CLARK FORKLIFT OH-362 SAFE MAINTENANCE OVERHAUL MANUAL

OH-362 SAFE MAINTENANCE

CUARK

(op)ngh1cd Molcrial lnlended for CL\R"- dealers onl) Do nol sell or di 1ribu1e

Technical Pu�lications Lexington, KY 40508

DH-3b2

INDUSTRIAL TRUCK DIVISION

OWNER SAFE MAINTENANCE PRACTICES Powered industrial trucks may become hazardous if adequate maintenance is not done. Therefore, maintenance facilities, personnel and procedures must be provided.

Maintenance and inspection of all powered industrial trucks should be done in agreement with the recommenda­

A scheduled preventive maintenance, lubrication, and inspect ion system

Before working on engine fuel system of LP gas powered trucks, close LP gas cylinder valve and run engine until there is no more fuel in the system and engine

Only qualified and authorized personnel should be permitted to maintain, repair, adjust, and

stops running.

inspect industrial trucks.

4.

Before Leaving The Truck: A.

Stop Truck.

B

Fully lower the load engaging means.

C.

Put directional controls in neutral.

D.

Apply the parking brake.

E.

Put blocks under the load engaging means, innermast(s), or chassis before working under them.

system of gasoline powered trucks

must be followed.

3.

C.

with gravity feed fuel systems, make sure fuel shutoff valve is closed.

practices.

2.

Use blocks or other positive truck positioning devices.

Before working on engine fuel

tion in thls manual and the following

1.

B.

Operation to check performance of the truck or attachments must be done in a clear, authorized, safe area.

5.

Before Starting To _Qperate The Truck: A.

Be in operating position.

B.

Stop the engine or turn off power.

Push clutch (or brake pedal on automatic transmission and electric trucks).

C.

F.

Lock the control or ignition circuit.

Put the directional controls in neutral.

D.

Start engine or turn on power.

G.

Put b locks at the wheels if truck is on a ramp, or being worked on.

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.

Before Working On Truck: A.

Raise wheels free of floor or disconnect power source.

- continued 1023-Z �Vg 1&El?la11IB1 (FRONT) Intended for CLARK deaJers only Do not sell or distnbute

INDUSTRIAL TRUCK DIVISION

OWNER SAFE MAINTENANCE PRACTICES (CONT.) 6

Avoid fire hazards and have fire protection equipment availab le.

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 flalIIIIlable cleaning fluids for cleaning parts.

7.

Provide ventilation to the work area, vent exhaust fumes, and keep shop clean and floor dry.

8.

Handle LP gas cylinders with care.

Do not drop, dent, or damage in any way.

9.

Brakes, steering mechanisms, con­ trol mechanisms, warning devices, lights, governors, lift overload devices, guards and safety devices must be inspected regularly and maintained in a safe operating condition.

10. All parts of lift and tilt mechan­ isms and frame members must be carefully and regularly inspected and maintained in a safe operating condition.

11. Special trucks or devices designed and approved for hazardous area operation must receive special attention to make sure that maint­ enance keeps the original, approved safe operating features.

12. Fuel systems must be checked for leaks and condition of parts.

Extra special consider ation 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.

13. All hydraulic systems must be regularly inspected and maintained in conformance with good practice.

Tilt cylinders, valves, and other like parts must be checked to make sure that "drift" has not devel­ oped to the extent that it .,iould create a hazard.

14. Capacity, operation and maintenance instructions plates, tags, or decals must be maintained in legible condition.

15. Batteries, motors, controllers, limit switches, protective devices, electrical conductors and connections must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of elec­ trical insulation.

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

17. Modifications and additions which affect capacity and safe truck operation must not be done by the customer or user without manufacturers prior written ap­ proval. Capacity, operation and maintenance instruction plates , tags or decals must be changed accordingly.

18. Care must be taken to make sure that all replacement parts are

interchangeable with the original

parts and of a quality equal to that provided in the original equipment.

1023-Z CoMj�1 '$E�tc1&!3 (BACK) Intended for CLARK dealers ortly Do not sell or distribute

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

TAB L E OF

CO N T E N T S

Engine - Perkins Diesel 4.236 Engine - Perkins Diesel 4.203 Engine - Perkins Diesel 4.2032 Hydratork Transmission ( H200 - H211) Starting MotorOverhaul .

AlternatorOverhaul Alternator Overhaul Electric Checks for Internal Combustion Lift Trucks .

DriveAxle Ends Overhaul DifferentialOverhaul - . • . . . . • .

Two Piece Case and Four Pinion Differential Overhaul - . . . . . .

