CLARK FORKLIFT Diesel Rough Terrain Lift Trucks DPR 202530 OVERHAUL MANUAL

CUARK ·

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Material Systems Technology Company

ADJUSTMENT AND REPAIR MANUAL

Diesel Rough Terrain Lift Trucks DPR 20/25/30 Rated Capacity: 2000/2500/3000 kg 4,000/5,000/6,000 lbs

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BOOK NO. OH-533 G-11tYTll,'hled\locml lnlltn.:k."J for Cl.ARK dub,-on�· J)u nut tdl or d1>lribuk'

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INTRODUCTION This r-ough · ter-r-ain for-Ir lift tr-uc:k has be!'n designed to inc:ar-por-.ite si■plieity af aper-atian far­ the dr-iver- and ease and ac:ces;ibility far- r-outine ser-vieing far- the ■echanie.

However-. befor-e oper-ating the tr-uc:k. attention should be given to the vadaus c:hapter-s in this • unud whic:h have been pr-epar-ed .to pr-avide all of the infar-ution r-equir-ed for- pr-oper- ser-vic:ing and oper-ating technique. Be sur-e that these instr-uetions ar-e followed and the tr-uck is oper-at■d withi� its capacity at all ti■es.

The ter-■s 11 LEFT11 and "RiliHT". "FRONT" and 11REAR" used in this ■anual r-efer- ta the position as if the dr-iver- was seating nor-■ally in the dr-iver- 1 s seat.

ALWAYS PROVIDE THE INFORMATION SHOWN IN ITEMS 1, 2, 3, ANO 4 BELo.'4 WHEN ORDERING P ARTS OR OBTAINING SERVICE INFORMATION

DATA PLATE AND DECALS

Know the rated capacity ol your truck and 00 NOT OVERLOAD IT. Read the rated capacity on the data plate and under• stand areas 1 thru 6 as shown In the Illustration.

1. Truck Model Number

4. Attachments

2. Serial Number

5. Capacity

3. Lot Number

6. Truck Weight

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TABLE OF CONTENTS ( INmODUCTION••• , ••••••••••••••••••••••••.•• , . , ••••••••• , ..••••, , •• ,

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DESCRIPTION ••••••••••,••·•••••••••••••••••••••••.•••••• •• •••• . ••••••

S

SPECIFICATIONS ••••••••••••••••••••••••..••••••.•.••••.••.••.•,• •••••.

6

INSTRUMENT PANELANO CONmOL LEVERS , , ••••.••••••.•.••••••••••••.•• , •• •

10

RECOMMENDATIONS TO TH E OPERATOR ......................... · ,.,, ....,....

15

RECOMMENDATIONS ON THE use OF THE FORKLIFT•••••••• ; ••, •....••, ••• • ' ••••••

16

BEFORE STARTING UP A NEW FORKLIFT ••••.•••...•••.••.••••.•. , , •••. , , •••..

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FORKt:JFT OPERATION •••••••••••••••••••••••••••••••••••••••• , •• , • , , , •. •

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OILS• GREASE·· LIOU IDS•FUEL• FILTERS • , • , ••••• , ••••••••••••.•••• , .••• ••••.

20

MAINTlaNANCE ANO UJBRICATION CHART.••• •••••..• ••••••••• .•••••••••• •••••

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EVERY DAY OR 10 HOURS OPERATION • . •••••.. •••.••••••••••••••••••••••

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2 •

EVERY SO HOURS OPERATION ••••••••••••••••••.••••••.•••.••• ••••••••

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3 • EVERY 1110 HOURS OPERATION •••••• • •••••• ••••••••••••.•••.•.•••••• •.•

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4

EVERY 4150 HOURS OPERATION ••••••••••••••••••.••••••••••••.••• , •.•••

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5 • EVeAY 900 HOURS OPERATION • .•••• . •• •••• •••••••••••••••• •••••••• •••

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BEFORE OR AFTER W INT'EA•••••.•••••••.• :.•• •• ••••••.•••• •.• • • .•••••• . •••

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ELECTRICITY •••••• ••••.••••.••••,•••••••••••••••••••••••• , •• , ••. •••

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HYDR�ULJC DIAGRAM ••• • • • • • • • • • . • • • • • • • • • • • • . • • • • • • • ••••••• , • • • •

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Product Description The Clark OPA Serles Is a lamlly of two­ wheel drive rough terrain lift trucks suited for use In lumbar and brick yards, orchards, packing houses, and In m;iny lleld applications: Their.aggressive tread tires, B•speed transmissions, and high underclearance are soma of the leatures that provide the OPA Series with eKcellent maneuverablllty on natural or semi-Improved surfaces.

