Clark Forklift C CY CFY CH CHY60-80 English O-126 Operator's Manual - PDF DOWNLOAD

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CLqAK

INDUSTRIAL TRUCK DIVISION

EQUIPMENT

CLqAK

EQUIPMENT

OPERATORS MANUAL CY60, CY70, CY80 CFY60, CFY70, CFY80 C60, C70, C80 CH60, CH70, CH80 CHY60, CHY70, CHY80 Effective Serial Numbers First Machine of Lot 406 thru Last Machine of Lot 2078 (1960 - 1970)

Book No. Printing

0-126-1 REV-4 NOV 80 REPRINT

CLARK EQUIPMENT COMPANY, INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES PUBLICATION DEPARTMENT BATTLE CREEK. MICHIGAN. U.S.A. 49016

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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.

J.

Before Leaving The Truck: A.

Stop truck.

B.

Fully lower the load engaging means.

C,

4.

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

Before Working On Truck: A.

R aise 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.

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.

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1023-Z

O R EV OCT 68 (FRNT)

•

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 flammable 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, lights, 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 I 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 quality equal to that provided in the original equipment.

1023-Z

R EV 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

U S E

0 N

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

Lubrication under the

TIME

Example: is

002 a

INTERVAL 8H the

customer

for

the

and Preventive TIME INTERVALS is

002-0; PAGE

8H

NUMBER,

should

benefit

part

of

is

disregard. of

the

the

the and

Maintenance Instructions are that they should be performed. page

TIME

INTERVAL

is

-0 The

a

dash

publisher

number

CODE number

and (8

number.

operating

NUMBER or

code

that

code

you

as

nu·nber

is

only.

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

Example:

(8

hours),

Hours)

Time Interval (H=Hours)

Hydraulic Sump Tank, level check ...

Brake Pedal Free Travel, check .... .

the

Page Number (000-)

&

8H 8H

503 373

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 373 for instructions.

Turn to the eight (8) hour section (8H) and then to the page listed 503 or 373 etc. The instructions covered 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 would then refer to the INDEX for "Brake Pedal adjust" which would be listed in the TIME INTERVALS 8 hour section.

Example:

Brake

Pedal Turn

(100

Hours)

Free to

the

Travel, one

Time Interval (H=Hours) adjust.... hundred

hour

AOOl-4

is incorrect, Free Travel, following the Page Number (000-)

&

!OOH section

302 (!OOH)

and

then

to

27 JAN 64

•

INDUSTRIAL TRUCK DIVISION (continued) I N S T R U C T I O N S

U S E

0 N

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 observance can best determine the frequency with which you should service your machine.

The care you give your machine will greatly determine the A satisfaction and service life that you will obtain from it. difinite maintenance program should be set up and followed.

Haphazard maintenance will only lead to faulty performance and short lifP..

27 JAN 64

A002-0

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INDUSTRIAL TRUCK DIVISION T A B L E

0 F

C O N T ENT S

Description AOOI A002 A003 A004 8001 8003 8004 BOOS 8006 8007 8031

Instructions on use of manual Instructions on use of manual Table of contents Table of contents Illustration of machine Specifications Specifications Specifications Specifications Specifications Specifications 0 P E R A T I ON S

C002 C003 C004 CI03 Cl33 Cl34 C203 C253 C303 C401 C402 C403 C404

Overall controls Instrument indicators Instrument indicators Starting instructions Diesel starting aid Diesel shut-down proceedures R eserve fuel cut-in valve Transmission shock valve Safety precautions Proper handling o f L.P. gas Proper handling of L.P. gas Proper handling of L.P. gas Proper handling of L.P. gas

L U B R I C A T I O N Time Interval (H=Hours)

Page Number (0000-)

