Clark WP45 Forklift Service Repair Workshop Manual
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2317 Alumni Park Plaza
Suite 500
Lexington, KY, 40517
USA
Service
Manual
SM698
WP45
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SM-698
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Standard Codes
F-code Section C-code
Version no T-code
000 390
1 SM-698
Standard Codes
B-Code = Business area
F-Code = Product family
T-Code = Product type
C-Code = Component function
Worksheet standard
W-Code = Working code
R-Code = Reason code
SO-Code = Assortment
F-Code List
PT Powered Pallet Trucks
T-Code List
No. Model
390 WP45
C-Code List
No Function Group C-Code
0 Chassis 0000
1 Motors 1000
2 Drive Gear / Transmission 2000
3 Brake / Wheel System 3000
4 Steering System 4000
5 Electrical System 5000
6 Hydraulic / Pneumatic System 6000
7 Operating Function-lifting Cylinder 7000
8 Peripheral / Installation Equipment 8000
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
000 390
Version no T-code
F-code Section C-code
Standard Codes
2
9 Optionals / Attachments 9000
10 Tools 10000
SM-698
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Do not sell or distribute
Table of Contents
3
Standard Codes ............................................................................................. 1
Warning Symbols ......................................................................................... 11
Warning Levels ......................................................................................... 11
Prohibitory Symbols .................................................................................... 12
Ordinance Symbols .................................................................................. 12
Safety ............................................................................................................ 13
General Safety .......................................................................................... 13
Battery Safety ............................................................................................... 17
Static Safety .................................................................................................. 22
Welding Safety ............................................................................................. 23
Introduction, Service Manual ...................................................................... 25
Contents, Section M ..................................................................................... 27
Machine Information ................................................................................. 27
General Product Information ...................................................................... 29
Truck Presentation. ................................................................................... 29
Truck Side Views ................................................................................... 29
Intended Truck Application .................................................................... 30
Prohibited Truck Application .................................................................. 30
Truck Data ............................................................................................. 30
Truck Dimensions .................................................................................. 31
Data Plate .............................................................................................. 32
Main Components ..................................................................................... 33
Inch and Metric (SAE) Fasteners ............................................................... 35
Introduction ............................................................................................... 35
Nomenclature, Threads ............................................................................ 36
Strength Identification ............................................................................... 37
Conversion of English and Metric Units .................................................... 44
Technical Service Data ................................................................................ 47
Ordering Spare Parts ................................................................................... 49
Contents, Section P ..................................................................................... 51
Planned Maintenance ............................................................................... 51
Introduction, Maintenance .......................................................................... 53
SM-698
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Table of Contents
4
Jacking Truck Off The Floor ..................................................................... 54
Elevate Rear of Truck ............................................................................ 54
Elevate Either Side of Truck .................................................................. 54
Lubricants ................................................................................................. 55
Standard ................................................................................................ 55
Corrosion ............................................................................................... 55
Cold Storage .......................................................................................... 56
Service Schedule ......................................................................................... 59
Planned Maintenance Schedule ............................................................... 59
Planned Maintenance Procedures ............................................................ 63
Services Performed Daily or Every 8 Operating Hours .......................... 63
Battery Discharge Indicator with lift interrupt (optional) .............. 63
Hydraulic System ....................................................................... 63
Frame/Sheet Metal ..................................................................... 64
Wheels/Tires .............................................................................. 64
Functions/Operations ................................................................. 64
Services Performed Monthly or Every 120 Operating Hours ................. 65
Inspection ................................................................................... 65
Transmission .............................................................................. 65
Brakes ........................................................................................ 65
Battery ........................................................................................ 65
Electrical Connections ................................................................ 66
Main Contactor ........................................................................... 66
Motor Brushes ............................................................................ 66
Drive Motor ................................................................................. 66
Hydraulic Reservoir .................................................................... 66
Frame Lube ................................................................................ 67
Pivot Points ................................................................................ 67
Services Performed Every 480 or 960 Operating Hours ........................ 68
Drive Motor ................................................................................. 68
Services Performed Annually or Every 1440 Operating Hours .............. 69
Inspection ................................................................................... 69
Transmission .............................................................................. 69
Battery ........................................................................................ 69
Hydraulic System ....................................................................... 70
Brakes ........................................................................................ 70
Lubrication Chart ......................................................................................... 71
Oil and Grease Specifications .................................................................... 72
Approved Oils and Grease ....................................................................... 72
Grease Location Points ............................................................................ 72
Contents, Section S ..................................................................................... 73
Service Instructions .................................................................................. 73
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Table of Contents
5
Chassis/Lift Frame ....................................................................................... 75
Pull rod ...................................................................................................... 76