Operat o r Comfort/Convenience •High-visibility upright •Cushion-ride seat •Full-time power steering Compartment design allows access from either side. Non-skid, dimpled steel steps and convenient hand-holds help assure operator salety while climbing on or off the truck. Wide-spaced upright members provide an ucellent window lor lorward vlslbillty•.

Cushion-ride suspension seat has tough, dee�ontoured covering and Is lully adjustable.

Instrument cluster Includes waming lights for engine oil pressure, directional lights, . and electrical contact; gauges for fuel level, engine coolant temperature, and battery charge. Engine start, and truck electrical system are activated by a key switch on the cowl. Engine shut-olt Is by cowl mounted pull cable.

A combined running lights, turn Indicator, and horn switch Is conveniently positioned at the handwheel.

Separate lift/lower, tilt, and side Shilt controls are floor mounted on the operator's right Extending from the floor In lront or the seat are the gear change lever and speed range selector. The forward/reverse selector Is on the lett side ol the seaL Foot pedals, from lelt to right, are clutch, service brake and accelerator. Parking brake Is actuated by a hand lever on the right hand side ol the operator's compartment Overhead guard has longitudinal bars to Improve overhead visibility.

Engine'

Hydraulic System

The OPR Serles lift trucks are powered by the IH 0155 diesel engine ollerlng high output and excellent power•to-welght ratio.

(See engine performance data on lollowlng page.)

Two rully Independent circuits assure responsive power to all hydraulic !unctions on demand. Each circuit contains Its own suction llne lllter and shares a common return line lllter.

This engine Is equipped with an electric heater In the Intake manifold to aid cold weather starting. A dry, 3•mlcron multl­ stage air lllter Is sell-cleaning, requiring attention only during periodic mainte­ nance.

Lilt, tilt, and attachments are powered by the main hydraulic clrcuiL This circuit lncorp0rates a gear-type engine driven pump. a three-section spooled control valve, and an accumulator lor absorbing shock and cushioning lraglle loads during rough travel.

Cooling Sy_stem Capacity 14.5 L (15 qts.).

Fuel Tank Capacity 63 L (16 U.S. gal.).

Engine 011 Crankcase Capacity 10.S L (11 qts.).

Electrical System This rough terrain lllt truck Is lltted with a complete electrical system operating on a 12•volt, 96 amp-hour battery and 2B amp alternator. Alternator has bullt•ln voltage regulator. Electric starter Is enclosed and oil sealed. Truck lighting, designed !or use on public roads, Includes headlights, stoplights, and directional turn Indicators.

Transmission/Drive Axle Clark OPR Serles 1111 truck powertraln Is designed ror exceptionally heavy duty applications. Fully synchronized, rugged manual transmission provides eight speeds lorward and reverse through a massive, 356 mm (14 In.) clutch. Drive axle reatures dry1 enclosed disc brakes.

Steering The lull-time, Independently circuited, power steering system consists ol an• engine mounted hydraulic pump, a power steering valve at the lower end ol the steer column, and a double-acting hydraullc cyllnder lltted to the steer axle. This lully hydrostatic system Increases steering rellablllty by eliminating the mechanical llnkage between the steering control and the axle.

Steer axle articulates, providing good wheel-to.ground contact over rough surfaces.

Brakes Service brakes are dry disc type, mechanically actuated. They are enclosed In the drive axle housing for protection against contamination.

Parking brake Is applied on the drive axle and Is actuated by a hand lever at the operator's right side.

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Power steering Is circuited Independently to assure positive truck control at all times.

A visual gauge for convenient lluld level check Is located In the operator's compartment.

Upright Assembly The nested rall, all roller upright members are spaced wide to provide the operator with excellent. lorward vlslblllty. Designed and constructed for the tough load charac• teristlcs ol rough terrain appllcatlons, the upright Incorporates heavy section steel channels telescoping on &Kira-large rollers lor smooth, stable lifting and lowering of loads.

