Clark Sm 568 Service Manual

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SM-568
PWDIHWD 25/30/36

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 Service
Manual

P-30
P-25 HWP-30
SM 566 HWP-25 PWD-30
PWD-25 HWD-30
HWD-25 HWD-36
PWD-36

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Intended for CLARK dealers only
Do not sell or distribute
 FOREWORD

This service publication provides information covering normal service,

maintenance and repair of the Clark industrial ltrucks noted on the cover. It has
been specifically prepared to help owners and service personnel maintain these
trucks in efficient and safe operating condition.

Regular, correct maintenance and care of industrial trucks is not only important for
long and efficient truck life; it is essential for safe operation. The importance of
proper maintenance through planned service, inspection and qualified repairs
cannot be emphasized too strongly.

To assist in keeping industrial trucks in good operating condition, this manual

includes preventive maintenance procedures to be performed at regular intervals.
These are essential to the service life and safe operation of all industrial trucks.
Instructions for safety inspections, operational checks, cleaning, and lubrication
are provided for reference in setting-up and conducting a recommended periodic
Planned Maintenance (PM) program.

Refer to the Operator’s Manual, located on the truck, for additional information on
the operation, care and maintenance of your truck.

Genuine Clark replacement parts should be used for all service and repair
requirements. Substitute parts from other sources may be different than original
parts and may not meet OSHA or other safety requirements.

Any reference to brand names other than Clark in this manual is made simply as
an example of the type of tools and materials recommended for use and, as such,
should not be considered as an endorsement. Equivalents, if available, may be
used.

For more information on maintenance and repair of these trucks, contact your
authorized Clark dealer.

NOTICE

The descriptions andspec@ations inclua’ed in thismanual were

in effect at the time of printing. Clark Equipment Company
reserves the right to discontinue models at any time, or make
improvements and changes in specifications or design without
notice and without incurring obligation. Specl@cations, torques,
pressures, measurements, adjustments, illustrations and other
items may change at any time. Contact your authorized CLARK
dealer for information on possible updates or revisions.

0 1989 Clark Equipment Company

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About This Manual

This manual is intended for use by persons who are trained and authorized to do lift
truck maintenance. It is designed to provide essential information about the correct and
safe service maintenance and repair of the truck by trained mechanics or service
technicians.

The information is organized by use of the Bask Group Numbering System

used in the Master Parts Book and the Customer Parts manuals. The manual includes:

P.M. Planned Maintenance Procedures including precautions and

safe maintenance practices.
01-40 Service specifications, adjustments, maintenance and overhaul
procedures including lubrication charts and recommended
lubricants, etc.

General and detailed service and repair procedures areoutlined (as required) for
each component or subsystem. Some procedures include explanations that are
common to several components or subsystems.

In general, each Section is written to show and describe the general arrangement,
adjustment, removal, disassembly, inspection, repair, and assembly steps that are
normally required to service thecomponent. Component specifications (as applicable),
information notes and safety messages are included within those procedures. In most
cases, specificationsarealsolisted in GROUP40,TruckSpecifications,forconvenience
of reference.

The Pictorial Index lists components or systems by Basic Group Number of Major
Parts. Additional content listings are placed at the beginning of each Section in the
manual,

This manual has been made easier to use by providing only specific steps when
necessary and general nstructions required to explain the activity, component,
assembly, or process being worked on. The technician is expected to include obvious
additional steps of standard procedure for removal, disassembly, cleaning, inspection,
reassembly, installation, etc., as needed.

To be better prepared to do the necessary service work, take time to completely read
the entire procedure, including any special instructions, before doing any work.

The technician is cautioned and expected to a hvays work in a safe manner by using
the correct procedure. Do not take chances which may result in injuries.

Dee 91 ii
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 Safety Notice

IMPORTANT SAFETY NOTICE

Read and understand all safety precautions and
warnings before performing repairs on lift trucks.

Appropriate service methods and proper repair procedures are essential to the safe, reliable operation of
industrial trucks as well as the personal safety of the individual doing the work. This Service Manual provides
general directions for accomplishing service and repair work with tested, effective techniques. Following
them will help assure successful repair and reliable truck operation.

There are numerous variations in procedures, techniques, tools, and parts for servicing industrial trucks, as
well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations
and provide advice or precautions as to each. Accordingly, anyone departing from the instructions provided
in this manual through procedures used or choice of tools, materials, and parts may jeopardize his or her
personal safety and/or the safety of the vehicle user.

