Clark Sm 556 Service Manual

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SM-556
ESM 12-25

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Intended for CLARK dealers only
Do not sell or distribute
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 SERVICE MANUAL
SM556
CONTENTS
GROUP PAGE

Foreword ii
...
How to Use this Manual III
Pictorial Index iv
Safety and Operational Checks iv
Recommended Planned Maintenance
and Lubricatiin Schedule V
Safety Signs and Messages vi
User Safe Maintenance Practices vi

GROUP PAGE

PM Planned Maintenance Program PM-1

’ 12. . Battery Removal & Maintenance 12-01-l
13 Accetkator and Directional Control System 13-01-f
13 Main Pump Motor Switch Check and Adjustment 13-02-l
14 Electrical System and Components 14-01-l
16 Electric Motor General Maintenance 16-01-l
16 Drive Motor 16-02-l
16 Main Pump Motor 16-03-l
16 Steer Pump Motor 16-04-l
16 Drive Motor Overhaul 16-23-l
17 Drive Motor Cut-Cut Switch Check and Adjust 17-01-l
19 Control Panel 19-01-l
19 Control Panel Operation and Troubleshooting 19-02-l
20 Drive Axle 20-01-l
22 Cushion Wheels and Tires 22-01-l
22 Pneumatic Drive Tire and Wheel Maintenance 22-02-l
23 Hydraulic Brake System 23-01-l
23 Brake Master Cyiinder 23-02-l
23 Brake Slave Cylinder 23-03-l
23 Service Brake 23-04-l
25 Steering Gear 25-01-l
26 Steering Axle 26-01-l
26 Power Steering Pump 26-02-l
26 Steer Torque Generator 26-03-l
29 Main Hydraulic Pump 29-01-l
30 Main Hydraulic Valve 30-01-l
31 Hydraulic System 31-01-l
32 Tilt Cylinder 32-01-l
33 Selector Solenoid Valve 33-01-l
34 Upright 34-01-l
34 UprigM Removal 34-9R-1
36 Counterweight 38-01-l
38 Machine Jacking & Blocking 38-02-l
39 Overhead Guard 39-01-l
39 Sheet Metal and Trim 39-02-l
40 Truck Data Plate and Decals 40-01-l
40 Truck Data and Specifications 40-02-l
40 Hydraulic and Electric Diagrams 40-03-l

SM556 i Rev Jan 90

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Intended for CLARK dealers only
Do not sell or distribute
 FOREWORD

Clark Equipment Company welcomes you to the growing group of professional people who own, operate
and maintain Clark lift trucks. This manual wiil familiarize you with service maintenance and overhaul
information about your new truck. It has been especially prepared to help you maintain your Clark lift truck
in an efficient and safe operating condition.

Regular, correct maintenance and care of your lift truck is not only important for full and efficient truck life, it
is essential for your safety. A faulty Iii truck is a potential source of danger to the operator, and to other
personnel working near it. The importance of maintaining your Iii truck in a safe operating condii by
servicing it regularly and, when necessary, repairing it promptly cannot be emphasized too strongly.

To assist you in keeping your fii truck in good operating condition, this manual includes an outline of
planned maintenance (PM) procedures that are considered essential to the life and safe performance of
your truck. Brief procedures for inspections, operational checks, deaning, tubncatiin, and adjustments are
included for your reference.
. ,.
Clark recommends that a planned maintenance and safety inspection program (PM) be performed by a
trained and authorized mechanic on a regular basis. The PM program provides the opportunity to make
thorough inspections and checks on the safe condition of your truck. Necessary adjustments and repairs
can be done during the PM, which will increase the life of components and reduce unscheduled downtime.
The need for major adjustments, repairs, or replacements is found and corrections made as required, not
after failure has occurred.

SM556 ii

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Do not sell or distribute
 HOW TO USE THIS MANUAL

This manual is intended to be used by persons who are trained and authorized to do lift truck maintenance.
The recommended procedures for routine servicing and adjustments as well as for removal and overhaul of
major components of the truck are outlined. It is written to show and describe the adjustment, removal,
disassembly, inspection, repair, and assembly steps that are normally required to service these compo-
nents.

The detailed procedures are arranged in sequence by numbered GROUP and Section. The GROUP
numbers are the same as the component group in the Master Parts Book. Each GROUP has its own Table
of Contents, so that you can find the various topics within more easily. If you cannot find a topic in the Table
of Contents, check the Index at the back of the manual.

Component specifications, information notes and safety messages are included at the proper step of each
procedure. To be better prepared to do the necessary service work, please take time to read the entire
procedure, including any speciaf instructions; before doing anywork.

Speciffcations of selected truck components are included at the back of the manual for easy reference.

Also refer to the Operator’s Manual, located on the truck, for additional information and instructions on the
operation and maintenance of your truck.

If you have need for more information on the care and repair of your truck, please contact your authorized
Clark dealer.

,_ . .

NOTICE - The descriptions and specifications included in this manual were in effectat the time ofprinting. Clark
Equipment Company reserves the right to make improvements and changes in specifications or design, with-
out notice and without incurring obligation. Please check w2h your authorized CLARK dealer for information
on possible updates or revisions.

