Clark Forklift P40 P60 English O-142 Operator's Manual - PDF DOWNLOAD

OPERATOR MANUAL P40 & P60

Book No. 0-142

CUARK

Technical Pu�lications Lexington, KY 40508

INDUSTRIAL TRUCK DIVISION r

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

There­

Maintenance and inspection of all powered industrial trucks should be performed in confor­ mance with the recOl!Vllendation 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:

4.

A.

Stop truck.

B.

Fully lower the load engaging means.

C.

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 Starting To 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.

D.

Start engine or turn on power.

E.

Before operating truck, check functioning of 1 ift and tilt systems, directional and speed controls, steering, warning devices, brakes, and any attachment. (If used)

F.

Release parking brake.

- continued 1O23-Z

REV OCT 68 (FRONT)

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 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 cylinders with care.

9.

Brakes, steering mechanisms, control mechanisms, warning devices, 1 ights, 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 I ift 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, 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 customer 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)

mm m=m

INDUSTRIAL TRUCK DIVISION

mm

�

I N D E X

PAGE Specifications Specifications

............................................. .............................................

3 4

D P E R A T I O N S 2 Operating Instructions ................... ..................

Lift-Lower Operation .... ..............................

3 Preventive Main., Safety & Operating Instructions ..... 3-4 Trouble Shooting ..•................................... 5-6 Lubr'cat'on Chart . .

Lubrication Diagram

L U B R I C A T I O N

........................................

9 8

B R A K E S Brake Adjustments ... ......................................

Brake Lining Replacement ..............................•....

Brake Spring Adjustment Illustration .. ..........•..........

Brake Spring Tension ................ .............. ........ .

Brake Switch Adjust nt Illustration .......................

Deadman Switch Adjustment ............••..................•.

D R I V E

l l 2 2 2

U N I T

Axle Shaft Bearing Removal .....................•...........

Cleaning and Inspection ....................................

Drive Tire Change ......... .......................... • ......

Drive Unit 11 lustration ....................................

Drive Unit Installation ....................................

Drive Unit Reassembly ......................................

Drive Unit Removal .................................. .......

Installation of Fabreeka Pads ..... .........................

Lubrication .......................•........................

Pivot Bearing and Support Removal ..•.................• .....

Radial Thrust Roller Replacement .... ......................

Reduction Gear Case Disassembly ............................

4 4 8 l 4 4 2 4 2 4 4 3

E L E C T R I C A L l Battery ........• .......................... • ................

2 Battery Cautions and Warnings ........ ......................

Check and Seating Brushes .....................•.......•.... 10 Contactor Pane 1 .................................... ........

8 Drive and Pump Motor 11 lustration .......................... 5-6 9 Field Coils, Brushes ........ ..............................

Resistor .......................... •.......•............. ...

I0 Switch (Li ft Limit) Adjustrrent ............................. 3-4

CODE 142-1

A

REV 9 DEC 69

INDUSTRIAL TRUCK DIVISION I N D E X (Continued)

H Y D R A U L I C S After Hydraulic Has Been Reassembled ............•.•....•.•.

Hydraulic Fluid ................•.•.••.•• • ••. •.••....••.•..• Hydraulic Unit ...•.... ..................•.•........•. •.....

Hydraulic Unit Check, Release and Relief Valves-Illus.

Hydraulic Unit Schematic .........•.... •.......... .. . • ..•.•.

Hydraulic Unit Service Procedure ....•••.....•••...•..•.•...

Lift Cylinder Disassembly and Reassembly ............•......

Lift Cylinder Removal ..•..•.....•.......••...•.•.•..•......

Removing and lnstal I ing Reservoir ...•....•...........•.....

PALL E T

7 I 2 5 3 4 10 9 6

FORKS

Lift Linkage D.U. Bushings ...•......•.•....•.••..•.•.......

LiftLinkage (Single and Dual Tire Install.) Illustrations..

Trail Tire Adjustment .........•.•....•...........•......•..

Trail Tire Replacement ......••......•........•..•......•..• Trail Tire Wheel LinkageAdjustment .......••......•........

