Clark P-25(HWP-25, PWD-25, HWD-25) P-30(HWP-30, PWD-30, HWD-30, HWD-36, PWD-36) Forklift* Factory Service / Repair/ Workshop Man

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM-568 PWDIHWD 25/30/36 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Service Manual P-30 P-25 HWP-30 SM 566 HWP-25 PWD-30 PWD-25 HWD-30 HWD-25 HWD-36 PWD-36 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material 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 SM568 i Dee 91 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute 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. 01-40 Planned Maintenance Procedures including precautions and safe maintenance practices. 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 SM568 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute 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. l Set 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”. SM568 . .. III Dee 91 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Material Handling CORK Company Wal kie Models Rider Models r39 PICTORIAL INDEX \ 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 SM568 Index-l act 91 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute 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. The nature of problems found during a PM should be noted in the “comments” portion of the check sheet. Whenever a svstem or comnonent is faultv or unsafe, it must be noted on the check sheet, and reported to the designated authority at the conclusion of the P.M. AWARNING Remove all jewelry before examining electrical components. Code $ = O.K. O.K. X = Adjust (Not P.M.) Potential r = Repair or Replace ~ L. i... ..L......... Requires Shop Repair ___ ____ ,,,,__ :~~.:.:.:.:.:.:.:.:.:.~I . . . . . . . .,.i,................. SM568 1 PM Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Planned Maintenance Procedures Visual Inspection 1. . . 2. . . 3. . 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. InsDect Batterv Cover for darn= 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. Inswct Pallet Forks for obvious damaye Forks should not be bent or warped. If the forks are damaged, report condition to the designated authority. Battery and check the Spring Loaded Connectors Typical Illustration - H\ND & HWP -Battery Cover \ Check Cover for Damage Typical Illustration PWD& P Typical Illustration PM 2 SM568 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Planned Maintenance Procedures 4. . . . 4A. . . . 5. . Rider Models @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. Walkie Models I Access Doors \ Insoect Frame ComDonents Check truck console, access covers and doors for damage. Inspect name plates and decals for damage and to be sure they are not missing. Control Handle Check for obvious oil leak% 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. Coast Control Decal /‘--(Optional Equipment) Typical Illustration Data Plates 1 Typical Illustration A+\ /O Lift Cylinder 8 tines 1 Typical Illustration SM568 3 PM Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute 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. Be sure wheel fasteners are secure and none are missing. Make certain grease fittings are not damaged or missing. 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. 8. Connect Truck Batterv . Connect truck battery and check truck operation. I Drive 1 \ \ Grease \ Fittings \ \ \ \ \ Wheel Fastener Caster Typical illustration Wheel Hinge/ Typical Illustration Tvoical Illustration PM 4 SM568 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

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Clark P-25(HWP-25, PWD-25, HWD-25) P-30(HWP-30, PWD-30, HWD-30, HWD-36, PWD-36) Forklift* Factory Service / Repair/ Workshop Man

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