0 Clark Equipment Company 1989

SM556 iii

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 PICTORIAL INDEX

1. Control Handle
2. Traction Control Panel
3. Lift Pump & Motor
4. Steer Pump & Motor
5. Service Brake
6. Drive Motors (2)
7. SumpTank
8. Battery
5 9. Steer Axle & Housing
1O.Steer Torque Generator
6 11. Brake Reservoir
12. Steer Control and Valve

SAFETY AND OPERATIONAL CHECKS

Daily Inspection . - CMWV
_-_. J S-10 hours ABCDE
Checktruckforobvic__ XIS damage
__...__ and leaks 0
Check / clean battery terminals Q
Check electrolyte level
Check capacity, wamina plates. decal I II I I
Check condition of ti,res and wheels and 0
remove embedded objects I I I
Check wheel lug nuts

bn and bolts
tration and other warning
V
devices
Check steering operation 0
Check brake operation 0
.
Check directional and speed control
operation
Check lift, tilt, aind aux.
_._ operation
Check upright, lift ch(ains and fasteners
Check load backrest extension and forks

SM556 iv

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 RECOMMENDED PLANNED
MAINTENANCE and LUBRICATION
SCHEDULE

Recommended Planned Maintenance Interval

A = 8-l 0 hours daily
B = 50-250 hours or every month
c= 450-500 hours or every 3 months
D = 900-l 000 hours or every 6 months
E = 2000 hours or every year

Rev Jan ‘96 Copyrighted

SM556Material
v
Intended for CLARK dealers only
Do not sell or distribute
Safety Signs and Safety Messages User Safe Inspection Practices

lmproperorcareless techniques cause accidents. Don’t The following instructions have been prepared from
take chances with incorrect or damaged equipment. current industry and government safety standards
READ and UNDERSTAND the procedures for safe applicable to industrial truck operations and
driving and maintenance outlined in this manual. maintenance. They are listed hereforthe reference and
safety of all workers during inspection / maintenance
STAY ALERT! Follow safety rules, regulations and operations. When in doubt of any inspection /
procedures. Accidents can be avoided by recognizing maintenance procedures, please contact your local
dangerous procedures or situations before they occur. CLARK dealer.

DRIVE AND WORK SAFELY and follow the safety 1.Powered industrial trucks can become hazardous if
signs and their messages displayed on the truck and in maintenance is neglected. Therefore, suitable
this manual. maintenance facilities, trained personnel and procedures
shall be provided.
SAFETY SIGNS and MESSAGES are placed in this
manual and also on the lift truck to provide instructions 2. Maintenance and inspection of all powered industrial
and to identify specific areas where potential hazards trucks shall be done in conformance with the
exist and special precautions should be taken. Be sure manufacturers recommendations.
you know and understand the meaning of these instruc-
tions, signs and messages. Damage to the truck or 3. A scheduled planned maintenance, lubrication and
death or serious injury to you or other persons may inspection system shall be followed.
result if these messages are not followed.
4. Only trained and authorized personnel shall be
NOTICE permitted to maintain, repair, adjust and inspect industrial
This message is used when special informa- trucks and in accordance with the manufacturer’s
tion is required to clarify procedures or identify specifications.
components pertaining to the truck.
5. Properly ventilate work area, vent exhaust fumes,
keep shop clean and floor dry.
IMPORTANT
This message is used when additional atten-
6. Avoid fire hazards and have fire protection equipment
tion is required for proper operation or mainte-
present in the work area. Do not use an open flame to
nance of the truck.
check electrolyte level. Do not use open pans of fuel or
flammable cleaning fluids for cleaning parts.

A ! CAUTION
This message is used as a reminder of safety
7.Before Starting To Work On Truck:
a) Raise drive wheel free of floor or disconnect power
practices which can result in personal injury if source and use blocksorother positive truck positioning
proper precautions are not taken. devices.
b) Put blocks under the load-engaging means,

A WARNING
This message is used when a hazard exists
innermast( or chassis before working on them.
c) Disconnect battery before working on the electrical
system.
which can result in injury or death, if proper
precautions are not taken. 8. Operation of the truck to check performance must be
conducted in an authorized, safe, clear area.

A DANGER
This message is used when an extreme hazard
exists which will result in death or serious injury
if proper precautions are not taken.

Copyrighted
SM556 vi Material Rev Jan ‘96
Intended for CLARK dealers only
Do not sell or distribute
9. Before Starting to Drive the Truck: connections must be inspected and maintained in
a) Be in operating position. conformance with good practices. Special
b) Turn on power. attention must be paid to the condition of electrical
c) Check functioning of lift and tilt systems. insulation.
d) Check directional and speed controls.
e) Check steering. 17. To avoid injury to personnel or damage to the
9 Check brakes. equipment, consult the manufacturers procedures
g) Check warning devices. in replacing contacts on any battery.
h) Check any load handling attachments.
18. Industrial trucks must be kept in a clean
10. Before Leaving the Truck: condition to minimize fire hazards and help in the
a) Stop truck. detection of loose or defective parts.
b) Fully lower forks or attachment device.
c) Allow directional control to return to neutral. 19. Modiiiations and additions that affect capacity
d) Turn off the control / ignition switch. and safe truck operation must not be done without
e) Chock wheels if truck must be left on an the manufacturer’s prior written approval.
incline. Capacity, operation and maintenance instruction
plates, tags or decals must be changed
11. Brakes, steering mechanisms, control accordingly.
mechanisms, warning devices, lights, lift overload
devices, guards and safety devices, lift, reach and 20. Care must be taken to assure that all
rotation mechanisms, and frame members must be replacement parts, including tires, are
carefully and regularly inspected and maintained in interchangeable with the original parts and of a
a safe operating condition. quality at least equal to that provided in the original
equipment. Parts, including tires, are to be
‘12. Special trucks or devices designed and installed per the manufacturers procedures.
approved for hazardous area operation must Always use genuine CLARK or CLARK - approved
receive special attention to ensure that parts. ;
maintenance preserves the original, approved safe
operating features. 21. When removing tires, follow industry safety
practiced. Most important, deflate pneumatic tires
13. All hydraulic systems must be regularly completely prior to removal. Following assembly
inspected and maintained in conformance with of tires on multi-piece rims, use a safety cage or
good practices. Tilt and lift cylinders, valves and restraining device while inflating.
other similar parts must be checked to assure that
“drift” or leakage has not developed to the extent 22. Use special care when removing heavy
that it would create a hazard. components from the truck, such as
counterweight, upright, etc. Be sure that lifting and
14. When working on hydraulic system, be sure handling equipment is of the correct capacity and
the battery is disconnected and upright is in its fully in good condition.
lowered position, and hydraulic pressure relieved
in hoses and tubing.

