Clark Sm 765 Service Manual

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SM-765
GEX 20-30
Service Manual

Rated Capacity: 2000 - 3000kg

October 2007

Technical
Publications
Lexington, KY 40510
www.Clarkmhc.com

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 Copyrighted Material
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Do not sell or distribute
 Truck Models Covered by this Manual
This manual consists of “base” module that pertains You may, however, purchase specific modules and
to all GEX20-30 models and other modules that per- expand your manual to fully cover multiple models.
tain only to specific models. Manuals shipped with To do so, order the desired modules as you would
the truck contain the base module and the modules any other Clark part.
specific to the purchased truck.

Arrangement and Use of this Manual

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

Copyright Clark Material Handling 2006 SM765, Nov ’06

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Do not sell or distribute
 NOTE :

, SM765, Nov ’06

Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
 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, Nov '06 CONTENTS -1

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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, Nov '06

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 CONTENTS

Alphabetical Listing of Topics

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

SM 765, Nov '06 CONTENTS -3

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NOTE :

Alphabetical Listing of Topics SM 765, Dec '04

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 REVISION HISTORY

When new or revised information is published to update this Jul. 2007

manual the action to be taken with the pages is indicated in Mark Indication Action required
the table. ❍ Page to be newly added Add
Pages not marked are not currently revised, but are
● Page to be replaced Replace
included for page numbering continuity.
( ) Page to be deleted Discard

Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision
number number number number
SA-1-1 12-1-2 13-4-6 19-2-10
SA-1-2 12-1-3 13-5-1 19-2-11
SA-1-3 12-1-4 13-5-2 19-2-12
SA-1-4 12-1-5 13-5-3 19-2-13
SA-1-5 12-1-6 13-5-4 19-2-14
SA-2-1 19-2-15
SA-2-2 13-1-1 16-1-1 19-2-16
SA-2-3 13-1-2 16-1-2 19-2-17
SA-2-4 13-1-3 16-2-1 19-2-18
SA-2-5 13-2-1 16-2-2 19-2-19
SA-3-1 13-2-2 16-2-3 19-3-1
SA-3-2 13-2-3 16-3-1 19-3-2
SA-3-3 13-3-1 16-3-2 19-3-3
13-3-2 16-3-3 19-3-4
PS-1-1 13-3-3 19-3-5
PS-1-2 13-3-4 17-1-1 19-3-6
PS-1-3 13-3-5 17-1-2 19-3-7
PS-1-4 13-3-6 19-3-8
PS-1-5 13-3-7 19-1-1 19-3-9
PS-2-1 13-3-8 ● 19-1-2 ① 19-3-10
PS-2-2 13-3-9 19-1-3 19-3-11
PS-2-3 13-3-10 19-1-4 19-3-12
PS-2-4 13-3-11 19-1-5 19-3-13
PS-2-5 13-3-12 19-1-6 19-3-14
PS-2-6 13-3-13 19-1-7 19-3-15
PS-2-7 13-3-14 19-1-8 19-3-16
PS-2-8 13-3-15 19-1-9 19-3-17
PS-2-9 13-3-16 19-1-10 ● 19-4-1 ①
PS-2-10 13-3-17 19-2-1 ● 19-4-2 ①
PS-2-11 13-3-18 19-2-2 19-4-3
PS-2-12 13-3-19 19-2-3 ● 19-4-4 ①
PS-2-13 13-3-20 19-2-4 ❍ 19-4-5
PS-2-14 13-4-1 19-2-5 ❍ 19-4-6
PS-3-1 13-4-2 19-2-6 ❍ 19-4-7
PS-3-2 13-4-3 19-2-7 ❍ 19-4-8
13-4-4 ● 19-2-8 ① ❍ 19-4-9
12-1-1 13-4-5 19-2-9

