SM 765

GEX 20/25/30s/30/32
Rated Capacity : 2000-3000kg
Part No. 8051045

Book No. SM 765 (Rev 2.4)
Aug. 2020
CLARK MATERIAL HANDLING INTERNATIONAL

215, Ojeong-ro, Bucheon-Si, Gyeonggi-do, Korea
Tel: 82-32-680-6300 [ www.clarkmhc.co.kr ]
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 6. Parking Brake Service

1. Safety
2. Lifting, Jacking, and Blocking 25 STEERING COLUMN AND GEAR
3. Towing 1. Steering System Specifications and Description
2. Steering System Troubleshooting
PS PERIODIC SERVICE 3. Steering Column Removal and Installation
4. Steering System Relief Pressure Check and
1. Maintenance Schedule Adjustment
2. Planned Maintenance 5. Steering Gear Overhaul
3. The PM Inspection Form
26 STEERING AXLE
12 BATTERY 1.Steering Axle Specifications and Description
1. Battery Service 2. Steering Wheel Bearing Maintenance and Adjust-
ment
13 WIRING, SWITCHES, AND INSTRUMENTS 3. Steering Axle Removal and Installation
1. Schematic Electric Circuit Diagrams 4. Steering Axle Overhaul
2. General Electrical Service Tips 5. Steering Cylinder Removal and Installation
6. Steering Cylinder Overhaul
3. Wiring and Cables
7. Pivot-Turn Steering Axle Maintenance
4. Switches and Sensors
5. Instrument Panel 29 HYDRAULIC SUMP, FILTERS, AND PUMP
1. Main Hydraulic Sump, Filters, and Pump Specifi-
16 ELECTRIC MOTORS cations and Description
1. Motor Specifications And Descriptions 2. Main Hydraulic Pump Troubleshooting
2. Drive Motors Overhaul 3. Main Hydraulic Removal and Installation
3. Pump Motor Overhaul
30 HYDRAULIC CONTROL VALVE/LIFT CIRCUIT
17 ELECTRICAL CONTACTORS 1. Hydraulic Control Valve/Lift Circuit Specifications
1. Contactors Specifications and Overhaul and Description
2. Hydraulic Schematic
19 MOTOR CONTROLS 3. Hydraulic System Troubleshooting
1. Description 4. Hydraulic System Pressure Checks and Adjust-
2. Control Programming ments
3. Control troubleshooting 5. Hydraulic Control Valve Removal and Replace-
4. GEX Factory Control Settings ment
20 DRIVE AXLE 32 TILT CYLINDERS

1. Specification and description of drive axle 1. Tilt Cylinder Specifications and Description
2. Troubleshooting of wheel drive axle 2. Tilt Cylinder Checks and Adjustments
3. General operation of drive axle 3. Tilt Cylinder Removal and Replacement
4. Disassembly and Reassembly of drive axle 4. Tilt Cylinder Overhaul
5. Disassembly and Reassembly of axle end
6. Adjustment 34 UPRIGHTS
1. Upright Specifications and Description
22 WHEELS AND TIRES 2. Troubleshooting
1. Wheels & Tires Specifications and Description 3. Upright Inspection
2. Pneumatic Wheels and Tires 4. Carriage and Upright Roller Clearance Checks
and Shim Adjustments
23 BRAKE SYSTEM 5. Cylinder Removal, Shimming, Overhaul and
1. Brake System Specifications and Descriptions Replacement
2. Service Brake Troubleshooting 6. Upright Chain Inspection, Adjustment, and
3. Brake Pedal Linkage & Adjustments Replacement
4. Brake Bleeding 7. Fork and Carriage Removal and Replacement
5. Pedal and Master Cylinder Service 8. Upright Removal and Replacement
SM 765 CONTENTS-1
CONTENTS
38 COUNTERWEIGHT AND CHASSIS

1. Counterweight Specifications and Description
2. Counterweight Removal and Installation
3. Overhead Guard Removal and Installation
4. Floor Plate, Seat, and Seat Deck Removal and
Installation
40 SPECIFICATIONS
1. Nameplate and Decals
2. General Specifications
3. Hydraulic Fitting Tightening Procedure
CONTENTS-2 SM 765
GROUP SA SAFE MAINTENANCE
GROUP SA
SAFE MAINTENANCE
Safety ................................................................. Section 1
Lifting, Jacking, and Blocking the Truck........ Section 2
Towing ............................................................... Section 3
SM 765 Group SA SAFE MAINTENANCE,

Group SA, Safe Maintenance
Section 1
Safety
Safety Signs and Messages .................................... 2
Safe Maintenance Practices .................................. 2

General Shop Precautions ................................... 4
SM 765 Safety • SA-1-1

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 applicble to
where potential hazards exist and special precautions industry truck operation and maintenance. These recom-
should be taken. Be sure you know and understand the mended procedures specify conditions, methods, and ac-
meaning of these instructions, signs, and messages. Dam- cepted practices that aid in the safe maintenance of indus-
age to the truck, death, or serious injury to you or other trial trucks. They are listed here for the reference and
persons may result if these messages are not followed. safety of all workers during maintenance operations.
Carefully read and understand these instructions and
NOTE
the specific maintenance procedures before attempting
This message is used when special informa- to do any repair work.
tion is required relating to procedures,
equipment, tools, pressures, capacities, and When in doubt of any maintenance procedure, please con-
other special data. tact your local Clark dealer.
1. Powered industrial trucks can become hazardous if
IMPORTANT maintenance is neglected. Therefore, suitable main-
This message is used when special precau- tenance facilities, trained personnel, and procedures
tions should be taken to ensure a correct must be provided.
action or to avoid damage to, or malfunction
of, the truck or a component. 2. Maintenance and inspection of all powered industrial
trucks shall be done in conformance with the manu-
facturer’s recommendations.
! CAUTION 3. 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
4. Only trained and authorized personnel shall be per-
proper precautions are not taken.
mitted to maintain, repair, adjust, and inspect indus-
trial trucks. Work should be performed in accordance
! WARNING with the manufacturer’s specifications.
This message is used when a hazard exists 5. 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. 6. Avoid fire hazards and have fire protection equip-
ment present in the work area. Do not use an open
! DANGER
flame to check for level or leakage of fuel, electro-
lyte, or coolant. Do not use open pans of fuel or flam-
This message is used when an extreme haz- mable cleaning fluids for cleaning parts.
ard exists that can result in injury or death
or serious injury if proper precautions are 7. Before starting work on truck:
not taken. a. Wear eye protection and remove all jewelry.
b. Raise drive wheels off of floor or disconnect
The above terms have been adopted by Clark Material power source. Use blocks or other positive truck
Handling Company. The same terms may be used in dif- positioning devices
ferent context in service literature supplied directly or c. Disconnect battery before working on the electri-
indirectly by vendors or truck components. cal system.
8. Before working on engine fuel system of gasoline or
diesel-powered trucks, be sure the fuel shut-off valve
is closed.
9. Operation of the truck to check performance must be
conducted in an authorized, safe, clear area.
SA-1-2 • Safety SM 765

10. Before starting to drive truck: 19. Modifications and additions that affect capacity and
a. Be in operating position. safe truck operation must not be done without the
b. Be sure parking brake is engaged. manufacturer’s prior written approval. Capacity, op-
c. Put direction control in neutral. eration and maintenance instruction plates, tags, or
d. Start engine. decals must be changed accordingly. This is an
e. Check functioning of direction and speed con- OSHA requirement.
trols, steering, brakes, warning devices, and any
20. Care must be taken to assure that all replacement
load handling attachments.
parts, including tires, are interchangeable with the
11. Before leaving truck original parts and of a quality at least equal to that
a. Stop truck. provided in the original equipment. Parts, including
b. Put directional control in neutral. tires, are to be installed per the manufacturer’s proce-
c. Apply the parking brake. dures. Always use genuine CLARK or CLARK
d. Turn key switch OFF. approved parts.
e. Put blocks at the wheels if truck is on an incline.
21. Use special care when removing heavy components
12. Brakes, steering mechanisms, control mechanisms, from the truck, such as counterweight, seat deck,
warning devices, lights, governors, guards, safety de- upright, etc. Be sure that lifting and handling equip-
vices, and frame members must be carefully and reg- ment is of the correct capacity and in good condition.
ularly inspected and maintained in a safe operating Also, this removal may upset stability of the truck.
condition. The frame must always be safely blocked for major
component removal.
13. Special trucks or devices designed and approved for
hazardous area operation must receive special atten-
tion to ensure that maintenance preserves the origi- NOTE
nal, approved, safe-operating features. Become familiar with additional operating
14. Fuel systems must be checked for leaks and condi- and maintenance safety instructions con-
tion of parts. Extra special consideration must be tained in the following publications:
given in the case of a leak in the fuel system. Action
must be taken to prevent the use of the truck until the ASME B56.1 - Safety Standard for Low Life and High
leak has been corrected. Lift Trucks. Published by: American Society of Mechani-
cal Engineers, Three Park Avenue, New York, NY 10016.
15. The truck manufacturer’s capacity, operation, and
maintenance instruction plates, tags, or decals must NFPA 505 - Powered Industrial Trucks. Including Type,
be maintained in legible condition. Areas of Use, Maintenance and Operation. Available
from: National Fire Protection Assoc., Inc., Batterymarch
16. Batteries, motors, controllers, limit switches, protec- Park, Quincy, MA 02269.
tive devices, electrical conductors, and connections
must be inspected and maintained in conformance General Industrial Standards, OSHA 2206: OSHA Safety
with good practices. Special attention must be paid to and Health Standards (29 CFR 1910), Subpart N-Materi-
the condition of electrical insulation. als Handling and Storage, Section 1910.178 Powered
Industrial Trucks. For sale by: Superintendent of Docu-
17. To avoid injury to personnel or damage to the equip- ments, U.S. Government Printing Office, Washington,
ment, consult the manufacturer’s procedures in DC 20402.
replacing contacts on any battery connection.
18. Industrial trucks must be kept in a clean condition to
minimize fire hazards and help in the detection of
loose or defective parts.

General Shop Precautions

! CAUTION
The following list contains general precautions that DO NOT STEAM-CLEAN
should be followed when working on a lift truck.
Do not steam-clean a solid state controlled
• Always wear safety glasses for eye protection. truck. Excessive moisture will interfere with
• Remove rings, watches, loose jewelry and open proper operation of the solid state compo-
clothing before working on a vehicle to avoid seri- nents.
ous injury.
Solid state controls should be cleaned at regular intervals.
• Do not smoke while working on a vehicle. Blowing dirt off with an air (207 kPa [30 psi] max.) hose
• Put power key switch in the OFF position, unless periodically will, for the most part, eliminate any serious
otherwise required by the procedure. cleaning problems. For a more thorough cleaning, water
• Set the parking brake. Place chocks to the front and may be hosed over the control. A mild detergent may be
rear surfaces of the tires to provide further restraint applied, such as that used for washing dishes. The deter-
from inadvertent vehicle movement. gent should be rinsed off, and the controls must be thor-
oughly air-dried before putting truck into service.
• Use safety stands or blocks whenever a procedure
requires you to be under the vehicle. Periodic cleaning should preclude the need for using a
• Service electric truck batteries in a well-ventilated degreaser. However, if a degreaser is used, we recom-
area to avoid the danger of lighting explosive mend Clark #1801146 Degreaser, or the equivalent to
gases. MS-180 Freon TF Degreaser and Cleaner. Only approved
solvents should be used to clean solid state control com-
• Follow the Safety Instructions outlined in Group
ponents.
12, Battery Handling.
• Always discharge the capacitors prior to working
on or around electrical components.
! CAUTION
• Avoid contact with battery acid. The battery con- CHECK POLARITY
tains corrosive acid which can cause injury. Follow Battery polarity must be correct or the truck
the instructions outlined in Group 12 and those will not operate.
instructions received with your battery and char-
ger. ! CAUTION
USE TRUCK BATTERY ONLY
Cautions Do not use a motor generator unit such as
The following is a list of “CAUTIONS” connected with “ready power” or a battery charger to move
the operation and maintenance of trucks equipped with and/or check this truck as serious damage
solid state control panels. may occur.
IMPORTANT
! CAUTION SAFETY NOTICE
WELDING ON TRUCKS Read and understand all Safety Precautions
1.Make sure the truck has no grounds. and Warnings before performing repairs on
lift trucks.
2.Disconnect truck battery.
Appropriate service methods and proper repair procedures
3.Protect electrical wiring and components are essential to the safe, reliable operation of industrial
from weld spatter with a shield. trucks, as well as the personal safety of the individual
4.Ventilate battery or remove battery doing the work. This Service Manual provides general
from truck. directions for accomplishing service and repair work with
If the above is not followed, damage can tested, effective techniques. Following them will help
result to wiring and electrical components assure successful repair and reliable truck operation.
on a solid state control truck.
SA-1-4 • Safety SM 765

There are numerous variations in procedures, techniques, Improper or careless techniques cause accidents. Don’t
tools and parts used for servicing industrial trucks, as well take chances with incorrect or damaged equipment. Read
as in the skill of the person doing the work. and understand the procedures for safe operation and
maintenance outlined in this manual.
This manual cannot possibly anticipate all such variations
and provide advice or precautions as to each. Accord- Drive and work safely. Follow the safety signs and
ingly, anyone departing from the instructions provided in their messages displayed in the work area, on the
this manual, through procedures used or choice of tools, truck, and in this manual.
materials, and parts may jeopardize his or her personal
safety and the safety of the vehicle user.

Section 2
Lifting, Jacking, and Blocking
Raising Drive Wheels ............................................ 2
Chaning the Upright in Raised Position .............. 3
Raised Rear of Truck ............................................ 3
Raised Entire Truck .............................................. 4
Shipping Tie-Down Instructions .......................... 5
! 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 765 Lifting, Jacking, and Blocking • SA-2-1

5. Block the truck under the frame behind the drive

! CAUTION wheels with solid blocking.
To perform these service procedures, first: 6. Turn key switch OFF.
• Park truck on a level surface.
7. Check for safe clearance between drive wheels,
• Put the upright in a vertical position and lower block and floor.
the carriage fully down.
8. Check the stability of the truck. Be sure that the
• Return control handle to neutral and turn key blocks are located securely under the frame before
switch OFF. operating the drive motor or working on truck.
9. Lower the drive wheels to the floor by reversing this
! WARNING
procedure.
Defective equipment can cause accidents: • Turn key switch ON.
All tools and lifting equipment must be in
good condition, meet the load capacity • Tilt upright fully back.
requirements and have OSHA labels when • Turn key switch OFF.
required. Tools with defects can fail, causing 10. Remove the blocks from under the frame and upright
severe injury or death. rails.
Raising Drive Wheels

This procedure uses the upright as a lever to lift the drive
wheels off the floor and prevent accidents due to inadver-
tent powering of the drive wheels.
1. Park the truck safely.
2. Turn key switch ON. Tilt the upright fully back.
3. 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.
4. Tilt the upright fully forward. This will raise the
drive wheels off the floor.
GENERIC ILLUSTRATION
SA-2-2 • Lifting, Jacking, and Blocking SM 765

Chaining the Upright in Raised Position Raising Rear of Truck

This procedure is used to safely provide clearance for The truck may be raised at the rear by jacking and block-
access from the front of truck to components on or near ing under the center of the frame member at either the
the drive axle. front or rear steer axle mounting, or under the center sec-
tion of the steer axle.
1. Park truck safely.
Refer to truck data plate for truck weights.
2. Put blocks at front of and rear of drive wheels.
3. Raise upright carriage. ! WARNING
4. Chain the center inner rail tie bar to the top outer rail An incorrectly installed counterweight can
tie bar as shown. 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.
1. Park truck safely.

2. Put blocks at front and rear of drive wheels.
! CAUTION
If possible, remove the battery from truck to
reduce weight for added safety and ease of
jacking.
Triple Stage Uprights: Chain the center intermediate rail
tie bar and the lower inner rail tie bar to the top outer rail 3. Put a floor jack under the steer axle mounting frame
tie bar. member, centered between the two wheels.
! WARNING
Never lift the truck by the counterweight.
5. Reverse the procedure to remove the chains.
If there is insufficient clearance under frame for your

! WARNING
jack, the truck may first be driven onto shims, such as
Keep hands, tools, etc. out of upright. 25x150x300 mm(1 x 6 x 12 in.) pieces of board, to
increase the truck frame underclearnce.

4. Raise the truck only as high as necessary to perform Raising Entire Truck
the maintenance work.
Refer to truck data plate for truck weights.
5. Put blocks at both sides of the truck, fully under the
frame main side structure. Put the blocks in front of 1. Park truck safely. Lower upright fully.
but close to the counterweight and steer wheels for
2. If necessary, drive truck onto boards to increase
best truck stability.
underclearance.
! WARNING
SIDE-TO-SIDE TIPOVER. When jacking
side of truck, be sure upright is lowered fully.
Do not raise one side of the truck more than
about 50 mm (2 in.) higher than the other, to
avoid tipping truck over laterally.
END-TO-END TIPOVER. If the upright and

drive axle are removed while the truck is
blocked up, the truck will tip backward due
to the heavy counterweight. Upright and
counterweight must both be removed before
Put an equal number of blocks under each side of the attempting to raise the truck for drive axle
truck to provide a level working position. removal. The back of the truck must be sup-
6. Lower the truck onto the blocks and remove the jack. ported by blocking under the steer axle to
prevent movement.
! CAUTION If the counterweight is removed while the
Before performing any maintenance work, truck is up on blocks, the weight of the
check the truck for stable condition on the upright and drive axle will cause the truck to
blocking by determining that it will not rock fall forward.
on blocks. 3. Put the jack under side frame, near the center of the
truck.
7. When maintenance work is completed, lower the rear
of truck to the floor by reversing the above procedure IMPORTANT
and lowering each side of the truck 50 mm (2 in.) at a Be sure to put the jack squarely and fully
time: under the main side structure of the frame.
• Put jack under frame and raise truck.
4. Carefully raise the truck one side at a time, only as
• Carefully remove blocks and lower truck. high as necessary to do the maintenance work, and
• Remove jack and blocks from drive wheels. not more than 150 mm (6 in.) total.
SA-2-4 • Lifting, Jacking, and Blocking SM 765

5. Put blocks under the side frame, at each side of the Shipping Tie-Down Instructions
jack. Spread the blocks close to the steer and drive
wheels for maximum stability. 1. Front of Truck
a. With Upright and Carriage Installed
6. If using one jack, lower the truck onto the blocks and
move the jack to the opposite side. Repeat the lifting • Lower the carriage fully.
procedure. • Put a tie-down (e.g., chain) between the car-
riage fork bars.
7. Put the same size blocks under each side of the truck
so it will be leveled.
! CAUTION b. Without Upright and Carriage Installed

Before performing any maintenance work, • Put a chain across the truck floor plate. Protect
check the truck for stable condition on the truck from chain damage by using covered
blocking. chain or protective material under the chain at
contact points.
8. When maintenance work is completed, lower the 2. Rear of Truck
entire truck to the floor by reversing this procedure.
Lower the truck one side at a time, while carefully • Attach the tie-down to the toe-pin in bottom of
removing the blocks. Be sure no tools or equipment counterweight.
are under the truck or wheels.
NOTE
Depending on jack height, shims under the
tires may be needed for clearance to allow
removal of jack.

Section 3
Towing
SM 765 Towing • SA-3-1

If your truck is disabled but can be moved freely on its 4. Check that the counterweight bolts on both trucks are
own wheels without further damage, use the following in place and properly torqued to 450-500 Nom (332-
procedures to tow the truck safely to a repair area. 369 ft-lb). These bolts are made of special, high-ten-
sile steel and are not commercially available. When
! WARNING necessary, replace these bolt only with genuine Clark
replacement parts.
For your safety and the care of your truck,
use the proper equipment and carefully fol- 5. Use an approved, solid metal tow bar with towing couplers
low these recommendations for safe towing. that connect to the towing pins in the counterweights of
each truck.
Do not tow a lift truck if there is a problem NOTE
with the brakes or tires, or if the steering DOT-approved towing equipment is available from
cannot be operated. your Clark dealer.
Do not tow up or down ramps or steep 6. Release the parking brake on the towed vehicle.
inclines. Place directional control lever in NEUTRAL.
7. Tow the disabled truck backward. An operator must
Do not tow the disabled truck if traction or be on the disabled truck.
weather conditions are poor.
1. Apply the parking brake or block the drive wheels on ! CAUTION

the disabled truck while working around it. The power steering will not operate on the
disabled truck when the power steering
2. When possible, raise the forks on the disabled truck
motor is not running. The steering hand-
300 mm (12 in) from the floor or ground. Secure the
wheel will be difficult to turn.
carriage on the upright with a chain.
3. Use a truck for towing that is of equal or larger 8. Tow the truck slowly. Careful towing is necessary to
capacity than the disabled truck. Carry a partial load prevent injury to personnel or damage to the disabled
on the towing truck for improved traction truck. The truck should be towed at a speed of less
than 8 kph (5 mph, or a moderate walking speed)
with a driver in place and steering the disabled truck.
SA-3-2 • Towing SM 765

IMPORTANT
Do not lift the disabled truck or any wheels
! WARNING
off the floor while the truck is being towed. Always engage the parking brake when
parking a lift truck. The truck can roll and
9. Park the disabled truck in authorized areas only. cause injury or death to personnel near it.
Fully lower the forks to the floor. Leave the direc-
tional control in neutral. Turn the key switch to OFF,
and engage the parking brake. Remove the key. Dis-
connect the battery. When necessary, block the
wheels to prevent the truck from rolling.
SM 765 Towing • SA-3-3

GROUP PS PERIODIC SERVICE
GROUP PS
PERIODIC SERVICE
Maintenance Schedule .................................... Section 1
Planned Maintenance Program ...................... Section 2
The PM Inspection Form ................................. Section 3
SM 765 Group PS PERIODIC SERVICE,

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

Determining Maintenance Intervals .............................................. 2
GEX Service Chart/Lubrication Points ......................................... 3
Recommended Periodic Service Schedule .................................. 4
SM 765 Maintenance Schedule • PS-1-1

“Periodic Service” and “Planned Main- Determining Maintenance Intervals

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
basis. normal operation. Standard operating condition classifica-
tions are:
The term “Planned Maintenance” indicates a formalized
program of basic inspections, adjustments, and lubrica- Normal Operation: Eight-hour material handling, mostly
tions that the CLARK service organization provides cus- in buildings or in clean, open air on clean, paved surfaces.
tomers at a prescribed interval, usually 500 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
tasks.that should be performed periodically, and suggests • In sandy or dusty locations, such as cement plants,
intervals at which they should be performed. lumber mills, and coal dust or stone crushing sites.
• 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.
IMPORTANT
MAINTENANCE INTERVALS. If the lift
truck is used in severe or extreme operating
conditions, the maintenance intervals should
be shortened accordingly. Put upright in ver-
tical position and fully lower the forks or
attachment.
Service Chart/Lubrication Points

This decal is a basic guide to periodic maintenance inter-
vals and tasks. A more detailed chart is supplied on the
next page.
PS-1-2 • Maintenance Schedule SM 765

GEX Service Chart/Lubrication Points
,
Oil
kG
1809371
or Mobil #424)

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 Operator’s Manual for Daily Checks.
Every Every Every

Every
TASKS 450- 500 Hours 900- 1000 Hours 2000 Hours
8-10 Hours
(or 6 months) (or 12 months) (or 1 year)
Group PS - Periodic Maintenance
Perform Planned Maintenance inspections,
̻
lubrications, and adjustments
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 ̻
Fluid change - drain/fill ̻
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 ̻
Fluid change - drain/fill ̻ ̻
PS-1-4 • Maintenance Schedule SM 765

Every Every Every

Every
TASKS 450- 500 Hours 900- 1000 Hours 2000 Hours
8-10 Hours
(or 6 months) (or 12 months) (or 1 year)
Group 25/26 - Steer Axle and Lines
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
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 ̻

Section 2
Planned Maintenance
Use PM Report Form ....................................................................... 2

How to Perform the PM PeriodicGInspections and Maintenance ............. 2
Visual Inspection ........................................................................... 2
Operational Checks ........................................................................ 5
Test Drive Truck with Load ............................................................ 6
Lift Mechanism and Controls ........................................................ 8
Battery Compartment Inspection ................................................. 10
Motor Transistor Controls Inspection .......................................... 10
Hydraulic Compartment Inspection ............................................. 10
Cleaning ........................................................................................... 11
Air-Cleaning .................................................................................... 12
Critical Fastener Torque Checks .................................................. 12
Lubrication, Fluids, and Filters .................................................... 12
Hydraulic Sump ........................................................................... 12
Hydraulic Fluid and Filter Change .............................................. 12
Sump Tank Breather Maintenance .............................................. 13
Access to the Drive Axle ............................................................. 13
Drive Axle Fluid .......................................................................... 13
Drive Axle Fluid Change ............................................................. 13
Truck Chassis Inspection and Lubrication .................................. 13
Upright and Tilt Cylinder Lubrication ......................................... 13
Lift Chains ................................................................................... 13
Air-Cleaning Motors ...................................................................... 14
SM 765 Planned Maintenance • PS-2-1

Use PM Report Form

A planned maintenance program of regular, routine
inspections and lubrication is important for long life and
troublefree 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 prob-
lems from occurring during operation.
As an aid in performing and documenting your PM
inspections, Clark has prepared an Electric Truck Planned
Maintenance Report form. Copies of this form may be
obtained from your authorized Clark dealer. We recom-
mend that you use this form as a checklist, to make a
record of your inspection and truck condition. Be sure all capacity, safety, and warning plates or decals
are attached and legible.
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 ! CAUTION
are done in a logical and efficient sequence. Do not operate a lift truck with damaged or
A check mark or entry is made on the PM Report Form missing decals and nameplates. Replace them
when the PM is performed. Please note the special coding immediately. They contain important infor-
system for indicating the importance of needed repairs mation.
and/or adjustments.
Inspect the truck for signs of external leakage of transmis-
When you have finished the PM inspections, be sure to sion fluid, etc. Check for hydraulic leaks and loose fit-
give a copy of the report to the designated authority or the tings. DO NOT use bare hands to check. Hydraulic Fluid
person responsible for lift truck maintenance. may be hot or under pressure.
Do not make repairs or adjustments unless authorized to
do so. ! DANGER
For safety: HYDRAULIC FLUID PRESSURE: Do not
use your hands to check for hydraulic leak-
• Remove all jewelry (watch, rings, bracelets, etc.) age. Fluid under pressure can penetrate your
before working on the truck. skin and cause serious injury.
• Disconnect battery from truck receptacle before
working on electrical components.
• Wear safety glasses. Wear a safety (hard) hat in
industrial plants and in special work areas where
protection is necessary or required.
How to Perform the PM Periodic

Inspections and Maintenance
Be sure that the driver’s overhead guard, load backrest
extension, finger guards, and any other safety devices are
Visual Inspection
in place, undamaged, and attached securely.
Perform a visual inspection of the lift truck and its compo-
nents. Walk around the truck and take note of any obvious ! WARNING
damage and maintenance problems. Check for loose fas-
For trucks equipped with spark-enclosed
teners and fittings.
(EE) construction, or with polyurethane
PS-2-2 • Planned Maintenance SM 765

tires, check the ground strap or chain for

wear and secure attachment. ! DANGER
Uprights can drop suddenly if not properly
Check all of the critical components that handle or carry blocked. Look at the upright, but keep hands,
the load. tools, etc. out.
IMPORTANT
Uprights and lift chains require special atten-
tion and maintenance to maintain them in
safe operating condition. Refer to Lift Chain
Check the overhead guard for damage. Be sure that it is Maintenance in Group 34 for additional
properly positioned and all mounting fasteners are in information.
place and tight.
Check the upright assembly. Inspect the upright rails, car-
! CAUTION riage rollers, lift chains, lift and tilt cylinders. Look for
obvious wear and damaged or missing parts. Check for
If load backrest has been removed, a bolt and
any loose parts or fittings. Check for leaks, damaged or
washer must be in place on each end of the
loose rollers, and rail wear (metal flaking). Carefully
top fork bar to act as a fork stop.
check the lift chains for wear, rust and corrosion, cracked
or broken links, stretching, etc. Check that the lift and car-
Check the load backrest for damage. Inspect the welds on
riage chains are correctly adjusted to have equal tension.
the carriage and load backrest for cracks. Be sure that the
Check that the lift chain anchor fasteners and locking
mounting fasteners are all in place and tight.
means are in place and tight.
Be sure all safety guards and chain retainers are in place
and not damaged. Inspect the carriage stops and cylinder
retainer bolts. Check all welded connections.
Inspect all lift line hydraulic connections for leaks. Check
the lift cylinder rods for wear nicks, grooves, and
scratches. Check the cylinder seals for leaks. Refer to
Group 34 for details on uprights.

Forks
Inspect the load forks for cracks, breaks, bending and
wear. The fork top surfaces should be level and even with
each other. The height difference between both fork tips
should be no more than 6 mm (0.25 in.)
Inspect the fork latches. Be sure they are not damaged or

broken, operate freely and lock correctly. Check the fork
stop pins (or bolt and washer) for secure condition.
Wheels and Tires

NOTE
Your Clark dealer has special tools for mea-
suring fork wear.
! WARNING
If the fork blade at the heel is worn down by
more than l0%, the load capacity is reduced
and the fork must be replaced. DO NOT
attempt to fill with weld. See Group 34 for
inspection procedure.
Check the amount of wear at the heel of the fork.
! CAUTION
If the forks are obviously bent or damaged,
have them inspected by a trained mainte-
nance person before operating the truck. Check the condition of the drive and steer wheels and
tires. Remove objects embedded in the tread. Inspect the
Inspect the forks for twists and bends. To check, put a 2 x tires for excessive wear, break, “chunking out,” and bond
4 x 24 in. long block on the blade of the fork with the 4 in. failure between the tire and rim.
surface against the blade. Put a 24 in. carpenter’s square
on the top of the block and against the shank. Check the
fork 18 in. above the blade to be sure it is not bent more
than 14.5 mm (0.6 in.) at Y.

2. Using the Display

Seat Belt: At start up this symbol displays
along with an audio alarm for 4 seconds. This
display reminds you to fasten your seat belt.
Parking Brake: The symbol is displayed and "-

255" status code appears on the numeric dis-
play when parking brake is applied. Release
parking brake to operate truck.
Service Status: The following 5 codes are usu-

ally operator fault codes, and can be corrected
by as explained in "Section 5, Operating Proce-
dures." If you see any other codes displayed,
the truck needs to be serviced.
Check all wheel mounting bolts to be sure none are loose • -01 Seat Switch Open
or missing. • -061, -065 ,-140, -203, -207 Overheat of motor
and controller (Restart after cooling
! CAUTION down)
Personnel working on wheels and tires must • -66 Low Battery (truck will go into lift lockout
be trained and qualified to do wheel and tire when the dash display shows less than
maintenance. 15%)
• -77 Maintenance Hours (preset hour meter reading
Replace missing bolts and tighten loose bolts to the cor- indicating that it is time to have the
rect torque before operating the truck. truck serviced. Truck will reduce the top
speed if desired)
Operational Checks • -79 Incorrect Start Up Sequence (SRO)
• -217, -245 Wrong set battery
1. Check horn to be sure it operates.
• -255 Parking Brake Switch Open
Battery discharge indicator

It displays the battery discharge
condition of forklift truck.
The one bar indicates 10%
Blue color
charging condition.
If the battery is charged more
Red color than 20% (8 bars or more), blue
LED is displayed, but it is less
than 20% (2 bars or less), red
IMPORTANT LED is displayed. If it is less than 10% (1 bar), it will
Because the battery is such an important flicker and buzzer sound.
part of electric truck operation, it requires its
own specialized maintenance program,
which should include full-scale cleaning and
inspection. Refer to Group 13 for specific
instructions.

Slow-speed indicator (Turtle shaped) • Release the control lever. It should return to neu-
tral without binding. The pump motor should turn
The traveling speed of truck is limited to off. The control lever should not bind when mov-
set speed. ing it to any position.
The upper mark is slow speed operating
icon, and the figure shows the limited • Repeat procedures with tilt control lever. Forks
max. speed. (In upper example, the lim- should tilt evenly and smoothly.
ited max. speed is 2km/h) • If lift truck is equipped with an attachment, test the
auxiliary control lever for a correct function.
Hourmeter & Speed • Briefly operate the attachment.
• It displays the accumulated oper-
ating hour and traveling speed of
truck.
• When the traveling speed is less
than 0.5km/h, it displays the accu-
mulated operating hour. Lift lever
• When the traveling speed is more
than 0.5km/h, it displays the traveling speed.
Tilt lever
Message display Option lever
The model name, POWER

Normal
selection, travel direction, warn- 4. Check Drive Motor (Brake) Cut-Off Switch
Error
ing and error message are dis- • Move the truck forward slowly. Slowly depress
Warning
BATTERY LOW played. brake pedal. Drive motor should cut off before the
• In normal operating condition:
brakes apply.
Model name/POWER/Travel direction
• If operation is not satisfactory, DO NOT operate
• When several messages are simultaneously dis-
the truck. Take truck out of service and report con-
played, it will be displayed in the order of Error,
dition to designated authority.
Warning and Normal condition.
• If many error conditions are 5. Check Upright
23 : FUSE ERROR
56 : FET SHORT simultaneously occurred, the • Note any excessive “slop” or “noise” in the
priority 2 Errors will be displayed. upright. It may indicate roller damage, or that
(The priority means Error number) roller shimming, repair or adjustment may be
required.
Travel direction icon 6. Check Tilt Cylinder (Refer to Group 32 to do the
• It displays the traveling direction or angle of following)
steering wheel.. • Perform drift test.
• The direction icon rotates in 10 degrees.
• Perform check and adjustment procedure.
(Total 36 icon)
• Check rod seal condition.
Error icon • Check mounting. Tighten as needed.
• When error occurs this icon is displayed to distin-
• Check rod end. Tighten as needed.
guish the condition easily. When the error message 7. Check Truck Performance
is displayed, this icon is simultaneously displayed.
3. Check Function Control Levers ! WARNING
• Gently pull back on the lift control lever. The Check all around to be sure that your
pump motor should turn on and the carriage should intended path of travel is clear of obstruc-
begin to elevate. tions and pedestrians.

• Drive the truck forward in a straight line at a high 2. Operaten the truck at a slow speed in a forward direc-
rate of speed. Listen for unusual drive train noise. tion of travel. Reverse direction of travel. The truck
Stop truck. should slow down to a smooth controlled stop, and
• Check acceleration from a stop to top travel speed. accelerate normally in the opposite direction.
Acceleration should be smooth without hesitation. If plugging is as specified, then repeat the procedure
Stop the truck. Repeat procedure in reverse. at high speed. The truck should come to a smooth
controlled stop in approximately 20 feet (6.10 mm)
• Report condition on PM report form.
with accelerator in maximum travel position.
3. Repeat the procedure at high speed with the direction
lever moved in reverse direction.
If plugging (braking) is not as specified, refer to the
adjustment instructions in Group 19 of this manual.
Report condition to designated authority.
Check Accelerator
1. After checking to see that you have a clear path
ahead, drive the truck in a straight line at a high rate
of speed in a forward direction of travel. Listen for
unusual drive train noise. Stop truck
Test Drive Truck with Load 2. Check acceleration from a stand still condition to top
travel speed. Acceleration should be smooth without
NOTE hesitation.
Conduct these tests with a rated capacity
load, if possible. 3. After checking to see that you have a clear path
behind, drive the truck in reverse. Check acceleration
Test the truck for proper operation and drive train function from stand still condition through top travel speed.
by driving the truck in both the forward and reverse direc- Acceleration should be smooth.
tions. Drive first in a straight line and slowly through a Check the accelerator pedal while conducting the speed
series of full right and left turns. Then repeat, driving in range tests. It must move easily and smoothly throughout
opposite direction. the acceleration stroke and return without binding. There
should be no restriction to movement on either accelera-
tion or deceleration.
Carry Load Low & Tilt Back
Test for correct function of the transistor control.
Check Controlled Plugging (Braking) ! CAUTION

DO NOT operate lift truck if the brakes are
1. Operate the truck with parking brake set. It should not operating properly. Use Hydraulic oil
not move. Release parking brake. RANDO HD32 or NUTO H32.

Test the service brake (drive motor cut-off) switch. Drive Test shifting from NEUTRAL to REVERSE, then back to
the truck FORWARD (or in REVERSE) at creep speed. NEUTRAL. Check for positive control action when
While holding the accelerator pedal steady in creep speed changing directions.
position, depress brake pedal. The braking action should
Listen for clunking, squealing, grinding, scraping, or other
interrupt power to the drive motor and stop the truck.
unusual noises. Check for vibration. Listen for wheel
Release the brake pedal. The drive motor should again
bearing or other specific running noise.
start moving the truck.
Lift Mechanism and Controls

NOTE
Conduct these tests with a rated capacity load.
Brake Pedal Test the operation of the hydraulic system and upright.
Accelerator Pedal
Test brake operation by depressing and releasing the

brake pedal several times while driving the truck. The
brakes should bring the truck to a smooth stop without
pulling, squealing, or shuddering. Have the brakes
adjusted or repaired as necessary. Drive motor should cut
off before brakes apply.
To check brake holding capability and adjustment, park
the truck on a grade and depress brake pedal. The brake
should hold a lift truck with rated load on a 15% grade.
! CAUTION
Check Steering Be sure there is adequate overhead clearance
before raising the upright.
! CAUTION
Cycle (raise to full height and then lower) the upright at
DO NOT operate lift truck if steering system
both slow and fast speed, with the upright tilted slightly
is not operating properly.
backward. Watch the upright assembly as it rises. All
movements of the upright, fork carriage, and lift chains
Check steering control operation. First, drive the truck in a
must be even and smooth, without binding or jerking
straight line. The truck must drive in a straight line with-
motions. Watch for chain wobble or looseness. The chains
out drifting toward either side. Then drive slowly (creep
should have equal tension and move smoothly, without
speed) through a series of full right and left turns. Check
noticeable wobble.
steering response and smoothness of operation. Turning
effort must be the same in either direction. You will hear Check function of the control lever and main hydraulic
the hydraulic pump operate over relief when in a full turn. valve. Listen for abnormal noises in the hydraulic valve,
If there is a steering problem, have it repaired. main hydraulic pump, and system components.
NOTE If the maximum fork height is not reached, either the fluid
Conduct the following test with a rated level in the hydraulic sump tank is low, or there is severe
capacity load. binding within the upright.
Test for general drive train operation. Drive the truck at

various speeds and operating conditions, in both FOR-
WARD and REVERSE directions. Test shifting from
NEUTRAL to FORWARD, then back to NEUTRAL.

Test for correct tilt cylinder rod adjustment. Raise the car-
! WARNING riage to an intermediate position. Tilt the upright fully for-
FALLING FORKS. Do not walk or stand ward without a load on the forks. Check for upright
under raised forks. The forks can fall and racking (twisting) as the tilt cylinders reach the end of
cause injury or death. their stroke. Tilt the upright fully back. The upright should
not rack (twist) when the tilt cylinders reach the end of
their travel. If forward upright racking is found, adjust-
ment of the tilt cylinder rod ends (yokes or spacers) is
required. If backward racking is found, adding or remov-
ing shims is required. Refer to Group 32.
! CAUTION
When you have completed the operational
tests, park and leave truck according to stan-
dard shutdown procedures.
Never Walk Under Raised Forks!

Check the upright rails, rollers, carriage, lift chains, and
cylinders as they move. Watch for binding or excessive
freeplay (looseness) between the carriage and the upright
rails and rollers. Listen for abnormal noises. If there is
excessive clearance between the rails and channels, the
upright roller needs adjustment. If the rails or carriage
bind or hesitate when lowering, the rollers are either dam-
aged or roller adjustment is incorrect.
Check the upright for excessive downdrift. Stop the fork
carriage in an intermediate position. Check that it holds its
position without moving down. If you observe downward
movement (drift) or have a report of a drift problem, the
lift cylinder seals may be worn. With forks elevated, turn Standard Shutdown Procedures:
key switch off. Pull back on the lift lever. The forks
• Come to a complete stop.
should not lower This tests the check valve.
• Park only in authorized locations.
Test the tilt function. Check for excessive tilt cylinder
• Lower the forks fully, tilt upright forward until
drift. Stop the upright at a position near vertical. Check
fork tips touch floor.
that the upright holds its position without moving for-
ward. If you observe forward movement (drift) or have a • Allow travel control to return to neutral.
report of a tilt drift problem, the tilt cylinder seals may be • Turn the key switch OFF.
worn. • Apply the parking brake.
Check fork height adjustment and carriage chain adjust- • Disconnect Battery
ment. Tilt the upright to the vertical position and fully
lower the carriage. The forks should stop and be held
approximately 13 mm (0.50 in.) above the floor. If the Make a record of all maintenance and operating problems
forks hit the floor, the carriage lift chains should be you find.
adjusted. Also check the rail chains.
If truck is equipped with an attachment, briefly operate
the attachment to check the controls for correct function.

Battery Compartment Inspection Turn key switch OFF. Disconnect battery from truck
receptacle. Remove the control compartment cover from
Turn key switch OFF. Disconnect battery from truck the counterweight.
receptacle.
Discharge the capacitor using a 10W~100W resistance
connected from the +Batt(pos.) to the -Batt(neg.).
Inspect the transistor controls for clean condition. Check
for oily dirt buildup on contactors, Inspect all control wir-
ing terminals for any obvious damage. Look for cracks or
worn areas in the wiring insulation. Check for loose con-
nections at the control terminals. Air-clean as necessary.
Treat the control panel plugs with Clark 1801145”Lectric-
Like” Spray or Clark 1803827-brush on cleaner.
Inspect condition of the battery connector and truck bat- Hydraulic Compartment Inspection
tery receptacle. Check the spring-loaded terminals, con-
Remove the floorplate.
nectors, and retaining tabs. Look for poor connections due
to burning, bad crimps, or broken or loose retainers. Check the condition of all hydraulic system components,
Check the molded body for damage from overheating, hoses, piping, and connections. Check for wear, leakage,
burning, and chips or cracks. Replace receptacle terminals and damage.
if pitted or corroded.
Remove the battery.
Inspect condition of the battery and cables. Check the bat-
Inspect the drive motor, hydraulic pump motor power
tery cables for wear or other damage. Check for signs of
cables. Check drive motor mounting fasteners. Check
interference or rubbing with other components. Be sure
hydraulic pump motor. Check pump motor mountings.
that the cable terminals are tight and clean. Clean off any
deposits of corrosion found on the battery.
! DANGER
Never wash the battery when it is in the truck.
HYDRAULIC FLUID PRESSURE: Do not
Check battery post terminals for corrosion and damage. use your hands to check for hydraulic leak-
Clean all corrosion from cable end and battery post. age. Fluid under pressure can penetrate your
Check tighmess of cable and post terminals. skin and cause serious injury.
If necessary, check the state-of-charge condition of the
battery. Take a specific gravity test of the electrolyte with
a hydrometer. Be sure to check a minimum of six battery
cells.
Check the electrolyte level of the battery. Add distilled
water, as required, to fill each cell to the correct level.
Check to be sure the vent hole in each battery cell cap is
open. If cap vents are plugged with corrosion, remove the Brake Shoe and Drum Inspection
caps and wash in a solution of baking soda and water.
The brake linings, drum and adjustment setting can be
Refer to Group 12, Battery, for additional information. inspected without removing the drum or hub. Refer to
Group 23, Section 6 for inspection procedure.
Motor Transistor Controls Inspection
IMPORTANT
Do not clean electrical components with
steam. Only approved solvents should be
used to clean controls.

CLEANING
Cleaning Summary
* Battery Compartment. * Hydraulic Compartment
* Drive Motor and Steer Motor. * Pump Motor.
* Axle Mounting * Control Compartment
* Upright.
IMPORTANT
Do not clean electrical components with steam. Only approved solvents should be used to clean Solid
State components. Scheduled cleaning (as outlined) should preclude the need for using a degreaser. Not
all degreasers are acceptable. If a degreaser is to be used, we recommend degreaser or the equivalent to
MS-180 Freon TF degreaser and cleaner.
! WARNING
When cleaning with compressed air:
• Wear eye protection and protective clothing when cleaning or drying with air pressure.
• Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.
Normal Cleaning
Blowing dirt off with an air hose periodically will, for the most part, eliminate any serious cleaning problems. Should the
need arise for a more thorough cleaning, water may be hosed over the control and if necessary a mild detergent applied
such as that used in washing dishes in the home. This detergent should be rinsed off and the control dried with an air hose.
The control must be thoroughly dry before putting the truck back into service.
IMPORTANT
Cleaning the components of the truck is a vital part of the P.M. process. Keeping the components clean
will increase their service life and assure trouble free truck operation.

Air-Cleaning ponents which directly support, handle or control the load,

or protect the operator.
Always maintain a lift truck in a clean condition. Do not
allow dirt, dust, lint, or other contaminants to accumulate Check torque of critical items, including: overhead guard,
on the truck. Keep the truck free from leaking oil and drive axle mounting, drive and steering wheel mounting,
grease. Wipe up all oil spills. Keep the controls and floor- counterweight mounting, load backrest extension, tilt cyl-
board clean and dry. A clean truck makes it easier to see inder mounting and yokes, upright mounting and compo-
leaks and loose, missing or damaged parts, and will help nents. Refer to Group 40 for torque specifications.
prevent fires. A clean truck will run cooler.
The environment in which a lift truck operates will deter- Lubrication, Fluids, and Filters
mine how often and to what extent cleaning is necessary.
For example, trucks operating in manufacturing plants Hydraulic Sump
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 Check the hydraulic sump tank fluid level. Correct fluid
more frequent cleaning. If air pressure does not remove level is important for proper hydraulic system operation.
heavy deposits of grease, oil, etc., it may be necessary to Low fluid level can cause pump damage. Overfilling can
use steam or liquid spray cleaner. DO NOT clean electri- cause loss of fluid or lift system malfunction.
cal components with steam. Hydraulic fluid expands as its temperature rises. Check
NOTE the fluid level at operating temperature, after approxi-
See special provision for blowing dust from mately 30 minutes of truck operation. To check the fluid
pump and drive motors on page 14 of this level, park the truck on a level surface. Put the upright in a
section. vertical position and lower the fork carriage fully down.
Remove the floorplate and observe the fluid level marking
on the sump tank. Refer to Group 29, Section 1 for more
! CAUTION information on the sump tank. DO NOT overfill.
Battery must be disconnected and capacitors Check the condition of the hydraulic fluid for color, clar-
discharged before inserting air wand ity, and contamination. Change (replace) the hydraulic
through access holes. fluid as necessary.
! CAUTION
Wear suitable eye protection and protective
clothing.
Lift trucks should be air-cleaned at every PM interval, and

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 com-
pressed air. Restrict air pressure to 207 kPa (30 psi).
Air-clean the following: upright assembly; drive axle; bat-
tery, cables, switches and wiring harness; transistor con-
trols and wiring; drive and hydraulic pump motors;
steering axle and steering cylinder.
Critical Fastener Torque Checks

Fasteners in highly loaded (critical) components can
quickly fail if they loosen. Loose fasteners can cause dam-
Hydraulic Fluid and Filter Change
age or component failure. For safety, it is important that Drain and replace the hydraulic sump fluid every 2000
the correct torque be maintained on all fasteners of com- operating hours, or sooner, as required. Replace the

hydraulic fluid filter at every fluid change. Replace the Drive Axle Fluid Change
sump tank breather/fill cap every 2000 operating hours.
NOTE
NOTE
Check the PM interval (operating hours), or
Always use genuine Clark Parts. the condition of the fluid to determine if the
drive axle fluid needs to be changed.
Sump Tank Breather Maintenance
Drain and replace the drive axle fluid every 2000 operat-
Remove the sump tank fil cap/breather and inspect for ing hours. The fluid should be drained when it is at operat-
excessive contamination and damage. Clean and replace ing temperature. Put the truck in a level position. Block
as recommended by the PM schedule, or as required by the wheels to prevent truck from moving.
operating conditions.
Inspect and clean the drive axle breather (air vent)
mounted on top of drive axle.. Refer to Lubrication Chart
and Group 40.
Access to the Drive Axle
Truck Chassis Inspection and Lubrication
Access the Drive axle by removing the floorplate or
through the upright. Lubrication and inspection of truck chassis components,
including steer wheels and wheel bearings, will be easier
! WARNING if the rear of the truck is raised and blocked up under the
frame. Refer to Group SA, Section 2, for additional infor-
An upright or carriage can move unexpect-
mation.
edly. Chain or block the carriage and rails.
Failure to follow this warning can result in IMPORTANT
serious injury or death. Do not raise truck by lifting under the coun-
terweight.
Refer to Group SA, Section 2 for additional information
on supporting the upright.
Block the wheels. Be sure to put blocking under the car-
! WARNING
riage and upright rails. Be sure to put blocking under the frame to
keep the truck safe.
Drive Axle Fluid Be sure to clean the grease fittings before lubricating.
Check the drive axle fluid level with the truck on a level Remove excess grease from all points after lubricating.
surface and fluid at operating temperature.
Remove the fluid level inspection plug located on the left Upright and Tilt Cylinder Lubrication
side of the drive axle housing. Fluid level should be at the Clean the fittings and lubricate the tilt cylinder rod end
bottom of the inspection hole. If fluid level is low, add bushings.
enough fluid to bring fluid level up to bottom of the
inspection hole. DO NOT overfill. Clean the fittings and lubricate the upright trunnion bush-
ings (one fitting on top of trunnion, each side).
Add the recommended fluid only, as required.
Inspect the fill plug for damage. Replace as needed. Install Lift Chains
and tighten the plug.
Lubricate the entire length of the rail lift and carriage
chains with Clark Chain and Cable Lube.

Air Cleaning of Motors tors by using a 10W~100W resistance

connected from the +Batt(pos.) to the -
Batt(neg.).
! WARNING
Before inserting metal air cleaning wand, dis- .
connect the battery and discharge the capaci-

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 765 The PM Inspection Form • PS-3-1

CODE
ELECTRIC AC TRUCK O.K. 3 = O.K.
Potential x = Adjust (Not P.M.)
CUSTOMER
PLANNED MAINTENANCE REPORT r = Repair or replace
Urgent
s = Requires shop repair
DATE HOUR METER
DATE LAST P.M. HRS. LAST P.M.
MODEL& SERIALNO. CUST. P.O. NO.