The two bar, rough terrain hook-type carriage ts 1500 mm (591n.) wide and has lour heavy duty rollers plus lour side thrust rollers. Ult cylinder hoses are reeved lor protection against abrasion.

Features and

Options

•Standard equipment: power steering, overhead guard, load backrest, adfust• able suspension seat, horn, lighting tor travel on public roads, key switch, tow pin, hydraullc accumulator. Engine hood has pressurized cylinders lor opening/closing ease. Flnlsh Is high vlslblllty Clark green with white wheels.

•Options and avallable accessories Include: various upright heights and designs, side shilling carriages. and special hydraullc kits. Consult your Clark dealer lor details.

The Oark OPA Serles 1111 trucks meet or •nceed the ANSI B56.6 safety standards.

SPECI Fl CATIONS ENC.IN& Typt ••••.•••••••••.••••••••••••••••••••••.•:•••• Nwnbffot cyllndan ••• ••••••• •••• •••••••• ••••• •••••• • Nwnberot ffl"Oka .•••••••••••••••••••••••••••••.•••• lnJ,ectlon SVfflffl, ••••••••••••••••••• , ••••••••••••• •••• • Firfr,g anfw ••••••••••••• •••••• •••••••• ••••• ••••••• Aacur arm play (ltot tngin,) , lmak• •••••••, ••••••••••••••••••, •••••••••••• . E,chain ..•...•.••.......••...• , .•.• ••.•...•...

01�'-- ..........•......................·.....

Boni ••••••.•••.•.•••••••• •••••••••••••••••••••• Scntke •••••••••••••••••••••• •••••••• ••'• ••••• •• •• C:.Omorealan ratio•••••••••••••••••••••••, •••••••••••• Nomlntl fl'tn rating•••••••••••••••••••••••••••••• , •••• Idling sONd ..•..•. , ., •••• , ••. · ••••• · •• · · ••••• · • · • · Maximum IPNd (unledtn)••••••••••••••.•••••••••• , ••••• DIN PoWW•••••••••••••••••••••••••••••••••••••••• Mt•lmum torqu• ••••••••••••••••••••', •••••••••••••••

IH 0 155 J In lln• 4

Olrtct 1 •J •2 .0098 in. .011 8 in • 155 cu.In, J.B7 In. 4.,:n In. 1 a :1 2.:ZOO fl'm 650 • 750 rpm 2,<4:JO lllffl �.S r:::v / 34.5 Kw 115.7 ft.lb, at I ,liOO fl'ffl

C:001.ING C1RCUIT Wttw cloltd circuit with by-9&11

Type •• • • • • • • • •• • • •• • • • • • • •• • • • •• • •• •• • • •• • • • • ••

Fen a 15.741n.

•Numbwof bled•...•..., .•. .. ....................

. o,.,,,_ . . . . . . . . . . . . . . . . . . . . . . .. ..... . .. . . . . . .

Thwmosat • Btllnnlntot ooenlng ••••••••••••••••••••••••••••••• . """" ag.,td ...• .•. .•...•..•.•..•.•............

170.a°F to 179.a°F ° 199..4 F

TRANSMISSO I N Cued! ••••••••••••••••••••••••••••••••••••••• , ••• • Ola,nectr.•, .•••••••••••• •• , • · • · · · · ••• · · ••• ••• '

Gear baa

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H--, dutV dry plat• 11.021n.

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•Nurntttrot fo"'"wd sp-t,.............................

• N\omti.ot r..,..._ lpttda ••. , •.•••.....•........• , .·..

R11191 c:amnsl ••••, , , ••••••••••••••••• •••• ••••••••• , Fa.-.:t J,- c:antr0I. , , ••••• , •••••••.•••.. ·• � • .•...•• N\omberot drive whffla

4 low/ 4 lllgh 4 low/ 4 high Manual Manual

Type •••• , •• •••••••••••••••••••••••••• •••• •••••• S.,,,lce bnlkt ...... , ••................• ...•• ....•.. l"lrlclng brakt •••• , •• ••• ••. •.•...•••.. •••..••••. ..••

Salad r..-in due Fo.ot -ciplltd on 2 rranr wh•I• Hind l..,ff 1pplltd an frant wheals

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&1.ECTRICAI. CIRC:UIT Ground•••.•••.•••...• , •••.•••••• , , •.•••••••••• , .

