Features and Benefits

1

• Features and Benefits

I.C. Products
Clark Simpson I.C. Product Manager
2

• CLARK Uprights

3

• CLARK Upright Features
• High-strength, low-alloy steel.
• Excellent fatigue life.
• Good weldability.
• High yield strength
• Nested I-channel (not flat-faced)
• Silent staging.
• Cylinders internally vented.
• Large view window.

4

• CLARK Upright Features
• Drop rail design for easy roller replacement.
• Low-glare black paint.
• Carriage and rail section stops.
• Canted rollers design.
• Over-sized rollers
• Available through parts to account for wear.
• Velocity fuse.
• Flow control.

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Why Does CLARK Use I-Channel?
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Why Does CLARK Use I-Channel? Shear Center
Location
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• Nested I-Channel
• Better arrangement of cylinders, chains and
  hosing to maximize view window width.
• Interlocking rails will not separate if roller
  fails.
• Can use wider sections without penalty. Stiffer
  upright design makes for less deflection and
  twisting.
• Better connection of tie-bars to rail sections.

8

• Nested I-Channel
• Allows use of external side thrust rollers
• Prevents inner rail from spreading rails with
  side loads.
• Less carriage twisting from side loads.
• Prevents carriage rollers from riding at edge of
  flange.
• Increased stiffness
• Better resistance to twisting
• Less deflection due to loads
• Longer fatigue life, less wear

9

• Silent Staging-Raising
• Cushioning on primary and secondary cylinders
  when raising, just prior to full extension.
• Oil is trapped and forced to bleed out slowly.
• No clanging during lifting.
• Avoid product damage.
• Longer component life.

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• Silent Staging-Raising

Air
OIL
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• Silent Staging-Lowering
• Cushioning on secondary cylinder when lowering,
  just prior to full retraction.
• Oil is trapped and forced to bleed out slowly,
  providing cushioning effect.
• No clanging during lowering.
• Avoid product damage.
• Longer component life.
• Not needed on primary cylinder since forks hit
  the ground.

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• Silent Staging-Secondary Cylinder- Lowering

Trapped Oil
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• Internally Vented Cylinders
• Seals designed to seep from high pressure to low
  pressure.
• Keeps fluid on top for cushioning.
• Caution Could run dry if wrong seal used.
• If excessive oil leaks past piston and is trapped
  on top side of piston, it will bleed back to
  pressure side via one-way valve.
• External return to tank not needed.

14

• Sealed Canted Rollers
• Roller face in full contact with rail flange.
• Increased contact area, reduces flange stress and
  bending.
• Radius of roller fits neatly in radius of rail.
• Reduces side-to-side free play.
• Eliminates need for slides or side thrust
  rollers.
• Reduces rattle.

15

• Shimable Rollers
• Can install shims behind roller to adjust
  clearance.
• Removes free play if wear occurs.
• Oversized Rollers
• Can install oversized rollers to account for
  flange face wear.
• Retains tight fit.
• Extends life of rail sections.

Shim
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• Negative Drop rails
• Allow rail rollers to be serviced without
  removing upright from truck or dismantling
  upright.
• Lift cylinders are disconnected and rails
  lowered to expose rollers for replacement or
  shimming.
• Minimizes time required to service upright.

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• Large View Window
• Nesting allows space for cylinders, hoses and
  chain.
• Maintains excellent view window even with 4-hose
  internal.
• Hoses and chains are over the top of the primary
  cylinder for max vision window.
• Lift chains share load, side-loading no problem

18

• CLARK Carriages

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• Carriage Features
• Six load rollers.
• External and/or internal side-thrust rollers.
• Heavy-duty fork bar sections.
• HSLA steel fork-bars and roller brackets.

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• Six Load Rollers
• Outermost rollers take load when in carrying
  position.
• Maximum spacing lowers load when load is highest
  
• Bouncing while traveling.
• Ground level pick-up.
• Innermost rollers take load when upright extended
  past free-lift.
• Not as much bouncing when upright is extended.
• Allows for competitive lowered heights.

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• Six Load Rollers

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• Side-Thrust Rollers
• Carriages have internal side- thrust rollers,
  external or both.
• More effective control of carriage under off-set
  loading conditions.
• Mounted on eccentric shaft that adjusts and locks
  into place.

