CLARK Service Update Teleconference Notes

February 18th, 2009

Attendees: Chuck Moratz, VP North American Truck Operations, CLARK Material Handling Company.
Glen Wood, Tech Pub Manager, CLARK Material Handling Company.
Clark Simpson, Sales Engineer, CLARK Material Handling Company.
Russ Davies, Elect. Truck Product Service Manager, CLARK Material Handling Company.
Debbie Tackett, CLARK Parts, Product Support.
Greg Pakis, CLARK Parts, International Customer Service.
Dave Nicolette, Technical Trainer, CLARK Material Handling Company.

96 Dealership Locations participated in the Teleconference.

Two separate Teleconferences were conducted, one at 10:00AM Eastern Daylight Time for
the Eastern and Central Time Zones, and the second Teleconference at 4:00PM Eastern Time
for the Mountain and Pacific Time Zones.

The next Service Update Teleconference is scheduled for Wednesday, April 15th, 2009, the Morning
Conference will be held at 10:00AM EDT, the Afternoon Conference will be held at 4:00PM EDT. If
you have any questions contact Dave Nicolette at davenicolette@clarkmhc.com.

TOPICS THAT WERE DISCUSSED

TRAINING & MISCELLANEOUS – DAVID T. NICOLETTE
Training:
The 2009 CLARK Training Schedule has been posted and is available on CLARK PartsPRO. The
schedules for the CLARK Regional Training Courses are listed below. We must have a minimum of ten
(10) Participants in order to conduct a Regional Course, if there are not enough Participants a decision to
cancel / reschedule the Course will be made fourteen (14) Days prior to the course.

Western Regional Training Course - March 24th to 26th

TIER II, TIER III, and CLARK Internal Combustion Lift Trucks,
at Team Power in Sacramento, CA

Southeastern Regional Training School, April 21st to 23rd, 2009

AC Technology and CLARK Sit Down Rider Lift Trucks,
at W.E. Johnson Equipment Co., Miami, FL

Northeastern Regional Training School - May 5th to 7th, 2009

AC Technology and the CLARK ESX Stand Up Rider Lift Truck
At Equipment Depot, Harrisburg, PA

Canadian Regional Training School - July 21st to 23rd, 2009

AC Technology and CLARK Sit Down Rider Lift Trucks
Location To Be Announced

Maximum of twenty (20) Participants per course.

Dealer Cost for Technical Training is $300.00 per Technician/Participant.

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SERVICE UPDATE TELECONFERENCE NOTES FEBRUARY 2009
 CLARK Service Update Teleconference Notes
February 18th, 2009

I.C. PRODUCT – DAVE NICOLETTE & MIKE MICHALSKI

All Engines
The Positive Crankcase Ventilation System (PCV System) was the first and is the oldest Emission
Control System both on Lift Trucks and in Automobiles, and it is also one of the most beneficial. The PCV
System is an Emissions Control System that routes unburned crankcase blow by gases back into the intake
manifold where they can be re-burned. Besides totally eliminating Crankcase Emissions as a source of Air
Pollution, the constant recirculation of air through the crankcase helps remove moisture which otherwise
would cause sludge and acids to form in the Crankcase. Thus the PCV Valve extends the life of the oil and
engine. The PCV System requires little maintenance but should be checked and cleaned every six
months or 1,000 hours, the PCV Valve should be replaced every 12 months or 2000 hour intervals,
failure to do so has resulted in several instances when the Woodward Emission Control System (Tier II and
Tier III) malfunctioned and the “Check Engine Light” has been illuminated resulting in a Service Call,
because a plugged or sluggish PCV System will introduce oil vapors into the Intake Airstream and Mixer.
The oil vapors can also get into the Bias and Vacuum Lines to the Regulator and Fuel Trim Valves and may
damage these components.

FF651 CLARK Woodward TIER III V09 Software Update:

The new software addresses the Fault Codes #481 & #461, these Fault Codes were generated because
of a software problem in the Throttle Spring Return Test software of the SECM. All New Trucks currently
being shipped from the Factory have the New VO9 Software loaded into the SECM. If you have a question
whether or not your Lift Truck needs updated, check the list for FF651 in PartsPRO. CLARK will not pay
any Travel Time for this Field Fix, only update Lift Trucks that you are working on for other repairs or you
are there to PM the Unit. The Field Fix must be completed by March, 31st, 2009, CLARK will not
accept Warranty Claims for this Software Update after this date.
Several Dealers have reported problems while attempting to get their Laptop Computer to
communicate with the Lift Truck SECM, most of these problems have been traced to the Laptop Operating
System or the Motoservice Software was not properly updated on the Laptop, also the Update Welcome
Screen Location MUST BE PCM1 in order to properly Update a TIER III System. One other item that
seems to keep Technicians from properly connecting their Laptops to the SECM is that the Key Switch must
be turned to the “ON” Position when attempting to hook up a Laptop to the SECM. If you are having
difficulty hooking up a Laptop to either TIER II or TIER III Systems contact Mike Michalski or Billy
Marksbury.