/\ ! WARNING
Always put blocks under the carriage and
upright rails when necessary to work with
upright in an elevated position.

15. The truck manufacturer’s capacity, operation

and maintenance instruction plates, tags or decals
must be maintained in legible condition.

16. Batteries, motors, controllers. limit switches,

protective device, electrical conductors and
SM556 vii

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 Planned Maintenance

GROUP PM

PLANNED MAINTENANCE

Visual Inspection .............................................................................. 2

Functional Tests ................................................................................ 5
Test Drive The Truck ........................................................................ 7
Air Cleaning ..................................................................................... 9
Brake Adjustment ........................................................................... 10
Critical Fastener Torque Checks .................................................... 10
Lubrication, Fluids and Filters ....................................................... 10

SM 556, Jan ‘96

Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Planned Maintenance

PM - PLANNED MAINTENANCE PROGRAM

A planned maintenanceprogramof regular,routine inspectionsand
lubrication is important for long life and trouble-free operation of
A WARNING
Failure to perform these checks and adjustments
your lift truck. Make and keep records of your inspections. Use will cause a loss of brakes and may result in prop-
these records to help establish the correCtPM intervals for your erty damage, and/or severe or fatal bodily injury.
applicationand to indicate maintenancerequired to prevent major
problems from occurring during operation. HOW TO PERFORM THE PM PERIODIC
INSPECTIONS AND MAINTENANCE
PM REPORT FORM
Asanaid in performing and documenting your PM inspections,
Clark has prepared an “ELECTRIC TRUCK PLANNEDMAIN-
TENANCE REPORT”form. Copies of this form may be obtained
from your authorizedCLARKdealer. We recommend that you use
this form as a checklist and to make a record of your inspectionand
truck condition.

The periodic maintenanceprocedures outlined in this manual are

intended to be used with the PM report form. They are arrangedin
groupings of maintenance work that are done in a logical and
efficient sequence.

AcheckmarkorentryismadeonthePMReportFormwhenthePM
is performed. Please note the special coding system for indicating
the importance of needed repairs and/or adjustments.

When you have finished the PM inspections,be sure to give a copy VISUAL INSPECTION
of the report to the designatedauthorityor thepersonresponsiblefor First, perform a visual inspection of the lift truck and its
lift truck maintenance. components. Walk around the truck and take note of any
obvious damage and maintenance problems. Check for loose
Do not make repairs or adjustments unless au- fasteners and fittings.
thorized to do so. For safety,it is good practice to:
Check to be sure all capacity, safety, and warning plates or
Remove all jewelry (watch, rings, bracelets, etc.) before decals are attached and legible.
working on the truck.
Disconnect battery from truck receptacle before work- IMPORTANT
ing on electrical components. NAMEPLATES & DECALS
Always weaf safety glasses. Wear a safety (hard) hat in Do not operate a lift truck with damaged or missing
industrial plants and in special work areas where protec- decals and nameplates. Replace them immediately.
tion is necessary or required. They contain important information.

IMPORTANT Inspect the truck for signs of external leakage of transmission

The ESM brakes are not self adjusting, but need to be fluid, etc. Check for hydraulic oil leaks and loose fittings. DO
periodically inspected and adjusted accordingly. If NOT USE BARE HANDS TO CHECK OIL. Oil may be hot
adjustments are not made as required, the slave or under pressure.
cylinder can run out of stroke, and the springs will
not apply the brakes. This condition will not be a
sudden event, but will result in a gradual loss of
braking capability. If the brakes begin to get “soft”,
this is an indication that the slave cylinder may be
A WARNING
HYDRAULIC FLUID PRESSURE
“bottoming out” and the brakes have not been ad- Do not use your hands to check for
justed as needed. Checking the brake adjustment hydraulic leakage. Fluid under pres-
setting in addition to the driving test must be part of sure can penetrate your skin and cause
the Planned Maintenance program. When the covers serious injury.
are removed for air cleaning the travel controls, the
brake arm positioning and lining wear must be in-
spected, recorded and corrected as necessary.

PM-2 Copyrighted Material SM 556, Jan’ 96

Intended for CLARK dealers only
Do not sell or distribute
 Planned Maintenance

A
Be sure that the driver’s overhead guard, load backrest
extension, finger guards, and any other safety devices are in DANGER
place, undamaged, and attached securely. Uprights can drop suddenly. Look at the up-
right, but keep hands out.
IMPORTANT
For trucks equipped with spark-enclosed (EE) con- Check the upright assembly. Inspect the upright rails, car-
struction, or with polyurethane tires, check the riage rollers, lift chains, lift and tilt cylinders. Look for
ground strap for wear and secure attachment. obvious wear, and damaged or missing parts. Check for any
loosepartsorfittings. Checkforleaks,anydamagedorloose
Check all of the critical components that handle or carry rollers, and rail wear (metal flaking). Carefully check the lift
the load. chains for wear, rust and corrosion, cracked or broken links,
stretching, etc. Check that the lift and carriage chains are
correctly adjusted to have equal tension. Check that the lift
chain anchor fasteners and lccking means are in place and
tight.

