Clark Forklift C100-120 CH100-120 English O-152 Operator's Manual - PDF DOWNLOAD

- INDUSTRIAL TRUCK DIVISION

OPERATORS MANUAL C 1 0 0 / 1 2 0 C H 1 0 0 / 1 2 0

BOOK No. 0-152-2 1st REVISION

CLARK EQUIPMENT COMPANY PUBLISHED BY TECHNICAL SERVICE DEPARTMENT, BATTLE CREEK, MICHIGAN, U.S.A.

INDUSTRIAL TRUCK DIVISION SAFETY INSTRUCTIONS FOR MAINTAINING INDUSTRIAL TRUCKS Powered industrial trucks may become hazardous if adequate maintenance is neglected. fore, adequate maintenance facilities, personnel and procedures should be provided.

There­

Maintenance and inspection of all powered industrial trucks should be performed in confor­ mance with the reconvnendation in this manual and the following practices.

1.

A scheduled preventive maintenance, lubrication, and inspection system should be followed.

2.

Only qualified and authorized personnel should be permitted to maintain, repair, adjust, and inspect industrial trucks.

3.

Before Leaving The Truck:

4.

A.

Stop truck.

B.

Fully lower the load engaging means.

C.

Place directional controls in neutral.

O.

Apply the parking brake.

E.

Stop the engine or turn off power.

F.

Lock the control or ignition circuit.

G.

Block the wheels if truck is on a ramp, or being worked on.

Before Working On Truck: A.

Raise wheels free of floor or disconnect power source.

B.

Use chocks or other positive truck positioning devices.

C.

Block load engaging means, innermast(s), or chassis before working under them.

Before working on engine fuel system of gasoline powered trucks with gravity feed fuel systems, be sure fuel shutoff valve is closed.

Before working on engine fuel system of LP gas powered trucks, close LP gas cylinder valve and run engine until fuel in system is depleted and engine stops running.

Operation to check performance of the truck or attachments should be conducted in an authorized, safe clearance area.

5.

Before Starting To Operate The Truck: A.

Be in operating position.

B.

Depress clutch (or brake pedal on automatic transmission and electric trucks).

C.

Place directional controls in neutral.

0.

Start engine or turn on power.

E.

Before operating truck, check functioning of lift and tilt systems, directional and speed controls, steering, warning devices, brakes, and any attachment. (If used)

F.

Release parking brake.

- continued 1023-Z

REV OCT 68 (FRONT)

INDUSTRIAL TRUCK DIVISION

SAFETY INSTRUCTIONS FOR MAINTAINING INDUSTRIAL TRUCKS 6.

Avoid fire hazards and have fire protection equipment present. Do not use an open flame to check level, or for leakage, of fuel, electrolyte or coolant. Do not use open pans of fuel or flanmable cleaning fluids for cleaning parts.

7.

Properly ventilate work area, vent exhaust fumes and keep shop clean and floor dry.

8.

Handle LP gas cylinders with care.

9.

Brakes, steering mechanisms, control mechanisms, warning devices, 1 ights, governors, 1 ift overload devices, guards and safety devices should be inspected regularly and maintained in a safe operating condition.

Do not drop, dent, or damage in any way.

10. All parts of 1 ift and tilt mechanisms and frame members should be carefully and regularly inspected and maintained in a safe operating condition.

11. Special trucks or devices designed and approved for hazardous area operation should receive special attention to ensure that maintenance preserves the original, approved safe operating features.

12. Fuel systems should be checked for leaks and condition of parts. Extra special consideration should be given in the case of a leak in the fuel system. Action should be taken to prevent the use of the truck until the leak has been corrected.

13. All hydraulic systems should be regularly inspected and maintained in conformance with good practice. Tilt cylinders, valves, and other similar parts should be checked to assure that "drift" has not developed to the extent that it would create a hazard.

14. Capacity, operation and maintenance instructions plates, tags, or decals should be maintained In legible condition.

15. Batteries, motors, controllers, I imit switches, protective devices, electrical conductors and connections should be inspected and maintained in conformance with good practice. Special attention should be paid to the condition of electrical insulation.

16. Industrial trucks should be kept in a clean condition to minimize fire hazards and facilitate detection of loose or defective parts.

17. Modifications and additions which affect capacity and safe truck operation should not be performed by the customer or user without manufacturers prior written approval.

