PDF Service Manual Clark GEX 40 45 50 Forklift - 4 MB
This is the complete service manual for the Clark GEX 40, 45, and 50 series electric forklifts.
It provides factory-authorized procedures for diagnostics, repairs, and maintenance.
The manual is filled with detailed diagrams, specifications, and step-by-step instructions to guide technicians through any service task.
This is an indispensable resource for keeping your Clark electric forklift fleet running reliably.
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--- Page 1 ---
GEX 40/45/50
RATED CAPACITY : 4000~4990kg
Part No. 8106230
Book No. SM 889 (Rev 1.4)
Aug. 2018
CLARK MATERIAL HANDLING INTERNATIONAL
215, Ojeong-ro, Bucheon-Si, Gyeonggi-do, Korea
Tel: 82-32-680-6300 [ www.clarkmhc.co.kr ]
COPYRIGHT WARNING!
Do not sell or distribute, information for CLARK dealers only.
--- Page 3 ---
Group SA, Safe Maintenance
Section 2
Lifting, Jacking, and Blocking
Raising Drive Wheels ............................................ 2
Chaning the Upright in Raised Position .............. 3
Raised Rear of Truck ............................................ 3
Raised Entire Truck .............................................. 4
Shipping Tie-Down Instructions .......................... 5
! WARNING
Lifting or jacking any large piece of equipment such as a fork truck presents obvious hazards.
It must be done with great care and forethought. Consult the truck weight information in
Group 40, Specifications, to ensure that your lifting equipment is of adequate capacity.
SM 889 Lifting, Jacking, and Blocking • SA-2-1
COPYRIGHT WARNING!
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--- Page 4 ---
Group PS, Periodic Service
“Periodic Service” and “Planned Main- Determining Maintenance Intervals
tenance” Time intervals on the charts on the next four pages and
elsewhere in this manual relate to truck operating hours as
The term “periodic service” includes all maintenance
recorded on the hourmeter, and are based on experience
tasks that should be performed on a regularly scheduled
Clark has found to be convenient and suitable under nor-
basis. mal operation. Standard operating condition classifica-
The term “Planned Maintenance” indicates a formalized tions are:
program of basic inspections, adjustments, and lubrica- Normal Operation: Eight-hour material handling, mostly
tions that the Clark service organization provides custom- in buildings or in clean, open air on clean, paved surfaces.
ers at a prescribed interval, usually 500 hours. The
recommended basic “Planned Maintenance” procedure is Severe Operation: Prolonged operating hours or constant
given in Section 2 of this Group. usage.
The current Section,”Maintenance Schedules,” specifies Extreme Operation:
all maintenance tasks.including Planned Maintenance • In sandy or dusty locations, such as cement plants,
tasks.that should be performed periodically, and suggests
lumber mills, and coal dust or stone crushing sites.
intervals at which they should be performed.
• High-temperature locations, such as steel mills and
foundries.
• Sudden temperature changes, such as constant trips
from buildings into the open air, or in refrigeration
plants.
IMPORTANT
MAINTENANCE INTERVALS. If the lift
truck is used in severe or extreme operating
conditions, the maintenance intervals should
be shortened accordingly. Put upright in ver-
tical position and fully lower the forks or
attachment.
Service Chart/Lubrication Points
This decal is a basic guide to periodic maintenance inter-
vals and tasks. A more detailed chart is supplied on the
next page.
PS-1-2 • Maintenance Schedule SM 889
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--- Page 5 ---
Group PS, Periodic Service
Check Controlled Plugging (Braking)
! WARNING
Check all around to be sure that your 1. Operate the truck with parking brake set. It should
intended path of travel is clear of obstruc- not move. Release parking brake.
tions and pedestrians. 2. Operaten the truck at a slow speed in a forward direc-
tion of travel. Reverse direction of travel. The truck
• Drive the truck forward in a straight line at a high should slow down to a smooth controlled stop, and
rate of speed. Listen for unusual drive train noise. accelerate normally in the opposite direction.