Drive Wheel Hub Seals:

The issues of Drive Wheel Hub Seal leaks in CLARK Lift Trucks using the #245020 Hub Seal seems
to be on the decline. However, you no longer need to use the Part Number #245020OEM, there is only one
Drive Wheel Hub Seal available, it is Part Number #245020, when you order the #245020 Seal you will now
receive the OEM Seal. If there is any question about the Seal you receive from CLARK, check the Seal
Manufacturer’s Number that is stamped on the Seal, use the Seal that has the Number #SKF38709, do not
use the Seal that has the Number #ASA3399. It is critically important that Technician’s understand and use
the proper installation procedures for the Drive Wheel Hub and Seal. The procedures listed in SM-709 for
the GEN2 are, for the most part correct, the torque values listed in the manual are incorrect. Use the
following NEW Procedure when installing a #245020 Drive Wheel Hub Seal and adjusting the Wheel
Bearings. SI-20-608-08R was released in January and includes the proper Adjustment Procedures it is
posted in PartsPRO on the SI Bulletin Page.
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The Drive Wheel Hub Seal must be replaced with a new one each time the Hub is removed, use
extreme care not to damage the Seal during installation, use ONLY the proper Driver for installing
the Seal.
INSTALLATION PROCEDURE FOR CLARK PART NUMBER #245020
DRIVE WHEEL HUB SEAL.
1.) Remove nicks, scratches and burrs from the Hub and Spindle Surfaces that will be
receiving the New Seal.
2.) Some previous Installation Instructions directed you to apply a coating of Gasket Maker to the
outside of the Seal and to the Inner Diameters of the Hub, DISREGARD this process; the
Green Vendor Coating on the O.D. of the Seal is sufficient.
3.) Press New Seal into the Hub using the Special Seal Driver as mentioned in the SM-709. The
Seal Driver can be ordered from R.J. Machine Company, Inc. as mentioned below, or you
can construct a Driver using the Drawing that is included in SI-20-608-08R.
4.) Install the Drive Wheel Hub onto the Spindle.
5.) Lube the Outer Bearing with Transmission Fluid (#1806885), and install the Bearing into
the Drive Wheel Hub.
6.) Install the Tongued Washer, Locking Washer, and Lock Nut and Finger Tighten.
7.) While turning the Drive Wheel Hub, torque the Locknut to 180 ft. lbs. with the Special
Wrench (constructed from the drawing in SM-709, and attached to the Service Bulletin).
8.) Loosen the Lock Nut until the Bearing is loose and free.
8.) Hand Tighten the Lock Nut until there is no Bearing End Play.
9.) If the Locking Tab of the Lock Washer does not align with one of the openings in the Lock
Nut, back of the Lock Nut Adjustment until the Lock Nut and the Locking Tab of the
Lock Washer align. DO NOT tighten the Lock Nut to make it align with the Lock Washer.
10.) Align the Inspection Slot in the Brake Drum with the Inspection Slot on the Drive Wheel
Hub. Install the Brake Drum by sliding it over the Studs in the Hub.
11.) Remount the Drive Wheel as described in SM-709, Group 22.
12.) If you encounter any problems contact Mike Michalski or Clark Simpson.

Again it is extremely important to follow the installation instructions as outlined in SI-20-608-94R.

This bulletin has drawings of the required Drivers for the Hub Seal Installation. The Hub Seal Drivers may
also be purchased from:
R.J. Machine Company, Inc.
3353 Market Street
Twin Oaks, PA 19014
Phone: 1-610-494-8107
FAX: 1-610-494-5881
Website: www.rjmachine.com

The Driver Tool Part Number #CL-9380 (CLARK Tool #ST95262) is required for the Hub Seal Part
Number #245020.
The Driver Tool Part Number #CL-9381 (CLARK Tool #ST95263) is required for the Hub Seal Part
Number #2786180.