REV 9 DEC 69

PAG E

B

2 3 I I I

CODE 142-1

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

POIYIIYOIKEI ®

PALLET TRUCK

SPECIFICATIONS - MODELS P40 AND P60 CAPACITY

DRIVE

Mod•I P40 - 4000 lb._ Modol P60 - 6000 lb,.

WEIGHT* P40 W,thour botlery 1090 lb1.

With leod-oud battery 1455 lb,.

Wi1h Edi,on battery 1400 lb,. ...

• aou:d on 4, long pollet fo,lts

P60 1120 lb, 1485 lb, 1430 lb1.

BAfflRY

12 voh battery h standard Choice of l(W h our c:opoc.hi-a ovolloble to 1uir o�ro1ion Soltery and lruc.l provided with 1tondord type "SI" conneclor with in1e,chongeobte. idet111col halves.

POWRWOIKEI '26" Single ltaw loyovt - 6 c..111 11 to 13 plo le lead-Acid o , compo roble N,clriel-Allal,ne bo lt•ry POW•wou:ER 32 Double low 10,ovt - 6 ulh 17 to 23 plat e lead.Ac id or comporobte N1ekel Al�ol,ne b attery POWIWORKEI JJ, for Ready Pow e, Unit

SPEEDS T,o..,el - no load - J 2 M P H full lood - 7 l M P H

The 1eriu-wound drive moto, 11 of lhe high lo,que type, horlz.onlal• ly "'ounted and equipped with ,eofed boll beorirgs. Electrogrophitic bnnhes provide proper comnu,totor lub,icot,on re.1uh1ng In long brush ond commufolor life. , Power fr-om the motor h lronunitted throvgh o 2 2 to I double •• duct,on of spur gcou to the drive wh••I o•I•. All g.-an ore drop fOfged alloy 1leel, heat treoled ond uown ,hawed for q11letneu and long Hfe. Tho complete gear train i, mounted on boll and taller bear­ ing, and operolu 1tt a tot ally encfou1d housing in o bolh of oil. ,.

The d rive wheel is provided with o 1tond ord 10½ it 6" • .5" I.D. c:u1hion tire. The qu,c�ly demo"ntoble tire mo�u replacement pouible w,th ti"'ple mecha nic:', tool,.

HAKE ,..

CONTROLS

DIMENSIONS Pollet Pollet Poller Polle t

Two spttd,, forward and re-11n1, provide ,mooth, 'l0f1 and efficient oper ation, A finger tip walking beam octuotes electric swhd,e, built into the controt head at the end of the ileer lng handle permilli.rig sel e c­ tion of duired speeds and dm11ction The walking be am makes it im pos• sible to direct both forward and re•er .Mt cuuent ro rhe drive m otor ,imultoneo utly. To ,eve,.,. direction, the contr ol m uu pou through MU• trol to �,mit movem.nt In the Mwfy Mlected duection. The 11ft and low.ring twitc.+.es ore m ounted in the handle far eo,y operation while moving truck Smooth progreuion to top speed " ouured by definite notched contr ol position, All wi,ing betwNn <ont,ol and motou is directed to the pow•, .w,urce Com mutotou o"d lo ng Rewing wiret have been elimi­ nated for m0Jt1mum elN"1t1col efficiency

For �, - over all spread 21• Fo rk longth, - JO.. to 12• in 6 .. inc,emenh Fo,k Wid1h - 9 Ye .. fo,k lift - _. .. •ertic.ol

WHEELS AND TIRES • 5 .. I 0. preued-on type uoh1on rvbber tire. leor wheeh, steel. mounted 1n p ain, each pair 6" wide -. l ¼,. d,ometer. ., Urethane t1rH 3 ¥. diofflele r ore 0¥01 lo ole for reo, whe•h ot •••ro Drive. 10½ .. • 6

FRAME

The d11 ve wheel i1 mounted on boll beorlng,, lra lting whHh both steel and u rethane ore mounted on Timhn tapered roller bea ring,. Of'ld h�"Y alloy 1teel shofh

The ,oWIWORkER choui, fr ame 0ftd load forks ore fo br tcotecf from plate ond bar steel, fo,med to shape oncf electttcolly welded into o unit ,t r\lclvre, p101tiding great tlr ength and rigi"ity with minimum weight. The fo,\ el eYot 1ng chon neh o re 1nlegrol w,th the frome load wheel rallen ore mounted under the ends of the fo,h and are c.on• nec:ted to the ele..,otlng hnli: age. Thi, Hnkage i, so orronged that with the wer1ical lift 10 the fo,li:s the whee lbase h shortened and unde r• cleo ronce n increased.