ATTACHMENTNO. c.
AUTHORIZED SIGNATURE INSPECTOR SPECIALINSTRUCTIONS
A. TEST DRIVE MACHINE 16MOTORS 23BRAKE SYSTEM 34UPRIGHT-CARRIAGE

a. Drive Train Noise a. Drive Motor Condition a. Check for Leakage a. Security of Mounting
PS-3-2 • The PM Inspection Form

b. Steering Operation b. Pump Motor Condition b. Cylinder Fluid Level b. Roller Condition/Clearance
c. Service Brake Operation c. Clean Vent Cap c. Chain and Anchor Condition
d. Speed Control d. Pedal Free Travel d. Chain Adjustment
e. Pedal Drift e. Latch and Stop Condition
Creep Speed
e. Plugging & Directional Control f. Master Cylinder Mounting f. Cylinder Condition
f. Return to Neutral g. Service Brake Wear/Adjustment g. Forks, Locks, Stops
g. Hydraulic System Operation h. Parking Brake Wear/Adjustment h. Rail Condition
h. Pedal Pads & Linkages i. Brake Line/Cable Condition i. Trunnion Ring Condition
i. Parking Brake Operation j. Brake Linkage check & Lubricate
j. Seat Switch(Brake) Operation 19ELECTRICAL TESTS 34LOAD BACK REST
k. Pedestrian Warning Devices a. Ground Tests 26STEER AXLE a. Condition
(if equipped) b. Cable and Terminal Condition a. Security of Mounting b. Security of Mounting
c. Wire Harness Condition b. Axle Stop Adjustment
d. Speed Pot Test c. Drag Link Adjustment 35LIFT LINKAGE (POW)
e. Contactor Assemblies d. Check Wheel Bearings a. Security of Mounting
f. Contactor Tip Condition b. Linkage Condition
g. Service Brake Switch Operation 26STEERING SYSTEM c. Linkage Adjustment
01CLEANING & LUBRICATION h. Park Switch Operation a. Check for Leakage d. Load Wheel Bearings
a. Air Clean Truck i. S.R.O. b. Oil Level - Condition
b. Air Clean Electrical Control j. P.M.T c. Security of Mounting 38SHEET METAL & CWT
c. Air Clean All Motors k. Speed Limit Switches d. Tilt Column Operation a. Decals-Missing/Condition
d. Lubricate Truck l. Steering Switches b. Data Plate Condition
m.Hydraulic Valve Switches 29/30 HYDRAULIC SYSTEM c. Seat Mounting and Operation
12 BATTERY AND CABLES * n. Drive Motor Current (Amps) a. Check for Leakage d. Seat Belts Condition
a. Cable Condition * o. Pump Motor Current (Amps) b. Fluid Level - Condition e. Door and Deck Latches
b. Fluid Level * p. Steer Motor Current (Amps) c. Clean/Replace Breather f. CTW Mounting Bolts
c. Battery Load Test * d. Replace Filter g. Slip Resistance Surfaces
d. Battery Retention/Stops 20DRIVE AXLE e. Linkage Adjustment h. Operator's Manual
e. Specific Gravity * a. Differential Fluid Level f. Hose Condition
f. Receptacle Condition b. Clean Air Vent g. Lift Speed (In./Sec.) 39OVERHEAD GUARD
g. Battery Connector Condition c. Security of Mounting No Load a. Condition
h. Battery Disconnect Operation d. Check Wheel Bearings Full Load b. Security of Mounting
h. Drift Test (In./Min.)
13GAUGES-LIGHTS-INDICATORS 23WHEELS AND TIRES Lift Cylinder 53 ATTACHMENTS
a. Hour Meter Operation a. Tighten Mounting Bolts Tilt Cylinder a. Mounting Bolts
b. Gauges - All Operate b. Tire Condition b. Leakage
c. Lights - All Operate c. Drive 32TILT CYLINDERS c. Operation
d. Wiring Condition d. Steer a. Check for Leakage
e. Horn e. Load b. Cylinder Rod Condition
f. Lift Interrupt f. Caster c. Mounting Security/Torque
g. Operation of Accessories g. Tire Pressure d. Tilt Cylinder Adjustment (Racking)
SM 765
GROUP 12 BATTERY
GROUP 12
BATTERY
Battery Service ................................................. Section 1
SM 765 Group 12 BATTERY,

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
SM 765 Battery Service • 12-1-1

Group 12, Battery
Battery Handling • Check to see that there is fire protection. Fire

extinguishers should be properly maintained and
located in designated areas.
! CAUTION
Remove all jewelry (watch, rings, bracelets,
etc.) before working on electrical systems.
Severe burns can result from contact with
electrical circuits.
! WARNING
Battery service must be done by trained per-
sonnel. Battery acid can cause severe burns
and injury. Do not smoke or have open
flames around batteries.
! WARNING ! DANGER
Electric truck batteries are heavy and awk- Explosive gas is always present around bat-
ward to handle. On charge, they give off teries, especially when they are being
hydrogen and oxygen which, in certain con- charged.
centrations, are explosive. Electric truck bat-
teries are also costly, so before you remove, • No smoking allowed in the charging area.
service, or install a truck battery, consult
• Battery electrolyte must never be checked with
BATTERY MANUFACTURER for more
an open flame.
recommendations and instructions on han-
dling and charging batteries. Carefully read • Open flame, sparks, or electric arcs must never
and follow recommendations and instruc- be allowed in the battery charging area.
tions. • The battery contains corrosive sulfuric acid
which can cause injury. If acid contacts your
Change or service batteries only in an area designated for eyes or skin, flush immediately with water and
this purpose. Refer to page 4 for additional information. get medical assistance.
• Be sure this area has provisions to flush and neu-
tralize acid spillage.
• Be certain the area has proper ventilation to venti-
late fumes from charging batteries.
Persons maintaining batteries must wear protective cloth-

ing such as:
12-1-2 • Battery Service SM 765

Group 12, Battery
• Face and head shields Be sure the battery service area is equipped with material
• Long shirt sleeves handling equipment designed for the purpose of removing
and replacing batteries, such as a conveyer or overhead
• Gauntlet gloves
hoist equipped with safety hooks.
• Rubber apron
IMPORTANT
To prevent side forces from damaging the
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.
• If the battery does not have a cover of its own,
cover it with a non-conductive material such as
plywood.

Group 12, Battery
3. Lift and latch seat deck to access battery.

! DANGER
4. If the battery to be handled is uncovered, cover bat-
Never lay tools or other metal objects on a tery with a non-conductive material (plywood, heavy
battery. Metal objects contacting battery ter- cardboard, etc.) prior to removal from truck.
minals will cause short circuits. The shorted
circuits could ignite battery fumes and cause IMPORTANT
the battery to explode. Do not wash battery in truck.
! CAUTION
An overhead hoist of sufficient lifting capac-
ity (refer to “Weights” in Group 40) should
be used to lift battery. The safety hooks of the
insulated spreader bar should be attached to
the lifting eyes provided in the battery casing.
5. Be sure battery is covered. Attach lifting device. Lift

and remove battery.
Battery Maintenance
Battery Removal
NOTE
1. Move truck to the designated battery service area.
To obtain maximum performance and bat-
tery life, follow the instructions supplied by
! CAUTION your battery vendor.
SAFE PARKING. Before working on truck:
Industrial batteries are used to supply the electrical power
• Park truck on a hard, level and solid surface, such to operate an electric industrial truck. Their voltage
as a concrete floor with no gaps or breaks. depends on the number of individual cells they contain.
• Put upright in vertical position and fully lower the There are approximately two volts for each cell in the
forks or attachment. commonly used lead-acid type battery. Batteries normally
range from 6 volts to 72 volts. Their capacity varies
• Put all controls in neutral. Turn key switch OFF depending on the application. Only use batteries that com-
and remove key. ply with factory specifications as to size and capacity.
• Apply the park brake and block the wheels.
2. Turn key switch OFF and disconnect battery. 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
age andcould ignite battery fumes, causing the bat- Battery Cleaning
tery to explode.
• Maintain good battery cable connections. The easiest and most satisfactory method of cleaning a
battery is to wash it with a low-pressure cold water spray.
• Check power cables and wiring for damage that The battery top can also be washed with a baking soda
can cause premature drainage of the battery. solution and rinsed with clear water.
• Do not overcharge a battery.
IMPORTANT
• Do not undercharge a battery.
. Remove battery from truck before wash-
• Follow the instructions provided by the supplier(s) ing.
of the battery and battery charging equipment. • Vent caps must be free of obstruction and in
• Maintain accurate battery records. If battery trou- good condition.
bles occur, these records will help you and your • Battery top should be clean and free of cracks
battery representative determine the nature of the or breaks.
problem. • Battery terminals must be clean and solidly
mounted.
• Damaged batteries should be repaired or
Battery Vents replaced. Consult your battery vendor.
• Check to be sure all vent caps are tight before
• When Charging Batteries: The vent caps must be
washing the battery.
kept in place to avoid electrolyte spray. Care must
be taken to assure that vent caps are functioning. • Fill a bucket with cold water. Add a box of baking
The vents must be open to allow the battery to soda to the bucket. Stir the solution until dissolved.
breathe. The battery cover must be removed/ Keep this solution around the battery service area
opened to dissipate heat and explosive gas. at all times.
• When Cleaning Batteries: The vent caps must be • After washing battery, thoroughly rinse with clear
tightly in place. cold water.
Battery Charging
Follow the instructions supplied by the battery charger
vendor.
Battery Electrolyte
• Check with battery manufacturer’s documentation
before working on battery electrolyte.
• Always use a carboy tilter or siphon when handling
battery electrolyte.
• When mixing electrolyte, always pour acid into
water-NEVER pour water into acid. Pouring water
into acid will cause a dangerous chemical action or
splash.

Group 12, Battery
Clean Battery Compartment Keeping Battery Records

. Using baking soda and water solution, clean the walls Records should be maintained to get the best service out
and floor of the compartment. Rinse with clear water. of your battery and truck.
. Blow off the compartment walls and floor with an air These records should contain:
hose. Allow to air-dry.
• Test Date. Each test should be dated for future ref-
erence and comparison.
! CAUTION • Specific Gravity and Temperature Readings.
Wear eye protection and protective clothing Each battery cell should be checked and recorded
when cleaning or drying with compressed before and after charging. The specific gravity
air. Reduce air pressure to 207 kPa (30 psi). reading of the electrolyte, calculated using a multi-
Debris removed with air pressure can cause plier to account for the ambient temperature,
injury. should not be less than 1.260. If below 1.250, the
battery should be recharged and tested.
• Variation Between Each Cell Tested. The varia-
tion in specific gravity reading between cells
should not be greater than 15 points (0.015). If
readings are greater, there are defective cells.
NOTE
The pilot cell should be changed occasionally
to distribute any electrolyte loss over the bat-
tery when taking readings.
Replacement Batteries • Load Voltage Tests should be performed and

recorded indicating the condition of a battery while
it is performing work.
! CAUTION
• Actual Operating Hours of the Battery. Record
Use a battery properly sized to the dimen- the actual time the battery is in use before putting it
sions of the battery compartment. Batteries on charger.
too small can shift and cause damage to the
truck or injury to the operator or bystanders. • Charging Time. Keep an accurate record of the
Only use batteries that comply with factory actual time the battery is on charger. After each
recommendations as to size and capacity. charge, check to see if the battery is fully charged.
Test the battery before placing it back into service.
Record these results.
Battery Installation • Visually Inspect for loose terminal connections or
If the battery is uncovered, cover the battery with a non- posts, a cracked case, damaged cell covers (vent
conductive material (i.e., plywood, heavy cardboard, etc.) caps), or excessive corrosion. This data should be
prior to installation. noted to help determine work environment and
possible trouble areas.
• 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
Battery Tests
NOTE
Use both tests described here.
Specific Gravity Test

Test at least six cells across battery with a temperaturecor-
rected hydrometer (see chart). Battery is fully charged
when the reading falls in the 1.280 to 1.300 range. If the
difference between cells is more than .015, battery needs
maintenance.
SPECIFIC GRAVITY TEST

SPECIFIC GRAVITY STATE OF CHANGE
1.260~1.300 100% CHARGED
1.230~1.250 75% CHARGED
1.200~1.220 50% CHARGED
1.170~1.190 25% CHARGED
1.140~1.160 VERY WEAK
1.110~1.130 DISCHARGED
The battery specific gravity is an indication of the bat-

tery’s state of charge. You can determine the specific
gravity of the electrolyte solution in a battery with an
hydrometer. If the state of charge is low, the hydrometer
will read low. If the state of charge is high, the hydrometer
will read high.
For, example a reading from:
• 1.260 to 1.300 indicates a fully-charged battery.
• 1.200 to 1.220 indicates a battery is in a discharged
condition and cannot give satisfactory service.
Load Test
Put the main hydraulic system into tilt by-pass while read-
ing battery volts with a voltmeter.
Battery needs recharge or repair if voltage drops below
80% of the rated voltage of the battery.
Minimum acceptable readings:
• 80 volt battery: 64 volts

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 765 Group 13 WIRING, SWITCHES, AND INSTRUMENTS,

Group 13, Wiring, Switches, and Instruments
Section 1
Schematic Electric Circuit Diagrams
Standard Truck ........................................................................................................................... IN-28374

ELH Options Truck .................................................................................................................... IN-38375
SM 765 Schematic Electric Circuit Diagrams • 13-1-1

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

3. Discharging Controller Capacitors
CAUTION It is necessary to discharge the capacitors before you work
Always wear safety glasses. 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.
2. Disable the truck:

• Turn the key switch to OFF.
• Remove key.
SM 765 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 Force or Pull

Pointer
Cuts
Typical Torque Wrench
Connecting and Mounting Compo-

Power cables having small cuts
may be repaired with electrical nents
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 by
Repairable Damage
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
Broken Wires Markers on Wire Harnesses and Power Cables
Cable Unfit for Further Service
13-2-2 • General Electrical Service Tips SM 765

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 components
Back to Front together.
Buss Bar
Barrel Latch t
Barrel cke
So
End seals g
must be firmly Plu
seated within Seal(s)
the assembly
Multiple Connections housing.
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 result. Check the plates and seal for damage and secure
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
So
cke
t tch
La
SO-6 Socket g
Plu
Pin Retainer Plates e)
Retainer Plates
PL-6 Plug Pin(s)
Example of Pin Lock Plug and Socket
SM 765 General Electrical Service Tips • 13-2-3

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

and connections for standard trucks and main accessory
harness.
Electrical Components ................................................................................................................ SI-47116

Main Harness ............................................................................................................................... SI-47202
Cables............................................................................................................................................. SI-47193
Accessory HarnessGand Components.......................................................................................... SI-47115
Option ("EE" Construction) ....................................................................................................... SI-48448
Option (Cold Storage) .................................................................................................................. SI-47781
SM 765 Wiring and Cables • 13-3-1

Electrical Components
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Main Harness
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Cables
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Accessory Harness and Components
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Option ("EE" Specification)
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Option (Cold Storage)
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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
Parking Brake Operation ...............................................................................................4
Seat Switch ...................................................................................................................5
Lift and Tilt Pump Switches .................................................................................................5
Description ....................................................................................................................5
Switch Adjustment ........................................................................................................5
Lift Pot Adjustment .......................................................................................................6
Program Adjustment ......................................................................................................6
SM 765 Switches and Sensors • 13-4-1

Accelerator Control Switch
Description trical pulses to the motor, which in turn will supply more
power to the drive train.
The accelerator control is operated by the accelerator foot
pedal to send a signal for power demand to the control. An internal spring returns the control to start position. The
accelerator is an integral unit and is not serviceable.
At the start, the accelerator control is stroked (by the Opening of the unit will void the warranty.
action of the accelerator pedal), and in turn sends a signal
to the motor control, requesting it to produce longer elec-
A
Torque:
8-10 N¡⁄m
(71-88 lbf¡⁄
in)
Accelerator
Pedal
C
Torque:
5-6 N¡⁄
m
(44-53 lbf¡⁄
in)
Accelerator
Control Switch
Roller
B
Torque
20-25 N¡⁄
m
(177-221 lbf¡⁄
in)
13-4-2 • Switches and Sensors SM 765

Program Adjustment • Display will show software version

• Turn the key switch Off and remove the tester cord
! CAUTION
from the control
• Plug the dash display harness into the "B" plug of
Before any adjustments are done, safely jack
the control
up the truck, block the drive wheels off the
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:
(Detailed handset operation instructions are in Group 19.)
• 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
• Handset will go through startup and display soft-
ware version
• Press the “ENTER” button
• Display will read "MAIN MENU' "PARAMETER
CHANGE".
• Press the “ROLL UP” button five times
• Display will read "MAIN MENU" “PROGRAM
VACC”
• Press the "ENTER" button
• Display will read "VACC SETTINGS"
• Press the "ENTER” button
• Display will read "MIN VACC MAX"
• Move the directional lever to Forward position
• Depress the accelerator pedal to the floor and than
release slowly
• Move the directional lever to the Reverse position
• Depress the accelerator pedal to the floor and than
release slowly
• 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
VACC”
• Press "OUT button

Brake Switches
Service Brake Switch Description Service Brake Switch Adjustment

The foot brake switch is on the brake link end, under the Adjust the switch so that it “clicks” just before the end of
flow plate. The switch operates when it is released by the pedal “freeplay” (the lag between pressing the brake and
brake pedal lever during braking. Depressing or releasing operating the master cylinder, covered in Group 23).
the switch operates a set of contacts that alternate from Adjust switch as follows.
open to closed to activate the Pedal Braking function of
1. Turn key switch OFF.
the control. This function uses the motor to help bring the
truck to a controlled stop. 2. Make sure freeplay is properly adjusted as described
in Group 23.
3. Loosen brake switch mounting screws.
4. Rotate switch against pedal until switch trips. (A
click can be heard.) Tighten mounting screws.
5. Check operation of switch by depressing brake pedal.
Switch should actuate just before the end of freeplay
(at which time you feel resistance in the pedal caused
by the master cylinder beginning to operate.)
Torque: 40-45 N·m

(30-33 lbf·ft)
Torque: 20-25 N·m

(177-221 lbf·in)
Capscrew height control
Brake switch
Torque: 40-45 N·m

(30-33 lbf·ft)
<SI-47239>

Parking Brake Switch Description Parking Brake Switch Adjustment

The parking brake switch is mounted to the hood under of 1. Turn key switch OFF.
parking brake assembly. The brake handle center pin
2. Loosen parking brake switch mounting screws.
depresses the switch when the hand lever is not applied.
This depressing of the switch closes the contacts. 3. Adjust position of switch so that there is contact with
the center pin and the switch actuates (clicks) just as
When the parking brake is applied, it releases the switch,
the parking brake lever is fully released.
allowing the contacts to return their normally open posi-
tion. This open circuit signals the controller to disable the 4. Tighten mounting screws.
drive motors.
5. Check operation of switch before truck is returned to
IMPORTANT service.
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
Parking Brake Switch

Parking Brake Operation Lift and Tilt Pump Switches

The operator applies the parking brake by pull up on a
parking brake, which is then held by a ratchet. The pull- Description
ing up the brake lever tensions cables connected to a brake
shoe at each brake assembly, thereby applying the brakes. The pump control switches are mounted on brackets at the
The operator releases the parking brake by push down on valve spools and they are normally open. Movement of th
a Parking lever. Return spring returns the lever and valve spools from the neutral position trips the switches
cable to the off position. The lever also operates the park- and closes their contacts. Current flow through the con-
ing brake interlock switch and the parking brake indicator tacts signals the pump controller to operate the pump
light switch. motor at the set speed for the selected function.
The lift lever activates a lift enable switch and also acti-
Seat Switch vates a Lift Pot. This potentiometer signals the pump con-
troller to run at an increasing speed proportional to the
The GEX trucks are equipped with a seat switch that sig- rearward movement of the lever.
nals the control to cut the power when the operator
leaves the seat.
Switch Adjustment
When the seat switch is open, a seat icon will be displayed
on the dash display. 1. Turn key switch to the OFF position.
There is a 1.5 second time delay built into the control to 2. Loosen switch mounting screws.
allow for momentary opening of the seat switch. If the 3. Adjust switch to activate after spool moves from
truck is operated over rough surfaces and the operator is neutral.
bounced, causing a momentary opening of the seat switch,
the truck will not shut down. 4. Tighten mounting screws.
5. Check operation of switch before truck is returned to
service.
Azdel Seat pan
SUSPENSION SEAT
Seat Switch
Wire harness
Seat Flexolater
STATIC SEAT

Lift Pot Adjustment Program Adjustment

1. Insure that the flag of the actuator is properly posi-
tioned on the flat of the large nut. ! CAUTION
2. Tighten the lock nut against the bottom of the actua- Before any adjustments are done, safely jack
tor. up the truck, block the drive wheels off the
floor and disconnect the battery.
3. Loosen the capscrews on the switch mounting
bracket and adjust the Pot to the point that it just Use the following method to program the Lift Potentiome-
touches the actuator plate. Insure that the Pot is paral- ter to the control panel with the handset:
lel with the lift linkage.
(Detailed handset operation instructions are in Group 19.)
Pot mounting screw • Disconnect the dash display harness from the con-
trol panel
Lift sensor • Plug handset into plug "B" of the control
• Plug in the battery
• Turn the key switch On
• Handset will go through startup and display soft-
ware version
• Press both the "ROLL UP" and "PARAM SET
UP" buttons (top outside buttons) simultaneously.
• Display will read "CONFIG MENU' "SET
MODEL"
• Press "ENTER" button
• Display will read "CONNECTED TO 3"
• Press "PARAM SET UP" button two (2) times
• Display will read "CONNECTED TO 5"
Actuator • Press "OUT" button
<SI-47116> • Display will read "ARE YOU SURE"
• Press "ENTER" button (this stores the connected
to value)
• Display will read "CONFIG MENU" “CON-
NECTED TO”
• Press "OUT" button
• Display will read Software Version for Pump Con-
trol
• Press the “ENTER” button
• Display will read "MAIN MENU' "PARAMETER
CHANGE".
• Press the “ROLL UP” button five times
VACC”
• Display will read "VACC SETTINGS"
• Press the "ENTER” button

• Display will read "MIN VACC MAX"

• Move the lift lever to full raised position
• Release the lift lever to the neutral position
• Display will read "ARE YOU SURE"
• Press "ENTER" button (this stores the value for
MIN and MAX lift potentiometer voltage)
• Display will show new settings
VACC”
• Press "OUT button
• Display will show software version
• Turn the key switch Off and remove the tester cord
from the control
• Plug the dash display harness into the "B" plug of
the control
• Lower truck to the ground and test drive truck

Section 5
Instrument Panel
1. DISPLAY
1.1 Display appearance
Dash Display
SM 765 Instrument Panel • 13-5-1

1.2 Name of section

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 6 7 8
9
10
05/8/10 [WED]
11
12
13
14
1. Battery discharge indicator 8. Error and check LED

2. Maximum speed limit icon (Turtle shaped) 9. Down arrow switch (Mode switch)
3. Date & Time 10. Up arrow switch (Enter switch)
4. Hourmeter & Speed 11. Left arrow switch (Turtle switch)
5. Message display & Travel direction icon 12. Right arrow switch (Travel mode switch)
6. Parking brake LED 13. Plus switch
7. Seat switch LED 14. Minus switch
13-5-2 • Instrument Panel SM 765

Seat switch: At start up this symbol displays Maximum speed limit icon (Turtle shaped)
along with an audio alarm for 3 times /4 sec-
onds. This display reminds you to fasten your The traveling speed of truck is limited to
seat belt. set speed.
The upper mark is slow speed operating
icon, and the figure shows the limited
max. speed. (In upper example, the lim-
ited max. speed is 2km/h or 2MPH)
Parking Brake: The symbol is displayed and "-
255" status code appears on the numeric dis-
play when parking brake is applied. Release Hourmeter & Speed
parking brake to operate truck. • It displays the accumulated oper-
ating hour and traveling speed of
truck.
Service Status: The following 5 codes are usu- • When the traveling speed is less
ally operator fault codes, and can be corrected than 0.5km/h, it displays the accu-
by as explained in "Section 5, Operating Proce- mulated operating hour.
dures." If you see any other codes displayed, • When the traveling speed is more
the truck needs to be serviced. than 0.5km/h, it displays the traveling speed.
• -01 Seat Switch Open

•-061, -065 ,-140, -203, -207 Overheat of Message display
motor and controller (Restart after The model name, POWER
cooling down) Normal
selection, travel direction, warn-
Error
• -66 Low Battery (truck will go into lift locking and error message are dis-
out when the dash display shows less Warning
BATTERY LOW played.
than 15%) • In normal operating condition:
• -77 Maintenance Hours (preset hour meter Model name/POWER/Travel direction
reading indicating that it is time to have • When several messages are simultaneously dis-
the truck serviced. Truck will reduce the played, it will be displayed in the order of Error,
top speed if desired) Warning and Normal condition.
• -79 Incorrect Start Up Sequence (SRO) • If many error conditions
23 : FUSE ERROR
• -217, -245 Wrong set battery 56 : FET SHORT are simultaneously
occurred, the priority 2
• -255 Parking Brake Switch Open Errors will be displayed.
(The priority means Error number)
Battery discharge indicator
It displays the battery discharge
condition of forklift truck. Travel direction icon
The one bar indicates 10% • It displays the traveling direction or angle of
Blue color
charging condition. steering wheel..
If the battery is charged more • The direction icon rotates in 10 degrees.
Red color than 20% (8 bars or more), blue (Total 36 icon)
LED is displayed, but it is less
than 20% (2 bars or less), red Error icon
LED is displayed. If it is less than 10% (1 bar), it will
flicker and buzzer sound. When error occurs this icon is displayed to dis-
tinguish the condition easily. When the error
message is displayed, this icon is simultane-
ously displayed.








3.2 Menu mode Chart
Menu
Parameter Description Min Max Base Adjust
No.
1 STATUS Status of analog signal on the truck
Battery voltage
1.1 BATT VOLTAGE (Master device profile˧ 0.0V 115.0V ACTUAL
Index˄2114˅,Sub-index˄0˅P
Accelerator output
1.2 ACCELERATOR (Master device profile˧ 0.0V 5.0V ACTUAL
Steer angle
1.3 STEER ANGLE (Master device profile˧ -127 ȋ 128 ȋ ACTUAL
Display operating hour
1.4 OPERATING HOUR (Master device profile˧ 0Hr 59999Hr ACTUAL
Index˄21F1˅,Sub-index˄0˅)
Display maintenance hour
1.5 MAINTENANCE HOUR (Master device profile˧ 25Hr 250Hr ACTUAL
Index˄20D3˅,Sub-index˄2˅)
2 SWITCH STATUS Status of switch input on the truck

Forward switch
2.1 FORWARD (Master device profile˧ OPEN CLOSE OPEN
Index˄212E˅,Sub-index˄0˅)
Reverse switch
2.2 REVERSE (Master device profile˧ OPEN CLOSE OPEN
Index˄212F˅,Sub-index˄0˅)
Parking brake switch
2.3 PARKING SWITCH (Master device profile˧ OPEN CLOSE OPEN
Index˄2148˅,Sub-index˄0˅)
Foot brake switch
2.4 FOOT BRAKE SWITCH (Master device profile˧ OPEN CLOSE OPEN
Seat switch
2.5 SEAT SWITCH (Master device profile˧ OPEN CLOSE OPEN
Hyd lift switch
2.6 LIFT SWITCH (Pump device profile˧ Index˄213F˅,Sub- OPEN CLOSE OPEN
index˄0˅)
Hyd tilt switch
2.7 TILT SWITCH (Pump device profile˧ Index˄21FC˅,Sub- OPEN CLOSE OPEN
index˄0˅)
Hyd AUX1 switch
2.8 AUX 1 SWITCH (Pump device profile˧ Index˄21FD˅,Sub- OPEN CLOSE OPEN
index˄0˅)
Hyd AUX2 switch
2.9 AUX 2 SWITCH (Pump device profile˧ Index˄21FE˅,Sub- OPEN CLOSE OPEN
index˄0˅)
(Master device profile˧
2.10 ACCEL ENABLE S/W OPEN CLOSE OPEN

Menu
No.
3 MODEL SETUP Set model name

3.1 GEX16/20s GEX16, GEX18, GEX20s GEX16 GEX20s GEX16
GEX20, GEX25, GEX30, GEX30s,
3.2 GEX20/32 GEX20 GEX32 GEX20
GEX30L, GEX32
3.3 GEX40/50 GEX40, GEX45, GEX50, GEX55 GEX40 GEX55 GEX40
3.4 GTX16/20s GTX16, GTX18, GTX20s GTX16 GTX20s GTX16
Fault storage(Clark code number, Error

4 ERROR HISTORY Message, times, temperature on controller,
hourmeter )
Display error codes in the MAST
4.1 MASTER ERROR
controller.
Display error codes in the MAST
4.1.1 MASTER ERROR
controller.
Reset command error codes in the MAST
4.1.2 MASTER ERROR RESET
controller.
Display error codes in the SLAVE
4.2 SLAVE ERROR
controller.
Display error codes in the SLAVE
4.2.1 SLAVE ERROR
controller.
Reset command error codes in the SLAVE
4.2.2 SLAVE ERROR RESET
controller.
Display error codes in the PUMP
4.3 PUMP ERROR
controller.
Display error codes in the PUMP
4.3.1 PUMP ERROR
controller.
Reset command error codes in the PUMP
4.3.2 PUMP ERROR RESET
controller.
5 PASSWORD Password management

5.2 PASSWORD LOCK Password LOCK LOCK UNLOCK LOCK
5.3 PASSWORD CHANGE Password change 00000 99999 10000
6 SETUP SETUP
6.1 T-PARAMETER Traction parameter change
6.1.1 ACCEL DELAY 0 9 3 +/-(Note #1)
6.1.2 RELEASE BRAKING 0 9 3 +/-(Note #1)
Index˄200B˅,Sub-index˄1˅)
6.1.3 INVERS BRAKING 0 9 6 +/-(Note #1)
Index˄200C˅,Sub-index˄1˅)
6.1.4 PEDAL BRAKING 0 9 7 +/-(Note #1)
Index˄200D˅,Sub-index˄1˅)
6.1.5 SPEED LIMIT BRK 0 9 0 +/-(Note #1)
6.1.6 BRAKE CUTBACK 0 9 5 +/-(Note #1)
Index˄201C˅,Sub-index˄1˅)

Menu
No.
6.1.7 CURVE BRAKING 0 9 5 +/-(Note #1)
6.1.8 MAX SPEED FORW 0 200hz 140hz +/-(Note #1)
6.1.9 MAX SPEED BACK 0 200hz 140hz +/-(Note #1)
6.1.10 CUTBACK SPEED 1 0 9 9 +/-(Note #1)
6.1.11 CURVE CUTBACK 0 100% 20% +/-(Note #1)
Index˄201D˅,Sub-index˄1˅)
6.1.12 CURVE CUTBACK #1 0 9 5 +/-(Note #1)
Index˄20C4˅,Sub-index˄1˅)
6.1.13 FREQUENCY CREEP 0 9 0 +/-(Note #1)
6.1.14 MAX CURRENT 0 9 9 +/-(Note #1)
6.1.15 AUXILIARY TIME 0 9 3 +/-(Note #1)
6.1.16 SEAT MICRO DELAY 0 9 5 +/-(Note #1)
6.1.17 ACC. SMOOTH 0 9 6 +/-(Note #1)
6.1.18 INV. SMOOTH 0 9 0 +/-(Note #1)
6.1.19 STOP SMOOTH 0 9 6 +/-(Note #1)
6.2 T-OPTION
6.2.1 STOP ON RAMP 0 1 0: OFF +/-(Note #1)
Index˄20E9˅,Sub-index˄1˅)
6.2.2 STEER TABLE 0 1 0: OPT #1 +/-(Note #1)
6.3 T-ADJUSTMENT
6.3.1 SET BATTERY TYPE 0 5 1 : 36V +/-(Note #1)
(Master device profile˧ 0x 255x 210x
6.3.2 MAX STEER RIGHT +/-(Note #2)
Index˄20F9˅,Sub-index˄2˅) (5V/255) (5V/255) (5V/255)
6.3.3 MAX STEER LEFT +/-(Note #2)
Index˄20F3˅,Sub-index˄2˅) (5V/255) (5V/255) (5V/255)
6.3.4 SET STEER O-POS +/-(Note #2)
Index˄2098˅,Sub-index˄2˅) (5V/255) (5V/255) (5V/255)
6.3.5 SET STEER RIGHT 0ȋ 127 ȋ 90 ȋ +/-(Note #1)
6.3.6 SET STEER LEFT 0ȋ 127 ȋ 90 ȋ +/-(Note #1)
6.3.7 THROTTLE 0 ZONE 0 9 1 +/-(Note #1)
Index˄20DD˅,Sub-index˄1˅)

Menu
No.
6.3.8 THROTTLE X POINT 0 9 0 +/-(Note #1)
6.3.9 THROTTLE Y POINT 0 9 1 +/-(Note #1)
6.3.10 MAINTEN RESET 0 1 0: OFF +/-(Note #1)
6.3.11 MAINTENANCE 0 2 0: NONE +/-(Note #1)
6.3.12 MAINTENANCE TIME 0 5 5 +/-(Note #1)
6.3.13 1 X 10000 HOUR 0 2 0 +/-(Note #1)
Index˄20CE˅,Sub-index˄1˅)
6.3.14 1 X 1000 HOUR 0 9 0 +/-(Note #1)
Index˄20CF˅,Sub-index˄1˅)
6.3.15 1 X 100 HOUR 0 9 0 +/-(Note #1)
6.3.16 1 X 10 HOUR 0 9 0 +/-(Note #1)
6.3.17 1 X 1 HOUR 0 9 0 +/-(Note #1)
6.4 T-SLAVE
(Slave device profile˧ Index˄20F2˅,Sub-
6.4.1 AUX OUTPUT VOLT 0 9 +/-(Note #1)
index˄1˅)
6.5 P-PARAMETER
(Pump device profile˧ Index˄2000˅,Sub-
6.5.1 ACCEL DELAY 0 9 0 +/-(Note #1)
index˄1˅)
6.5.2 DECELER DELAY 0 9 0 +/-(Note #1)
index˄1˅)
(Pump device profile˧
6.5.3 ACC. DELAY TILT 0 9 6 +/-(Note #1)
Index˄20DB˅,Sub-index˄1˅)
6.5.4 DEC. DELAY TILT 0 9 0 +/-(Note #1)
Index˄20DC˅,Sub-index˄1˅)
(Pump device profile˧ Index˄20D7˅,Sub-
6.5.5 AUX1 ACC. DELAY 0 9 6 +/-(Note #1)
index˄1˅)
6.5.6 AUX1 DEC. DELAY 0 9 0 +/-(Note #1)
index˄1˅)
6.5.7 AUX2 ACC. DELAY 0 9 6 +/-(Note #1)
index˄1˅)
6.5.8 AUX2 DEC. DELAY 0 9 0 +/-(Note #1)
Index˄20DA˅,Sub-index˄1˅)
(Pump device profile˧ Index˄20F6˅,Sub-
6.5.9 MAX SPEED UP 0hz 200hz 125hz +/-(Note #1)
index˄1˅)
(Pump device profile˧ Index˄20E7˅,Sub-
6.5.10 MIN SPEED UP 0 9 3 +/-(Note #1)
index˄1˅)
6.5.11 1ST SPEED FINE 0hz 200hz 30hz +/-(Note #1)
index˄1˅)

Menu
No.
6.5.12 2ND SPEED FINE 0hz 200hz 30hz +/-(Note #1)
index˄1˅)
6.5.13 3RD SPEED FINE 0hz 200hz 81hz +/-(Note #1)
index˄1˅)
6.5.14 HYD SPEED FINE 0hz 200hz 16hz +/-(Note #1)
index˄1˅)
(Pump device profile˧ Index˄203F˅,Sub-
6.5.15 MAX CURRENT 0 9 9 +/-(Note #1)
index˄1˅)
6.5.16 AUXILIARY TIME 0 9 2 +/-(Note #1)
index˄1˅)
6.6 P-OPTION
(Pump device profile˧ Index˄20DF˅,Sub-
6.6.1 THERM PROTECTION 0 1 0: OFF +/-(Note #1)
index˄1˅)
6.6.2 HOUR METER TRUCK 0 1 1: ON +/-(Note #1)
index˄1˅)
6.7 P-ADJUSTMENT
6.7.1 SET BATTERY TYPE 0 5 1 : 36V +/-(Note #1)
index˄1˅)
(Pump device profile˧ Index˄20F0˅,Sub-
6.7.2 THROTTLE 0 ZONE 0 9 1 +/-(Note #1)
index˄1˅)
(Pump device profile˧ Index˄20EE˅,Sub-
6.7.3 THROTTLE X POINT 0 9 5 +/-(Note #1)
index˄1˅)
(Pump device profile˧ Index˄20EF˅,Sub-
6.7.4 THROTTLE Y POINT 0 9 3 +/-(Note #1)
index˄1˅)
6.8 OPTION
Set command the SLOW SPEED(Turtle 3Km/h 15Km/h 10Km/h
6.8.1 SLOW SPEED +/-
mode case). 1MPH 10MPH 6MPH
Display software version in the MAST
6.8.2 DISPLAY VERSION V1.00 ~
controller.
6.8.3 SPEED UNIT Display speed unit (Km/h or MPH). Km/h MPH Km/h +/-
7 TIME SETUP
7.1 YEAR 2000 2099 +/-
7.2 MONTH 1 12 +/-
7.3 DATE 1 31 +/-
7.4 WEEK MON SUN +/-
7.5 HOUR 0 23 +/-
7.6 MINUTE 0 59 +/-
7.7 AM/PM AM PM +/-




1.3 MODEL Model name Min Max Base Adjust

3.2 GEX20/32 GEX20, GEX25, GEX30, GEX20 GEX32 GEX20
GEX30s, GEX30L, GEX32






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 765 Group 16 ELECTRICAL MOTORS,

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

Frame Size: 240 mm (9.449in) diameter Frame Size: 200 mm (7.874 in) diameter
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: 149 mm (5.866 in)
Rotor inside Diameter: 65 mm (2.559 in) Rotor outside Diameter: 124 mm (4.882 in)
Number of Slots: 44 Rotor inside Diameter: 46 mm (1.811 in)
Number of Slots: 48
Stator outside Diameter: 240 mm (9.449in)
Stator inside Diameter: 150 mm (5.905 in) Stator outside Diameter: 200 mm (7.874 in)
Number of Slots: 36 Stator inside Diameter: 125 mm (4.921 in)
Number of Slots: 36
Nominal Air Gap: 0.5 mm (.0196 in)
Nominal Battery Voltage: 80V Nominal Air Gap: 0.4 mm (.0157 in)
Maximum Battery Voltage: 84.5V Nominal Battery Voltage: 80V
Nominal Speed: 1800 RPM Maximum Battery Voltage: 84.5V
Stall Current: 275A Nominal Speed: 2160 RPM
Insulation: Class F Stall Current: 450A
Winding: Delta Insulation: Class F
Encoder: 64 Pulses / Rev Winding: Delta
Encoder: 64 Pulses / Rev
SM 765 Motor Specifications and Descriptions • 16-1-1

Description and Location Should it sense that the motor is approaching the tempera-
ture limit, the control will cutback motor current until the
The truck has three electric AC motors: temperature decreases. Since it is cutting back current and
• Two identical traction motors not voltage, the top end speed will not be affected, unless
the loads are close to capacity.
• One main hydraulic/power steering pump motor.
Drive motors
The two drive motors are three-phase AC motors with
class F insulation. These motors do not use brushes and
the motors are totally enclosed, minimizing the service
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. There is outside speed sensor that is control to
motor feed back as ND-shield. 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. It is also a brushless motor and totally
enclosed. 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 during a
PM. There is outside speed sensor that is control to motor
feed back as ND-shield. 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.
The external connections are easily accessible from the
top of the motor where they are protected from external
damage.
The pump 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).
16-1-2 • Motor Specifications and Descriptions SM 765

Section 2
Drive Motor Overhaul
Inspection Procedure 6. Remove the bolts securing the lower battery plate
and tilt the plate back against the rear battery plate.
Before performing these service procedures:
7. Remove all electrical cables from the motor. Tag
• Park truck safely. cable terminals to aid in reinstallation. Position
• Fully lower the upright. cables out of the way of motor removal.
• Apply the park brake 8. Remove bolts holding motor to axle. Have drain pan
• Turn the key switch OFF. in place to catch axle oil.
• Disconnect battery from truck receptacle. 9. Lower motor onto floor or through the top using a
• Discharge capacitors by connecting a 200 ohm 10 suitable chain hoist or come-a-long.
watt resistor between the positive and negative 10. Reinstall in reverse order. Use new O-ring, coated
input post of the controller for 10 seconds. with drive axle fluid.
11. Spline of the drive axle and motor should be coated
Motor Cleanliness with grease selected one among next page list.
Electric motors should be kept clean at all times to prevent (RH&LH)
shorting, minimize wear, and optimize cooling. 12. Check and fill drive axle oil as described in Group
• Wipe off all dust, dirt, oil, water, etc., from outer 20.
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
• Air-clean (blow off) motors using clean, dry while turning the upper fastening nut with
(moisture-free) compressed air at 207 kPa (30 psi) another wrench.
maximum 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
motor damage occurs.
Drive Motor Removal and Installation

1. Remove the battery from the truck.
2. Tilt the steering column fully forward and remove
the floor plate.
3. Remove all electrical cables from the drive motor.
Tag cable terminals to aid in reinstallation and posi-
tion the cable out of the way.
4. Remove the mast from the truck.
5. Remove the drive axle from the truck.
SM 765 Drive Motor Overhaul • 16-2-1

Grease Specifications
1) Kluberplex BEM34-132(Kluber Lubrication)(P/No:8091780)
2) Optimol Paste White T(Castrol)
3) Molykote G-N Plus Paste(Dow Corning)
4) Molykote G4700(Dow Corning)
5) Kluberpaste 46 MR 401(Kluber Lubrication)
6) Ceritol Paster PT1(Carl Bechem GmbH)
7) Berulub FGH 2 EP(Carl Bechem GmbH)
The four products of number 1),2),3),4) should be used primarily.

No standard multi-purpose grease is used at any time.
Coating Amount : 2~4g
Torque to 70 - 75 N-M
(51 - 55 lb/ft)
Coat O-Ring with Transmission

Fluid Prior to Installation (SI-47075)

Ball Bearings Speed Sensor

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

Replacing Speed sensor
• Turn key OFF.

• Set park brake.
• Disconnect battery.
• Remove the socket bolt on the speed sensor.
• Remove the speed sensor from motor.
Speed sensor Reassembly

• Reinstall in reverse order
16-2-4 • Drive Motor Overhaul SM 765

Section 3
Pump Motor Overhaul
Inspection Procedure 3. Have drain pan in place to catch axle oil. Remove
the hydraulic pump from the motor (see group 29 for
Before performing these service procedures: instructions).
• Park truck safely. IMPORTANT
• Fully lower the upright. The pump motor assembly weighs over 110
• Apply the park brake pounds. A suitable lifting device may be
• Turn the key switch OFF. needed to help hold and then raise the motor
from the truck.
• Disconnect battery from truck receptacle.
• Discharge capacitors by connecting a 200 ohm 10 4. Remove the 4 nuts securing the pump motor mount-
watt resistor between the positive and negative ing plate to the frame bottom.
input post of the controller for 10 seconds.
5. Lift the motor assembly and place it on a bench for
service.
Motor Cleanliness 6. Reinstall in reverse order.
Electric motors should be kept clean at all times to prevent
NOTE
shorting, minimize wear, and optimize cooling.
When removing or installing cables to motor,
• Wipe off all dust, dirt, oil, water, etc., from outer hold the terminal's lower nut with a wrench
surface of motor. while turning the upper fastening nut with
• Remove any debris from cooling fan air vents and another wrench.
around motor frame to prevent overheating.
• Air-clean (blow off) motors using clean, dry
(moisture-free) compressed air at 207 kPa (30 psi)
maximum 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
motor damage occurs.
Pump Motor Removal and Installation

1. Tilt the steering column fully forward and remove
the floor plate.
2. Disconnect battery and remove all electrical cables
from the motor. Tag cable terminals to aid in rein-
stallation. Position cables out of the way of motor
removal.
Torque to 40 - 45 N.m
(29.5 - 33.2 Lbs.ft)
SM 765 Pump Motor Overhaul • 16-3-1

NOTE Motor Reassembly

• Press new encoder bearing on to rotor at the inner
ring with a steady pressure. The inner ring of the
Replacing Encoder Bearing bearing must to be pressed against the shaft shoul-
der.
In general the encoder bearing should be replaced every
time the motor is disassembled. NOTE
The encoder bearing is very sensitive to static
To replace the encoder bearing: electricity. If you are going to be working on
the encoder bearing you should have a
• Turn key OFF. ground strap on to insure that the encoder
• Set park brake. bearing does not get damaged.
• Disconnect battery.
• Insure that the encoder cables are installed cor-
• Remove the pump motor (see page 2 of this sec- rectly and do not get pinched or touch the rotor.
tion).
• Install the end housing carefully onto the encoder
• Remove motor bolts. bearing and press it on with a steady pressure. The
• Loosen the silicone sealer around the cables at the lead from the bearing must located in the notch in
end housing. the housing frame.
• Remove the non-drive end housing from motor. • Install the rotor into the stator housing.
• Remove rotor from motor. • Tie strap the encoder bearing lead to one of the
• Use a gear puller to remove encoder bearing from motor leads to prevent it from being pulled and
the rotor. contacting the rotor.
• Install the drive end onto the motor making sure
that the terminal block mounting bracket is aligned
with the slots in both end frames.
• Install the motor through bolts and tighten.
• Fill the void around the drive motor leads with Sil-
icone # 1758629.
• Install the fan and snap ring onto the shaft.
16-3-2 • Pump Motor Overhaul SM 765

Pump Motor Exploded View
Ball Bearings Speed sensor

The Speed sensor is used to communicate the motor speed
to the controller.
Both ball bearings are maintenance free. If it becomes
necessary to remove the bearings to repair the motor, they NOTE
should be replaced. In any case the seals (shaft oil seal and The Speed sensor is very sensitive to static
O-ring) must be replaced. electricity. If you are going to be working on
In general bearings should be replaced at approximately the Speed sensor you should have a ground
10,000 operating hours. strap on to insure that the Speed sensor does
not get damaged.
SM 765 Pump Motor Overhaul • 16-3-3

GROUP 17 ELECTRICAL CONTACTORS
GROUP 17
ELECTRICAL CONTACTORS
Contactors Specifications and Overhaul .......... Section 1
SM 765 Group 17 ELECTRICAL CONTACTORS,

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

Standard Truck: One Drive Line Contactor, one Pump 1. Disconnect power cables from contactors. Move
Line Contactor. Mounting Fastener Torque: 8-10 N.m power cables out of the way.
(71-88 in-lb).
2. Disconnect connecting bus bars from contacts.
3. Disconnect wiring from contactor coil terminals.
4. Remove mounting bolts and contactor assembly
from truck.
5. Reverse procedure for installation.
Line Contactor Line Contactor
[ELH Option Truck] [Stand Truck]
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 765 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
1. 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.
2. 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
3. To replace tips on the contactors, loosen and remove
two cover mounting screws attaching it to coil frame. Top Cover
(Observe position of positive (+) marking on cover).
Be careful not to lose return spring fitted under
cover.
Remove locknut and lockwasher from contact studs Fixed Contact
or
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. M oving Contact
or
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. Co ilAssembly
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 (+)
markings located correctly. Use a bar or rod
to move contacts. Be sure movement is free of
17-1-2 • Contactors Specifications and Overhaul SM 765

GROUP 19 MOTOR CONTROLS
GROUP 19
MOTOR CONTROLS
Description ....................................................... Section 1
Control Programming .......................................Section 2
Control troubleshooting .................................. Section 3
GTX Factory Control Settings ......................... Section 4
SM 765 Group 19 MOTOR CONTROLS,

Group 19, Motor Controls
Section 1
Description
The CLARK GEX uses a Dual AC controller to control both drive motors and a single AC controller
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 a valve provide unique inputs to the control. The speed of
single cover. The right 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 power
The left portion of the control is referred to as the "mas- losses. When the key is in the "ON" position and a direc-
ter" control and operates the right drive motor. The con- tion is selected, the control will operate the motor at a
trol receives inputs from the speed control (accelerator) fixed rpm (roughly 500~600 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 speed sensor, motor input from the lift potentiometer, tilt or aux switches, then
thermistors and other miscellaneous switches. The control it will ramp up the motor speed to match the desired
is 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 thermal protection and the motor has a speed sen-
speed of the vehicle is controlled by the accelerator con- sor(external sensor) 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 GEX 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 speed sensor(external sensor)
which allow for precise speed regulation. Every motor
also has a built-in thermistor which constantly monitors
the winding temperature and reports this information to
the control. Should it sense that the motor is approaching
the temperature limit, the control will cutback motor cur-
rent 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. 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 765 Description • 19-1-1

Operational Features apply the service brake. See parameter-programming

chart later in this manual.
Creep Speed
Speed Limit
Parameters THROTTLE X POINT and THROTTLE Y
POINT control how the truck reacts when you first push Parameters MAX SPEED FORWARD and MAX SPEED
on the accelerator. Increasing THROTTLE X POINT will BACKWARD allow for the adjustment maximum speed
give you more pedal stroke with less speed at the begin- that the vehicle can travel in each direction. The maxi-
ning of the stroke. Increasing THROTTLE Y POINT mum speed is adjustable from 0 Hz to 143 Hz in 1 Hz
will give more speed with less pedal stroke. See Chart increments.
below.
SPEED f(Hz) Example: 143 Hz = approx. 11.3 mph empty

78 Hz = approx. 6.2 mph empty
MAX SPEED
Stop on Ramp
When this feature is ON it lets the vehicle electrically hold
on an incline. Time is adjustable with AUXILIARY
TIME parameter.
TROTTLE Y
POINT
When this feature is OFF the vehicle uses regen braking to
FREQ. CREEP
V
stop on an incline. Once the vehicle has stopped it will
VACC TROTTLE X VACC
hold for 1 second then continue to creep down the incline
TROTTLE 0
MIN ZONE POINT MAX at approx. 1 mph. The vehicle can continue up the ramp at
any time without hesitation.
Control acceleration Steering Time Delay

Parameter ACCELERATION DELAY allows the adjust- This feature uses the AUXILIARY TIME in the pump
ment of the time it takes to accelerate a stop to full speed. control to delay turn off time when the directional lever is
See parameter-programming chart later in this manual. returned to neutral. This parameter is adjustable from 0 to
20 seconds of delay.
Regenerative braking
Static Return to Off (SRO)
Parameter INVERSION BRAKING allows for the adjust-
ment of the amount of time that it takes to stop the vehicle This feature requires the operator to return the directional
when changing from one direction to the other. See lever to the neutral position anytime they leave the vehicle
parameter-programming chart later in this manual. and return. If the parking brake, seat switch or key switch
is opened, the control shuts down and can not be restarted
Accelerator Pedal Position Plug braking (The dash display will show a -79 fault code) until the
directional lever is returned to neutral. A time delay of
Parameter RELEASE BRAKING allows for the adjust- approximately 2 seconds is built in to allow momentary
ment of the amount of time that it takes to stop the vehicle opening of the parking brake or seat switch.
when you remove your foot from the accelerator. See
parameter-programming chart later in this manual.
Thermal Protector
Brake Pedal Regen Braking Each controller has an internal thermal protector on the
heat sink. The controllers will reduce the output current
Parameter PEDAL BRAKING allows for the adjustments to 50% of the set current when the heat sink temperature
of the amount of regen braking you receive when you reaches 75°C. The dash will display the following codes
19-1-2 • Description SM 765

depending on which controller in over temperature, (Mas- • Monitor or adjust the control functions
ter -61 code, Slave -140 code, and Pump -203 code). • Use as a tester to monitor input and output infor-
mation.
Standard Fault Codes
The control has over 75 fault codes assist the service tech- NOTE
nicians and operators in the trouble shooting the vehicle. The Handset instructions and Troubleshoot-
If mis-operation of the vehicle occurs, a fault code will be ing can be found in Group 19, Section 3 of
displayed on the Dash Display of the vehicle, or by plug- this manual.
ging the handset into the "B: plug of the master controller
and reading the fault code. Protection Features
With the fault code number, follow the procedures out-
lined in Group 19, Section 03 ,"Fault Codes", section to Reverse Battery Polarity:
determine the problem and a solution.
The MAIN CONTACTOR is there to protect the control-
Stored Fault Codes ler against reverse battery polarity and for safety reasons.
This feature records the last 5 fault codes in controller. Connection Errors:
The last 5 fault codes can be accessed through the alarm
log using a handset, or a laptop computer with the PcCon- All inputs are protected against connection errors.
sole software and adapter cable. The faults are stored
with the hour meter reading when the fault first happened,
the number of time the fault has happened, and the tem-
Thermal Protection:
perature the first time the fault happened. If the controller temperature exceeds 80° C, the maximum
current is reduced in proportion to the thermal increase.
Hour Meter Readings The temperature can never exceed 100° C.
When the traveling speed is less than 0.5km/h, it displays

the accumulated operating hour.
External Agents:
The controller is protected against dust and the spray of
Battery Discharge Indication (BDI) liquid to the degree of protection meeting IP54.
Provides accurate battery state of charge information to

the vehicle operator, Features and Functions: Protection Against Uncontrolled Movement:
• Displays 100 to 0 percent charge in 10% incre- The main contactor will not close if:
ments. The power unit is not functioning
• Lift Circuit is disabled at 10% discharge The controller is not functioning perfectly.
The output of the accelerator does not fall
Handset below the minimum voltage value stored, with
1V added
This is a multifunctional tool used with the AC controls. Running microswitch is in closed position.
The handset (Clark part #8033636) has a display and a
key board for data entry. Low Battery Charge:
Features and functions: When the battery charge is low, -66 Code, the maximum
current is reduced to half the maximum current pro-
• Monitor existing fault codes for both traction and grammed.
pump controls.
• Monitor hour meter readings on traction and pump
controls.

