Clark Forklift PWD565, HWD565, P600, HWP600 English OM-568 Operator's Manual

Operator's Manual

Do not remove this manual from the truck.

PWD25/30/36 HWD25/30/36 P/HWP25/30

Book No. 2779043 OM-568

Record the following information pertaining to your truck.

Model No.-------------------­ Serial No.-------------------­ Customer Truck Identification No. -----------­ Truck Weight, Empty---------------­ Truck Rated Capacity ---------------Truck Gross Weight, Loaded w / Rated Load ________ Special Equipment _________________

IMPORTANT Do not expose this manual to hot wat�r or steam.

©1991 Clark Equipment Company

Title

CONTENTS

INTRODUCTION........................................................................

Page iv

User Daily Inspection - Safety and Operating Checks.......

About This Manual ...............................................................

Sat ety Signs and Safety Messages ................... ..................

A Message To Clark Lift Truck Operators ...........................

Truck Application .................................................................

vi vii viii xii ixv

1

KNOW YOUR TRUCK.........................................................

Component Location (PWD & P Models ) ...........................

Component Location (HWD & HWP Models) ......................

Operators Controls (PWD & P Models)...............................

Operator's Controls (HWD & HWP Models) ........................

Maintenance Component Location (PWD & P Models).......

Maintenance Component Location (HWD & HWP Models).

System Description ............ ............... ...................................

Nameplate Description ........................................................

Warning Decals .................... ...............................................

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1 .8 1.1 O 1.11

2

GENERAL SAFETY RULES................................................

Do's and Don'ts ...................................................................

No Riders.............................................................................

Pedestrians..........................................................................

Grades.................................................................................

Travel...................................................................................

Pinch Points.........................................................................

Parking.................................................................................

2.1 2.2 2.3 2.4 2.5 2.6 2. 7 2.8

3

OPERATING HAZARDS ................................................... ..

Fast Turns............................................................................

Corner "Cutting" ...................................................................

Loose Loads ........................................................................

Long or Wide Loads.............................................................

Dock or Trailer Drop-Offs .....................................................

Trailer Creep ........................................................................

Debris on Floor ....................................................................

Floor and Elevator Capacity ................................................

Damaged Pallets and Skids.................................................

Loading Dock ...................................................................... .

3.1 3.2 3.2 3.3 3.3 3.4 3.4 3.5 3.5 3.6 3.7

I

L Title

CONTENTS

( Page

4

OPERATING PROCEDURES..............................................

Beginning Truck Operation ..................................................

Travel Control ......................................................................

High Speed Travel Control ..................................................

Emergency Reversal Switch Disengagement......................

Lift and Lower Control (PWD & P Models) ..........................

Lift and Lower Control (HWD & HWP Models) ....................

Braking.................................................................................

Horn Control ........................................................................

Coast Control (HWD & HWD Models) .................................

Load Handling ......................................................................

Parking.................................................................................

4.1 4.2 4.3 4.3 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.11

5

DAILY INSPECTION ............................................................

Daily Inspection Sheet .........................................................

Operator Repairs .................................................................

Emergency Reversal Switch ................................................

Travel Control ......................................................................

Horn .....................................................................................

Lift and Lower Controls (PWD & P Models) .........................

Lift Controls (HWD & HWP Models) ....................................

Lower Controls (HWD & HWP Models) ...............................

Brake ...................................................................................

Coast Control (HWD & HWP Models) .................................

Wheels and Tires .................................................................

Hydraulic System .................................................................

Maintenance Problem ..........................................................

5.1 5.2 5.3 5.4 5.4 5.5 5.6 5.7 5.8 5.9 5.9 5.10 5.11 5.12

6

PLANNED MAINTENANCE AND LUBRICATION ...............

Typical Operating Conditions...............................................

Daily Inspection Points ........................................................

Recommended P.M. and Lubrication Schedule ..................

User Safe Maintenance Practices .......................................

Sat ety Standards .................................... .............................

Battery .................................................................................

Battery Handling ..................................................................

Battery Removal and Installation .........................................

Battery Maintenance, Records, and Life..............................

6.1 6.2 6.3 6.4 6.5 6.8 6.9 6.10 6.13 6.14

ii

Title

CONTENTS

Page

6

PLANNED MAINTENANCE AND LUBRICATION (Cont'd)..

Battery Maintenance ............................. ..... ....... ...................

Battery Cleaning ............... .. .. ........ .......... ....... ..... ....... ..........

6.1 6.15 6.17

7

TOWING ............................................................................. 7.1

8

SPECIFICATIONS ..............................................................

8.1

iii

I

( Introduction Clark Material Handling Company welcomes you to the growing group of professional people who own, operate and maintain Clark lift trucks. We take pride in the long tradition of quality products and superior value that the Clark name represents. This manual will familiarize you with safety, operating, and maintenance information about your new truck. It has been especially prepared to help you use and maintain your Clark lift truck in a safe and correct manner.

