CLARK FORKLIFT C30-1-EQ-177 thru 70-305 MAINTENANCE MANUAL - PDF DOWNLOAD

- INDUSTRIAL TRUCK DIVISION

MAINTENANCE MANUAL FOR MACHINE SERIAL NUMBER

Clarklift 30 (C30-1-EQ-177 thru 70-305) Clarklift 40 (C40-1-EQ-l78-thru 125-306) Clarklift 50 (C50-I-EQ-l79 thru 70-307)

Code 81

CLARK EQUIPMENT COMPANY PUBLISHED BY TECHNICAL SERVICE DEPARTMENT, Copyrighted Material BA TTLE , CRE E K, MICHIGAN, U. S .A. Intended for CLARK dealers only Do not sell or distribute

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Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

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 recommendation 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.

D.

Apply the parking brake.

E.

Stop the engine or turn off power.

F.

Lock the control or ignition circuit.

G.

Block the 1•1heels 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 v1orking 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 Truckj A.

Be in operating position.

B.

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

C.

Place directional controls in neutral.

D.

Start engine or turn on power.

E.

Before operating truck, check functioning of 1 ift 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)

Intended for CLARK dealers only Do not sell or distribute

r:rr;rn mm:tttl

INDUSTRIAL TRUCK DIVISION

r:rr;rn mm:tttl

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 flammable cl eaning 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, lights, governors, I ift overl oad 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.

1 1. 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. Al l 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 �,ould create a hazard.

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

15. Batteries, motors, controllers, 1 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 quality equal to that provided in the original equipment.

1023-Z

REV OCT 68 (BACK)

Co ri ohted Material Intended for CLARK dealers only Do not sell or distribute

INDUSTRIAL TRUCK DIVISION

INSTRUCTIONS ON USE OF MANUAL This Maintenance Manual and Parts Book is published as a service refer• ence guide and includes Parts Information, Trouble Shooting and Specifica• tions where these are applicable.

The Index for the Maintenance Manual is placed at the front of the manual for easy reference. A separate Index for obtaining Parts information is con• veniently located at the beginning of the Parts Section.

The Maintenance Manual is divided into Sections. These being arranged alphabetically according to major assemblies, with the exception of the Op· eration and Lubrication Sections which are placed immediately following the Index.

The Section title and page number appears at the top of the page. Pages are numbered consecutively within each section.

The illustrations appearing, herein, are numbered consecutively within each section and are intended to show typical constructions of the various parts. In some instances, the shapes or details of the parts illustrated may not exactly represent their actual appearance, however, they will serve to show the servicing methods explained and help

to

identify parts performing

the same function.

315-z

- 't'J b

r"'I

_,11...

Intended for CLARK dealers only Do not sell or distribute

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\ y Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

8

INDEX

CLARK EQUIPMENT COMPANY, SERVICE DIVISION

CL.ARKLIFT MAINTENANCE MANUAL INDEX L�bdc:adoo Cb•rr- ..............---• ..-··-Oper.cl1141 l11eauc:do11e-..-.........,-.... _.._ Spcc:lflcadooe and Capacidea --,-•-·· ..·-

Vl-4 Filtlos Plstoo Pia.a._·----..-... ........

Vl-4 Flttlas Pl■IDll Ria.g s--..-..............-...

Vl-6 Governor •.•.-·_____.....-........--···vi.. 7 Gonruor Adjuscmear_ .._............. ............ v1.. 2 Mull Beari11ss-....-..... ...,_............-··-·Speclfi c:atloas_.. _...._.... ..., ........ ......... .Y 1-8 & 9 Trouble Shoociag Gulde_.............,..___ Vl-7 Valve.......... -... ...............-.....- ......-.... Vl.. 5 Vl-6 Guides ........ .......... _...,................-.......

Vl..5 Grladlag- ..............,..-•••-• ..·•••-•---• Vl-6 Sprlaa•-· ·-··-·-......----· ..--...

Vl-5 Tappets-• ._..., ............ ..., ................ _._ Vl-6 Timlas--..-·•· ..-........ _...,_... ____

13 10 9

SECTION I BRAKES Blecdla.g Brakeo-··--··-..--_.._.._ .....

Brd:e Aasembl7.. ........-............ ..:._···Brake Shoee ........-••• _.. ___.._..__.;._.._.._ Muter Cylinder...... _..___.....--···-......_ Par king Brake____..........___..... �.... _.._ AdjHIIDCllt............ __....- .........- .......... .

Pedal AdJ11s1meot..-··-·--·······---··-··-Tro11ble Shoodog Gulde.. .. _...... _.._._.. _ Vlhecl Cylloders_ ...........__.......... -...·--

SECTION Vil FUEL SYSfEM Air Cleaner ........ ...,........................-.... ·Carb11reior Adjaa1111e11t..............................-.. _...... .