Stop truck. If plugging is as specified, then repeat the procedure
• Check acceleration from a stop to top travel speed. at high speed. The truck should come to a smooth
Acceleration should be smooth without hesitation. controlled stop in approximately 20 feet (6.10 mm)
Stop the truck. Repeat procedure in reverse. with accelerator in maximum travel position.
• Report condition on PM report form. 3. Repeat the procedure at high speed with the direction
lever moved in reverse direction.
If plugging (braking) is not as specified, refer to the
adjustment instructions in Group 19 of this manual.
Report condition to designated authority.
Check Accelerator
1. After checking to see that you have a clear path
ahead, drive the truck in a straight line at a high rate
of speed in a forward direction of travel. Listen for
unusual drive train noise. Stop truck
2. Check acceleration from a stand still condition to top
Test Drive Truck with Load travel speed. Acceleration should be smooth without
hesitation.
NOTE 3. After checking to see that you have a clear path
Conduct these tests with a rated capacity behind, drive the truck in reverse. Check acceleration
load, if possible. from stand still condition through top travel speed.
Acceleration should be smooth.
Test the truck for proper operation and drive train function
Check the accelerator pedal while conducting the speed
by driving the truck in both the forward and reverse direc-
range tests. It must move easily and smoothly throughout
tions. Drive first in a straight line and slowly through a the acceleration stroke and return without binding. There
series of full right and left turns. Then repeat, driving in should be no restriction to movement on either accelera-
opposite direction. tion or deceleration.
Carry Load Low & Tilt Back
Test for correct function of the transistor control.
SM 889 Planned Maintenance • PS-2-7
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--- Page 6 ---
GROUP 12
GROUP 12
BATTERY
Battery Service ................................................. Section 1
SM 889 Group 12, BATTERY
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--- Page 7 ---
Group 13, Wiring, Switches, and Instruments
Standard Truck
OpuTY_\]^P
13-1-2 • Schematic Electric Circuit Diagrams SM 889
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--- Page 8 ---
Group 13, Wiring, Switches, and Instruments
Main Harness - (1/6)
zpT[`]_]OXV]P
13-3-6 • Wiring and Cables SM 889
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--- Page 9 ---
Group 13, Wiring, Switches, and Instruments
Accessory Harness and Components - (1/2)
zpT[`]__OXVYP
13-3-16 • Wiring and Cables SM 889
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--- Page 10 ---
Group 13, Wiring, Switches, and Instruments
Mini Lever (Option) - 2/2
czpT\X\_`GYVYe
13-3-26 • Wiring and Cables SM 889
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--- Page 11 ---
Group 13, Wiring, Switches, and Instruments
• Display will read "MIN VACC MAX"
• Move the lift lever to full raised position
• Release the lift lever to the neutral position
• Press the “OUT” button
• Display will read "ARE YOU SURE"
"YES=ENTER" "NO=OUT"
• Press "ENTER" button (this stores the value for
MIN and MAX lift potentiometer voltage)
• Display will show new settings
• Press the “OUT” button
• Display will read "MAIN MENU" “PROGRAM
VACC”
• Press "OUT button
• Display will show software version
• Turn the key switch Off and remove the tester cord
from the control
• Plug the dash display harness into the "B" plug of
the control
• Lower truck to the ground and test drive truck
13-4-8 • Switches and Sensors SM 889
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--- Page 12 ---
Group 13, Wiring, Switches, and Instruments
13-5-10 • Instrument Panel SM 889
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--- Page 13 ---
Group 13, Wiring, Switches, and Instruments
13-5-20 • Instrument Panel SM 889
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--- Page 14 ---
GROUP 16
GROUP 16
ELECTRICAL MOTORS
Motor Specifications And Descriptions ......... Section 1
Drive Motor Overhaul ...................................... Section 2
Pump Motor Overhaul ..................................... Section 3
SM 889 Group 16, ELECTRICAL MOTORS
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--- Page 15 ---
GROUP 17
GROUP 17
ELECTRICAL CONTACTORS
Contactors Specifications and Overhaul .......... Section 1
SM 889 Group 17, ELECTRICAL CONTACTORS
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--- Page 16 ---
Group 19, Motor Controls
Description of Power Connections
-B Negative of the battery
+BT Positive of the battery; if the power fuse is not present,positive cable coming from the
Line contactor must be connected to this power connection
Um: Vm; Wm Connection bars for the three phases of the right motor; follow this sequence and the indi-
cation on the motor.
