CLARK FORKLIFT SM-724 CBX, TRX, FBXR SERVICE MANUAL

SM-724

CBX, TRX, FBXR

Rev Oct, 2014

[cLqRK)' THE FORKLIFT

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

Technical Publications 700 Enterprise Dr. Lexington, KY 40510 www.Clarkmhc.com

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

FOREWORD The CLARK electric-powered cars are designed for use in a wide range of applications from moving stock within a ware­ house or factory site to transporting people at an outdoor venue, club, or resort. To meet these demanding applications, the cars must be properly operated, inspected regularly, and serviced in accordance with the required maintenance schedule.

This manual provides the necessary information for the safe operation and maintenance of the car.

Organization and Content

The information is presented in fourteen defined service groups: Group SA, Safe Maintenance- covers practices established for the safe operation of the car, site preparation for operation of the car, as well as safe maintenance practices.

Group PS, Periodic Service - provides the periodic maintenance schedule, lubrication diagram, and service in­ spection and check procedures.

Component Groups (see Table of Contents)- cover batteries, wiring, motor, controls, axles, suspensions, brakes, wheels and tires, and chassis components. A description of system components is provided when required, along with removal, installation, and adjustment procedures.

Group 40, Specifications - provides general specifications applicable to both Transit and Flatbed models as well as car dimensions that are specific to each model.

Finding Information

A Table of Contents listing the major components Groups is provided at the front of the manual. This is supported by Contents pages within each Group, listing the sections and subsections.

Safety IMPORTANT Read the section on "Safe Car Operation" and "Driving the Car" in Group SA, Safe Maintenance and observe all safety precautions before operating the car.

BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive bann.

WASH HANDS AFTER HANDLING!

BATTERIES AND RELATED PARTS CONTAIN LEAD

WASH RANDS AFTER HANDLING! WARNIN(i: Battery posts, lcnninals and rclstcd accessories contain ICll.d and lead compounds, chemicals known to cause cancer and rcproducti�·e hann.

WARNING

WARNING

WARNING

SHARP LEFT TURN

SHARP RIGHT TURN

SHARP STEEP BILL

APPLY BRAKE TO LIMIT SPEED

APPLY BRAKE TO LIMIT SPEED

APPLY BRAKE TO LIMIT SPEED

The information contained in this manual, including illustrations and specifications, is current as of the time of publica­ tion. CLARK reserves the right to change the content at any time without notice.

SM-724

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CONTENTS

Contents by Groups and Sections SA

SAFE MAINTENANCE 1. Safety 2. Lifting, Jacking, and Blocking 3. Towing

PS

PERIODIC SERVICE 1. Maintenance Schedule 2. Planned Maintenance Program

23

BRAKE SYSTEM 1. Specifications and Description 2. Brake System Troubleshooting 3. Brake System Maintenance and Adjustments 4. Brake System Service

25

STEERING SYSTEM 1. Steering System Troubleshooting 2. Steering System Component Removal and Installation

12

BATTERY 1. Battery Service

13

WIRING, SWITCHES, AND INSTRUMENTS 1. Schematic Electric Circuit Diagrams 2. General Electrical Service Tips 3. Wiring and Cables 4. Switches and Sensors

26

SUSPENSION 1. Front Axle and Suspension Service 2. Rear Suspension Service

38

ELECTICAL MOTORS 1. Drive Motor Description and General Service 2. Drive Motor Overhaul

CHASSIS 1. Body Components Removal and Installation 2. Paint

40

SPECIFICATIONS 1. Name Plates and Decals 2. General Specifications

16

19

MOTOR CONTROLS 1. Description 2. General Troubleshooting 3. Motor Controls Component Replacement 4. Control Programming

20

DRIVE AXLE 1. Specifications and Description of Drive Axle 2. Troubleshooting of Drive Axle Assembly 3. General Operation of Drive Axle 4. Axle Shaft and Axle Shaft Seal Removal and Installation 5. Gear Box Oil Pan Removal and Installation 6. Rear Axle Removal and Installation 7. Gear Box Removal and Installation

22

WHEELS AND TIRES 1. Wheels and Tires Description 2. Wheels and Tires Removal and Installation 3. Tire Repair

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ii

GROUP SA

GROUP SA SAFE MAINTENANCE Safety .................................................................Section 1 Lifting, Jacking, and Blocking .........................Section 2 Towing ...............................................................Section 3

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SA-0

Group SA

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SA-0

Group SA, Safe Maintenance

Section 1 Safety

Safety Signs and Messages .........................................2 Safe Operational and Maintenance Facilities ..............2 Safe Car Operation .........................................................3 Safe Maintenance Practices ..........................................5

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SA-1-1

Group SA, Safe Maintenance Safety Signs and Messages Safety signs and messages in this manual and on the car provide instructions and identify specific areas where po­ tential hazards exist and special precautions should be taken. Be sure you know and understand the meaning of these instructions, signs, and messages. Damage to the car, serious injury or death to you or other persons may result if these messages are not followed.