Protection against accidental startup: NPOT (C20) is the accelerator negative supply. This out-
put is feed back to the microprocessor A/D converter to
A precise sequence of operations is necessary before the test the continuity of the accelerator unit circuit (test of
control will start (SRO). Startup cannot occur if the pot wire disconnection). The procedure for automatic
sequence is not followed completely. (Request for drive, potentiometer signal acquisition is carried out using the
must be made after closing the key switch). handset. This enables adjustment of the minimum and
maximum useful signal level (PROGRAM VACC func-
Capacitor Charge: tion), in either direction. This function is unique when it is
necessary to compensate for asymmetry with the mechan-
The controllers can hold an electrical charge for several ical elements associated with the Potentiometer. Espe-
seconds, due to the power capacitor bank. A discharge cially relating to minimum level. The sequence of
resistance is built in the controller, which ensures capaci- procedure is described later in this manual.
tor discharge to a safe voltage in about one minute, after
the key is switched off. If it is necessary to work on the
Analog control unit
controller before that time, discharge the capacitors as
described below. Connection C25 (PTHERMR) and C24 (NTHERMR) are
used for the right motor thermal sensor. Connection C35
Discharging Controller Capacitors (PTHERML) and C34 (NTHERML) are used for the Left
motor thermal sensor. Sensors are analog.
It is necessary to discharge the capacitors before you work
on the controller. To discharge the capacitors, disconnect
Speed Feedback
the battery at the battery receptacle, connect a 200 ohm 10
watt resistor between the positive and negative input post The traction motors control is based upon the motor speed
of the controller for 10 seconds. feed back. The speed transducer is an incremental
encoder, with two phases shifted at 90°. The encoder is
Communications with CLARK Dash: supplied with +12V from the control panel.
The traction controller communicates by CANBUS to

Steer Angle Transducer
CLARK dash. The dash shows Battery State of charge,
Hourmeter and fault code if a fault occurs. Angular position of steered wheels in transduced to an
electric information (voltage) by means of a potentiome-
Microswitches: ter, with following characteristics:
Positive supply: 12V±2V
The micro switches must have a contact resistance lower
Voltage potentiometer : 1V~9V
than 0.1ohm and a leakage current lower than 100 micro
Netural : 5V
amps.
Potentiometer is installed in a way that in the
When full load is connected, the voltage between the key zero position (straight wheels), pot output volt-
switch contacts must be lower than 0.1 volt. age is in the middle of the electric range corre-
sponding to a full left-to-right transition of
The micro switches send a voltage signal to the micropro-
steer wheels;
cessor when a function is requested (for example: running
The potentiometer is installed in a way that,
request) is made.
when the truck turns right, pot voltage
increases;
Accelerator Unit: Use "SET STEER MIN" and "SET STEER
MAX" functions of the handset to record the
The accelerator unit consists of a potentiometer in 3 wire extremes (minimum and maximum) of the
configuration. potentiometer range;
CPOT (C21) signal. Use "SET STEER 0-POS" function of the
handset to record the pot output when the steer
EN ACC (C8) is the accelerator enable. It is fed with wheels are straight.
+Batt from the key switch.

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 - Dual AC2
A1 CAN H High level CANBUS

A2 CANT H CANBUS termination output, 120 ohm internally connected to CAN_H. Connect to
CAN_L_OUT to insert termination.
A3 CAN_POS Positive of CAN circuit; to be used in case of optoisolated CANBUS
A4 CAN_L_OUT Low level CANBUS: to be used as repetition for CAN_L line or 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

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
+BTF Positive of battery before power fuse,
must be connected to positive cable com-
ing from line contactor.
Um: Vm; Wm Connection bars for the three phases of
the right motor; follow this sequence and
the indication on the motor.
Us, Vs, Ws Connection bars for the three phases of
the left motor; follow this sequence and
the indication on the motor.

Description of Connections - Hydraulic AC3
A1 +12V (+5V) Positive of encoder power supply.

A2 ENC GND Negative of encoder power supply.
A3 PPOT Lift potentiometer positive: 10 V output; keep load > 1 k.
A4 4 TH Input for fourth speed request; it is active HIGH.
A5 LIFT ENABLE Input for potentiometer lifting enable input; it is active HIGH.
A6 1 ST Input for first speed request; it is active HIGH.
A7 DIG IN. This is a digital input, free for customer request.
A8 3 RD Input for third speed request; it is active HIGH.
A9 2 ND Input for second speed request; it is active HIGH.
A10 HYDRO Input for hydraulic steering request. Active high.
A11 SR Speed reduction input. Active low (switch opened).
A12 SAFETY If not connected to -Batt the MC coil power output will be disabled. It can also be used as a
general purpose input.
A13 ENC A Phase A of encoder.
A14 ENC B Phase B of encoder.
A15 NPOT Negative of lift potentiometer, tested for wire disconnection diagnosis.
A16 CPOT Lift potentiometer wiper.
A17 CAN T CAN termination; connect to CAN H (A18) to insert can termination resistance.
A18 CAN H High level CAN-BUS voltage I/O.
A19 CAN L Low level CAN-BUS voltage I/O.
A20 NPOT-AUX -Batt.
A21 CPOT-AUX Free analog input (used for auxiliary potentiometer).
A22 ENC A* Phase A inverted of encoder (encoder with differential output).
A23 ENC B* Phase B inverted of encoder (encoder with differential output).
A24 -BATT -Batt.
A25 MOT TH Input for motor temperature sensor.
A26 NAUX This output can be used to drive the main contactor coil (single pump configuration) or to drive
an auxiliary load (combi configuration).

A27 PAUX Positive of the auxiliary output.

A28 NHYDRO Output for driving an hydraulic steering contactor; it drives the load to -Batt.
Maximum current: 3 A.
A29 PHYDRO Positive for the hydraulic steering contactor.
A30 CM Common of LIFT ENABLE / 1 ST / 2 ND / 3 RD / 4 TH /HYDRO / SR microswitches.
A31 MODE This input allows the customer to select the software for traction or lifting application.
Configuration:
MODE: Open (not connected) Traction inverter
MODE: Close (connected with A35) Pump inverter
A32 PPOT-AUX Auxiliary potentiometer positive: 10 V output; keep load > 1 k.
A33 KEY Connected to the power supply through a microswitch (CH) with a 10 A fuse in series.
A34 -BATT -Batt.
A35 -BATT -Batt.
B1 PCLRXD Positive serial reception.

B2 NCLRXD Negative serial reception.
B3 PCLTXD Positive serial transmission.
B4 NCLTXD Negative serial transmission.
B5 GND Negative console power supply.
B6 +12 Positive console power supply.
B7 FLASH It must be connected to B8 for the Flash memory programming.
B8 FLASH It must be connected to B7 for the Flash memory programming.

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 3.07, 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 765 Control Programming • 19-2-1

The Handset display will than show a screen simular to the one shown below.
DA2M2BGCPE CK 0.13
80V 280A 00000
As shown in this Example; the “M” in DA2M2BGCPE, 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 0.13 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 GEX Factory Control Settings
19-2-2 • Control Programming SM 765

Gex Handset
Master Control Configuration
DA2M2BGCPE CK 0.13 DA2M2BGCPE CK 0.13

DISPLAY DISPLAY
80V 280A 00000 80V 280A 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 Roll Aux Input #1 Exclusive Hyd / Option #1 / Option #2
Brake Cutback 0-9 Up Pedal Braking Analog / Digital / None
Roll Max Speed Forward Hz Steer Table Option #1 / Option #2
Up Max Speed Reverse Hz
Curve Cutback %
Enter
Frequency Creep Hz Adjustments Set Pot Brake Minimum ... V
Maximum Current 0-9 Set Pot Brake Max ... V
Auxilary Time Sec Set Battery Type 80V
Seat Micro Delay Sec Adjust Battery ... V
Acc Smooth Sec Max Steer Right ... V
Inv Smooth Sec Max Steer Left ... V
Stop Smooth Hz Set Steer 0-Position ... V
Idle Time Min Set Steer Right ...”
Set Steer Left ...”
Throttle 0 Zone ...%
Enter Throttle Y Zone ...%
Tester Motor Voltage %
Throttle X Zone ...%
Frequency Hz
Encoder Hz Adjustment #04 ”C
Slip Value Hz Adjustment #01 (Display) 0-9
Current RMS A Adjustment #02 (Shut Down) 0-9
Main Contactor Voltage ... V
Temperature ”C
Roll ”C Aux Output Voltage ... V
Temperature #1
Up Temperature #2 ”C Maintenance Done On/Off
Accelerator V Maintenance None / Opt #1 / Opt #2
Steer Angle ...” 1 X 10,000 Hours 0-6
Brake Pedal Pot % 1 X 1,000 Hours 0-9
Inner Wheel Cutback % 1 X 100 Hours 0-9
Seat Switch On/Off 1 X 10 Hours 0-9
Forward Switch V 1 X 100 Hours 0-9
Reverse Switch V
Enable Switch On/Off
Brake Switch On/Off
Cutback Switch On/Off
Exclusive Hydraulics On/Off
Hand Brake On/Off
Voltage Booster %
Battery Voltage V
Battery Charge %
Save
Parameter
Roll
Up
Restore
Parameter
Roll
Up
Enter
Alarms Code, h, N”, ”C
Roll
Up
Program Enter
VACC VACC Settings Min/Max
Roll
Up
Enter Not Available
Motor Data

Master Control - "Dualac2 Power 80V"

SUBMENU "SET OPTIONS"
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 th programmed value.
OFF: the battery discharge level is carried out but no fault is signaled.
3. HYDRO ON
ON/OFF 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.
8. MODE SELEC- Used to set up the working mode of truck. (0=Economy, 1=Normal, 2=Power, 3=Turtle mode)
TION

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.
16. ADJUSTMENT #02 Adjust the lower level of the battery discharge table.
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 C26).
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. FREQUENCY CREEP: Minimum speed when the forward or reverse switch is closed, but the accelerator
(Do Not Change) is in a minimum position.
14. MAXIMUM CURRENT: Changes the maximum current of the controller
(Do Not Change)
15. AUXILIARY TIME: Determines the time that the truck will hold on a ramp if the "stop on ramp" option
(Do Not Change) is ON.
16. SEAT MICRO DELAY: Used to set up the Delay value to open the seat switch.
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 ACCELERA-
TION 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.
20. IDLE TIME Sets the main line Contactor open time.

PARAMETERS PROGRAM LEVEL

Unit 0 1 2 3 4 5 6 7 8 9
Acceleration Delay (*) Sec. 1 1.5 1.8 2.0 2.5 3 3.5 4 4.5 5
Release Braking (**) Sec. 25 20 18 15 10 8 6 4 3 2
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
Max speed Forw Hz 0 ~ 200
Max speed Back Hz 0 ~ 200
Dual
Cutback Speed % 10 20 30 40 50 60 70 80 90 100
AC2
PW(8 Cutback Speed 2 % 0 ~ 100
0V) Curve Cutback % 0 ~ 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 47 53 59 65 71 76 82 88 94 100
Auxiliary Time Sec. 0 1.5 3.0 4.5 6.0 7.5 9.0 10.5 12 15
Seat Micro Delay Sec. 2.0 2.1 2.3 2.4 2.6 2.8 2.9 3.1 3.3 3.5
Acc. Smooth Sec. 1.0 1.2 1.5 1.7 2.0 2.2 2.5 2.7 3.0 3.5
Inv. Smooth Sec. 1.0 1.2 1.5 1.7 2.0 2.2 2.5 2.7 3.0 3.5
Stop Smooth Hz 5 7 10 12 15 17 20 22 25 27
Idle time Min 1 2 3 4 6 8 10 12 15 20
(***)
*)The acceleration time shown is the time from 0 Hz to 100 Hz. This is theGideal 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.
(***)(Always closed).
PARAMETERS SPEED EMPTY MPH

MPH 1 2 3 4 5 6 7 8 9 10 11.3
MAX SPEED FORWARD HZ 13 26 38 51 63 76 88 101 114 126 143
MAX SPEED REVERSE HZ 13 26 38 51 63 76 88 101 114 126 143
NOTE
Maximum speed for the GEX20/30 can not exceed 143 Hz.
Maximum speeds are adjustable from 0 Hz to 143 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)

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 Power 80V"
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
CUTBACK: words, 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 The level of the Reverse direction digital input BW.
SWITCH: ON /+BV = input active, switch closed.

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 Power (80V)"
Submenu "Adjustments"
1. SET BATTERY TYPE: Selects nominal battery voltage
2. ADJUST BATTERY: Fine adjustment of the battery voltage measured by the controller.
GEX Handset
Slave Control Configuration
DISPLAY DM2S2BGCPE CK 0.13

80V 280A 00000 DISPLAY DM2S2BGCPE CK 0.13
80V 280A 00000
KEYBOARD KEYBOARD
HEADING
Enter
Main Menu Set Model Connected to 4 (Slave) (3 = Master, 5 = Pump)
Roll
Parameter Enter Up
Not Available
Change Enter
Set Options Not Available
Roll Roll
Up Up
Enter
Enter Adjustments Set Battery Type 48/72/80/96
Adjust Battery
Frequency Hz
Aux Output Voltage
Encoder Hz
Slip Value Hz
Current RMS A
Roll Temperature
Up Seat Switch On/Off
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
Program Enter
VACC Settings Min/Max
VACC
Roll
Up
Enter
Motor Data Not Available
See Group 19, Section 4 for GEX Factory Control Settings

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 Power 80V"
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 This is the booster voltage supplied to the motor in load condition; It is expressed in a
BOOSTER: percentage of the full voltage.
12) BATTERY VOLT- Level of the battery voltage measured at the input of the key switch.
AGE:

PUMP CONTROL
Using the configuration menu of the programming console, the user can configure the following functions.
GEX Handset
Pump Control Configuration
AC3P2BIG CK0.09 AC3P2BIG CK0.09

DISPLAY DISPLAY
80V 450A 00000 80V 450A 00000
KEYBOARD KEYBOARD
HEADING
Enter
Main Menu Set Model Connected to 5 (Pump) (3 = Master, 4 = Slave)
Enter Roll
Parameter Acceleration Delay 0-9
Up
Change Decelleration Delay 0-9
Enter
Acc delay Tilt 0-9 Set Options Hour Meter Running / Key On
Dec delay Tilt 0-9 Set Temperature Analog / Digital / None
Roll Aux1 Acc delay 0-9 Roll Therm Protection On/Off
Up Aux1 Dec delay 0-9 Up Hour Meter Truck On/Off
Aux2 Acc delay 0-9 Pressure Funct On/Off
Aux2 Dec delay 0-9 Digital lift On/Off
Max Speed Up Hz
Min Speed Up Hz
Cutback speed %
1st Speed Hz Enter
Adjustments Set Battery Type 48/72/80/96
2nd Speed Hz Adjust Battery
3rd Speed Hz Adjustment #04
4th Speed Hz Adjustment #03
Hydro Speed Hz Throttle 0 Zone
Idle Speed Hz Throttle Y Zone
Idle Time Sec Throttle X Zone
Maximum Current 0-9 Motor Shutdown
Auxilary Time Sec IMAX Protection
Enter
Frequency Hz
Encoder Hz
Slip Value Hz
Current RMS A
Temperature
Roll Motor Temperature
Up Accelerator V
Lift Switch On/Off
1st Speed Switch On/Off
2nd Speed Switch On/Off
3rd Speed Switch On/Off
4th Speed Switch On/Off
Save Hydro Speed Req On/Off
Parameter Voltage Booster V
Battery Voltage V
Roll COS FI
Up Battery Current A
Restore Battery Charge %
Parameter
Roll
Up
Enter
Alarms
Roll
Up
Program Enter
VACC VACC Settings Min/Max
Roll
Up
Enter
Motor Data Not Available

SUBMENU "SET OPTIONS"
1 HOUR METER TRUCK

RUNNING: The meter registers when the "key" is ON
KEY ON: The meter registers travel time only.
2 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.
3 THERMO PROTECTION
ON: When motor winding temperature is over 90°…, reduce the torque
OFF: Always pull torque should be provided.
4 HOUR METER TRUCK
ON: Equipment usage time should be shared between travel and hydraulic controller.
OFF: Equipment usage time should not be shared.
5 PRESSURE FUNCT
ON: Use pressure sensor to operate steering motor.
OFF: Operate steering motor by ahead/astern lever without pressure sensor.
6 DIGITAL LIFT
ON: Operate lift without potentiometer(operated by ON/OFF switch)
OFF: Lift speed is relative to the output value of potentiometer.

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

TYPE:
2. ADJUST BATTERY: Fine adjustment of battery voltage measured by the controller.
3. ADJUSTMENT #4: Used to decide the motor temp level on which the motor temp abnormal signal is dis-
played. The temp range will be adjusted from 70°C to 160°C in the unit of 10°C. This
parameter shall be adjusted only when the “Temp Adjustment” (“Option” menu) parame-
ter has been programmed in analog.
4. MOTOR SHUT- Used to shut down the hydraulic operation when the set value is reached. (However, the
DOWN: steering can work.)
5. THROTTLE 0 ZONE: Establishes a deadband in the accelerator input curve.
6. THROTTLE X This parameter changes the characteristics of the accelerator input curve.
POINT:
7. THROTTLE Y This parameter changes the characteristics of the accelerator input curve.
POINT:
8. IMAX PROTECTION: The value to start the current reduction when the motor temperature reaches adjustment
#4 value.
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 pressure sensor is not moving. (Not used)
18. Idle Time: The set time delay before stopping the motor when steer demand is active and pressure
sensor is not moving. (Not used)
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.
PROGRAM LEVEL
PARAMETERS
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
AC3
Max Speed Up Hz 0-200
PW
Min Speed Up Hz 0 13.5 15 16.5 18 19.5 21 22.5 24 25.5
(80V)
Cutback Speed % 10 20 30 40 50 60 70 80 90 100
1st Speed Fine Hz 0-200
2nd Speed Fine Hz 0-200
3rd Speed Fine Hz 0-200
4th Speed Fine Hz 0-200
Hyd Speed Fine Hz 0-200
Idle Speed Hz 6 8 10 12 14 16 18 20 22 24
Idle Time Sec. 1 2 4 8 10 12 14 16 18 20
Max Current % IMAX 44 50 56 63 69 75 81 87 94 100
Auxilary Time Sec. 0 1 2 3 4 6 8 10 12 15

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 per-
centage 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 TEMPERA- This is the temperature of the right motor; if this option is programmed "None" it
TURE: 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) TILT SPEED SWITCH:
11) AUX1 SPEED SWITCH:


14) HRYDRO SPEED REQ.:
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.
16) BATTERY VOLTAGE: Level of the battery voltage measured at the input of the key switch.
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.
1) Select the options required.
2) Select and set battery voltage.
3) Confirm correct installation of all wires. Use Handset's TESTER function to assist.
4) Perform the accelerator signal acquisition procedure using the Handset "PROGRAM VACC".(See Group 13, Sec-
tion 4 for programming procedures).
5) 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.

6) Set the maximum steering angles, right and left; use the parameters in "Adjustment" menu. (See Group 13, Sec-
tion 4 for programming procedures).
7) Verify “BATTERY VOLTAGE”. Use volt meter to determine voltage between +BT and -B on the controller.
8) Verify the "MAXIMUM CURRENT"
9) Verify the acceleration delay requirements for the truck. Test the parameter setting in both directions.
10) Verify the FREQENCY CREEP level starting from level 0.3 Hz. The truck should just move when the accelera-
tor start switch is closed. Increase the level accordingly.
11) Verify speed reduction.
12) Set Hour Meter to correct hours.

Section 3
CONTROL TROUBLESHOOTING
FAULT CODES FOR GEX
This is the list of codes that the CLARK dash display may show
Fault
Fault Name Control
Fault Code
Fault Name Control 110 "VMN HIGH" SLAVE
Code
1 "NO SEAT SWITCH" MASTER 112 "WATCHDOG" MHYRIO
2 "CHOPPER RUNNING" MASTER 113 "HI DRI KO" MHYRIO
8 "WATCHDOG" MASTER 114 "EVPG1 KO" MHYRIO
9 "INPUT MISMATCH" MASTER 115 "EVPG2 KO" MHYRIO
10 "IGNITION ON" MASTER 116 "EVPG3 KO" MHYRIO
13 "EEPROM KO" MASTER 117 "EVPG4 KO" MHYRIO
17 "LOGIC FAILURE #3 MASTER 118 "COIL SHT" MHYRIO
18 "LOGIC FAILURE #2 MASTER 119 "EV SHORT" MHYRIO
19 "LOGIC FAILURE #1 MASTER 120 "UND VOLT" MHYRIO
30 "VMN LOW" MASTER 121 "CANBUSKO" MHYRIO
31 "VMN HIGH" MASTER 122 "EVP KO" MHYRIO
33 "IDLE TIME" MASTER 123 "EV DR KO" MHYRIO
36 "INPUT ERROR#1" TRAC 124 "EVPG1SHT" MHYRIO
37 "CONTACTOR CLOSED" MASTER 125 "EVPG2SHT" MHYRIO
38 "CONTACTOR OPEN" MASTER 126 "EVPG3SHT" MHYRIO
49 "I=0 EVER" TRAC 127 "EVPG4SHT" MHYRIO
53 "STBY I HIGH" MASTER 128 "EVP SHT" MHYRIO
60 "CAPACITOR CHARGE" MASTER 129 "EEPROMKO" MHYRIO
61 " HIGH TEMPERATURE" MASTER 130 "WAIT PEV" MHYRIO
65 "MOTOR TC START" MASTER 132 "STBY I HIGH" SLAVE
66 "BATTERY LOW" MASTER 139 "CAPACITOR CHARGE" SLAVE
71 "MOTOR SHUTDOWN" MASTER 140 " HIGH TEMPERATURE" SLAVE
72 "MOTOR LOCKED" MASTER 148 "ENCODER ERROR" SLAVE
74 "DRIVER SHORTED" MASTER 150 "WATCHDOG" PUMP
75 "CONTACTOR DRIVER" MASTER 151 "CHOPPER RUNNING" PUMP
76 "COIL SHORTED" MASTER 152 "WATCHGOG #2" PUMP
77 "MAINTENANCE HOURS" MASTER 153 "SAFETY OUTPUT" PUMP
78 "VACC NOT OK" MASTER 154 "COIL SHORTED HW KO" PUMP
79 "INCORRECT START (SRO)" MASTER 155 "EEPROM KO" PUMP
80 "FORWARD + REVERSE" MASTER 159 "LOGIC FAILURE #3 PUMP
81 "TH MOTOR SENSOR KO" MASTER 160 "LOGIC FAILURE #2 PUMP
82 "ENCODER ERROR" MASTER 161 "LOGIC FAILURE #1 PUMP
84 "STEER SENSOR KO" MASTER 171 "MOTOR SHUTDOWN" PUMP
86 "PEDAL WIRE KO" SLAVE 172 "VMN LOW" PUMP
87 "WATCHDOG" SLAVE 173 "VMN HIGH" PUMP
88 "CHOPPER RUNNING" SLAVE 174 "TH MOTOR SENSOR KO" PUMP
93 "CAN BUS KO" CANTILLER 182 "MOTOR LOCKED" PUMP
96 "LOGIC FAILURE #3 SLAVE 183 "ACQ JOY2" PUMP
97 "LOGIC FAILURE #2 SLAVE 184 "SHT RANG" PUMP
98 "LOGIC FAILURE #1 SLAVE 185 "AUX RANG" PUMP
99 "TH MOTOR SENSOR KO" SLAVE 186 "MHY ALM" PUMP
109 "VMN LOW" SLAVE 187 "TLT RANG" PUMP
SM 765, Dec ’06 CONTROL TROUBLESHOOTING • 19-3-1

Fault
Fault Name Control
Code
188 "LFT RANG" PUMP
189 "ACQ JOY" PUMP
190 "MHY ALM" PUMP
191 "SHT RANG" PUMP
192 "AUX RANG" PUMP
193 "ACQ JOY2" PUMP
194 "TLT RANG" PUMP
195 "STBY I HIGH" PUMP
196 "THERMIC SENSOR KO" PUMP
197 "LFT RANG" PUMP
198 "ACQ JOY1" PUMP
199 "CONT CLO" PUMP
200 "PRSS SW" 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
211 "COIL SHORTED" PUMP
212 "COIL INTERUPTED" PUMP
213 "DATA ACQUISITION" PUMP
217 "WRONG SET BATTERY" PUMP
218 "SAFETY" PUMP
222 "NO CAN MSG" PUMP
223 "WAITTRAC" PUMP
224 "SEAT KO" PUMP
225 "AUX OUTPUT KO" PUMP
227 "DATA ACQUISITION" SLAVE
232 "MASTER KO" SLAVE
233 "NO CAN MSG 3" SLAVE
234 "SB SW OP" TRAC
235 "THERMIC SENSOR KO" SLAVE
236 "INPUT MISMATCH" SLAVE
241 "DATA ACQ" MASTER
243 "NO CAN MSG 5" MASTER
244 "SAFE KO" TRAC
245 "WRONG SET BATTERY" MASTER
246 "SLAVE KO" MASTER
247 "NO CAN MSG 4" MASTER
248 "CHECKUP NEEDED" MASTER
249 "THERMIC SENSOR KO" MASTER
251 "WAITNODE" TRAC
253 "AUX OUTPUT KO" MASTER
255 "HANDBRAKE" MASTER
Blank "DASH DISPLAY" MASTER
19-3-2 • CONTROL TROUBLESHOOTING SM 765

Fault Code Charts

Fault Action
Fault Name Fault Description Control Troubleshooting
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
2 “CHOPPER FET is running MASTER • XXXX
RUNNING”
8 "WATCH- Watchdog circuit MASTER • 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 replacing the controller , check
the Canbus
9 "INPUT Seat Switch mis- MASTER • The seat switch input for traveling is dif-
MIS- matched ferent from that of hydraulic system.
MATCH" • Check the seat switch line connected to
travelling controller and hydraulic con-
troller.
10 "IGNITION Entered the pass- MASTER • When you entered password the truck
ON" word can move.
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
troller
OFF and ON again.
• 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 protection hard- board that manages the hardware current troller
#3 ware circuit protection.
SM 765 CONTROL TROUBLESHOOTING • 19-3-3

Fault Action
Code Required
18 "LOGIC Failure in U,V,W MASTER • Fault in the hardware section of the logic Replace con-
FAILURE voltage feedback board that manages the phase 's voltage troller
#2 circuit feedback.
19 "LOGIC An over voltage or MASTER • This fault signals that the under voltage /
FAILURE under voltage con- over voltage protection interrupt has
#1 dition has been been triggered
detected • A real under voltage / over voltage key
input (C3) happened. Voltage has been
below 30V
• A real over voltage on the power capaci-
tors happened, voltage has been 115V.
• 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 +
Battery terminal place positive meter
If code presist replace control
• Fault in the inverter power section.

Fault Action
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.
33 "IDLE Displayed when MASTER • The main line contactor open function
TIME" the Idle time con- starts.
dition starts • Any traction inputs (Accelerator, pedal
brake, direction S/W-ON) need to close
the contactor.
36 "INPUT Test performed if TRAC • Operator should not leave seat when
ERROR #1" "AUX OUTPUT truck is running.
#1" is set to
BRAKE. This
alarm is set if seat
disappear and rpm
truck are greater
than "PARK
SPEED LIMIT"
parameter.
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
capacitor bank. If they don't dis charge,
the fault condition is entered. It is sug-
gested 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
49 "I=0 EVER" Current is too low. TRAC • The problem could be in the current sen- Replace the
sor or in the related circuit. controller

Fault Action
Code Required
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. Possi-
ble 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.
61 " HIGH Warning: Master MASTER • Temperature of control is greater than
TEMPERA- or Slave or both 75°C. Maximum current reduced propor-
TURE" temperature higher tionally to the temperature increase. At
that 75 degrees C 100°C 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 (130°C) 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 tes-
ter mode
• If it happens when the motor is cold,
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 (145°C) 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

Fault Action
Code Required
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
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
damaged or Stby If 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

Fault Action
Code Required
78 "VACC Warning: Acceler- MASTER • This fault indicates that the accelerator
NOT OK" ator signal voltage is 1volt greater than the mini-
(CPOT) voltage mum value programmed by PROGRAM
higher than VACC VACC function.
MIN+1V While • The potentiometer is not correctly cali-
the traction enable brated.
switch is open Replace accel-
• The potentiometer is defective.
erator
• Use tester mode to check for voltage
change when accelerator is depressed,
should be approx 1.5volts (0.[~XU`volts
accelerator), YU^volts (0.[~3.Xvolts
accelerator) of change. If not 1.5volts
(0.[~XU`volts accelerator), YU^volts
(0.[~3.Xvolts accelerator) check for wir-
ing shorts, if no shorts, replace accelera-
tor. If accelerator still doesn’t change
and voltage is greater than YUWvolts
(0.[~XU`volts accelerator) & 3.Yvolts
(0.[~3.Xvolts accelerator) replace con-
trol.
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 starting active when key switch is turned on.
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.

Fault Action
Code Required
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
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, C8) from
connector, now connect a 4.7K ohm If it sill read 0
resistor between PPOT (C8) and NPOT VDC the control-
(C20) now plug the connector back in, ler has a failed
this will polarize NPOT. Now check input
voltage 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

Fault Action
Code Required
87 "WATCH- Watchdog circuit SLAVE • It is a self-diagnosing test within the
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
88 “CHOPPER FET is running SLAVE • XXXX
RUNNING”
93 "CANBUSK It is signalled CANTIL- • CAN wiring disconnected or damanged , Check any mod-
O" when the tiller LER Check them ule connected
card doesn't via CANbus
receive any mes-
sage from the
CANBUS Line.
96 "LOGIC Failure in overload SLAVE • Fault in the hardware section of the con- Replace con-
FAILURE protection hw cir- troller that manages the hardware current troller
#3 cuit protection.
97 "LOGIC Failure in U,V,W SLAVE • Fault in the hardware section of the con- Replace con-
FAILURE voltage feedback troller that manages the phase 's voltage troller
• Line contactor not closing, check param-
eter setting for main contactor.
98 "LOGIC An over voltage or • This fault signals that the under voltage /
FAILURE under voltage con- over voltage protection interrupts been
#1 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.
on.
99 "TH Warning:Motor SLAVE • The range of the motor temperature ana-
MOTOR Slave temperature log sensor is always checked and a fault
SENSOR sensor is out of is signaled if it's out of range
KO" range • When this fault occurs. The maximum
speed is reduced to 60 Hz.

Fault Action
Code Required
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
Replace con-
• Fault in the controller power section. 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
• Fault in the controller power section.
112 "WATCH- The test is made in MHYRIO • If an alarm should occur. Replace the
DOG" both running and logic.
standby. It is a
self-diagnosing
test within the
logic.
113 "HI DRI The high side MHYRIO Replace the
KO" driver which sup- controller
plies the positive
of the valve coils
is shorted or Open.
114 "EVPG1 One of the Group MHYRIO • This alarm can appear if a coil shorted is
KO" 1 valve drivers is present or if the driver is not able to drive
Open. It does not the load.
close when it is • Check if a short circuit is present across
commanded by the the coil connected to Group 1.
microcontroller.
• In case of driver not able to drive the Replace the
load replace the controller. controller
microcontroller.

Fault Action
Code Required
microcontroller.
microcontroller.
118 "COIL SHT" ON/OFF Valve MHYRIO • Check if a short circuit is present across
drivers are pro- the coil connected to ON/OFF valves or
tected against coil if the current on these outputs is too high.
short circuit ; if a
short is present
across the coil, the
flip-flop circuit is
set and the alarm
is signalled.
119 "EV One of the ON/ MHYRIO • Check the external connection.
SHORT" OFF valve drivers • If it is O.K the driver is probably dam-
is shorted. aged.
120 "UND This fault is sig- MHYRIO • Check the external connection & wiring.
VOLT" nalled if an under-
voltage condition
is detected in the
MHYRIO power
supply.
121 "CAN- There is a problem MHYRIO • Check the CANBUS wiring & connec-
BUSKO" related to the CAN tion.
BUS line. The • If it's O.K , the problem is on the logic Replace the
error is signalled if board which must be replaced. board
the MHYRIO con-
troller does not
receive any mes-
sage from the
CAN BUS line.
122 "EVP KO" The single Pro- MHYRIO • Same as EVPG1.
portional valve
driver is open. It
does not close
when it is com-
manded by the
microcontroller.

Fault Action
Code Required
123 "EV DR One of the ON/ MHYRIO Replace the
KO" OFF valve drivers controller.
is open. It does
not close when it
is commanded by
the microcon-
troller.
124 "EVPG1SH One of the Group MHYRIO • Check the external connection.
T" 1 valve drivers is • If it is O.K the driver is probably dam-
shorted aged.
shorted aged.
shorted aged.
shorted aged.
128 "EVP SHT" One of the ON/ MHYRIO • Check the external connection.
OFF valve drivers • If it is O.K the driver is probably dam-
is shorted aged.
129 "EEPROMK Fault in the area of MHYRIO • If the fault is still present when the key
O" memory where the switch is OFF and ON , Replace the
adjustment param- logic board.
eters are • If the fault disappears, the previous
stored.this alarm stored parameters will have been
does not inhibit replaced by the default parameters.
machine opera-
tion but operation
goes on with
default values.
130 "WAIT There isn't the pos- MHYRIO • Check the B2 input then Verify the valve
PEV" itive power sup- supply parameter is correctly set.
ply of the valves.
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
ble causes for the fault. Replace the
• Current sensor failure. power unit
• Failure in the controller
• If the fault persist.

Fault Action
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
140 " HIGH Warning: Master SLAVE • Temperature of control is greater than
TEMPERA- or Slave or both 75°C. Maximum current reduced propor-
TURE" temperature higher tionally to the temperature increase. At
that 75 degrees C 100°C the maximum current of both con-
148 "ENCODER Motor speed sen- SLAVE • 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
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
151 “CHOPPER FET is running PUMP • XXXX
RUNNING”
152 “WATCH- At start-up,the PUMP • The WatchDog hardware circuit or
GOG #2” watchdog signal is microcontroller output port are damaged.
already active In both cases,
before the soft-
ware has gener-
ated it. At Stand-
by or running con-
dition the Watch-
dog is not active (
in alarm status).
153 “SAFETY The Safety Out PUMP • Check if there is a short or a low imped-
OUTPUT” driver is shorted ance pull-down between safety out and -
BATT. The driver circuit is damaged in
the logic board, which has to be replaced.

Fault Action
Code Required
154 “COIL The Hardware cir- PUMP • This type of fault is not related to exter-
SHORTED cuits which man- nal components, replace the logic board.
HW KO” age short circuits
protection of LC
and EB/AUX .
155 "EEPROM Warning: Eeprom PUMP • Fault in the area of memory in which the
KO" fault controller adjustment parameters are stored; this
will use default fault does not inhibit truck operation, but
parameters the controller will use default parame-
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.
160 "LOGIC Failure in U,V,W PUMP • Fault in the hardware section of the con- Replace con-
FAILURE voltage feedback troller that manages the phase 's voltage troller
161 "LOGIC An over voltage or PUMP • This fault signals that the under voltage / Replace con-
FAILURE under voltage con- over voltage protection interrupt has troller
#1 dition has been been triggered. Two possible reasons:
detected • A real under voltage / over voltage situa-
tion happened.
• Verify battery setting.
tection. Replace logic Card.
on.
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
(145°C) 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.

Fault Action
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
the motorPUMP Replace con-
troller
tection.
• 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 -
Battery terminal place negative meter
Place negative meter lead on control +
Battery terminal place positive meter
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-
troller
• Fault in the inverter power section.
• Possible bad battery, Excessive voltage
to case of battery.

Fault Action
Code Required
174 "TH Warning:Motor PUMP • The range of the motor temperature ana-
MOTOR Pump temperature log sensor is always checked and a fault
SENSOR sensor is out of is signaled if it's out of range
KO" range • When this fault occurs. The maximum
speed is reduced to 23% of the maximum
setting speed..
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).
183 "ACQ Acquired JOY2 PUMP • Check the output of the JOY2.
JOY2" function value is • Teach the JOY2 Value.
not valid.
184 "SHT Potentiometer PUMP • Check the potentiometer output value
RANG" value of Shift is teach the shift value.
out of range.
185 "AUX Potentiometer PUMP • Check the potentiometer output value
RANG" value of Aux is out teach the Aux value.
of range.
186 "MHY There's an alarm in PUMP • Check an Alarm of MHYRIO CB.
ALM" Mhyrio CB.
187 "TLT Potentiometer PUMP • Check the potentiometer output value
RANG" value of Tilt is out teach the Tilt value.
of range.
188 "LFT Potentiometer PUMP • Check the potentiometer output value
RANG" value of Lift is out teach the Lift value.
of range.
189 "ACQ JOY" Acquired JOY- PUMP • Check the output of the JOYSTICK.
STICK function • Teach the JOYSTICK Value.
value is not valid.
190 "MHY There's an alarm in PUMP • Check an Alarm of MHYRIO CB.
ALM" Mhyrio CB.
191 "SHT Reading from shift PUMP
RANG" potentiometer
exceed acquired
value.
192 "AUX Reading from aux PUMP
RANG" potentiometer
exceed acquired
value.
193 "ACQ Incorrect acquired PUMP • Perform joystick 2 acquisition.
JOY2" value for joystick
2.

Fault Action
Code Required
194 "TLT Reading from tilt PUMP
RANG" potentiometer
exceed acquired
value.
195 "STBY I Wrong voltage in PUMP • The microprocessors verify if the feed-
HIGH" current sensor back of current sensor device output is
ble 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 sensor always checked and a warning is sig-
KO" is our of range naled if it is out of range. This fault will
reduce the maximum current output of
the controller to 50%.
197 "LFT Reading from lift PUMP
RANG" potentiometer
exceed acquired
value.
198 "ACQ Incorrect acquired PUMP • Perform joystick 1 acquisition.
JOY1" valyue for joy-
stick 1.
199 "CONT At start up, the PUMP • Check the contactor contacts, in particu-
CLO" controller checks lar if they are mechanically stuck or
if the MC Contact pasted. Notice that this test isn't carried
is already closed out if,at start-up, the capacitors are com-
when the coil is pletely discharged.
not driven yet. The
test is carried out
by trying to dis-
charge the capaci-
tor bank. If they
don't discharge,
the failure condi-
tion is entered and
any function is
prevented.
200 "PRSS SW" Test is performed PUMP • Check the pressure switch.
only if option
"PRESSUR
FUNCT." is set to
ON. Alarm is set if
exclusive idro
input is ON for
more than
30seconds.

Fault Action
Code Required
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
203 "HIGH Warning: Pump PUMP • Temperature of control is greater than
TEMPERA- Controller temper- 75°C. Maximum current reduced propor-
TURE" ature higher that tionally to the temperature increase. At
75 degrees C 100°C the maximum current of both con-
204 "VACC Warning: Acceler- PUMP • This fault indicates that the accelerator
NOT OK" ator siganal voltage is 1volt greater than the mini-
(CPOT) voltage mum value programmed by PROGRAM
higher than VACC VACC function.
MIN+1V While • The potentiometer is not correctly cali-
the traction enable brated.
switch is open
• The potentiometer is defective.
• Tilt or sideshift switch activated at
startup
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).

Fault Action
Code Required
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 (130°C) in the
ADJUSTMET submenu.
• When this fault occurs, current goes
down to IMX PROTECTION value and
motor rpm begins to decrease. Motor Check tempera-
current and speed decrease linearly as theture shown on
temperature increases until MOTOR- handset in tes-
SHUTDOWN is reached. ter mode
Replace con-
• If it happens when the motor is cold,
troller
check the wring. If all is ok,,
208 "BATTERY Warning: Battery PUMP • When battery level reaches 20% or less,
LOW " charge level below the current level for the drive motors is
20% reduced to 50% of the programmed level
209 “DRIVER The MC driver is PUMP • Mc is opened(the command is released), Traction/Pump

SHORTED” shorted so it is not Traction/Pump stopped request
able to open the
contactor
210 “CONTAC- Driver of MC coil PUMP • Mc is opened(the command is released), Traction/Pump
TOR is damaged(not Traction/Pump stopped request
DRIVER” able to colse)
211 "COIL Init: Line contac- PUMP • When the key is turned on, the micropro-
SHORTED" tor and EB coil cessor checks that the line contactor coil
driver protection driver short circuit protection hardware
circuit is damaged If 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 cor-
rect
213 "DATA This alarm is sig- PUMP • Wait the end of acquisition activity.
ACQ" nalled in the cur-
rent gain
acquisition phase.
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 The safety input is PUMP • Mc is opened(the command is released),
IN OUT" open(it is not con- Traction/Pump stopped
nected to -batt)

Fault Action
Code Required
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 trac-
tion ok. The fault must be looked for in
the traction controller or can-bus circuit.
223 "WAIT- The controller via PUMP • Check the traction.
TRAC" CANBUS,Waits
some synchroniza-
tion signal from
the Traction
before performing
a perticular action.
For example,
Closing the LC. If
this signal is not
received in time,
the controller stays
stuck in an idle
state, showing this
warning.
224 "SEAT KO" The Pump control- PUMP • Check the connection of the seat switch
ler uses the one of to Traction and Pump. If no failure is
its digital input ( found, the problem is internal of the con-
B4 pin ) to read troller.
the status of the
SEAT switch
together with the
Traction control-
ler.the traction and
pump compare the
two read status via
CAN message.
The alarm is sig-
nalled if a mis-
match is found.
225 "AUX OUT- EB coil driver PUMP • The microprocessor checks the driver of
PUT KO" shorted or open the electromechanical brake coil. If the
(Not used) 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.
227 "DATA This alarm is sig- SLAVE • Wait the end of acquisition activity
rent gain
acquisition phase.

Fault Action
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.
234 "SB SW OP" The seatbelt TRAC
switch is open.
235 "THERMIC Warning: Slave SLAVE • The range of the temperature sensor is
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 mis-
micro processor match between its inputs and MASTER
inputs, it brings the controller to a safe
status opening the power bridge and the
line contactor.
241 "DATA This alarm is sig- MASTER • Wait the end of acquisition activity/
rent gain
acquisition phase.

Fault Action
Code Required
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.
244 "SAFE KO"At start up, the TRAC • This alarm arises if a short is detected.:
traction controller the MC does not close and any function
tests if the is prevented
SAFETY input is • The safety pin has an external short :
not active while check the wires
the pump control-
• The output driver of pump is shorted ;
ler has not yet acti-
check the pump controller Safety out .
vated its driver. In
this way, the trac- • The internal safety circuit has a failure ;
tion controller can replace the controller
detect the presence
of a short circuit
between SAFETY
pin (B5-Traction)
and (B9 - Pump).
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: Master MASTER • The range of the temperature sensor is

Fault Action
Code Required
251 "WAIT- The controller via TRAC • Verify the other modules to determinate
NODE" CANBUS,Waits in which of them there is the problem.
some synchroniza-
tion signal from en
external module
before performing
a perticular action.
For example,
Closing the LC. If
this signal is not
received in time,
the controller stays
stuck in an idle
state, showing this
warning.
253 "AUX OUT- EB coil driver MASTER • The microprocessor checks the driver of
PUT KO" shorted or open the electromechanical brake coil. If the
(Not used) 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

19, Motor Controls
Section 4
GEX Factory Control Settings

Parameters in White are customer preference adjustable.
Parameters in Orange are factory preset and not adjustable.
Traction control Settings

TRACTION CONTROL (DUAL AC2 PW MASTER) 80V
SCALED VALUE
DESCRIPTION
Turtle Mode Economic Mode Normal Mode Power Mode
PARAMETER CHANGE
ACCELER. DELAY LEVEL = 6 LEVEL = 6 LEVEL = 5 LEVEL = 4
RELEASE BRAKING LEVEL = 3 LEVEL = 2 LEVEL = 2 LEVEL = 1
INVERS. BRAKING LEVEL = 4 LEVEL = 5 LEVEL = 6 LEVEL = 6
PEDAL BRAKING LEVEL = 7 LEVEL = 7 LEVEL = 7 LEVEL = 7
SPEED LIMIT BRK. LEVEL = 0 LEVEL = 0 LEVEL = 0 LEVEL = 0
BRAKE CUTBACK LEVEL = 5 LEVEL = 5 LEVEL = 5 LEVEL = 5
CURVE BRAKING LEVEL = 5 LEVEL = 5 LEVEL = 5 LEVEL = 5
MAX SPEED FORM 47 Hz 79 Hz 119 Hz 143 Hz
MAX SPEED BACK 47 Hz 79 Hz 119 Hz 143 Hz
CUTBACK SPEED 1 80% 90% 100% 100%
CURVE CUTBACK 40% 40% 40% 40%
CURVE CUTBACK #1 100% 100% 100% 100%
FREQUENCY CREEP 0.30 Hz 0.30 Hz 0.30 Hz 0.30 Hz
MAXIMUM CURRENT LEVEL = 9 LEVEL = 9 LEVEL = 9 LEVEL = 9
AUXILIARY TIME 4.5 4.5 4.5 4.5
SEAT MICRO DELAY 3.5 3.5 3.5 3.5
ACC. SMOOTH 2.5 2.5 2.0 1.5
INV. SMOOTH 2.0 2.5 2.0 1.5
STOP SMOOTH 20Hz 15Hz 10Hz 10Hz
IDLE TIME 15 15 15 15
SET OPTION
HOUR COUNTER RUNNING RUNNING RUNNING RUNNING
BATTERY CHECK ON ON ON ON
HYDRO KEY ON OFF OFF OFF OFF
STOP ON RAMP OFF OFF OFF OFF
AUX INPUT #1 OPTION #1 OPTION #1 OPTION #1 OPTION #1
PEDAL BRAKING DIGITAL DIGITAL DIGITAL DIGITAL
SET TEMPERATURE ANALOG ANALOG ANALOG ANALOG
STEER TABLE OPTION #1 OPTION #1 OPTION #1 OPTION #1
MODE SELECTION LEVEL = 3 LEVEL = 0 LEVEL = 1 LEVEL = 2
SET MODEL
CONNECTED TO 3 3 3 3
SM 765 GEX Factory Control Settings • 19-4-1

TRACTION CONTROL (DUAL AC2 PW MASTER) 80V

SCALED VALUE
DESCRIPTION
ADJUSTMENTS
SET POT BRK MIN 0.5 V 0.5 V 0.5 V 0.5 V
SET POT BRK MAX 4.5 V 4.5 V 4.5 V 4.5 V
SET BATTERY TYPE 80V 80V 80V 80V
ADJUST BATTERY
MAX STEER RIGHT
MAX STEER LEFT
SET STEER 0-POS.
SET STEER RIGHT 103 Degrees 103 Degrees 103 Degrees 103 Degrees
SET STEER LEFT 77 Degrees 77 Degrees 77 Degrees 77 Degrees
THROTTLE 0 ZONE 1% 1% 1% 1%
THROTTLE X POINT 54% 54% 54% 54%
THROTTLE Y POINT 47% 47% 47% 47%
ADJUSTMENT #04 130୅ 130୅ 130୅ 130୅
MOTOR SHUTDOWN 145୅ 145୅ 145୅ 145୅
ADJUSTMENT #02 LEVEL = 4 LEVEL = 4 LEVEL = 4 LEVEL = 4
ADJUSTMENT #01 LEVEL = 4 LEVEL = 4 LEVEL = 4 LEVEL = 4
ADJUSTMENT #03 20% 20% 20% 20%
MAIN CONT. VOLT. 80 V 80 V 80 V 80 V
AUX OUTPUT VOLT. 36 V 36 V 36 V 36 V
MAINTEN. RESET OFF OFF OFF OFF
MAINTENANCE NONE NONE NONE NONE
MAINTENANCE TIME 250 250 250 250
1X10000 HOURS 0 0 0 0
1X1000 HOURS 0 0 0 0
1X100 HOURS 0 0 0 0
1X10 HOURS 0 0 0 0
1X1 HOURS 0 0 0 0
DISP. GEAR RATIO 42 42 42 42
TRACTION CONTROL (DUAL AC2 SLAVE) 80V
SCALED VALUE
DESCRIPTION
SET MODEL
ADJUSTMENTS
ADJUST BATTERY
AUX OUTPUT VOLT. 12V 12V 12V 12V
19-4-2 • GEX Factory Control Settings SM 765

Pump control Settings

PUMP CONTROL (AC3 PW) 80V
SCALED VALUE
DESCRIPTION
PARAMETER CHANGE
DECELER. DELAY LEVEL = 0 LEVEL = 0 LEVEL = 0 LEVEL = 0
ACC. DELAY TILT LEVEL = 0 LEVEL = 0 LEVEL = 0 LEVEL = 0
DEC. DELAY TILT LEVEL = 0 LEVEL = 0 LEVEL = 0 LEVEL = 0
AUX1 ACC. DELAY LEVEL = 0 LEVEL = 0 LEVEL = 0 LEVEL = 0
AUX1 DEC. DELAY LEVEL = 0 LEVEL = 0 LEVEL = 0 LEVEL = 0
MAX SPEED UP 60 Hz 75 Hz 100 Hz 130 Hz
MIN SPEED UP 16.50 Hz 16.50 Hz 16.50 Hz 16.50 Hz
CUTBACK SPEED 100% 100% 100% 100%
1ST SPEED FINE* 40 Hz 40 Hz 40 Hz 40 Hz
2ND SPEED FINE* 25 Hz (S/Shift) 25 Hz (S/Shift) 25 Hz (S/Shift) 25 Hz (S/Shift)
3RD SPEED FINE* 50 Hz 50 Hz 50 Hz 50 Hz
4TH SPEED FINE* 50 Hz 50 Hz 50 Hz 50 Hz
HYD SPEED FINE 21 Hz 21 Hz 21 Hz 21 Hz
IDLE SPEED 12 Hz 12 Hz 12 Hz 12 Hz
IDLE TIME LEVEL = 5 LEVEL = 5 LEVEL = 5 LEVEL = 5
AUXILIARY TIME 2 2 2 2
SET OPTION
THERM PROTECTION OFF OFF OFF OFF
HOUR METER TRUCK ON ON ON ON
PRESSURE FUNCT. OFF OFF OFF OFF
DIGITAL LIFT OFF OFF OFF OFF
SET MODEL
ADJUSTMENTS
ADJUST BATTERY
ADJUSTMENT #04 130G¶C 130G¶C 130G¶C 130G¶C
MOTOR SHUTDOWN 145G¶C 145G¶C 145G¶C 145G¶C
IMAX PROTECTION 100% 100% 100% 100%
ADJUSTMENT #03 55 °C 55 °C 55 °C 55 °C
PWM ON MAIN CONT ON ON ON ON
PWM ON AUX CONT OFF OFF OFF OFF