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• Heavy-Duty Fork Bars and Load Roller Brackets
• Made from HSLA steel.
• Massive section size.
• Better impact strength.
• Holds up better in demanding operations.

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Fuel SystemsEPA 2004--EPA 2007
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• EPA 2004 Spark Ignited Engines
• Low Emissions of unburned Hydrocarbons, Oxides of
  Nitrogen and Carbon Monoxide
• Must meet requirements both new and throughout
  3500 hours of use, cannot degrade out of
  specification
• System must be tamper-proof so that mechanics
  cannot readjust and destroy fuel settings

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• The Basics
• Computer controlled fuel mixture using oxygen
  sensor
• Three-way catalyst further removes contaminants
• Patterned after automotive systems
• Similar to conventional LP systems with Trim
  Valve added
• Drive by wire

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• EPA 2007--Large Spark Ignited Engines (LSI)
• Similar to 2004 levels of HC Nox, Co during
  steady state running.
• Must meet requirements during transient
  conditions, (acceleration, deceleration, sudden
  load applied).
• System must be tamper-proof so that mechanics
  cannot readjust and destroy fuel settings
• Technology not much different from 2004 to 2007
• Venturi systems (Impco, Woodward, Aisan) will
  shorten response times to get back to stoich
• Major development is in testing to certify.

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• System Strengths
• Simplicity
• Only one additional fuel system component, Trim
  Valve all remaining fuel parts are conventional
• Trim valve meters air, not fuel
• Service with fault codes and manual-expensive
  tools not required
• Proven ECM
• Over 100,000 in use
• Manufactured by Motorola quality, consistency
  excellent
• Self-Correcting
• Adaptive Learn allows adjusting for wear, fuel
  deposits
• Adapts to specific application-truck
  configuration, altitude, operation

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• Fabricated Axle Beam
• High strength ASTM A-572 steel
• good weldability, high impact strength
• Extra thick top plate
• prevents deflection and misalignment of kingpin
  bearing for long life
• Deep I-Beam style design
• prevents bending under extreme conditions
• Fully machined
• results in accurate bearing alignment, steering
  geometry, long life

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• Knuckle
• Alloy steel forging
• AISI 4140 forging heat treated for superior
  fatigue life and impact

• Steer Linkage
• Sealed, greaseable, spherical bearings
• Double shear link pins

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• Kingpin and Bearings
• Tapered Roller bearings
• Resist impact loads without fracture, high
  capacity, long life
• Precision bearing adjustment
• Castellated nut allows precise bearing
  adjustment, no bearing play
• Captured kingpin design
• Prevents deflection of top and bottom plates,
  prevents uneven bearing loading
• Double metal seal
• Excludes dirt, fibers, retains grease

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• Design Goals
• Enhance model family ergonomics
• Improved cushion model footprint
• Design a truck reflecting Built To Last
• Improve performance

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• Cushion Models
• C15C 3000 lb _at_ 24 L.C.
• C18C 3500 lb _at_ 24 L.C.
• C20sC 4000 lb _at_ 24 L.C.

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• Pneumatic Models
• C15 3000 lb _at_ 24 L.C.
• C18 3500 lb _at_ 24 L.C.
• C20s 4000 lb _at_ 24 L.C.

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Dimensional Comparisons-Cushion
C15C CMC 15
Toyota Mitsubishi Head room 39.5 37.5
37.8 Knee room 29.5 27.0
29.5 Knee room, sides 34 31 30.0 Foot
room, center 13.5 12.5 17.0 Foot room,
sides 18.0 12.5 18.0 Seat Back to Steer
Wheel 17/23 13/19 15/20 OAW 37.0 40.0
37.0 38.2 Length 80.2 80.53
82.3 82.0 Height over guard 81.1 79.1
80.1 81.1 Load Center Distance 14.9 14.63
15.7 15.3 Drawbar Pull 3913 3530
3750 4245
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Dimensional Comparisons-Pneumatic
C15 CMP 15
Toyota Mitsubishi Head room 40.25
37.5 40.1 Knee room 31.0
27.0 31.0 Knee room,
sides 37.5 29.0 33.0 Foot
room, center 16.0 12.5 17.0
19.0 Foot room, sides 21.0 12.5 18.0
13.0 Seat Back to Steer
Wheel 17/23 13/19 15/20
15/21 OAW 42.1 43.7 42.2
42.0 Length 86.4 85.5 88.4
89.0 Height over guard 83.5 81.0 81.9
83.0 Load Center Distance 15.5 15.0
15.8 15.7 Drawbar Pull 3908 2980
3950 4125
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Styling Comparison
C15C
C25C
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Model Commonality Mitsu. 4G63 2.0L same base engine as CMC/CMP15/20S
EPA compliant fuel system common with GEN2
TA12 transmission w/ gearing improvements common with CMC15/20S, CMP15/20S, GCX/GPX12/17E
Base upright common with TMG including hosing kits, carriages, LBR's
Instrument panel with all improvements, common with GEN2
Tilt steering column / wheel common with GEN2
Hood latch system similar to CMC / CMP No Cables
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• Operator Compartment

