Clark TMX12-25 EPX16-18 Electric Forklift Service Manual SM-715 2005 – PDF Download

Description

CLARK TMX12-25 & EPX16-18 Electric Forklift Service Manual – SM-715

This is the complete CLARK service manual for the TMX12-25 and EPX16-18 electric forklift series, Book No. SM-715, Part No. 8037870, published June 2005. It is the same manual issued to CLARK service technicians and covers every major system on these electric trucks: Dual AC traction and pump motor controls, drive axle, brakes, steering, hydraulic system, uprights, tilt cylinders, battery, wiring and full specifications. Whether you are servicing a TMX 12, TMX 15, TMX 20, TMX 25, EPX16 or EPX18, this PDF gives you the procedures, torque values and diagnostics you need to do the job correctly.

File Details

• Manual Type: Service Manual
• Brand: CLARK
• Models Covered: TMX 12-25, EPX 16-18 (electric forklifts)
• Language: English
• File Format: PDF
• Page Count: 485
• Book No.: SM-715
• Part No.: 8037870
• Publication Date: June 2005

Chapters Covered

• SA – Safe Maintenance
• PS – Periodic Service
• 12 – Battery
• 13 – Wiring, Switches, and Instruments
• 16 – Electric Motors
• 17 – Contactors
• 19 – Motor Controls
• 20 – Drive Axle
• 22 – Wheels and Tires
• 23 – Brake System
• 25/26 – Steer System
• 29/30 – Hydraulic System
• 32 – Tilt Cylinders
• 34 – Uprights
• 38 – Counterweight and Chassis
• 40 – Specifications

SA – Safe Maintenance

Safety signs and messages, safe maintenance practices, lifting and jacking procedures, blocking the truck, chaining the upright in the raised position, raising drive wheels, raising rear of truck, raising entire truck, shipping tie-down instructions and towing procedures. This group includes specific warnings for counterweight handling and tip-over prevention.

PS – Periodic Service

Maintenance schedules, the Planned Maintenance (PM) program, PM inspection form and determining maintenance intervals for normal, severe and extreme operating conditions. Includes the TMX and EPX service chart/lubrication points diagrams with detailed decal references, plus recommended periodic service schedule tables covering 50-hour through 2000-hour intervals. The PM program walks through external inspection, operational checks, internal inspection, fluid and filter service, air cleaning, minor adjustments, chain adjustments, racking adjustments and critical fastener torque checks.

12 – Battery

Battery service including removal, maintenance, maximum battery life, vents, cleaning, charging, electrolyte, compartment cleaning, replacement, installation, record keeping, specific gravity test, load test and connector/negative terminal/static chain installation. Includes safety warnings for acid handling, explosive gas, and proper lifting equipment.

13 – Wiring, Switches, and Instruments

Schematic electric circuit diagrams for both TMX and EPX trucks, general electrical service tips, wiring and cable routing, switches and sensors (accelerator, brake, parking brake, seat, direction control, lift/tilt pump switches and steer angle sensor), and instrument panel operation. Includes controller connector locations, capacitor discharge procedure, torque wrench usage, wire harness identification and connector assembly guidelines.

16 – Electric Motors

Motor specifications and descriptions for the two drive motors and the lift/steer pump motor, including frame sizes, weights, bearing details, terminal torque, rotor and stator dimensions, encoder specifications and thermal protection. Drive motor overhaul covers removal, installation, inspection, cleanliness, encoder bearing replacement and motor reassembly. Pump motor overhaul follows the same structure.

17 – Contactors

Contactor specifications (drive line and pump line), removal and replacement procedures, and overhaul including contact tip inspection, replacement and assembly notes.

19 – Motor Controls

Dual AC traction control and single AC pump control description. Programming and adjustments using the ZAPI handset, control troubleshooting with a full fault code table and fault code charts for Master, Slave and Pump controls, and TMX factory control settings. Covers creep speed, acceleration, regenerative braking, release braking, pedal braking, speed limit, stop on ramp, steering time delay, static return to off (SRO), thermal protection, battery discharge indication, handset functions and protection features. Includes detailed fault code descriptions with troubleshooting steps and actions.

20 – Drive Axle

Drive axle specifications and description for the separate housing and drive train design. Drive axle troubleshooting, fluid check and change (Clark part no. 2776236, 3.8 L per housing), removal and installation procedures, and complete overhaul including drive unit disassembly, ring gear shaft, input pinion gear carrier, axle shaft, bearing removal, cleaning, inspection, reassembly and gear tooth bearing contact patterns. Includes special tool fabrication diagrams.