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 CLARK Service Update Teleconference Notes
February 18th, 2009

TIER III GM 4.3L Engine Crankshaft Sensor:

The GM 4.3L Engine used in CLARK TIER II Lift Trucks did not use a Crankshaft Sensor. NGVI
began installing Crankshaft Sensor’s onto the GM 4.3L Engines with the initiation of the TIER III Emission
Controls, and early in the Tier III implementation they made a change to the Crankshaft Sensor which also
required a change in the SECM Software. When ordering a replacement SECM, it is extremely important
the Technician know what Crankshaft Sensor is being used to ensure they receive an SECM with the correct
Software installed on it. The part numbers for the two different SECM’s are listed correctly in PartsPro, but
the Technician should double check the SECM to make sure it is correct.
In order to Determine which Crankshaft Sensor is in the Engine look for the Manufacturer’s Engine
Code on the Leftside of the Oil Pan (Sitting on the Operator’s Seat of the Lift Truck). If the Engine
Code begins with a large 8LT, the Engine uses a 58X Encoder. If the Engine Code begins with a large
7LT, the Engine uses a 3X Encoder.
The Technician can also tell which Encoder the Engine uses by looking at the Software Version on
the SECM in the Moto Update Screen of the Service Tool. If the Software version is
MI07SEQ062Vxx_G43_58_C_T_P_xxx the 58 in the Software String indicates the Engine uses a 58X
Encoder. If the Software version is MI07SEQ062Vxx_GM43_LP_C_T_P_xxx the LP in the Software
String indicates the Engine uses a 3X Encoder.

Torque Converters:
CLARK has experienced a number of Transmission failures due to overheating and /or Torque
Converter failure. The problem seems to occur in heavy use, high cycle applications. If you experience a
Transmission that acts like the Clutches are slipping but the Clutch Pack Pressures are good we recommend
that you unbolt the Torque Converter from the Torque Converter Adapter and check the movement between
the Torque Converter and the Adapter, there should be approximately 1/8th (.125) inch of clearance. If you
do not have the correct clearance you most likely have a bad Torque Converter. Also copy the number off
of the Torque Converter and contact Clark Simpson with the number from the Torque Converter. If you
fined you have the correct clearance please contact Mike Michalski or Clark Simpson.

Fleet Averaging for the California Market/Dealers:

CLARK’s TIER II and TIER III Lift Trucks have already been calibrated to meet this standard,
however in order to be used in California they must have a new ULE Decal applied to the engine, CLARK
can supply this decal. If you are purchasing a new Lift Truck in California, or if you are shipping a Lift
Truck into the California Market contact Ken Phelps at 1-859-422-6533 or Kenphelps@clarkmhc.com, for
more information.
For older Lift Trucks, CLARK is working with Nett Technologies Inc., to support the Fleet
Averaging Requirement in California. The deadline to for compliance for Fleet Averaging has been moved
from January 2009 to April 2009. Nett Technologies “BlueCat 300” has been verified by the C.A.R.B. for
retrofit onto TIER I and TIER 0 Lift Trucks. California Dealers are to work directly with Nett
Technologies, for more information go to www.nett.ca , E-Mail sales@nett.ca , or call 1-905-672-5453.

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ELECTRIC PRODUCT – RUSS DAVIES

CLARK ESX Electric Brake Update:
The CLARK ESX has exhibited some issues with the Electric Braking System, these Brakes are only
and Emergency/Parking Brake System. In some High Use, High Cycle operations the Electric Brake Coils
may overheat and burn up. CLARK has developed a New Braking System for this Lift Truck. The New
Brakes and Harnesses are in stock at CLARK’s Louisville Location, the Part Numbers and requirement per
Lift Truck are listed below. Contact Russ Davies for instructions on installing the New Brakes, Harness,
and Software.
(2) 2827688 EM Brake
(1) 2827689 Update Harness

You will also need to FLASH the ZAPI Controllers (Traction and Pump) with new Software. In
order to download the required ZAPI Files you will need the WinFlash Program, and the Laptop Interface
Cable Part Number #8032294. The WinFlash Program can be downloaded from PartsPRO. Using your
Laptop, go to the PartsPro PDF Index, select”Truck Service and Service Manuals”, select “AC Truck
Programming”, select Laptop Programming, finally select WinFlash_1_23.zip. When you select
WinFlash_1_ 23.zip a Download Menu will appear, click on the Save Button and save the
WinFlash_1_23.zip File to your Desktop. Once you have saved WinFlah_1_23.zip to your Desktop you can
open it up and select the SETUP File, this will install the WinFlash _1_23.zip Program onto your Laptop. If
you cannot connect your Laptop to PartPro, use a Computer that can be connected to PartsPro and follow the
steps listed above but do not save the WinFlah_1_23.zip File to the Desktop, save it to a CD or to a Jump/Zip
Drive.
In order to communicate with the ZAPI Controllers your Laptop must have a 9 Pin Com1 Port, a
USB Port does not have a heavy enough Power Supply to power up the Interface Cable. If you do not have
a 9 Pin Com1 Port you will need to purchase a RS232-PCMCIA Card for your Laptop. Again, if you have
any questions contact Russ Davies at 1-859-422-6421, or russdavies@clarkmhc.com.

