Clark Forklift NST245 English O-286 Operator's Manual - PDF DOWNLOAD

CL'IRK

Industrial Truck Division

NST 15/20/25/30/40 SG

Book No. Printing

r

0-286-1 _'J,tA-y_:._82

Clark Equipment Company Customer Service P�blications Department Battle Creek, Michigan 49016

Ull,o U.S.A.

-------- .. ------

CLqAK

EQUIPMENT

INDUSTRIAL TRUCK DIVISION

SAFETY INSTRUCTIONS FOR MAINTAINING INDUSTRIAL TRUCKS Powered Industrial trucks may becane hazardous if adequate maintenance Is neglected. fore, adequate maintenance facllltles, personnel and procedures should be provided.

There­

Maintenance and Inspection of all powered industrial trucks should be performed in confor­ mance with the reconmendatlon 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.

Befor e Leaving The Truck; A.

Stop truck.

B.

Fully lower the load engaging means.

c.

4.

Place d Irect IonaI controls in neutral.

D.

Apply the parking brake.

E.

Stop the engine or turn off power.

F.

Lock the control or Ignition circuit.

G.

BI ock 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, lnnermast(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 ls depleted and engine stops running.

s.

I

Operation to check performance of the truck or attachments should be conducted in an authorized, safe clearance area.

Before Starting To Operate

The

T ruck;

A.

Be in operating position.

B.

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

C.

Place directional controls in neutral.

D.

Start engine or turn on power.

E.

Before operating truck, check functioning of lift 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)

CLqRK

EQUIPMENT

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 flanmable cleaning fluids for cleaning parts.

7.

Properly ventilate work area, vent exhaust funes and keep shop clean and floor dry.

8.

Handle LP gas cylinders with care.

9.

Brakes, steering mechanisms, control mechanisms, warning devices, I lghts, 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 lift 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, limit 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 whtch affect capacity and safe truck oper�tlon should not be performed by the custaner 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)

----------

INST R·u C T I ON s-·

M A N lJ P. L

0 F

US E

ON

. This· Operator's .. -��al• is published as a. service refer­ ence . guice- ·· and ·includes Specif · ications, Operating· I nstructions, LUbrication and Preventive �ia.intenance I nstructions, and T=ouble ·· Shooting GUide.

T?'le.

TABLE OF .COL'lN TE S T · for this · manual is prir..tec on green .paper and, is· -placed·. at ·the: front for easy referer.ce.

A ·separate .INDEX (also printed on green paper) is placed in £rant of the Lubrication- anc 'Preventi.ve i-1aintenance Section. listed The

Examo'e:

a

INTERVAL

TIM�

002

.!..s

BH the

custc:ner

for

and Preventive Maintenance !nstructions • are T'IME L'ITERVALS that they should �e perfo=�ed.

Lubrication under the

the

is

002-0; P.a.GE

�art

BH

Ls

NUMBER,

should

benefit

of t..lie

and

disregard.

c.f

the

paae

INTERVAL

L T �

-0

is

The

a

dash

c;:1e publisher

number

COOl" m.:rnber

anc

(8

cede

nur:ibe=.

ooeratinc

!-TUM.BER or

tha:.

code

:iou=si,

vcu

as

nu itl:er

is

onlv.

The t?-.'DEX is set up under the 'I'Ii-1.E �TERVALS t::iat Lubrication and Preventive Maintenance should be perforr.:ed .. Ex�p_le: . . · . ( 8 , H<?',LrS} • .. •

�--.. .. ·-- .. ·,._ . � :... 1·•·:

. • _r_·. ••

.... ,.

-· -••.:,,�.

.'

'0 T\. 0_,, ,,•.• ..

Page N1.;mber (:)00-)

Ti:ne

.

--..•••· .: . �..:f.� :•.•.__. : ·_::.•·•. �-a•• . ' :: ._Y ♦.�:,

••

·-

• �

i::iterval (H•Eours}

&

:•:�-.

Eiycr�li�-- sump Taz;k, · ·1evei ··chec.'lt·... · Brake Pedal Free Travel ,. ·check •••. •·

503 373

The above states to check the sump tank fluid level eyery a·. operating hours--· and refer to page 503 for flu1.d recommendations.-' etc .,. Also •; . -to- . check brake ?edal free travel at t.l'lir.,l.nt�FVa.l, :and_ . turn' to - p�ge.

373 for instructions.

• • .. . .. • � \.,, :��: ,-:· •••.o:· .... ,-

':. ••"'""··• .:�

:•

·'Turn· . to.- ·-the eight (8) · .hour section (BP.) and l:�er. to the page ·r:rsted '.'.' "-:.:.... 503 ...oi:·.::: 3'73 etc� The instructi.ons cove=ec therein will pert�in· only to the checks or adjuetments that should be performed a"t this rT ME U!TERVAL. ,. . ·If, for insta.>1ce-, the Brake Pedal Free Travel is i:icorrect. yO\! would then refer to. �he :"NDEX for "Brake Pedal Free T:.-ave!., adjust" _. which wou-ld be ;usted in the TL"tE' INTERVALS follcwing t�e 8 hour sect.ion.