Pump joystick option Settings

PUMP AC3 PW(80V) - JOTSTICK OPTION
SCALED VALUE
DESCRIPTION
PARAMETER CHANGE
DECELER. DELAY LEVEL = 0 LEVEL = 0 LEVEL = 0 LEVEL = 0
ACC. DELAY TILT LEVEL = 0 LEVEL = 0 LEVEL = 0 LEVEL = 0
DEC. DELAY TILT LEVEL = 0 LEVEL = 0 LEVEL = 0 LEVEL = 0
MAX SPEED UP 60 Hz 75 Hz 100 Hz 100 Hz
MIN SPEED UP 16.50 Hz 16.50 Hz 16.50 Hz 16.50 Hz
CUTBACK SPEED 100% 100% 100% 100%
1ST SPEED FINE* 40 Hz 40 Hz 40 Hz 40 Hz
2ND SPEED FINE* 25 Hz (S/Shift) 25 Hz (S/Shift) 25 Hz (S/Shift) 25 Hz (S/Shift)
3RD SPEED FINE* 50 Hz 50 Hz 50 Hz 50 Hz
4TH SPEED FINE* 50 Hz 50 Hz 50 Hz 50 Hz
HYD SPEED FINE 21 Hz 21 Hz 21 Hz 21 Hz
IDLE SPEED 12 Hz 12 Hz 12 Hz 12 Hz
IDLE TIME LEVEL = 5 LEVEL = 5 LEVEL = 5 LEVEL = 5
AUXILIARY TIME 2 2 2 2
SET OPTION
THERM PROTECTION OFF OFF OFF OFF
HOUR METER TRUCK ON ON ON ON
PRESSURE FUNCT. OFF OFF OFF OFF
DIGITAL LEFT OFF OFF OFF OFF
4TH FUNCTION OFF OFF OFF OFF
4TH FUNC. ENABLE ABSENT ABSENT ABSENT ABSENT
SET MODEL
ADJUSTMENTS
MAX. POT LIFT 0.4
MIN. POT LIFT 2.3
MAX. POT LOWER 4.5
MIN. POT LOWER 2.6
MAX. TILT BACK 4.5
MIN. TILT BACK 2.6
MAX. TILT FWD. 0.4
MIN. TILT FWD. 2.3

PUMP AC3 PW(80V) - JOTSTICK OPTION

SCALED VALUE
DESCRIPTION
MAX. SHIFT RIGHT 4.5
MIN. SHIFT RIGHT 2.6
MAX. SHIFT LEFT 0.4
MIN. SHIFT LEFT 2.3
MAX. AUX BACK 4.5
MIN. AUX BACK 2.6
MAX. AUX FORW. 0.4
MIN. AUX FORW. 2.3
(ADJUST BATTERY 84.8 V 84.8 V 84.8 V 84.8 V
ADJUSTMENT #04 130 ¶C 130 ¶C 130 ¶C 130 ¶C
MOTOR SHUTDOWN 145 ¶C 145 ¶C 145 ¶C 145 ¶C
IMAX PROTECTION 100% 100% 100% 100%
ADJUSTMENT #03 55 ¶C 55 ¶C 55 ¶C 55 ¶C
PWM ON MAIN CONT ON ON ON ON
PWM ON AUX CONT OFF OFF OFF OFF

MHYRIO CB (80V)
JOTSTUCK/MINI LEVER CONTROL - (MHYRIO-CB)
NAME SCALED VALUE DESCRIPTION
PARAMETER CHANGE
MIN EVP 25.10%
MAX EVP 85.10%
MIN EVP 1 25.10%
Lower-C1
MAX EVP 1 85.10%
MIN EVP 2 25.10%
Lift-C3
MAX EVP 2 85.10%
MIN EVP 3 25.10%
Aux IN/Back-C4
MAX EVP 3 85.10%
MIN EVP 4 25.10%
Aux OUT/Forward-C6
MAX EVP 4 85.10%
MIN EVP 5 25.10%
Tilt UP/Back-C7
MAX EVP 5 85.10%
MIN EVP 6 25.10%
Tilt DOWN/Forward-C15
MAX EVP 6 85.10%
MIN EVP 7 25.10%
Side Shift Right-12
MAX EVP 7 85.10%
MIN EVP 8 25.10%
Side Shift Left-C14
MAX EVP 8 85.10%
EVP OPEN DELAY 0.2
EVP CLOSE DELAY 0.4
EVP 1 OPEN DELAY 0.2 Lift
EVP 1 CLOSE DELAY 0.1
EVP 2 OPEN DELAY 0.2 Lowering
EVP 3 OPEN DELAY 0.2 Aux1 IN
EVP 4 OPEN DELAY 0.2 Aux1 OUT
EVP 5 OPEN DELAY 0.8 Tilt IN
EVP 6 OPEN DELAY 0.8 Tilt OUT
EVP 7 OPEN DELAY 0.2 Aux2 IN
EVP 8 OPEN DELAY 0.2 Aux2 OUT
SET OPTION
SET BATTERY TYPE 80V
V VALVES COIL 24V
VALVES SUPPLY 80V
EVP TYPE ANALOG

JOTSTUCK/MINI LEVER CONTROL - (MHYRIO-CB)

NAME SCALED VALUE DESCRIPTION
EVP1 TYPE ANALOG
EVP2 TYPE ANALOG
EVP3 TYPE ANALOG
EVP4 TYPE ANALOG
EVP5 TYPE ANALOG
EVP6 TYPE ANALOG
EVP7 TYPE ANALOG
EVP8 TYPE ANALOG
SET MODEL
CONNECTED TO 9

GROUP 20 DRIVE AXLE
GROUP 20
DRIVE AXLE
Specification and description of drive axle ....Section 1
Troubleshooting of wheel drive axle ...............Section 2
General operation of drive axle ........................Section 3
Disassembly and Reassembly of drive axle ...Section 4
Disassembly and Reassembly of axle end......Section 5
Adjustment .........................................................Section 6
SM 765 Group 20 DRIVE AXLE,

Group 20, Drive Axle
Section 1
Specification and description of drive axle
Specifications
General specification Torque specification
Reduction ratio : 26 - Boss bearing and plate housing socket bolt, tightening
Speed : Forward/Reverse 1 torque : M8 x 1.25 x 20 (330 kgf½cm, 24 lbf½ft) 12T
Oil capacity : 1.0 liter - Brake piston and plate housing socket bolt, tightening
Gear type : Plant gear torque : M6 x 1.0 x 36 (130 kgf½cm, 9.5 lbf½ft) 8T
Drive axle oil : Mobil # 424 - Brake stopper fixing socket bolt, tightening torque
Weight : 62kg (excl. oil) : M6 x 1.0 x 12 (130 kgf½cm, 9.5 lbf½ftP
- Wheel bearing free load adjusting nut, tightening torque
: M55 x 2.0P (3920 kgf½cm, 285 lbf½ft)
Brake specification
- Final housing socket bolt, tightening torque
Service brake type : Wet brake
: M8 x 1.25 x 25 (380 kgf½cm, 28 lbf½ft) 12T
Required flow of service brake: 1.95cc x 2
- Wheel cap fixing socket bolt, tightening torque
Service brake setting stroke: 0.85 ~ 0.90mm
: M8 x 1.25 x 15 (330 kgf½cm, 24 lbf½ft) 12T
Brake oil : Mineral oil
- Master hinge mounting bolt : M16 x 2.0 x 40
Parking brake lever ratio : 1 : 8.27
Fitting specification
Brake port : M10 x 1.0P
Oil drain plug : PT 1/4, PT 3/8
Air bleeder : PT 1/8
Air bleeder (Brake): M12 x 1.25P
Oil port : PT 1/2
Nipple : M6 x 0.75P (Grease)
Stud bolt (Wheel bolt): M14 x 1.5P
Loctite specification
Bolt : Loctite 277
Fitting : Loctite 572
SM 765 Specification and description of drive axle • 20-1-1

DESCRIPTION shaft(01). The gear(03) meshed in drive gear(02), which is

locked to the shaft with key, and the sun gear shaft(04) are
one body type as locking with key. The sun gear shaft(04)
and the planetary gear(05) are meshed in the ring
Drive axle ass'y gear(06), so that the third reduction will be occurred. The
final reduced rotating force will be applied to wheel
adapter(08) through the carrier shaft(07) in order to rotate
Wheel Ass'y the shaft.
Drive axle
As this drive axle is power transmission system that is

installed to driving wheel for electric forklift, it includes
service brake and parking brake systems. It transmits the
rotating force from the driving motor to the drive
20-1-2 • Specification and description of drive axle SM 765

Section 2
Troubleshooting of wheel drive axle
Troubleshooting for wheel drive axle Maintenance period

Following contents help to solve the problem of wheel • Replacement period of wheel drive axle oil : 1,000
drive axle that does not perform right functions. hours
• Park the forklift truck on a flat surface
Please make sure that the wheel drive axle is just a key
part of related power train components group, when han- • Apply the parking brake and put wedges under the
dles the problem of wheel drive axle. The wheel drive drive wheels
axle is in normal operation based on the condition of other • Remove drive tires
related components of power train. Therefore, examine • Unscrew the oil inlet plug (PT 1/2)
the problems and maintain the wheel drive axle oil, wheel • Unscrew the magnetic plug (PT 3/8)
drive axle assembly, control system, brake system and • Unscrew the drain plug (PT 1/4)
driving motor to be the perfect system.
• Drain drive axle oil completely
To check and repair the defectiveness of wheel drive axle, • Screw magnetic plug (PT 3/8) and
please refer to the description based on the symptom and drain plug (PT 1/4)
cause.
• Unscrew oil level plug(PT 1/4) to check oil level
For the inspection of doubtable components, please refer while filling up oil
to the maintenance manual. • Fill up new drive axle oil until overflowing at oil
level port.
Symptom and Cause • Screw oil inlet plug(PT 1/2) and oil level plug (PT
1/4) after filling up oil.
Following is general defectiveness of wheel drive axle • Assemble drive tires.
and possible causes. • Wheel drive axle oil volume : 1.0 liter
• Replacement period of service brake disc : 10,000
When the forklift does not move. hours
• Poor contact of battery.

• Check the operational condition of parking brake
• Check the electric control system
• Check the direction-control switch
• Check the connecting unit of connector
• Check the normal operation of driving motor
• Check the condition of bearing
When the forklift is overheated

• Check if the oil level is low or is polluted
• Check the overloading of fork
• Check the condition of bearing
• Check if there is dragging to service brake
SM 765 Troubleshooting of wheel drive axle • 20-2-1

Section 3
General operation of drive axle
General operation Cleaning of part

Following procedure shall be applied to disassembly, Do not use gasoline because it is very combustible. It is
inspection, washing, repair, installation and assembly pro- also not safe to the working environment.
cess of wheel drive axle component. Especially, disas-
To complete the disassembly, appropriate cleaning is
sembly and reassembly procedures are described at the
required.
latter part of this section. Those procedures have to be
observed. Clean the processing surface of steel part with industrial
solvent.
Disassembly of components Wash out inside and outside of bearing, cap and housing.
Before disassemble the wheel drive axle, drain out the It is possible to clean the unprocessed or unpolished cast
wheel drive axle oil, remove the required hydraulic line iron part with steam.
and take off the wheel drive axle from the forklift as illus- Treat the part or cast iron that is being washed by solvent
trated to the manual to disassemble the wheel drive axle. or steam at the light alkali liquid tank. Complete dry the
Please observe followings. part before rinsing.
Cleanness - Work at the clean place. Make sure that For the part with rough surface like castings, do not clean
impurities or dirt should not get into the unit while repair- with dust cloth.
ing. The bearing can be worn and damaged by the dirt.
Before start the disassembly, always keep clean the out- Rinse all parts completely. Clean all part except rough-
side of unit. surfaced part with clean cloth and dry it. Slightly apply
the oil to the part and wrap it with anti-corrosive paper for
Assembly - When disassemble many assemblies, place all store. Keep it to clean and dry place.
parts with the same order of disassembly on the clean
bench. It makes the assembly simple and there is no Until the bearing gets clean, wash out with clean solvent.
chance to lose the part. When dry the bearing with compressed air without mois-
ture, make sure that the bearing does not get out of its
Use of part-disassembly tools - Always control the place or damaged because of compressed air.
load that is applied to the shaft, bearing and housing. The
removal of these parts is limited. Never apply the power Do not rotate the bearing while drying. It is no problem to
to drive the parts when they are completely stopped. For slowly rotate it with hands for faster dray.
removal, it is recommended to use soft hammer, bar and NOTE
wooden hammer.
Do not wash out the emulsion product with
Bearing - Use designated puller when takes off the reus- solvent.
able bearing. Apply the clean oil to bearing and cover it
with clean cloth without fuzz or clean paper when store it.
Part checking
Snap ring - Take off the snap ring with designated pliers.
This snap ring is reusable if there is no groove and it is not Check all wheel drive axle components before reassemble
loosened. after cleaning, and decide it if it needs to be replaced.
It is important to carefully and completely check all parts.
When replace all he parts that seem to be worn, stressed or
damaged, it saves money and time.
SM 765 General operation of drive axle • 20-3-1

Checking: Check the steel part if there is mark, deforma- When it needs to be replaced, use official product of
tion or discoloration that is related to inappropriate lubri- CLARK to maintain the unit performance and extend the
cating work, notch, and step or scratch. life.
Check the pitting, discoloration and broken area of bear- The checking procedure that is advised to various parts is
ing ball, cage or retainer, roller and raceway as follows.
Check the abnormal contacting pattern of gear that has
serious symptom of abrasion, pitting and crack across to Bearing
the contacting line.
Replace the bearing if there is hole or it is broken or dis-
Check the crack, scratch and abrasion of processed sur- colored. Always replace one set of bearing cup and cone.
face for casting or malleable parts, wider drill hole and Do not separately replace the bearing and race.
crack or burr of contacting surface.
Replace the bearing with considerable gap.
Check the fastener if it has rounded head or damaged spi-
ral area or is curved or cracked. Check the pitting of bearing. The internal race of bearing
has to be firmly inserted into the shaft. Tighten the outer
IMPORTANT race to the housing bore. If the bearing gets out from the
All damaged parts that affect to the align- bore, replace the housing.
ment and structure should be replaced. The
repair with welding or correction is not
Gear and Shaft
allowed. These works can cause the malfunc-
tion when the load is applied because it Check the frosting and pitting of gear tooth. The frosting
affects the housing of casting product. on the tooth surface of gear does not affect to the malfunc-
Curved head, crack or leakage, loosen stud, tion of transmission. When continuously uses unit, the
crossed-type screw hole of all housings frosting of gear won't be developed to the pitting condi-
tion. Most likely, the gear tooth that is a little bit fitted can
Repair and replacement of part be reusable. However, if the fitting is serious, the gear has
to be replaced.
Protect the wheel drive axle such as seal and washer from
If it is possible to use Magnaflux, check the damage of
the early abrasion, and replace it with low-priced parts
part with it.
that do not give big cost of repair.
If the heat-treated part of gear tooth is worn or cracked,
Replace the seriously worn part even though it is not bro-
replace the gear.
ken.
Check all shafts if the tooth is curved or cracked or the
The steel parts such as shaft or gear can't be repaired. If it
spline is broken.
is worn or damaged, it should be replaced.
The seal and washer has to be periodically replaced. For
Spline
the fastener with auto-locking patch, it is possible to reuse
if it is fixed by dropping the heavy duty thread locker for Check the abnormal abrasion from the spline of all gear
many times. and shaft. If the spline is excessively worn or pitted,
The repair of wheel drive axle housing is limited to the replace the relevant part.
removal of scratch or burr on the processing surface or
replacement of damaged stud. Because the cost of new O-Ring
part is very small in comparison to the total cost of labor
power and malfunction time of machine and it may Replace all O-ring whenever overhauling. Lubricate the
require more cost after the repair, it is better avoiding the O-ring and seal with gear oil (Mobil #424) before the
reuse of the damaged parts. To decide reuse or replace- reassembly.
ment of drive axle part, the internal force, time to use and
application of unit shall be considered.
20-3-2 • General operation of drive axle SM 765

Section 4
Disassembly and Reassembly of drive axle
Disassembly of drive axle ass'y

Drive shaft assembly
Mounting plate
Service brake piston
Driven assembly
Mast hinge
Parking lever
Disc and plate set
Wheel assembly
Cautions to disassemble the drive axle

• Arrange the parts under the order of disassembly.
• Pay attention to the parts and removal order when
disassemble.
• Record with irremovable pen if necessary and dis-
tinguish the parts.
• Place the disassembled units to the clean area. Dis-
assembly of service brake
SM 765 Disassembly and Reassembly of drive axle • 20-4-1

Disassembly of service brake
D-ring
D-ring
Piston
Return spring Stopper brake
Socket bolt
Spacer
Hexagon bolt Driven gear
Shaft sun gear
Guide pin
Return spring
Reaction plate
Key
Paper disc
• Remove the shaft sun gear and driven gear from

the bearing bore.
• Remove twelve stopper fixing socket bolts with
relevant tools.
• Remove the reaction plates (4EA) and the brake
discs (4EA) from the housing.
NOTE
Pay attention not to lose or damage the
springs (16EA).
• Remove the piston fixing hexagon bolts from the

housing by using spanner or wrench box.
NOTE
When remove the piston, apply the air pres-
sure into the brake port.
20-4-2 • Disassembly and Reassembly of drive axle SM 765

Disassembly of bearing boss Disassembly of parking lever and drive

shaft
Thrust needle bearing
Spacer (shim)
Housing plate
Bolt
Needle roller bearing
Bearing boss
O-ring
Plate housing
Pin spring
King brake pin
O-ring
Parking brake lever
Disassembly of bearing boss
• Remove the thrust needle bearing and shim from Disassembly of parking brake lever and drive
the bearing boss. shaft
• Remove the bearing boss fixing bolts (3EA) from
• Remove the spring pin by using pliers.
the plate housing with appropriate tool.
• Remove the parking brake pin and O-ring from the
• Pay attention to the damage or separation of O-
plate housing by using rubber hammer and screw
ring from bearing boss.
driver.
NOTE
NOTE
When reassembly, use new O-ring.
Pay attention not to damage the O-ring of
parking brake pin.
• Remove the parking brake lever from the plate

housing.
SM 765 Disassembly and Reassembly of drive axle • 20-4-3

Disassembly of drive shaft ass'y Disassembly of master hinge, brake

fitting and plug
Bearing Brake air bleeding port
Gea(13T) Brake port
Bearing Plug
Drive shaft
Level plug
Key Bolt
Snap ring
Snap ring Master hinge

• Remove the snap ring from the drive shaft.
• Remove the gear (13T) and key from the drive
shaft. Disassembly order of brake fitting and plug
• Remove the ball bearing from the drive shaft by
using gear puller. • Remove the master hinge fixing socket bolts
(When install the gear puller, fix it to inner ring of (2EA) from plate housing by using appropriate
bearing and remove it) tool.
• Remove the fittings of brake port and brake air
bleeding port.
• Remove the level plug and insertion plug.
20-4-4 • Disassembly and Reassembly of drive axle SM 765

Section 5
Disassembly and Reassembly of axle end
NOTE Disassembly of carrier and hub bear-

Arrange all the parts under the order of dis- ing
assembly.
Pay attention to the parts and removal order
when disassemble. Plant gear shaft
Record with irremovable pen if necessary Pin spring
and distinguish the parts. Taper roller bearing
Spacer
Housing final
Removal of axle end from the drive axle
Bearing taper
Oil seal
Bolt stud
Adaptor
Washer
Needle bearing
Planetary gear Spacer

Washer Lock nut
O-ring
Lock washer
Lock nut Wheel cap
Bolt
Remove hexagon socket bolts from the plate housing by

using appropriate tool to disassemble the wheel assembly
and drive axle.
SM 765 Disassembly and Reassembly of axle end • 20-5-1

Disassembly of axle end The way to assemble the oil seal: Use jigDisassembly of
carrier shaft ass'y
Taper roller bearing
Spacer
Disassembly of carrier shaft ass'y
Housing final
Thrust bearing
Taper roller bearing Thrust washer
Planetary shaft
Oil seal Needle bearing
Stud bolt Planetary gear
Adaptor Washer
Stud bolt
Lock nut Pin spring

O-ring
Wheel cap Carrier shaft
Bolt
Disassembly of wheel sub assembly

• Remove the wheel cap fixing socket bolts (4ea)
from the wheel adaptor with appropriate tool.
Disassembly of carrier shaft ass'y
• Remove the fixing bolts (4ea) of lock nut.
• Remove the lock nut fixed to the wheel adaptor • Set the carrier shaft ass'y on the flat bottom place.
from the carrier shaft. • Remove the planetary gear shaft fixing pin spring
• Remove the wheel adaptor from the carrier shaft by using pliers or tool.
by using gear puller. • Remove the planetary gear shaft by tapping two or
three times with hammer or tool.
NOTE
• -Repeat the removal to three places.
Pay attention not to do damage the oil seal
assembled to the wheel adaptor.
! CAUTION
• Place the axle end on the press and remove the When reassemble, the pin spring can be
taper roller bearing. omitted.
Check if the pin spring is assembled when the
assembly is completed.
20-5-2 • Disassembly and Reassembly of axle end SM 765

Section 6
Adjustment
Preloading and adjustment of hub • Re-measure the assembly product with dial gauge.
taper roller bearing • When compare the measured value with gauge, if
the space is plus value based on the gap, insert
spacer with small width and if it is minus value,
insert the space with big width. Apply different
spacer based on the measured value.
Lock Nut
Lock nut
Measuring
Master Adapter
Oil Seal
Taper roller
bearing
Spacer
Figure A Carrier ass'y
Required tool for assembly

Lock nut assembly adaptor
Torque wrench, 20kgf.m (145 lbf.ft) setting Figure B
(-) Screwdriver
Rubber hammer
Adjustment order of preloading
How to measure the space • Place the bearing cup into final housing and press-
fit it to the housing with assembled jig.
Measurement when the space isn't assembled • Locate the measuring spacer as shown in the
• Use measuring master to measure the space. above figure.
(Refer to the figure A for measurement of space)
• Press-fit the outer ring of bearing to the housing.
• Place the taper roller bearing as shown in the fig-
• Assemble the taper roller bearing to carrier shaft,
ure B.
set the preload adjustment nut up to 20kgf.m (145
lbf.ft) and measure and record with dial gauge. • Press-fit the bearing with press and pressurizing
jig.
Measurement when the space is assembled • Press the adapter into carrier shaft.
• Hit it with plastic hammer and rotate the wheel
• Assemble the spacer based on the above method adaptor two or three times.
and apply the preload. Set the torque value by tightening the preloading
SM 765 Adjustment • 20-6-1

adjustment nut.
(Torque wrench, torque setting: 3920 kgf.cm, 285
lbf.ft)
• Tighten the 4 bolt to prevent the looseness with
loctite #277.
• Measure the preloading value with push-pull
gauge as shown in the figure C.
(Specification: Push-pull gauge torque: 12kgf.cm
~15kgf.cm, 10 lbf.in~13 lbf.in)
mGj
20-6-2 • Adjustment SM 765

Adjustment of brake disc gap
Required tool for setting Measured value and stroke specification

Measuring jig
Dial gauge Measured value Setting stroke
-0.15 0.95
Preloading adjustment order -0.10 0.9
• Assemble the disc and plate to the plate housing. -0.05 0.85
• Install the jig for measurement to contact on the 0 0.8

disc and plate housing surfaces. 0.05 0.75
• Place the dial gauge on the jig. 0.1 0.7
• Measure the stage differences between jig sur- 0.15 0.65
faces.
(Caution: measure it when apply the preload to
brake disc[150kg.cm, 107 lbf.ft]) - Specification : 0.85~0.9mm
• The gap when the deviation of dial gauge is "0".
(It accurately sets to 0.9mm)
• Set the gap adjustment according to the measured
value of gap based on the thickness of back plate.
• Refer to the specification to set the stroke.
• When measuring gap is based on 0.9mm, if it is
plus value, apply the thicker plate.
• When measuring gap is based on 0.9mm, if it is
minus value, apply the thinner plate.
SM 765 Adjustment • 20-6-3

Adjustment of thrust needle • Record the value that the dial gauge shows.
bearing gap • Calculate the stage differences of drive axle and
wheel, and set the gap of shaft direction.
• Set the thrust needle bearing based on gap specifi-
cation.
(Specification : 0.05~0.1mm)
Calculation of measured value and shim

adjustment
• Adjust it by summing the measured values of
wheel and drive axle and deducting the existing
shim (3t).
Figure D. Drive axle assembly • If the summed value is "0", set the gap with
0.1mm.
Apply the different spacer based on the measured
value (for example, 3T, 3.1T, 3.2T)
Required tool for setting
Measuring jig
Dial gauge
How to measure the gap

• Install the assembled axle ass'y to the exclusive jig
or flat bottom.
• Set the measuring jig as shown in the figure D.
• Place the dial gauge on the measuring jig and mea-
sure the stage differences of jig.
• Record the value that the dial gauge shows.
• Install the assembled wheel ass'y to the exclusive
jig or flat bottom as above method.
• Set the measuring jig to axle end assembly as
shown in the figure E.
Figure E. Axle end assembly
20-6-4 • Adjustment SM 765

GROUP 22
GROUP 22
WHEELS AND TIRES
Wheels and Tires Specifications and

Description ................................................ Section 1
Pneumatic Wheels and Tires ....................Section 2
SM 765 Group 22, Wheels and tires

Group 22, Wheels and Tires
Section 1
Wheels and Tires Specifications and Description
Specifications Description
Steer Tire Types : Pneumatic rubber/Cushion rubber, non- The wheels and tires used on the truck come in pneumatic
marking, and urethane. or cushion types in a variety of sizes depending on truck
model and application. Pneumatic tires are mounted on
Drive Tire Types : Pneumatic rubber/Cushion rubber,
multi-piece rims with locking rings.
nonmarking, and urethane.
Pneumatic Drive and Steer Tire Inflation Pressure : ! WARNING
Drive : 800 kPa (116psi) For your safety and the safety of others,
Steer : 1000 kPa (145psi) before you do tire or rim maintenance or ser-
vice, read the OSHA rules regarding owner
responsibility. Do not work on tires or rims
Fastener Torques unless you have been trained in the correct
procedures. Read and understand all mainte-
Steer Tire Mounting Nut Torque : Check mounting proce-
nance and repair procedures on tires and
dure in Sections 2 and 3 for cushion and pneumatic tires
rims. Serious injury or death can result if
and wheels.
safety messages are ignored.
Drive Wheel Mounting Nut Torques :
1 Piece (black) 180-210 Nm (133-155 lbft) The Occupational Safety and Health Act (OSHA) speci-
fies required procedures for servicing multi-piece rim
wheels in 29 CFR Section 1910.177. It is the owner’s
Service Intervals responsibility to comply with OSHA.
Wheel Mounting Bolts Check and Tightening : Every 50- In accordance with OSHA, the owner must provide a
250 hours of operation and each PM. training program to train and instruct all employees who
Tire Condition : Daily inspection. service multi-piece rim wheels in the hazards involved
and the safety procedures to be followed. Do not let any-
Tire Pressure Check : Daily inspection. one mount, demount, or service multi-piece rim wheels
without correct training.
The owner should obtain and maintain in the service area
current copies of the United States Department of Trans-
portation, National Highway Traffic Safety Administra-
tion publications entitled “Safety Precautions for Mount-
ing and Demounting Tube-Type Truck/Bus Tires,” and
Multi-Piece Rim/Wheel Matching Chart” or other similar
publications applicable to the types of multi-piece rim
wheels being serviced.
SM 765 Wheels and Tires Specifications and Description • 22-1-1

Section 2
Pneumatic Wheels and Tires
in this manner can result in damage to the rim and

! CAUTION truck tip-over and driver injury.
SAFE PARKING. Before working on truck : 4. Do not fill a tire with air that has been run flat with-
1. Park truck on a hard, level, and solid out first inspecting the tire, rim, and wheel assembly.
surface, such as a concrete floor with no Double check the lock ring for damage. Make sure
gaps or breaks. that it is secure in the gutter before filling the tire
with air.
2. Put upright in vertical position and fully
lower the forks or attachment. 5. Always remove all air from a single tire and from
both tires of a dual assembly prior to removing any
3. Put all controls in neutral. Turn key switch rim components, or any wheel components, such as
OFF and remove key.
nuts and rim clamps. Always remove the valve core
4. Apply the parking brake and block the to remove air from tire. Be sure all air is removed.
wheels.
6. Check rim components periodically for fatigue
cracks. Replace all cracked, badly worn, damaged,
Pneumatic Tire Maintenance and severely rusted components.
Precaution 7. Do not, under any circumstances, attempt to rework,
weld, heat, or braze any rim components that are
The following instructions supplement the OSHA require-
cracked, broken, or damaged. Replace with new parts
ments. In the event of any conflict or inconsistency
or parts that are not damaged, which are of the same
between these instructions and the OSHA requirements,
size, type, and make.
the OSHA requirements shall be controlling.
8. Never attempt to weld on an inflated tire/rim assem-
! WARNING bly.
Before you do tire or rim maintenance, read 9. Clean rims and repaint to stop detrimental effects of
the OSHA rules regarding owner responsib- corrosion. Be very careful to clean all dirt and rust
lilty. Read and understand all maintenance from the lock ring gutter. This is important to secure
and repair procedures on tires and rims. Do the lock ring in its proper position.
not work on tires or rims unless you have A Filter on the air filling equipment to remove the
been trained in the correct procedures. Seri- moisture from the air line prevents a lot of corrosion.
ous injury or death can result if the safety The filter should be checked periodically to make
messages are ignored. sure it is working properly.
10. Make sure correct parts are being assembled. Ask
1. Do not let anyone mount or demount tires without your distributor or the manufacturer if you have any
proper training. doubts.
2. Never sit on or stand in front of a tire and rim assem- 11. Do not be careless or take chances. If you are not
bly that is being filled with air. Use a clip-on chuck sure about the proper mating of rim and wheel parts,
and make sure the hose is long enough to permit the consult a wheel and rim expert. This may be the tire
person filling the tire with air to stand to the side of man who is servicing your fleet, the rim and wheel
the tire, not in front or in back of the tire assembly. distributor in your area, or the CLARK dealer.
3. Never operate a vehicle on only one tire of a dual 12. Mixing parts of one manufacturer’s rims with those
assembly. The carrying capacity of the single tire and of another is potentially dangerous. Always ask man-
rim is dangerously exceeded, and operating a vehicle ufacturer for approval.
SM 765 Pneumatic Wheels and Tires • 22-2-1

13. Do not use undersized rims. Use the right rims for handled gauge to keep your body away from
the job. the side.
14. Do not overload rims. Ask your rim manufacturer if
special operating conditions are required.
15. Do not seat rings by hitting with a hammer while the
tire is filled with air pressure. Do not hit a filled or
partially-filled tire/rim assembly with a hammer.
16. Double check to make sure all the components are
properly seated prior to filling tire with air.
17. Have the tire in a safety cage when filling with air.
18. When removing wheels, regardless or how hard or
firm the ground appears, put hardwood blocks under
the jack. • If tires are low, do not add air. Have the tire and
wheel inspected by a person trained and autho-
19. Block the tire and wheel on the other side of the vehi- rized to do tire and wheel maintenance. The tire
cle, before you place the jack in position. Place may require removal and repair.
blocks under the truck frame as near as possible to • Incorrect (low) tire pressure can reduce the sta-
the jack to prevent the truck from falling if the jack bility of a lift truck and cause it to tip over.
should fail.
IMPORTANT
20. Remove the bead seat band slowly to prevent it from
Check wheels and tires for damage every
dropping off and crushing your toes. Support the
time you check tire pressure. Make repairs
band on your thigh and roll it slowly to the ground.
when needed. Dirt can get into cuts and cause
This will protect your back and feet.
damage to the tire cord and tread. Remove
21. Bead breakers and rams apply pressure to bead debris from all cuts.
flanges. Keep your fingers away from the bead
flanges. Slant bead breaker about 10q to keep it 2. Check the condition of the drive and steer wheels and
firmly in place. If it slips off, it can fly with enough tires. Remove objects that are imbedded in the tread.
force to kill. Always stand to one side when you Inspect the tires for excessive wear, cuts and breaks.
apply hydraulic pressure.
General Tire Maintenance, Inspection,

and Repair
1. Park the truck as described in “Safe Parking” and
check for correct tire inflation air pressure.
• Drive : 800 kPa (116psi)
• Steer : 1000 kPa (145 psi)
3. Check all wheel lug nuts or bolts to be sure none are
! CAUTION loose or missing. Have missing bolts replaced and
loose bolts tightened to the correct torque before
Check tire pressure from a position facing operating the truck.
the tread of the tire, not the side. Use a long-
• Torque pneumatic steer tires to 225-250 Nm (165-
185 ftlb).
• Torque 1 piece black lug nuts for pneumatic drive
tires to 180-210 Nm (133-155 ftlb).
22-2-2 • Pneumatic Wheels and Tires SM 765

Inspection and Minor Repair 2. Loosen the five lug nuts on the wheel.
Inspect pneumatic tires and wheels carefully for.

1. Low inflation pressure.
2. Damaged tires. Check tires for cuts and breaks.
3. Damaged wheels or loosening of the lock ring on
multi-piece rims.
Steering
Axle hub
Wheel
wedge
Lock
ring
4. Check for loose nuts or bolts not in position.

5. Check the nuts or bolts for damage.
6. Check the surface of the wheels for bent flanges.
7. Check all parts for rust or corrosion. Drive
Axle hub
8. Mark the damaged areas with chalk so that the parts
can be removed from operation. 3. Use a portable jack of adequate capacity placed
9. Remove all parts that are damaged and install new under the frame of truck to raise drive or steer wheels
parts in the same position. off floor.
10. Replace parts with the correct sizes and types. See 4. Once tire is off the ground enough to rotate freely,
your parts manual. remove the lug nuts and lift the wheel from the hub.
Use caution when lifting tire and wheel.
11. Include your truck serial number when ordering
replacement parts.
Drive and Steer Wheel Remounting
Wheel Dismounting and Remounting IMPORTANT
See “Tire Installation” in this Section to
Refer to “Lifting, Jacking, and Blocking” in Group SA for
make sure the wheel and tire mounting ori-
information on jacking up or raising the truck for wheel
entation is correct. Check the information for
removal. Always start with the truck parked safely.
correct tire-to-wheel mounting and wheel-to-
hub mounting.
Drive and Steer Wheel Dismounting
1. Make sure the truck is parked on a flat, hard surface
1. Remove the valve core from the valve stem to be and the jacking and blocking devices are secure to
sure all air is removed from the tire. hold the truck in a safe position.
2. Inspect the removed lug nuts for damage to the
threads. Also inspect all hub studs for thread damage.

Replace any lug nuts or studs that have damaged rate from the rim with enough force to cause
threads. Make sure studs are secure in the axle hub. injury or death.
Wheel Disassembly and Tire Removal

1. Remove valve core from the valve stem to be sure all
air is removed.
! WARNING
Before starting disassembly, remove the air
3. Set the wheel on the hub and start the lug nuts on the
from the tire. Failure to remove the air from
hub studs. Tighten the nuts only enough to seat the
the tire can result in serious injury.
nuts into the beveled openings on the wheel and to
secure the wheel on the axle hub.
2. Remove lock ring.
4. Use a crisscrossing nut tightening sequence to torque
Lock Ring
the nuts to a pre-final torque of 54-81 Nm (40-60
ftlb). Make sure all nuts seat into beveled spacer
holes correctly. Wheel
Wedge
3. Remove wheel wedge.

4. Remove tire from wheel.
5. Begin the crisscrossing sequence again and tighten

the lug nuts to final torque.
• Torque drive wheel 1 piece lug nuts to 180-210
Nm (133-155 ftlb).
• Torque steer wheel lug nuts to 225-250 Nm
(165-185 lbft).
6. Carefully lower the truck and remove the jack.
7. Check tire pressure for correct inflation pressure. 5. Remove the rubber inner tube protector (flap).
• Drive wheel pressure is 800 kPa (116psi)
• Steer wheel pressure is 1000 kPa (145 psi).
! WARNING
If tires are not fully inflated, see “Adding Air
Pressure To Mounted Wheel/Tire Assem-
blies” and follow the procedures for adding
air to the mounted tires.
Before you add air pressure to the tire, make
sure the lock ring is correctly positioned in 6. Repair tire and/or tube, as needed.
the rim and side ring. The lock ring can sepa-

7. Check for cracks in the wheel. 12. Clean the tire bead seat area. Remove all rust and
rubber with a wire brush or wheel.
Cracks in the wheel are caused by :

• Deep rim tool marks.
13. Clean wedge and lock rings. Make sure the seating
• Overload on wheels. surface and bead seat areas are clean.
• Too much air pressure in the tires.
• Using the wrong size tires.
8. Check for cracks in the lock ring.
9. Check for cracks between the stud holes in the wheel.
Cracks are caused by :
• Loose wheel nuts.
• Wheel not installed correctly.
• Wrong size or type of parts used.
• 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 14. Apply paint to the tire rim with a brush. Or, use an
between the stud holes. aerosol can of metal primer.
• Too little torque on the wheel fasteners. If the The parts must be clean and dry before you apply the
wheel mounting parts are too loose, damage to paint. Make sure to apply paint to the outside or tire
parts and tire wear will result. side of the rim. This is important because air is on the
metal surface of the tire side of the rim
10. Check wedge ring for wear or damage. Corrosion
buildup will cause wear and damage to the wheel 15. Apply lubricant on the tire side of the rim base. Do
wedge ring. not use a lubricant that has water or solvent which
will cause damage to the rubber.
11. Clean the wheels. Remove rust and dirt.
NOTE
Clark dealers can supply the correct lubri-
cant, which contains a rust inhibitor.

Tire Replacement and Wheel 5. Install the wheel wedge.

Reassembly
1. Put the tube into the tire.
6. 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
7. Connect air chuck and turn the tire over with the
2. Put the rubber tube protector(flap) over the tube. valve stem down. Put 21 kPa (3 psi) of air into the
tire.
3. Install the tire onto the wheel rim, against the bead
seat area.
8. Turn wheel to the other side. Check to make sure

lock ring is in correct location.
4. Put the wheel wedge over the rim.

9. Disconnect the air chuck. Use a mallet and hit the Directional-Tread Single Drive Tires
ring to make sure the ring is fully installed. • Tire arrow to point in the dirction of forward rota-
tion. Rotate wheel to bring arrow on tire above the
wheel center. Arrow must point toward front of
truck.
Inside
10. Put the tire in an OSHA-approved safety cage.

Front of truck
Tire-to-Wheel Mounting
Directional-Tread Tires
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.

Filling Tires with Air 2. Turn the regulator valve counterclockwise (CCW)
until you can feel no resistance from the regulator.
Follow these procedures when putting air into tires. All This will adjust the regulator presssure to a low pres-
wheel and tire assemblies must be filled in a safety cage. sure near zero.
The hose must have an adapter that can be connected to
the valve stem.
1. Attach an air hose to valve stem.
2. Open the control valve which will let compressed air
into the tire.
3. At intervals, close the control valve and check the
pressure in the tire by reading the gauge. Do not put
too much presssure into the tire.
4. Continue to fill the tire to the correct air pressure
reading of 3. Slowly turn the cylinder valve counterclockwise
Drive tire 800 kPa (116 psi). (CCW) to open position.
Steer tire 1000 kPa (145 psi)
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

If your air supply does not have enough pressure to fill the
tire, you can use a pressurized cylinder of commercial 4. The tank gauge will now show tank pressure.
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, regula-
tor, gauges, hoses) are UL approved and in
good condition. Use the correct regulator and
hose for the pressures that are necessary. 5. Turn the regulator valve clockwise (CW) until the
regulator gauge reads the correct tire pressure. Fill
1. Be sure tank valve is closed to connect hose to valve the tire with nitrogen.
stem. Tank vlave is closed by turning handle on top
of tank clockwise to a stop.

6. Turn the tank valve clockwise (CW) and close the Checking and Adjusting Tire Pressure
valve.
! 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.
1. 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.
8. Turn the regulator valve counterclockwise (CCW) to

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

fill the tire, you can use a nitrogen cylinder to get the
correct pressure.
9. 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.
3. Put a clip-on type air chuck on the nitrogen cylinder
! CAUTION hose and attach it to the valve stem. Follow the pro-
Use a long-handled gauge so that your hand cedures described previously for adjustment of the
does not go inside the cage, or in front of any nitrogen cylinder valves.
component of a multi-piece wheel.
! WARNING
Use nitrogne only. Do not use oxygen or any
other gas to fill tires.

GROUP 23
GROUP 23
BRAKE SYSTEM
Brake System Specifications and Description ..... Section 1
Service Brake Troubleshooting ............................ Section 2
Brake Pedal Linkage & Adjustments .................. Section 3
Brake Bleeding ....................................................... Section 4
Pedal and Master Cylinder Service ...................... Section 5
Parking Brake Service ........................................... Section 6
SM 765 Group 23, Brake system

Group 23, Brake System
Section 1
Brake System Specifications and Descriptions
Specifications ......................................................... 2
General Description .............................................. 2
Service Brake Operation ....................................... 2
Park Brake Operation ........................................... 2
Service Requirements ............................................ 2
SM 765 Brake System Specifications and Descriptions • 23-1-1

Specifications Service Brake Operation

The Service brake pedal operates a master cylinder
Service Brake:
mounted on the front frame. The master cylinder operates
Type: Wet disc brake a wheel cylinder. The wheel cylinder operates a shoe lin-
ings to be contacted on drum.
Fluid: Hydraulic fluid, RANDO HD32 or NUTO H32
in accordance with CLARK specification MS-68
(CLARK #2776239) Parking Brake Operation
Pedal Freeplay: None Operate the brake by pulling the hand brake mounted on
the battery hood. The depressed pedal tensions cables
Parking Brake: connected to a brake shoe at each brake assembly, thereby
Type: Hand brake linked to service brake at each wheel. applying the brakes.
Holding Test: Rated load on 15 % grade. Press the button on the front side of hand brake, then the
parking brake will be released. This handle releases the
ratchet, and a return spring returns the pedal and cable to
the off position. The ratchet also operates the parking
brake interlock switch and the parking brake indicator
light switch.
General Description
Brake pedal linkage - A mechanical system through which Service Requirements
the brake pedal operates the master cylinder.
Operational checks and inspection of linkage, brake lin-
Master cylinder - The pistons are activated by brake pedal ing, and brake lines are specified in the Periodic Service
movement. Chart in Group PS.
Brake lines - These lines carry the brake flow from the Service brake linkage adjustment and lube are not nor-
master cylinder to the wheel cylinders. mally required.
Service brake assembly - The drums, shoes and wheel cyl- Brakes are self-adjusting and normally require no adjust-
inders. ment.
Parking brake-Operates the service brake shoes via A leaking master cylinder should be overhauled or
cables. See “Parking Brake Adjustment”, in this Group for replaced.
details.
23-1-2 • Brake System Specifications and Descriptions SM 765

Brake lever &

Pedal
Master Cylinder
Return spring
Brake Line to
Master Cylinder
SM 765 Brake System Specifications and Descriptions • 23-1-3

Section 2
Service Brake Troubleshooting
Service Brake Troubleshooting ............................ 2
SM 765 Service Brake Troubleshooting • 23-2-1

Service Brake Troubleshooting

Causes/Corrective
Condition Actions
Brake pedal drops to floor .................................................................................................................... A C E
Brake pedal spongy ................................................................................................................................. A B
Brakes stick, drag excessively, make noise, or overheat ..................................................................... D E F
Excessive effort required to apply brake ................................................................................................. A E
Causes/Corrective Actions
A. External leak in wheel cylinder or other component of braking system ............. Inspect/replace/repair.
B . Air in braking system ............................................................................................... Bleed and recheck.
C . Linkage broken or return spring damaged ...................................................................... Inspect/repair.
D. Brake master cylinder defective..................................................................Inspect/overhaul or replace.
E . Brake disc. worn or brakes misadjusted................................................................ Inspect/repair/adjust.
F . Parking brake misadjusted .......................................................................................................... Adjust.
23-2-2 • Service Brake Troubleshooting SM 765

Section 3
Brake Pedal Linkage & Adjustments
Introduction ........................................................... 2
Adjustment ............................................................. 2
SM 765 Brake Pedal Linkage & Adjustments • 23-3-1

Introduction If you want to adjust the height of brake pedal, adjust the
height as 25mm by use of stop bolts of brake pedal and
The illustration shows the service brake linkage which then lock the nuts.
links the brake pedal to the master cylinder.
Tighten the stop bolts and nuts with torque of 20-
25N.m(14-18 ft.lb).
Adjustment
Adjust the master cylinder push rod assembly to eliminate
any slack in the pedal linkage. Adjust only the minimum
required to remove pedal play.
Brake Reservoir
Brake Lever &

Pedal
Master Cylinder
Jam Nut &
Push Rod Assembly
Stop Bolt
Return Spring
Brake Line to
Master Cylinder
23-3-2 • Brake Pedal Linkage & Adjustments SM 765

BRAKE MASTER
CYLINDER
AXLE DISK.
BRAKE
Tire
SM 765 Brake Pedal Linkage & Adjustments • 23-3-3

Section 4
Brake Bleeding
Bleed brakes when: 3. Attach a clear hose to a bleed screw on one of the
brake cylinders. Place the other end of the hose in a
• The brake pedal feels spongy.
jar containing Hydraulic fluid, RANDO HD32 or
• The brake master cylinder or wheel cylinders-or NUTO H32
lines between-have been leaking and/or have been in accordance with CLARK specification MS-68
repaired or replaced. (CLARK #2776239).
• Troubleshooting otherwise indicates that air has
4. Open the bleed screw.
been introduced into the system.
5. Depress the brake pedal and watch fluid flow into the
Bleed the brakes as follows: jar. When the fluid appears to be free of bubbles,
1. Park truck on level floor. Put direction control in tighten the bleed screw, then release the pedal.
neutral. Lower forks to floor, tilt forward, and apply 6. Check the fluid in the brake reservoir. Refill as
parking brake. required.
2. Remove cap from the brake reservoir to be sure it is 7. Release the parking brake and operate the brake
full of fluid. pedal. If the brake pedal does not come up or still
feels spongy, bleed the system again.
SM 765 Brake Bleeding • 23-4-1

Section 5
Pedal and Master Cylinder Service

(Removal, Replacement, and Adjustment)
SM 765 Pedal and Master Cylinder Service (Removal, Replacement, and Adjustment) • 23-5-1
Components Disassembly Freeplay Adjustment

Use Figures 1, 2, and 3 as guide to disassembly and When the brake pedal linkage is properly adjusted, brak-
adjustment. ing should begin only after the pedal is depressed a certain
distance, This is “Freeplay” is Adjusted as follows :
Components Reassembly 1. Loosen the jam nut on the rod brake master cylinder
(Figure 1).
Replace the brake pedal components as shown in Figures
1 and 2 using fastener torques where shown. Also use the 2. Depress the brake pedal 4~6mm (0.16~0.24 in).
following notes: 3. Adjust the rod until you feel the push rod make clear-
1. Clean the reservoir and master cylinder hoses and fit- ance with the cylinder piston.
tings. Make sure no contaminants enter the braking
system.
2. Adjust pedal free play as described in “Pedal Adjust-
ment” on the page.
3. After re-assembly and adjustment, the brake system
must be bled, see Section 2 in this Group. After
bleeding, check all fluid connections for leaks and
test brakes completely before returning truck to ser-
vice.
23-5-2 • Pedal and Master Cylinder Service (Removal, Replacement, and Adjustment) SM 765
Reservoir
Brake Lever &

Pedal Hose to Master Cylinder
Master Cylinder
Stop Screw
Pedal Spring
SM 765 Pedal and Master Cylinder Service (Removal, Replacement, and Adjustment) • 23-5-3
Section 6
Parking Brake Service
Operation 2. Actuate and release pedal six to eight times.
Operate the brake by pulling the hand brake mounted on 3. Readjust and tighten nuts.
the battery hood. The pulled hand lever tensions cables
connected to a brake shoe at each brake assembly, thereby Removal and Replacement
applying the brakes.
As shown in illustration below, with these notes:
Press the button on the front side of hand brake, then the
parking brake will be released. This handle releases the • Adjust position of interlock and indicator switches
ratchet, and a return spring returns the pedal and cable to with pedal upstop against tab on bracket. Switch
the off position. The ratchet also operates the parking contacts should snap from their operated contact
brake interlock switch and the parking brake indicator position to their normal position when pedal is
light switch. depressed one ratchet click.
• Torque switch mounting nuts 0.8-1.0 Nm (7-9
lbfin). Torque bracket mounting nuts 20-25 Nm
Adjustment (177-221 lbfin).
1. With the lever fully lower, upstop against tab on • Apply a thin coat of Clark lubricant, part
bracket, adjust slack out of brake cables and tighten #1802155, to ratchet teeth and ball end of wire
adjusting/locking nuts. rope prior to assembly.
Parking Brake handle Boot
Parking Brake handle
Switch
Parking Brake Cable
<SI-48319>
SM 765 Parking Brake Service • 23-6-1

Parking Brake Cable Removal and 2. Remove the parking cable from the service brake
assembly by first removing the brake shoes as
Installation described in the “Brake Overhaul and Adjustment”
1. Disconnect each parking brake cable from the ratchet Section of this Group.
assembly as shown in the illustration below. 3. Pull out the C-clip that holds the parking brake cable
to the backing plate.
4. Unhook the parking brake cable end from the lever
on the shoe and pull the cable from the assembly.
Lock Nut
Pin
5. Installation is the reverse of removal.
23-6-2 • Parking Brake Service SM 765

GROUP 25
GROUP 25
STEERING COLUMN AND GEAR
Steering System Specifications and Description . Section 1
Steering System Troubleshooting ......................... Section 2
Steering Column Removal and Installation ........ Section 3
Steering System Relief Pressure Check

and Adjustment ...................................................... Section 4
Steering Gear Overhaul ........................................ Section 5
SM 765 Group 25, Steering Column and gear

Group 25, Steering Column and Gear
Section 1
Steering System Specifications and Description
Specifications Description
Steering System Type: Hydrostatic power steering with All truck models have a hydrostatic power steering sys-
load sensing, dynamic signal neutral circuit. tem, which is supplied with oil pressure from the main
hydraulic pump. The steering hand wheel operates the
Steering System Relief Pressure Setting: 10000 kPa (1450
steering gear (steering control unit), which directs oil flow
psi)
to the steering cylinder on the steer axle. A steering sys-
tem pressure relief valve is built into the steering control
unit to prevent over-pressurization of the steering system.
The pressure relief setting can be tested by installing a test
Service Intervals
fitting install Quadrigage at pressure inlet of steering gear.
Check the steering system relief pressure annually or after The power steering gear is a remote positioning control
every 2000 hours of operation. Make a visual inspection valve that senses the input signal from the steering hand
of steering control unit hydraulic fittings periodically to wheel, multiplies this signal to assist in reducing the steer-
ensure that the fittings are tight with no leakage. ing effort, and causes the steering axle to turn the wheels
to the desired position by supplying hydraulic flow to the
Fastener Torques steering cylinder.
Steering Handwheel Nut: 40-45 Nm (30-33 lbfft) The steering gear is connected to the bottom of the steer-
ing column. When the steering hand wheel is turned, it is
linked mechanically to the steering gear spool and causes
this spool valve to shift from its closed neutral position to
a “turn” position that allows oil under pressure to flow to
the steering cylinder.
When the steering hand wheel stops turning, centering
springs in the valve automatically center the spool, stop-
ping the flow of oil to the cylinder.
The low pressure oil from the opposite side of the steering
cylinder is returned through the opposite port in the gear.
It is controlled by the same spool as the high pressure
port.
In the event of a pump failure, the steering gear can gener-
ate sufficient hydraulic power by movement of the steer-
ing handwheel to serve as a limited steering method. An
internal check valve automatically closes to divert this
generated oil flow to the proper port of the steering cylin-
der. The handwheel turning effort is considerably higher,
however, than with power steering.
SM 765 Steering System Specifications and Description • 25-1-1

