Clark CTM, CEM 10-20 With HPB1 Control Training Manual (SM5167)

These Clark CTM/CEM 10–20 trucks with HPB1 control spend their lives in warehouses, docks, and tight indoor aisles, starting and stopping all day under load. This training manual helps you understand how the HPB1 control and truck systems behave so you can approach problems methodically instead of guessing. For example, if a truck won’t travel but still lifts, this guide helps you read the control logic, trace signals, and decide whether you’re chasing an input issue, a wiring fault, or a control problem before you ever touch a component.

Applications & Use Cases

• Build system understanding so new techs can learn how the HPB1 control talks to contactors, motors, and switches.
• Trace intermittent faults by following the diagnostic approach and verifying what to test first instead of random parts-swapping.
• Practice safe checks on control circuits before working live on the truck, reducing the chance of shorts or miswiring.
• Train apprentices on how to read diagrams, route their meter leads, and interpret results correctly.
• Prepare for real jobs by walking through sample fault paths before you’re under pressure on the customer’s floor.

FAQ

Q: Is this something I can keep open on a tablet next to the truck?

A: Yes, it works well digitally; you can zoom in on diagrams and scroll while you test and measure.

Q: Should I still print parts of it?

A: Many techs print key pages so they can mark voltages, trace circuits with a pen, and keep them in a job folder.

Safety Note

Always verify the truck is properly secured, power-isolated, and safe to energize before performing any tests described in this training material.

Clark CTM, CEM 10-20 With HPB1 Control Index:

GENERAL MAINTENANCE INSTRUCTIONS

TROUBLESHOOTING DIAGNOSTIC DIAGRAM
– How to Use the Diagnostic Diagram
– The Diagnostic Diagram

DESCRIPTION OF OSCILLATOR CARD INPUTS AND OUTPUTS
– Inputs
– Outputs

CHECKING COMPONENTS
– Main SCR Control Card
– Capacitor 1C
– Contactors F, R, 1A, and P
– Potentiometer in Accelerator
– Driver Module
– Hourmeter Module
– SCR (1 REC, 1 REC, 5 REC)
– 1 REC
– 2 REC
– 5 REC
– Rectifiers (3 REC and 4 REC)
– Thermal Protector (TP)
– Transformer
– Voltage Check
– Milliamp Check

REPLACEMENT OF COMPONENTS
– Replacement of the 1 REC Module
– Torquing Instructions
– Replacement of the Capacitor
– Replacement of the Transformer/Choke
– Replacement of the Control Card
– Placement of the Components

CONTACTORS
– 150 and 300 Amp Contactors
– 75 Amp Contactors

ACCELERATOR SWITCH
– EV-1 SCR Control Accelerator Switch

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