Descripdo11 ____._ ...___.....- •• - • Malacenuce ,ud Iaapec:rloo ........... Re moval ........._.._. ___ ... ..., ..-...·-·•· Fuel Filter .......... -...... _.._.......-....- .

Fuel Pump .........,................ _....................

Trouble Sboodag Galde _.........._.. ___.

SECTI(,)N ll COOLING SYSTEM Aatl • Freeze Chart.. -·--..-..-·-· ...._ •• ., Deecrlptio11 ...........- -.........--·-·------ ..

Fan Deir .Adjasaneat ......_ ........ �---·Mainte41Ulce _.. _..........,- ...-..-.:.............. _.

Oil Cooler ·· ·--···--·- ....-- ....-••--.--.....

Thermostat .......-- ....- .........-......._ ..__ Tro!lble SboodDg Gulde ·-· ...• ..···--·· ..-· 11'.c•,r PW11p .... ...,-• •--..•--.... ..____ ..

SECTION lll DIFFERENTIAL AND AXLE ENDS Adaprer RemOYel ..-••- ...............,.-···--..

A:de Ead Dl■use111bly _ ........ _...,...........

Backlasli _.................... -·-··-- · ......... .

Deec:riptloo -·-----·--··-··-·----·· Dliferearial RemoYel .......·---�---....I,upec:doo aad NaJ11ce11uc:e -----------· Reassembly ·•··-- ··· ......----··--····---.

Tro11ble Sboodaa G11lde

-··----i--.........

11·1 IH 11..1 11-1 11..1 11-1 11.. 2 11.. 1

SECTION V ELECTRICAL SYSl'EN Battery...._.-_. ....-..---.

Descrlptfo11 ___.. _..--..-----.---Dl•tribatDr _______ ..___ .,_;. ___ Geaemcor DJsusembly ___..________..;_ ___ Iilspec:doo _______ .. ______ Iilstelladoa____..__________

MalDiea.aa.ce _______.._____...-....-

Igaldoo Coll _ ----------..-..-•--'Igaldoa Tlmiog_.... _______...._..__ _ Solenoid--·------........ --·--'----Spllfk Pluas ___ .. _..........,.... ...,.. ___ Speciflc:atloa ...,.............-----·-- _.. _ Srartlas Moior Dls�•.•embly _ ...- ........ --···--..-Cbec:klllg.....................-........... : ...-..-

Deoetlpdoa ....... ____...._.. ...,_ ......__ ..

Free-Life ap.ratfoa ..__ .......,.. ...,.... .. ..

Hydraulic OU .... -....--··-------..·­ Llft.Cb•la• •-'-•_..:.•··------··-----Oll Linea..........__.._..___........-...·--Pump Oyerb•ul ....... ...,_.. _......_.._...............

Shaft Rocatioll _ _.. __.....-..--'..--.

SWop Tile Cylia.dcr Adju1meat.. .. ...,.... __......... ---···Malaceaance __.., _____ ..........".,_ .. · Tile Lock Valve Dueripdoa·---·--....-............-..........

Mali1teaucc .................-.............. .. .. .

Updgbc Hl•Lo• ..., ...... _.. _.._.._....- ... -··-Si,aJl<ldrd..__----..-............- . _... _ V111Ye By-P-■s AdJasaacat_ ..�._.. _____...

Malaceaaace ...................... ...,_._.. _ ..

m..1

m.. 2 m;3

111-1 111�2

lll,2 111.. 2 Ul..C

Tw ...__....--.-.....-..-•·•-•-..

IV•6.

IV•l IV-3 IV-4 Jy.. 4 iv-·3 IV· l IV-6

v..1

Ade Adj11atme11cs______ ;.......___.,.... _ f Maiatcauee ..,, 1aepccclo11•• _ ..._..

Gear Adjuatmenrs.... ---..- ..-....--..-- .

MaJlltelllUIC:C am IHpeodon- ....--·-

Y-1 v..1

v.. 2 V•2 v..3 V•.2 V◄ V-6 v..4

VI.IJ..l

vw.. 6 vm..1 Vlll-6

vm.., vm.. 2 vm..z v111.. 1 vm..,.

VIll-4

Vlll•.C Vlll..C

vm..5 vm.. 5 vm..3 vm..3

1x.. 2 IX-1 IX•2 1x.. 2

SECTION X TRANSMISSION

v-,

v..e

Mllliatenance ............ -. ................ --··-

SECTION VI ENGINE v1.. 5 ·v1-3 v1..3

v1.. 3

Vl-3 V.1-1 Vl;l VI-◄

Vll·.3

vu..3

SECTION lX STEERING SYSTEM

Trouble Sboodag Gulde- ....... ..;. .... ._...; Volrage Regulaior..............--·--··-.. -

Comsbaft................- ....................---Coiloec:dag Rod_.....................- ....-... Cooaecdog Rod J3earlng■ ···········-·· ..-..

Cr■aksbaft. Ead Play-········ ......... _ .........