22 – Wheels and Tires

Wheel and tire specifications for cushion and pneumatic tires across all TMX and EPX models, drive and steer wheel removal and installation, cushion tire replacement, pneumatic tire maintenance, safety precautions, inspection and minor repair, wheel disassembly and tire removal, directional tread tire mounting, filling tires with air or nitrogen, and checking and adjusting tire pressure.

23 – Brake System

Brake specifications and description, brake system fluid check, fill and bleed, brake pedal and master cylinder removal/replacement/adjustment for TMX and EPX, brake caliper removal and replacement, parking brake removal/replacement/adjustment for TMX and EPX, and complete brake overhaul including caliper disassembly, carrier and lining removal, parts inspection and assembly. Covers DOT 3 brake fluid, pedal freeplay, and parking brake holding test.

25/26 – Steer System

Steering system specifications and description for both load sensing hydrostatic (TMX) and dynamic signal load sensing (EPX) systems. Steering system troubleshooting, steering column and component removal/replacement, steering system relief pressure check and adjustment (8340-8830 kPa / 1210-1280 psi), steering gear overhaul for TMX and EPX, steer axle service for TMX (trunnion bearings, wheel bearings, steer angle sensor, steer cylinder, trunnion, linkage), steering axle wheel bearing maintenance for EPX, steering axle removal/replacement for EPX, steer cylinder removal/replacement for EPX, and steer cylinder overhaul for EPX.

29/30 – Hydraulic System

Main hydraulic system specifications and description, fluids and filters (Clark MS-68 hydraulic fluid, 19 L usable sump capacity), hydraulic system troubleshooting, hydraulic system pressure checks and adjustments, main hydraulic pump overhaul, hydraulic system schematic, and main hydraulic control valve removal and overhaul. Covers lift, tilt and auxiliary circuit operation, priority valve function, relief valve settings (main 18,000-18,700 kPa / 2600-2700 psi, auxiliary 13,300-14,300 kPa / 1925-2075 psi), flow control adjustments, and the load lowering flow valve.

32 – Tilt Cylinders

Tilt cylinder specifications and description, checks and adjustments including drift test, racking check, forward and backward adjustment, tilt flow control adjustments, removal and installation, and complete overhaul including disassembly, inspection and reassembly.

34 – Uprights

Upright specifications and description for standard, triple-stage (TSU) and Hi-Lo uprights, troubleshooting, upright inspection (forks, lift chains, carriage and upright weldments, rollers, cylinders, hydraulic plumbing, upright drift), carriage and upright roller clearance checks and shim adjustments, cylinder removal/shimming/overhaul/replacement for primary and secondary cylinders, upright chain inspection/adjustment/replacement, fork and carriage removal/replacement, and upright removal/replacement. Includes chain length adjustment procedures for standard and TSU/Hi-Lo uprights.

38 – Counterweight and Chassis

Counterweight specifications and description, counterweight removal and installation, overhead guard removal and installation, and floor plate, seat and seat deck removal and installation. Includes counterweight weights by model and capacity, and mounting bolt torque specifications.

40 – Specifications

Nameplate and decal locations for TMX and EPX, truck data and capacity plate information, warning decals, operator safety decals, hand safety warning decals, keep away from forks decals, battery disconnect warning decals, polarity warning decals, electric truck warning decals, general specifications including truck weights, axle weights, travel speeds, turning radius, drift limits, lift speeds, critical fastener torque specifications, and hydraulic fitting tightening procedures.

Why This CLARK Service Manual Matters

Electric forklifts like the TMX12-25 and EPX16-18 use advanced AC motor controls, regenerative braking, hydrostatic power steering and complex hydraulic systems. Without the correct service procedures and specifications, even a simple repair can lead to premature failure, unsafe operation or expensive damage. This manual gives you the exact torque values, pressure settings, fault code diagnostics, shimming procedures, chain adjustment specs and component overhaul steps that CLARK engineers specified for these trucks.

Whether you are a fleet maintenance technician, an independent repair shop or a forklift owner doing your own service, having the complete SM-715 service manual means you can diagnose faults using the ZAPI handset, interpret fault codes correctly, adjust the steering angle sensor, shim upright rollers, replace encoder bearings, bleed brakes, set tilt cylinder racking, and perform every other procedure to factory specification.

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Instant PDF Delivery – No Shipping, No Waiting

This Clark TMX12-25 EPX16-18 service manual is delivered as an instant PDF download. After payment you can download it immediately and view it on any device – laptop, tablet, smartphone or desktop computer. The PDF is printable, so you can print the pages you need for the workshop and keep the digital copy for quick reference. No shipping fees, no waiting for a physical book, no missing pages. Whether you need to look up a torque spec, trace a wiring fault, overhaul a drive motor or adjust an upright chain, the information is right there.