Capacity, operation and maintenance instruction plates, tags or decals should be changed accordingly.

18. Care should be taken to assure that all replacement parts are interchangeable with the original parts and of a qua I ity equal to that provided in the original equipment.

1023-Z

REV OCT 68 (BACK)

INDUSTRIAL TRUCK DIVISION P L E A S E

I N S T R U C T I O N S

N O T E

0 N

U S E

M A N U A L

0 F

This Operator's Manual is published as a service refer­ ence guide and includes Specifications, Operating Instructions, Lubrication and Preventive Maintenance Instructions, and Trouble Shooting Guide.

The TABLE OF CONTENTS for this manual is printed on green paper and is placed at the front for easy reference.

A separate INDEX (also printed on green paper) is placed in front of the Lubrication and Preventive Maintenance Section. listed The

TIME

Example: 002 a

is

INTERVAL 8H the

the

is

002-0;

8H

should

benefit

part

NUMBER,

PAGE

customer

for

and Preventive TIME INTERVALS

Lubrication under the

of

is

disregard.

of

the

the

the

and

Maintenance Instructions are that they should be performed. page

TIME -0

INTERVAL

is

The

a

CODE

dash

publisher

number

number

and

(8

number.

operating

NUMBER or

code

that

code

you

(8

as

number

only.

The INDEX is set up under the TIME INTERVALS that Lubrication and Preventive Maintenance should be performed.

Example:

hours),

Hours)

Time Interval (H=Hours)

Hydraulic Sump Tank, level check•..

Brake Pedal Free Travel, check ••••.

the

Page Number (000-)

&

503 303

SH 8H

The above states to check the sump tank fluid level every 8 operating hours and refer to page 503 for fluid recommendations etc. Also, to check brake pedal free travel at this interval and turn to page 303 for i.nstructions.

Turn to the eight (8) hour section (8H) and then to 503 or 303 etc. The instructions covered the page listed therein will pertain only to the checks or adjustments that should be performed at this TIME INTERVAL. If, for instance, the Brake Pedal Free Travel you woul� then refer to the INDEX for "Brake Pedal adjust" which would be listed in the TIME INTERVALS 8 hour section.

Example:

Pedal Turn

(100

Hours)

Free to

Travel,

the

one

Time Interval (H=Hours)

Page Number (000-)

100H

302

adjust.•••� hundred

is incorrect, Free Travel, following the

hour

section

(lOOH)

and

then

t

AOOl-3

27 JAN 64

INDUSTRIAL TRUCK DIVISION (continued) O N

I N S T R U C T I O N S

U S E

page 302. Complete instructions as to free travel, the method to check and travel with illustrations are included

0 F

M A N U A L

the importance of pedal adjust for correct free therein.

N O T E YOU TION

WILL AND

LOCATION

NOTE

THAT

PREVENTIVE OF

THE

AT

THE

BEGINNING

MAINTENANCE

COMPONENTS

TO

OF

EVERY

ILLUSTRATION BE

IS

SECTION SHCMN

A

LUBRICA­

GIVING

THE

SERVICED.

It is impossible to cover all types of machine operations in one manual. · Operating conditions should determine the lubrication and maintenance intervals. Common sense and a close observ­ ance can best determine the frequency- with which you should service your machine.

The care you give your machine will greatly determine the satisfaction and service life that you will obtain from it.

A difinite maintenance program should be set up and followed. will only lead to faulty performance and Haphazard maintenance I short life.

INDUSTRIAL TRUCK DIVISION T A B L E Page AOOI A003 B001 B003 B031

0 F

C O N T E N T S

Description Instructions on Use of Manual Table of Contents Illustration of Machine Specifications New Machine 50 Hour Inspection

0 P E R A T I O N S C002 C003 C006 Cl03 C303 C403 L U

Time Interval & (H=Hours)

B R I C A T I O N

Page

Number (0000-)

Overall Controls Instrument Indicators Oiesel Engine Cold Weather Starting Aid Starting and Operating Instructions To Move, Stack and Lower Loads. Safety and Operating Suggestions Proper Handling of L. P. Fuel