Description

H H

001 002

Index Index

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

002 003 103 203 204 303 403 404 503 602 603 604 703

IOOH IOOH IDOH IOOH IOOH IOOH IOOH lOOH IOOH IOOH IOOH IOOH

002 003 103 203 302 303 304 403 503 603 604 703

A N D

P R EV ENTIV E

M A I N T E N A N C E

8 Hour Lubrication and Preventive Maintenance Illustration Engine crankcase check Engine cooling system check Instrument indicators check Instrument indicators check Brake pedal free travel, parking brake check Air cleaner check Air filter element clean Hydraulic sump and control levers check Tire and rim maintenance Tire and rim maintenance Directional tread tires Power steering pump 100 Hour Lubrication and Preventive M aintenance Illustration Engine crankcase and oi 1 filter check Cooling system check Fan and generator drive belt check Brake pedal free travel check Brake system check Master cylinder check Lifting mechanisms check Hydraulic sump tank breather Steering gear and battery check Battery check Lubrication chart A003-IO

REV 8 M AR 66

INDUSTRIAL TRUCK DIVISION T A B LE L U B R I C A T I ON T ime Interval (H"'Hours)

Page Number (0000-)

AN 0

OF

C ONTENT S

P R EV ENTI V E

M AINT E N AN CE

Description

500H 500H 500H 500H 500H 500H 500H 500H 500H

002 003 004 103 202 203 302 303 403

Lubr icat ion and preventive maintenance il lustration Transmission oiI f ilter check Hydraulic sump tank and filter check Hydraul ic sump tank and filter check Steering gear adjust Steering gear adjust Steering axle and l inkage adjustments Steering axle and l inkage adjustments M ani folds check

IOOOH IOOOH IOOOH IOOOH IOOOH IOOOH lOOOH IOOOH IOOOH lOOOH IOOOH IOOOH IOOOH IOOOH lOOOH lOOOH IOOOH IOOOH lOOOH lOOOH lOOOH IOOOH IOOOH lOOOH lOOOH lOOOH IOOOH IOOOH IOOOH IOOOH lOOOH lOOOH lOOOH IOOOH lOOOH lOOOH lOOOH lOOOH

002 003 004 103 203 204 303 304 4:)3 503 504 603 604 703 704 803 805 912 913 1003 1103 1202 1203 1503 1504 1505 1507 1 703 1 704 1705 1 793 1803 1806 1 807 1808 1811 1 812 1 815

lubrication and preventive maintenance iIlustration Cylinder head, manifolds, crankcase, and valves adjustments Valve adjustment Compress ion test Distributor adjustments D istributor adjustments D istributor adjustments and timing Timing Vacuum Test Governor adjustment Governor adjustment Starting motor Starting motor Generator adjustment Generator adjustment Steer wheel bearings lubrication Axle ends lubrication Brake bleeding proceedure Brake bleeding proceedure Brakes service Hand brake adjustment Cooling system inspect and clean Cooling system inspect and clean Hydraulic system check Hydraulic system check Hydraulic system check Hydraulic system check Transmission stall and pressure checks Transmission stall and pressure checks Battery check Neutral starting switch Lift and upright adjustments R oller adjustments Upright roller adjustments Upright roller adjustments Lift carriage roller adjustments l ift carriage roller adjustments Upright roller adjustment T R 0 U B LE

S H O 0T IN G

Description TS TS TS TS TS TS TS

001 25 l 321 341 361 381 401

REV 9 M AR 66

Page

Engine Fuel system CooIi ng systern Ign ition system Starting motor Generator troubles Battery, I ights and horn

TS TS TS TS TS TS A004-2

483 521 531 541 653 963

G UI D E Description Drive axle Steering axle Steering Brakes Hydraulic system Transmission, converter and axle adaptor {hydratork drive)

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INDUSTRIAL TRUCK DIVISION ILLUSTRATION OF MACHINE

Plate 7239. CLARKLIFT C60, C70, C80

Plate 7240. CLARKLIFT CY60, CY70, CY80 B001-11

REV JAN 70

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