• 80 dba - weighted average at operators ear -
  various engine speeds and periods of time per
  ASME test requirements
• Designed for 95 percentile person - additional
  headroom, seat travel

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Operator Compartment Comparison
C15C
CMC 15
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Operator Compartment Comparison
Mitsubishi
Toyota
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• Operator Compartment
• Welded Integral Structure
• Structural rigidity
• Optimum Visibility
• Forward/upward
• Modular design
• Simple removal
• (4 bolts/wiring/plumbing)

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• Operator Compartment
• Welded, integral construction
• Long lasting, more strength

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• Cell mounted on rubber isolators
• -Reduced vibration
• -Less fatigue

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• Operator Compartment
• Pneumatic same as Gen 2
• Open steps both sides
• Cowl-mounted levers
• Cushion similar
• Vertical dimensions identical
• Right side step only
• 4.5 in narrower
• Cowl, rear guardleg more vertical
• 18 in foot space vs 21

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• Operator Compartment
• Low Step
• 15.2 in height on cushion
• Easy on, easy off
• Non-slip tread
• Excellent traction
• Large step
• 5 in. deep, even fits boots

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• Operator Compartment
• Low Step
• -16 in. pneumatic
• -Easy on, easy off - either side
• Non-slip treads
• -Excellent traction
• Large steps
• -5 in. deep, even fits boots

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• Operator Compartment
• Floor plate - no tools required for removal
• Uncluttered foot area
• Two-piece hinged construction - always lays flat
• Floormat - thick, molded
• Reduces vibration
• Reduces noise
• Cushioned comfortable

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• Operator Compartment
• Brake pedals - 2-pedal system
• - Proven most effective in lift truck
  operation
• Left inching brake - slow forward travel -
  maximum lift speeds
• Unmatched productivity
• Right brake - dedicated
• Prevents roll-back
• Operator has pedal choice
• Operator has full control

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• Operator Compartment
• Park Brake
• Foot Operated
• Uses strong leg muscles
• Easy operation
• Fingertip release
• Low effort
• Electric transmission interrupt
• Prevents driving against park brake

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• Operator Compartment
• Electrical fuse panel mounted on front cowl
• Easy access

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• Operator Compartment
• Easy to operate Hood Latch
• No Cables
• Simple Adjustment

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• Operator Compartment
• Soft touch control valve levers
• Ergonomically correct
• Easy to use, less fatigue
• Single aux valve standard
• Adding attachments is made easier

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• Operator Compartment
• Directional control electrically operated
• No adjustments necessary
• Fingertip operation
• Short travel
• Low effort

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• Operator Compartment
• 2 front headlights on the OHG are standard
• With the order of one rear accessory light the
  complete harness is included- optional additional
  lights can easily be connected
• Mounted inside the profile of the overhead guard

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• Instrument Panel Features
• Full LED/digital display
• No mechanical parts to replace
• 3 pieces top/bottom housing, circuit board
• Rugged design
• Common with GEN2
• Hi-impact resistant polymer
• Sealed with gasket -
• Truck can be steam cleaned
• Circuit board is coated with moisture resistant
  film
• Heat and extreme cold protected
• Ultra Violet protected-
• Sunlight does not affect surface

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• Instrument Panel
• Design features
• -No maintenance instrument panel
• -Eliminate relays and switches for lights
• -No bulbs to burn out
• -Horn will sound if the park brake not set when
  key is turned off
• -Powertrain protection
• -Liquid Crystal Display (LCD) hour meter
• -Maintenance interval indicator