AoANGER This message is used when an extreme haz­ ard exists that can result in injury or death or serious injury if proper precautions are not taken.

AwARNING This message is used when a hazard exists that can result in injury or death if proper precautions are not taken. fficAUTION This message is used as a reminder of safety hazards that can result in personal injury if proper precautions are not taken.

IMPORTANT This message is used when special precautions should be taken to ensure a correct action or to avoid damage to, or malfunction of, the car or a component.

NOTE This message is used when special informa­ tion, instructions, or identification is required relating to procedures, equipment, tools, pres­ sures, capacities, and other special data.

The above terms have been adopted by CLARK. The same terms may be used in different context in service literature supplied directly or indirectly by vendors of car components.

Safe Operational and Maintenance Facilities The following general safety information applies to end users (site owners/operators) and their facilities, person­ nel training, car operation, and maintenance. It is based on industry standards established by the American National Standards Institute (ANSI)/ Industrial Truck Standards Development Foundation (ITSDF).

More complete instructions covering operation and main­ tenance safety is provided in publication ANSIIITSDF B56.8-2005, Safety Standard for Personnel and Burden Cars.

Owner/Facility Operator Responsibilities Covered under this heading are broad safety practices recommended for safe operation of the car by the owner/ facility operator. In addition to what follows, the owner/ facility operator should establish specific safety practices as may be reasonably required for safe operations on their premises.

Cars are safe when properly operated in accordance with the safety and operation warnings affixed to every car.

Safe operation is guaranteed when the cars are operated within a specific set of operational instructions, safety rules, and practices established to meet actual operating terrain and conditions on their premises.

Safety survey - The owner/facility operator shall per­ form a safety survey periodically, to identify possible haz­ ards and/or areas which can affect the traction and stabil­ ity of the cars. Such hazardous areas include: •

Areas where steep grades exist Wet, slippery areas Terrain with loose substrate, sharp turns, blind spots, bridge approaches Car/pedestrian interference

Identified hazards and areas shall have suitable warnings displayed restricting car operation in these areas.

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SA-1-2

Group SA, Safe Maintenance General Safety Practices

Car stability - A well-maintained car is stable when properly operated in accordance with speci£c safety rules and practices established to meet actual site terrain and conditions. However, failure of the owner/facility operator to provide proper facility and site maintenance, as well as car maintenance and safety practices, may contribute to a condition of instability.

The owner/facility operator shall train car opera­ tors to adhere strictly to the operating instructions stated in the safety regulations.

The owner/facility operator shall survey operating conditions and the working environment, and train car operators to comply with any additional spe­ ci£c safety practices required.

Nameplates and labels - The owner/facility operator shall maintain in a legible condition all nameplates, warn­ ings, and instruction labels on the car as supplied by the manufacturer.

Modifications - The owner/facility operator shall not modify the car or add equipment which affects the capac­ ity or safe operation without the manufacturer's prior writ­ ten authorization. Where authorized modi£cations have been made, the owner/facility operator shall ensure that capacity, operation, warning, and maintenance instruction plates, tags, or decals are changed accordingly as supplied and instructed by the manufacturer.

Car lights - In accordance with responsibility for the environment and operating conditions, the owner/facil­ ity operator shall determine if the car requires additional lights or a change in light types. If so, the change in lights must be made in accordance with the manufacturer's rec­ ommendations.

Warning devices - The owner/facility operator shall inspect the car periodically to be certain that the sound­ producing and/or visual device is maintained in good op­ erating condition.

The owner/facility operator is also responsible for de­ termining if operating conditions require the car to be equipped with additional sound-producing and/or visual devices. If so, the installation and maintenance of such de­ vices must be done in accordance with the manufacturer's recommendations.

Battery handling, storage, and charging - The own­ er/facility operator is required to provide proper battery changing facilities. The owner/facility operator is also re­ quired to periodically inspect the equipment and review operating procedures to ensure safe practices in accor­ dance with applicable ordinances or regulations.