The column tilt lock mechanism allows the operator to The cover can be removed for service to steering column
adjust the steering column. The column tilt lever knob components. The entire column can be removed for ser-
releases the adjustment setting and the column returns to vice or replacement.
the up position by the use of gas springs. The tilt lock
mechanism, the directional control lever are protected by
the steering column cover.
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25-1-2 • Steering System Specifications and Description SM 765

Section 2
Steering System Troubleshooting
No steering Handwheel kickback

• Hydraulic fluid level very low. • Check valve faulty (or not in system).
• Air in hydraulic oil.
• Steering column sections not connected properly. Slow steering response
• Hose broken. • Oil viscosity too high.
• Hydraulic pump contaminated or defective. • Contaminated or defective steering gear.
• Priority valve spool stuck.
Chatter conditions
Hard steering
• Loose mountings or linkage. Make certain all
• Hydraulic fluid level low. mounting fasteners and other linkage is tight.
• Air in hydraulic oil. • Pressure relief valve set too low and is out of
• Steering gear contaminated or defective. adjustment; adjust or replace the relief valve.
• Relief valve setting too low; adjust or replace. • Insufficient pump flow. Check pump for leaks and
see Section 5 of this Group.
• System leaking.
• Axle load too heavy. Unsatisfactory steering in either direction
• Lack of lubrication.
• Air in system due to excessive wear in steering cyl-
• Defective steering gear.
inder. Check for air in system. Excessive noise or
• Spring in priority valve broken. foamy condition of hydraulic fluid indicates aera-
tion. Check that air is not entering the system
High number of handwheel turns through poor threads, cracked, split, or worn hoses,
bad pump seals, bad O-rings, bad gaskets, or loose
• Steering cylinder seal leakage. connections.
• Worn steering gear.
Worn cylinders result in leakage past the piston.
Overhaul (see Group 26, Section 6) or replace the
Steering handwheel spins freely steer cylinder.
• Air in system (cavitation). • Incorrect system pressure due to worn pump.
• Low oil supply. Replace the relief valve or repair or replace the
• Steering column detached from steering gear. hydraulic pump.
• Defective steering gear.
Noise during turns
Jerky steering • Worn bearing(s) in steering arm; replace bearings.
• Steering gear malfunction because of worn parts or • Worn pin in steering knuckle; replace pin.
contamination. Steering gear may require over- • Worn bearings in steering knuckle; replace bear-
haul. ings.
• Steering knuckle is loose; tighten castle nut.
Truck turns in wrong direction
• Hydraulic lines not installed correctly.
SM 765 Steering System Troubleshooting • 25-2-1

Constant noise from steering axle Low pressure at the steering gear
• Loose or worn hub bearing cones. Adjust or • Refer to Group 26.
replace hub bearing cones. Replace bearing cones
and bearing cups as a set.
Steer cylinder rod binding or sticking
Noise when axle pivots • Binding of linkage. With hydraulic flow shut off
from the cylinder and the rod end uncoupled, the
• Steering axle mountings worn; replace mountings. rod should slide freely in or out by hand. If the pis-
• Steering axle mounting cap(s) loose; tighten ton is binding, overhaul or replace the cylinder.
mounting cap(s).
Fluctuating pressure
• Faulty operation of relief valve. Fluctuating pres-
sure or loss of pressure in the system is usually
caused 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.
25-2-2 • Steering System Troubleshooting SM 765

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 ................................................................2
Steering Gear and Lower Steering Column Removal. .........................................3
Steering Column and Component Replacement ............................................ 4
IMPORTANT
Before removing any component for overhaul, make sure the
correct repair parts, seals, and gasket sets are available.
Steer Handle Upper
Column Upper Cover
Torque: 40-45 N·m

Housing Tilt Lever
(30-33 lbf·ft)
Upper Axis
Torque: 40-45 N·m(30-33 lbf·ft) Lever Nut
Torque:
19 N·m(14 lbf·ft)
Bolt
Column Lower Cover Torque:
44 N·m(32 lbf·ft)
Torque: 40-45 N·m

(30-33 lbf·ft)
Lower Axis
Column Tilt Lock Support
Steer Gear
<SI-46982>
Column Outside Column Inside
Typical Steering Column Assembly
SM 765, Dec ’06 Steering Column and Component Removal and Replacement • 25-3-1
locker switch and pull rear cover smoothly after

! CAUTION removing tilt lock leveler.
1. Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
lower the forks or attachment.
3. Put all controls in neutral. Turn key
switch OFF and remove key. Tilt Lock Lever
4. Apply the parking brake and block the
wheels.
Steering Column and Component Cover Screw

Removal
Determine which component requires service and check
the procedure for removing that component. Read the pro- NOTE
cedure completely before beginning disassembly. Use care when removing the backside cover
as the rocker switch wiring is attached.
Hand Wheel, Light Switch Lever, and
4. Disconnect wire connector assembled to direction
Directional Control Assembly Removal control lever and light switch lever and remove
direction control lever and light switch lever from
1. Disconnect the battery.
steering column by releasing screw.
Steer Handle Cover
Column Tilt Lock Assembly Removal

NOTE
The tilt lock assembly is not serviceable; only
the gas springs are serviceable. The tilt lock
Steer Handle Screw
assembly should be removed only for
replacement as a complete assembly.
Steer Handle Washer
1. Remove the negative cable of battery.
Steer Handle 2. Refer to "Handle, light switch lever and direction
control assembly removal" to remove upper cover.
2. Remove a hand cover and release nut and washer

securing handle to steering column.
3. Remove screws securing both column cover using
(+) driver. Disconnect connector assembled on
25-3-2 • Steering Column and Component Removal and Replacement SM 765, Dec ’06
3. Use (+) drive to remove screws securing lower col- 4. Remove bolts securing tilt assembly to frame.
umn lever and then lower cover.
Tilt Lock Assembly

Column Upper Cover
Column Lower Cover
c_W^\[[è
<SI-46982>
Upper
Steering Gear Removal

Housing Tilt Lever 1. Put a pan under the truck to catch hydraulic fluid
which will drip when fittings are loosened. Label the
Upper Axis hose fittings of the steering gear to make sure they
Lever Nut are reassembled correctly. Loosen and remove the
Torque: hydraulic fittings at the steering gear. Cap the ends to
19 N·m(14 lbf·ft) prevent fluid leaks. Cap the steering gear ports to
Bolt prevent dust and debris from getting into the steering
Torque:
gear. Keep hydraulic ports and hoses clean.
44 N·m(32 lbf·ft)
Lower Axis
Column Tilt Lock Support
Steering Gear
SM 765, Dec ’06 Steering Column and Component Removal and Replacement • 25-3-3
2. Remove the bolts securing the lower column shaft Steer Column and Component
and steering gear to the bracket on the frame.
Replacement
These steps cover the procedures for reinstallation of the
steering column including the steering gear, the tilt lock
Mounting Screw assembly, directional control assembly, ignition switch,
and steering hand wheel and horn.
IMPORTANT
Make sure all parts are clean and dry before
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
Steering Gear
have the correct alignment, torque all fittings
<SI-46982> to their correct specifications.
1. Component replacement and reassembly is in reverse

order of removal.
3. Remove the lower shaft and steering gear assembly
from the truck.
25-3-4 • Steering Column and Component Removal and Replacement SM 765, Dec ’06
Section 4
Stering System Relief Pressure Check and Adjustment
! CAUTION ! WARNING
SAFE PARKING. Before working on truck: Do not use your hands to check for hydraulic
leakage. Use a piece of cardboard or paper to
1. Park truck on a hard, level, and solid search for leaks. Escaping fluid under pres-
surface, such as a concrete floor with no sure can penetrate the skin causing serious
gaps or breaks. 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
3. Put all controls in neutral. Turn key which eject fluids under high pressure.
switch OFF and remove key. If any fluid is injected into the skin, it must
be surgically removed within a few hours by
a doctor familiar with this type of injury or
wheels.
gangrene may result.
Description and Operation Steering System Relief Pressure Setting

Steering system relief pressure settings above the speci- Check and Adjustment
fied values can cause failure of the hydraulic lines, dam-
age to seals in the steering gear, and ball joint breakage on This procedure requires installation of a pressure gauge at
the steer axle. the gauge port on the main hydraulic pump. The pressure
is measured while the steering wheel is fully turned in one
The steering system’s pressure relief valve is part of the direction to put the steering system in bypass.
main hydraulic pump assembly. Steering system relief
pressure is adjustable and should be checked if indicated The steering system relief pressure setting may be
by troubleshooting. Use the gauge port on the pump to checked using a Mico Quadrigage (Clark Part No.
check steering relief pressure. 1800106) or with a conventional pressure gauge with a
range of 0-20,700 kPa (0-3000 psi).
Steering system relief pressure setting should be 10000
kPa (1450 psi). 1. Tilt the steering column fully forward and raise the
seat deck to access the hydraulic control valve.
NOTE 2. Remove the floor plate to access the steering gear.
If relief pressure is not correct, the problem See removal and replacement procedures in Group
may be caused by dirt in the valve or worn 38.
parts, including steering control valve and
main hydraulic pump. Generally, if the relief
pressure measured when the steering system
is in bypass is not correct, the priority
demand valve should be replaced.
SM 765 Stering System Relief Pressure Check and Adjustment • 25-4-1

3. Clean the ports on the steering gear and the pressure

gauge.
4. Connect the pressure gauge to the pressure (P) inlet
port on the steering gear.
To increase
To decrease
8. Repeat check and adjustment procedure until correct

relief pressure is set.
• Once you adjust to the correct relief pressure set-
5. Put the key in the key switch and turn the truck ON. ting, replace the plug in the control valve.
6. Turn the steering wheel in one direction until the • If the correct relief pressure cannot be maintained,
steering cylinder reaches its stop (relief bypass). consider overhauling or replacing the steering gear
Hold the steering wheel fully in relief position the and/or the pressure relief valve section.
pressure reading is taken, and then release. Turn the
9. Disconnect the pressure gauge from the steering
key switch to OFF. The pressure should read approx-
gear.
imately 10 000 kPa (1450 psi).
10. Replace the floor plate and lower the seat deck.
IMPORTANT
Do not operate system over relief any longer
than required to read the pressure gauge.
Prolonged time at relief pressure can result
in a damaged pump and/or valve.
7. To adjust the steering pressure relief to 10000 kPa

(1450 psi).
a. Carefully remove the plug on the steering pres-
sure relief valve of the main control valve.
b. Adjust the relief pressure:
- Specification : 10000 kPa (1450 psi)
- To increase : turn clockwise
- To decrease : turn counterclockwise.
25-4-2 • Stering System Relief Pressure Check and Adjustment SM 765

Section 5
Steering Gear Overhaul
IMP ORTANT
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 765 Steering Gear Overhaul • 25-5-1

Disassembly 5. 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.
6. Remove seal from meter.

Meter (Gerotor) End
7. Remove drive spacer(s).
1. Clamp unit in vise, meter end up. Clamp lightly on
edges of mounting area, as shown. Use protective 8. 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.
3. Remove end cap.

4. Remove seal from end cap.
25-5-2 • Steering Gear Overhaul SM 765

12. Place assembly so shaft is horizontal. Rotate spool IMPORTANT

and sleeve until pin is horizontal. Push spool and Do not bind spool and sleeve in housing.
sleeve assembly forward with your thumbs just far Rotate spool and sleeve assembly slowly
enough to free seal gland bushing from housing. when removing from housing.
Remove bushing.
17. Push pin from spool and sleeve assembly.
18. 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.
14. Use a thin-bladed screwdriver to pry dust seal from

seal gland bushing. Do not damage bushing.
15. Remove two bearing races and the needle thrust
bearing from spool and sleeve assembly. 19. Push spool back through and out of sleeve. Rotate
spool slowly when removing from sleeve.
20. Remove seal from housing.
16. Remove spool and sleeve assembly from cap (14-

hole) end of housing.
21. Remove set screw from housing.

22. 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.
23. Remove two seals from check valve seat.
24. Tip housing to remove check ball and check ball
retainer.

Parts Inspection 4. Lubricate check ball seat and seals thoroughly before
installing seat in housing. When installing seat do not
Inspect all parts for damage, cracks, broken parts, dam- twist or damage seals. Install check ball seat in hous-
aged threads, corrosion or erosion of surfaces, worn spots, ing; insert open end of seat first. Push check ball seat
nicks or scratches. to bottom of hole.
Check all mating surfaces. Replace any parts that have 5. Install set screw. Use a 5/16-inch Allen wrench to
scratches or burrs that could cause leakage. Discard all old torque set screw to 11 Nm (100 in-lb; 8.3 ftlb). To
seals and replace with new ones. prevent interference of parts, make sure top of set
Clean all metal parts in clean solvent. Blow dry with air. screw is slightly below housing mounting surface.
Do not wipe dry with cloth or paper towel because lint or 6. Assemble spool and sleeve carefully so that the
other matter can get into the hydraulic system and cause spring slots line up at the same end. Rotate spool
damage. Do not use a coarse grit or try to file or grind while sliding parts together. Some spool and sleeve
these parts. sets have identification marks ; align these marks.
If parts are left exposed, cover them with a clean cover to Test for free rotation. Spool should rotate smoothly
prevent airborne dust from collecting on them. in 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. 7. Bring spring slots of both parts in line and stand parts
Do not use excessive lubricant on seals for on 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 inter- (or two sets of 3 each) on bench so that extended
nal 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
1. 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
2. Install check ball in housing.
pairs of centering springs) units.
3. Lubricate 5/8-inch diameter seal and 7/16-inch diam-
eter seal. Install seals on check ball seat, as above.

8. Compress extended end of centering spring set and 13. Install two bearing races and the needle thrust bear-
push into spool sleeve assembly withdrawing instal- ing in the order shown.
lation tool at the same time.
9. Center the spring set in the parts so that they push
down evenly and flush with the upper surface of the
spool and sleeve.
10. Install pin through spool and sleeve assembly until
pin becomes flush at both sides of sleeve.
14. Install 1-1/4-inch diameter dust seal in seal gland

bushing; flat or smooth side of dust seal must face
11. Position the spool and sleeve assembly so that the down towards bushing.
splined end of the spool enters the 14-hole end of 15. Install dry quad ring seal in seal gland bushing.
housing first. Smooth 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.
12. Place housing on clean, lint free cloth. Install 2-1/8-

inch diameter seal in housing.

16. 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 18. Clamp housing in vise, as shown. Clamp lightly on
the bearing race. edges 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 Teflon NOTICE
seals and the non-grooved bushings used only Check to ensure that the spool and sleeve are
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.
17. 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.
20. Install spacer plate. Align bolt holes in spacer plate

with tapped holes in housing.

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. 25. Install 3-inch diameter seal in end cap.
26. Install end cap on gerotor, and align holes.
NOTE
To assure proper alignment, mark spline end 27. Install 7 dry cap screws in end cap. Pretighten screws
of drive shaft with a line parallel to slot on to initial torque of 17 Nm (150 inlb), then torque
other end, before installing. screws to final torque of 31 Nm (275 inlb) in the
sequence shown.
22. Install 3-inch diameter seal in meter (gerotor).
23. With seal side of meter toward spacer plate, align star
valleys on drive. Note the parallel relationship of ref- 28. Inspect the assembly to be sure all parts have been
erence lines A, B, C, and D in figure. Align bolt installed and fasteners correctly installed and tight-
holes without disengaging meter from drive. Be sure ened.
star has engaged drive spline in position shown.

GROUP 26
GROUP 26
STEERING AXLE
Steering Axle Specifications and Description ...... Section 1
Steering Wheel Bearing

Maintenance and Adjustment ............................... Section 2
Steering Axle Removal and Installation .............. Section 3
Steering Axle Overhaul ......................................... Section 4
Steering Cylinder Removal and Installation ....... Section 5
Steering Cylinder Overhaul .................................. Section 6
Pivot-Turn Steering Axle Maintenance ................ Section 7
SM 765 Group 26, Steering Axle

Group 26, Steer Axle
Section 1
Steering Axle Specifications and Description
Specifications Service Intervals

Steering System Relief Pressure Setting : 10000 kPa Steering Linkage Inspection and Lubrication: Every 50-
(1450 psi) 250 hours and each PM.
Steer Cylinder Type : Double-acting, piston-type Steer Wheel Bearing Inspection and Lubrication: Every
50-250 hours of operation.
Turning Arc : 100q maximum inside turning angle
70q maximum outside turning angle. Steer Cylinder Seals Leakage Check: Every 50-250 hours
and each PM.
Bearing Grease : Grade No. 2 EP multi-purpose grease,
Clark Part MS-107C. Steer Axle Mounting Inspection: Every 50-250 hours and
each PM.
Fastener Torques Power Steering Relief Pressure Check: Every year or
2000 hours of operation.
Steer Axle Mounting Bolts: 170-190 Nm (125-140 lbfft)
Cylinder to Axle Mounting Bolts: 280-320 Nm (205- Description
234.5 lbfft)
The steer axle has the steer cylinder, steer knuckles, and
steering links mounted on it. All these components can be
removed, serviced, and replaced.
The steering gear (steering control unit) at the base of the
steering column directs hydraulic fluid to one end or the
other of the steer cylinder to pivot the steer wheels.
The steer axle is bolted to the truck frame. The steer cylin-
der is connected to the steering knuckles by steer links.
Mounting trunnions allow the axle to tilt independently of
the truck and “silent” mounts cushion the axle on the trun-
nions.
All bearings used in the steer axle linkage have lubrication
fittings and are serviceable. Axle removal, replacement,
and service for all components, including overhaul of the
steer cylinder, is explained in the Sections for this Group.
SM 765 Steering Axle Specifications and Description • 26-1-1

Steer Axle Trunnion Mount
Steer Axle
Plate Bottom Rubber Mount
<SI-47599>
Steer Axle and Mounting
26-1-2 • Steering Axle Specifications and Description SM 765

Section 2
Steering Axle Wheel Bearing maintenance and Adjustment
Wheel Bearing Check.............................................. 1

Wheel Bearing Lubrication .................................. 1
Bearing Disassembly ................................................ 2
Bearing Reassembly ................................................. 3
Wheel Bearing Adjustment .................................. . 4
IMPORTANT
Before removing any component for overhaul, make sure the correct repair parts, seals, and gasket sets
are available.
movement, the bearings require additional service and/or

! CAUTION adjustment.
1. Park truck on a hard, level, and solid Wheel Bearing Lubrication
gaps or breaks. These procedures cover bearing lubrication for steer
wheels used on the truck ; pneumatic-tire wheels which
are mounted on a hub that contains the bearing compo-
nents. Use the procedures to clean, repack and adjust bear-
3. Put all controls in neutral. Turn key ings for both the pneumatic-tire hub.
switch OFF and remove key. The bearing components and arrangement are the same
4. Apply the parking brake and block the for both the pneumatic types. Instructions for repacking/
wheels. lubricating the bearing components apply to both types.
5. Remove Battery Connector.
Steer Axle Knuckle
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 truck’s PM schedule. See steer
wheel bearing lubrication procedure below.
To check the steer wheel bearings for excessive free play
or looseness:
Pneumatic-Tire
1. Grasp the wheel with both hands and try to move it Wheel Mounting
by a rocking motion top-to-bottom. Hub
2. Try to pull it in and out along the wheel spindle. <8102780>
Watch for excessive free movement in wheel bearings or
steering knuckle bearings. There should be a small wheel-assembly
amount of free movement. If the wheel has excessive free
SM 765 Steering Axle Wheel Bearing maintenance and Adjustment • 26-2-1

Bearing Disassembly 2. Refer to the exploded view illustration of the wheel

bearing assembly. Loosen and remove the hubcap
1. Be sure truck is parked and blocked up correctly and from wheel or hub. You may have to lightly tap hub
safely to raise steer wheels off the floor. Refer to cap with a hammer and chisel and use a pry bar to
“Lifting, Jacking, and Blocking,” in the Group “SA.” loosen. Be careful not to damage mounting surfaces.
NOTE Remove O-ring from hubcap.
Because of the heavy weight of the wheel and 3. Clean the excess grease from around the wheel nut.
tire, it is suggested to first remove the wheel
4. Remove cotter pin, loosen and remove wheel nut and
and tire assembly from spindle when servic-
bearing washer.
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.
Wheel Bearing Assembly.
26-2-2 • Steering Axle Wheel Bearing maintenance and Adjustment SM 765

5. Pull the wheel or hub off the spindle. Support the 1. Install new inner and outer bearing cups by pressing
wheel or hub to avoid dragging the grease seal at the into hub or wheel. Be sure cups are fully seated in
back side across the thread on spindle end. bore.
6. Clean the old grease out of center of the wheel or
hub.
7. To remove inner bearing and seal, lay wheel or hub
down with outer edge up (support hub on blocking).
Remove the inner bearing cone and grease seal, using
a brass drift pin, rod, or piece of pipe to drive the
bearing and seal out of the hub.
2. Pack the bearings with grease and install the inner

bearing in the hub or wheel.
8. Clean and inspect the bearing cups and cones for 3. Pack cavity between bearing and grease seal half full
wear or other damage. Replace, as necessary. with grease.
IMPORTANT 4. Install new grease seal in hub or wheel inner bore.
Keep serviceable bearing cups and cones Apply coating of grease to inside diameter of seal
matched together. Always replace bearing lips prior to assembly, then install seal in hub or
cups and cones as a set. wheel bore.
9. Inspect grease seal for wear and damage. Replace as

necessary. It is recommended to install a new grease
seal whenever old ones are removed.
10. Use a standard puller to remove bearing cups from
hub or wheel if bearings require replacement.
Bearing Reassembly
NOTE 5. Carefully press or tap grease seal into place with
Use Grade No. 2 EP multi-purpose grease, asoftfaced mallet until seal is seated in bottom of
Clark MS-107C. bore.
6. Install hub or wheel on spindle. Be careful not to
damage grease seal lip when moving the hub over the
end of spindle and threads.
7. Pack cavity in hub between bearings one-half full
with grease.

8. Install the outer wheel bearing after it has been 16. Refit O-ring on hubcap and install hubcap by tapping
packed with grease. into place with a rubber or plastic-faced hammer.
9. Install bearing washer and hand tighten wheel nut.

Wheel Bearing Adjustment
The steer wheel bearings are retained and adjusted by the
wheel nut.
NOTE
You should clean and repack the wheel bear-
ings before performing a wheel bearing
adjustment. See “Wheel Bearing Lubrica-
tion” in this Section for the complete proce-
dure.
10. Rotate hub or wheel counter clockwise and torque

wheel nut to 27-31 Nm (20-23 lbfft). ! CAUTION
11. Back wheel nut up until it is loose. SAFE PARKING. REFER TO PAGE 1.
12. While turning the hub or wheel counter clockwise, 1. Make sure the truck is parked on a level, hard sur-
torque the wheel nut to 29.3-33.9 Nm (21.7-25 face, the upright is fully lowered, the drive wheels
lbfft). are chocked, and the steer wheels are jacked and
13. Back up wheel nut to nearest slot and install new cot- blocked securely. Refer to “Lifting, Jacking, and
ter pin. Bend cotter pin tabs. Blocking” for safe procedures.
14. Recheck for correct bearing adjustment by rotating 2. Remove hubcap.

the wheel by hand. Wheel should rotate freely or 3. Remove and discard cotter pin.
with only slight “drag”. Readjust bearings by adjust-
ing wheel nut as necessary to avoid binding in bear- 4. Loosen wheel nut.
ings. 5. After wheel nut is loosened, hit the top of wheel to
15. Pack the area around wheel nut with grease. loosen the bearings. This moves the bearings free of
their seated, running position.
wheel nut to 27-31 Nm (20-23 lbfft).
7. Back wheel nut up until it is loose.
8. While turning the hub or wheel counter clockwise,
torque the wheel nut to 29.3-33.9 Nm (21.7-25
lbfft).
9. Back up wheel nut to nearest castellation slot and
install new cotter pin.
26-2-4 • Steering Axle Wheel Bearing maintenance and Adjustment SM 765

10. Recheck for correct bearing adjustment by rotating

the wheel by hand. Wheel should rotate freely or
ing wheel nut as necessary to avoid binding in bear-
ings.
11. Bend cotter pin tabs over.
12. Pack the area around wheel nut with grease.
13. Refit O-ring on hubcap if removed or replaced and
install hubcap by tapping into place with a rubber or
plastic-faced hammer.

Section 3
Steering Axle Removal and Replacement
Steer Axle Removal ................................................ 2

Steer Axle Replacement ........................................ 3
SM 765 Steering Axle Removal and Replacement • 26-3-1

! CAUTION
gaps or breaks.
switch OFF and remove key.
4. Apply the parking brake and block the Disconnect cylinder lines here.
wheels.
<SI-47007>
Steer Axle Removal
1. Remove the counterweight before removing the steer
axle. Refer to Group 38, Section 2, “Counterweight ! CAUTION
Removal and Replacement.” (It is possible to remove Axle must be supported before any attaching
the steer axle without removing the counterweight fasteners are removed.
but much easier if it is removed).
4. If another lift truck is used to temporarily support
! WARNING axle while removing, put forks in center of carriage
about 305 mm (12 in) apart. Move forks under axle
Do not remove the counterweight unless you and raise itjust toremoveits weight from mounting-
have training and are familiar with the cor- bolts. Or use a portable floor jack to carefully support
rect procedures. Counterweights can fall if the axle at its center section.
not handled correctly and cause severe
injury or death. 5. Loosen and remove nuts from axle mounting bolts,
front and rear.
• Remove the mount plates from the bottom of the
! WARNING trunnion mounts of the steer axle (Figure A.).
Do not raise truck by hoisting on overhead
6. Remove the mounting bolts.
guard or by jacking or lifting on counter-
weight. 7. Lower the axle allowing its weight to pull the silent
blocks out of frame recesses. Watch the silent blocks
2. Block the drive wheels of the truck and raise and to be sure they release freely from frame. You may
block the rear end. Remove steer wheels. See “Lift- have to loosen blocks with a pry bar if they bind.
ing, Jacking, and Blocking” in Group “SA” for safe
8. Carefully withdraw the axle from beneath the truck
procedures to jack the truck.
and move to safe storage.
! CAUTION
Make sure truck is correctly raised and
safely blocked using hardwood blocks under
the frame. Be sure the blocking will permit
installation of the axle without disturbing the
blocking.
3. loosen and remove hydraulic steering lines from

steering cylinder. Plug fittings and cap open ends of
lines. Keep all hydraulic fittings and openings clean.
26-3-2 • Steering Axle Removal and Replacement SM 765

! WARNING
New Steer Axle Heavy components can fall and cause severe
injury. Keep your body clear at all times.
Steer Axle 4. Install axle assembly into frame by slowly raising it

up while guiding silent block bushings into frame
sockets.
Steering Link
5. Install silent block mounting bolts through frame
socket holes and silent block, front and rear.
Reset the two mounting plates under the silent blocks
of the axle.
6. Install silent mount fasteners and tighten to 240-265
Nm (180-196 ft-lb).
Steering Knuckle
7. Remove temporary axle support from under truck.
Silent Mount
8. Connect the hydraulic lines to steering cylinder.
Steer Axle Mounting Tighten fittings to 12-14 Nm (106-123 in-lb; 8.8-
10.3 ft-lb).
IMPORTANT
Steer Axle Replacement Make sure all fittings and openings on the
hydraulic lines are clean.
Replacement is the reverse of removal. Refer to Figure A
for replacement.
! CAUTION
Make sure truck is correctly raised and
safely blocked using hardwood blocks under
the frame. Be sure the blocking will permit
installation of the axle without disturbing the
blocking.
1. 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 the axle trun-
nions.
2. Make sure that the silent blocks are positioned cor-
rectly front and rear on the steer axle trunnions at the czpT[^WWê
start of installation. Align the silent blocks square
with the axle. 9. Carefully raise the truck off the blocking as
3. Use a fork lift truck or mobile floor jack to temporar- described in “Lifting, Jacking and Blocking”.
ily support and raise the axle into place under the Remove the blocking and lower the truck to the
truck. If another lift truck is used to handle axle, cen- floor.
ter the forks with about 305 mm (12 in) spread 10. If removed, reinstall countenveight; refer to Group
between them. Place steer axle assembly in secure 38, Section 2, “Counterweight Removal and
position on fork tips. Replacement”.
If hydraulic jack is used, be sure axle is securely sup-
ported on jack pad.
SM 765 Steering Axle Removal and Replacement • 26-3-3

11. Check the axle and steering system for proper opera-
tion. Operate the steering gear to move the steer
wheels to maximum travel in both directions. Note
any unusual motion or noise.
If the system appears to be operating correctly, drive
the truck slowly. Fully steer the vehicle in each direc-
tion and check response.
12. Check steering cylinder hose line connections and
cylinder rod seals for any evidence of oil leakage
before returning the truck to service.
26-3-4 • Steering Axle Removal and Replacement SM 765

Section 4
Steering Axle Overhaul
Preparation for Steer Axle Disassemble and Overhaul .... 2

Steer Axle Disassembly ....................................................... 2
Parts Inspection ................................................................... 3
Steer Axle Reassembly ........................................................ 3
IMPORTANT
Before removing any component for overhaul, make sure the correct repair parts, seals, and gasket sets
are available.
! CAUTION
1. Park truck on a hard, level, and solid surface, 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.
SM 765 Steering Axle Overhaul • 26-4-1

Preparation For Steer Axle 2. Remove and discard cotter pin from kingpin castel-
lated nut. Remove the nut.
Disassembly and Over haul
NOTE
Cleanliness is of extreme importance in the Steer Axle Knuckle
repair and overhaul of this assembly.
• Before starting disassembly, thoroughly clean the

axle assembly of all accumulations of dirt, oil, cor-
rosion, and other substances to prevent contamina-
tion of the parts during disassembly and overhaul.
• Work in a clean area.
• Keep all parts in order as disassembly progresses.
Take care to properly identify each part and its
order of removal. If necessary, keep notes and put Pneumatic-Tire
markings on parts using a non-destructive marker Wheel Mounting
Hub
such as a grease pencil or felt-tipped pen.
• If necessary, see Section 3, “Steer Axle Removal <8102780>
and Replacement,” for the procedures to remove
3. Drive the kingpin down and out of the assembly.
the steer axle from the truck.
Remove the steering knuckle. Note right and left
• See Section 5, “Steer Cylinder Removal and knuckle parts.
Replacement,” for the procedures to remove the
steering cylinder and steering links from the steer IMPORTANT
axle. Do not let the knuckle or pin fall when the
• See Section 6, “Steering Cylinder Overhaul,” to pin is removed.
disassemble the steer cylinder.
4. Remove the kingpin retainer pin from the base of
the kingpin.
Steer Axle Disassembly
5. Remove the knuckle bearing washers, dust cov-
To disassemble the steering knuckle, kingpin, and bearing ers, upper and lower grease seals, bearings, and
from the steer axle, it is not necessary to remove the axle bearing cups from the assembly.
from the truck.
1. Remove the cotter pin from the lower of the steering
link pin and remove the pin. Steering link is free to
be removed from the cylinder rod and knuckle.
Steering Link Pin

Cylinder Rod
Steering Link
Bearing cups may be removed by hand, by using a bearing

Cotter Pin puller, or by tapping out using a brass drift pin.
Pivot Turn Steer Axle
26-4-2 • Steering Axle Overhaul SM 765

Parts Inspection 3. Set the retainer pin into the king pin and slide the
king pin into the steer axle/knuckle bore.
1. Clean all bearings, cups, seals, pins, and other parts
IMPORTANT
in an approved cleaning fluid.
Make sure that retainer pin enters the hole in
2. Inspect all parts for scratches, chips and wear. Check the underside of the axle
the steering arms of the knuckles to be sure they are
not bent or twisted. Check all threaded parts for dam-
age. Steer Axle Knuckle
3. Replace all parts which show damage.
4. If parts are to be left exposed, coat all mating sur-
faces of parts with a light coating of engine oil.
Steer Axle Reassembly

Recommended greasing procedure:
a. Use Grade No. 2 EP multi-purpose grease, Clark
MS-107 or equivalent. Pneumatic-Tire
Wheel Mounting
b. Pack all tapered roller bearings with grease Hub
before assembly.
c. Pack knuckle pin (bearing) seals with grease <8102780>
before assembly.
4. Reset the kingpin castellated nut to the top of the
d. Fill steer link sockets with grease through grease kingpin. Torque nut to 50-60 Nm (36.5-44 ft-lb).
fittings after axle is assembled.
5. Rotate the steer knuckle three times through its full
1. Install the upper and lower knuckle bearing cups into range of movement. Check to be sure that it is free to
the knuckle housing bore. Tap into place with a brass rotate in the bearings without binding.
drift pin or equivalent. 6. Loosen the kingpin nut and retorque the nut to 30-
35Nm (22.2-25.5 ft-lb).
7. Advance the nut to the next castellated slot and
lock the nut into position with a new cotterpin.
Bendcotterpin tabs over.
8. Replace steering link pin and snap ring to join the
cylinder rod to the steering link and knuckle.
Steering Link Pin

Cylinder Rod
Steering Link
IMPORTANT
Make sure that bearing cup is fully seated
against the shoulder in bore. There must be Cotter Pin
no gap left between cup and the shoulder in
the bore at assembly. Pivot Turn Steer Axle
2. Apply grease to upper and lower knuckle bearings

and install bearings, grease seals, and washers to
bores of knuckle.
SM 765 Steering Axle Overhaul • 26-4-3

9. Reinstall grease fitting in knuckle housing and lubri-

cate with recommended grease.
czpT[^\`è
26-4-4 • Steering Axle Overhaul SM 765

Section 5
Steering Cylinder Removal and Replacement
! CAUTION
Steer Cylinder Rod
SAFE PARKING. Before working on truck: Steering Link Pin
1. Park truck on a hard, level, and solid Steering Link
2. surface, such as a concrete floor with no
gaps or breaks.
5. Apply the parking brake and block the Old Steer Axle Steering Link Bearing
wheels. Snap Ring
Steer Cylinder Removal Steering Link Pin

The steer cylinder can be removed from the steer axle for Cylinder Rod
overhaul or replacement without removing the steer axle Steering Link
from the truck. The cylinder should be overhauled or
replaced if steering problems or troubleshooting informa-
tion indicate the cylinder is malfunctioning. See Group
2.5, Section 2, “Steering System Troubleshooting,” for
steering problem diagnoses. See Section 6 in this Group
for steer cylinder overhaul procedures.
New Steer Axle
1. Place a dram pan under the steer cylinder and remove Cotter Pin
the hydraulic lines from the cylinder fittings. Cap fit-
tings and lines to prevent fluid from leaking and to
protect the components and hydraulic system from
NOTE
dust and dirt. Label hoses and fittings for correct
Mark left-side and right-side parts for cor-
reassembly.
rect reassembly.
3. Tap steer link pin upward until it clears the steering
link bearing and remove the pin.
4. Remove steer link bearing from steering link-to-cyl-
inder rod end bore.
5. Rotate the steering link away from the cylinder rod
end.
6. Repeat steps 1 through 5 for the opposite side of the
steer cylinder.
7. Remove the four steer cylinder mounting bolts and
Remove fittings. washers from the steer axle. Removal torque on these
bolts can be as high as 405 Nm (300 ft-lb).
2. Remove the cotter pin from the lower of the steering

link pin. Steering link pin attaches steer cylinder rod
end to steering link.
SM 765 Steering Cylinder Removal and Replacement • 26-5-1

Cylinder is now ready to be removed from the steer axle

body. Cylinder must be lifted off dowel pins positioning
cylinder to axle body.
! CAUTION ! CAUTION
Cylinder is somewhat heavy and bulky. Cylinder is somewhat heavy and bulky.
When removing cylinder from mounting be When remounting cylinder to steer axle
prepared to lift and move the full weight of body, be prepared to lift and maneuver the
the cylinder. full weight of the cylinder as you set it into
position.
Parts Inspection 2. Position the steering link with the cylinder rod end.
Completely inspect all parts: Reuse steer link bearing if still serviceable. Install
new bearings if scoring or wear marks are evident or
1. Clean all bearings, cups, seals, pins, and other parts if the bearings do not operate smoothly.
2. Inspect all parts for scratches, chips, scoring, and
uneven or heavy wear. Check steering links to be Steer Cylinder Rod
sure they are not bent or twisted. Check all threaded Steering Link Pin
parts for damage. Steering Link
3. Replace all parts showing excessive wear or signs of
damage.
faces of parts with a light layer of engine oil. Keep
all parts clean and covered.
5. Remove and clean all grease fittings before reassem-
bling cylinder components.
Old Steer Axle Steering Link Bearing
Snap Ring
Refer to Section 6, “Steer Cylinder Overhaul”, if pressure
check or troubleshooting tips indicate a problem with Steering Link Pin
steer cylinder performance.
Cylinder Rod
Steering Link
Steer Cylinder Replacement
1. Remount the steer cylinder onto the steer axle dowel
pins; set bolts and washers in place and torque
mounting bolts to 280-320 Nm (205-234.5 ft-lb).
New Steer Axle

Cotter Pin
26-5-2 • Steering Cylinder Removal and Replacement SM 765

3. Rotate steering link into cylinder rod end and align

bearing hole with rod end.
4. Tap pin through steer link bearing hole with cotter
pin groove on lower end.
IMPORTANT
Make sure bearing is properly aligned with
pin in the hole.
5. Install the cotter pin to the steering link pin.

6. Repeat steps 1 to 5 for rod end-to-steering link con-
nection for opposite side.
7. Clean and replace hydraulic hoses on correct, clean,
cylinder fittings. See Group 40, Hydraulic Fitting
Tightening Procedure” for replacement procedures.
Replace fittings.
<SI-47007>
8. Check to be sure all lube fittings are installed. Fill all

lubrication points with correct lubricant. See recom-
mended greasing procedure above.
9. Test function of steer cylinder before returning the
truck to service.
SM 765 Steering Cylinder Removal and Replacement • 26-5-3

Section 6
Steer Cylinder Overhaul
Preparation for Steer Cylinder

Disassembly and Overhaul ................................... 2
Steer Cylinder Disassembly .................................. 2
Parts Inspection ..................................................... 2
Steer Cylinder Reassembly ................................... 3
Operational Pressure Test ................................... . 4
IMPORTANT
Cylinder Tube
Gland Cylinder Rod
c_XWYYXXe
SM 765 Steer Cylinder Overhaul • 26-6-1

Preparation for Steer Cylinder Disas- 4. Remove gland from opposite end of steer cylinder.
sembly and Over haul 5. Remove the seal and O-ring set from the piston. Dis-
card seals. Replace with new seal set at assembly.
Refer to Section 5 for removal of steer cylinder from the
steer axle body.
IMPORTANT
Cleanliness is of extreme importance in the
1. Overhaul steer cylinder only in a clean, dust-free

location, using clean tools and equipment. Dirt or grit
will damage the highly-machined 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.
6. Remove (inner) gland packing (O-ring) seal. Replace
2. Before disassembly, the exterior of the steer cylinder
should be carefully cleaned to remove all dirt and with new seals at assembly.
grease accumulation.
3. Be sure all hydraulic fluid has been removed from
the cylinder. Stroking the piston rod will help force
the fluid out.
4. Before starting disassembly, the steer cylinder should
be carefully examined to determine if there is any
external damage.
Steer Cylinder Disassembly

1. Clamp the steer cylinder assembly in a vise. Wrap
the cylinder in a course cloth to prevent slipping and
scratching. Use extreme caution when tightening vise 7. Remove the rod (U-cup) seal and rod wiper from
and do not overtighten; cylinder can be bent, dis- gland and discard. Note direction of seal and wiper
torted, and potentially destroyed. seating for correct reassembly. Replace with new
seals and wipers at assembly.
2. Remove one gland by pulling it from cylinder barrel
and pulling it off the piston rod.
Parts Inspection
1. Carefully clean all parts in an approved solvent and
place on a clean surface.
2. Check the piston for chips, cracks, and looseness on
the rod. If loose, replace rod and piston assembly.
3. Be sure the piston-seal groove in the piston is
smooth, true, and undamaged.
4. Check the piston rod for damage. Look for scratches,
grooves, gouges, pitting, corrosion or other evidence
of unusual wear. Minor surface damage may be
repaired by use of fine abrasion cloth or stoning.
3. Remove the piston and rod assembly from the Cylin- Deeper damage will require replacement of piston
der. rod assembly.
26-6-2 • Steer Cylinder Overhaul SM 765

5. Carefully inspect the cylinder internal bore for wear,

scratches, corrosion or other damage. Check the out-
side for damage. Inspect all welds for cracks.
6. Inspect the cylinder ports and threads to be sure they
are free of contamination and that the threads are
clean and not damaged.
7. Check the gland for cracks or damage that could
cause failure.
8. Deep gouges or pitted surfaces require replacement
of parts.
9. Put a light coating of hydraulic fluid on all parts. If
parts are to be left disassembled for a period of time, 3. Install new gland packing (O-ring) seal on inner end
such as overnight, they should be covered with a of gland.
clean cloth.
Steer Cylinder Reassembly

Check to make sure the overhaul kit you have is correct
and that all parts are included.
IMPORTANT
Be sure inside of cylinder and all parts are
clean before starting reassembly.
Assemble cylinder carefully to prevent dam-
age to seal lips and O-rings. Seals should be
lubricated with hydraulic oil to assist assem-
bly into cylinder barrel and gland. Heating
seal rings in boiling water before starting
assembly will aid in assembly. 4. Install new rod wiper and rod (U-cup) seal in outer
end of gland.
1. Install new O-ring seal on the piston.
2. Install new piston seal over the O-ring seal. IMPORTANT

Be sure the rod wiper and rod (U-cup) seal
are installed in the correct directions.
5. Lightly lubricate the cylinder and gland mating sur-

faces with hydraulic oil before assembly.
SM 765 Steer Cylinder Overhaul • 26-6-3

6. Install the gland onto the cylinder bore rim, making Operational Pressure Test
sure gland is fully seated on cylinder.
Once cylinder is remounted on axle (see Section 5), con-
7. Install piston and rod assembly into the cylinder. nect pressure source in turn at each port. Extend piston
NOTE rod at each side and test with internal pressure of 13790
A special part is included in the parts kit to kPa (2000 psi). At this pressure no leakage must occur.
allow you to slip the gland over the rod end Typical operating pressure is 7585 kPa (1100 psi).
without damaging the gland seals.
8. Repeat above procedure for installation of opposite

gland.
26-6-4 • Steer Cylinder Overhaul SM 765

Section 7
Pivot-Turn Steering Axle Maintenance
Specifications ........................................................... 2
Description ............................................................... 2
Wheel Bearing Check............................................. 4
Wheel Bearing Lubrication ................................... 4
Wheel Bearing Adjustment ................................... 7
Steer Axle Disassembly .......................................... 7
Part Inspection........................................................ 9
Steer Axle Reassembly ........................................... 9
SM 765 Pivot-Turn Steering Axle Maintenance • 26-7-1


Steering System Relief Pressure Setting : 10000 kPa Steering Linkage Inspection and Lubrication: Every 50-
(1450 psi) 250 hours and each PM.
Steer Cylinder Type : Double-acting, piston-type Steer Wheel Bearing Inspection and Lubrication: Every
50-250 hours of operation.
Turning Arc : 100q maximum inside turning angle
75q maximum outside turning angle. Steer Cylinder Seals Leakage Check: Every 50-250 hours
and each PM.
Bearing Grease : Grade No. 2 EP multi-purpose grease,
Clark Part MS-107C. Steer Axle Mounting Inspection: Every 50-250 hours and
each PM.
Fastener Torques Power Steering Relief Pressure Check: Every year or
2000 hours of operation.
Steer Axle Mounting Bolts: 240-270 Nm (177-200 lbfft)
Cylinder to Axle Mounting Bolts: 100-110 Nm (74-81 Description
lbfft)
The steer axle has the steer cylinder, steer knuckles, and
Steering Link to Steering Knuckle Nuts: 135-150 Nm
steering links mounted on it. All these components can be
(98-110 lbfft)
removed, serviced, and replaced.
The steering gear (steering control unit) at the base of the
steering column directs hydraulic fluid to one end or the
other of the steer cylinder to pivot the steer wheels.
The steer axle is bolted to the truck frame. The steer cylin-
der is connected to the steering knuckles by steer links.
Mounting trunnions allow the axle to tilt independently of
the truck and “silent” mounts cushion the axle on the trun-
nions.
All bearings used in the steer axle linkage have lubrication
fittings and are serviceable. Axle removal, replacement,
and service for all components, including overhaul of the
steer cylinder, is explained in the Sections for this Group.
26-7-2 • Pivot-Turn Steering Axle Maintenance SM 765

Steer Axle
Steering Link
Silent Mount
Steering Knuckle
Steer Axle and Mounting

IMPORTANT Wheel Bearing Lubrication

Before removing any component for over-
haul, make sure the correct repair parts, These procedures cover bearing lubrication for steer
seals, and gasket sets are available. wheels used on the truck ; pneumatic-tire wheels which
are mounted on a hub that contains the bearing compo-
nents. Use the procedures to clean, repack and adjust bear-
! CAUTION ings for both the pneumatic-tire hub.
The bearing components and arrangement are the same
for both the pneumatic types. Instructions for repacking/
1. Park truck on a hard, level, and solid lubricating the bearing components apply to both types.
gaps or breaks.
Pneumatic-Tire
2. Put upright in vertical position and fully Wheel Mounting
lower the forks or attachment. Hub
wheels.
5. Remove Battery Connector.
Wheel Bearing Check

Wheel bearings check should be performed every PM.
Wheel bearings need adjustment only after 2000 hours or Steer Axle Knuckle
as needed. It is recommended that you clean and repack
the bearings before adjustment. Check hourmeter total wheel-assembly
hours and refer to the truck’s PM schedule. See steer
wheel bearing lubrication procedure below.
To check the steer wheel bearings for excessive free play
or looseness:
1. Grasp the wheel with both hands and try to move it
by a rocking motion top-to-bottom.
2. Try to pull it in and out along the wheel spindle.
Watch for excessive free movement in wheel bearings or
steering knuckle bearings. There should be a small
amount of free movement. If the wheel has excessive free
movement, the bearings require additional service and/or
adjustment.

Bearing Disassembly a brass drift pin, rod, or piece of pipe to drive the
bearing and seal out of the hub.
1. Be sure truck is parked and blocked up correctly and
safely to raise steer wheels off the floor. Refer to
“Lifting, Jacking, and Blocking,” in the Group “SA.”
NOTE
Because of the heavy weight of the wheel and
tire, it is suggested to first remove the wheel Bearing &
and tire assembly from spindle when servic- Cone
ing the bearings to avoid damage to the
grease seal when the wheel hub is moved off Grease Seal
or on the spindle. It also makes the work sim-
pler and easier.
2. Refer to the exploded view illustration of the wheel 8. Clean and inspect the bearing cups and cones for
bearing assembly. Loosen and remove the hubcap wear or other damage. Replace, as necessary.
from wheel or hub. You may have to lightly tap hub
cap with a hammer and chisel and use a pry bar to IMPORTANT
loosen. Be careful not to damage mounting surfaces. Keep serviceable bearing cups and cones
Remove O-ring from hubcap. matched together. Always replace bearing
cups and cones as a set.
3. Clean the excess grease from around the wheel nut.
4. Remove cotter pin, loosen and remove wheel nut and 9. Inspect grease seal for wear and damage. Replace as
bearing washer. necessary. It is recommended to install a new grease
seal whenever old ones are removed.
Steering Axle Knuckle 10. Use a standard puller to remove bearing cups from
Spindle hub or wheel if bearings require replacement.
Tire and Whel
Bearing
Bearing
Washer
O-ring
Hub cab
Wheel nut and

Cotter pin
Wheel Bearing Assembly.
5. Pull the wheel or hub off the spindle. Support the
wheel or hub to avoid dragging the grease seal at the
back side across the thread on spindle end.
6. Clean the old grease out of center of the wheel or
hub.
7. To remove inner bearing and seal, lay wheel or hub
down with outer edge up (support hub on blocking).
Remove the inner bearing cone and grease seal, using

Bearing Reassembly 6. Install hub or wheel on spindle. Be careful not to

damage grease seal lip when moving the hub over the
NOTE end of spindle and threads.
Use Grade No. 2 EP multi-purpose grease,
7. Pack cavity in hub between bearings one-half full
Clark MS-107C.
with grease.
1. Install new inner and outer bearing cups by pressing 8. Install the outer wheel bearing after it has been
into hub or wheel. Be sure cups are fully seated in packed with grease.
bore.
9. Install bearing washer and hand tighten wheel nut.
2. Pack the bearings with grease and install the inner

bearing in the hub or wheel.

wheel nut to 27-31 Nm (20-23 lbfft).
3. Pack cavity between bearing and grease seal half full
with grease. 11. Back wheel nut up until it is loose.
4. Install new grease seal in hub or wheel inner bore. 12. While turning the hub or wheel counter clockwise,
Apply coating of grease to inside diameter of seal torque the wheel nut to 2.3-2.8 Nm (1.7-2 lbfft).
lips prior to assembly, then install seal in hub or 13. Back up wheel nut to nearest slot and install new cot-
wheel bore. ter pin. Bend cotter pin tabs.
14. Recheck for correct bearing adjustment by rotating
the wheel by hand. Wheel should rotate freely or
ings.
5. Carefully press or tap grease seal into place with

asoftfaced mallet until seal is seated in bottom of
bore.

16. Refit O-ring on hubcap and install hubcap by tapping 10. Recheck for correct bearing adjustment by rotating
into place with a rubber or plastic-faced hammer. the wheel by hand. Wheel should rotate freely or
ings.
11. Bend cotter pin tabs over.
13. Refit O-ring on hubcap if removed or replaced and
install hubcap by tapping into place with a rubber or
plastic-faced hammer.
Wheel Bearing Adjustment Steer Axle Disassembly

The steer wheel bearings are retained and adjusted by the IMPORTANT
wheel nut. Before removing any component for over-
haul, make sure the correct repair parts,
NOTE seals, and gasket sets are available.
You should clean and repack the wheel bear-
ings before performing a wheel bearing
adjustment. See “Wheel Bearing Lubrica- ! CAUTION
tion” in this Section for the complete proce- SAFE PARKING. REFER TO PAGE Z.
dure.
NOTE
! CAUTION Cleanliness is of extreme importance in the
SAFE PARKING. REFER TO PAGE Z.
• Before starting disassembly, thoroughly clean the
1. Make sure the truck is parked on a level, hard sur- axle assembly of all accumulations of dirt, oil, cor-
face, the upright is fully lowered, the drive wheels rosion, and other substances to prevent contamina-
are chocked, and the steer wheels are jacked and tion of the parts during disassembly and overhaul.
blocked securely. Refer to “Lifting, Jacking, and
Blocking” for safe procedures. • Work in a clean area.
• Keep all parts in order as disassembly progresses.
2. Remove hubcap. Take care to properly identify each part and its
3. Remove and discard cotter pin. order of removal. If necessary, keep notes and put
markings on parts using a non-destructive marker
4. Loosen wheel nut. such as a grease pencil or felt-tipped pen.
5. After wheel nut is loosened, hit the top of wheel to • If necessary, see Section 3, “Steer Axle Removal
loosen the bearings. This moves the bearings free of and Replacement,” for the procedures to remove
their seated, running position. the steer axle from the truck.
6. Rotate hub or wheel counter clockwise and torque • See Section 5, “Steer Cylinder Removal and
wheel nut to 27-31 Nm (20-23 lbfft). Replacement,” for the procedures to remove the
steering cylinder and steering links from the steer
7. Back wheel nut up until it is loose. axle.
8. While turning the hub or wheel counter clockwise, • See Section 6, “Steering Cylinder Overhaul,” to
torque the wheel nut to 2.3-2.8 Nm (1.7-2 lbfft). disassemble the steer cylinder.
9. Back up wheel nut to nearest castellation slot and
install new cotter pin.