A N D

P R E V E N T I V E

M A I N T E N A N C E

Description

H

001

Index

8H 8H 8H 8H 8H 8H 8H 8H 8H

000 001 003 103 303 403 503 603 605

8 Hour Lubrication and Preventive Maintenance Illustration Horn, Fuel Tank and System Fuses Crankcase OiI Level check; Recommended Lubricants Cooling System Check Brake Pedal Free Travel check; Parking Brake Operation check Engine Air Cleaner service {Oiesel Models on Tangerine Paper) Hydraulic Sump Tank Level check; Hydraulic Control Lever Operation check Tires, inspect Clutch Pedal Free Travel {Hydracool Models)

IOOH IOOH IOOH

000 001 003

IOOH IOOH IOOH IOOH

103 203 302 303

IOOH

403

IOOH IOOH IOOH IOOH

503 603 653 702

100 Hour Lubrication and Preventive Maintenance lllustratron Converter, Transmission & Axle Adaptor Level check; Fuel Tank & Lines Inspect Engine Crankcase drain & refil I ; Crankcase Ventilation inspect, Engine Oil Filter Element change Cooling System inspect; clean radiator fins Fan and Generator Belt adjustment Brake Pedal Free Travel check Brake Pedal Free Travel adjust; Master Cylinder level check (Hydracool Models on Tangerine Paper) Lift and Tilt Cylinders inspect; lift Chains check and adjust; Visually inspect alI wiring and hydraulic piping; lubricate alI miscellaneous Iinkage.

Hydraulic Sump Tank Breather inspect or replace Steering Gear verify lubricant level; Battery inspect Hydracool Clutch adjustment Lubrication Chart

SCOH SCOH SCOH

000 001 003

SCOH SCOH SCOH SCOH

103 202 302 403

500 Hour Lubrication and Preventive Maintenance Illustration Fuel Pump Strainer clean; Fuel Pump Operation check Converter, Transmission and Axle Adaptor drain & refill; Transmission Oil Filter Element change {Hydratork Models) Hydraulic Sump Tank Oil Filter change Steering Gear adjust Steering Axle and Linkage adjust Manifolds check security of mounting; Nuts, Bolts and Capscrews security check

A 003-16

REV 15 JUN 65

INDUSTRIAL TRUCK DIVISION T A B L E

L U B R I C A T I 0N Time Page Interval & Number (H-Hours) (0000-) I000H I000H I000H

000 001 003

I000H I000H I000H I000H I000H I000H I000H I000H I000H I000H I000H I000H I000H I000H I000H I000H I000H I000H I000H I000H I000H I000H

004 103 203 204 303 403 503 603 703 803 805 912 1003 1103 1202 1303 1403 1503 1703 1793 1803 1811

AN D

C 0 N T EN T S

PR EV ENT IV E

M A I N T E N A N C E

Description 1000 Hour Lubrication and Preventive Maintenance Illustration Engine Tune Up; Air Cleaner, Fuel Pump EngineTune Up; Cylinder Head StudNuts Intake and Exhaust Manifolds, Crankcase Ventilation; Intake and ExhaustValve Clearance adjustments Engine Tune Up; Intake and ExhaustValve Clearance adjustments EngineTune Up; Compression test, Spark Plugs Engine Tune Up; Distributor Engine Tune Up; Tach Dwell Meter EngineTune Up; Contact Point Adjustment; IgnitionTiming EngineTune Up; VacuumTest and Carburetor adjustment Engine Tune Up; Governor adjustment Starting Motor inspect Generator inspect Wheel Bearings clean and repack; adjust Axle Ends clean and replace Bleeding Brake System (Hydracool Models on Tangerine paper} (Follow tangerine page procedure if applicable} Brakes Hand Brake adjustment Cooling System inspect and clean Transmission and Axle Adapter, drain and refiII (Hydracool Models} Hydraulic SumpTank drain and refill Main Hydraulic System Pressure checks Transmission Stall and Pressure checks Neutral Starting Switch (Hydratork Models} Upright Roller adjustments Carriage Roller adjustments (Follow tangerine page procedure if applicable) T R 0 U B L E Page TS TS TS TS TS TS TS TS TS TS TS TS

REV 7 JUN 65

0 F

001 251 321 341 361 381 401 483 521 541 653 963

s

H 0 0 T IN G

G U I D E

Description Engine Fuel System Cooling System lgnition System Starter Generator Battery & Horn Drive Axle Steering Axle Brake System Hydraulic System Hydratork Drive (Transmission}

A 004-7

INDUSTRIAL TRUCK DIVISION

Plale 7666.

lllusl1ation of Machine

B 001-IS

23 JUN 64