Improper or careless techniques cause accidents. Don’t take chances with incorrect or damaged
equipment. Read and understand the proceduresforsafe operation and maintenance outlined in this
manual.

STAY ALERT! Follow safety rules, regulations and procedures. Accidents can be avoided by recognizing
dangerous procedures or situations before they occur.

DRIVE AND WORK SAFELY and follow the safety signs and their messages displayed on the truck
and in this manual.

General Precautions
The following list contains general precautions that should be followed when working on a lift truck:

l Always wear safety glasses for eye protection.

l Remove rings, watches, loose jewelry and open clothing before working on a vehicle, to avoid serious injury.

l Do not smoke while working on a vehicle.

. Put ignition switch in the OFF position, unless otherwise required by the procedure.

lSet the parking brake. Place wheel chocks orwood blocks of 4” x 4” size or larger to the front and rear surfaces
of the tires to provide further restraint from inadvertent vehicle movement.

9 Use safety stands or blocks whenever a procedure requires you to be under the vehicle.

l Service Electric Truck Batteries in a well-ventilated area to avoid the danger of igniting explosive gases.

l Follow the Safety Instructions outlined in GROUP 12 “Handling Storage Batteries”.

l Always Discharge the Capacitors prior to working on or around electrical components. Refer to the
instructions outlined in GROUP 19 “Discharging Capacitors:.

l Avoid contact with Battery Acid. The battery contains corrosive acid which can cause injury. Following the
instructions outlined in GROUP 12 “Handling Storage Batteries”.
...
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PICTORIAL INDEX

Wal kie Models

Rider Models

r39

\ 28

01 Lubrication Charts
12 Battery
16 Motors
17 Contactors
19 EV-T5 Control
20 Drive Unit
23 Brakes
25 Caster / Stabilizer
28 Hydraulic Unit & Liness
34 Lit Cylinder
35 Load Wheel / Lift Linkage
39 Body Partss
40 Specifications

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 Planned Maintenance Procedures

P.M. CHECK SHEET

A special coding system on the P.M. Check Sheet
allows truck conditon to be reported with a minimum
number of words. As the P.M. is performed, a check
mark should be made in the appropriate box of the
component being checked.
l (4) indicates the particular truck component or
system has been checked and is O.K.
l (x) indicates the component or systemisinneed
of a minor adjustment or service (not part of the
normal P.M.) that should be taken care of in the
near future.
l ( r ) indicates there is a potential problem that
couldresultindamage to acomponentorsystem
and requires attention.
l ( s ) indicates the need for urgent repair or
replacement of a component or system and the
truck should be shut down as eminent damage or
possible injury may result. Code
The nature of problems found during a PM should be $ = O.K.
noted in the “comments” portion of the check sheet. O.K. X = Adjust (Not P.M.)
Whenever a svstem or comnonent is faultv or unsafe, Potential r = Repair or Replace
it must be noted on the check sheet, and reported to the ~ Requires Shop Repair
L.
i...
..L.........
___ ____,,,,__
:~~.:.:.:.:.:.:.:.:.:.~I
........,.i,.................
designated authority at the conclusion of the P.M.

AWARNING
Remove all jewelry before
examining electrical com-
ponents.

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Planned Maintenance Procedures
Visual Inspection
1. Inswct Batterv Plug & Truck Rec@acle
. Disconnect battery from truck.
. Inspectthespringloadedconnectors inthetruck
battery receptacle and check the battery plug
connectors. Severely burned connectors should
be noted on the P.M. check sheet.

Battery and check the

Spring Loaded Connectors
Typical Illustration

2. InsDect Batterv Cover for darn=

-Battery Cover Check Cover for Damage
. The cover should not be dented. A badly dented \
cover could short out across the battery cell
connectors.
. The cover should be free to swing open and
closed without binding.

Typical Illustration

-
Typical Illustration
3. Inswct Pallet Forks for obvious damaye
PWD& P
. Forks should not be bent or warped. If the forks
are damaged, report condition to the designated
authority. H\ ND & HWP

PM 2
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 Planned Maintenance Procedures
Coast Control Decal
4. Rider Models /‘--(Optional Equipment)

. @SDeCt Frame ComDonen&

. Check truck console, access cover and doors for
damage.
. Inspect name plates and decals for damage and
to be sure they are not missing.

Typical Illustration

4A. Walkie Models I Access Doors

\
. Insoect Frame ComDonents
. Check truck console, access covers and doors
for damage. Control Handle

. Inspect name plates and decals for damage and

to be sure they are not missing.