Us, Vs, Ws Connection bars for the three phases of the left motor; follow this sequence and the indica-
tion on the motor.
SM 889 Description • 19-1-7
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--- Page 17 ---
Group 19, Motor Controls
PARAMETERS PROGRAM LEVEL
Unit 0 1 2 3 4 5 6 7 8 9
Acceleration Delay (*) Sec. 1 1.5 1.8 2.0 2.5 3 3.5 4 4.5 5
Release Braking (**) Sec. 25 20 18 15 10 8 6 4 3 2
Inversion Braking (**) Sec. 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1
Pedal Braking (**) Sec. 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1
Speed Limit Barking (**) Sec. 8.9 8.3 7.7 7.1 6.6 6 5.5 4.9 4.4 3.8
Brake Cutback (**) Sec. 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1
Curve Braking Sec. 1.5 1.4 1.3 1.2 1.1 1 0.9 0.8 0.7 0.6
Max speed Forw Hz 0 ~ 200
Max speed Back Hz 0 ~ 200
Dual
Cutback Speed % 10 20 30 40 50 60 70 80 90 100
AC2
PW(8 Cutback Speed 2 % 0 ~ 100
0V) Curve Cutback % 0 ~ 100
Curve Cutback #1 % 55 60 65 70 75 80 85 90 95 100
Frequency Creep Hz 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 3
Maximum Current % IMAX 47 53 59 65 71 76 82 88 94 100
Auxiliary Time Sec. 0 1.5 3.0 4.5 6.0 7.5 9.0 10.5 12 15
Seat Micro Delay Sec. 2.0 2.1 2.3 2.4 2.6 2.8 2.9 3.1 3.3 3.5
Acc. Smooth Sec. 1.0 1.2 1.5 1.7 2.0 2.2 2.5 2.7 3.0 3.5
Inv. Smooth Sec. 1.0 1.2 1.5 1.7 2.0 2.2 2.5 2.7 3.0 3.5
Stop Smooth Hz 5 7 10 12 15 17 20 22 25 27
Idle time Min 1 2 3 4 6 8 10 12 15 20
(***)
*)The acceleration time shown is the time from 0 Hz to 100 Hz. This is theGideal ramp calculated by the software; the real
ramp could change as afunction of motor control parameter setting and, obviously, a function of the load.
(**)The braking feature is base on deceleration ramps. The value shown in the table is the time to decrease the speed from
100 Hz to 0 Hz. This is the ideal ramp calculated by the software; the real ramp could change as afunction of motor con-
trol parameter setting and, obviously, a function of the load.
(***)(Always closed).
PARAMETERS SPEED EMPTY MPH
MPH 1.03 1.98 3.01 4.05 4.99 6.03 6.97 8.01 9.04 9.99 11.02 11.97 12.49
(Km/h) (1.66) (3.19) (4.85) (6.51) (8.04) (9.70) (11.22) (12.89) (14.55) (16.07) (17.74) (19.26) (20.09)
MAX SPEED
HZ 12 23 35 47 58 70 81 93 105 116 128 139 145
FORWARD
MAX SPEED
HZ 12 23 35 47 58 70 81 93 105 116 128 139 145
REVERSE
NOTE
Maximum speed for the GEX40/50 can not exceed 145 Hz.