SM 765, Jul ’07 ① REVISION HISTORY - 1

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REVISION HISTORY

Revision Revision Revision Revision

Mark Page number Mark Page number Mark Page number Mark Page number
20-1-1 25-3-1 34-1-5
20-1-2 25-3-2 29-1-1 34-1-6
20-2-1 25-3-3 29-1-2 34-1-7
20-3-1 25-3-4 29-1-3 34-2-1
20-3-2 25-4-1 29-1-4 34-2-2
20-4-1 25-4-2 29-1-5 34-2-3
20-4-2 25-5-1 29-1-6 34-2-4
20-4-3 25-5-2 29-2-1 34-3-1
20-5-1 25-5-3 29-2-2 34-3-2
20-5-2 25-5-4 29-2-3 34-3-3
20-6-1 25-5-5 29-3-1 34-3-4
20-6-2 25-5-6 29-3-2 34-3-5
20-6-3 25-5-7 29-3-3 34-3-6
34-3-7
22-1-1 26-1-1 30-1-1 34-3-8
22-2-1 26-1-2 30-1-2 34-3-9
22-2-2 26-2-1 30-2-1 34-3-10
22-2-3 26-2-2 30-2-2 34-4-1
22-2-4 26-2-3 30-3-1 34-4-2
22-2-5 26-2-4 30-3-2 34-4-3
22-2-6 26-3-1 30-4-1 34-4-4
22-2-7 26-3-2 30-4-2 34-4-5
22-2-8 26-3-3 30-4-3 34-4-6
22-2-9 26-3-4 30-5-1 34-4-7
26-4-1 30-5-2 34-4-8
23-1-1 26-4-2 30-5-3 34-4-9
23-1-2 26-4-3 30-5-4 34-4-10
23-1-3 26-5-1 34-5-1
23-2-1 26-5-2 32-1-1 34-5-2
23-2-2 26-5-3 32-2-1 34-5-3
23-3-1 26-6-1 32-2-2 34-5-4
23-3-2 26-6-2 32-2-3 34-5-5
23-3-3 26-6-3 32-3-1 34-5-6
23-4-1 26-6-4 32-3-2 34-6-1
23-5-1 26-7-1 32-3-3 34-6-2
23-5-2 26-7-2 32-3-4 34-6-3
23-5-3 26-7-3 32-4-1 34-6-4
23-6-1 26-7-4 32-4-2 34-6-5
23-6-2 26-7-5 32-4-3 34-6-6
26-7-6 34-6-7
25-1-1 26-7-7 34-1-1 34-6-8
25-1-2 26-7-8 34-1-2 34-7-1
25-2-1 26-7-9 34-1-3 34-7-2
25-2-2 26-7-10 34-1-4 34-7-3

2 - REVISION HISTORY SM 765, Nov ’06

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 REVISION HISTORY

Revision Revision Revision Revision

Mark Page number Mark Page number Mark Page number Mark Page number
34-7-4
34-8-1
34-8-2
34-8-3
34-8-4

38-1-1
38-1-2
38-2-1
38-2-2
38-2-3
38-3-1
38-3-2
38-4-1
38-4-2
38-4-3

40-1-1
40-1-2
40-1-3
40-1-4
40-1-5
40-1-6
40-2-1
40-2-2
40-2-3
40-2-4
40-3-1

SM 765, Nov ’06 REVISION HISTORY - 3

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REVISION HISTORY SM 765, Nov ’06

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 GROUP SA SAFE MAINTENANCE

GROUP SA

SAFE MAINTENANCE

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

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

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

SM 765, Nov ’06 Group SA SAFE MAINTENANCE

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NOTE :

Group SA SAFE MAINTENANCE SM 765, Nov ’06

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 Group SA, Safe Maintenance

Section 1

Safety

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

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

General Shop Precautions ................................... 4

SM 765, Nov ’06 Safety • SA-1-1

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Group SA, Safe Maintenance

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, equip-
ment, tools, pressures, capacities, and other When in doubt of any maintenance procedure, please con-
special data. tact your local Clark dealer.
1. Powered industrial trucks can become hazardous if
IMPORTANT maintenance is neglected. Therefore, suitable mainte-
This message is used when special precau- nance 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 not 7. Before starting work on truck:
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, Nov ’06

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 Group SA, Safe Maintenance

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, DC
ment, consult the manufacturer’s procedures in 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.

SM 765, Nov ’06 Safety • SA-1-3

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Group SA, Safe Maintenance

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 recommend
area to avoid the danger of lighting explosive Clark #1801146 Degreaser, or the equivalent to MS-180
gases. Freon TF Degreaser and Cleaner. Only approved solvents
should be used to clean solid state control components.
• Follow the Safety Instructions outlined in Group
12, Battery Handling.
• Always discharge the capacitors prior to working
! CAUTION
on or around electrical components. CHECK POLARITY
• Avoid contact with battery acid. The battery con- Battery polarity must be correct or the truck
tains corrosive acid which can cause injury. Follow will not operate.
the instructions outlined in Group 12 and those
instructions received with your battery and charger. ! 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 from doing the work. This Service Manual provides general
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, Nov ’06

Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
 Group SA, Safe Maintenance

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. Accordingly, Drive and work safely. Follow the safety signs and
anyone departing from the instructions provided in this their messages displayed in the work area, on the
manual, through procedures used or choice of tools, mate- truck, and in this manual.
rials, and parts may jeopardize his or her personal safety
and the safety of the vehicle user.

SM 765, Nov ’06 Safety • SA-1-5

Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Clark Sm 765 Service Manual
Full download: http://manualplace.com/download/clark-sm-765-service-manual/

NOTE :

Group SA, Safe Maintenance SM 765, Nov ’06

Copyrighted Material
Intended for CLARK dealers only
This is the cut pages sample. Download all 418 page(s) at: ManualPlace.com
Do not sell or distribute