CLARK FORKLIFT CRX10131415182025 SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL CRX10/13/14/15/18/20/25

RATED CAPACITY: 1000~2500kg

Part No. 8051047 Book No. SM 776 Oct. 2006

[CLqRK"] THE FORKLln

(Head office) 202-1 Ojung-Dong, Ojung-Gu, Bucheon-city, Kyunggi-do, Korea (Factory) 40-1 Ungnam-dong, Changwon-city, Kyungnam, Korea Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Truck Models Covered by this Manual This manual consists of "base" module that pertains to all CRX I 0-25 models and other modules that per­ tain only to specific models. Manuals shipped with the truck contain the base module and the modules specific to the purchased truck.

You may, however, purchase specific modules and expand your manual to fully cover multiple models.

To do so, order the desired modules as you would any other Clark pa,t.

Arrangement and Use of this Manual Clark arranges parts and service procedures by stan­ dardized Groups. In this manual, Groups are similar to "chapters". Groups are listed in the indexes on the next page.

Each Group begins with a table of contents that shows the Sections contained within the Group.

Lengthy Sections also begin with a table of contents.

Each Group and Section has an identifying name and number, or "ID".

Each page also has a unique ID. The page ID con­ sists of three numbers separated by hyphens. The three numbers represent the Group number, the Sec­ tion number, and the page number. For example, "00-1-2" on the lower corner of the page indicates Group 00, Section I, page 2.

The Group number sometimes has a letter or letters added to it in parentheses if one or more variations of the Group exist. For example, if the truck has a stan­ dard transaxle, Group 06 is expressed as "06(S)"; if the truck has a hydrostatic transmission, Group 06 is expressed as '·06(H)".

You can quickly locate a specific point in the manual by using the headers and footers that appear on every Section page. The following illustration points out these areas.

Group ID

Page ID Section ID

-m� �-

�---- EEE! -=

-�

Manual ID

Group ID

Page ID Section ID

This manual is intended for the use of trained service personnel. Please read Group SA, '·Safe Mainte­ nance", and the Operator's Manual before working on or operating the truck.

Copyright Clark Material Handling 2004 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM ns, Jan '07

GROUP SA SAFE MAINTENANCE

GROUP SA SAFE MAINTENANCE

Safety ................................................................. Section 1

SM 776, Jan '07

Group SA SAFE MAINTENANCE, Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group SA, Safe Maintenance

Section 1.

Safety

Safety Signs and Messages

Safe Maintenance Practices

Safety signs and messages in this manual and on the lift truck provide instructions and identify specific areas where potential hazards exist and special precautions should be taken. Be su.re you know and understand the meaning of these instructions, signs, and messages. Dam­ age to the truck, death, or serious injury to you or other persons may result if these messages are not followed.

The following insu·uctions have been prepared from cur­ rent industry and government safety standards applicable to industrial u·uck operation and maintenance. These rec­ ommended procedures specify conditions, methods, and accepted practices that aid in the safe maintenance of industrial trucks. They are listed here for the reference and safety of all workers during maintenance operations.

Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work.

NOTE

This message is used when special informa­ tion, instructions or identification is requil-ed relating to pl'Ocedures, equipment, tools, pressures, capacities, and other special data.

IMPORTANT This message is used when special precau­ tions should be taken to ensure a correct action or to avoid damage to, or malfunction of, the truck or a componenL

ffi CAUTION

This message is used as a remjnder of safety hazards that can result in personal injury if proper precautions are not taken.

A WARNING

This message is used when a hazard exists that can result in injury ot· death if propet· precautions are not taken.

A DANGER

This message is used when an extreme haz­ ard exists that can result in injury or death or serious injury if proper precautions are not taken.

The above terms have been adopted by Clark Material Handling Company. The same terms may be used in dif­ ferent context in service literature supplied directly or indirectly by vendors of truck components..

When in doubt of any maintenance procedure, please con­ tact your local Clark dealer.

I. Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable mainte­ nance facilities, trained personnel, and procedures must be provided.

2. Maintenance and inspection of all powered indusu-ial trucks shall be done in conformance with the manu­ facturer's recommendations.