B■rtarv ...............•.......•..•...•.•.....•••.

Alttmttor , •••••.•••••••••.• , ••••••••..••••••••••• Suntr .••••••••.•••.••.••••••••...•..•..•••.•••• HYORAU I.IC CIRCUIT

N1911tlve 1lV-96Ah 14 V•:tl A wltn built •In rt111ularor llV 20

25

30

I-Iola •tilt • nacftment drc:ult • Pump tYlle •••••••••••••• , ••••, ••••••••••••••••• • Flaw It 2.lOO fl'"" ••••••.•••••.••.•••••••••••••••• . P,-,,. ................•.............•.......

Gar pump 12.1 0 lmc,.pt• 2422.5 sni

2707.5 psi

StNl'ing circuit , Pump 1y1,a•• •••• , , , •••••••••••••, ••• •••• ••• •••• • Plow ar 2.:ZOO rpm •••••••••••• , • , , ••••• , • , ••, ••••• '

....:.... .......................... .",

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Oar pump 6.47 lmci.vet.

1852.5 p,I

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SPECIFICATIONS

20

25

30

Maximum fork l lft speed • Forward without lolld

12.85 Mph

12.85 Mph

with nom ln■I load••••••••.••••••••

5,6 0 Mph

5 , 60 Mph

12.85 Mph S.60 Mph

. R-u without load• •• •••••••••••••••• with nomlna l load•••••••••••••••••

1 4.9 1 Mph S.60 Mph

14.91 Mph 5.60 Mph

14.91 Mph S.60 Mph

Whn l and tyre 1lu • Front •••••••••••••••••••••••••••• •Reer •••.••••••••••••••••••••••••

12.5-20 8.5 R 17.5

lnflat lng PrtUUrl

30 psi 87 psi

• Front •••••••••••••••••••••••••••• • Anr ••••••••••••••••••••••••••• • Mulmum 11ft h■l11ht with rtand■ rd mat••••••••••••

40 psi 87 psi

44 psi 87 psi

129.92 In.

129.92 I n .

129.92 In.

98.4 ftJm ln.

9 8.4 ftJmln•

98.4 ftJmln.

9 8.4 ftJmln.

98 , 4 ftJmln• 98.4 ft/min.

42 JI 4.9 X 1.8

42 X 4.9 X 1.9

Sundvd mat ral1 lng �ted • Without load•••••••••••••••••••••••• • With nomln■l load •• •••••••••• •• •••••• Dlrnemlon■ of rtand■rd forkl (length x width JI thlckneul Un lncha)

42 JI 4.9 X 1.8

MaJ1lmu!"1 width bftw"n oute r lldgtt of fo rlu ••••••••

58.86 In.

58.86 In.

58.86ln.

Load c:11nter of gravity dln■nce ••••••••• •• ••• • ••

19.68 In.

19.69 ln.

19.6 8in.

4409,0l b , 3295.8 lb.

5511.0 lb

6 6 :J 1 .O lb.

496 0.0 lb.

Nominal capacity fo r on■ lift height with standard mm • With man In v■rtlca l po1 ltion •••••••••••••• • With man In m1J1 lmum forw■rd tilt ••••..••••

4 122.0 lb.

Weight of forklift with mnd■rd man and fork, . Without lo9d••••••••••••••••. , •••••• • Wlth1o■d.•..••..•....•.••.•• .'; ..•.

Weight distribution peraxle with mndard malt In wrt lcal po1lt lon and standard forkl •No loed

• front •••••.••••••••••••••• • ru r •••..•.•..•..•..•.••..

• With nomina l load • f ront ••••••••••••••• • rn r •.•.•••••••• •••.

Orawm r pull . Without load. •• ••• •.....••••••.•• ...

• With nomina l load .••.•..•..••••••••..

3!107.0 lb• 9921.0 lb.

Maximum gBdeeb ll lty at 0.6 Mph •Without load••••••••••••.••.•.•.•••. . With nomina l load •••.••••.••..••.•• ••

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DIMENSIONS IN INCHES

.