To disassemble the steering knuckle, kingpin, and bearing 5. Remove the knuckle bearing washers, dust covers,
from the steer axle, it is not necessary to remove the axle upper and lower grease seals and bearings from the
from the truck. assembly.
1. Remove the cotter pin and washer from the bottom of
the steering link pin and remove the pin. Steering
link is free to be removed from the cylinder rod and Spacer
knuckle. Grease Seals
Bearing
Steering Link Pin
Cylinder Rod
Steering Link Bearing cups may be removed by hand, by using a

bearing puller, or by tapping out using a brass drift pin.
Cotter Pin
2. Remove the stop bolts from the steering knuckle.

3. Remove the bearing protection covers which lie over
and under the steering knuckle. Don’t remove the
bearing cap.
Bearing Cover
4. Drive the kingpin down and out of the assembly.

Remove the steering knuckle. Note right and left
knuckle parts.
IMPORTANT
Do not let the knuckle or pin fall when the
pin is removed.

Parts Inspection 3. Put the King pin on the steering axle/knuckle bore.
4. Tighten the stop bolt to the center hole of the King
1. Clean all bearings, cups, seals, pins, and other parts
pin.
IMPORTANT
2. Inspect all parts for scratches, chips and wear. Check
the steering arms of the knuckles to be sure they are Make sure that retainer pin enters the hole in
not bent or twisted. Check all threaded parts for dam- the underside of the axle
age. Bearing Cover
faces of parts with a light coating of engine oil. Center Hole
Steer Axle Reassembly

Pneumatic-Tire
Recommended greasing procedure: Wheel Mounting
Hub
a. Use Grade No. 2 EP multi-purpose grease, Clark
MS-107 or equivalent. <8102780>
b. Pack all tapered roller bearings with grease
before assembly.
c. Pack knuckle pin (bearing) seals with grease
before assembly.
d. Fill steer link sockets with grease through grease 5. Shimming adjustment for steer axle bearing pre-load
fittings after axle is assembled. a. When installing the bearing carrier, rotate the
steer knuckle through its full range of movement
1. Install the bearing cup to the axle housing bore. Tap
3-4 times before tightening the retainer bolts.
into place with a brass drift pin or equivalent. This will allow the knuckle trunnion to properly
seat in the bearing.
Spacer
Axle Housing b. Measure dimension "A" and "B" with a gage.
Grease Seals Assemble a set of shims. Thickness of the shim
Bearing pack to be: Dimension A minus Dimension "B"
plus 0.127-0.299mm. [(A-B+(0.127-0.229)]
c. Disassemble the bearing carrier and bearing.
Install the shim pack. Reassemble the bearing and
bearing carrier, then install and torque the bolt.
Bearing
Shim pack
IMPORTANT
Make sure that bearing cup is fully seated
“B”
“A”
against the shoulder in bore. There must be

no gap left between cup and the shoulder in
the bore at assembly. Bottom cover
Bolt
2. Apply grease to upper and lower knuckle bearings
and install bearings, grease seals, and washers to
bores of axle housing.

6. Replace steering link pin and snap ring to join the

cylinder rod to the steering link and knuckle.
Steering Link Pin

Cylinder Rod
Steering Link
Cotter Pin
7. Reinstall grease fitting in knuckle housing and lubri-

cate with recommended grease.
Knuckle
Housing
Grease fitting

GROUP 29
GROUP 29
HYDRAULIC SUMP, FILTERS, AND PUMP
Main Hydraulic Sump, Filters, and Pump

Specifications and Description .............................. Section 1
Main Hydraulic Pump Troubleshooting .............. Section 2
Main Hydraulic Pump Removal and Installation Section 3
NOTE
This group covers the main hydraulic pump for the load
handling system.
Other hydraulic-related components and circuits are
described and illustrated in Group 25 “Steering Column and
Gear,” Group 26 “Steering System,” Group 30 “Hydraulic
Control Valve/Lift Circuit,” Group 32 “Tilt Cylinders,” and
Group 34 “Uprights.” Refer to these groups for hydraulic
components not covered in this group.
SM 765 Group 29, HYDRAULIC SUMP, FILTERS, AND PUMP

Group 29, Hydraulic Sump, Filters, and Pump
Section 1
Main Hydraulic Sump, Filters, and Pump

Specifications and Description
Specifications ......................................................... 2
Service Intervals ................................................. 2
System Description ................................................ 2
Sump Tank Fill Levels .......................................... 4
Hydraulic Fluid and Filter Change ..................... 5
Remove, clean and replace the strainer ............... 5
SM 765 Main Hydraulic Sump, Filters, and Pump Specifications and Description • 29-1-1
Specifications The hydraulic sump is located in the rear side compart-

ment of the truck frame. The sump is equipped with a suc-
Hydraulic Pump Type : IntegraI gear-type pump and tion line screen, return line filter, filter cap/breather.
motor assembly.
The hydraulic pump and motor assembly is mounted to
Sump Capacity : Usable oil = 24 Litres (6.3 Gal) the flow plate.
Hydraulic Fluid Type : CLARK Hydraulic Fluid MS-68 The hydraulic pump draws oil from the sump and sends
Filter Type : Disposable, 25 micron, return line oil filter, oil to main valve.
100 mesh suction line screen and a 10 micron filter cap/ The oil which was supplied from the main valve to the
breather filter. steering unit and attachment returns to sump.
Serviceable items are the pump, motor, suction line screen
Service Intervals and the return line filter. Other components, such as
hoses, fittings, and clamps, are nonserviceable and should
Hydraulic Fluid Level Checks : Every 8-10 hours or daily.
be replaced if worn or damaged.
Hydraulic Fluid Change (Drain and Refill) : Every 2000
hours of operation or every year.
Hydraulic Fluid Filter Replacement : After the first 50
hours of operation, then every year or 2000 hours of oper-
ation.
Description
NOTE
Se group 30 for a description of the complete
hydraulic circuit.
Sump Breather Cap
Return line Filter
29-1-2 • Main Hydraulic Sump, Filters, and Pump Specifications and Description SM 765
Control Valve
Filter
Steer Gear
Pump
Sump Tank Fill Levels

Pull out the dipstick for the hydraulic oil.
Hydraulic Fluid and Filter Change Disconnect drain line from truck.
NOTICE
! CAUTION If old oil is excessively dirty or hydraulic sys-
SAFE PARKING. Before working on truck: tem is contaminated, it is recommended that
the sump tank be completely drained by
1. Park truck on a hard, level, and solid removing the pump suction line from the
surface, such as a concrete floor with no sump outlet and flushed withy clean oil.
gaps or breaks.
2. Put upright in vertical position and fully Remove, clean and replace the strainer.
wheels.
There is drain plug in the hydraulic sump tank. When the
sump tank must be drained of all fluid, the procedure is to
remove the drain plug and allow the fluid to drain into a
suitable drain pan. Unless the sump tank is to be removed
for other repair or maintenance, the hydraulic fluid can
also be changed by one of the following methods:
Pressure gauge to the diagnostic check port fitting.
NOTE: Use quick-disconnect adapter fitting.
You will need a drain pan of 24 L (6.3 gal) minimum

capacity. Be sure the outlet end of the drain line is
directed into the drain pan and held from moving when
pressurized. Remove and discard old oil filter. Install new filter. Fol-
low the installation instructions printed on the filter body.
Turn key switch ON.
Move tilt control lever to the back tilt position to start the
lift pump. Hold tilt lever in this position until sump tank is
emptied. A steady stream of used oil should flow from the
drain line.
Continue operation until the sump tank is emptied. This
point will be reached when the pump starts to cavitate.
When cavitation occurs the pump speed will increase and
the speed sound will whine. Release the tilt lever immedi-
ately when pump cavitation occurs.
IMPORTANT
Be careful when sump is nearly emptied and
oil flow becomes erratic as the pump
approaches cavitation Do not operate pump
after cavitation occurs.
Turn the key switch OFF.
Also, check that the hydraulic line connections at the filter

head are tightened correctly.
Filter Head
Filter Turn the key switch OFF.
Refill the sump tank with Clark MS-68 Hydraulic Fluid.

Check truck operation. Turn key switch ON. Operate the
hydraulic system. Cycle the lift system serval times: raise
the lift carriage to full height and lower fully down. Check
for leaks. Recheck sump tank fluid level.
! CAUTION
Be sure there is adequate overhead clearance
before raising upright.
Section 2
Main Hydraulic Pump 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 ................................................... 3
SM 765 Main Hydraulic Pump Troubleshooting • 29-2-1

The following is a list of problems and solutions relating Pump Not Developing Sufficient
to the main hydraulic pump and associated components.
For other hydraulic system troubleshooting, refer to
Pressure
Groups 30 and 34. • Leak in hydraulic control system; check system for
and correct leaks.
Noisy Pump • Inlet line restriction; check for foreign material or
line kinks, check and clean sump suction screen.
• Hydraulic fluid level low; measure and correct
• Suction screen dirty; clean screen.
fluid level.
• Defective hydraulic pump; continue other trouble-
• Fluid viscosity too high; change to specified fluid.
shooting items, then consider servicing or replac-
• Sump strainer dirty; check and clean. ing pump.
• Air leak at pump inlet line; check plumbing tight-
ness.
Pump Output Low
• Inlet line restriction; check for foreign material or
line kinks, check and clean sump suction screen. • Cavitating pump; see “Noisy Pump.”
• Air leak at pump shaft packing; replace packing. • Air in fluid or wrong fluid; drain and fill with cor-
• Defective hydraulic pump; continue other trouble- rect fluid.
shooting items, then consider servicing or replac- • System relief valve set too low or too high, stuck
ing pump. or leaking; correct relief valve, pump may be OK.
• Overheated fluid; see “Overheated Pump and/or
Pump Not Delivering Hydraulic Fluid Fluid.”
• Contaminated fluid; eliminate contamination
• Hydraulic fluid level low; check and correct fluid source and replace fluid.
level.
• Gear face, body or cover nicked; repair or replace
• Sump suction screen dirty; check and clean. pump.
• Inlet line restriction; check for foreign material or • Excessive side loading, wear plate tight in body
line kinks, check and clean sump suction screen. bore, pinched thrust plate; inspect and service
• Air leak in suction line: check plumbing tightness. pump.
• Fluid viscosity too high: check fluid viscosity and
change to specified fluid. Foaming Fluid
• Defective hydraulic pump; continue other trouble-
shooting items, then consider servicing or replac- • Cavitating pump; see “Noisy Pump.”
ing pump. • Wrong fluid; drain and fill with correct fluid.
Failure to Build Pressure Overheated Pump and/or Fluid

• Hydraulic fluid level low; measure and correct • Low viscosity fluid; drain and fill with correct
fluid level. fluid.
• Defective relief valve or pump: perform pressure • Contaminated fluid; drain fluid, clean suction
check to test valve and pump. screen, replace filter and fill sump.
• Cavitating pump: see “Noisy Pump.”
• Pump drive shaft misaligned; check mounting and
alignment.
• Axial loading on drive shaft; check shaft end clear-
ance and shaft alignment; check for worn key/
spline.
• Relief valve usually in bypass; check relief setting.
29-2-2 • Main Hydraulic Pump Troubleshooting SM 765

External Leakage
• Excessive system pressure; replace pressure con-
trol valve on main hydraulic valve.
• Faulty or distorted pump seal gasket; replace seal
gasket.
• Damaged surfaces on pump body or cover; correct
and replace as required.
SM 765 Main Hydraulic Pump Troubleshooting • 29-2-3

Section 3
Main Hydraulic Removal and Installation
Main hydraulic Pump Removal ........................... 2
Main Hydraulic Pump Installation ...................... 3
SM 765 Main Hydraulic Removal and Installation • 29-3-1

Main Hydraulic Pump Removal NOTE

Capacity of hydraulic sump is 24 L (6.3 gal).
! CAUTION
1. Place a drip pan under the hydraulic pump for oil that
SAFE PARKING. Before working on truck: will drain from the pump and hoses when they are
1. Park truck on a hard, level and solid sur- disconnected.
face, such as a concrete floor with no 2. Disconnect suction line from pump and plug the line.
gaps or breaks.
3. Put ail controls in neutral. Turn key
4. Disconnect the battery.
5. Apply the park brake and block the
Pump Suction Line
wheels.
The main hydraulic pump is located beneath the flow
plate. The pump can be removed from the truck without
removing the pump and motor assembly.
Serviceable items are the pump, motor and the suction
line filter. Other components such as hoses, fittings and
clamps are non-serviceable and should be replaced if
faulty.
Control Valve
Filter
Steering Gear
Pump
29-3-2 • Main Hydraulic Removal and Installation SM 765

3. Disconnect the pressure line from the pump. Cap the 4. Connect pump outlet hose and tighten. Use two
hose and set aside. wrenches to tighten hose fittings to prevent twisting
of lines.
NOTE
Always clean or replace hydraulic sump suc-
tion screen fitting when installing new or
Pressure Line rebuilt pump. See Section 1, Main Hydraulic
Filters and Fluid Maintenance.
Hydraulic
Pump 5. Refill sump as necessary using Clark Specification
MS-68 hydraulic fluid. See Section 1 for description
Hydraulic Motor of sump tank fill levels.
6. Reinstall hose and cable support bracket.
7. Check operation of hydraulic system. See Section 1,
Main Hydraulic Filters and Fluid Maintenance.
8. Check fluid level of sump again. Add fluid as neces-
sary.
4. Remove the pump mounting fasteners.The ground
strap will come off with the fasteners. Routine Maintenance
• No maintenance is necessary other than periodic
checks for tightness of the mounting bolts and port
Hydraulic Motor Hydraulic fittings plus visual examination for oil leaks. The
Pump
unit should be kept externally clean.
• 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 IS04406
17/14 or better is recommended to give maximum
life.
Main Hydraulic Pump Installation

IMPORTANT
Keep all components clean during installa-
tion.
1. Be sure new or serviced pump is well lubricated

before installation.
2. Install pump onto motor. Install and tighten cap-
screws.
3. Slide suction hose and clamp into place and tighten.
SM 765 Main Hydraulic Removal and Installation • 29-3-3

GROUP 30
GROUP 30
HYDRAULIC CONTROL VALVE/LIFT CIRCUIT
Hydraulic Control Valve/Lift Circuit

Specifications and Description .............................. Section 1
Hydraulic System Schematic ................................ Section 2
Hydraulic System Troubleshooting ...................... Section 3
Hydraulic System Pressure Checks

and Adjustments .................................................... Section 4
Hydraulic Control Valve Removal

and Replacement .................................................... Section 5
IMPORTANT
Other hydraulic-related components and circuits are
described and illustrated in Group 25, “Steering Column
and Gear”, Group 26 “Steer Axle”, Group 29, “Hydraulic
Sump, Filters and Pump”, Group 32, “Tilt Cylinders”, and
Group 34, “Uprights”. Refer to these other groups for
hydraulic components not covered in this group.
SM 765 Group 30, HYDRAULIC CONTROL VALVE/LIFT CIRCUIT

Group 30, Hydraulic Control Valve/Lift Circuit
Section 1
Hydraulic Control Valve/Lift Circuit

Specifications and Description
Specifications
Hydraulic Fluid Type: Clark specification MS-68 (Clark Service Intervals
part #1802155 and #1800236)
Hydraulic System Relief Pressure Check: Every year or
Main Relief Valve Setting: 20.6 to 21.1 MPa (2988 to every 2000 hours of operation.
3060 psi) at rated flow.
Auxiliary Relief Valve Setting: 13.7 to 14.2 kPa (1987 to
2060 psi) at rated flow.
Rated Flow: 70 L/min (18.5 gpm).
Maximum Pressure Drop at Rated Flow:

Inlet to outlet: 700 kPa (101 psi).
Lift spool (spool #l):
Inlet to cylinder port: 1471 kPa (213 psi)
Cylinder port to outlet: 981 kPa (142 psi).
Tilt spool (spool #2):
Auxiliary spools (spools #3 and #4):
SM 765 Hydraulic Control Valve/Lift Circuit Specifications and Description • 30-1-1

Description moved. Excess oil flow is returned to the sump. A check

valve prevents reverse flow.
The following description focuses primarily on hydraulic
circuitry controlled by the main hydraulic control valve, When all the control valve spools are in neutral, the micro
that is, the lift/tilt/aux circuit. Various other hydraulic sys- switch turns the pump motor OFF and not fluid flows.
tems come into play, however, and are mentioned. The When a spool is partially shifted and the associated cylin-
entire hydraulic system is depicted in the schematics in der or other actuator has not reached its end-of-travel,
Section 2 (next page). some of the fluid flows to the cylinder (actuator) and the rest
flows to the sump line. In both cases, the pressure in the system
Descriptions of the braking and steering circuits are given should be less than the amount required to open the relief valves.
in Groups 23 and 25.
The main relief valve vents flow to the sump when one of
The main hydraulic pump (described in Group 29) is the following conditions is present:
driven by the pump motor and draws fluid from the sump
• The operator continues to hold the lift control in
through a particle-blocking suction screen.
the lift position after the lift mechanism reaches its
The main hydraulic control valve features an open-center, endof-travel.
parallel-circuit type modular design. It has the main (lift/ • Too heavy a load is being lifted.
tilt) pressure relief valve (steering pressure relief valve
• The operator continues to hold the tilt control in
located in the steering control assembly (Orbitrol)), a sec-
the tilt position after the tilt mechanism has
ondary pressure relief valve for optional auxiliary compo-
reached its end-of-travel (This is called “tilt
nents, a lift spool, a tilt spool with an integral
bypass.“)
counterbalance valve, optional auxiliary spools, and
adjustable pressure-compensated flow controls. All spools • Auxiliary relief fails to operate.
are low-leakage design. The auxiliary relief valve vents flow to the sump when the
The main hydraulic valve has from two to four valve sec- operator continues to hold the attachment control in the
tions. Each section performs a separate function; standard operated position after the attachment reaches its end-of-
two spool assemblies have a inlet/lift section (with fluid travel.
inlet port), a tilt section, and an outlet section. A third and Main and auxiliary relief pressure settings can be checked
fourth section may be added to control auxiliary compo- through a gauge port on the main valve.
nents.
A tilt-lock valve built into the main control valve assem-
When lift attachments are used, an auxiliary section may bly locks the upright into its current tilt position when the
be added to the outer (RH) side of the standard (lift/tilt truck is turned off. A load lowering flow valve mounted
only) main valve. The optional auxiliary sections also on the upright limits the speed at which the operator can
have an adjustable relief valve and can be assembled with lower a load, decreasing the speed for heavier loads. A
optional flow control levels. velocity fuse built into one of the lift cylinder ports pre-
The valve spools are arranged in standard sequence (from vents the upright from falling rapidly should a hydraulic
the operator’s position) to first provide lift control, then line rupture or be disconnected.
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 con-
trolled by the amount or distance the control handles are
NOTE
Hydraulic plumbing arrangement is illustrated in Group 29.
30-1-2 • Hydraulic Control Valve/Lift Circuit Specifications and Description SM 765

Section 2
Hydraulic Schematic
Hydraulic Circuit(For Normal Valve)
SM 765 Hydraulic Schematic • 30-2-1

Hydraulic Circuit(For ELH Valve)
30-2-2 • Hydraulic Schematic SM 765

Section 3
Hydraulic System Troubleshooting
The following is a list of problems and solutions relating • Cavitating pump; check hydraulic plumbing for
to the main hydraulic control valve and associated compo- airtight hoses and connections.
nents. For other hydraulic system troubleshooting, refer to • Pump driveshaft misaligned; check mounting and
Groups 29 and 34.
alignment.
No lift, tilt, or auxiliary function • Axial loading on drive shaft; check shaft end clear-
ance and shaft alignment; check for worn key/
• Hydraulic fluid very low; check and fill to correct spline.
level.
• Relief valve in bypass; check relief setting.
• Hose or fittings broken; replace component.
• Defective main lift valve; check other Trouble- Load cannot be lifted to maximum height
shooting items for possible cause, then consider
rebuilding or replacing main lift valve. • Hydraulic fluid low: check and fill to correct level.
• Hydraulic pump defective: check other Trouble- • Hydraulic pump defective; check other Trouble-
shooting items for possible cause, then consider shooting items for possible cause, then consider
rebuilding or replacing pump. rebuilding or replacing pump.
No motion, slow or jerky action of hydraulic Oil leaks at top of lift (secondary) cylinder(s)
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 See Group 34, “Cylinder Removal, Overhaul, and
worn; check and clean valve, replace if necessary. Replacement.”
• Dirt or foreign particles lodged between relief
valve control poppet and seat: check valve and Oil leak at tilt or auxiliary function cylinder
clean.
• Valve body cracked inside; check and replace • Worn or damaged seal; rebuild cylinder.
entire valve. • Scored piston rod; repair or replace rod.
See Group 34, “Cylinder Removal, Overhaul, and
Foaming hydraulic fluid Replacement.”
• Low oil level; check and fill to correct level.
• Wrong fluid; drain and refill with correct oil.
Load will not hold
• Oil too heavy; change to correct viscosity. • .Oil bypassing between lift spool and valve body; over-
• Pump inlet line restriction or line kinked; clean line haul valve and spool.
and suction screen or repair kinked hose. • Spool not centered; see spool remedies for correct-
• Hydraulic pump cavitating (pumping air with ing problems when spools do not return to neutral.
fluid); check hydraulic plumbing for airtight hoses • Oil bypassing piston in cylinder; repair or replace
and connections. cylinder.
Overheated hydraulic fluid Oil leaks at either end of main hydraulic valve
• Thin fluid; drain and fill with correct fluid. spool
• Fluid contaminated; drain sump, clean suction
screen, replace filter, and refill. • Defective O-ring seals; rebuild valve.
SM 765 Hydraulic System Troubleshooting • 30-3-1

Spring-centered spools do not return to No relief valve action (high pressure)

neutral • Small particles of dirt in relief valve subassembly;
• Broken springs; rebuild valve. check, clean, and/or replace relief valve, clean
hole.
• Entrapped foreign particles; check and clean sys-
tem and valve. • Relief valve subassembly installed backwards;
reinstall correctly.
• Bent spool; replace with new valve section.
• Misalignment or binding of linkage; check and
align/adjust linkage. 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.
30-3-2 • Hydraulic System Troubleshooting SM 765

Section 4
Hydraulic System Pressure Checks and Adjustments
! CAUTION
gaps or breaks.
wheels.
2. Remove the cap from the gauge port on the valve and
Relief Pressure Checks connect pressure gauge to the fitting.
Following is the procedure for checking main hydraulic

valve lift pressure and auxiliary relief pressure (if the
truck is equipped with an auxiliary component).
Hydraulic system relief pressure setting may be checked
using a Mica Quadrigage (Clark Part No. 923770) or with
a conventional pressure gauge with suitable pressure
range calibration. To cover all models of the truck, a
gauge with capacity range of 0 to 34,475 kPa minimum (0
to 5000 psi) is recommended.
! WARNING
HYDRAULIC FLUID SAFETY. Keep all NOTE
hydraulic ports and components clean. Wipe Use quick-disconnect adapter fitting, Clark
the area on the pump around the diagnostic Part #913125.
check port completely clean to prevent any
contamination from entering the hydraulic 3. Check main relief pressure: Turn key switch on,
system. move the lift control lever to full back lift relief posi-
When checking the hydraulic system, do not tion. Hold lift control in relief position until pressure
use your hands to check for leakage. Use a reading is obtained, and then release. Gauge should
piece of cardboard or paper to search for read 20,600 to 21,100 kPa (3988 to 3060 psi).
leaks. Escaping fluid under pressure can pen- IMPORTANT
etrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or Do not operate system in relief any longer
other lines. Tighten all connections before than required to read the pressure gauge.
applying pressure. Keep hands and body 4. Check auxiliary relief pressure: (Truck must have
away from pinholes and nozzles which eject auxiliary component and auxiliary section added to
fluids under high pressure. main hydraulic valve.) Move the auxiliary control
1. Remove the covers enclosing the main hydraulic lever to full back or forward relief position. Hold
valve to access the hydraulic system pressure diag- auxiliary control in relief position until pressure
nostic check port. reading is obtained, and then release. Gauge should
read 13,700 to 14,200 kPa (1987 to 2060 psi).
SM 765 Hydraulic System Pressure Checks and Adjustments • 30-4-1

Main Pressure Relief Adjustment Auxiliary Pressure Relief Adjustment

IMPORTANT IMPORTANT
Main pressure relief setting is set at the fac- The auxiliary relief setting only applies to a
tory. If the relief pressure does not measure hydraulic valve that has auxiliary sections
within the setting range, main pressure relief added.
setting is adjusted.
To adjust the hydraulic system auxiliary pressure relief
To adjust the hydraulic system main pressure relief valve: valve:
1. Loosen the jam nut on the main relief valve adjust- 1. Loosen the jam nut on the auxiliary relief valve
ment screw. adjustment screw.
Pressure
check port
Secondary Secondary
relief valve relief valve Main
Main
relief valve relief valve
Jam nut
Jam nut
Adjustement screw
2. Turn the adjustment screw to set the main pressure 2. Turn the adjustment screw to set the auxiliary pres-
relief setting to the normal range. sure relief setting to the normal range.
3. Reset the jam nut on the main relief valve adjustment 3. Reset the jam nut on the auxiliary relief valve adjust-
screw. ment screw.
30-4-2 • Hydraulic System Pressure Checks and Adjustments SM 765

Flowrate per RPM GEX 30

Lift Tilt in
GEX 20/25 Flowrate Speed velocity
RPM Hz Remark
Lift Tilt in lpm gpm mm/ mm/ deg/
Flowrate Speed velocity sec sec sec
RPM Hz Remark
mm/ mm/ deg/ 500 15 8.0 2.1 68 19.29 3.10
lpm gpm sec sec sec 600 18 9.8 2.6 83 23.63 3.80
500 15 9.7 2.6 82 23.39 3.76 700 21 11.6 3.1 99 27.97 4.50
600 18 11.8 3.1 100 28.45 4.57 800 25 13.4 3.6 114 32.31 5.19
700 21 14.0 3.7 118 33.76 5.43 900 28 15.2 4.0 129 36.65 5.89
800 25 16.1 4.3 137 38.82 6.24 1000 31 17.1 4.5 145 41.24 6.63
900 28 18.2 4.8 155 43.89 7.05 1100 35 18.9 5.0 160 45.58 7.32
1000 31 20.4 5.4 173 49.19 7.91 1200 38 20.7 5.5 175 49.92 8.02
1100 35 22.5 5.9 191 54.26 8.72 1300 41 22.5 5.9 191 54.26 8.72
1200 38 24.7 6.5 209 59.56 9.57 1400 45 24.3 6.4 206 58.60 9.42
1300 41 26.8 7.1 227 64.63 10.39 1500 48 26.1 6.9 221 62.94 10.12
1400 45 28.9 7.6 245 69.69 11.20 1600 51 27.9 7.4 236 67.28 10.81
1500 48 31.1 8.2 263 75.00 12.05 1700 55 29.7 7.8 252 71.62 11.51
1600 51 33.2 8.8 282 80.06 12.87 1800 58 31.5 8.3 267 75.96 12.21
1700 55 35.3 9.3 300 85.12 13.68 1900 61 33.3 8.8 282 80.30 12.91
1800 58 37.5 9.9 318 90.43 14.53 2000 65 35.1 9.3 298 84.64 13.60
1900 61 39.6 10.5 336 2100 68 36.9 9.8 313 88.98 14.30
2000 65 41.8 11.0 354 2200 71 38.7 10.2 328
2100 68 43.9 11.6 372 2300 75 40.5 10.7 344
2200 71 46.0 12.2 390 2400 78 42.3 11.2 359
2300 75 48.2 12.7 408 2500 81 44.1 11.7 374
2400 78 50.3 13.3 427 2600 85 45.9 12.1 389
2500 81 52.4 13.9 445 2700 88 47.7 12.6 405
2600 85 54.6 14.4 463 2800 91 49.5 13.1 420
2700 88 56.7 15.0 481 2900 95 47.7 13.6 435
2800 91 58.9 15.5 499 3000 98 53.2 14.0 451
2900 95 61.0 16.1 517 3100 101 55.0 14.5 466
3000 98 63.1 16.7 535 3200 105 56.8 15.0 481
3100 101 65.3 17.2 553 3300 108 58.6 15.5 497
3200 105 67.4 17.8 572 3400 111 60.4 15.9 512
3300 108 69.5 18.4 590 3500 115 62.2 16.4 527
3400 111 71.7 18.9 608
3500 115 73.8 19.5 626 * The above are only theoretical value.
• Displacement of pump : 19 cc/rev
* The above are only theoretical value.
• Volumetric efficiency of pump : 0.95
• Displacement of pump : 22.5 cc/rev
• Volumetric efficiency of pump : 0.95
SM 765 Hydraulic System Pressure Checks and Adjustments • 30-4-3

Section 5
Hydraulic Control Valve Removal and Replacement
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
Operational Checks ............................................... 4
! CAUTION
1. Park truck on a hard, level, and solid surface, 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.
SM 765 Hydraulic Control Valve Removal and Replacement • 30-5-1

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.
removal and replacement to prevent any con-
tamination from entering the hydraulic sys-
tem.
Preparation for Valve Removal

1. Park truck in a safe position and fully lower the
upright.
2. Return all controls to neutral, apply the parking
brake, and turn key switch OFF.
3. Move all hydraulic control levers to all working posi-
tions and return them to neutral. Be sure there is no Clevis Pin
hydraulic pressure applied to the system by attach-
ments. Cotter Pin
Valve Spool
4. Remove floor plate.
5. Remove the right cowl cover from under the dash in
the operator’s compartment. See removal and Valve Removal
replacement procedures in Group 38.
1. Remove the three hex capscrews mounting the
6. Air clean the hydraulic valve and fittings. hydraulic valve to the hydraulic valve mounting
7. Place a drain pan under the truck and loosen and bracket .
remove all hydraulic lines from the valve. Plug the
valve ports. Mark or tag each line as removed to Hydraulic Valve mounting
Bracket
assure correct position of line at assembly.
Tilt Cylinder
Lines
To upringt
Feed Line
from Pump Return Line
to Sump
2. Remove valve assembly from valve mounting
bracket. See Section 6 for valve overhaul instruc-
tions.
NOTE
Be sure to clean up any oil spills and dry the
floor to prevent accidents.
8. Cap ends of lines to keep them clean. Tie ends of
lines to truck to prevent loose ends dropping and
leaking oil onto floor
30-5-2 • Hydraulic Control Valve Removal and Replacement SM 765

Hydraulic Control Valve Replacement Control Valve Linkage Reassembly

1. Insert the clevis pins through the rod-end clevises
Valve Replacement and valve spools of the lift and tilt spools (and auxil-
iary-lever rods and spools where applicable) and
1. Install the main valve on the valve mounting bracket.
secure with the cotter rings. Rotation of the valve
2. Install theGvalve mounting bracket on the frame. spools is required to allow insertion of the clevis
pins. Rotate spools back so all pins are in line.
Torque to : 40-45 N.m (30~33 ft.lbf)
Torque to : 70-80 N.m (52~59 ft.lbf)
3. Install the hydraulic lines on the proper ports. Make Clevis Pin
sure all lines are clean, arerouted correctly in the
truck, and are not kinked. Torque fittings according Cotter Pin
to “Hydraulic Fitting Tightening Procedure” in Valve Spool
Group 40.
NOTE
Tilt Cylinder The illustration above and system specifica-
Lines tion torques also apply for auxiliary hydrau-
lic functions, such as a side-shifter or rotator.
2. Set the interval of lever, then tighten the nuts under

To Upringt the lever with torque of 40-50Nm(30-33ft.lb).
Feed Line
from Pump Return Line
to Sump
SM 765 Hydraulic Control Valve Removal and Replacement • 30-5-3

Reinstall Valve Operational Checks

1. Reinstall valve and valve plumbing. 1. Operate the truck and hydraulic system. Check the
system for leaks.
Torque to : 40-45 N.m (30~33 ft.lbf) ! 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 surgically removed within a few hours by
Torque to : 70-80 N.m (52~59 ft.lbf) a doctor familiar with this type injury or
gangrene may result.
2. Check the operation of the valve and hydraulic sys-
Lift and Tilt Pump Switches tem by moving the valve control levers to the various
positions. The levers must operate smoothly with no
binding. When released from any working position,
Adjustment the levers must return sharply to their neutral posi-
1. Turn key switch to the OFF position. tions.
If valve spools do not moved or return to correct
2. Loosen switch mounting screws. position for full function of lift, tilt, or auxiliary cyl-
3. Adjust switch to activate after 2 mm (0.08 in.) of inders:
spool travel from neutral. a. When inserting the pin to the lever, check it is
smoothly inserted.
4. Tighten mounting screws.
Micro Switch
Switch Mounting Switch shown

Bracket mounted
Clevis Pin
Cotter Pin
Valve Spool
3. Refer to Section 4, “Hydraulic System Pressure-

Check” if valve was disassembled or overhauledU
30-5-4 • Hydraulic Control Valve Removal and Replacement SM 765

GROUP 32
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, “Steering Column
and Gear”, Group 26 “Steer Axle”, Group 29, “Hydraulic
Sump, Filters, and Pump”, Group 30, Hydraulic Control
Valve/Lift Circuit.” and Group 31, “Uprights.” Refer to
these other groups for hydraulic components not covered in
this group.
SM 765 Group 32, tilt cylinders

Group 32, Tilt Cylinders
Section 1
Tilt Cylinder Specifications and Description

See Group 30 for hydraulic system specifications. Tilt Cylinder Drift Test: Every 50-250 hours or each PM.
Tilt Cylinder Type : Double-acting Tilt Cylinder Check and Adjustment: Every 50-250 hours
or each PM.
Maximum Operating Pressure : 21,000 kPa (3,000 psi)
Tilt Cylinder Rod Seal Condition Check: Every 50-250
Tilt Ranges* : hours or each PM.
MAST BACK FORWARD
MFH mm (in) Tilt Cylinder Mounting Check and Tightening: Every 50-
TYPE "B"( ȋ ) "F"( ȋ ) 250 hours or each PM.
GEX
STD ~2015(83) 5 6 Tilt Cylinder Rod-End Check and Tightening: Every 50-
250 hours or each PM.
STD 2680(105.5)~3860(152) 5 6
STD 4165(164)~4620(182) 5 6 Tilt Cylinder Rod-End Lubrication: Every 50-250 hours
STD 5170(203.5) 5 3 or each PM.
TSU 3860(152)~4800(189) 5 6
TSU 5050(199)~6100(240) 5 3 Description
TSU 6370(251)~ 3 3
QUAD ALL 3 3 The tilt cylinders provide backward and forward tilt of the
upright. The forward and back tilt angles are governed by
the cylinder stroke and by use of spacers and different
*Abbreviations: Std=Standard, high-visibility upright; length rod ends. The tilt cylinders are pin-mounted to the
TSU=Triple-stage upright; MFH=maximum fork height; truck frame and upright using yokes, clevises, and pins.
B=back tilt; F=forward tilt. Pins are held in place by a lock plate and fastener to pre-
See truck data plate for upright MFH. vent the pins from working their way out.
The tilt cylinders are serviced by removing them from the
Fastener Torques truck and disassembling them for complete overhaul,
including installation of new seals and or other cylinder
Rod-End Yoke Bolts : 166-193 N½m (122-142 lbf½ft) components.
Rod-End Pin Lock Plate Fasteners : 40-45 Nm (30-33 The tilt lock valve is integrated into the tilt section of the
lbf½ft). main hydraulic control valve. The tilt lock valve prevents
the upright from tilting forward when the truck is not run-
Base Mount Pin Lock Plate Fasteners : 40-45 Nm (30-33 ning. The tilt lock valve is not serviceable and must be
lbf½ft). replaced as a valve section if defective.
SM 765 Tilt Cylinder Specifications and Description • 32-1-1

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
3. Raise the capacity load 2500 mm (98.5 in) off the

! CAUTION ground and tilt the upright vertical. Shut off the
SAFE PARKING. Before working on truck: truck.

gaps or breaks.
wheels.
Tilt Cylinder Drift Check
2500 mm(98.5 in)

2500 mm(98.5 in)
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 full-
capacity 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 must be stacked to provide load stability and
must not extend beyond the pallet. It must be secured on
the pallet. Refer to the truck data plate for capacity rating.
1. Adjust fork width as wide as possible to distribute 4. Measure and write down the distance between the
the load. Refer to truck nameplate for capacity rating. cylinder-spacer face and the rod-end yoke.
! CAUTION Measure rod

distance here
Test load must be stacked stably, not extend
beyond the pallet, and be secured on the pal-
let. Clamp the load on the load backrest or
fork bar to avoid sliping out from fork.
2. Drive the forks into the load pallet until the test load
and pallet rest against the load backrest. Apply the
parking brake and chock the wheels.
SM 765 Tilt Cylinder Checks and Adjustments • 32-2-1

5. Wait five minutes and measure and write down dis-

tance between rod end and spacer.
6. The measurement must not exceed the following
measures:
Temperature Drift
0.5q, 3.9mm @ 1 min
50qC(122qF)
5q, 39 mm @ 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.
Forward Adjustment
• Cylinder piston seals are worn, damaged, or defec-
tive allowing fluid past the piston and causing the 1. Slowly tilt upright fully forward to the end of the tilt
rod to drift. Consider rebuilding the cylinders if the cylinder stroke.
other remedies in this list are not successful. See
2. As the cylinders approach the end of the stroke,
Section 3 for cylinder removal and replacement
watch both piston rods for equal movement and
and Section 4 for cylinder repair, if necessary.
upright for twisting. Note if upright “racks” (is
• The main hydraulic tilt valve is misadjusted, worn, twisted at the end of its movement by unequal stroke
or defective. Fluid is leaking past the valve and of tilt cylinders).
causing the tilt cylinders to drift. See Group 30 for
hydraulic valve troubleshooting. NOTE
Correct the twisting effect by shortening the
Tilt Cylinder Racking Check cylinder that is the longest length. Forward
twisting must be adjusted before backward
Upright racking occurs when tilt cylinder strokes are twisting. If forward adjustment is not
unequal. Cylinders should be checked regularly during needed, continue with backward adjustment.
operation to determine if cylinder strokes are the same. To
check for racking: 3. To adjust, loosen rod-end yoke capscrew on the tilt
• Make sure uuck is parked on level surface with cylinder that extends the farthest, and turn piston rod
parking brake applied and wheels chocked. into rod-end yoke to shorten.
• Check condition of the tilt cylinder, rod-end yoke,
mounting pins, piston rod, rod wiper, cylinder Loosen
gland, etc., for excessive wear or damage. Make capscrew.
repairs before making twisting adjustment.
Turn to adjust.
• Use a capacity load (see truck nameplate) centered
on 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 Forward Adjustment: Pneumatic-tire truck rod-end yoke
tilted fully forward. orientation shown.
32-2-2 • Tilt Cylinder Checks and Adjustments SM 765

NOTE 4. Use rod shims to fill in the space between the rod-
Use wrench flat on rod under spacer (if end yoke and spacer. Screw rod back into yoke the
installed). Move spacer for access. same number of turns needed to remove.
4. Continue to turn rod into rod end until tilt cylinder

strokes are equal. Rod Shim
IMPORTANT Rod-End
Cylinder Rod Yoke
The rod must he 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
Spacer
mm (.25
in) to
diameter
of rod.
Thread rod into rod- 5. Tighten capscrew of the rod-end yoke to 166-193
end yoke the rod Nm (122-142 lbf½ft), and repeat the racking test.
diameter plus 6.5 mm
(0.25in). 6. Repeat steps l-5 for fine corrections if any racking
remains evident.
7. When no racking occurs, retighten yoke capscrew to
5. Tighten capscrew of the rod-end yoke to 166- 193
166-193 Nm (122-142 lbf½ft).
N½m (122-142 lbf½ft), and repeat the racking test.
8. Check all tilt functions before returning the truck to
6. Repeat steps 1-5 for fine corrections if any racking service.
remains evident.
7. When no racking occurs, retighten capscrew of the
rod-end yoke to 166-193 Nm (122-142 lbf½ft).
8. Check all tilt functions before returning the truck to
service.
Backward Adjustment
Perform forward check and adjustment first. Then:
1. Slowly tilt upright fully backwards while watching
piston rods. They should both bottom out at the same
time. If they don’t, adjust backward tilt using the fol-
lowing steps.
2. Stop the upright when the first tilt cylinder bottoms
out against its rod spacer.
3. 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 765 Tilt Cylinder Checks and Adjustments • 32-2-3

Section 3
Tilt Cylinder Removal and Replacement
Tilt Cylinder Removal .......................................... . 2
Parts Inspection ..................................................... 3
Tilt Cylinder Replacement .................................... 3
SM 765 Tilt Cylinder Removal and Replacement • 32-3-1

! CAUTION ! WARNING
SAFE PARKING. Before working on truck: The upright assembly is heavy. Use only
hoists with enough capacity to lift the entire
1. Park truck on a hard, level,-and solid
assembly. Keep hands and feet away from
the assembly. Use prybars to move the
gaps or breaks.
assembly into position for tilt cylinder
2. Put upright in vertical position and fully replacement.
3. Remove the floorboard.
switch OFF and remove key. 4. Put a drain pan under the truck at each tilt cylinder
position before removing the hydraulic lines. Discon-
nect and cap hydraulic lines from the tilt cylinders
wheels.
(see illustration on facing page). Remove the hose
connections on both sides of the tee fittings of
Tilt Cylinder Removal therightside cylinder. Keep all fittings and ports
clean.
1. Move tilt lever back and forth several times to relieve
any pressure.
2. Use an adequate chain and hoist to support the
upright so that it cannot fall when tilt cylinder pins
are removed.
Bearing
Rod-End Yoke
Base Pin
Mounting Bolt
Grease Fitting
Base Pin
32-3-2 • Tilt Cylinder Removal and Replacement SM 765

Tilt Cylinder Mounting Components

5. Support cylinder with a sling to prevent the cylinder Tilt Cylinder Replacement
from dropping when pins are removed.
1. Position tilt cylinder base yoke on frame mounting
6. Remove lock-plate from tilt cylinder rod-end yoke. bracket.
Use a soft drift and hammer to tap rod-end pin out of
yoke. 2. Insert base pin in cylinder base yoke and through
frame mounting bracket, making sure slot in pin is in
7. Pop the cover from tilt cylinder base access port on line with the lock-plate. Grease fitting must point
the step to the operator’s compartment. toward center of truck.
8. Remove the lock-plate from cylinder base yoke. Use IMPORTANT
a soft drift and hammer to tap pin out of yoke.
Make sure the spherical bearing is aligned so
9. Remove cylinder assembly. that pin fits smoothly in yoke.
3. Install base pin lock-plate in slot and fasten to yoke

Parts Inspection with fastener. Tighten fastener to a torque of 40-45
1. Clean all bearings, pins, and other components in an Nm (30-33 lbfft).
approved cleaning fluid. 4. Position rod-end yoke on upright mounting bracket
2. Inspect all parts for scratches, nicks, dents, and wear. and insert rod-end pin, making sure lock-plate slot is
Check the cylinder rods to be sure they are smooth in correct position. Grease fitting must be toward
with no scratches. Check all threaded parts for dam- center of truck. Make sure the spherical bearing is
age. aligned so that pin fits smoothly in yoke.
faces of parts with a light layer of engine oil.
SM 765 Tilt Cylinder Removal and Replacement • 32-3-3

Tee Fitting
Till Cylinder Hydraulic Fittings

NOTE 6. Install tilt cylinder hydraulic lines. Check Group 40
If the rod-end yoke has been removed from for hydraulic fitting tightening procedures. O-rings
the rod or loosened for adjustment, reinstall of fittings should be lightly coated with clean
the clamp bolts to a torque of 166-193 N.m hydraulic fluid or compatible oil.
(122-142 ft-lb). Nuts must be on inside of 7. Remove hoist chain from upright.
upright rails Orientation of the rod-end yoke
bolt hole is to be up as shown on the left side 8. See Section 2 for tilt cylinder adjustment procedures.
of the illustration on the previous page. When adjustments are made, check all upright com-
ponents under load before returning the truck to ser-
5. Install rod-end lock-plate in slot and fasten to yoke vice. Nuts must be on inside.
with fastener and washer. Tighten fastener to a
torque of 40-45 Nm (30-33 lbfft).
32-3-4 • Tilt Cylinder Removal and Replacement SM 765

Section 4
Tilt Cylinder Overhaul
Preparation for Disassembly ............................... . 2

Disassembly ............................................................ 2
Inspection ............................................................... 3
Reassembly .............................................................. 3
IMPORTANT
4 3 6 9 5 7 8 2 1 13 11 12 10 14 15
Typical Tilt Cylinder Cross section
1 Tube Assy 9 O-ring 1B G75

2 Rod 10 Piston
3 Gland 11 Piston Seal
4 Dust Wiper 12 Wear Ring
5 Rod Seal 13 O-ring
6 Du Bush 14 Set Screw
7 O-Ring 15 Steel Ball
8 Back up ring
SM 765 Tilt Cylinder Overhaul • 32-4-1

Preparation For Disassembly 2. Carefully pull the rod, piston assembly, and gland
from the cylinder barrel. Remove gland from rod.
IMPORTANT
Overhaul tilt cylinders only in a clean, dust- ! WARNING
free location, using clean tools and equip-
ment. Dirt or grit will damage the highly- The use of compressed air to blow the piston
machined surfaces and will result in leakage out of the barrel is not recommended. High-
or premature failure of components. Cleanli- pressure air can result in piston and rod
ness of the hydraulic circuit is extremely being ejected at high velocity (explosively),
important to the proper operation and main- causing severe injury to personnel and prop-
tenance of the system. Be sure the work area erty damage.
is clean.
3. Remove and discard the piston packing and wear
1. Before disassembly, the exterior of the tilt cylinder rings from the piston.
should be carefully cleaned to remove all dirt and Piston Seal Wear Ring
grease accumulation.
2. Be sure all hydraulic oil has been removed from the
cylinder. Stroking the piston rod will help force the
oil out.
3. Before starting disassembly, the tilt cylinder should
be carefully examined to determine if there is any
evidence of external damage.
4. Remove and discard the rod U-cup seal, O-ring, and

Disassembly piston rod wiper from the gland.
The tilt cylinder can be held by clamping the base end or
the barrel in a vise while disassembling. O-Ring + Backup Ring
O-Ring
IMPORTANT DU Bush Rod Wiper
Do not use excessive force when clamping on Dust Wiper
the barrel.
1. Remove the gland with a hook wrench. Carefully

pull the gland assembly from the cylinder tube and
slide it off the cylinder rod.
O-Ring
32-4-2 • Tilt Cylinder Overhaul SM 765

Inspection 2. Replace the piston packing and wearing.
1. Carefully clean all parts in an approved solvent and Piston Seal Wear Ring
place on a clean surface.
2. Check the piston and rod for damage. Look for
gouges, scratches, corrosion, or evidence of unusual
wear. Minor surface damage may be repaired by use
of fine abrasion cloth or stoning. Deeper damage will
require replacement of piston rod assembly.
3. Be sure the threads on rod are undamaged.
4. Inspect the tilt cylinder barrel internal bore for wear, 3. Install gland on piston rod. Use gentle pressure and
scratches or other damage. Check the outside for careful movements to avoid damage to the U-cup
damage. Inspect all welds for cracks. seal and rod wiper when these parts are moved over
Deep gouges or pitted surfaces require replacement the piston rod end.
of parts.
Check the gland, base end, and ports for cracks or NOTE
damage that could cause failure. Inspect the ports to Reassemble cylinder carefully to prevent
be sure they are free of contamination and that the damage to seal lips and O-rings.
threads are clean and not damaged.
4. Install piston into cylinder barrel. Be careful not to
5. Put a light coating of hydraulic fluid on all parts. If damage the piston seals when installing the piston
parts are to be left disassembled for a period of time, into end of cylinder.
e.g., overnight, they should be covered with a clean
cloth. 5. Install gland into cylinder them screw the gland into
the cylinder barrel with a hook wrench. When tight-
ing, do not damage the seal. Tighten torque : 60±6
Reassembly kgfm
Be sure inside of cylinder and all parts are clean before
starting reassembly. Seals may be lubricated with hydrau- O-Ring
lic oil to assist assembly into cylinder barrel.
1. Install piston dust wiper, rod seal, and O-ring on the
gland. Make sure rod seal and dust wiper are
installed in proper orientation as shown in the illus-
tration.
O-Ring + Backup Ring

O-Ring
DU Bush Rod Wiper
Dust Wiper 6. 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.
SM 765 Tilt Cylinder Overhaul • 32-4-3

GROUP 34
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
IMPORTANT
Related service information is covered in Group 29, “Hydrau-
lic Sump, Filters, and Pump,” Group 30, “Hydraulic Control
Valve/Lift Circuit,” and Group 32, “Tilt Cylinder.”
SM 765 Group 34, Uprights

Group 34, Uprights
Section 1
Upright Specifications and Description
General Specifications
Upright Upright
Upright Weight : (Approximately 341 kg (753 lb) to Cylinder Type
Type Number
approximately 971 kg (2140 lb) without carriage. <GEX20-32>
Carriage Weight : Approximately 126 kg (278 lb) to 150 V2316
kg (330 lb) STD V2324 Piston-Type Lift Cylinder
Fork Weight : Approximately 50 to 106 kg each (110 to V2330
231 lbs). M2316
TSU M2324 Piston-Type Secondary Cylinder
IMPORTANT M2330
Before hoisting, the weights of upright, car- H2317
riage, forks and attachments being lifted Hi-Lo Ram-Type Secondary Cylinder
H2320
must be combined to determine what lifting
capacity is required of the hoisting equip-
ment. Drift
Capacities and Lift Heights : Upright, carriage, and fork With the upright substantially vertical the descent of the
capacity and upright lift heights are listed on the truck’s rated load caused by an internal leakage in the hydraulic
data plate. system shall not exceed 100mm (4in) during the first
10min with the oil in the hydraulic system at normal oper-
Lubricants: ating temperature. If drift over 100 mm (4 in) in ten min-
• All Purpose Grease (MS-9) utes is evident, cylinder should be checked for internal
leakage. See Section 3 for drift test procedures.
• Innerslide Lubricant (Clark P/N 886396)
• Chain and Cable Lube (Clark P/N 886399) Fastener and Fitting Torque Specifications
Pin Mounting Bolts : 130~160 Nm (96~118 lbfft)
Cylinder Types
Load Back Rest : 220-270 Nm (160-200 lbfft)
Standard uprights use two lift cylinders. Triple stage and Chain Anchor Bolt Jam Nut : 100-200 Nm (74-148 lbfft)
Hi-Lo uprights use three cylinders, a primary (center-
mounted) cylinder, and two secondary cylinders. All pri- Carriage Side-Thrust Roller Bolts(External) : 40-50 Nm
mary cylinders used on triple-stage uprights (TSUs & Hi- (29.5-37 lbfft)
Lo) are piston cylinders. The lift and secondary cylinders Carriage Side-Thrust Roller Bolts(Internal) : 70-80 Nm
used on standard, Hi-Lo uprights and TSUs can be piston (52-59 lbfft)
cylinders. Hose Fittings : See Group 40, “Hydraulic Fitting Tighten-
The types of cylinders used on the truck are listed below. ing Procedure.”
Check the first five characters of the upright number Rod End Bolts : 170-190 Nm (125-140 lbfft)
stamped on the upright of the truck to determine the type
of cylinder, piston used on the upright. Tilt Cylinder Rod-End Pin Lock Plate : 40-45 Nm (30-33
lbfft).
IMPORTANT
seals, and gasket sets are available.
SM 765 Upright Specifications and Description • 34-1-1