One Piece Case and Two Pinion Brake Bleeding . . • . . .

Master CylinderOverhaul Inching CylinderOverhaul Disc BrakeOverhaul . .

Hydrovac Overhaul Parking BrakeOverhaul Steering GearOverhaul Power Steering CylinderOverhaul Hydraulic (Steer) Pump Overhaul Hydraulic Pump Overhaul .

Hydraulic Valve Overhaul Tilt CylinderOverhaul Tilt Cylinder Overhaul Lubrication Specifications and Recommendations

Code: OH-362, OCT 83 PSL

cCA.NitE:mcrial Intended f�r CL/\RK dealers only Do not sell or distribute

GROUP

SECTION

00 00 00 06 11 12 12 12 20 20

10 11 12 08 04 01 03 05 06 19

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23 23 23 23 23 23 25 26 29 29 30 32 32

01 02 02 11 38 40 05 09 02 11 08 06 09

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CIARK

GROUP

OH

FO RE WO R D This overhaul manual has been written to aid the mechanic in the disassembly and assembly of the main components of the specific truck that this manual includes. Every improvement has been made to help the mechanic to discharge his duties in a safe and practical procedure.

If the mechanic does not understand the correct procedure in the maintenance of this truck, he is told to see his immediate supervisor instead of risking injury of personnel.

This manual has been written in groups and sections with a table of contents for easy reference.

Approved methods of service and correct procedures of repair are important for the safe operation of all trucks as well as the safety of personnel and the mechanic doing the work. This manual gives directions for service and repairs with procedures that are tested.

The mechanic is told to always use Genuine Clark Parts when replacements are needed. "Look alike" parts from other supplies never work as well as the original parts.

There are many different procedures, tools, and parts for servicing vehicles, as well as in the ability of the mechanic doing the work. This manual cannot be written for all such variations. Any mechanic who works differently from this manual nust first make sure that he works safely and accurately.

Each section includes many photographs and drawings to directly show how to do these operations.

Specifications and notes on safety have been included as needed for each step to be done. The mechanic is told to use safety and accuracy in his work because we cannot control his work and procedures.

Code: 00-510, REV OCT 83 PSL

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

FOREWORD

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

S A FE T Y M E S SA G E S

A WARNING

A WARNING

PERSONAL INJURY

LIFT TRUCK MAINTENANCE

WEAR EYE GLASSES, SAFETY SHOES AND CORRECT FITTING CLOTHING w-!EN WORKING ON L.ffT TRUCKS. INJURY CAN RESULT IF YOU DO NOT WEAR PROTECTION.

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

A WARNING

A WARNING

BATTERY SERVICE MUST BE DONE

BY TRAINED PERSONNEL. BATTERY ACID CAN CAUSE SEVERE BURNS ANO INJURY.

INTERNAL C0'1BUSTION ENGINES GENERATE TOXIC GASES 1n\-i ICH CAN CAUSE SERIOUS INJURY OR DEATH WHEN ItttALED. BE SURE THERE IS ENOUG-l VENTILATION.

CARBON MONOXIDE

BATTERY SERVICE

A WARNING

A WARNING

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

WEAR EYE PROTECTION & PROTEC­ TIVE CLOTHING WHEN CLEANING OR DRYING WITH AIR PRESSURE. REDUCE PRESSURE TO [207 kPa] 30 PSI. OCBRIS REMOVED WITH AIR PRESSURE CAN CAUSE INJURY.

A WARNING

A

AIR PRESSURE

HYDRAULIC FLUID PRESSURE

STEAM

DO NOT REMOVE THE RADIATOR CAP WHEN THE RADIATOR IS HOT. STEAM FROM THE RADIATOR WILL CAUSE SEVERE BURNS.

MAY 83

WARNING FALLING FORKS

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

Cop}rightcd Motcriol Intended for CLARK deolers only Do not sell or distribute

1308-Z

GROUP 00

GROUP 00 SECTION

10

E N G I NE O VE RHA UL PE RK I N S

DIE SEL

4 • 2 3 6

PerkinsEngine manuals are available from: Customer Services, 525 N. 24th ST. Battle Creek, Mi. 49016

Code: OH-362, REVO C T 83 P.S . L.

Conrigh100 Material Intended for CLARK dealers only Do not sell or distribut�

Section 10, Page 1

GROUP

00

GROUP 00 SECTION

11

ENGINE OVERHAUL

P E RK I N S

D IESE L

4 • 2 0 3

Perkins Engine manuals are available from; Customer Services, 525 N. 24th St. Battle Creek, Mi. 49016

Code: OH-362, R EV OCT 83 P.S.L.

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

Section 11, Page 1