3. A scheduled planned maintenance, lubrication, and inspection program shall be followed.

4. Only trained and authorized personnel shall be per­ mitted to maintain, repair, adjust, and inspect indus­ trial trucks. Work should be performed in accordance with the manufacturer's specifications.

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

6. Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open name to check for level or leakage of fuel, electrolyte. oil, or coolant. Do not use open pans of fuel or nammable cleaning nuids for cleaning parts.

7. Before starting work on truck: a. Raise drive wheels off of tloor and use blocks or other positive truck positioning devices. b. Disconnect battery before working on Lhe electri­ cal system.

8. Before working on engine fuel system of gasoline- or diesel-powered trucks, be sure the fuel shut-off valve is closed.

SM 776, Jan '07

Safety • SA-1-1 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group SA, Safe Maintenance 9. Operation of Lhe truck to check performance must be conducted in an authorized, safe, clear area.

10. Before starting to drive truck: a. Be in operating position with seat belt fastened. b. Be sure parking brake is engaged. c. Put direction control in neutral. d. Start engine. e. Check functioning of direction and speed controls, steering, brakes, warning devices, and any load handling attachments.

dures. Always use genuine CLARK or CLARK­ approved parts.

20. Use special care when removing heavy components from the truck, such as counterweight. seat deck, upright, etc. Be sure that lifting and handling equip­ ment is of the correct capacity and in good condition.

Also, this removal may upset the stability of the truck. The frame must always be safely blocked for major component removal.

11. Brakes, steering mechanisms, control mechanisms, warning devices, lights, govemors, guards, safety devices, and frame members must be carefully and regularly inspected and maintained in a safe operat­ ing condition.

12. Special trucks or devices designed and approved for hazardous area operation must receive special arten­ tion to ensure that maintenance preserves the origi­ nal, approved, safe-operating features.

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

14. The Lruck manufacturer's capacity, operation, and maintenance instruction plates, tags, or decals must be maintained in legible condition.

15. Batteries, motors, controllers. limit switches, protec­ tive devices, elecLrical conductors, and connections must be inspected and maintained in confonnance with good practice. Special attention must be paid to the condition of electrical insulation.

16. To avoid injury to personnel or damage to the equip­ ment, consult the manufacturer's procedures in replacing contacts on any battery connection.

17. Industrial trucks must be kept in a clean condition Lo minimize fire hazards and help in the detection of loose or defective parts.

18. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturer's p1ior written approval. Capacity, operation and maintenance instruction plates, tags, or decals must be changed accordingly. This is an OSHA requirement.

19. Care must be taken to assure that all replacement parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the oiiginal equipment. Parts, including tires, are Lo be installed per the manufacturer's proce-

SA-1-2 • Safety

SM ns, Jan '07

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

GROUP PS PERIODIC SERVICE

GROUP PS PERIODIC SERVICE

Maintenance Schedule .................................... Section 1 Planned Maintenance Program ...................... Section 2 The PM Inspection Form ................................. Section 3

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Group PS PERIODIC SERVICE, Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group PS, Periodic Service

Section 1.

Maintenance Schedule

"Periodic Service" and "Planned Maintenance" ......................... 2 Determining Maintenance Intervals .............................................. 2

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Maintenance Schedule• PS-1-1 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group PS, Periodic Service "Periodic Service" and "Planned Main­ tenance" The term "periodic service·• includes all maintenance tasks that should be performed on a regularly scheduled basis.

The term "Planned Maintenance.. indicates a formalized program of basic inspections, adjustments, and lubrica­ tions Lhat the Clark service organization provides custom­ ers at a prescribed interval, usually 50-250 hours. The recommended basic "Planned Maintenance.. procedure is given in Section 2 of this Group.

The cun-ent Section,"Maintenance Schedules;· specifies all maintenance tasks.including Planned Maintenance tasks.that should be performed periodically, and suggests intervals at which they should be performed.

Determining Maintenance Intervals Time intervals on the charts on the next four pages and elsewhere in this manual relate to truck operating hours as recorded on the hourmeter, and are based on experience Clark has found to be convenient and suitable under nor­ mal operation. Standard operating condition classifica­ tions are: Normal Operation: Eight-hour material handling, mostly in buildings or in clean, open air on clean, paved surfaces.

Severe Operation: Prolonged operating hours or constant

usage.