Maximum speeds are adjustable from 0 Hz to 145 Hz in 1 Hz increments. Forward speed and reverse speeds can be set
independently (Forward speed can be set to 8 MPH and Reverse speed can be set at 5MPH if desired)
19-2-8 • Control Programming SM 889
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--- Page 18 ---
Group 19, Motor Controls
12) AUX2 SPEED SWITCH:
ON /+BV = input active, switch closed.
OFF / GND = input non-active, switch open.
13) AUX3 SPEED SWITCH:
ON /+BV = input active, switch closed.
OFF / GND = input non-active, switch open.
14) HRYDRO SPEED REQ.:
ON /+BV = input active, switch closed.
OFF / GND = input non-active, switch open.
15) VOLTAGE BOOSTER: This is the booster voltage supplied to the motor in load condition; It is expressed in a
percentage of the full voltage.
16) BATTERY VOLTAGE: Level of the battery voltage measured at the input of the key switch.
17) COS FI: This is cosj (real time calculated) of the motor.
18) BATTERY CURRENT: This is the battery current (not measured but calculated.
19) BATTERY CHARGE: The percentage charge level of the battery
OTHER HANDSET FUNCTIONS
Save and Restore Function
SAVE Function allows the transfer of controller parameters to the PC memory. With this function, a copy of the control-
ler's set of parameters can be retained in a Pc and downloaded to another controller (see restore).
RESTORE Function allows you to download controller parameters from the PC memory to the controller Eeprom. Thus
a copy of the parameters stored in the Pc can be downloaded in a controller avoiding the parameter setting operation.
SETUP for INSTALLING A NEW CONTROL PANEL
Sequence for AC Traction Controller Setting
When the "Key Switch" is turned ON, if no faults are present, the Zapi Handset Display will be showing the standard
Opening Display.
If the controller is not configured to your requirements, follow the sequence detailed below. Remember to cycle the key
switch if you make any changes to the controller configuration.
1) Select the options required.
2) Select and set battery voltage.
3) Confirm correct installation of all wires. Use Handset's TESTER function to assist.
4) Perform the accelerator signal acquisition procedure using the Handset "PROGRAM VACC".(See Group 13, Sec-
tion 4 for programming procedures).
5) Perform the steering potentiometer signal acquisition, using the parameters in "Adjustment" menu.(See Group 13,
Section 4 for programming procedures).
Remember: when turning the wheel to the right the voltage will increase.
19-2-18 • Control Programming SM 889
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--- Page 19 ---
Group 19, Motor Controls
Fault Action
Fault Name Fault Description Control Troubleshooting
Code Required
86 "PEDAL Fault in Accelera- SLAVE • Check accelerator wiring and connections Repair wiring as
WIRE KO" tor negative for opens required
(NPOT) Input cir- • Check accelerator input voltage using If accelerator
cuit. PcConsole handset in tester mode (voltage voltage is greater
This fault indi- should range from 2.0 VDC to approx. 0.30 than 2.0 VDC or
cates that accelera- VDC). less than 0.30
tor wiring (NPOT VDC replace
• Check voltage between NPOT (pin C20)
or PPOT) wire is accelerator
Battery Neg. (pin C12) voltage should be
open.
greater than 0.30 VDC. This voltage If voltage is not
should remain constant all the way through greater than 0.3
the pedal stroke. VDC proceed to
the next step
• Check if controller input NPOT (C20) is
good. Remove pins (C20, C21, C8) from If it sill read 0
connector, now connect a 4.7K ohm resis- VDC the control-
tor between PPOT (C8) and NPOT (C20) ler has a failed
now plug the connector back in, this will input
polarize NPOT. Now check voltage If it reads cor-
between (C12) -Batt and (C20) NPOT the rectly 0.6 VDC
reading should be approx. 0.6 VDC the problem is in
the accelerator or
the harness
87 "WATCH- Watchdog circuit SLAVE • It is a self-diagnosing test within the logic
DOG" has been triggered between Master and Slave micro controllers.