Cylinder Bore ...............................·-······ · Ducrlpdoa............ ... ......... . . . . :• • . . • E11glae Compression ... .... -. ................ _ F ltdng P ls,on ....-••-•-..•-••• ••• .... ........

.v11..1 vn..1 v11..2 vu.. 1 v11..2

SECTION VIII HYDRAULIC SYSTEM

SECTION IV DRIVE, HYDRATORX

Cbec:kl111 011 Pressure ......- ..... ..;---..Descriptlo11 ___..........-------�---· Forward Dlrec:tioo ---- ....---•-----Oil Cooler_ .._ _._.. ____......_...._____ Oil System_ .._________....____ Rneue. l>lrec:doa __..______..__...._ Torqnc CoclYctter ____...,.. _...;__.. _ TrDllblc Sbood11g Glllde-....- ..............__

v11.. 2

81

Conrrol CoYer Diaaasembly ........-...... ................ -.....Rea..embly .. __.....-............- ...- ...... ..

Coaverter -Housiag Disassembly .... .. . . -........ .-... . ...........

Rea■sembly...._...._...... . . . . ..........Oescriptioa---·-·.. ·----u-••··••MUH_H_ • Dlrectloo Selecrer Di■•ssembly_ ...,.. _ .......... ....................

Rcasaem bly..........................................

Dlsas11embly ..... ....-................... ........ l11specdo·a and Nal.are11S11ce ..............lurallation ...........- ... ····-·····--·- .. -Lubdc:•tloa-• ................- -··-·-••...... ._ Pre-■11re Resalator ValYC Disu■embly .... h...............- .............. _ R.easacmbly ___.,.... ""······-·-·--··-···�· Pump Gear CoYe•·-·· ·- ··· .........._ .......

Reassembly .......•..- . ............ :.............. ..

Reroov.... ········-·------

x..3

x..6

x.. x..

4 x.. , 1 x..3

x.. 6 x.. 2 ,t..;i­ X•B x..1 x.. 4 x.. , x.. ,

x..,

X•2

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�

CLARK EQUIPM ENT COMPANY, SERVI CE DIVISION

SPECIF ICATIO NS 9

SPECIFICATIONS

B

---D----------------....:.._-1--..,

BASIC AISLE FOR RIGHT ANGLE STACK! NG; ADD LOAD LENGTH

-�� 12 TO 16

ADJUSTABLE

83

130 M.F.E.

42

t,lodel A

3

C

D

E

C.-30 31 38 70

82¼ 3¼

C•40 30 38 74½

86!"

C·50 31 40 78

90¼ 3!4 R

F

G

H

I

49% 38% 17¾ 48

J 78

Cooling Trans. Axle Sump Diff.

Cap. Ends Tanlc 18,,;7d2 1/8 6-5 Gal. 11.5 Qrs. 15 Qrs. l Pr. 6 Gal. K

Fuel Cap.

4 I/SR 42% 40% 17¼ 53 82½ 18K8x12 l/8 8.5 Gal. 11.5 Qrs. 15 Qrs. l Pr. 7.6 Gal. 41% 38% 18¾ 55 86

18s9d2 l/8 8.5 Gal. 11.5 Qrs. 15 Qts. l Pr. 7.6 Gal. 81

11-18-65

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10

CLARK EQUIPMENT COMPANY,

OPERATION

SERVICE DIVISION

OPERATING INSTRUCTION'S freeze as required.

3. Check service brake and parking bralce.

4. Check air c lean er.

5. Check c rankcase oil level 6. Check transmission oil level.

7. Check hydraulic system oil supply.

It is not essential that the prospective operator have experience with this type machine, but it is important that he have sound practical knowledge of mac hinery and its care.

An operator with p revious experience o n automotive equipment should readily become acquainted with construction and operation of the lift truck.

STARTING

BEFORE STARTING

Place direction control lever in 'neutral'.

The machine is equipped with a neutral starting switch and will not start unless transmission is in 'neutral'. Pull out on choke button and tum ignition switch key. The starter is engaged when the key is turned. CAUTION: Do not

Before putting mac hine into service there are a few preventive maintenance instru ctions that should be followed: 1. Check fuel supply and fuel system lines and connections.

2. Check cooling system: add water or anti-

FORWARQ.QFVl:RSf' C()NT�OL LEVER

engage

the starter

AIIIIETE�

longer than

15 seconds

LIFT AND TILT OPERATlt.J(; HAt.JDLE

FUEL GAUGE---"T".;:::;.�rl

ARTER ANO ITl()N SWITCH

T�.<1.·1s•.11ss1n•1 P'<ESS'J'<': 1►,')ICIITn<! LIS!lT

4377-MX-81-56 Fig. 1 Location of Controls

"

1 1- 1 8-5 6

CAUTION

,,

81

Standard Gas Fuel Systems Only

"

CAUTION

,,

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