Your Clark lift truck has been designed and built to be as safe and efficient as today's technology can make it. As manufactured, it meets all the applicable mandatory requirements of ANSI 856.1 - 1 969 - 1 988 Safety Standard for Powered Industrial Trucks. In addition, all standard trucks conform to Underwriters Laboratories requirements for the Type Designation shown on the truck capacity plate. Each truck is also furnished with certain safety devices, e. g. , horn, as standard equipment.

ANSI 856. 1 is the standard for lift truck operation, including rules about operation selection, training and supervision and maintenance.

We suggest you read this standard and make it available for your operators and their supervisors. If you do not have one, contact the American Society of Mechanical Engineers, 34 5 East 47th Street, United Engineering Center, New Yon<, NY, 10017, and ask for a copy of ASME /ANSI 856. 1.

See page 6.8 of this manual for additional safety standard information.

Safe, productive operation of a lift truck requires both skill and knowledge on the part of the operator. The operator must know, understand and practice the safety rules and safe driving and load handling techniques described in this manual. To develop the skill required the operator must become familiar with the construction and features of the lift truck and how they function. The operator must understand its capabilities and limitations, and see that it is kept in a

iv

Introduction Routine Servicing and Maintenance Regular maintenance and care of your lift truck is important not only for economy and utilization reasons, it is also essential for your safety. A faulty lift truck is a potential source of danger to the operator and to other personnel working near it. As with all quality equipment, keep your lift truck in good operating condition by following the recommended schedule of maintenance.

V

I

User Daily Inspection - Safety and Operating Checks A lift truck must always be examined by the user before driving to be sure it is safe to operate. OSHA & ANSI requires it. The importance of this procedure is emphasized in this manual with a brief illustrated review and later with more detailed instructions. Copies of a "Driver's Daily Check List" are available from your Clark dealer to assist you with thisexamination.

Planned Maintenance Program In addition to the daily user inspection, Clark recommends that a planned maintenance and safety inspection program ( PM ) be performed by a trained and authorized mechanic on a regular basis.

The PM will provide an opportunity to make a thorough inspection of the safety and operating condition of your truck. Necessary adjustment and repairs can be done during the PM, which will increase the life of components and reduce unscheduled downtime.

The PM can be scheduled to meet your particular application and lift truck usage.

The procedures for a periodic planned maintenance program which covers inspection, operational checks, cleaning, lubrication and minor adjustments are outlined in this manual. Your Clark dealer is prepared to help you with a Planned Maintenance Program with trained service personnel who know your lift truck and can keep it operating safely and efficiently. If you plan to do any of your own maintenance or repairs, contact your Clark dealer for copies of the proper service manuals. Also, remember to always use genuine Clark parts.

This manual is intended to be stored in the pocket in the front cover.

Keep it on the truck as a ready reference for anyone who may drive or service it. If the truck you operate is not equipped with this manual, ask your supervisor to obtain one and have it attached to the truck. And remember, your Clark dealer is pleased to answer any questions about the training, operation, and maintenance of your lift truck and will provide you with additional information should you require it. He is glad to help you. vi

About This Manual The purpose of this manual is to provide a digest of essential information about the safe operation of your truck, acquaint you with its features, how they function and are maintained. This manual is organized into 8 major parts for easy reference: Part 1 Know Your Truck... describes the major operation components, systems controls and other features of your truck and how they function.

Part 2 General Safety Rules... reviews and illustrates accepted practices for sate operation of a lift truck.

Part 3 Operating Hazards... illustrates and describes the hazards that you might encounter most often when operating your lift truck.

Part 4 Operating Procedures... discusses more specific instructions on the safe, efficient operation of your lift truck.

Part 5 Daily lnspection... describes the safety and maintenance checks that assist in maintaining your lift truck in a safe operation condition.

Part 6 Planned Maintenance and Lubrication... describes a PM program for your truck.

Part 7

Towing... discusses towing your truck.

Part 8 Specifications... provides reference information and data on features, components, and maintenance items for your truck.

vii

( Safety Signs and Safety Messages Throughout this manual, you will find safety signs and safety messages, as well as other notes and informational instructions.

These messages are given to remind you of either essential procedures or to prevent you from making an error which could damage the truck and possibly cause personal injury. Please refer to the following "Safety Signs and Safety Messages" pages for further definition and explanation of the messages.

Notice - - - The descriptions and specifications included in this manual were in effect at the time of printing. Clark Equipment Company reserves the right to make improvements and changes in specifications or design, with out notice and without incurring obligation. Please check with your authorized Clark dealer for information on possible updates or revisions.

viii