CLARK ESX Fault Code 248 (EM Brake Open):

This Fault Code is meant to inform the Technician there is a problem with the Parking Brake System,
it may or may not indicate and electrical problem. This Fault Code could be set if the Lift Truck were
sitting still, with the Key Switch turned to the “ON” Position, and the truck is bumped by another vehicle
causing the Lift Truck to move ever so slightly. If the Lift Truck is bumped and moved with the Key Switch
turned “ON”, the Traction Motor Encoders will send a signal to the Controller telling it the Drive Wheels are
turning. The Controller knows there is no one in the Operator Compartment and there is no demand from
the Accelerator so the Lift Truck should not be moving, but since the Lift Truck is moving the Parking Brake
must be bad, and the Controller Displays a Fault Code 248.
To clear the 248 Fault Code, using the ZAPI Handset, access the Right Side Menu and scroll to the
“Set Options” Menu. Enter the “Set Options” Menu and scroll to the “EM Brake Test” Option, select the
“EM Brake Test” Option and turn it “ON”, then save it. After saving the “EM Brake Test” Option “ON”,
move the Multifunctional Control Handle to the “FULL Forward” Position and hold it there for
approximately ten (10) seconds. If the Parking/EM Brakes are good the Fault Code 248 will disappear, if
there is a problem with the Parking/EM Brake the Fault Code will remain on.
After concluding the “EM Brake Test” you must go back into the “Set Options” Menu and turn the
“EM Brake Test” “OFF”.
CLARK has issued Bulletin SI-19-804-09 which explains the above process in detail.

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CLARK TMX Fault Code 85 Pedal Failure, CLARK ECX No Fault Code on the Dash, and CLARK
TMX & ECX Fault Code 78 at Key On, the Lift Truck is ready to Operate but there is little or no
movement when the Accelerator is depressed:
On both the TMX and ECX the Lift Truck may or may not begin to move, in either case the Traction
Motor dies. We have found that occasionally, when the Battery Voltage Setting is changed, or the battery
has been disconnected for a long period of time, the ZAPI AC Controller may loose its calibration for the
Accelerator. Using the ZAPI Handset, go to the Left Side Menu and “Relearn the Accelerator” using the
Program VACC Menu. After Re-Learning the Accelerator, if the Lift Truck still does not work the
Accelerator may need to be replaced. The current Accelerator for both the TMX and ECX is Part Number
#8074900. Contact Russ Davies at 1-859-422-6421 if you require additional assistance.

CLARK HWX/PWX Intermittently will not Operate:

Several Dealers have experience a problem with the CLARK HWX and PWX where the unit will not
operate, but when the Control Handle is moved in either direction the problem goes away and the unit
operates properly. This problem may show up as intermittent Fault Codes or it may not display a Fault
Code at all. CLARK is still reviewing the problem, currently what we have found is that broken wires in the
Wiring Harness at the Wiring Harness Clamp on the Drive Unit. The problem is not isolated to any one
particular wire, it could be any wire in the Harness. If you experience this problem please contact Russ
Davies at 1-859-422-6421.

MISCELLANEOUS SERVICE AND PARTS UPDATES – GLEN WOOD

New Web Based Warranty System:
CLARK is in the final stage of development and is due to be delivered to CLARK by the end of
March 2009. Once CLARK receives delivery of the New System we will begin our Testing Phase, we are
expecting to release the New Web Based System some time around July 2009. The New Web Based
Warranty System will have the same functionality of the current Warranty System with the exception of one
field, the individual filing the Warranty Claim will be asked to list their E-Mail Address. With the
Submitter’s E-Mail Address recorded, every time the Claim is worked on by the Warranty Department at
CLARK and E-Mail will automatically be sent to the Individual who submitted the Warranty Claim in order
to keep them informed of the status of the Claim.

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SERVICE UPDATE TELECONFERENCE NOTES FEBRUARY 2009