Group 34, Uprights
Service Intervals specialized handling operations. The hydraulic circuit is

• All upright components should be visually checked modified with a hose adapter kit and an auxiliary section
every day during the Operator’s Daily Inspection. is added to the main hydraulic valve to operate the attach-
ment.
• A thorough visual inspection should be performed
by a trained service professional every 50-250 The lift and secondary cylinders on standard uprights and
hours. triple-stage uprights (TSUs) are piston type cylinders. The
• Lift chains should be inspected and lubricated primary cylinder on TSUs and HILO are piston-type cyl-
every 50-250 hours or monthly. inder. See the chart under “Specifications” to determine
• Lift chain tension should be checked every 50-250 the type of cylinder used on the upright you are servicing.
hours or monthly. Piston-type cylinders contain a by-pass check valve in the
• Upright and carriage roller checks should be per- piston that allows air and fluid that have accumulated in
formed every 50-250 hours or monthly. the rod end of the cylinder to return to the system. The
• Roller patterns should be checked every 6 months check valve can be removed and cleaned if indicated by
or after 1000 hours of service. troubleshooting. A non-serviceable check-ball-type cush-
• Racking and drift tests should be performed every ioning function is built into ram and piston cylinders for
50~250 hours or monthly. smooth staging during the lowering cycle. The primary
cylinder on TSUs incorporates cushioning on the lift
• The complete extended inspection should be per-
cycle. A velocity fuse in the hydraulic port of the lift cyl-
formed at least every year or 2000 hours of opera-
inders (secondary cylinders on TSUs) prevents the mast
tion.
from falling rapidly in case of sudden fluid pressure loss
Description due to line breaks or other malfunction of the hydraulic
circuit.
The upright assembly includes the lift chains, lift cylin-
As the cushion system is added to lift cylinder of standard
ders, carriage, forks, and mast or rail sets. Each of the
upright and the 1st cylinder of TSU, the speed will get
components can be serviced using the tests, checks,
adjustments, and removal and replacement procedures in slow for a moment before the fork touches the ground. It
the following Sections. is helpful to protect the ground.
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 counter-
primary (free-lift) cylinder lifts the carriage by chains. balance valve that prevents upright tilt when the truck is
When the primary cylinder reaches its maximum exten- not 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 the non-adjustable “load-lowering” flow valve mounted on
carriage by chanis. The secondary cylinders directly lift the upright limits upright lowering speed.
the inner rail set by rod. Hi-Lo uprights not used second Groups 29 and 30 contain general hydraulic information
set of chain for secondary cyliner. including upright hydraulic functions. Other hydraulic
Friction and play between the nesting rails is controlled by checks for the upright appear in “Troubleshooting,” Sec-
roller sets mounted on the rails and carriage. When rails or tion 2.
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
roller bearing surface can be reduced by the use of over-
size rollers on a one-time basis.
Forks use a hanger design for mounting on the carriage.
Auxiliary attachments may be added to the upright for
34-1-2 • Upright Specifications and Description SM 765

Group 34, Uprights
Chain Sheave
Chain Anchor
Lift Cylinder
Outer Rail Set
Lift Chain
Flow Limiting Valve

Inner Rail Set
Lower Roller
<SI-50590>
Typical Standard Upright Assembly

Group 34, Uprights
Upper Roller
Chain Sheave
Regulator Inner Rail Set

Valve
Chain Sheave
Chain
Anchor
Inter Rail
Set
Chain
Secondary Anchor
Cylinder
Outer Rail Set
Lower Roller
Primary Cylinder Carriage
Chain
<SI-50591>
Typical Triple Stage Upright Assembly

Group 34, Uprights
Upper Roller
Inner Rail Set

Regulator
Valve
Secondary
Cylinder
Chain
Sheave
Chain
Anchor
Outer Rail Set

Lift Chain
Lower Roller
Primary Cylinder
<SI-50592>
Typical Hi-lo Upright Assembly

Group 34, Uprights
Typical Triple Stage Upringht-Overhead View
Shim Carriage
Roller
Side thrust Roller
Carriages and Roller Sets

Group 34, Uprights

Group 34, Uprights

Group 34, Uprights

Group 34, Uprights
Four-Hose Adaptation for the Standard Upright

Group 34, Uprights
Four-Hose Adaptation for the Triple-Stage Upright

Group 34, Uprights
Four-Hose Adaptation for the Hi-Lo Upright

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 cir- • Excessive fork hanger or carriage fork bar wear;
cuit and components appears in the troubleshooting Sec- inspect and replace as necessary.
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.
• Damaged or blocked sump strainer; check and
Do not walk or stand under raised forks.
clean.
Block carriage and upright whenever mak-
ing checks with the upright elevated. • Hydraulic pump defective; see Group 29 for pump
Keep clear of load and carriage when making troubleshooting.
any check or adjustment. • Defective main hydraulic control valve; see Group
Keep your arms and fingers away from mov- 30 for valve troubleshooting.
ing parts of the upright. • Defective upright load-lowering flow valve; disas-
Do not reach through open areas of the semble valve, check and clean or replace.
upright.
No lift function but tilt operates

Upright noise
• Broken hoses or fittings; check and repair.
• Bent or broken components; inspect upright thor-
• Cylinder is damaged; inspect and repair.
oughly and repair or replace components as
required. • Main hydraulic control valve, lift section defec-
tive; see Group 30 for valve troubleshooting and
• Damaged upright roller; check condition of rollers
service information.
and replace defective rollers.
• Upright load-lowering flow valve damaged; disas-
• Roller scuffing rails; clean and lubricate rails.
semble valve, check and clean or replace.
• 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. See “Upright Roller Clearance Check and
Shim Adjustment.”
• Dry lift chain; lubricate chain.
SM 765 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;
• Debris in upright; check and clean. remove valve clean, inspect, and replace if neces-
• Hydraulic hose fittings loose or damaged; check sary.
and torque correctly (see Group 40 for specifica-
tions) or replace. Lowering speed sluggish
• Check cylinder for external leakage; replace cylin- • Damaged or binding upright roller; check condi-
der if cracked. tion 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- necessary.
ders; remove rod and piston and clean check • Defective upright load-lowering flow valve; check,
valves; also clean and inspect/replace piston seals. clean and replace valve if necessary.
See 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
cylinders; set capacity load on upright and lift form
• Upright rails binding:
fully collapsed to full lift height for 10-15 cycles.
a. Perform a visual inspection and check for worn,
or 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
b. 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 lifting)
• Hydraulic fluid level low; check level and fill.
• Debris in upright roller area of carriage; check and
• Broken hoses or fittings; check and repair.
clean.
• Pump inlet line restricted; remove from pump and
• Interference between carriage and inner rail or cyl-
clean.
inder; check staging alignment and adjust or repair
• Damaged or binding upright roller; check condi- as necessary.
tion of roller and replace if necessary.
• Bent or broken carriage or inner rail; replace part -
• Internal leakage on piston-type lift and secondary do not try to repair by welding.
cylinders (with load); perform cylinder checks
• Damaged or binding carriage roller; check condi-
listed under “Load cannot be lifted to maximum
tion of roller and replace if necessary.
height.”
• Carriage roller shimming or thrust roller out of
• Hydraulic pump defective; see Group 29 for pump
adjustment; perform roller checks on carriage and
troubleshooting information.
make adjustments as necessary.
• Defective main lift valve; see Group 30 for valve
• Damaged or kinked primary cylinder hose; check
troubleshooting and service information.
condition of hose, repair or replace as necessary.
• Primary cylinder chain or chain sheave binding or
hydraulic port, clean and recheck for proper opera-
damaged; inspect and repair.
tion.
34-2-2 • Troubleshooting SM 765

Group 34, Uprights
• Internal leakage in primary lift cylinder; perform • Bent or broken carriage or inner rail; replace part -
cylinder checks listed under “Load cannot be lifted do not try to repair by welding.
to maximum height.” • Carriage and upright roller shimming or thrust
• Damaged primary lift cylinder causing binding in roller out of adjustment; perform roller checks on
the cylinder; inspect and repair or replace cylinder. upright and/or carriage and make adjustments as
• Defective velocity fuse; remove fuse from cylinder necessary.
hydraulic port, clean and recheck for proper opera- • Defective velocity fuse; remove fuse from cylinder
tion. hydraulic port, clean and recheck for proper opera-
tion.
Upright mis-staging (TSU lowering)
External leakage on primary cylinder
• Debris in upright roller area or tie bar area; check
and clean. • Gland loose; check and tighten primary cylinder
• Bent or broken carriage or inner rail; replace part - gland to 588 Nm (432 ft-lb) and glands on lift
do not try to repair by welding. (secondary) cylinders to 392 Nm (289 ft-lb).
• Damaged or binding roller on upright; check con- • Cracked cylinder tube; replace tube.
dition of roller and replace if necessary. • Rod seal damage; replace seals and check for:
• Carriage and upright roller shimming or thrust Damaged rod seal groove in gland; check for
roller out of adjustment; perform roller checks on damage to groove and replace seal or gland if
upright and/or carriage and make adjustments as necessary
necessary. Scored cylinder wall; repair or replace cylinder
tube if necessary
• Damaged or kinked lift cylinder hose; check condi-
Leaking check valve; clean and replace if nec-
tion of hose, repair or replace as necessary.
essary
• Lift cylinder chain or chain sheave binding or dam- Leaking O-ring seal on check valve; replace
aged; inspect and repair. check valve.
• Bent cylinder rod; inspect and replace rod and/or • Gland static seals (O-rings and back-up ring) dam-
cylinder as necessary. aged; replace back-up ring.
• Internal leakage in piston-type cylinders; perform • Gland static seals sealing surface damaged; check
cylinder checks listed under “Load cannot be lifted groove and bore and repair or replace as necessary.
to maximum height.”
• Damaged lift cylinder causing binding in the cylin-
External leakage on lift (Standard) and sec-
der; inspect and repair or replace cylinder.
ondary cylinder (TSUs and Hi-Lo)
hydraulic port, clean and recheck for proper opera- • Gland loose; check and tighten gland on cylinders
tion. to 392 Nm (289 ft-lb).
• Cracked cylinder tube; inspect and replace tube.
Upright mis-staging (Standard and Hi-Lo • Seal damage in piston-type cylinders; replace pis-
upright lowering) ton seals and rod seals.
• Damaged seal groove, piston-type cylinders; check
• Damaged or binding roller on upright; check con-
for scratches, nicks, or burrs and repair or replace
dition of roller and replace if necessary.
rod and piston.
• Top carriage roller retaining cap screw loose;
• Scored cylinder wall, TSU piston-type cylinders;
check and replace cap screw.
replace tube and all seals.
• Lift cylinder chain or chain sheave binding or dam-
• Scored or damaged rod; replace rod and all seals.
aged; inspect and repair.
• Damaged gland back-up seal; inspect and replace
• Debris in upright roller area or tie bar area; check
seal.
and clean.
SM 765 Troubleshooting • 34-2-3

Group 34, Uprights
• Gland static seals sealing surface damaged; check • Cylinder hydraulic fittings loose or worn; check
grooves and bore. fitting O-rings, tighten fittings according to Group
40, “Hydraulic Fitting Tightening Procedure.”
Oil leak at top of lift cylinder • Check valve worn or damaged; remove rod and
• Scored cylinder wall; see Section 5. piston, clean check valve and replace if necessary.
• Worn or damaged gland rod-seal; see procedures • Control valve spool linkage malfunctioning, dam-
for piston-type cylinders under “Cylinder leaking aged, or worn; see Group 30, Section 5 for linkage
internally.” adjustment and/or replacement.
• Counterbalance function in main hydraulic control
Unsatisfactory lift or tilt cylinder drift test results valve malfunctioning, damaged, or worn; inspect
• Cylinder leaking internally; remove cylinder gland and clean or replace if necessary.
and check:
a. Primary cylinder should have only 3.4 ounces
(100 ml) on rod side of the piston
b. 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 pis-
ton seals
See Section 5.
34-2-4 • Troubleshooting SM 765

Group 34, Uprights
Section 3
Upright Inspection
! CAUTION
1. Park truck on a hard, level, and solid sur-
face, such as a concrete floor with no gaps or
breaks.
3. Put all controls in neutral. turn key switch
OFF and remove key.
wheels.
Upright
Load Back Res
Carriage
Fork
SM 765 Upright Inspection • 34-3-1

Group 34, Uprights
Basic Visual Inspection Lift Chains

Use the following steps to conduct an initial visual inspec- Inspect the chains for:
tion of the upright. This is the same type of inspection
• Proper lubrication. The links should have a coat of
operators should be conducting on a daily basis.
oil on all surfaces. Lubrication oil should penetrate
If you note problems with any component during the basic completely into chain joints.
visual inspection, continue with “Extended Inspection” • Good condition of the chain links and pins. No
for checks and service. rust, corrosion, stiffness, or cracking should be evi-
dent. Pins should not be turned or protruding.
! WARNING • Excessive side wear or edge wear on the chain
The procedures for checking, maintaining, plates.
and adjusting uprights, carriages, and forks • Correct, equal tension on chain sets.
involve movement of the components. Failure • Secure anchor bolt, adjustment nut, and jam nut
to follow these warnings can result in serious mounting.
injury. Always use extreme caution.
Do not walk or stand under raised forks. • Correct alignment of the chain anchors to the chain
Keep clear of load and carriage when making and chain sheaves. Adjust turned chain anchors.
any check or adjustment. • Loose, broken, or damaged anchor bolt pins and
Keep your arms and fingers away from mov- cotter pins. Replace defective pins and cotter pins.
ing parts of the upright.
Do not reach through open areas of the Rollers
upright.
Inspect the upright and carriage rollers for:
General • Broken or loose rollers.
• Check to make sure all fasteners are secure. • Loose, broken, or misadjusted thrust roller on the
carriage.
• Check to make sure the upright lifts and lowers
smoothly with and without a capacity load. • Obvious signs of failed bearing seals.
• Check for visible damage to components. NOTE
Some grease will purge from the bearings in
Forks the first 100-200 hours of operation.
• Check function and security of the fork latch. • Excessive looseness in carriage or upright roller
• Inspect the forks for cracks, especially the hanger shimming.
and heel areas.
• Check for wear in the fork heel. If heel wear is evi- Upright and Carriage Weldments
dent, perform the extended inspection.
Inspect the upright and carriage for:
• Inspect the fork hanger and carriage fork bar for
excessive wear. • Debris or foreign objects on the components.
• Inspect for bent forks. • Bent, cracked, or broken components.
• Undesirable wear on or contact between compo-
Load Backrest nents.
• Irregular roller patterns and signs of excessive
• Inspect load backrest for damage such as cracks or wear or scraping on the rails.
bending.
• Check for tight mounting fasteners.
34-3-2 • Upright Inspection SM 765

Group 34, Uprights
Hydraulic System Fork Bending

Overloading, glancing blows against solid objects, or
Inspect the upright hydraulic system components for:
picking up loads unevenly can bend or twist a fork. Use
• Damage or wear on all hoses and hydraulic tubes. the following procedure to check for fork bending.
• Leaks on hoses, fittings, or valves. 1. Place a 50 x 100 x 610 mm (2 x 4 x 24 in) wood
• Leakage on the cylinders. block flat on the fork. Make sure the block is not
• Excessive drift in lift or tilt operations. resting on the heel radius.
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 Fork Bending Check
check, and a fork gap check. If replacement is necessary,
always replace the pair to ensure fork integrity. 2. Set a carpenter’s square on the block against the fork
shank
Fork Alignment
3. Check the fork 508 mm (20 in) above the blade to
1. Park the truck on a flat, even surface, tilt upright to make sure it is not bent more than 14.5 mm (0.6 in) at
vertical position, and set forks 25-50 mm (1-2 in) the maximum.
above the ground.
4. If blades are bent over the 14.5 mm (0.6 in) allow-
2. Compare fork arms to be sure they are straight, on ance they should be replaced as a set.
the same plane (level), and the same length. See Section 7, “Fork and Carriage Removal and Replace-
3. Measure the distance from the fork tips to the ment,” for procedures to remove and replace the forks.
ground. The height difference between the forks tips Fork Fatigue
should be no more than 1.5% of the blade length. 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
XU\LGGU
thickness is reduced by 10% over its original thickness. If
G the heel is 10% smaller than the arm, the load capacity
could be reduced by 20%. A 5,000-pound (2272 kg)
Fork Arm Height capacity fork with 10% wear can only safely handle 4,000
4. If the fork tips are not aligned within the specified pounds (1818 kg).
1.5% difference, the cause of the problem must be Use of fork wear calipers are recommended (CLARK part
determined and corrected before returning the truck number 1803641) to gauge fork wear as follows:
to service. If replacement is necessary, always
replace the forks in a set. 1. Use the outside jaws of the caliper to measure fork
thickness in the shank area of the fork.

Group 34, Uprights
NOTE
A small amount of lubricant can be applied
NOTE to the fork latch. Do not over lubricate and
Hold the caliper square and use light pres- allow lubricant to run down on carriage fork
sure to squeeze the outer jaw tips against the bar.
fork shank. Take care not to accidentally
alter the reading of the calipers. 2. Check fork stops for widening of notches or round-
ing of top edge. Replace the carriage if fork stops are
2. Check the fork blade area to the inside jaws of the excessively worn.
caliper.
3. If the inside jaws fit over the fork in the blade area, Lift Chains
wear exceeds allowable 10% wear and a new set of
The following checks should be performed every 50-250
forks should be installed.
hours to ensure correct chain performance See Section 6
Fork Hanger Wear and Carriage Fork Bar Wear for more complete chain inspection and maintenance pro-
Inspect the fork hangers and carriage fork bar. Excessive cedures.
wear can cause the fork to disengage the fork bars or Chain Wear (Stretch) - All Lift Chains
reduce fork hanger life. Lift chain stretch due to wear in the joints can be mea-
sured using a measuring tape or chain check ruler.
When any section of the chain has worn and increased its
• If fork hangers are excessively worn, replace the
original length by 3% or more, the chain must be replaced.
forks as a set.
When checking chain wear, always measure a segment of
• If carriage fork bar is excessively worn, replace the the chain that rolls over a sheave.
carriage.
IMPORTANT
Welding is not recommended for repairing
forks or carriage. Replace the worn parts
with new parts.
Fork Latch and Carriage Fork Stops
1. 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
Never replace a single chain in a set. Always
! WARNING
replace the two chains in a set for consistent Do not reach through the upright to push
lift operation. Always replace anchor pins chains for tension check.
when replacing chains.
3. If one chains moves more than the other;
1. For example, measure a 305 mm (12 in) segment of a. Lower the forks to ease tension on the chains.
the chain that does not roll over a sheave and count b. Adjust chain adjustment nuts for equal tension on
the number of links in the segment. both chains. See Section 6 for chain adjustment
procedures
2. Find an area of the chain that normally runs over the
sheave. This can usually be identified by wear on the 4. Repeat the tension test and make adjustments until
plate edges that roll over the sheave. the tension is equal on both chains when the carriage
and upright are raised.
3. If the same number of links measures over 315 mm
(12.36 in) the chain must be replaced.
If using a chain check ruler, see instructions on the ruler. Carriage and Upright Weldments
Chain replacement procedures appear in Section 6. The carriage and upright should be checked for fatigue
Chain Length cracks and bent components every 2000 hours or every
year..Fatigue cracks start in areas of stress after a high
IMPORTANT number of load cycles. Stress concentrations typically
Perform a chain length check and adjust- exist in welded joints, in the area around a welded joint, or
ment every 50-250 hours. Checks and adjust- in the corners of parts. Dye penetrant, magnaflux, or other
ments should also be performed to adjust for crack detection methods can be used to find or trace
chain stretch and tire wear. cracks. If cracks are found in any structural weldment, the
component should be replaced before returning the truck
Chain length must be adjusted if: to service.
• The fork-to-ground clearance is less than 5 mm • Bent components indicate excessive loading or
(.20 in) or more than 25 mm (1.0 in) when the high impacts to the weldments. Bent components
upright is vertical. are usually structurally damaged and should be
• The center of the bottom carriage roller comes replaced.
within 20 mm (0.80 in) of the bottom edge of the • Inspect roller contact patterns on the rail sections.
inner rail. Roller contact patterns should be smooth and regu-
• The carriage safety stop hits the inner rail stop at lar.
full lift height. In some applications, it may take up to 500
hours of operation to develop a roller contact
• On TSUs and Hi-Lo, the difference between the
pattern on the flange of the rail.
bottom of the inner rail and the outer rail is greater
In applications where heavy loads are common,
than 10 mm (0.40 in).
a rail lubricant may be required to allow proper
See Section 6 for chain length adjustment procedures.
wear-in on the roller.
Chain Tension • Check rails and carriage for wear due to undesir-
IMPORTANT able contact between components. Such contact
can be an indication of broken rollers, loose com-
Center any auxiliary attachments before
ponents, foreign objects or debris on the upright, or
beginning tension check
a broken weldment.
If contact or rubbing exists, the condition must
1. Raise the upright enough to put tension on the chains
be corrected immediately.
to be checked.
Rail and carriage weldments with damage
2. Push the chains forward and pull them backward; the should be replaced.
amount of tension should be equal on both sides.

Group 34, Uprights
• Tie bar areas should be free of foreign objects and NOTE

debris. The roller area of the rail should be cleaned Some grease will purge from the bearings in
every 500-1000 hours in a normal application. the first 100-200 hours of operation. This is
In applications where excessive amounts of not necessarily a sign of a failed roller bear-
contaminants settle in the rail channels, cleaning seal.
ing may be required on 50-250 hour intervals.
If excessive contamination exists, the rollers The external thrust rollers are not adjustable. The internal
should be exposed and the bearing seal areas thrust roller adjusts using a locking cam on the mounting
cleaned thoroughly. cap screw. See Section 4 for roller replacement and inter-
See Section 4 for carriage roller and upright nal thrust roller adjustment procedures.
roller removal and installation.
Carriage and Upright Main Load Rollers
Inspect the carriage and upright main load rollers for bro-
Carriage and Upright Rollers ken, loose, or rough bearings. Defective rollers should be
replaced.
Carriage Thrust Rollers
Shoulder
The carriage uses two types of thrust rollers.
Roller shaft
• The internal thrust roller is found on both standard
shims
and TSUs. The carriage internal thrust rollers are
located on the lift bracket and run on the inside Bearing outer race
web of the inner rail. The internal thrust roller is

intended to carry a portion of the carriage lateral
load.
• The second type of carriage thrust roller is an Indications of broken or damaged rollers include:
external thrust roller. The external thrust roller
runs along the outside flange of the inner rail to • Part of all of roller bearing missing
control lateral load on the carriage. External thrust • Bearing outer race loose
rollers are found on STD, Hi-Lo CL III and TSUs. • Scraping noise from the upright
Internal thrust roller • Scraping of carriage fork bar on inner rail (carriage
rollers)
• Upright rail sections scraping together (upright
rollers)
External thrust roller
• Upright misstaging
(not in 2.0/2.5 ton STD
and Hi-Lo CL ) • Excessive looseness of the rail section or carriage
demonstrated by the following load test.
NOTE
Both types of thrust rollers should be checked for smooth Some grease will purge from the bearings in
rotation, seal integrity, radial bearing tightness, and a tight the first 100-200 hours of operation. This is
cap screw. A roller should turn smoothly without sticking not necessarily a sign of a failed roller bear-
and be grit free. Replace the roller if any defect is found. ing seal.
External thrust roller cap screws have a locking patch to
Load Test
prevent the cap screw from backing out. Repeated
A load test helps you to determine the amount of clear-
removal will deteriorate the ability of the patch to hold the
ance between the moving upright parts. The upright
cap screw. If the cap screw is backing out without hold-
requires some lateral movement between the interlocking
ing, a new cap screw is recommended. The cap screw can
rails and the carriage. But, too much or too little clearance
also be cleaned and set using thread locking compound
can be the cause of binding and uneven operation.
Loctite 271 (Clark Part 1802302). The internal thrust roll-
ers use a jam nut to ensure that the bearing remains
secure.

Group 34, Uprights
manufacturing tolerances and wear in the upright rail sec-

! WARNING tions.
An upright or carriage can move unexpect- Side Clearance
edly during service procedures causing Roller
severe injury:
Do not walk or stand under raised forks.
Roller Shaft
Keep clear of load and carriage when making and shoulder
any check or adjustment. Rail Web
Keep your arms and fingers away from mov-
ing parts of the upright.
Do not reach through open areas of the
upright.
Failure to follow these warnings can result in
serious injury. Signs of loose shimming include:
1. Excessive lateral (side-to-side) movement in the
1. Place a capacity load on the forks and secure it to the upright rail sections
carriage.
2. Excessive lateral shift in the upright at, or near, full
! maximum fork height (MFH)
CAUTION
Test load must be stacked stably, not extend 3. Irregular roller patterns on the rail.
beyond the pallet, and be secured on the pal- Signs of over shimming include:
let. Operate the truck only from within the
operator’s compartment. 1. Mis-staging or hanging up of the upright
2. Excessive wear in the rail web
2. Tilt the upright back slightly and raise the upright to
its maximum extension several times. Note the 3. Premature bearing failure.
smoothness of operation, the carriage play, and play Perform the following roll pattern check and the load test
between the rails. if the need for roller shimming is suspected. See Section 4
for detailed clearance measurement procedures.
3. Move the load 102 mm (4 in) off center on the forks
and resecure it to the carriage. Roll Patterns
Impressions made by rollers on upright rails are called roll
4. Raise the upright to its maximum extension and patterns. Roll patterns can provide indication of the need
lower the load to the floor several times. for upright or carriage adjustment.
5. Repeat the step, moving the load 102 mm (4 in) off
center to the other side. ! WARNING
6. Raise the upright to its maximum extension and Keep clear of load and carriage when making
lower the load to the floor several times. any checks or adjustments.
Carefully observe the smoothness of operation, particu-
larly in carriage play, and play between the rails. If any 1. Elevate the carriage about 4 feet (1.3 m).
unusual movement, staging, or noise occurs during the 2. Apply a light, thin layer of grease to the roller con-
test, correct the problem before returning the truck to ser- tact area.
vice. Continue with the following roller shimming checks
if too much play is evident in the carriage and rails in the 3. Lower the forks and pick up a capacity load. Raise
load test. The troubleshooting guide may also help to and lower the upright several times.
identify specific problems with upright operation. 4. Back out from the load and raise the carriage.
Roller Side-Clearance Compare the impressions of the rollers on each side of the
The carriage and upright rollers are shimmed between the upright rails. The impressions should look the same on
inner race and the roller shaft shoulder to maintain mini- both sides. Look for signs of metal scoring or gouging
mal clearance between the side of the roller and the web which can indicate excessive pressure caused by damaged
of the adjacent rail. Shim adjustments help accommodate or misadjusted rollers.

Group 34, Uprights
Carriage rollers, including side-thrust rollers, and all NOTE

upright rollers can be checked by examining roll patterns. The seals are installed with lubricant and a
If irregular impressions result from the checks, perform trace amount will be in the gland/tube inter-
the “Lift Cylinder Shimming Check” and the “Load Test” face area.
to further diagnose problems.
See Section 4 for procedures to measure clearances and 4. After cleaning the top of the gland and the barrel,
adjust carriage or upright rollers. cycle the upright 5-10 times. If a ring of oil forms to
run 3 mm (0.125 in) down the rod, the cylinder must
be overhauled or replaced.
Cylinders
Internal Leakage on Primary Cylinder
Use the Drift Test, presented under “Hydraulic Checks” To check for internal leakage on the primary cylinder:
below, for additional diagnosis of cylinder condition. See
Section 5 for cylinder repair. 1. Lift the upright to maximum height then lower forks
completely.
External Leakage (All Cylinders)
To check for external leakage on the primary cylinder: 2. Cycle the upright 5-10 times through the first 2/3
length of the primary stroke and lower forks com-
1. Clean the top of the gland and rod to remove any pletely.
buildup of debris.
3. Slowly lift the carriage 305-610 mm (1-2 ft) into the
2. Check rod surface for defects or unusual wear. secondary lift stage then lift to full extension.
• Nicks, burrs, or other sharp defects can cause dam-
4. If the carriage does not lift to full height, the problem
age to the seal and will lead to leaks. The rod
is likely an internal leak and the cylinder should be
should be repaired or replaced.
overhauled.
• For piston-type cylinders, small blunt defects in
the top and midsection of the rod can be tolerated 5. If the carriage does lift to full height, but you still
in this cylinder design. The high pressure sealing is suspect an internal leak, repeat the procedure with a
over the last several inches of stroke. This type of 40-70% capacity load.
defect is acceptable if leakage is not evident. NOTE
3. Check for external leakage from the cylinder barrel, The primary cylinder normally has approxi-
gland O-rings and backup ring, and the rod seal. mately 100 ml (3.4 oz) of hydraulic fluid on
the rod side of the piston as a pre-charge.
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:
1. Lift the upright to MFH then lower forks completely.
2. Cycle the upright 5-10 times through the first 2/3
length of the lift cylinder stroke and lower forks
completely.
• The gland O-rings and backup ring are near-zero
3. 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
have an internal leak and requires overhaul.
• External leakage from the barrel requires replace-
ment of the barrel.

Group 34, Uprights
If the upright does not increase lifting speed, but you still a. Hoses or tubes with scrapes or kinks should be
suspect an internal leak, repeat the procedure with a replaced.
capacity load. If the upright does not extend to full MFH, b. Hoses with outer cover wear exposing the rein-
the problem is likely an internal leak and the cylinder forcement braiding should be replaced.
should be overhauled.
Lift Cylinder Shimming Upright Drift
The lift cylinders on both standard uprights, Hi-Lo and
TSUs bottom out at the end of the stroke to limit upright Drift tests check cylinder, main valve, and hydraulic cir-
extension. The upright has dual lift cylinders and the cyl- cuit integrity under load pressures. A load is held elevated
inders’ extension length must be equal. If not, “racking,” for an extended period to determine how much the upright
or side-to-side shifting, results. Rod extension length is “drifts” (moves) over a specified time period. A tilt cylin-
made equal by using shims under the rod end of the cylinder drift test appears in Group 32, Section 2, “Tilt Cylin-
der. To determine if shimming of the cylinders is required der Checks and Adjustments.”
to prevent racking, perform the following operational
check: ! WARNING
! CAUTION edly during service procedures causing
Make sure truck is parked on level surface severe injury:
with parking brake applied and wheels Do not walk or stand under raised forks.
chocked; make sure overhead clearance is Keep clear of load and carriage when making
adequate to extend upright to its full height. any check or adjustment.
Keep your arms and fingers away from mov-
1. Center the forks or attachments on the upright. ing parts of the upright.
Do not reach through open areas of the
2. Check for equal chain tension. upright.
3. Raise the upright from the retracted position to full Failure to follow these warnings can result in
lift height. Note the point when the lift cylinders serious injury.
reach the end of their stroke.
1. Raise upright with the rated capacity and carriage to
• If the upright shifts right or left noticeably, shim-
its full extension and lower to a point halfway down
ming is required.
from full extension with the upright substantially
• Repeat the check three times before adding shims. vertical.
NOTE 2. Shut off the truck. Apply the parking brake and
Offset or unbalanced loads and off-center chock the wheels.
attachments can cause the upright to shift
3. With a pencil or chalk, make a mark across the rails
even with proper lift cylinder shimming.
on one side of the upright.
See Section 5 for lift cylinder shimming procedure. Rack-
ing adjustments for tilt cylinders appear in Group 32, Sec-
tion 2, “Tilt Cylinder Checks and Adjustments.”
Hydraulic Plumbing
Use the Lift Cylinder Shimming Check, the Load Test,
and the following Drift Test to check the performance of
the hydraulic system.
1. Check all fittings for leakage. Disassemble fittings
and inspect the seals. Replace seals as required. See
Group 40 for hydraulic fitting tightening procedures. Mark upright
rails here
2. Check all hoses and tubes for wear and damage.

Group 34, Uprights
Consider rebuilding the cylinders if the first two remedies

! WARNING in this list are not successful. See Section 5 for removal,
Keep clear of load and carriage when making overhaul, and replacement procedures for primary and
any checks or adjustments. Do not use the secondary cylinders.
upright to climb; use an approved platform.
Upright Mounting Check
4. Wait ten minutes and recheck the mark. Measure
and write down the distance the marks on the inner To check the Upright mounting:
and intermediate rails have drifted from the mark on
1. Check for missing, broken, bent, or loose trunnion
the outer rail.
cap fasteners. Replace any damaged parts.
5. If the rated load drift 50 mm (2 in) or more in the ten
2. Lift the upright 305-610 mm (1-2 ft) and tilt the
minutes, read and follow the procedures presented in
upright fully forward.
“Drift Causes and Remedies.”
3. Check for Bushing or cap wear by inserting a feeler
! CAUTION gauge between the upright mounting cap and the
axle-mounting bearing surface.
Test load must be stacked stably, not extend
beyond the pallet, and be secured on the pal-
let.
Drift Causes and Remedies

If drift of 50 mm (2 in) or more is evident under the rated
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- Bushing
tive allowing fluid past the piston causing drift. Mounting Cap
• 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. • The gap should not exceed 0.75 mm (0.03 in).
• If the gap exceeds 0.75 mm (0.03 in) the bearing or
cap may need replacement.
See Section 8, “Upright Removal and Replacement,” for
procedures to remove and replace the bushing.

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

Adjustments
IMPORTANT
! WARNING
haul, make sure the correct repair parts and/ Use an approved safety platform to reach the
or kits are available. upper areas of the upright. Never use the
upright as a ladder.
! WARNING
Introduction
edly: Standard and Hi-Lo upright assemblies have two lift roller
• Do not walk or stand under raised forks sets mounted on the rails, three lift roller sets mounted on
• Kee clear of load and carriage when mak- the carriage, and two internal and external (except 2.0/2.5
ing any check or adjustment ton STD) thrust roller set mounted on the carriage.
• Keep your arms and fingers away from
External thrust roller set used more than 3.0ton trucks.
moving parts of the upright.
• Block the carriage or upright when work- The triple-stage upright assemblies have four lift roller
ing with the components in a raised posi- sets mounted on the rails, three lift roller sets mounted on
tion. the carriage, and two thrust roller sets (“internal” and
• Do not reach through open areas of the “external”) mounted on the carriage. (see the “Roller Side
upright. Clearance Chart” on next page.)
• Never attempt to move or align the rails
Each carriage and upright lift roller is nested within its
by hand. Use a prybar.
adjacent rail set. The front “face” of the lift roller handles
front-to-back friction and play between the nesting seg-
serious injury.
ments of the upright assembly, the side “face” of the roller
radius handles side-to-side friction and play. The rollers
SM 765 Carriage and Upright Roller Clearance Checks and Shim Adjustments • 34-4-1
Group 34, Uprights
are canted (tilted) to allow the side face to bear properly tainty that the clearance is excessive, you perform the
on the web. checks given below.
Rail flange wear can cause excess play between the lift To correct excessive lift roller side clearance, you add
rollers and the rail flange. The only way to correct this is shims as described later in this Section. To correct internal
to install oversize rollers-only one size of which is avail- thrust roller clearance, you adjust thrust roller position as
able. If oversize rollers were fitted previously, the only described later in this Section.
remedy for excessive front-to-back play is to replace the Gap
rail set. (carriage middle rollers are always standard-size
Lift Roller
rollers; see “Oversize Rollers” later in this Section for
details on roller replacement.)
Side Face
The gap between the roller “side” and the web of adjacent Shoulder Of Clearance
rail set affects the side-to-side motion of the upright-
Rail Web
which should be as small as possible without causing the
sliding segments to bind. The same is true of the internal
thrust rollers. Rail Flange
You check the performance effect of the lift roller side
clearance and internal thrust roller clearance by means of
the load test described in Section 3. To evaluate with cer-
Roller Side Clearance Chart

Roller Side Clearance Chart
Web Area Gap at Mimimumm Span of Rail Set Gap at Maximum Span of Rail Set
Roller Set# Forming Gap Targeta Allowedb Targeta Allowedb
(mm) (in) (mm) (in) (mm) (in) (mm) (in)
#1 Front, Inner railc 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 0-1.5e 0-0.06 d d 2.25 0-0.09
#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. d. Ideal is same as final measured gap at minimum width point of rail set.
b. Allowed is the acceptable gap when checking roller set. e. Measured at top of inner rail.
c. Internal side thrust rollers should extend 0.25-0.50mm(0.01-0.02 in)
beyond #1 rollers.
34-4-2 • Carriage and Upright Roller Clearance Checks and Shim Adjustments SM 765
Group 34, Uprights
Roller Side Clearance Checks 2. Position the carriage or rails so that the roller set you
want to check is at the mark for the narrowest span
The same basic procedure is used for checking all the lift on the adjacent nesting rail set.
rollers. That general procedure is given in the subsection
directly below. Special instructions for specific rollers fol-
low that subsection. Follow those directions (in the sub-
section called “Directions for Checking Specific Rollers”) Narrowest
and you will be directed to general and specific informa- span
tion you need.
General Roller Side Clearance Checking Pro-

Widest
cedure span
For each roller set, you need to measure the gap between
the outside face of a roller and its adjacent nesting rail. In
general, the lift roller side clearance check procedure is as Example of Aligning Roller Set with Widest and
follows: Narrowest Spans Marked on Adjacent Rail Set.
Rail sets are shown separated for clarity.
1. With the spanner tool, find and mark the narrowest
and widest spans in each rail set at the roller-contact 3. Clamp the rails together opposite the roller you
areas in the rail webs: intend to check. Use wooden shim blocks to protect
• Inner Rail Set-Mark narrowest and widest spans the rails. Place clamp as close to roller as possible.
for both the front and back web areas. Torque clamp to 25 Nm (20 ft-lb).
• Outer and Intermediate Rail Sets-Mark narrowest
and widest spans for the back web area only.
4. 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
5. Repeats steps 2 through 4 for the widest span marked

on the rail set.
Spanner Tool. Clark Part #180109
Group 34, Uprights
6. If the clearance at the widest rail set span is more Top Carriage Rollers and Internal Thrust Rollers
than 2.25 mm (0.09 in), the roller set needs shim- The internal thrust rollers are nearly perpendicular to the
ming. top carriage lift rollers and contact the same flange area as
If the clearance at the narrowest rail set span is more the carriage rollers. The top carriage lift rollers and the
than 1.0 mm (0.04 in), the roller set should be internal thrust rollers should be checked together.
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
the instructions in “Directions for Checking Specific Interral Thrust
Rollers” below. Rollers
Rollers
Directions for Checking Specific Rollers
Use these directions to supplement the general procedures
given above. 1. Move the top carriage lift roller to the narrowest span
Carriage Rollers on the inner rails set.
Bottom Carriage Rollers 2. Clamp rail to one side as in general procedures.
Follow the general procedure above. Check clearance of lift roller on clamped side. Locate
Middle Carriage Rollers the clamp between the thrust roller and the bottom
The middle rollers are difficult to access and require the roller of the carriage.
following special procedures.
1. Raise the carriage until the middle rollers are at the
top of the inner rails.
2. 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
required.
If gap is more than 1.5 mm (0.06 in), check clearance
at narrowest span by comparison with the top of the
rail set as follows:
a. With spanner tool, measure span of inner rail set
at top of the front web area. Note measurement
The internal thrust roller should contact the web and
here: _____________________.
cause the lift roller to stand off from the web by .01
b. With spanner tool, measure span of inner rail set
to 1 mm (0.001-0.03 in). If the gap is outside this
at narrowest span of front web area. Note mea-
range, the internal thrust roller must be adjusted as
surement here: _____________________.
explained later in this Section under “Internal Thrust
c. Subtract measurement in step b from measure-
Roller Adjustment.”
ment in step a, Write result here:
b-a= _____________________. 3. Check clearance on lift roller opposite clamped side
If the calculated gap is less than or equal to the as in the general procedures. If clearance is greater
gap measured in step 2, the roller set does not than 1.25 mm (0.05 in), the roller set should be
require shimming. Otherwise, the roller set shimmed.
should be shimmed.
4. Move clamp to opposite side and check clearance on
clamped side as in step 2 directly above. Gap should
be 0.01-1.0 mm (0.001-0.03 in).
5. Move the top carriage lift roller to the widest span on
the inner rail set and check clearance as in general
procedures.
Group 34, Uprights
Upright Rollers Internal Thrust Roller Adjustment

1. Remove the carriage as described in Section 7 of this The internal thrust rollers should be adjusted to extend 0-
Group. 0.75 mm (0.03 in) into the top carriage roller side clear-
2. Fully extend the upright making sure carriage hoses ance. Carriage roller side clearance should be within toler-
and chains are secured out of the way to prevent ances before you adjust the thrust rollers.
damage. NOTE
! WARNING Carriage must be replaced on upright before
adjusting internal thrust rollers. See Section
An upright or carriage can move unexpect- 8 for carriage replacement procedures.
edly:
• Do not walk or stand under raised forks 1. Lift the carriage to the top of the inner rail.
• Keep clear of load and carriage when
making any check or adjustment 2. Loosen the jam nut on the back of the thrust roller
• Keep your arms and fingers away from cap screw and then loosen the cap screw. Rotate the
moving parts of the upright. bearing to pivot toward the carriage and away from
• Do not reach through open areas of the the rail.
upright.
• Use an approved safety platform to reach
the upper areas of the upright. Never use
the upright as a ladder.
serious injury.
3. Follow the “General Roller Side Clearance Checking
Procedure” given earlier in this Section. 3. Lower the carriage to a convenient height to do the
The clamping procedure is as illustrated below. adjustment.
4. Clamp the carriage between the top and middle car-
riage roller.
• Use a shim block under the clamp on the outside of
the channel rail.
• Torque on the clamp should not exceed 25 Nm (20
ft-lb).
5. Insert a 0.5 mm (0.02 in) temporary shim between
the top carriage roller and the rail web on the side
opposite the clamp. If a 0.5 mm (0.02 in) shim will
not fit, insert a 0.25 mm (0.01 in) shim.
Group 34, Uprights
6. Move the clamp to the shimmed side and clamp the Oversize Rollers
rollers against the shim and the rail web by position-
ing the clamp between the top and middle carriage At the time of roller shimming,
rollers. you may want to replace the lift
rollers with oversize rollers to
counter rail flange wear as
detected by inspection and the
load test. Because there is only
one size of oversize rollers, you
can install them only if they were
not installed previously.
Identify oversize rollers as fol-
lows: If a roller is oversize, it has
an indented radius in the outer
7. Cam the thrust roller on the shimmed side against the edge of its mounting side, as shown below.
rail clockwise and tighten the cap screws firmly.
NOTE Lift Roller Shimming
Make sure the roller does not rotate with the
cap screw when tightening. You need to shim lift rollers if the roller side clearance
checks indicated that clearance was excessive at either the
8. Insert a 0.5 mm (0.02 in) shim in the opposite roller. narrowest or widest span of the roller set’s adjacent rail
If a 0.5 mm (0.02 in) shim will not fit, insert a 0.25 set.
mm (0.01 in) shim. Your objective in shimming is to add only enough shims
9. Loosen the clamp and remove the shim. to bring the clearances at both the widest and narrowest
spans into tolerances. In practice, you achieve this by
10. Reposition the clamp on the opposite side and draw shimming to obtain the smallest possible clearance at the
the roller against the shim and rail web. narrowest span of the rail set.
11. Cam the thrust roller on this shimmed side toward
the rail clockwise and tighten the cap screws firmly. Carriage Roller Shimming
NOTE
Using the measurement you recorded in previously in the
Make sure the roller does not rotate with the “Roller Side Clearance Checks,” determine the number of
cap screw when tightening. shims required to reduce the carriage roller clearance at
the narrowest span on the inner rail to 0-0.75 mm (0-0.03
12. Loosen the clamp and remove the shim. in):
13. Use a crow’s foot to torque the cap screws 70-80 1. Remove the carriage as described in Section 8, “Fork
Nm (51.5-59.2 ft-lb). and Carriage Removal and Replacement.”
NOTE 2. Remove the rollers (note the number of shims
If a crow’s foot is not available, the carriage already on the roller shafts, if any).
can be raised to the top of the inner rail and a
socket used to tighten to the correct torque.
14. Position the carriage to access the jam nut on the

back side of the cap screw and torque to 70-80 Nm
(51.5-59.2 ft-lb).
• Clean and inspect roller bearings, shims, and

shafts.
Group 34, Uprights
• Replace any defective parts. Upright Roller Removal
3. Add shims to the top and bottom rollers as deter- 1. After the carriage has been removed, lower the
mined in the previous steps. upright rails until both of the secondary (final) lift
• Install shims with the same number on each side. cylinders are completely collapsed.
• When an odd number of shims is required, always 2. Jack the truck and block under the frame so that the
place the odd shim on the same side on all roller bottom of the upright is approximately 254 mm (10
sets. in) off the floor. See “Lifting, Jacking, and Blocking”
in Group SA for safe procedures.
4. Use a straight bar to determine the number of shims
3. Set the parking brake and block the steer wheels.
to add to the middle roller shaft as shown in the fol-
lowing illustration. This shimming may be asymmet- 4. Tilt the upright to as near vertical as possible.
ric, meaning the numbers of shims do not have to 5. Using a hoist and lifting strap of adequate capacities,
match those of the top and bottom rollers. connect the lifting strap to the inner rail on standard
and Hi-LO uprights or intermediate rails on triple-
stage uprights. Lift hoist to remove slack from the
strap.
5. Reinstall all bearings; torque top roller fasteners to

40-45 Nm (30-33 in-lb).
Carriage internal thrust rollers must be adjusted after the
carriage is shimmed. Adjust as described previously.
Upright Roller Shimming

Use the following procedures to remove, shim, and
replace rollers. Use the preceding checks to determine the 6. Disconnect the flow control valve manifold from the
number of shims required to reduce the roller clearances upright bracket.
to 0.75 mm (0.03 in) or less.
! WARNING
Use an approved safety platform. Never use
the upright as a ladder.
! CAUTION
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.
czpT\W\`We
Group 34, Uprights
7. Disconnect the cylinder guide bolts. Roller Removal, Shimming, and Replacement
In Hi-Lo upright, disconnect the secondary cylinder To add shims to, or replace the rollers:
hose.
1. 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.
΄΅͵͠΅΄Ά͙΅ΣΚΡΝΖ͑΄ΥΒΘΖ͚
8. Secure the cylinder to prevent its falling and discon-

nect the cylinder rod retaining bolts.
2. Inspect all roller components when removed:

a. Clean and inspect the rollers, shims, and roller
shafts.
b. Bearings should be in good condition and allow
the roller to spin smoothly with a true rotation.
c. Clean rail sections and add lubricant if necessary.
d. Replace any worn or damaged component.
3. If the clearance check indicated an even number of
NOTE shims needed, split the number evenly between the
rollers on either side of the upright.
For 4-hose adapters, you must disconnect the
hose sheave and bracket. This is not neces- 4. If the clearance check indicated an odd number of
sary for 2-hose adapters. shims needed, keep the odd number to the same side
on all rails of the upright. If three shims are needed,
9. Move the sheave with the hoses and any other con- for example, add one to the rollers on the left side.
nected components out of the way. Add the other two on the rollers on the right side.
10. Disconnect the rail cylinders by raising the rails to 5. Reposition the rollers onto the roller shaft and use a
free the cylinder rod ends from the tie bar. Tilt the plastic or hard-rubber mallet to gently tap the roller.
cylinders inward and secure out of the way of the tie Seat the roller evenly by continuing to tap gently
bars. until it is fully seated and snug against the added
shims.
11. Lower the assembly completely to expose the rollers.
The lower roller set of the inner rail and upper roller set of
the outer rail on standard and triple-stage uprights are now
exposed for shim adjustment.
Group 34, Uprights
Upright Reassembly 3. Reconnect the cylinder guide bolts. Do not tighten

The following steps detail the procedures for reassem- until inner and/or intermediate rails are in the fully
bling the upright. lowered position. Torque guide bolts nuts to 20-25
Nm (14.8-18.5 ft-lb).
! WARNING
The upright can move unexpectedly:
• Do not reach through open areas of the
upright.
Failure to follow these warnings can result in 4. Reconnect the cylinder rod retaining bolts. Torque
serious injury. rod retaining bolts to 20-25 Nm (14.8-18.5 ft-lb).
In Hi-Lo upright, Reconnect the Secondary cylinder
1. Connect the lifting strap to the inner rail on standard
hose.
and 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.
5. Replace the 4-hose sheave and bracket assembly

onto the upright. Torque nuts to 20-25 Nm (14.8-
18.5 ft-lb).
6. Reconnect the load lowering flow valve to the
upright bracket. Torque nuts to 20-25 Nm (14.8-18.5
ft-lb).
2. Reposition the rail cylinders and slowly and carefully

lower the rails to seat the rod end into the mounting.
czpT\W\`We
Group 34, Uprights
Overshimming
7. Jack up the truck only enough to remove the block- Use these steps to check for overshimming:
ing and slowly lower the truck so that its full weight
is on the floor. 1. With the forks removed, lift the upright to maximum
fork height.
8. Replace the carriage and forks.
2. Slowly lower the upright.
9. Test the upright lift and tilt functions; make sure all
• The carriage should not bind or hang up at any
upright components work correctly and smoothly.
point along the rails.
Check for overshimming as described in the next
subsection. Repeat the load test to make sure the • If the carriage binds or hangs up, and the rails are
upright works correctly under load. When you are not clogged with grease or debris, the carriage
sure all components are operating correctly, perform requires reshimming. See “Troubleshooting” for
the chain adjustment checks in Section 3 before other mis-staging problems.
returning the truck to service.
Group 34, Uprights
Section 5
Cylinder Removal, Shimming, Overhaul, and Replacement
Cylinder Types Lift Cylinder Shimming Procedure

Standard uprights use two lift cylinders. Hi-Lo and Triple To shim the lift cylinders to correct unequal cylinder
stage uprights use three cylinders, a primary (center- stroke:
mounted) cylinder, and two secondary cylinders. All pri-
1. Fully lower upright until both lift cylinders are col-
mary cylinders used on Hi-Lo and triple-stage uprights
lapsed.
(TSUs) are piston cylinders. The lift and secondary cylin-
ders used on standard, Hi-Lo uprights and TSUs are either 2. Attach a hoisting strap to the tie bar of the inner rail
piston or ram cylinders. or intermediate rail tie bar of TSUs.
IMPORTANT
seals, and gasket sets are available.
Upright Upright
Type Number Cylinder Type
<GEX20-32>
V2316
STD V2324 Piston-Type Lift Cylinder
V2330
M2316
TSU M2324 Piston-Type Secondary Cylinder
M2330
H2317
Hi-Lo Ram-Type Secondary Cylinder
H2320
! CAUTION
! CAUTION Make sure hoisting equipment is of adequate
capacity and in good working order.
To remove, or partially remove, the cylinders
from the upright for shimming or overhaul,
start with the truck in a safe position:
• Ignition off
• Parking brake applied
• Directional lever in neutral
• Forks lowered completely
• Wheels blocked.
SM 765 Cylinder Removal, Shimming, Overhaul, and Replacement • 34-5-1

Group 34, Uprights
3. Remove the cylinder rod retaining bolt. 2. Disconnect and cap the hydraulic line at the base of
In Hi-Lo Upright, Remove the Cylinder Hose. the cylinder.
Load Lowering
Flow Valve
3. Remove and discard cotter pins from chain anchor
bolt pins on the cylinder.
4. Slowly lift the inner (or intermediate) rails off the top 4. Remove the pins, draw the chain through the sheave,
of the cylinder to expose the cylinder rod top. and drape the chain over the carriage.
! CAUTION
Block rail in up position.
5. Insert shim(s) over rod end of cylinder with the

shorter stroke to compensate for unequal stroke
length.
6. Slowly lower the inner or intermediate rail back onto
the rod ends.
! WARNING
Do not try to maneuver the cylinder or rails
with your hands. Use a prybar.
5. Remove the snap ring holding the chain sheave (and
7. Replace cylinder rod retaining bolt to secure rod end hose bracket, if equipped) on the rod end and move
into inner or intermediate rail mounting hole. Torque assembly off top of rod.
the cylinder rod retaining bolts to 20-25 Nm (14.8-
18.5 ft-lb).
Snap Ring
8. Repeat the racking test and adjustment until no rack-
ing is evident during upright lift extension.
9. Check all upright functions before returning the truck
to service.
Primary Cylinder Removal and

Replacement (Hi-Lo & TSU)
Remove the primary cylinder for replacement only. Cylin-
der can be overhauled without removing it from the
upright. See “Cylinder Overhaul” for procedures.
1. Make sure the cylinder is completely collapsed and
pressure is released.
34-5-2 • Cylinder Removal, Shimming, Overhaul, and Replacement SM 765

Group 34, Uprights
6. Disconnect cylinder mounting bolts and cylinder 4. Disconnect and cap the hydraulic line from the base
base mounting bolts. of 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-
45 Nm (30-33 ft-lb).
Lift and Secondary Cylinder Removal

and Replacement 5. Lower the carriage
Only piston-type lift and secondary cylinders must be 6. Using a hoist and lifting strap of adequate capacities,
removed from the upright for overhaul. The cylinder connect the lifting strap to the inner rail on standard
gland and rod can be removed for overhaul while leaving & Hi-Lo uprights and inner and intermediate rails on
the cylinder tube mounted on the truck. triple-stage uprights.
1. Make sure the cylinders are completely collapsed

and pressure is released.
2. Tilt the upright to as near vertical as possible.
3. 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.