A

B

C

0

e

F

G

Gl

G2

H

I

J

N

u

w

z

y

DPR 20

42

70.B

7:1:.l

122.5

164.8

56.5

11.B

18.S

9.7

92.5

74.5

51.2

68.1

90.6

65.4

120

2!f1

DPR 25

42

70.B

27:.l

122.5

164.8

!18.5

11.8

18.S

9.7

92.5

74.5

St .2

88.1

90.6

65.4

12

°

2tf

47

70.B

7:1:6

175.5.

167. 8 56.5

11.8

18.S

9.7

94.3

77.0

51.2

88.1

90.6

65.4

12°

2d'

DPR 30 G

G1 G2

: Under outw m■n : Under foot � ·: Und■r rar axl■

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INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPT.

S A F E TY M E S S A G E S

PLEASE READ AND UNDERSTAND THE SAFETY MESSAGES SHOWN BELOW BEFORE YOU DO ANY WORK ON A LIFT TRUCK -

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A WARNING

A WARNING NAMEPLATES & DECALS

LIFT TRUCK MAINTENANCE

DO NOT OPERATE A LIFT TRUCK WITH DAMAGED OR LOST DECALS AND NAMEPLATES. REPLACE THEM IMMEDIATELY . THEY CONTAIN IMPORTANT INFORMATION . ·•

DO NOT WORK ON THIS TRUCK UNLESS YOU ARE TRAI NED AND AUTHORIZED AND KNOW THE CORRECT MAINTENANCE PROCE­ DURES.

.....

A. WARNING AIR PRESSUR E

PERSONAL INJURY

WEAR EYE GLASSES , SAFETY SHOES AND CORRECT FITTING CLOTHING WHEN WORKING ON LIFT TRUCKS. INJURY CAN RESULT IF YOU DO NOT WEAR PROTECT! ON.

WE�R EYE PROTECTION & PROTEC­ TIVE CLOTHING WHEN CLEANING OR DRY ING WITH AIR PRESSURE. REDUCE PRESSURE TO [207 kPa] 30 PSI . DEBRIS REMOVED WITH AIR PRESSURE CAN CAUSE INJURY .

. . ·.

A_ WARNING-

A WARNING.

HYDRAULIC FLUID PRESSURE

FALLING FORKS

DO NOT USE YOUR HANDS TO CHECK FOR HYDRAULIC LEAKAGE. FLUID UNDER PRESSURE CAN PEN�RATE - YOUR SKIN AND CAUSE SERIOUS INJURY .

DO NOT WALK OR STAND UNDER RAISED FORKS. THE FORKS CAN FALL AND CAUSE INJURY OR DEATH .

.. ""'I .. ,. ... ��--.

C'l1fl'1'1d,k'd M1i.s-11J ln......,'\J hir(l.ARk. Ol:Wfflonl-�n.,o ,klk o,;,

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I NSTR U M E NT PAN E L A N D CO NTR O L LEV E RS

1 - OPERATOR'S SEAT

10 -

2 -

11

IGNITIOl':4 KEY HOLE

-

RANGE CHANGE LEVER MOTION REVERSAL LEVER

3 - INSTRUMENT CONTROL INDICATOR PANEL

12 - PARKING BRAKE LEVER

4 -

13 -

LJGHT, HORN AND DIR ECTION INDICATOR SWITCH

5 - ENGINE STOP KNOB

HYDRAULIC. CONTROL VALVE LEVERS

- TOWING PIN

6 - ACCELERATOR PEDAL 7 - SERVICE BRAKE PEDAL 8 - CLUTCH PEDAL 9 - GEAR CHANGE LEVER

RECOMMENDATlONS Whatever his level of experience, the operator should get well acquainted with the position and operation of all .controls and instrUments prior to using the foriclift.

Check all control lnstrUmdnts immedlmly after start.Ing up, when the engine is hot, and at regular Intervals thereafter so a.s to detect any malfunction and correct it Immediately.

If an Instrument does not give the proper reading, stop the engine and carry out repairs immediately.

CAUTION :

Any attempt to use the foriclift without taking above recommendations into account could be dangerous.

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