Pollet for ks ore hea vy sleel plate fOf,ned ta ,hope with can1invov, inlegrol forf'!"led tubular ,ecllon fo r ngidity. all elect,,colly welded [nto a v nlt section.

The ta. of eoc:h fork is pt"ovided w,th o p ollet entry disc for sm ooth, eosy 1n1,y into dat.1ble foc.ed po lleb

HYDRAULIC un The heavy dvly motor, pump. hydrovlic "uid ,uenoir. uoled relief volvo and c ontrol vol•e a,e ouembled i nto one c.ompod. hor,z.onlolly• mounted vnlt The ,4 vertica l Uh and lo""'•' of fo,tu It regulated by push puttan, built Into the col"trol heod mounted on the end of the uee.ring hon.die.

Two heavy-duty ram 1ype, ,elf-a l,gnlng hyd rovlic cyUndeu with preu11rited potklng ore ,11ed lo roiu lhe fork, u,ppotted by faw 2� .. d,ome ter rolleu t ro1tehng in ver tical gvide cha ririelt.

Pos1t,ve fodi. ,et1,1rn aswred by rel1i1rn ,pungt in tern al •1 thin c-yl 1nd eu

GENERAl High p rusu re lvbric:ohon lhravgh standard ovtomoti1te fittings.

All bolls ond nuh ore c:odmiv,n plated for prot ection ogoin,1 cat• ro,ion.

Standard equipment tncl11du electri c h0<n Ofld lock ogoln1t un01,1lho,ited operolion.

T,uc:lc po1n1ed yellow.

STEERING The lr1i1c.l ii gvided eos,ly by tu rning the dr ive wheel ouembly which Ti mo1o,nted wilh,n the fram e on widely-sp aced 1elf-0H9ning roller thrust b•orlng, and rolle" for rod,ol load, lear ings ore sealed and lvbt-1coted f or Ufe. The tub1,1lor lleel steer ing handle h fflovnted on the dri•e o uembly.

N,nety degrees of turn ore O¥Oilable tn each dir-echon

CODE 142-1

,..

Smooth and poshive brolung 11 o.uvred by the 5 d?ometer " 1 ½ wide broke drum movnled on lhe dr i"• motor ,h aft. lra lriing effor t IS tran•m•tted l rom the 1ou,ut of pow e, through the 22 to 1 gear ratio to the drive ..-heel. The brali:e h spring applied when Iha slee,ing h andle il In the ver tical ot hanr.onlol position. A1 the br oke is op• phed o dead "' an swilch it ocu,ated whtc:h o"tornolicofly brea ks the power cfruit. h h impou1ble to operate Iha tr uck when the handle h eithe r ver tical a, horizontal. The steer in g handle outoanotic:ally retvrn, to the vertical. broke applied positlan when released by the operator .

The security of loads i1 further in1ured by elec lr 1c b,oking which h pon1ble by the rever10I of power in ""' speed through the fvll •olue of resi,tonce.

NOTE

3

C/Jr! p,odvm «nd /Jtr1,r�1ton1 "" 1vb1u1 to 1mp,01tmtnll a,rd rLn111 u ,rl,0111 noru,

27 NOV 63

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INDUSTRIAL TRUCK DIVISION 'DUAL' FORWARD & REVERSE CONTROL LEVERS "PRESS" REVERSE DIRECTION

"PRESS" FORWARD DIRECTION

LI FT

SWITCH----�----J

LOWER SWITCH

-------------7 MACHINES so EQUIPPED /l

0

HORN BUTTON

I

I I KEY SWITCH

I

- - - - - - _ _J Plate 99 1 1 . Steer Handle and Controls OPERATING INSTRUCTIONS SAFETY ANO OPERATION SUGGESTIONS PREVENTIVE MAINTENANCE INSTRUCTIONS It is not essential that the prospective operator have experience with this type of hand truck, but it is important that he be thoroughly instructed as to the use and operation of the various controls.