Data Plates

1 Typical Illustration

A+\ Lift Cylinder 8 tines

5. Check for obvious oil leak% /O

. Make a quick overall inspection for leakage. If

anoil leakappears tobemajor,noteconditionon
the check sheet for immediate attention. Minor
leaks should be repaired during the P.M.

1 Typical Illustration

PM
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Planned Maintenance Procedures

6. Insrxct Tires & Wheel%

. Check for obvious damage to tires on the load,
caster and drive wheels.
. Look for excessive tire wear, cuts, breaks,
chunking or bond failure between the tires and
wheels. Note condition on the PM check sheet.
. Remove embedded objects from the tires. \
I \ Grease
Drive 1 \ Fittings
. Be sure wheel fasteners are secure and none are \
\
missing. \
\
. Make certain grease fittings are not damaged or \
Wheel Fastener
missing. Caster
Typical illustration Wheel

7. ExDose Internal ComDonent$

. Open the access doors exposing the drive unit,
brake, lift cylinder, hydraulic unit, and SCR
control. Each door hangs on a hinge pin. Lift the
doors from their pins and set them to one side.

Hinge/ Typical Illustration

8. Connect Truck Batterv

. Connect truck battery and check truck opera-

tion.

Tvoical Illustration

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 Planned Maintenance Procedures
Operational Tests
9. Turn the key switch on.

10. All Models

l Check the horn to be sure it operates.

Walkie Models

Typical lllustratior

11. All Models

l Check the hour meter to be sure it operates.

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Planned Maintenance Procedures’
12. Check Steer Control Handle
1Omm Allen Head Socket Scre
. Walkie Models
. Be certain the control handle is mounted se-
curely at the base of the drive unit.
. Make sure fasteners are tight and none are none
missing.

8mm Allen Head

. Rider Models Steer Control

Mounting Bracket
. Check the mounting bracket to be sure it is
securely mounted to the base of the drive unit.
. Make sure fasteners are tight and none are
missing.

-.-
Early Models Late Models
Typical Illustration

13. Check Steering

Make Full
. Operate truck in reverse at a slow rate of speed. Right & Left 0 cl
Move control handle through a full right and full Turns
left turn. Steering should be smooth without
binding or his&ion.
. If there is binding, hard spots or movement :;i’
appears to be stiff this indicates either lack of
lubrication, misadjusted or damaged steering
ring.
. Report condition on the P.M. check sheet.

PM 6
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 Planned Maintenance Procedures

14. Check Brake heration 1 _ Forward I Reverse . L

Direction 1 Direction
l Move the steer control handle downward 10
degrees from vertical (brake on) position.
l Operatetruckinreverse ataslowrateofspeed. Brake On
0 .. ‘L
l Slowly move control handle upward from the
10” travel (brake off) position.. Brake Off (0 q i

Check Braking
in
Reverse DIrection
Forward Direction
As Control Handle annroaches “Brake On” postion: at a
slow rate of speed
(1st) high rate of speed

the brake switch should operate shut-

ting off the drive motor.

(2nd)
the brake should operate bringing the
truck to a stop.
l Operate the truck in forward at a slow rate of
speed.
l Slowly move control handle upward from the
10” (brake off) position. The brake should apply
when handle reaches the full up (brake on)
position.
l Now, check the brake at a high rate of speed in Walkie Models Rider Models
both forward and reverse directions.

14A. Next, check for proper brake operation by mov- Check Braking
ing the handle downward from the lo” (brake in
Reverse Direction
off) position. The brake check should be done at Forward Direction
Low and High Speeds, and in Forward & at a
slow rate of speed
Reverse directions. high rate of speed

l If operation is not satisfactory, note condition on

Brake Off
the P.M. check sheet. Report condition to desig- (O?Y
nated authority for immediate attention.
NOTE
Plugging Controlis normally used
for gradual brake applications.
Braking with the steer control
handle is normally used in
emergency situations and parking Tvoical Illustration
the truck.

PM
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Planned Maintenance Procedures
Typical
AWARNING Brake On lllustratior
After checking the coast
control, be certain to return the
coast control lever to the (brake
on) position before resuming
normal truck travel.

15. 1 h k ‘n
. Move steer control handle past the full vertical
position to partially compress a spring loaded
rubber stop, see illustration.
. Now move the coast control lever out of the Brake Of1
“brake on” position and into the “brake off’
position.
. Release the steer control handle. The truck is
now set up for a “coast mode” of operation
allowing the operator to “jog” the truck with the
F & R speed control.
. Slowlly operate truck in a reverse direction of
travel.
. Move steer control handle into vertical (brake
on) position stopping truck.
. If brake operation is not satisfactory, note con-
dition on P.M. check sheet. Report condition to
designated authority for immediate attention.
. Return the coast control lever to the (brake on) Coast Control Lever Coast Control Lever
position.