Be sure all safety guards and chain retainers are in place and
not damaged. Inspect the carriage stops and cylinder retainer
bolts. Check all welded connections.

Inspect all lift line hydraulic connections for leaks. Check the
lift cylinder rods for wear marks, grooves, and scratches.
Check the cylinder seals for leaks.

IMPORTANT
. Uprights and lift chains require special attention
and maintenance to maintain them in safe oper-
ating condition. Refer to Lift Chain Mainte-
nance section for additional information.
Check the overhead guard for damage. Be sure that it
is properly positioned and all mounting fasteners are in
Forks
place and tight.
Inspect the load forks for cracks, breaks, bending and wear.
The fork top surfaces should be level and even with each
Check the load backrestfordamage. Inspect the welds
other. The height difference between both fork tips should be
on the carriage and load backrest for cracks. Be sure
no more than 0.25 inch (6mm).
that the mounting fasteners are all in place
and tight.

IMPORTANT
Ifload backrest has been removed,
a bolt and washer must be in place
on each end of the top fork bar to
act as a fork stop.

max. wear

Check the amount of wear at the heel of the fork.

A WARNING
If the fork blade at the heel is worn down by more
than lo%, the load capacity is reduced and the fork
must be replaced. Do not attempt to fill with weld.

Copyrighted Material PM-3

SM 556, Jan ‘96
Intended for CLARK dealers only
Do not sell or distribute
Planned Maintenance

Inspect the forks for twists and bends. To check, put a IMPORTANT
2”x4”~24” long block on the blade of the fork with the 4” Personnel working on wheels and tires must be
surface against the blade. Put a 24” carpenters square on the trained and qualified to do wheel and tire maiu-
top of the block and against the shank. Check the fork 18” tenance.
above the blade to be sure it is not bent more than 1 inch
maximum. Pneumatic Tires
Carpenter Square Check for the correct air pressure on trucks with pneumatic
\
tires.

Blade -

them inspected by a trained maintenance person

before operating the truck.

A ! CAUTION
Check tire pressure from a position facing the
tread of the tire, not the side. Use a long-handled
gauge to keep your body away from the side. If
tires are low, don’t add air. The tire may require
removal and repair. Have the tire and wheel
inspected by a person trained and authorized to
do tire and wheel maintenance. Low tire pres-
sure can reduce the stability of your lift truck
and cause it to tip over.
Inspect the fork latches. Be sure they are not damaged or
broken and operate freely and lock correctly. Check the fork Inspect pneumatic tires and wheels carefully for:
stop pins (or bolt and washer) for secure condition. Damaged tire.
Damaged wheels or loosening of the locking rings on
multi-piece rims.
Wheels and Tires Loosening of the clamping bolts and nuts on two-piece,
Check the condition of the drive and split-rim wheels.
steer wheels and tires. Remove Low inflation pressure.

A DANGER
objects that are embedded in the

RIM SEPARATION
Remove the air from tires before doing any work
on tires or rims. Multi-piece rims cans separate
with enough force to cause injury or death.
Check all wheel mounting bolts to
be sure none are loose or missing.
Replace missing bolts and tighten
loose bolts to the correct torque
before operating the truck.

PM-4 Copyrighted Material SM 556, Jan’ 96

Intended for CLARK dealers only
Do not sell or distribute
 Planned Maintenance

FUNCTIONAL TESTS

Operate the control handle in the travel, lift, and lower

positions. The control handle should operate smoothly and
return to the neutral position when released. If there is any
binding or sticking, have the problem corrected before oper-
ating the truck.
Check to make sure all controls and systems are functioning
Before operating a lift truck, make sure it is in a safe
correctly.
condition.
Test all warning &vices, horn, lights, and other safety
equipment and accessories. Be sure they areproperly mounted
Check to see that:
and working correctly.
l Forks are fully lowered to the floor.
l You are familiar with how all the controls function.
Press the horn button to check horn l All controls are in neutral or other correct position.
function. If the horn does not operate,
report the failure and have it repaired Turn key switch ON, but do not depress brake pedal.
beforethetruckisputbackintoopera-
tion.

Check hourmeter operation. With key switch ON, rotate the

control lever to the FWD or REV travel position. The steer
pump and hourmeter should begin operating. Watch for
movement of the indicator in the right-hand dial opening.
Note any malfunction or damage.

Return control handle to NEUTRAL.

Write the hourmeter reading on the PM report form.

Operate the brake pedal. If there is any binding or sticking,
have the problem corrected before operating the truck. For
Check battery discharge indicator. The indicator should
further brake checks see pages 7 and 10.
register in the green area when key switch is ON. Also, check
Travel function of battery discharge indicator when making the
Forward battery load test below.

Travel
Reverse

SM 556, Jan ‘96 Copyrighted Material PM-5

Intended for CLARK dealers only
Do not sell or distribute
Planned Maintenance

Battery Load Test The main pump motor should start to run as the lever moves
from the neutral position and upright should rise. Return the
Battery Indicator
Tilt Control control handle to the neutral position. Pump motor should
stop. Push control handle forward into the LOWER position
until upright starts to lower.