• This fault could also be caused by a Can-
bus malfunction, which blinds Master -
Slave communication. So , before replac-
ing the controller , check the Canbus
88 “CHOPPER FET is running SLAVE • XXXX
RUNNING”
96 "LOGIC Failure in overload SLAVE • Fault in the hardware section of the con- Replace con-
FAILURE protection hw cir- troller that manages the hardware current troller
#3 cuit protection.
97 "LOGIC Failure in U,V,W SLAVE • Fault in the hardware section of the con- Replace con-
FAILURE voltage feedback troller that manages the phase 's voltage troller
#2 circuit feedback.
• Line contactor not closing, check parame-
ter setting for main contactor.
98 "LOGIC An over voltage or SLAVE • This fault signals that the under voltage / over
FAILURE under voltage con- voltage protection interrupts been triggered
#1 dition has been • A real under voltage / over voltage situa-
detected tion happened.
• Verify battery setting.
• Fault in the hardware section of the con-
troller that manages the over voltage pro-
tection. Replace logic Card.
• Possible plugging in or unplugging of bat-
tery or charger with the key switch on.
SM 889 CONTROL TROUBLESHOOTING • 19-3-9
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--- Page 20 ---
Group 19, Motor Controls
Fault Action
Fault Name Fault Description Control Troubleshooting
Code Required
249 "THERMIC Warning: Master MASTER • The range of the temperature sensor is
SENSOR temperature sensor always checked and a warning is signaled
KO" is our of range if it is out of range. This fault will reduce
the maximum current output of the control-
ler to 50%.
253 "AUX OUT- EB coil driver MASTER • The microprocessor checks the driver of
PUT KO" shorted or open the electromechanical brake coil. If the
(Not used) status of the driver output does not corre-
spond to the signal coming from the micro-
processor, the fault is signaled. It is
suggested to check for an external short or
a low impedance pull-down between
NAUX (C31) and -Batt. Replace con-
• If no external cause is found troller
255 "HAND- Handbrake switch MASTER • Indicate that handbrake is activated
Repair wiring or
BRAKE" closed • Check wiring and handbrake switch. replace switch if
needed
Blank "DASH DIS- Dash Display MASTER • Check 5 volt power supply for dash display Replace 5 V
PLAY" blank If no 5 volts power supply
• Check wiring and connector at control and Replace dash
display. If not wiring or connections display
SM 889 CONTROL TROUBLESHOOTING • 19-3-19
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--- Page 21 ---
Group 19, Motor Controls
COB-ID ID-Name Byte-Nr. Function Data Type Value Meaning
DOWNLOAD (WRITE IN CONTROLLER) PUMP
0 SDO specifier U8 0x22 initiate download request expedited
1 Index OD U16 Index object
0x615 DUAL_SDO_rx
3 Subindex OD U8 Subindex object
4 Data U32 Value Data
0 SDO Specifier U8 0x60 initiate download response expedited
1 Index U16 Index object
0x595 DUAL_SDO_tx
3 Subindex U8 Subindex object
4 Data U32 0 Data
UPLOAD (READ IN CONTROLLER) PUMP
0 SDO specifier U8 0x40 initiate upload request expedited
1 Index OD U16 Index object
0x615 DUAL_SDO_rx
3 Subindex OD U8 Subindex object
4 Data U32 0 Data
0 SDO Specifier U8 0x43 initiate upload response expedited
1 Index U16 Index object
0x595 DUAL_SDO_tx
3 Subindex U8 Subindex object
4 Data U32 Value Data
SM 889 CAN - Bus addresses • 19-5-3
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--- Page 23 ---
Group 20, Drive Axle
Section 6
Brake installation and maintenance
The brakes chamber shares the reduction gear oil and it is The M10x1 plug is used as connection to the hydraulic
continuously feeded during the working processing. service brake circuit.