Examole: '

( l.00

Hour!!)

Time I nterval (H•Rours)

..

Brake

Pedal TUrn

Free to

the

Travel, one

adjust ••. • hundred

hour

AOOl-4

Page Nurnbe:.­ (000-)

&

302

lOOH section

(100H)

and

then

:.o

I N S T R U C T r O N S

:.::.--..

ON

page 302. C(?lllplet9- instructions as . to free travel, the method·· to check .. -and travel with 'illustr.ations ·· are·· �eluded

YOO TION

WILL NOTE :_. THAT"· A'l! .THE" AND

LOCATION

PR-"'VENTIVE OF

..

the L'tlportance of pedal adjust for correct free therein.

BEGINNING · OF .•

. .

1-1.�NTENANCE ,-

I�LOSTR.�TION"

LS

SECTION

saCMN

A

.LUBRIQ-

GIVJ:NG

T"r'.E

SERVICED.

BE

'!SE Cot-1.PONENTS TO

EVERY

It is ·1r.1possib"le· _to · cover all-· types of machine operatior:s in one manual-.. Operating :\cpnditions. should ·determine the lubrica­ . tion and maintenance 'iatervals-.:·•:common sense and a close observ­ ance can best determine•. the:·frequency with which you should service your machine.

The care you give-. yo�r · machine· will greatly determine satisfa�tion and service life that _you will obtain £rem it. difinite maintenance program should be set up and f�llowed. naphazard !:laiotenance will only lead ·· ·to f�ulty -?erformance · · · · .., ·. short. lifP..

•.t "·- -: • • "'

. : .,,::

. . .. -

.. .

. -;., .... :...,, ·:, . .

-

......... ....'

. -�· ,� .:

27 JAN 64

.-

A002-0

the A

INDUSTRIAL TRUCK DIVISION TA B LE

,-....

0 F

C O NT E N TS

PAGE

DESCRIPTION

PAGE

DESCRIPTION

A001 A002 A073 A074 B071 B073 B074 B075 B076 B077 B078

Instructions on us• of manual Instructions on us• of manual Table of contents Table of contents Illustration of truck(s) Specifications Specifications

C070 C071

overall controls Battery connector Power key switch, controls Battery charge Indicator, Hour meter Brake and Parking brake To pick-up a load To 1110Ye a load To deposit a load Safety and Operating Suggestions

C073 C 173 CJ03

II II II

II

L U BR I CAT I O N Time Interval (H-HOURS) H H

Page Number

(000-)

07 1

on

A N D

P R E V E N T I V E

H A I NTE NA N C E

DESCRIPTION INDEX INDEX

PAPER COLOR -- GREEN

8 HOUR (Every 8 operating hours, or every shift) SH

000 273 375 473 474 475 476 477 479 50J

Battery charge Indicator, hour meter Brake (deadman) switch check Battery, service checks and maintenance Battery, service checks and maintenance Battery, service checks and maintenance Battery, service checks and maintenance Battery, service checks and maintenance

Battery, service checks and maintenance Battery, removal and installation procedure(s) Hydraulfc sump tank level check

100 HOUR (Every 100 operating hours) !OOH

000 185 186 187 188 302 303 306 307 403

473 503 673

n2

867-L

thru 881-L

100 Hour PH illustration

Drive control adjustment Drive control adjustment Drive control adjustment Drive control adjustment Brake, check and adjust Brake, check and adjust Brake, check and adjust Brake, check and adjust

Lift cylinder operation check Tilt cylinder operation check Reach cylinder operation check Lift chaln(s), check and adjust Lubricate truck Hydraulfc control valve and lines, Inspect Lift carriage (Pantograph), Inspect Lift and tilt switches, check Hydraulic sump (breather) filter, check Contactors, Inspect Lubrication chart PAPER COLOR -- BLUE II Lubrication chart II Lubrication •continued­ II Lubrication recorrmendations II Lubrication specifications II Lubrication chart(s) key A073· 1

REV JAN 72

INDUSTRIAL TRUCK DIVISION

CLqAK

EQUIPMENT Time Interval (H-HOURS)

Page Nwnber (000-)

DESCRIPTION 500 HOUR (�very 500 Operat Ing hours)

500H

000

1n

174

4n

500 HOUR PH Illustration Suqr tank, drain, flush and refill Suq,. tank fl lter, change Suq, tank breather, check/replace II

Caster adjustment 1000 HOUR (Every 1000 operatIng hours)