If control handle movement is excessive before the pump

starts, or if pump does not stop running when control handle
returns to neutral, the microswitches need adjustment or
replacement.
Check the battery condition by holding the tilt lever in full
Test function of control handle TILT and AUX push-buttons
back-tilt position, allowing main pump to run against load of
and control valve solenoids. Depress the TILT push-button
bypass relief pressure valve for a few seconds. Watch the
and slowly pull back the control handle. The main pump
battery discharge indicator. The needle should stay in the
should start and the upright should tilt back. Return the
green area. If needle falls into the red area, the battery is
control handle to the neutral position. The pump should stop.
faulty or charge level is low and battery must be recharged
With the TILT push-button still depressed, push the control
before completing other electrical tests and performance
handle forward Thepump should start and the upright should
parts of the PM. Turn key switch OFF.
tilt forward. Repeat this test for each AUX push-button
installed. If truck does not function properly, have the prob-
Refer to Group 12, Battery Maintenance, for additional
lem corrected before operating.
information.
Test function of the power steering pump switch and system.
Battery Disconnect Turn key switch ON, and depress the brake pedal. Rotate the
control handle from neutral to either FORWARD or RE-
VERSE position. The steer pump motor should begin oper-
ating.

With the truck not moving, check the steering system by

moving the steering handwheel in a full right turn, and then
in a full left turn. Return the truck steer wheels to the straight-
ahead position. The steering components should operate
smoothly when the steering wheel is turned. Listen for the
steering pressure reliefvalve to bypass when the steer wheels
are fully turned. The steer pump and motor should not stall or
exhibit excessive loading. If it does, the power steering
system relief pressure valve may be malfunctioning.

Check the battery disconnect by pulling back the disconnect Return control handle to NEUTRAL. Steer pump motor
lever. The connector should separate smoothly. If it does not, should stop.
have it repaired.
IMPORTANT
Before Driving The Truck, Do These Tests: The steering system and steer axle should be
inspected periodically for wear, leaking seals,
etc. Check for any changes in steering action.
Hard steering, excessive freeplay (looseness) or
unusual sounds when turning or maneuvering
indicates a need for inspection and servicing.
Never operate a truck which has a steering sys-
tem fault.

Test function of mainpump motor switches on control handle

in LIFT position. Turn key switch ON. Slowly pull the
control handle back into the LIFT position.

PM-6 Copyrighted Material SM 556, Jan’ 96

Intended for CLARK dealers only
Do not sell or distribute
 Planned Maintenance

TEST DRIVE THE TRUCK Check the accelerator control while conducting the speed
range tests. It must move easily and smoothly throughout the
IMPORTANT acceleration stroke, andreturn withoutbinding. There should
It is recommended that these tests be conducted be no restriction to movement on either acceleration or
with a rated capacity load, if possible. deceleration.

Operate ONLY in a pedestrian and traffic free aisle. An Test the service brake (drive motor cut-off) switch. Drive the
empty parking lot with a smooth, level surface is also a good truck FORWARD (or in REVERSE) at creep speed. While
operating location. holding the control handle steady in creep-speed position,
release brake pedal. The braking action should interrupt
Test the truck for proper operation and drive train function power to the drive motor and stop the truck. Depress the
by driving the truck in both the forward and reverse direc- brake pedal. The drive motors should again start moving the
tions. Drive first in a straight line and slowly through a series truck.
of full right and left turns.

Test for correct function of the SCR control.

Check CREEP SPEED, 1A RANGE, and PLUGGING.

1. Check CREEP SPEED and 1A RANGE while driving

the truck in a straight line in both FORWARD and
REVERSE directions. CREEP SPEED should be ob-
tained at the beginning of SCR RANGE after slightly Test brake operation by depressing and releasing the brake
rotating the control handle and closing 1MS switch. 1A pedal several times while driving the truck. The brakes
RANGE - When the control handle is rotated farther and should bring the truck to a smooth stop, without pulling,
then completely, the truck should accelerate in SCR squealing, or shuddering. Have the brakes adjusted or re-
RANGE and make a smooth transition into 1A RANGE paired as necessary.
for maximum travel speed. As the 1A contactor closes, IMPORTANT
there should be very little surge as the truck goes out of The ESM brakes are not self adjusting, but need to be
SCR RANGE and into 1A. All speed changes should be periodically inspected and adjusted accordingly. If
smooth while increasing and decreasing speed. Listen adjustments are not made as required, the slave
for any unusual drive train noises or actions of the cylinder can run out of stroke, and the springs will
controls and drive train components. not apply the brakes. This condition will not be a
sudden event, but will result in a gradual loss of
Stop truck with the service brakes by releasing the brake braking capability. If the brakes begin to get “soft”,
pedal. Note any unusual reactions in driving or braking this is an indication that the slave cylinder may be
performance, and need for adjustment. “bottoming out” and the brakes have not been ad-
justed as needed. Checking the brake adjustment
2. PLUGGING is an SCR control function which provides setting in addition to the driving test must be part of
for reversing the direction of travel under controlled the Planned Maintenance program. When the covers
conditions. A correctly-adjusted plugging control should are removed for air cleaning the travel controls, the
result in a smooth deceleration and stop from any speed brake arm positioning and lining wear must be in
spected, recorded and corrected as necessary.
in one direction, and acceleration in the opposite direc-
tion. Plugging speed and distance are determined by
The ANSI standard requirement for these brakes is that they
control handle travel position.
hold the truck and a rated load on a 15% grade. If such a grade
is available, after adjustment, the brakes can be tested by
Check PLUGGING function first at a slow speed. If plug-
slowly and carefully driving the truck with a rated capacity
ging operates correctly, then test at full speed. First, drive load straight up a known 15% grade, with the load upgrade
truck in the FORWARD direction. Accelerate to the desired and bringing the truck to a stop with the brakes applied. If the
travel speed. Then, rotate the control handle to the same speed brakes hold the loaded truck stationary on the grade the
in REVERSE travel position. The truck should slow to a brakes are satisfactorily set. Even if this test shows satifactory
smooth, controlled stop and then accelerate in the opposite performance, the adjustment check on PM-10 m still be
direction. Repeat test by turning control handle back to done. After observing the performance of the brakes slowly
FORWARD position. drive the truck straight back down the grade. Do not try to
perform any maneuvers on the grade. While this is a test