ExtJ:eme Operation:

•

ln sandy or dusty locations, such as cement plants, lumber mills, and coal dust or stone crushing sites.

• High-temperature locations, such as steel mills and foundries.

• Sudden temperature changes, such as constant trips from buildings into the open air, or in refrigeration plants. lf the lift truck is used in severe or extreme operating con­ ditions, the maintenance intervals should be shortened accordingly.

IMPORTANT MAINTENANCE INTERVALS. If the lift truck is used in se\'ere 01· extreme operating conditions, the maintenance inter\'als should be shortened ace. Put upright in \'ertical posi• tion and fully lower the forks 01· attachment.

PS-1-2 • Maintenance Schedule

SM 776, Jan '07 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group PS, Periodic Service

Section 2.

The Planned Maintenance Program This Section defines a set o f basic service procedures, known as the "Planned Maintenance Pro­ gram,"::md describes a systematic approach for pe1fo1ming them.

Introduction to Planned l\'laintenance ........................................................................................ 2 External Inspection ...................................................................................................................... 3 Operational Checks ..................................................................................................................... 4 Internal Inspection ...................................................................................................................... 8 Critical Fastener 'Jbrque Checks ................................................................................................. 14 Wrapping Up the Pl\'l ................................................................................................................... 14

SM 776, Jan '07

The Planned Maintenance Program • PS-2-1 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group PS, Periodic Service

Introduction to Planned Maintenance A program of regular, routine inspections, lubrication, and other service tasks is important for the long life and trou­ blefree operation of the lift truck.

The Clark service organization offers customers a formal­ ized program.called Planned Maintenance. or PM.for per­ fom1ing these tasks.

PM Intervals The PM inspections, adjustments, and lubrications are typically performed on each covered truck at 50-250 hour intervals. (See Section I , in this Group about defining ser­ vice intervals.)

The PM Form As an aid to service technicians performing and docu­ menting PM inspections, Clark has prepared a "Planned Maintenance Report" form. A copy of this form is inserted in Section 3 of this Group.

We recommend that you use this form as a checklist and Lo make a record of your inspection and truck condition.

This record can be used lo inform the owner of needed repairs and help establish the optimal PM intervals.

When you have finished the PM inspections, be sure to give a copy of the report to the person responsible for lift truck maintenance.

The Basic PM Procedures The basic PM procedure is to perfonn checks first, repairs and adjustments last. As you go through each step of the PM, you should note all your findings on the PM report fonn.

The PM procedure, in outline form, is as follows: I. External visual checks. Perfo,m these as you walk around the u11ck with il turned off.

2. Operational checks. Perform these while operating the truck.

3. Internal visual checks. Perform these after remov­ ing the floor board and cowl cover.

4. Air cleaning internal components. Do this while performing the previous step.

5. Critical fastener torque checks.

6. Minor adjustments and repairs you found in your

inspection.

7. Fluid level checks and fill.

8. Chassis luhrication.

9. Final clean up.

JO.Minor adjustments to the responsible party.

Each of these steps is explained in detail beginning on the next page.

ffi CAUTION

. Do not make repairs or adjustments unless authorized to do so. . Disconnect the hattery before you woi·k on electrical components. . Always wear safety glasses. . Wear a safety (hard) bat in industrial plants and in special areas where protection is necessary or required. . Remove all jewelry (watch, rings, hracelets, etc.) before working on the truck.

Truck Location and Parking

The PM report fom1 serves as a record of what you did in the PM and what further service needs to be performed.

"Further service" consists of any repair, adjustment, inspection, or lubrication that you discovered during the PM or any periodic service procedure that is due but not covered by the PM agreement).

Before starling the external inspection, make sure the truck is parked on a clean, level surface. Fully lower upright, tum truck off, and engage the parking brake.

You should consult the previous PM report forms, peri­ odic service chart, and truck hour meter lo determine what periodic service is due. List the service due on the new PM form.

To perform the operational checks, the truck must be where there is sufficient clearance lo raise the upright and room to maneuver the truck al full speed without endan­ gering personnel, equipment, or materials.

If it is necessary to drive the truck lo a suitable inspection location, perfonn the initial braking and steering checks, given later in this Section, as you begin to move the truck.

PS-2-2 • The Planned Maintenance Program Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM ns, Jan '07