Ventilation - The owner/facility operator shall provide ventilation to remove the accumulation of flammable hydrogen gas emitted during the charging process. The amount of hydrogen gas emitted depends upon a number of factors, such as the condition of the batteries, the out­ put rate of the battery charger, and the amount of time the batteries are on charge. Hydrogen emissions are generally considered to be in the area of 10 to 20 cubic liters per car per charge. Because of the highly volatile nature of hydro­ gen gas and its propensity to rise and accumulate at the ceiling in pockets, a minimum of 6 air changes per hour is recommended to prevent the accumulation of signi£cant quantities of vapor-air concentrations from exceeding 25 percent of the lower flammable limit (LFL). The owner/ facility operator shall consult applicable fire and safety codes for the speci£c ventilation levels required as well as the use of explosion-proof electrical apparatus.

Safe Car Operation Personnel Qualifications

Car operation - Only persons who are trained in the proper operation of the car, and have the visual, auditory, physical, and mental ability for safe operation shall be au­ thorized.

Personnel training- Successful completion of the own­ er/facility operator's training program shall be required to qualify a driver for operation of the car. The program shall be presented in its entirety to all new drivers and not con­ densed for those claiming previous experience. The pro­ gram content should include the following:

•

Instructional material provided by the manufac­ turer Emphasis on safety of passengers, material loads, driver, and other employees General safety rules and additional speci£c rules (including the rationale for additional rules) as de­ termined by the owner/facility operator in accor­ dance with actual site conditions Introduction to the cars, the control locations and functions (with explanation of the effects when properly and improperly used), surface conditions, grade, and other conditions of the environment in which the car is to be operated Operational performance tests and evaluations of personnel during program and at completion

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SA-1-3

Group SA, Safe Maintenance On-Site Safeguards Following are safeguards that apply to the car and its op­ eration under varying environmental and site conditions:

•

Safeguard pedestrians at all times. Do not drive car in a manner that would endanger anyone.

The number of persons authorized to ride on the car including the driver is limited to the number of seats provided by the manufacturer. Riders must be positioned properly in the seats within the plan view outline of the car.

When a car is to be left unattended, stop the car and apply the parking brake, turn off the control circuit, and remove the key. Clark recommends that a car be parked on a level surfase only. If the car is to be parked and left unattended on an incline, block the wheels.

NOTE

A car is considered unattended when the driver is 7.6 m (25 ft) or more from the car which remains in his view, or is not within his view. Whenever the driver is out of the car and within 7.6 m (25 ft) of the car still in his view, the controls must be neutralized, and the parking brake set to prevent movement.

•

Maintain a safe distance from the edge of ramps and platforms.

Do not use the car in hazardous locations for which the car is not designed as defined in the appropriate safety standards.

Report all accidents involving personnel, building structures, and equipment.

Cars shall not be parked or left unattended in a manner that they block or obstruct fire aisles, ac­ cess to stairways, or fire equipment.

Keep a clear view of the path of travel, observe other traffic and personnel, and maintain a safe clearance.

Ascend or descend grades slowly.

Avoid turning, if possible, and use extreme caution on grades, ramps, or inclines. Travel straight up and down at all times possible.

Under all travel conditions, the car shall be oper­ ated at a speed that will permit it to be brought to a stop in a safe manner.

Make starts, stops, turns, or direction reversals in a smooth manner so as not to shift the load, endanger passengers, or overturn the car.

Do not indulge in dangerous activities, such as stunt driving or horseplay.

Slow down when approaching, or on, wet or slip­ pery surfaces.

Do not drive the car onto any elevator unless spe­ cifically authorized to do so. Approach elevators slowly and enter squarely after the elevator is prop­ erly leveled. Once on the elevator, neutralize the controls, shut off power, and set the parking brake.

NOTE It is advisable that all other personnel leave

the elevator before a car is allowed to enter or exit.

Avoid running over loose objects, potholes, and bumps.

To negotiate turns, reduce speed to improve stabil­ ity. Then turn steering wheel in a smooth, sweeping motion.

Car Loading

Driving the Car

Handle only stable and safely arranged loads. Operate with extra caution when handling off-center loads which cannot be centered.

Driving must be done by a qualified person trained in the operation of the car and attentive to the following rules.

Handle only loads within the capacity of the car as speci­ fied on the nameplate.

Observe all traffic regulations, including autho­ rized speed limits. Maintain a safe distance, based on speed of travel, from a car ahead, and keep the car under control at all times.

Keep car to the right under normal traffic condi­ tions.

Yield the right of way to pedestrians, ambulances, fire trucks, or other cars in emergency situations.

Do not pass another car traveling in the same direc­ tion at intersections, blind spots, or at other danger­ ous locations.

Handle loads exceeding the dimensions used to establish the car's capacity with extra caution. Stability and maneu­ verability may be adversely affected.

•

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SA-1-4