SM 556, Jan ‘96 Copyrighted Material PM-7

Intended for CLARK dealers only
Do not sell or distribute
Planned Maintenance

method, the ESM is m intended for use on 15% grades, FORWARD, then back to NEUTRAL. Next, test shift from
except as encountered for short distances such as dock plates. NEUTRAL to REVERSE, then back to NEUTRAL. Check
If no grade is available, the brakes can be approximately for positive control action when changing directions.
tested by measuring the stopping distance as follows. Test
only with an unloaded truck in a pedestrian and traffic free Listen for clunking, squealing, grinding, scraping or other
aisle. An empty parking lot with a smooth, level surface is unusual noises. Check for vibration. Listen for wheel bearing
alsoagoodoperatinglocation.Markalineonthefloorornote or other specific running noise.
a floor joint as a measurement line. Starting at a point
approximately 150 to 200 feet in front of the line, drive the Lift Mechanism and Controls
truck in a straight line at full speed towards the line. As the NOTE: It is recommended that these tests be conducted with
front wheels roll over the line apply the brakes by raising the a rated capacity load, if possible.
brake pedal. When the truck has come to a complete stop,
safely park the truck at this same spot and measure the Test the operation of the hydraulic system and upright.
distance from the front wheels to the measurement line. This
is your stopping distance. Compare to the table below for the A ! CAUTION
model you are working with. If the measured distance is less Be sure there is adequate overhead clearance
thanthetablevaluethenthebmkesaresatisfactorilyset(The before raising the upright.
approximate rule of thumb is that the stopping distance for an
ESM without a load shall be between l-1/4 (one and one
quarter)and 1-1/2(one and one half) times the length of the
truck with no forks.)
Modei Distance inches
ESMl2 100
ESM15S 100
ESM15 97
ESM17 94
ESM20 92
ESM22 90
ESM25 90

Cycle (raise to full height and then lower) the upright at both
Do not operate lift truck if the brakes are not slow and fast speed, with the upright tilted slightly back-
operating properly. wards. Watch the upright assembly as it rises. All move-
ments of the upright, fork carriage, and lift chains must be
Check steering control operation. First, drive the truck in a even and smooth, without binding or jerking motions. Watch
straight line. The truck must drive in a straight line without for chain wobble or looseness; the chains should have equal
drifting toward either side. Then, drive slowly (creep speed) tension and move smoothly without noticeable wobble.
through a series of full right and left turns. Check steering
response and smoothness of operation. Turning effort must Check function of the control handle and main hydraulic
be the same in either direction. If there is a steering problem, valve. Listen for abnormal noises in the hydraulic valve, main
have it repaired. Also refer to Group 17, Drive Motor Cut-Out hydraulic pump, and system components.
check and adjustment.
If the maximum fork height is not reached, there is low oil
level in the hydraulic sump tank, or severe binding within the
upright.
Do not operate lift truck if steering system is not
operating properly.
A WARNING
FALLING FORKS
IMPORTANT
It is recommended that the following tests also be Do not walk or stand under raised forks. The
conducted with a rated capacity load, if available. forks can fall and cause injury or death.

Test for general drive train operation. Drive the truck at Check the upright rails, rollers, carriage, lift chains and
various speeds and operating conditions, in both FORWARD cylinders as they move. Watch for binding or excessive
and REVERSE directions. Test shifting from NEUTRAL to freeplay (looseness) between the carriage and the upright

PM-8
Copyrighted Material SM 556, Jan’96
Intended for CLARK dealers only
Do not sell or distribute
 Planned Maintenance

rails and rollers. Listen for abnormal noises. If there is

excessive clearance between the rails and channels, the need
for upright roller adjustment is indicated. If the rails or
carriage bind or hesitate when lowering, the rollers are either
damaged or roller adjustment is incorrect.

Check the upright for excessive downdrift. Stop the fork

carriage in an intermediate position. Check that it holds its
position and raises or lowers smoothly from any height
position. If the fork carriage does not hold its position when
stopped, the lift cylinder seals may be worn. Conduct an
upright cylinder downdrift test, with rated load, as needed.
Test the tilt function. Check for excessive tilt cylinder drift.
Stop the upright at a position near vertical. Check that the
upright holds its position without moving forward. If you Standard Shutdown Procedures:
observe forward movement (drift), or have a report of a tilt l Always come to a complete stop.
drift problem, the tilt cylinder seals may be worn. l Park only in authorized locations.
l Lower the forks to the floor and tilt them forward.
Test for correct tilt cylinder rod adjustment. Raise the car- l Allow travel control to return to neutral.
riage to an intermediate position. Tilt the upright fully l Turn the key switch off.
FORWARD, without a load on the forks. Check for upright l Step from the truck; the brake will set itself.
racking (twisting) as the tilt cylinders reach the end of their
stroke. Be sure to make a record of all maintenance and operating
problems you find.
Tilt the upright fully BACK. The upright should not rack
(twist) when the tilt cylinders reach the end of their travel. If Battery Compartment Inspection
upright racking is found, adjustment of the tilt cylinder rod Turn key switch OFF. Disconnect battery from truck recep-
ends (yokes) is required. tacle.
Inspect condition of the battery connector and truck battery
Check fork height adjustment and carriage chain adjustment. receptacle. Check the spring-loaded terminals, connectors,
Tilt the upright to the vertical position and fully lower the and retaining tabs. Look for poor connections due to burning,
carriage. The forks should stop and be held approximately bad crimps, or broken or loose retainers. Check the molded
0.50 inch [13 mm] above the floor. If the forks hit the floor, body for damage from overheating, burning and chips or
the carriage lift chains should be adjusted. cracks. Clean all corrosion from contacts, as necessary.