Group 34, Uprights
7. Disconnect the cylinder guide bolts. Cylinder Overhaul

Use these steps to overhaul the primary and lift and sec-
ondary (TSU) cylinders.
NOTE
During overhaul, set rod or cylinder on a
work bench with adequate support for safe
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.
Cylinder Disassembly
8. Disconnect the cylinder rod retaining bolts.
• To overhaul the primary cylinder, it is not neces-
In Hi-Lo upright, Remove the cylinder hoses.
sary 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 replacement.
1. Clean the rod-end and gland thoroughly to prevent
contamination from falling into the cylinder during
disassembly.
΄΅͵͠΅΄Ά͙΅ΣΚΡΝΖ͑΄ΥΒΘΖ͚ 2. With a blunt punch or chisel, bend the lock ring out
of the locking grooves of the gland.
9. Remove the cylinders by raising the inner rail (and
intermediate rail on the triple stage upright) to free 3. Use a spanner wrench to remove the gland. Reuse the
the cylinder rod ends from the tie bar. lock ring if undamaged.
10. Remove any shims and note number and location. 4. Carefully lift the rod out of the cylinder and place in
a clean area.
11. Lift the cylinders off the base mount.
5. Inspect the tube and tube end for damage and cover
Use these steps in reverse to replace the cylinders. Torque the cylinder tube end to prevent contamination.
the cylinder rod retaining bolts to 20-25 Nm (14.8-18.5
ft-lb). Torque the cylinder guide bolt nuts to 30-35 Nm
(22.2-25.6 ft-lb). Check Group 40 for hydraulic fitting
tightening procedures.

Group 34, Uprights
6. Remove all rings and seals from the piston and the Parts Inspection and Service
gland.
1. Clean all parts completely in a suitable solvent. Dry
Rod Wiper
all parts with a soft clean cloth.
Rod Seal
O-Ring 2. Inspect cylinder barrel and bore for cracks, pining,
Back-Up Ring
Gland
scoring, or other irregularities that may require
O-Ring replacement of the barrel.
Tube
3. Inspect the piston and rod for nicks, scratches, scor-
Rod
ing, or other defects that may demand new parts.
4. Check all gland and piston seal grooves for nicks,
Spacer burrs, and scratches that can damage seals during
Retaining Ring reinstallation.
Check Valve 5. Inspect and clean the check valves.
Piston
6. Inspect all seals, including the check valve O-ring.
Cylinder Seal
Snap Ring NOTE
Wear Ring Pin 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-of-roundness may
cause excessive leakage during operation and
7. For piston-type cylinders: a shortened life.
a. Remove the check valve from the piston for
inspection and cleaning by removing the snap 7. Use new parts as necessary. Always use the Packing
ring from the piston bore. Kit listed in the parts manual. New kits include all
the seals, wiper rings, wear rings and O-rings neces-
sary for the particular cylinder.
Check Valve. Arrow shows direction of flow

b. Use a blunt hook to pop the check valve out.
IMPORTANT
Use extreme care that you do not make nicks
and burrs on the interior surface area of the
cap or cylinder or the piston.

Group 34, Uprights
Cylinder Reassembly the piston. Install the cylinder seal from the top of
the rod.
Take care when installing these parts to make sure that no
parts are damaged.
1. Coat all packing, seals and rings in clean, hydraulic
oil (Clark part number 1800236 qt., 1802155 gal.)
prior to reassembly. Coat the inside of the gland nut
bore with hydraulic oil.
2. Replace the U-cup seal (groove toward bottom of
cylinder), rod wiper, and O-ring and back-up seals on
the gland.
4. For protection against corrosion, lubricate spacers
(where used) with petroleum-based hydraulic fluid.
Slide the spacer onto the rod.
5. Insert the piston and rod into the cylinder. Be careful
not to scratch or damage the cylinder gland nut
threads.
6. For primary cylinders, add 3.4 oz (100 ml) of
hydraulic oil into the cylinder on the rod side of the
piston.
NOTE
7. Install the lock ring onto the gland. Lubricate cylin-
O-rings should be carefully installed to elimi-
der threads and screw gland onto cylinder. Be careful
nate cuts or twisting.
not to damage gland seal. Make sure the gland is
fully seated on the cylinder barrel. Deform the lock
3. Replace the piston seals:
ring into slots in the tube and the gland.
a. Primary cylinder pistons require a piston seal and
wear ring. Install the piston seal from the top of 8. Check the assembly by making sure the piston slides
the rod. Use a ring compressor to compress the freely in and out of the cylinder.
piston seal. This prevents damage to the seal dur-
9. Tighten the gland nut:
ing reassembly.
• On primary cylinders, tighten the gland nut to 135
Nm (100 ft-lb).
• On lift and secondary cylinders, tighten the gland
nut to 100 Nm (75 ft-lb).
b. Piston-type lift and secondary cylinder require a

cylinder seal, a back-up ring, and a wear ring on

Group 34, Uprights
This competes the cylinder repair procedure. Replace the for correct carriage and rail position. When all adjust-
cylinders as described in “Cylinder Removal and Replace- ments are completed, return the truck to service.
ment.” Complete the chain length adjustment in Section 3
Typical Piston-Type Standard Hi-lo and Triple-Stage Upright Hi-lo Upright Lift and TSU
Upright Lift and TSU Primary Cylinder Secondary Cylinder
Secondary Cylinder

Group 34, Uprights
Section 6
Upright Chain Inspection, Adjustment, and Replacement
<SI-50590>
Chain Configuration-Standard Uprights
34-6-1 • Upright Chain Inspection, Adjustment, and Replacement SM 765

Group 34, Uprights
<SI-50591>
Chain Configuration-Triple Stage Uprights
SM 765 Upright Chain Inspection, Adjustment, and Replacement • 34-6-2

Group 34, Uprights
<SI-50592>
Chain Configuration-Hi-lo Uprights

Group 34, Uprights
Periodic Inspections resulting in pin rotation. When chain is allowed to operate

in this condition, a pin, or series of pins, can begin to twist
Each 50-250 hours of operation (more frequently in out of a chain resulting in failure. The pin head rivets
severe or extreme environments), chains should be should be examined to determine if the "VEE" flats are
inspected and lubricated. Inspection should focus on the still in correct alignment. Chain with rotated/displaced
following: heads or abnormal pin protrusion should be replaced
immediately. Do not attempt to repair the chain by weld-
Elongation ing or driving the pin(s) back into the chain. Once the
press fit integrity between outside plates and pins has been
When a length of 12.00 inches (305 mm) of new chain has altered, it cannot be restored. Any wear pattern on the pin
elongated to a length of 12.360 inches (315 mm), it should heads or the sides of the link plates indicates misalign-
be discarded and replaced. It is important to measure the ment in the system. This condition damages the chain and
chain in the section that moves over the sheaves because it increases frictional loading, and should be corrected.
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 by
chain so the condition does not repeat itself.
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 chain's 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 the
edge of the link plate approximately 90o from the line of
Turning or Protruding Pins pull.
Highly loaded chain operating with inadequate lubrication Fatigue cracks almost always start at the link plate
can generate abnormal frictional forces between pin and pin hole (point of highest stress) and are perpendic-
link plates. In extreme instances, the torque could surpass ular to the chain pitch line. They are often micro-
the press fit force between the pins and the outside plates, scopic in their early stage. Unlike a pure tensile

Group 34, Uprights
failure, there is no noticeable yielding (stretch) of Ultimate Strength Failure

the material.
This type of failure is caused by overloads far in excess of
• Stress - Corrosion Cracking - The outside link the design load.
plates, which are heavily press fitted to the pins,
are particularly susceptible to stress corrosion
cracking. Like fatigue cracks, these initiate at the
point of highest stress (pin hole) but tend to extend
in an arc-like path between the holes in the pin
plate.
Broken plate caused by overload.
Tight Joints
All joints in leaf chain should flex freely. Tight joints
Arc-like cracks in plates are a sign of stress corrosion. resist flexure and increase internal friction, thus increas-
More than one crack can often appear on a link ing chain tension required to lift a given load. Increased
plate. In addition to rusting, this condition can be tension accelerates wear and fatigue problems.
caused by exposure to an acidic or caustic medium
or atmosphere.
Stress corrosion is an environmentally assisted
failure. Two conditions must be present: a corro-
sive agent and static stress. In the chain, static
stress is present at the pin hole due to the press fit If lubrication does not loosen a tight joint, the chain may
pin. No cyclic motion is required, and the plates have corrosion and rust problems or bent pins and must
can crack during idle periods. The reactions of be replaced.
many chemical agents (such as battery acid fumes)
See Section 3 for detailed chain stretch, length, and ten-
with hardened steel can liberate hydrogen which
sions checks.
attacks and weakens the steel grain structure.
For this same reason, never attempt to electroplate
a leaf chain or its components. The plating process Chain Length Adjustments
liberates hydrogen, and hydrogen embrittlement
cracks will appear. These are similar in appearance ! WARNING
to stress corrosion cracks. An upright or carriage can move unexpect-
If a plated chain is required, consult Clark. Plated edly:
chains are assembled from modified, individually • Do not walk or stand under raised forks
plated components which may reduce the chain • Keep clear of load and carriage when mak-
rating. ing any check or adjustment
• Corrosion Fatigue - Corrosion fatigue cracks are • Keep your arms and fingers away from
very similar (in many cases identical) to normal moving parts of the upright.
fatigue cracks in appearance. They generally begin • Block the carriage or upright when work-
at the pin hole and move perpendicular (90q) to the ing with the components in a raised posi-
chain pitch line. tion.
Corrosion fatigue is not the same as stress corro-
sion. Corrosion fatigue is the combined action of
upright.
an aggressive environment and a cyclic stress (not
a static stress alone, as in stress corrosion). • Never attempt to move or align the rails by
hand. Use a prybar.
serious injury.

Group 34, Uprights
Standard Upright Chain Length Adjustment 3. Carriage stop-to-upright:

a. Lift upright to its full height and check for clear-
To adjust chain length on the standard upright use the fol- ance on the carriage safety stop.
lowing illustration and procedures: b. If the carriage stop hits the upright stop, adjust
the chain anchor adjustment nuts out until there is
at least 3 mm (0.12 in) clearance between the
stops.
IMPORTANT
The carriage stop must not be allowed to con-
tact the upright stop under any circumstance
Adjust chain
during normal operations.
length here
To carriage If all three chain length requirements listed above cannot

be met, the tire diameter may be out of the design range
1. Fork-to-ground clearance: allowance. Also, excessive tire wear will decrease car-
a. Set the upright to vertical position. riage stop clearance.
b. 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
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.
Triple-Stage and Hi-Lo Upright Chain Length

Adjustments
c. Turn the chain adjustment nuts until clearance Triple-stage uprights use two chain sets; one set for car-
between forks and ground is 10-20 mm (0.40- riage lift and one set for rail lift. Adjustment anchors for
0.80 in). the lift cylinder stage are located at the back of the outer
IMPORTANT rail. Adjustment anchors for the primary lift stage are
behind the primary cylinder. Carriage chain anchors are
For all chain anchor adjustments:
not intended for adjustment.
• Threaded chain anchors must be left free
to pivot in mounting hole. Hi-Lo Uprights use one chain set for carriage lift.
• 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 rail and the outer rail is greater than 10 mm (0.40 in).
100-200 Nm (74-148 ft-lb).
• Make sure chain anchors are secured so For the TSUand Hi-Lo primary cylinders lift chain, the
that no twist is evident in the chains. chain length must be adjusted if:
2. Carriage roller position: • The fork-to-ground clearance is less than 5 mm
a. Raise carriage about 1 m (3.2 ft) and smear a (0.20 in) or more than 25 mm (1.0 in) when the
bead of grease on the bottom 75 mm (3 in) inner upright is vertical.
rail in the area of the roller pattern. • The center of the bottom carriage roller comes
b. Tilt upright fully back and completely lower. within 20 mm (.80 in) of the bottom edge of the
c. Raise carriage about 1 m (3.2 ft) and measure the inner rail.
distance from where the center of the bottom car-
• The carriage safety stop hits the inner rail stop at
riage roller stopped to the bottom edge of the
full lift height.
inner rail. Distance should not be less than 20 mm
(0.80 in) or chain length adjustment is required.

Group 34, Uprights
To adjust the cylinder lift chains on a TSU use the follow- IMPORTANT
ing illustration and procedures: For all chain anchor adjustments:
• Threaded chain anchors must be left free
to pivot in mounting hole.
• Anchor cotter pin heads must be to the
inside of the upright.
• Torque jam nuts to adjustment nuts to
100-200 Nm (74-148 ft-lb).
• Make sure chain anchors are secured so
that no twist is evident in the chains.
Adjust chain
length here 2. Carriage roller position:
a. Raise carriage about 1 m (3.2 ft) and smear a
To inner rail
bead of grease on the bottom 75 mm (3 in) of the
1. Set the upright in the vertical position. inner rail in the area of the roller pattern.
b. Tilt upright fully back and completely lower.
2. Break the jam nuts loose on the chain anchors. c. Raise carriage again about 1 m (3.2 ft) and mea-
3. Adjust the chain anchor adjustment nuts until the sure the distance from where the center of the
bottom of the inner rail is within 2.5 mm (0.10 in) of bottom carriage roller stopped to the bottom edge
the bottom of the outer rail. of the inner rail. Distance should not be less than
To adjust the primary cylinder lift chain on TSU and Hi- 20 mm (0.80 in) or chain length adjustment is
Lo use the following illustration and procedures: required.
3. Carriage stop-to-upright:
a. Lift upright to its full height and check for clear-
ance on the carriage safety stop.
b. If the carriage stop hits the upright stop, adjust
the chain anchor adjustment nuts out until there is
at least 3 mm (0.12 in) clearance between the
stops.
IMPORTANT
The carriage stop must not be allowed to con-
tact the upright stop under any circumstance
during normal operations.
To carriage
If all three chain length requirements listed above cannot
be met, the tire diameter may be out of the design range
Adjust chain allowance. Also, excessive tire wear will decrease car-
length here riage stop clearance.
1. Fork-to-ground clearance: Oversized tires will reduce the bottom carriage roller
a. Set the upright to vertical position. engagement on the inner rail when the carriage is in the
b. Break the jam nuts loose on the chain anchors. lowered position. The fork-to-ground clearance can devi-
c. Turn the chain adjustment nuts until clearance ate from the 10-20 mm (0.40-0.80 in) allowance by a
between forks and ground is 10-20 mm (0.40- small amount if necessary to maintain the safe 20 mm
0.80 in). (0.80 in) clearance of the bottom carriage roller to the
lower edge of the inner rail.

Group 34, Uprights
Chain Lubrication Failure to follow these warnings can result in

serious injury. See “Lifting, Jacking, and
Like all bearing surfaces, the precision-manufactured, Blocking” for safe blocking procedures.
hardened-steel, joint-wearing surfaces of leaf chain
require a film of oil between all mating parts to prevent
accelerated wear. General Guidelines
Maintaining a lubricant film on all chain surfaces will: • Chain Movement - Make sure that the chain oper-
ating path is clear and that the chain articulates
• Minimize joint wear. freely through its full range of operation.
• Improve corrosion resistance. • Lubrication - Assure that the chain is well lubri-
• Reduce the possibility of pin turning. cated with the heaviest oil that will penetrate the
• Minimize tight joints. void between the link plate apertures and the pins.
• Promote smooth, quiet chain action. • Paint - Make sure the chain does not get painted
over at any time.
• Lower chain tension by reducing internal friction
in the chain system. • Protection - Where necessary, as a protection from
atmosphere or sliding wear, the chain may be cov-
Laboratory wear tests show #40 oil to have greater ability ered with a layer of grease. It should be noted,
to prevent wear than #10 oil. Generally, the heaviest however, that the grease will have to be removed at
(highest viscosity) oil that will penetrate the joint is best. a later date for chain inspection and relubrication.
Whatever method is used, the oil must penetrate the chain • Chain Mountings - Double check to be sure all
joint to prevent wear. Applying oil to external surfaces chain fastening devices are secured and all adjust-
will prevent rust, but oil must flow into the live bearing ments have been made to assure uniform loading
surfaces for maximum wear life. of multiple chain applications. Check chain
To prepare the chain for oiling, the leaf chain plates anchors and pins for wear, breakage, and misalign-
should be brushed with a stiff brush or wire brush to clear ment. Damaged anchors and pins should be
the space between the plates so that oil may penetrate the replaced.
live bearing area. • Sheaves - Sheaves with badly worn flanges and
outside diameter should be replaced. This wear
Oil may be applied with a narrow paint brush or directly may be due to chain misalignment or frozen bear-
poured on. Chain should be well flooded to be sure the oil ings.
penetrates the joint.
In locations difficult to reach, it may be necessary to use a Lift Chains (Standard and TSUs)
good quality oil under pressure such as an aerosol can or
pump pressure spray. To remove and replace the lift cylinder and/or carriage
chain set on standard and triple-stage uprights (TSU):
Chain Removal and Replacement 1. Attach a hoist strap on the carriage of the standard
upright or inner rail of the TSU.
! WARNING 2. Lift the carriage or inner rail slightly to create slack
The procedures for removing and replacing in the chains. Block the carriage or inner rail up for
chain sets involve hoisting and blocking com- safety.
ponents. 3. Remove the chain anchor pins on the outer rail and
• Do not walk or stand under raised forks. pull the chains off of the sheaves on the inner or
intermediate rails.
upright.

Group 34, Uprights
4. Remove the chain anchor pins from the carriage on 2. Remove the chain anchor pins from the back of the
the standard upright or the inner rail on the TSU. On primary cylinder. Pull the chains through the chain
the TSU, the inner rails must be lowered to the floor sheave and lay over the carriage load backrest.
to access the chain anchor pins.
3. Remove the chain anchor pins from the back of the

Lift Chain Removal from Carriage (standard upright) carriage.
Triple-Stage Upright Lift Chain Removal from Inner Rail 4. Use these steps in reverse to replace the primary cyl-
inder/carriage chain.
NOTE
If a hose adapter assembly is used, the chain Perform the chain length adjustment and chain tension
sheaves must be loosened and removed to check before returning the truck to service.
prevent the hoses from stretching when the
inner rails of the TSU are lowered to access Other Chain Service Notes
the chain anchor pins.
• Use lengths of factory assembled chain. Do not
5. Use the steps in reverse order to replace the lift chain build lengths from individual components.
set. • Do not attempt to rework damaged chains by
replacing only the components obviously faulty.
Primary Cylinder/Carriage Chains (TSU and The entire chain may be compromised and should
be discarded.
Hi-Lo)
• Never electroplate assembled leaf chain or its com-
1. Tilt the upright forward, lower it, and completely ponents. Plating will result in failure from hydro-
collapse the primary cylinder to create slack in the gen embrittlement. Plated chains are assembled
chains. The carriage may also be lifted and blocked from modified, individually plated components.
in position and the primary cylinder completely col- • Welding should not be performed on any chain or
lapsed to create slack in the chains. component. Welding spatter should never be
allowed to come in contact with chain or compo-
nents.
• Leaf chains are manufactured exclusively from
heat treated steels and therefore must not be
annealed. If heating a chain with a cutting torch is
absolutely necessary for removal, the chain should
not be reused.

Group 34, Uprights
Section 7
Fork and Carriage Removal and Replacement
3. Lift tip of each fork and put a 100 x 100 mm (4 x 4

! CAUTION 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 weight 44-99 kg (97-220 lbs) each.
or breaks. Take care when lifting.
wheels.
Fork Removal
NOTE
Blocking the Fork
Forks do not need to be removed to remove
the carriage. 4. Push down on tips of the forks to disengage the fork
hooks from the carriage fork bar.
1. Release the fork latches.
5. 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 6. Back the truck away from the forks.

2. Move each fork to the notch on the bottom of the
lower 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 765 Fork and Carriage Removal and Replacement • 34-7-1

Group 34, Uprights
4. Lift tips of forks to engage the fork hooks on the

upper carriage fork bar. ! WARNING
5. Remove blocks from under fork. You may need to pull on the hoses/cables and
chains while lowering the primary cylinder
6. Check fork latches when repositioning forks to upper to get it all the way down. This is done to cre-
carriage fork notches. ate slack in hoses/cables and chains and to
displace as much oil as possible, which will
reduce oil loss when disconnecting hydraulic
Carriage Removal lines for auxiliary components.
The carriage should be removed for shimming or when
any service procedure is performed on the upright. 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
! WARNING primary cylinder (on Hi-Lo & TSUs). When
The procedures for checking, maintaining, pulling on the chains to lower the primary
and adjusting uprights, carriages, and forks cylinder (on Hi-Lo & TSUs), the ignition
involve movement of the components. must be off.
• Do not walk or stand under raised forks. 4. Once the carriage is fully lowered, clamp the front of
• Keep clear of load and carriage when mak- one fork to the pallet to prevent the carriage from
ing any check or adjustment. falling over backwards when removed.
upright.
• Always use a prybar to move the upright or
carriage.
serious injury.
1. Set upright tilt to 0 degrees (vertical). Raise the car-
riage about 12 in (305 mm).
2. Place a heavy pallet under the forks. Turn the key
off.
3. Lower the carriage onto the pallet and keep lowering 5. For carriage auxiliary components, the hose sheave
(until the primary cylinder is all the way down on bracket must be unbolted from the primary cylinder
TSUs and Hi-Lo). Before proceeding with the next chain sheave bracket. Move the hose bracket off the
step read the following warning. chain bracket.
34-7-2 • Fork and Carriage Removal and Replacement SM 765

Group 34, Uprights
6. Disconnect the carriage chains at the base of the car- 10. Remove steer wheel blocks. Release the parking
riage. Pull chains back off primary cylinder sheave. brake and slowly back the truck away from the car-
riage.
11. Lower the upright rails until both of the secondary
cylinders are completely collapsed.
Carriage Replacement
To replace the carriage:
1. First check to be sure the carriage is securely
clamped to the pallet.
7. For carriage auxiliary components, disconnect hoses 2. Move the truck up to the carriage assembly with the
(2- or 4-hose assemblies) from carriage. Remove the inner rail centered on the carriage.
bolts and strap fixture also.
3. Raise the upright until the inner rail is high enough to
clear the upper carriage rollers.
4. Tilt the upright until it is at the same angle as the car-
riage assembly.
5. Now slowly move the truck forward until the inner
rail is centered over the carriage rollers.
• Cap all lines to prevent leaks.

• Label all lines and fittings for correct reassembly.
8. Elevate the primary cylinder to its maximum height.
Be sure all hoses and loose parts are secured out of
the way to prevent damage.
9. Continue elevating the upright until the inner rail
clears the carriage.
SM 765 Fork and Carriage Removal and Replacement • 34-7-3

Group 34, Uprights
10. Reconnect the hoses and mounting strap to the car-

! WARNING riage auxiliary component if the carriage is so
Never attempt to move or align the carriage equipped.
or bearings by hand. Use a pry bar.
6. 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.
7. When the inner rail has cleared the carriage rollers,

continue to lower the upright until the lift cylinders
are lowered completely.
• Lubricate all O-rings with a light coating of system
8. Reset the truck in a safe position: hydraulic fluid or a compatible oil.
• Ignition off • Use two wrenches to tighten hose fittings to pre-
• Parking brake applied vent hoses from twisting.
• Directional lever in neutral • See Group 40 for hydraulic fitting tightening pro-
• Forks completely lowered cedures.
• Block steer wheels. 11. Adjust carriage height according to Section 6 and
chain tension according to Section 3.
9. Reinstall the carriage lift chains to the base of the
carriage. 12. Remove the “C” clamp from the pallet and check the
operation of the carriage and the upright. Carefully
check for oil leaks. Make sure the carriage and
upright work smoothly and correctly before returning
the truck to service.
• Set anchor bolts so that no twist develops in the

chains.
• Anchor pin heads must be pointing to the inside of
the upright.
• Use new cotter pins.
IMPORTANT
Always use new anchor pins when replacing
chain sets.
34-7-4 • Fork and Carriage Removal and Replacement SM 765

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
side-shifter for example, the two hydraulic hoses power- 1. Park truck on a hard, level, and solid sur-
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.
wheels.
Nipple-grease
Outer rail set
Bushing
Bolt of upright mounting
Mounting cap
Typical Upright Installation
SM 765 Upright Removal and Replacement • 34-8-1

Group 34, Uprights
Upright Removal 2. 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.
1. Attach a hoist and strap of adequate capacity to the

upright as shown below. Tension the hoist so that the
upright cannot fall when upright mounting pins and
tilt cylinder pins are removed.
NOTE
For two-hose adapter assemblies, the
hydraulic lines to the upright must also be
disconnected and capped.
Disconnect
lines here
34-8-2 • Upright Removal and Replacement SM 765

Group 34, Uprights
3. Remove tilt cylinder rod-end lock plates and rod-end Upright Replacement
pins from upright.
1. 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
Tilt cylinder
mounting Bolt
4. Remove trunnion ring bolts and lift upright off

frame. See illustration on page 1. ! WARNING
5. Slowly set upright down on the floor, 100 x 100 mm Use prybars to move the assembly into posi-
(4 x 4 in) blocking, or sturdy pallets set end-to-end. tion for reattachment.
SM 765 Upright Removal and Replacement • 34-8-3

Group 34, Uprights
2. Install rod end pins, lock plates, and fasteners. NOTE

Tighten lock plate fasteners to a torque of 40-45 Nm Reconnect two-hose adapter assembly
(30-33 ft-lb). hydraulic lines to the upright-mounted
bracket.
Tilt cylinder
Rod end Tilt cylinder
Mounting
Tilt cylinder
mounting Bolt Reconnect
lines here
4. Remove the lift chain between the upright and hoist.

5. Completely check all upright and hydraulic compo-
nents under load before returning the truck to service.
3. Attach hydraulic lines to the upright flow control
valve: 6. See Section 7, “Fork and Carriage Removal and
Replacement,” for steps to replace the carriage and
Connect the fork assembly.
mounting bolts
to the manifold
Reconnect
line here
• 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 765

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 765 Group 38, Counterweight and chassis

Group 38, Counterweight and Chassis
Section 1
Counterweight Specifications and Description
Specifications ......................................................... 2
Description ............................................................. 2
General Maintenance ........................................... . 2
SM 765 Counterweight Specifications and Description • 38-1-1

Specifications General Maintenance
Fastener Torques ! WARNING

The counterweight is extremely heavy. Do
Counterweight Mounting Bolts : 340-380 N.m (25l-280
not remove the counterweight unless you
lb-ft)
have training and are familiar with the cor-
rect procedures. Counterweights can fall if
Description not handled correctly and can cause severe
injury or death. Keep your hands, feet, and
The counterweight is a solid, cast-iron piece mounted to body clear of the counterweight at all times.
the back of the lift truck. It is used to counterbalance the Hoisting equipment must be capable of han-
loads placed on the upright at the front of the truck. The dling the weight of the counterweight when
weight must be great enough to counteract forward tip- removing or replacing. Make sure your lift-
ping when lifting or stopping with a capacity load. The ing equipment is of adequate capacity to han-
battery provides much of the counterweight on an electric dle the weight.
truck.
The counterweight must be maintained in good condition
! WARNING and securely attached to the lift truck. Because of its
The minimum battery weight for your truck heavy weight and bulky mass, the counterweight must be
is stamped on the nameplate. Never operate carefully supported and handled. When removed from the
the truck with a battery that weighs less. truck, store at floor level as shown below to be sure it will
not fall or tip, causing damage or injury.
Large, hardened steel bolts hold the counterweight to the
frame.
Different counterweights are used based on truck capacity
and battery compartment length.
Counterweight weights(GEX):
Short wheel base Long wheel base
28.2 BC 33.9 BC
560 kg (1235 lbs) GEX20 -
760 kg (1675 lbs) GEX25 -
720 kg (1587 lbs) - GEX30
Generic Illustration
985 kg (2171 lbs) GEX30s -
985 kg (2171 lbs) - GEX32
38-1-2 • Counterweight Specifications and Description SM 765

Section 2
Counterweight Removal and Installation
Conterweight Removal .......................................... 2
Counterweight Installation ................................... 3
SM 765 Counterweight Removal and Installation • 38-2-1

Counterweight Removal 4. Raise the hood of operator's seat, and remove the bat-
tery
! CAUTION 5. Install the eyebolt in the counterweight. The eyebolt
should bear 1193kg(2630lb).
6. Using an overhead hoist with sufficient lifting capac-
1. Park truck on a hard, level and solid sur- ity, attach hoist chain to eye bolt. Slowly lift hoist
face, such as a concrete floor with no until slack is removed from chain.
gaps or breaks.
7. Remove the counterweight mounting bolts.
2. Put upright in vertical position and fully Counterweight mounting fastner
wheels.
! WARNING
Observe proper, safe lifting practices when
lifting counterweight on or off truck.
Counterweight should only be lifted by

appropriately-sized eye bolt installed
through the top lifting hole.
Counterweight mounting fastner
Use only overhead lifting equipment having a
safe lifting capacity in excess of that of the
counterweight. ! WARNING
1. Remove the Electronic Controls cover. Stand clear of the counterweight as it is being
hoisted, moved, or mounted.
2. Remove the controller from the counterweight.
3. Remove the battery connector from the counter- 8. Slowly lift the counterweight from the truck frame
weight. until it is free from the counterweight hooks on the
frame and can be moved back to clear the eleclronic
controls. Take care not to damage the controls.
9. Slowly lower the counterweight onto a sturdy pallet.
Set the counterwcighl on its flat side if possible.
38-2-2 • Counterweight Removal and Installation SM 765

Counterweight Installation 2. Inspect the counterweight mounting bolts to make

sure they are in good condition before installing. Use
only Clark replacement parts. Torque the mounting
! WARNING
bolts to 450-500 Nm (332-369 lb-ft).
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.
1. Place the counterweight fit to the mounting
hole of frame by use of the hoist and
eyebolt.
3. Remove the hoist and eye bolls.

IMPORTANT
Never allow a truck to be put into service
without the counterweight mounting bolts in
place. Check the bolts and torque regularly.
SM 765 Counterweight Removal and Installation • 38-2-3

Section 3
Overhead Guard Removal and Installation
Overhead Guard Removal .................................... 2
Overhead Guard Installation ............................... 2
SM 765 Overhead Guard Removal and Installation • 38-3-1

! Overhead Guard Installation

CAUTION
SAFE PARKING. Before working on truck: 1. Put overhead guard in place on the truck chassis.
1. Park truck on a hard, level and solid sur- 2. Install the eight overhead guard mounting bolts.
face, such as a concrete floor with no Tighten to 88-95 Nm (65-70 lb-ft).
gaps or breaks.
wheels.
Overhead Guard Removal

1. Remove the battery.
2. It is not anticipated that it should be necessary to
remove the overhead guard from the truck in thc-
coursc of normal service or repair. The instrument
panel/cowl assemblies are supported by the overhead
guard.
! WARNING
Overhead guard must be in place to protect
operator from falling objects.
3. If the overhead guard shall be disassembled from the

fork lift truck for repair or replacement, make sure to
install the lifting hook to the overhead guard.
4. Remove the battery cover and control cover, and then
remove the floor. Disassemble all the kinds of wir-
ings from the overhead guard.
5. Remove the overhead guard mounting bolts.
6. Lift overhead guard from the truck
38-3-2 • Overhead Guard Removal and Installation SM 765

Section 4
Floor Plate, Seat and Seat Deck Removal and Installation
Floor Plate Removal and Installation .................. 2
Operator’s Seat Deck Removal ............................ 2
Operator’s Seat Deck Reinstallation ................... 3
SM 765 Floor Plate, Seat and Seat Deck Removal and Installation • 38-4-1
! Operator's Seat Deck and Hood

CAUTION
Removal and Installation
1. Park truck on a hard, level and solid sur-
face, such as a concrete floor with no Removal
gaps or breaks.
1. Push the hydraulic control lever bracket which locks
2. Put upright in vertical position and fully the deck of operator's seat. Pull the handle on the
lower the forks or attachment. right side of hydraulic control lever bracket and push
3. Put all controls in neutral. Turn key the lever bracket forward, then the deck of operator's
switch OFF and remove key. seat can be lifted.
4. Apply the park brake and block the 2. Remove the nuts holding the seat slide studs to the
wheels.
seat deck.G
Floor Plate Removal and Installation

1. Tilt the steering column fully forward.
2. Fold the floor plate on its hinge and lift out the oper-
ator’s compartment. Rubber mat lifts out with floor
plate. Floor plate is not fastened to the truck.
3. To replace the floor plate, position the front of floor
plate first, then unfold it out into position.
Torque to :
6-13 N.m
(60-120 in-lb)
IMPORTANT
Make sure the accelerator pedal has a full
stroke and does not bind.
Torque to :
23-25 N.m
(203-221 in-lb)
3. The seat deck, which is held on the seat deck by the

seat mounting fasteners, may now also be removedU
38-4-2 • Floor Plate, Seat and Seat Deck Removal and Installation SM 765
Seat Deck
Seat deck
mounting bolt
Rear hood
Gas spring
Frame
4. Remove the hoodGmounting fasteners and remove the

hood.
Reinstallation.
1. Reinstall the hood in reverse order that it was
removed.
! WARNING
Failure to follow this reinstallation proce-
dure may result in operator injury. Ensure
full latch engagement for battery retention.
SM 765 Floor Plate, Seat and Seat Deck Removal and Installation • 38-4-3
GROUP 40
GROUP 40
SPECIFICATIONS
Nameplate and Decals............................................. Section 1
General Specifications ........................................... Section 2
Hydraulic Fitting Tightening Procedure ............. Section 3
SM 765 Group 40, SPECIFICATIONS

Group 40, Specifications
Section 1
Nameplate and Decals
Nameplate and Decal Locations ........................... 2
Nameplate and Decals .......................................... . 4
SM 765 Nameplate and Decals • 40-1-1

Nameplate and Decals Locations
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.
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
2372604
WARNING
Read the
manual
Buckle up!
Apply brake
when leaving
truck
Watch Out
For Other
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
2798235
! WARNING
WARNING
Disconnect battery before handling
TRUCK CAN MOVE UNEXPECTEDLY!
BEFORE WORKING ON THIS TRUCK.

electrical components.
Raise drive wheels clear of operating surface.
Disconnect battery.
Connect positine to positive, negative
Discharge capacitor(s).
Refer to maintenance procedures.

to negative to prevent damage. 2811139
BREAKING THESE RULES MAY CAUSE
SERIOUS OR FATAL INJURY TO
YOURSELF AND OTHERS.
2770314
40-1-2 • Nameplate and Decals SM 765

Nameplate and Decals on plate). Personal injury and damage to the truck
can occur if these capacities are exceeded.
This section shows the nameplate (data and capacity
plate) and decals required to be on all operating Clark 5. 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 the
- type and serial number - and the capacities of the truck. weight of the load must be considered when operat-
Decals depict or explain the hazards the operator must ing on elevators, elevated floors, etc., to be sure it is
avoid when operating the truck. The nameplate and decals safe.
are placed in specific locations on the truck and are
intended to warn others working around the truck of its ! CAUTION
hazards as well. The nameplate and decals MUST BE IN Before attachments are added, or if the truck
PLACE on all trucks. is modified after leaving the factory, you
If any decals or the nameplate are missing from the truck, must contact your authorized Clark dealer
check with your local Clark dealer for replacements. This for authorization and a new nameplate as
is required by OSHA. capacity will be affected. This is required by
OSHA.
IMPORTANT
Do not allow a lift truck with damaged or
missing decals or data plate to be placed in
service. Replace them immediately. They
contain important information as described
on the following pages. This is required by
OSHA. The location of all decals is also
shown on the following pages.
Truck Data and Capacity Plate

The truck data and capacity plate provides essential infor-
mation about the truck. This information is important for
both operators and service personnel. Operators can see
what the truck’s capacities and load ratings are. Service
personnel must identify the truck model, type, and serial
number when ordering parts. Refer to numbers on exam-
ple data plate illustration.
1. Truck model number or registered name.
2. Truck serial number--An identification number
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.
3. Attachment description (if any installed)--The user
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-
ment.
4. Capacity rating, load center, and lifting height data
Shows the maximum load capacity of this truck with
relation to load centers and fork heights (see diagram

Warning Decal Operator Safety Decar

The Operator Safety Warning Decal describes basic safe The Operator Safety Decal depicts
WARNING
operating procedures that should be used when operating impotant points about truck operation
Read the
the truck. This decal depicts important points about truck and warns operators about truck safety manual
operation and warns operators about truck safety hazards. hazards. The Operator Safety Decal is
This decal is meant as a reminder for operators. It is meant as a reminder for operators and is
placed where operators can review the points daily as they placed where operators can review the Buckle up!
conduct a visual inspection and prepare the truck for points daily as they conduct a visual
work. inspection and prepare the truck for
work.
Apply brake
when leaving
truck
WARNING
WARNING Watch Out
For Other
People
BEFOREOPERATING
BEFORE OPERATING lift lift truck,
truck, operator
operator must:
must:
BeBetrained
trainedand andauthorized.
authorized.
Readand
Read andunderstand
understand operator's
operator's
manual.
manual.
Not operate a faulty lift truck.
Not operate a faulty lift truck. Most lift truck
Not repair lift truck unless trained and authorized. INJURIES
Not repair lift truck unless trained and authorized.
Have the overhead guard and load backrest are to other
Have the overhead
extension in place. guard and load backrest people near
extension in place. the lift truck.
DURING OPERATION, lift truck operator must:
DURING
Wear aOPERATION,
seat belt. lift truck operator must: Prevent
Wear
Keepaentireseat belt.
body inside truck cab. Overturns!
Keep
Never entire
carrybody inside truck
passengers or lift cab.
people.
Never
Keep carrytruck passengers
away from people or lift and
people.
obstructions.
Keep
Travel truck
withaway from people
lift mechanism andas
as low obstructions.
possible.
Travel
and tiltedwithback.
lift mechanism as low as possible.
and tilted back. AVOID :
TO PARK lift truck, operator must: slippery,
TO Completely
PARK lift truck, loweroperator
forks or attachments.
must:
PP sloping,
PP
or uneven
Shift into neutral.
Completely lower forks or attachments. surfaces
Turninto
Shift off neutral.
key. loads over
Set off
Turn parking
key. brake. capacity on
Clark Material Handling Co. Sit Down Rider 2798233 nameplate
Set parking brake.
Clark Material Handling Co. Sit Down Rider 2798233 unstable or
high loads
low tire
pressure
IMPORTANT poorly
Safety and warning decals are placed in con- maintained
lift truck
spicuous locations on the truck to remind fast or
sharp turns
operators of essential procedures or to pre-
vent them from making an error that could In Case of
damage the truck or cause personal injury. Tip-Over:
Safety and warning decals should be Don't
jump
replaced immediately if missing, damaged or
illegible. This is required by OSHA.
Hold on
Lift trucks can be tipped over if operated improperly. tight
Experience with lift truck accidents has shown that the
driver cannot react quickly enough to jump clear of the
Brace feet
truck and overhead guard as the truck tips. To protect
Lean
operators from severe injury or death in the event of a tip- away
over, make sure this decal is in place to remind them to
always use their seat belts.
2798235

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.
danger of injury from movement between rails, chains, It warns of the danger of truck movement when removing
sheaves, fork carriage, and other parts of the upright or inserting the battery connector by calling for turning
assembly. Operators and others should never climb on or the key switch to OFF and setting the parking brake.
reach into the upright. Personal injury will result if any
body part is put between moving parts of the upright.
! WARNING
Turn key switch off
and set parking
brake before
removing
or inserting battery
2791862
connector.
Truck may start in

Keep Away from Forks Decal
motion if you do not.
This safety decal is placed on the upright to warn of the
2743642
danger of injury from forks when they are in the raised
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 positivc to positive and negative to negative to
prevent damage.
WARNING
! WARNING
Disconnect battery before handling
electrical components.
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

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

Critical Fastener Torque Specifications ....................... 4
SM 765 General Specifications • 40-2-1

Weights and Performance Specifications

Capacities
For standard trucks.
At 500 mm At 600 mm
Models Load Center Load Center
GEX 20 2000 kg (4000 lbs) -
GEX 25 2500 kg (5000 lbs) -
GEX 30 3000 kg (6000 lbs) -
GEX 30s - 2750 kg (5500 lbs)
GEX 32 - 3000 kg (6000 lbs)
Note: Rated capacity applies when using uprights with maximum fork height up to and including 3195 mm (126 in) For
GEX 20-32.
Truck Weights and Axle Weights
Approximate weights for standard trucks with 3195 mm (126 in) Standard upright and GEX20/25/30s : 28.2”, GEX30/32
: 33.9” comportment.
Gross Vehicle Empty Vehicle Loaded Drive Empty Drive Empty Steer
Weight Weight Axle weight Axle weight Axle weight
kg(lbs) kg(lbs) kg(lbs) kg(lbs) kg(lbs)
GEX 20 6164(13589) 4350(9592) 5560(11880) 2389(5268) 1961(4243)
GEX 25 6818(15031) 4550(10033) 6400(13636) 2436(5371) 2114(4661)
GEX 30 7301(16096) 4580(10099) 7103(15084) 2469(5444) 2111(4655)
GEX 30s 7510(16556) 4789(10557) 7214(15336) 2438(5376) 2350(5181)
GEX 32 8171(18014) 5223(11514) 7712(16550) 2758(6081) 2465(5433)
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.
Travel Speeds
Maximum speeds with standard upright for Standard Models.
No Load
- GEX20~32 (80V) : 18.0kph (11.2mph)
With load
- GEX20~32 (80V) : 18.0kph (11.2mph)
Turning Radius
Battery Compartment (716mm/28.2in)
- GEX20/25/30s : 1925mm/75.8in
Battery Compartment (860mm/33.9in)
- GEX30/32 : 2087mm/82.2in
40-2-2 • General Specifications SM 765

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 5q 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.
Lift and Lowering Speeds, Upright

Lift Loaded Lower Loaded Lift Empty Lower Empry
m/s(fpm) m/s(fpm) m/s(fpm) m/s(fpm)
GEX 20, 80V
- Standard 0.48(94) 0.47(92) 0.54(106) 0.43(85)
- Triple-Stage 0.47(92) 0.47(92) 0.52(102) 0.43(85)
GEX 25, 80V
- Standard 0.41(81) 0.47(92) 0.54(106) 0.43(85)
- Triple-Stage 0.45(89) 0.47(92) 0.52(102) 0.43(85)
GEX 30s/30/32, 80V
- Standard 0.38(75) 0.47(92) 0.50(98) 0.43(85)
- Triple-Stage 0.39(77) 0.47(92) 0.48(94) 0.43(85)
Critical Fastener Torque Specifications

For standard transaxle trucks.
Tightening Torque. Dry
N½m lbf½ft
Drive Axle-to-Frame Mounting Bolts: 450-500 332-369
Drive Wheel Lug Nuts 180-210 133-155
Steer Axle Mounting Bolts 170-190 125-140
Steer Wheel Lug Nuts 225-250 165-185
Steering Handwheel Retaining Nut 40-45 30-33
Tilt Cylinder Yoke Clamp Bolts 170-190 125-140
Tilt Cylinder Pin Retainer Bolts
- Front 40-45 30-33
- Rear 40-45 30-33
Counterweight Mounting Bolts (Bottom) 450-500 332-369
Brake System Specifications
Service Brake
Type : Wet disc brake
Fluid : Hydraulic fluid, RANDO HD32 or NUTO H32 in accordance with CLARK specification MS-68 (CLARK
#2776239)
Pedal Freeplay : None
Parking Brake
Type : Hand brake linked to service brake shoe at each wheel.
Holding Test : Rated load on 15% grade.
SM 765 General Specifications • 40-2-3

Drive Axle System Specifications Tilt Cylinders Specifications

Fluid : Mobil # 424 oil Tilt cylinder type: double-acting with shims
Maximum Operating pressure : 21,000 kPa (3,045 psi,
Steering Column and Gear Specifications 210 bar)
Steering System Type : Hydrostatic power steeing. Tilt Ranges
Steering System Relief Pressure Setting : 10,000 kPa (Abbrcviations : Std = Standard, high-visibility upright;
(1450 psi) TSU = Triple-stage upright, HI-LO = Full Free lift
upright; MFH = maximum fork height, B = back tilt; F =
forward tilt)
Steer Axle Specifications
MAST BACK FORWARD
MFH mm(in)
Steer Cylinder Type : Double-acting, piston-type. TYPE "B"( ȋ ) "F"( ȋ )
GEX
Hydraulic Sump, Filters, and Pump STD 2015(83)~3860(152) 5 6
STD 4165(164)~4620(182) 5 6
Specifications STD 5170(203.5)~ 5 3
TSU 3860(152)~4800(189) 5 6
Hydraulic Pump Type : Integral gear type pump and
TSU 5210(199)~6100(240) 5 3
motor assembly.
TSU 6370(251)~ 3 3
Sump Type and Capacity : Removable tank mounted in QUAD ALL 3 3
truck side frame with maximum capacity of 25 L (6.6 gal-
lons)
Upright Specifications
Hydraulic Fluid Type : CLARK Hydraulic Fluid specifi-
cation MS-68. Upright Weight : approximately 341 kg (753 lb) ~
approximately 971 kg (2140 lb)
Hydraulic Fluid Filters : Return line filter and suction line
screen mounted in sump. Carriage Weight : approximately 126 kg (278 lb) ~ 150kg
(330 lb)
Return Filter Type : Disposable, 25 micron, full flow. Fork Weight : approximately 50 ~ 106 kg each (110 ~ 231
Suction Screen : 100 mesh stainless steel screen. lb)
IMPORTANT
Hydraulic Valve/Lift Circuit Specifications Before hoisting, the weights of upright, car-
riage, and forks must be combined to deter-
Rated Flow : 70 L/min (18.5 gpm) mine what lifting capacity is required of the
hoisting equipment.
Counterweight and Chassis Specifications Capacities and Lift Heights: Upright, carriage, and fork
capacity and upright lift heights are listed on the truck’s
Counterweight weights : data plate.
Short wheel base Long wheel base Lubricants:
28.2 BC 33.9 BC All Purpose Grease (CLARK specifications MS-9)
560 kg (1235 lbs) GEX20 - Innerslide Lubricant (CLARK part #886396)
760 kg (1675 lbs) GEX25 - Chain and Cable Lube (CLARK part #886399)
720 kg (1587 lbs) - GEX30
985 kg (2171 lbs) GEX30s -
985 kg (2171 lbs) - GEX32
40-2-4 • General Specifications SM 765

Section 3
Hydraulic Fitting Tightening Procedure
1. Tighten fitting finger tight until it stops turning, 2. Using finger tips only, lightly snug fitting with a
while moving the fitting lightly side to side to pre- wrench until it bottoms out on the seat or port. Do
vent cocking or thread damage. not overtightcn.
SM 765 Hydraulic Fitting Tightening Procedure • 40-3-1

G
G
CLARK MATERIAL HANDLING INTERNATIONAL

215, Ojeong-ro, Bucheon-Si, Gyeonggi-do, Korea
Tel: 82-32-680-6300 [ www.clarkmhc.co.kr ]

SM 765

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GEX 20/25/30s/30/32

Rated Capacity : 2000-3000kg

Part No. 8051045

CLARK MATERIAL HANDLING INTERNATIONAL

Contents by Group and Section

SA SAFE MAINTENANCE 6. Parking Brake Service

20 DRIVE AXLE 32 TILT CYLINDERS

38 COUNTERWEIGHT AND CHASSIS

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

Lifting, Jacking, and Blocking the Truck........ Section 2

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

SM 765 Group SA SAFE MAINTENANCE,

Safety Signs and Messages .................................... 2

Safe Maintenance Practices .................................. 2

SM 765 Safety • SA-1-1

Safety Signs and Messages Safe Maintenance Practices

SA-1-2 • Safety SM 765

SM 765 Safety • SA-1-3

General Shop Precautions

SA-1-4 • Safety SM 765

SM 765 Safety • SA-1-5

Lifting, Jacking, and Blocking

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

Chaning the Upright in Raised Position .............. 3

Raised Rear of Truck ............................................ 3

Raised Entire Truck .............................................. 4

Shipping Tie-Down Instructions .......................... 5

SM 765 Lifting, Jacking, and Blocking • SA-2-1

5. Block the truck under the frame behind the drive

Raising Drive Wheels

SA-2-2 • Lifting, Jacking, and Blocking SM 765

Chaining the Upright in Raised Position Raising Rear of Truck

1. Park truck safely.

If there is insufficient clearance under frame for your

SM 765 Lifting, Jacking, and Blocking • SA-2-3

END-TO-END TIPOVER. If the upright and

SA-2-4 • Lifting, Jacking, and Blocking SM 765

! CAUTION b. Without Upright and Carriage Installed

SM 765 Lifting, Jacking, and Blocking • SA-2-5

SM 765 Towing • SA-3-1

1. Apply the parking brake or block the drive wheels on ! CAUTION

SA-3-2 • Towing SM 765

SM 765 Towing • SA-3-3

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

Planned Maintenance Program ...................... Section 2

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

SM 765 Group PS PERIODIC SERVICE,

“Periodic Service” and “Planned Maintenance” ......................... 2

SM 765 Maintenance Schedule • PS-1-1

“Periodic Service” and “Planned Main- Determining Maintenance Intervals

Service Chart/Lubrication Points

PS-1-2 • Maintenance Schedule SM 765

GEX Service Chart/Lubrication Points

SM 765 Maintenance Schedule • PS-1-3

Recommended Periodic Service Schedule

Every Every Every

PS-1-4 • Maintenance Schedule SM 765

Every Every Every

SM 765 Maintenance Schedule • PS-1-5

Use PM Report Form ....................................................................... 2

SM 765 Planned Maintenance • PS-2-1

Use PM Report Form

How to Perform the PM Periodic