1000H

000

6n

674

n3

n4

912 913 1507 1573 1940

1000 HOUR PH Illustration Drive motor, Inspect Drive motor brush spring tension, check Pu1111 motor, Inspect Pu1111 motor brush spring tension, check Brake, bleeding procedure Brake, bleeding procedure Hydraulic system flow and pressure check Hydra.illc system flow and pressure check 'tlleels TROUBLE SHOOTING GUIDE

17.7500 1000H

Solid state control

PAPER COLOR -- GREEN

Uprl ght - "IW MODELS

PAPER COLOR -- PINK

UPRIGHT - 11C' 1 MODELS

1000ti TSH001

Hydraulic circuit dlagr•

IN - fo Id-out

Wiring diagram

REV JAN 72

---

-------

PAPER COLOR -- YELLOW

INDUSTRIAL TRUCK DIVISION F I C A T I O N S

S P E C

Overall height with 128 MFH Std. Upr. . . . ... . . . . .. ... . . . . .... . 164 1/4 inches

POWER SU PPL Y

Type battery ..... . . . . . . . . .. . . . . . . Lead Acid

OveralI width . . . ..... . . ...... . . .. . ....

34 rear front varies 34 to 58 inches

Voltage . . ..... ... ...... . . . . . . . .. .... . . . . 24 Ampere Hour Capacity . .. . . . . . . . . .. .. ...

500

Ground clearance - under Straddle Arms..... .... . ••. ••. . ••.••.. . . . ••.. ••. . . . . . ..••. ..• 2 inches

Battery Weight . . ..... . . . . .. .. . . . . 1260 lbs.

Grade cle·arance . . . . . . . . . .. .. . .. . . . ... .. . 15.6%

CONTACTORS Replacement:

HYDRAULIC SYSTEM

when approximately l/1611 wear is reached.

Suction Filter (cleanable). . 100 Mesh Screen

N . O. contact gap wi 11 be 5/16" !. 1/32" N. C. contact gap will be 1/ij' !. 1/3�'

Return line filter (replaceable). . 10 micron Sump tank breather (replaceable). . 5 micron

Battery Compartment Size . . . . . . . . . . ... .. . . . . . . . ... . 32 3/4 W x 12 1/8 L x 31 1/2 H

Sump tank capaci ty . ... . ... .... 6. 5 ga 11 ons

Optional Sizes: 37 x 12 1/8 x 31 1/2 32 3/4 X ]6 5/8 X 31 ]/2 37 X 16 5/8 X 31 1/2

HYDRAULIC VALVE Pressure relief valve setting. ..1750 P.S. I.

TIRES (in inches) OPTIONAL Front Load (Polyurethane) (Polyurethane) (Tandem) 4 Dia. x 2 5/8; (Tandem), 5 x 2 2/8 Front Load (Single), Rear Steer-Drive Caster

BRAKE SYSTEM Type .... Spring applied, Hydraulic release

OPTIONAL (Rubber) 10 x 5

Service-Parking Brake Effectiveness....... . . . . . . .. . . . . . . . ... . . . Refer to page 100H 912

SPEEDS ANO GRADES

Rubber (Single), 10 1/2 x 6 x 5 (Dua1)

DIMENSIONS Without forks

Forward M. P.H. Loaded ... . ... .. .. . . .. .. . .. .. .. 4.9

Polyurethane 6 X 2

Empty .... . . . . . .. .. .. . . . . . .. ...

Reverse Loaded . . . . . . . . . . . ....... . . . . . .

66 3/8' 1

Empty . . .. . •. .. .. . . . .. . ... . .. ..

Width Height with upright lowered (12811 MFH Standard Upright) . . . .. .. . . . . .. . . . 83

Gradeabi1ity WI th Rated Load. . . . ... .. . . .. .. .

Empty .... . .. .. . . . . . .. · . .·. · · · ·

Basic aisle for right angle stacking. . . . . . . . . . . . . . . 71" + 611 operating clearance

5.5 4. 9 5-5 1 0"/4 I 0"/4

LI fti ng Speed Loaded . . . . . . . . . .. . . . . . . .. . . .. 33 FPM Emtpy . ... . . . . . ... . . . ..... .. .. 50 FPM

Free lift (in inches)

Lowering Speed Loaded . . . . . . . . . . . . . . . . . . . .... 60 FPM

Standard upright. . . . . . . . . . . .. 1 7 1/4 Hi lo upright . . . . . . . . . . . . . . . . 46 3/4 Triple stage................ ..... 13

Empty . . . ... . . . ... . .. . .. ... .. . 80 FPM

�

B073-5

REV 30 NOV 67

INDUSTRIAL TRUCK DIVISION S P E C I F I C A T I O N S BATTERY CONNECTOR••. ••••. ••••••••. . . ••. . . •• SB-2 HYDRAULIC PUMPS ••••••. ••••••See page 1000H 1573 BRUSH SPRING TENSION. ••. ••••. See page 1000H 774

REV 30 NOV 67

B074-2