUTS WITH NYLON INSERT
TYPE OF
FASTENER
INCH FASTENERS. METRIC FASTENERS.
STREHGIHLEVELS SAE GRADES STRLNGTI( LEVCLS.PROPCRTY CLASSES
NYLON INSERT PRE-
VAILING-TORQUE
NUTS
MARKINGS NOT REWIRED OR
NYLON INSERT PRE-
VAILING-TOROUE
FLANGE NUTS
O-10

TABLE 5
CONVERSION TABLE FOR METRIC AND ENGLISH UNITS
MULTIPLY BY TO GET
AREA
MULTIPLY BY TO GET
LINEAR
MULTIPLY BY TO GET MULTIPLY BY TO GET
MASS
POWER
PRESSURE
TEMPERATURE
MULTIPLY BY TO GET MULTIPLY
(“Celsius x 1.8)
BY TO GET

TORQUE
IULTIPLY
pound inches
pound feet
BY
0.113
1.356
TO GET
Newton meter
(N-m)
Newton meter
fN.m1
MULTIPLY BY TO GET
Newton meter 8.851 pound inches
(lbf in)
Newton meter 0.738 pound feet
(lbf in)
4ULTIPLY BY
miles/hour 1.609
TO GET MULTIPLY BY TO GET
kilometer/hour (km/h) kilometer/hour 0.621 miles/hour
Cmvh)
VOLUME
o-12

-I 3RQUE VALUES FOR COARSE THREAD
Zze and Pitchs
M5 x 0.8
M6 x 1
MS x 1.25
Ml0 x 1.5
Ml2 x 1.75
Ml4 x 2
Ml6 x 2
M20 x 2.5
M24 x 3
M30 x 3.5
Property, Class
8.8*
N.m
5-6
8-10
20-25
40-45
70-80
1lo-125
580-650
Ibf ft
Ibf in.
44-53
71-88
177-221
Ibf ft
30-33
428-479
Property, c
10.9**
N.m
7-8
12-14
30-35
60-65
100-l 10
155-180
800-900
M36 x 4
TABLE 6
SS
lbf ft
Ibf in
62-7 1
106-124
Ibf ft
22-26
44-48
KY33
177-199
332-369
590-664
Property, Class
13 a***
I N.m I lbf ft
Ibf in
8-10 71-88
14-16 124-142
Ibf ft
34-40 26-30
70-75 52-55
280-320 207-236
550-600 406-443
900-1050 664-774
* Property class 8.8, Protective Treatment CMHC Specification “H” (zinc phosphate), apply also to internally threaded
fasteners made of property class 8 material.
**Property class 10.9, Protective Treatment CMHC Specification “H” (zinc phosphate), apply also to internally threaded
fasteners made of property class 10 material.
*** Property class 12.9, Protective Treatment CMHC Specification “H” (zinc phosphate), apply also to internally threaded
fasteners of property class 12 material.
3 METRIC FASTENERS
o-13

0.4.1 Maintenance
Planned Maintenance is a critical part of safe pallet truck operation. By following a
regular schedule of planned maintenance procedures the correct and safe functioning
of the pallet truck can be better assured. A good planned maintenance program will
alert you to the need for adjustments and minor repairs and will greatly reduce the
potential for unexpected failures.
An effective planned maintenance program will include a daily inspection to be made
by the operator prior to each operating shift. This should include a visual inspection
for damage, leaks, and fluid levels as well as testing for the correct operation of safety
devices.
In addition to the operator’s daily inspection a regular scheduled planned maintenance
service should be performed by a qualified Clark technician. This service should include
a thorough visual inspection, lubrication of service points, operational checks and minor
adjustments.
The basic planned maintenance visit should be made every 200 operating hours or
once a month. More detailed service should be performed once a year. A
comprehensive schedule of planned maintenance operations and detailed planned
maintenance procedures are in the sections that follow.
o-15