1 . Connect battery to the truck. The battery connector is located to the left of the machine just beneath the top cover.

2. Lower steering (control) handle to release the brake. The brake is applied when

CODE GOV' T 2 1 1

the control handle is in a vertical or horizontal position.

3. Press the dual directional control lever gently to the indexed notch in the direction desired, see Plate 991 1 .

4. Press the dual d irectional lever beyond index position for second point of power.

5. Norma 1 Stop: Move cont ro 1 hand'( e to vertical or horizontal position. As the brake is applied, a deadman switch is actuated which automatically breaks the travel power control

OPERATIONS 2

1 5 MAR 68

INDUSTRIAL TRUCK DIVISION circuit. It is impossible to operate the truck in either forward or reverse when the control handle is in a vertical or horizontal position.

6. Emergency Stop: Press the dual direc­ tional lever in opposite direction MOMENTARILY to reverse power. If the truck is in a forward point of power and an emergency stop is neces­ sary, press the dual directional lever to reverse position MOMENTARILY. This wi 1 1 reverse electrical current through the drive motor bringing the truck to a stop.

LIFT

LOWER CONTROL OPERATION

1 . Depression of the lift switch button on the control handle wi 1 1 operate the pump motor and hydraulic pump for lifting the forks and load.

2. Gently depressing the lower switch button will lower the forks and load. This button is located directly below the lift switch button, refer to Plate 99 1 1 .

SAFETY AND OPERATION SUGGESTIONS The use of Industrial Power Trucks is subject to certain hazards that cannot be overcome by purely mechanical means. The exercise of intelligence, care, and common sense by the truck operator is necessary to eliminate hazards of overloading, slipping, or falling of the load; obstruction in the path of travel, or the use of equipment for which it is not intended or designed.

The following are a few suggestions that should be followed in the operation of the machine.

I. Avoid sudden stops or starts.

1 0. Observe highway traffic laws in the operation of the vehicle in the plant.

1 1 . Operate the hand truck carefully on wet or slippery floors.

1 2. Observe the Operating Rules and Preventive Maintenance Instructions ASA B56. I Safety Code for Powered Industrial Trucks.

1 3. Avoid overloading the truck - this is a safety measure against possible injury to the driver and fellow workmen. Overloading shortens the lift of the truck and increases maintenance.

1 4. Be sure the brakes are in proper work­ ing condition. Be sure all mechanical and elec­ trical components are working correctly.

1 5. The operator should walk with and not ride on the hand truck. This is designed as a walking type unit only and should not be used to transport the operator from point to point (loaded or unloaded) PREVENTIVE MAINTENANCE 1 . Arrange for systematic inspection and lubrication. See that the truck is kept properly lubricated and in good repair at all times. Refer to the Lubrication Chart for proper lubrication instructions.

2. Avoid overloading the truck - this is a safety measure against possible injury to the driver and fellow workmen. Overloading shortens the life of the truck and increases maintenance.

3. Proper maintenance means more con­ tinuous hours of service at lower operating costs.

2. Operate the hand truck carefully at all times. Take caution at cross aisles.

3. Be sure loads are safe to move. Be sure loads are properly centered on forks.

Full capacity loads MUST be centered on forks.

4. An operator should be assigned to truck.

9. Do not operate machine with wet or greasy hands.

a

5. The operator should be qualified and operate the truck in accordance with Government safety rules and no one should operate the truck except the assigned operator.

6. If the truck does not respond inme­ diately, check Trouble Shooting Chart. ]. Do not transport riders or hitchhikers.

4. Take proper care of your battery. Check the height of electrolyte solution daily. � allow water level to drop below top of plates.

When replacing evaporation, fi I I cells to proper level only - overfi 1 ling causes loss of acid and therefore reduces capacity. Use only water approved for battery use. Keep top of battery clean and dry at al I times. Normally, wiping top of battery with a damp cloth is sufficient. A light coating of vaseline or a light cup grease on the battery terminals will help prevent corrosion. If terminals have be­ come corroded, wash off corrosion with a soda solution and rinse thoroughly. See that the battery is properly charged after each day or shift.

8. Operate the machine at safe distances behind other vehicles.

1 5 MAR 68

OPERATIONS 3

CODE

GOV' T 21 1