Clark Forklift CY100-140 CHY100-140 English O-153 Operator's Manual - PDF DOWNLOAD

- INDUSTRIAL TRUCK DIVISION

OPERATORS MANUAL C Y 1 0 0 / 1 2 0 / 1 4 0 C H Y 1 0 0 / 1 2 0 / 1 4 0

BOOK No. 0-153 3rd REVISION

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

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INDUSTRIAL TRUCK DIVISION

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

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: 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.

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 StartingTo 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 I 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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REV OCT 68 (FRONT)

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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, el ectrolyte 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 cyl inders with care.

9.

Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, lift 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 l ift and til t mechanisms and frame members shoul d 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 pl ates, tags, or decals should be maintained in legible condition.

15. Batteries, motors, controll ers, 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 custcxner 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)

INDUSTRIAL TRUCK DIVISION P L E A S E I N S T R U C T I O N S

N OT E U S E

0 N

M A N U A L

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

TIME

Example: 002 a

INTERVAL 8H

the

part 8H

of

the

the

the and

disregard.

should

benefit

of

is

NUMBER,

PAGE

customer

for

is

002-0;

the

is

Maintenance Instructions are that they should be performed.

and Preventive TIME INTERVALS

Lubrication under the

oage

TIME

INTERVAL a

is

-0

CODE

dash

The

publisher

number

number

and

(8

number.

ooeratina

NUMBER or

code

that you

code

(8

as

number

is

onlv.

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

Example:

hours),

Time Interval (H=Hours)

Hours)

Hydraulic Sump Tank, level check...

Brake Pedal Free Travel, check.....

the

Page Number (000-)

&

503 303

8H 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 instructions.

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 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

Free to

Time Interval (H=Hours)

Hours)

Travel,

the

one

adjust.... hundred

hour

AOOl-3

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

&

302

100H section

(lOOH)

and

then

to 27 JAN 64

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

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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.

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

27 JAN 64

A002-0

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INDUSTRIAL TRUCK DIVISION T A B L E

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C O N T E NT S

Description AOOI A003 8001 8002 8003 8031

Instructions On Use Of Manual Table of Contents 1 llustration of Machine Post Printing Note Specifications New Machine 50 Hour Inspection O PE RAT

C002 C003 Cl03 Cl30 C134 C253 C303 C401

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

Page Number (0000-)

H

001

8H 8H 8H 8H SH SH 8H 8H 8H 8H

000 001 003 103 203 303 403 503 602 605

IOOH IOOH IOOH

000 001 003

IOOH IOOH IOOH IOOH IOOH IOOH IOOH IOOH IOOH IOOH

103 203 302 303 403 503 603 653 657 702

500H 500H 500H

000 001 003

500H 500H SOOH 500H

103 202 302 403

0 N S ·

Overal I Controls Instrument Indicators Starting and Operating Instructions Diesel Cold Starting Aid Engine Stop Controls Transmission Shock Valve To Move, Stack, Lower Loads Proper Handling of L.P. Gas A N D

P R E V E NT I V E

M A I N T E N A N C E

Description Index �

8 Hour Lubrication and Preventive Maintenance I Ilustration Horn, Fuel Tank and Fuses Crankcase Oil Level Check, Recommended Lubricants Cooling System Check Instrument Indicators, Check Brake Pedal Free Travel Check, Parking Brake Check EngineAir Cleaner Service Hydraulic SumpTank Level Check, Hydraulic Control Lever Operation Check Tires, Inspect Clutch Pedal Free Travel Check 100 Hour Lubrication and Preventive Maintenance Illustration Transmission & Differential Level Check, Fuel Tank & Lines Inspect Engine Crankcase Drain & Refill, Crankcase Ventilation Inspect, Engine Di I Fi1ter Change Cooling System Check Fan and Generator BeltAdjust Brake Pedal Free Travel Check Brake Pedal Free TravelAdjust, Master Cylinder Level Check Lift and Ti It Cylinders Inspect, Li ft Chains Check andAdjust Hydraulic SumpTank Breather Inspect Steering Gear Level and Battery Check Hydracool ClutchAdjustment Hydracool Fluid Reservoir Level Check Lubrication Chart 500 Hour Lubrication and Preventive Maintenance Illustration Fuel Pump Strainer Clean, Fuel Pump Operation Check Converter, Transmission and Transfer Case Check, Transmission Di I Filter Change Hydraulic Sump Tank Oi I Filter Change Steering GearAdjust SteeringAxle and LinkageAdjust Manifolds, Universal Joints, Nuts, Bolts and Cap Screws Check

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REV 22APR 66

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INDUSTRIAL TRUCK DIVISION T A B L E

L U Time I nterval {H=Hours}

B R

C A T I O N

A N D

0 F

C O N T E N T S

P R EV EN T I V E

M A I N T EN AN C E

Page

Number {0000-}

IOOOH I OOOH I OOOH

000 001 003

I OOOH I OOOH I OOOH IOOOH I OOOH I OOOH IOOOH IOOOH IOOOH IOOOH IOOOH I OOOH I OOOH I OOOH 1000H I OOOH I OOOH I OOOH I OOOH I OOOH I OOOH I OOOH IOOOH I OOOH

004 1 03 203 204 303 403 503 603 703 803 805 913 914 1 003 1 103 1 202 1 303 1 304 1 353 • 1 403 1 503 1 703 1 793 1 803

Description 1 000 Hour Lubrication and Preventive Maintenance 1 1 lustration Engine Tune Up; Air Cleaner, Fuel Pump service Engine Tune Up; Cylinder Head Stud Nuts, I ntake and Exhaust Manifolds, CrankcaseVent·ilation; Intake and Exhaust Valve Clearance adjust Engine Tune Up; I ntake and ExhaustValve Clearance adjustments Engine Tune Up; Compression test, Spark Plugs inspect Engine Tune Up; Distributor Engine Tune Up; Tach Dwell Meter Engine Tune Up; Contact Point adjustment; Ignition Timing Engine Tune Up; Vacuum Test and Carburetor adjustment Engine Tune Up; Governor adjustment Starting Motor inspect Generator inspect Steering Wheel Bearings clean and repack; adjust Drive Wheel Bearings clean and repack; adjust Bleeding Brake System Bleeding Hydratork I nching System Brake Lining Clearance adjust Hand Brake adjustment Cooling System inspect and clean Transmission and Transfer Case drain and refill (Hydracool Models) Differential drain and refill Hydracool Clutch Fluid Reservoir drain and refi 1 1 .,..

Hydraulic Sump Tank drain and refi 1 1 Main Hydraulic System Pressure checks Transmission Stal I and Pressure checks { Hydratork Models) Neutral Starting Switch (Hydratork Models) Upright Roller adjustments T R O U 8 L E

S H O O TING

G U I D E

Description TS TS TS TS TS TS TS TS TS TS TS TS

20 JUL 64

001 251 321 341 361 38 1 401 483 521 541 653 963

Engine Fuel System Coo I ing System I gnition System Starter Generator Battery & Horn Drive Axle Steering Axle Brake System Hydraulic System Hydratork Drive { T ransmission)

A 004-8

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INDUSTRIAL TRUCK DIVISION

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Plate 7691.

ILLUSTRATION OF MACHINE B 001-16

29 JUN 64