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• Instrument Panel
• Maintenance interval programmable to customer
  requirements
• -Can be set to 50 hour increments
• -Time remaining until scheduled service indicated
  on LED display upon each start
• -Maintenance indicator illuminates when scheduled
• maintenance is due
• Operator and Maintenance personnel have clear
  indication of truck service status
• Facilitates tracking of fleet maintenance

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• Instrument Panel
• Features
• Negligible current draw with Key Off (.010 amp).
  Typical automotive practice is .007to .012 amps.
• Positive starter lockout-engine must be stopped
  for 2 seconds before starter will crank
• Failsafe hour meter-cannot lose hours due to
  faults
• Key switch turns off electrical system
• Programmable headlight and work light function
• Key switch controlled accessory fuse block
• If key switch is left on with engine off, lights
  shut off after 5 minutes
• Reverse polarity protection
• Voltage spike protection
• Short circuit protection-shorted circuit
  displayed as fault code

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• Instrument Panel
• Major Component
• Covered by 2 year / 4000 hour Standard Owner
  Protection Warranty

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• Shutdown functions - protects investment
• Low oil pressure
• High engine coolant temperature
• High transmission oil temperature
• Fuel system malfunction

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Powertrain
66

• TA-12 Transaxle
• Electric Solenoid controlled forward-reverse
  shifting
• Eliminates mechanical linkage that requires
  adjustment and high effort
• Modulated clutch engagement gradually increases
  clutch pressure
• Smooth, jerk-free direction changes
• No drive park brake
• Applying park brake puts transmission in neutral
• Hydraulic inching control
• Allows smooth, positive transmission engagement
  at high engine speeds and low travel speeds

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• TA-12 Transaxle
• TA-18 Charge Pump
• TA-18 Cooler Bypass Circuit
• Speeds convertor filling on start-up
• Prevents Morning Sickness
• Cast-Shoe, Perrot-Style drum and shoe brakes
• Long life
• Low noise
• Single-stage master cylinder
• Higher gear ratio for pneumatic models

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• Engine
• 2.0 liter dynamic internally balanced, overhead
  cam Mitsubishi engine
• Proven reliability on current trucks
• Simple design and fewer parts
• EPA compliant low emission fuel system
• Improved acceleration
• Improved fuel economy
• Increased speed on long runs
• Minimal CO, HC, NOx emissions

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• Engine
• Air intake System
• High air intake
• - Provides clean and cooler air for engine, also
  location reduces noise level

70

• Engine Air Intake System
• High efficiency 2 stage air intake system
• Long engine life
• Air restriction indicator is standard equipment
• Visual warning when air filter needs service
• Optional safety element and pre-cleaner
• Additional protection for engine in dirty
  environments
• Operators cell is pre-punched for field
  installed pre-cleaner

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• Engine Cooling System
• 3 row, 8 fin per inch, 313 sq. in. open core with
  plate/fin design and 9 plate water to oil cooler
• Reduced plugging, better tolerance for pushing
  loads, high cycle operations

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• Engine Cooling System
• Venturi type shroud and 7 blade plastic fan
• High air volume, low noise cooling system
• Radiator hand guard standard equipment
• Protection from accidental injury in radiator
• Radiator fan centered
• More efficient air flow

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• Over 900 parts common with existing models
• For example, hosing, upright components and
  sideshifter common with TMG
• Pneumatic operator compartment, steering
  components, pedals, floorboard, hood
• Transaxle gearing, brakes, axle components

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• Optional Equipment
• Convenience console
• Cloth suspension seats
• Mirrors
• Swing-down LP bracket
• Seat activated engine shutdown protection
• Mounting holes provided for options standard on
  cell
• Speed Control

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• Optional Full Suspension Seat
• Full 60 mm travel
• Constant ride height
• Wide weight range--designed for operators from 90
  to 350 lb.
• Dial in weight adjustment--put the pointer on
  your weight.
• Easy adjustment--no springs are compressed
• Easy cushion replacement--two screws and no
  dismantling suspension parts.