Inspect condition of the battery and cables. Check the battery

Auxiliary Function Control cables for wear or other damage. Also check for signs of
interference or rubbing with other components. Be sure that
the cable terminals are tight and clean. Clean off minor
deposits of corrosion that you find on the battery.

Never wash the battery when it is in the truck.

Check battery post terminals for corrosion and damage.

Clean all corrosion from cable end and battery post. Check
Single Auxiliary Double Auxiliary tightness of cable and post terminals.
Function Function
If necessary, check the state-of-charge condition of the bat-
If truck is equipped with an attachment, check the control for
tery. Take a specific gravity test of the electrolyte with a
correct function by briefly operating the attachment.
hydrometer. Be sure to check a minimum of six battery cells.
IMPORTANT
Checktheelectrolytelevelof thebattery. Adddistilledwater,
When you have completed the operational tests,
as required, to fill each cell to the correct level. Check to be
park and leave truck according to standard shut-
sure the vent hole in all battery cell caps is open. If cap vents
down procedures.
are plugged with corrosion, remove the caps and wash in a

Copyrighted Material PM-9

SM 556, Jan ‘96
Intended for CLARK dealers only
Do not sell or distribute
Planned Maintenance

solution of baking soda and water. etc.) in the air or on the floor, will require more frequent
cleaning. If air pressure does not remove heavy deposits of
Refer to Group 12, Battery Maintenance, for additional grease, oil, etc., it may be necessary to use steam or liquid
information. spray cleaner. Do not clean electrical components with steam.

Motor SCR Controls Inspection IMPORTANT

Lift trucks should be cleaned at every PM inter-
IMPORTANT val, and otherwise as often as required.
Do not clean electrical components with steam.
Only approved solvents should be used to clean Air cleaning should be done using an air hose with special
controls and SCR components. Use Clark adapter or extension having a control valve and nozzle to direct
#1801146 Degreaser (or the equivalent to MS- the air properly. Use clean dry, low-pressure compressed air;
180 Freon TF Degreaser and Cleaner). restrict air pressure to 30 psi [207 kPa] , maximum. Wear
suitable eye protection and protective ciothing.
Turn key switch OFF. Disconnect battery from truck recep- Air clean the following: Upright assembly; drive axle;
tacle. Remove control and hydraulic compartment cover battery, cables, switches and wiring harness; SCR controls
from truck. and wiring; drive, lift, and steer motors; steer axle, steer
cylinder.
Discharge the capacitor. Use an insulated tool, such as a
screwdriver with plastic or wood handle, to short between the Brake Adjustment
terminals. In addition to the functional brake checks previously per-
formed it is very important that the brake arm and spring
Inspect the SCR controls for clean condition. Check for oily settings be checked. When the covers are removed for the air
dirt buildup on contactors, SCR control card, capacitor, etc. cleaning this check must be made.
Inspect all controls wiring and terminals for any obvious
damage. Look for cracks or worn areas in the wiring insula- IMPORTANT
tion. Check for loose connections at the control terminals. The ESM brakes are not self adjusting, but need to be
Air clean, as necessary. periodically inspected and adjusted accordingly. If
adjustments are not made as required, the slave
cylinder can run out of stroke, and the springs will
Control and Hydraulic Compartment Inspection not apply the brakes. Thii condition will not be a
Check the condition of all hydraulic system components, sudden event, but will result in a gradual loss of
hoses, piping and connections. Check for wear, leakage, and braking capability. If the brakes begin to get “soft”,
damage. this is an indication that the slave cylinder may be
“bottoming out” and the brakes have not been ad-
Inspect all control levers, and linkages. justed as needed. Checking the brake adjustment
setting in addition to the driving test must be part of
Inspect the drive motor, lift pump motor and steer pump the Planned Maintenance program. When the covers
motor power cables. Check drive motor mounting fasteners. are removed for air cleaning the travel controls, the
brake arm positioning and lining wear must be iu-
Check steer and lift pump mountings.
spected, recorded and corrected as necessary.

AIR CLEANING
Always maintain a lift truck in a clean condition. Do not
A WARNING
Failure to perform these procedures will cause a
allow dirt, dust, lint, or other contaminants to accumulate on
loss of brakes and may cause property damage
the truck. Keep the truck free from leaking oil and grease.
au/or severe or fatal bodily injury.
Wipe up all oil spills.
Keeptbecontmlsandfloorboardcleananddry. Acleantruck
With the brakesreleasedrotate thebrake drum by hand so that
makes it easier to see leaks, loose, missing or damaged parts,
the shoe pivot pins are visible. Let the foot pedal return to its
and will help prevent fires. A clean truck will mn cooler.
full up position. Measure the angle of the brake arm to a
suaightlinethroughthepivotpins.Seesection23-4-02. If the
The environment in which a lift truck operates will determine
angle is more than 12’ the brakes need adjusting. Also inspect
how often and to what extent cleaning is necessary. For
the shoe lining condition. If the lining appears to be less than
example, trucks operating in manufacturing plants which
3/32” further checking by disassembly is needed. Record on
have a high level of dirt or lint (e.g., cotton fibers, paper dust,
the PM report form and, if you are not the maintenance