Removal ................................................................................................. 76
Inspection ............................................................................................... 77
Installation .............................................................................................. 78
Carrier Frame Bushings ............................................................................ 80
Inspection Covers ........................................................................................ 81
General Information .................................................................................. 81
Driver Controls ............................................................................................. 85
Decals ............................................................................................................ 87
Decal with Protective Sheet ...................................................................... 87
Decal without Protective Sheet ................................................................. 87
Motor Maintenance Schedule/Troubleshooting ........................................ 89
General Information .................................................................................. 89
Operating Conditions ................................................................................ 89
Troubleshooting ........................................................................................ 90
Pump Motor .................................................................................................. 97
Mounting Points ........................................................................................ 97
Removal ................................................................................................. 97
Installation .............................................................................................. 97
Pump Motor Repair ................................................................................... 98
Disassembly ........................................................................................... 99
Inspection and Troubleshooting ............................................................... 100
Drive End Head ..................................................................................... 100
Commutator End Head ......................................................................... 100
Bearings ................................................................................................ 100
Brush Inspection ...................................................................................... 101
Brush Replacement Determination ....................................................... 101
Replacement Procedures ..................................................................... 102
Drive Motor .................................................................................................. 105
Mounting Points ....................................................................................... 105
Drive Motor Brush ................................................................................. 106
Drive Motor Removal ............................................................................ 106
Drive Motor Installation ......................................................................... 108
Component Repair .................................................................................. 110
Motor Disassembly ............................................................................... 112
Motor Inspection ..................................................................................... 113
External Motor ....................................................................................... 113
Brush and Commutator ......................................................................... 113
Bearings ................................................................................................ 116
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Table of Contents
6
Armature Electrical Check .................................................................... 116
Frame and Field Service Recommendation .......................................... 116
Assembly/Testing .................................................................................. 117
Transmission ............................................................................................... 119
System Description .................................................................................. 119
Troubleshooting ....................................................................................... 119
Transmission Mounting ............................................................................ 120
Wrap Around Bumper ........................................................................... 121
Guards .................................................................................................. 122
Removal ................................................................................................ 123
Installation ............................................................................................. 124
Transmission Repair ................................................................................ 125
Disassembly .......................................................................................... 126
Reassembly .......................................................................................... 127
Axle Seal .................................................................................................. 129
Removal ................................................................................................ 129
Installation ............................................................................................. 129
Parking Brake System ................................................................................ 131
Brake Theory of Operation ...................................................................... 132
Brake Adjustment .................................................................................... 133
Brake Shoe Removal / Installation ........................................................... 134
Drive Wheel .................................................................................................. 135
Removal ................................................................................................... 135
Installation ................................................................................................ 136
Tire Pressing Procedure .......................................................................... 137
Support/Swivel Wheel (Optional) ............................................................... 139
Maintenance and Adjustments ................................................................ 141
Caster Adjustment ................................................................................ 141
Troubleshooting ....................................................................................... 141
Stabilizing Caster .................................................................................. 141
Caster Replacement ................................................................. 141
Fork Wheels ................................................................................................. 143
Removal/Installation ................................................................................ 143
Steering ........................................................................................................ 145
Control Handle Head ............................................................................... 146
Removal ................................................................................................ 146
Installation ............................................................................................. 146
Driver Protection (Reverser) Assembly Replacement ............................. 147
Direction Control Switches ....................................................................... 149
Removal ................................................................................................ 149
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Table of Contents
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Installation ............................................................................................. 149
Raise, Lower, and Horn Switches ............................................................ 151
Removal ................................................................................................ 151
Installation ............................................................................................. 152
Potentiometer .......................................................................................... 153
Removal ................................................................................................ 153