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• Gen 2 Features and Benefits

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• Operator Compartment
• Optional factory installed cab
• One piece door
• Folds back for easy access to seat deck
• No side pillar
• Better visibility to the side
• Heater mounted on right-side door
• No obstructions on floor or front cowl
• Front and rear wiper with washer
• AM-FM Radio

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• Akebono Brake System
• Automotive style drum and hub easily removable
  drum
• Ensures quick Serviceability
• Basic brake used by Toyota, Nissan, Mitsubishi,
  Hyster and Yale. Clark lining has improved
  friction and wear characteristics
• Proven in many other lift trucks
• New heavier backing plate, reinforced shoe
  anchor, larger shoe tables

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• Transaxle Controls
• Electric Solenoid controlled forward-reverse
  shifting
• Eliminates mechanical linkage that requires
  adjustment and high effort
• Modulated clutch engagement gradually increases
  clutch pressure
• Smooth, jerk-free direction changes
• No drive park brake
• Applying park brake puts transmission in neutral

80

• Transaxle Seep Control
• Viton Seal Kit 934671 for Charge Pump
• Applications with hard usage, high temperatures,
  long hours
• Seals both pump gearing and suction/supply
  connection
• Close fit Dipstick Tube Kit 1813270
• Machined case insert
• Tighter tolerance on fit
• Viton O-ring with back-up ring

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• CGC 40/70 Features and Benefits

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• Engine
• GM 4.3 liter (262 CID)
• Industry standard
• Cast iron head block
• Proven durability
• Hydraulic lifters
• No maintenance
• Quiet running
• Hardened valve seats faces
• Long valve life on LP

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• Engine
• Single balance shaft
• Reduces secondary engine vibration, improves
  operator comfort
• Low speed, high torque industrial engine

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• Brake System
• Direct power assist system
• Steering pump provides hydraulic power
• Full flow brake valve meters hydraulic oil to
  brakes
• No reservoir required- oil provided by hydraulic
  system
• Brakes can be bled by simply opening bleeder with
  engine running
• Later versions have reduced kickback

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• Service Brake
• Higher temperature Cosid lining material
• Longer life in high cycle applications
• Larger lining area on axle end side of disc
• Longer life, less chance of damage to axle
  housing
• High temperature Viton piston seals
• Reduced leakage, longer life in high cycle
  applications
• Plated steel pistons
• Closer seal tolerances

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• Service Brake
• Inspection port added
• Allows easy access to view lining and rotor to
  allow inexpensive lining change without damage to
  brake pistons, discs

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• Parking Brake
• Separate drum-type parking brake
• Not affected by service brakes
• Applies to transmission shaft
• Multiples holding power
• Quick change lining
• Drum can be removed and lining changed without
  removing any other components

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• Steer Axle
• Double shear pins and linkage
• No tapered tie rod ends
• Sealed spherical bearings
• Interchangeable with old style axle

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• CMP 450 Features and Benefits

90

• Transaxle
• Pressure lubricated tapered roller bearings
  throughout the transmission
• Long life, good heat dissipation
• Helical gearing
• Low noise, high torque capacity
• Smooth inching, same inching components from
  TA-12,18
• Improved oil flow, clutch spring retainer,
  bearing adjustment

Helical Gears
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• Transaxle
• Special Reman program
• New turbine shaft with larger drilling, increased
  oil flow
• Reworked Lube relief for more oil flow
• Improved clutch spring retainer
• Precision bearing adjustment
• Flow and pressure tested
• Order 930234REM

Helical Gears
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CMP 20,25,30 Features
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• Simple Design-Durable Components
• Rugged curved beam overhead guard
• Reliable Engines
• Mitsubishi 4G-64 EPA 2004 compliant LPG
• Yanmar 4TNV94 diesel
• Automatic engine shutdown from low oil pressure
  or high coolant temperature on LPG engines.
• Long-Life Powertrain, steer axle

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• Simple Design-Durable Components
• Proven TA-18 Transmission
• Electric shift control
• Long Lasting, Perrot style brakes-same as
  CGC20/30
• Two-stage master cylinder

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CMP 50,60,70,75S Features
96

• Simple Design-Durable Components
• Proven T-12000 Dana/Spicer Transmission, 3 speed
• Electronic Gear Selector
• Prevents Fwd-Rev shifts until speed is less that
  1 mph
• Prevents overspeed downshifts
• Starts in 2nd gear
• Twist grip for up and downshifts
• Self diagnosing

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• Simple Design-Durable Components
• Pressure-compensated hydraulic valve
• Hood mounted levers mounted directly on valve
• Improve feathering
• Reduced lever effort
• Integral counterbalance in tilt spool
• Minimal lift and tilt drift
• Reduced horsepower loss
• Simultaneous spool function

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