16. Check Travel Speeds

Check Acceleration
Check High SDeed

Drive truck in a straight line, looking in the

direction of travel.
1) w Always face in the direction of travel e r)
Listen for any unusual drive train noise.
Accelerate fromlow to high speed. Acceleration
shouldbeasmoothtransitionfromcreepthrough
top speed to 1A (battery volts). If transition is
irratic, the accelerator potentiometer circuit
should be checked (Group 19). Note condition
on the P.M. check sheet. -continued next page-
Operating Truck in REVERSE Direction

PM 8
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 Planned Maintenance Procedures
17.
. Drive truck forward, in a straight line of travel.
. Fully rotate Directional Speed Control (1) until
maximum(solidstatecontro1) speedisobtaiined
. Depress Hi-SpeedButton (2) for approximately
two seconds. The 1A contactor should close
Trwel COnaol
providing direct battery volts across the drive
motor for maximum travel speed. This transi-
tion should be smooth. Ifit is not, if it is erratic,
jerky etc., the accelerator potentiometer circuit
should be checked (Group 19). Note condition
on the P.M. check sheet.
Tvniul Illustration \

18. Override Control Depress Button

he Override Control Circuit
. The override control is used to by-pass the nly functions in slow speeds to override
ReversalControlCircuit
emergency reversal (belly) switch circuit. This
is desireable when the truck is operating in areas Typical Illustration
whereplastic strip curtain doors (etc) are used.
Example: When moving a truck through this type door,
pressure from the door strips can cause the emergency
reversal (belly) switch tooperate changing the direction of
truck travel. By overriding the reversal switch, the truck
can pass through the curtain door without miss hap.

. To simulate the above, operate truck in slow

speed reverse. “Depress button to override” and
then depress the reversal (belly) switch. Truck
travel shouldremainin slow speedreverse. Note
condition on the P.M. check sheet.

19. Elevate and Lower Pallet Forks

. Elevate pallet forks to maximum lift. As the
forks elevate, check to be sure they elevate
smoothly and evenly without binding.
. Lower forks. Look for erratic motion as they
lower. They should lower smoothly without Typical Illustration
hesitation.
. If there is erratic, jerking motion or binding of
linkage as the forks elevate or lower, the lift
linkage should be checked and adjusted (Group
35). Note condition on the P.M. check sheet.

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Planned Maintenance Procedures

20. Dischawe the CaDacitors

l Be sure the battery is unplugged.
l Discharge capacitors using a 100 ohm, 2 watt
resistor connected between the Positive and
Negative power terminalson the SCR Con- I IIICover Should Be In Place
trol. Hold the restitor in place for2 seconds
before removing.

ACAUTION
Usingashorting device without
a “resistor load” could cause
damage to the control.

AWARNING
Discharging the capacitors
without using specified resistor
could cause serious injury to
yourself and bystanders.

AWARNING
Prior to discharging the
capacitors, make certain the
Cover is installed on the Control
Panel Power Base. DischargeCapacitors Typical Illustration

21. Rider Models

l Inmect Moderator Hand Rail
l Check hand rail for security of mounting. Try
moving hand rail fore & aft checking for loose
connections and damage. The mounting bolts
shouldbe torqued to 177-221 Ibin (20-25 Nom).
l Make certain the switch housing is mounted
securely and the switches are not damaged.
l Check wire harness condition. Check for loose
connections and harness damage. Report condi-
tion on P.M. check sheet.

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ELqRRMaterial
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GROUP 01

GROUP 01
LUBRICATION & Planned Maintenance
Contents
Grease Chart & Specifications (Rider Trucks) .................................... 01-l-4
Grease Chart & Specifications (Walkie Trucks) ................................. Ol- l-5
Fluids -Illustrated Instructions & Specifications ................................ 01-l-3
Optional Equipment Lubrication Illussttations & Specifications ....... ..Ol- l-6
h4iscellaneous Linkage Illusstrations & Specifications ..................... ..Ol-l- 7

Test truck ground

Clean drive motor air vents

1 Check brake shoe linings I I.1 I I I

SM568 01-1-I
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GROUP 01 Lubrication

LUBRICATION SPECIFICATIONS

The listing of lubrication specifications compiled in this manual isfor the reference of Clark Engineering
and Service personnel, Dealers and Customers. The listof products is intended as a guid in the selection of
a lubricant to meet the requirements of Clark Industrial Truck Operation.
CLARK makes no representation as to the relative merits of any commercial oil product. With the exceDtion
of MS-68 Hvdraulic Fluid, CLARK has no formal system for approving oil products, but has published herein
general specifications which it believes will provide adequate or superior component lubrication of life.