PLANNED MAINTENANCE SCHEDULE
SERVICES TO BE PERFORMED DAILY OR AT EACH 8 HOUR OPERATING SHIFT
ITEM SERVICE TO BE PERFORMED NOTES
BATTERY CHARGE AND CHECK WATER
HYDRAULIC SYSTEM INSPECT FOR LEAKS
FRAME/SHEET METAL INSPECT FOR LOOSE, DAMAGED, OR MISSING PARTS
WHEELS/TIRES INSPECT FOR DAMAGE AND FOR TRASH IN BEARINGS
FUNCTIONS/OPERATIONS TEST FOR PROPER OPERATION OF ALL FUNCTIONS
EQUALIZE CHARGE ONCE A WEEK
ALL SHIELDS MUST BE IN PLACE
SAFETY DEVICES MUST FUNCTION
SERVICES TO BE PERFORMED EVERY THREE MONTHS OR EVERY 200 OPERATING HOURS
I ITEM SERVICE TO BE PERFORMED NOTES
II I
_Y INSPECTION PERFORM DAILY INSPECTIONS J
CHECK FLUID LEVEL
ADJUST AS NEEDED
CHECK SPECIFIC GRAVITY
CHECK FOR TIGHT AND CLEAN
DO NOT FILE TIPSCONTACTOR TIPS
MOTOR BRUSHES
HYDRAULIC RESERVOIR
FRAME LUBE
PIVOT POINTS
DRIVE MOTOR
INSPECT FOR ARCING AND PITTING
INSPECT FOR MINIMUM LENGTH
CHECK FLUID LEVEL
LUBRICATE ALL GREASE FITTINGS
LUBRICATE ALL PIVOT POINTS
BLOW OUT DRIVE MOTOR VENTS
DRIP LUBE WITH 10 WT MACHINE OIL
COMPRESSED AIR USED FOR CLEANING
MUST BE REDUCED TO LESS THAN 30
PSI AND THEN ONLY WITH EFFECTIVE
CHIP GUARDING AND PERSONAL
PROTECTIVE EQUIPMENT
SERVICES TO BE PERFORMED EVERY 2000 OPERATING HOURS
ITEM SERVICE TO BE PERFORMED NOTES
DAILY INSPECTION PERFORM DAILY INSPECTIONS
MONTHLY INSPECTION PERFORM 200 HOUR INSPECTIONS
TRANSMISSION D-WIN, FLUSH AND REFILL
BA-ITERY REMOVE FROM TRUCK AND CLEAN ALSO CLEAN BATTERY COMPARTMENT
HYDRAULIC SYSTEM DRAIN, FLUSH AND REFILL
HYDRAULIC SYSTEM SET PRESSURE RELIEF VALVE AND LOAD TEST
BRAKES INSPECT BRAKE SHOE WEAR
o-1s

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A
B
C
D
F
G
H
HYDRAULIC OIL LEVEL
TRANSMISSION PIVOT TUBE
HANDLE PIVOT
TRANSMISSION OIL LEVEL
TRANSMISSION DRAIN PLUG
LIFT LINKAGE
LOAD WHEEL
o-17

0.4.3 Planned Maintenance Procedures
This section describes how to perform the services listed in the Schedule of Planned
Maintenance Operations. As with the “Schedule” this section is sub-divided into
service intervals.
Services to be performed daily or at each 8 hour operating shift:
The daily inspection is to be made by the operator prior to each operating shift. It is
the operator’s responsibility to report any defects to the proper authorities and the
truck should not be operated until it has been inspected and repaired by a qualified
technician. The operator is ultimately responsible for the safe operation of this pallet
truck.
Battery -
The battery should be charged when it reaches the 80% discharged level. This is
indicated on the optional Battery Discharge Indicator when the single red LED bar on
the far left is illuminated. A warning will be given at the 70% discharged level by
means of the two red LED bars flashing alternately on and off. If the truck is
equipped with the optional Lift Interrupt then lift lockout will occur at the 80%
discharged level. If the optional Battery Discharge Indicator is not mounted then the
battery should be charged after 6 to 8 operating hours.
Hydraulic System -
Inspect the entire truck for leaks; especially around the hydraulic pump assembly and
the lift cylinder. Any sign of oil on the floor under the truck is an indication that the
truck may be leaking hydraulic oil or transmission fluid. Report any problems to the
proper authorities and do not operate the truck until it has been inspected and repaired
by a qualified technician.
Frame/Sheet Metal -
Inspect the truck for loose, damaged or missing parts. All shields must be in place
and functional. Report any problems to the proper authorities and do not operate the
truck until it has been inspected and repaired by a qualified technician.
Wheels/Tires -
Inspect wheels and tires for wear and damage. Trash wrapped around wheels and
axles will cause premature tire wear and bearing damage. Any trash should be
removed before operating the truck and the floors should be kept clear of trash to
prevent damage to the wheels and tires.
Functions/Operations -
Test the truck for the proper operation of all functions; including the travel controls,
lift and lower functions, the brakes and the emergency reverser button. Safety devices
must be operational. Report any problems to the proper authorities and do not operate
the truck until it has been inspected and repaired by a qualified technician.
O-18

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