Installation ............................................................................................. 154
Steering Stem .......................................................................................... 158
Removal ................................................................................................ 158
Installation ............................................................................................. 158
Electrical Functions .................................................................................... 159
General .................................................................................................... 159
Adjustable Settings: .............................................................................. 159
References ............................................................................................ 159
Key Switch S17 in the ON Position ....................................................... 159
Operating Arm in Drive Position, S10, Brake Switch Closed ................ 160
Travel Request, Fork First .................................................................... 160
Travel Request, Forks Trailing .............................................................. 160
Reversing/Motor Brake Forks First Direction to Forks Trailing Direction 160
Reversing/Motor Brake Forks Trailing Direction to Forks First Direction 161
Reverser switch .................................................................................... 161
Lifting Forks .......................................................................................... 161
Lowering Forks ..................................................................................... 161
Horn ...................................................................................................... 162
Lift Interrupt ........................................................................................... 162
Electrical Symbols ...................................................................................... 165
Electrical Schematics ................................................................................. 169
Battery .......................................................................................................... 173
Removal ................................................................................................... 173
Installation ................................................................................................ 173
Battery Maintenance ................................................................................ 174
Battery Inspection and Care ................................................................. 174
Battery Exterior Cleaning ...................................................................... 175
Charging ............................................................................................... 175
Storage .................................................................................................... 176
Battery History Record ............................................................................. 176
Swing Out Battery Pack .............................................................................. 177
Battery Cable Routing Diagram ............................................................... 179
Charger Diagram ..................................................................................... 181
Troubleshooting ....................................................................................... 182
Electrical Testing ................................................................................... 182
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Table of Contents
8
Equipment required: .................................................................. 182
Instructions ................................................................................ 182
Battery Connector ....................................................................................... 189
Location ................................................................................................... 189
Inspection ................................................................................................ 189
Installation ................................................................................................ 190
Battery Controller/Hourmeter/ Lift Interrupt (Optional) ........................... 191
General Information ................................................................................. 191
Electrical .................................................................................................. 192
Voltage .................................................................................................. 192
Battery Controller (BC) ............................................................................ 193
General Information .............................................................................. 193
Discharge Adjustment ............................................................... 193
Reset ..................................................................................................... 195
Key Switch ............................................................................................ 195
Hourmeter ............................................................................................. 196
Troubleshooting ....................................................................................... 196
Battery Discharge Indicator (BDI) ......................................................... 196
No Reset ................................................................................... 196
Reset After Break in Power ....................................................... 196
No Discharge, Gauge Does Not Run Down .............................. 197
No Lockout ................................................................................ 197
No Lift ........................................................................................ 198
Early Lockout ............................................................................ 198
LEDs Do Not Light .................................................................... 198
Hourmeter ............................................................................................. 199
No Display ................................................................................. 199
Hourmeter Glass Icon Does Not Flash ..................................... 199
Hourmeter Glass Icon Always Flashes ..................................... 199
Battery Discharge Indicator / Hourmeter .................................................. 201
General Information ................................................................................. 201
Electrical .................................................................................................. 202
Voltage .................................................................................................. 202
Battery Discharge Indicator (BDI) ............................................................ 202
General Information .............................................................................. 202
Key Switch ............................................................................................ 202
Hourmeter ............................................................................................. 203
Troubleshooting ....................................................................................... 203
Battery Discharge Indicator (BDI) ......................................................... 203
No Reset ................................................................................... 203
Reset After Break in Power ....................................................... 204
No Discharge, Gauge Does Not Run Down .............................. 204
LEDs Do Not Light .................................................................... 204
SM-698
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The Clark WP45 Forklift Service Repair Manual is an essential resource for both professional mechanics and DIY enthusiasts. This comprehensive manual provides easy-to-read text sections accompanied by high-quality diagrams and instructions, covering a wide range of topics including standard codes, warning symbols, prohibitory symbols, safety guidelines, battery safety, static safety, and welding safety. The manual is available in English and is compatible with all versions of Windows and Mac, requiring Adobe Reader for access.
Whether you are looking to save time and money by performing repairs yourself or simply aiming to gain a deeper understanding of your Clark WP45 Forklift, this manual is designed to provide you with the confidence and knowledge needed to get the job done effectively. With the ability to print any page as needed, this manual offers convenience and accessibility for all your repair needs.