It is the PREROGATIVE of each user to choose suppliers and products as they feel necessary for proper
operation of the equipment under the conditions of the individual application. RESPONSIEHIJTY for the
quality of the product and its performance in service must remain with the oil supplier, in agreement with the
user.

Hvdraulic Fluids and &wine Oils

CLARKdoesnotfollow aformal testandapprovalprocedureforspecificbmndedproducts. RatheritisCLARK
policy to establish basic specifications for oils (and fluids) which demonstrated suitable performance for the
application. Ingeneral these specificationsfollowtherecommendationsofthemajorcomponentmanufacturer,
such as engines and hydraulic pumps. Any oil or fluid which meets the respective specification is considered
acceptable for use in CLARK products. Component operation should not be affected as long as the oil or fluid
meets the stated specification and the recommended oil and filter change intervals are followed.
ForExtendedOilor FluidDrainIntervals,periodicanalysisbyareputabletestinglaboratory shouldbemade.
It is the responsibilityof the manufactureror supplierof the oil or fluids to insure that thisproduct meets the
specificationsand gives the expectedpeq5ormance.

Technical Societies referenced on these Daaes

AGMA -- American Gear Manufacturers Association
API _- American Petroleum Institute
ASTM - American Society for Testing Materials
EMA -- Engine Manufacturers Association
_- Military Specification
MGPA -- Natural Gas Processors Association
NLGI -- National Lubricating Grease Institute
SAE -- Society of Automotive Engineers

Section 1 01-l-2 Material

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Lubrication GROUP 01
HYDRAULIC SYSTEM
l Wipe outside of reservoir clean before remov- Hydraulic Unit
ing the fill/level plug. Fluid level should be to the
plug opening Add fluid as required.. Checkfluid
level withtheforksfilly lowered andtruckon a
level surjSace.
Reservoir Capacity
MS 68Recommendation NormaZ overation use
1.5 Quarts (nominal)
Hydraulic Fluid per Clark Specification MS68.
Specification Hydraulic Fluid must be high quality
with Zinc or equivalent Anti-Wear additive which
meets the requirements of ASTMD-2882pump wear
test with 50 mg total weight loss maximum per Clark
Specifications MS-68.
Hydraulic System Fluid available under
Clark Part Numbers;

885385 One (1) Quart Can (MS-68).

@ 885382

u
One (1) Case of Six (6)
Reservoir ,, ji
one gallon cans (MS-68). ‘x. .,ji ::
-:i
::
Recommendation Cold Storage Operation Use
Hydraulic Fluid which meets ML-H-5606A per
Clark Specification MS-226.
Specification A petroleum base hydraulic fluid with

2
h=
MS 68
additives to improve viscosity index, oxidation resis-
tance and anti-wear characteristics blended to form a
stable product under storage and operational condi-
tions between -65 and +160” F., meeting MIL-H-
5606A* per Clark Specifications MS-226.
Typical lllusstration
(*)The restrictive cleanliness specifications of later
revisions is not required.
Drive Unit
l Wipe area around flluid level plug before re-
moving plug. Fluid level should be to the plug
opening. Add fluid as required.
Recommendation Use Dexron II Automatic Trans-
mission Fluid.
Transmission Fluid available under
Clark Part Numbers;

897804 One (1) Quart Can.

@
941615 One (1) Case of Six (6) one
gallon cans.

SM568 01-l-3
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Clark Sm 568 Service Manual
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GROUP 01 Lubrication
LUBRICATION CHART Cold
Storage
RIDER MODELS

Two Fittings each link.

Three fittings each bracket.

99

$9 Two Fittings.

T- General Pumose Chassis arease

Recommendation Use a Grade NLGI #2 per Clark Specification MS-107C.
Specification MS-107C A multi-purpose grease of refined mineral oil blended with lithium soap thickner or
equal containing anti-wear, anti-rust and anti-oxidants with EP additives. Per Clark Specification MS-107C

T Cold Storaae ODeration

Low Temperature Grease An extreme low temperature aircraft quality grease meeting Specification
MIL-G-23827A, or equivalent product. Temperature range -100 to +250 F.
Wipe grease fittings clean before applying a grease gun.

Section1 01-l-4 Material

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