Copyrighted Material SM 556, Jai’ 96

PM-10
Intended for CLARK dealers only
Do not sell or distribute
 Planned Maintenance

mechanic, notify the maintenance department. Do not use the Hydraulic Oil Filter
truck until these conditions are corrected. Repeat these checks Remove and replace the hydraulic system fluid filter per
on both left and right-hand side brakes. recommended PM schedule, or as required by truck operating
conditions and usage. Install a new oil filter. Be sure to
Critical Fastener Torque Checks follow the installation instructions printedon thefilter. Check
Fasteners in highly loaded (critical) components can quickly for leaks after installation of the filter. Also, check that the
fail if they loosen. Loose fasteners can cause damage or hydraulic line connections at the filter adapter are tightened
component failure. For safety, it is important that the correct correctly.
torque be maintained on all fasteners of components which Always use genuine CLARK parts.
directly support, handle or control the load, or protect the
operator. Sump Tank Breather Maintenance
Remove the sump tank fill cap/breather and inspect for
excessive contamination and damage. Clean or replace the
Check torque of critical items, including:
fill cap/breather, per recommended PM schedule or as re-
Overhead guard; drive axle mounting; drive and steer wheel
quired by operating conditions.
mounting; counterweight mounting; load backrest exten-
sion; tilt cylinder mounting and yokes; upright mounting &
components. Access to the Drive Axle
The best method to use for reaching the drive axle check
points (oil level/fdlerplug and drain plugs) is dependent upon
LUBRICATION, FLUIDS AND FILTERS
the style of upright, carriage and attachments on your truck.
Hydraulic Sump
One method is to raise the upright carriage to provide easy
Check the hydraulic sump tank fluid level. Correct fluid level
access to the drive axle from the front.
is important forproper hydraulic system operation. Low fluid
level can cause pump damage. Overfilling can cause loss of
RefertoMachineJackingandBlockingsectionforadditional
fluid or lift system malfunction.
information on supporting the upright.
Hydraulic fluid expands as its temperature rises. Therefore,
it is preferable to check the fluid level at operating tempera-
ture, after approximately 30 minutes of truck operation.
Tocheckthefluidlevel,firstparkthetruckonalevelsurface. Block the wheels. Be sure to put blocking under
Put the upright in a vertical position and lower the fork the carriage and upright rails.
carriage fully down. Pull the dipstick out, wipe it with a clean
wiper and reinsert it fully into the dipstick tube. Remove the
dipstick and check the oil level. Keep the oil level above the
A WARNING
AN UPR%HT OR CARRIAGE CAN
LOW mark on the dipstick by adding recommended hydrau- MOVE UNEXPECTEDLY.
lic fluid only, as required. DO NOT OVERFILL. Chain or block the carriage and rails. Failure to
follow this warning can result in serious injury.
Check the condition of the hydraulic fluid for color, clarity,
and contamination. Change (replace) the oil as necessary. Drive Axle Fluid
The drive axle inspection and service plug openings are
Hydraulic Fluid and Filter Change shown by the following illustration.
Drain and replace the hydraulic sump fluid every 2000
operating hours, or sooner, as required. Replace the hydrau-
lic oil filter at every oil change. Replace the sump tank
breather/fill cap every 1000 operating hours.

There is no drain plug in the hydraulic sump tank. The

hydraulic fluid can be changed by one of the following
methods:
a. Removal of the hydraulic sump tank cover assembly and
pumping the fluid out by suction using a separate pump
and hose.
b. Pumping the fluid out by using the truck hydraulic
system. This method may be used most easily and
satisfactorily for routine changes of the fluid.

SM 556, Jan ‘96 Copyrighted Material PM-1 1

Intended for CLARK dealers only
Do not sell or distribute
Clark Sm 556 Service Manual
Full download: http://manualplace.com/download/clark-sm-556-service-manual/
Planned Maintenance

1. Fill/oil level dipstick plug. Also acts as the breather cap. Upright and Tilt Cylinder Lubrication
2. Drain plug. Clean the fittings and lubricate the tilt cylinder rod end
bushings, front end only.
Check the drive axle fluid level with the truck on a level
surface and oil at operating temperature. Clean the fittings and lubricate the upright trunnion bushings
(one fitting on top of trunnion, each side).
Remove the flmd level inspection plug located in the front
surface of the drive axle center housing. Wipe dipstick clean Lift Chains
and reinstall. Remove dipstick and examine. Oil level should Lubricate the entire length of the rail lift and carriage chains
be between the two marks on the dipstick. If oil level is low, with Clark Chain and Cable Lube.
add enough oil to bring oil level up to full mark on dipstick.
DO NOT OVERFILL. NOTE: Do not lubricate the carriage roller rails.
Add recommended fluid only, as required. Refer to Specifi-
cations for drive axle recommended oil specification.

Inspect the fill plug for damage. Replace as needed. Install

and tighten the plug.

IMPORTANT
Check the PM interval (operating hours), or the
condition of tbe oil to determine if the drive axle
fluid needs to be changed.

Drive Axle Fluid Change

Drain and replace the drive axle fluid every 1000 operating
hours. The oil should be drained when it is at operating
temperature. Put the truck in a level position. Block the
wheels to prevent truck from moving.

Inspect and clean the drive axle breather (air vent).

Truck Chassis Inspection and Lubrication

Lubrication aud inspection of truck chassis components,
including steer wheels and wheel bearings will be easier if the
rear of the truck is raised and blocked up under the frame.
RefertoMachineJackingandBlockingsectionforadditional
information.

A DANGER
Do not raise truck by lifting under the counter-
weight. Be sure to put blocking under the frame
to keep the truck safe.

Be sure to clean the grease fittings before lubricating and

remove the excess grease from all points after lubricating.

PM-12 Copyrighted Material SM 666, Jan’ 96

Intended for CLARK dealers only
Do not
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