Industrial Truck Division
C30B-l-331 AND ABOVE C40B-l-331 AND ABOVE C50B-l-331 AND ABOVE CLR40B-l- 548 AND ABOVE
Book No.
O-B81, 2nd REV
Clark Equipment Company Customer Service Publications Department Battle Creek, Michigan 49016 ·
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INDUSTRIAL TRUCK DIVISION SAFETY INSTRUCTIONS FOR }IAINTAINING 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 inspect ton of a 11 powered i,:,!ustria 1 trucks should be performed in confor mance with the recommendation 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.
J.
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. R aise 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 P L 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 lift and tilt systems, directional and speed controls, steering, warning devices, brakes, and any attachment. I ( f used)
F. R elease parking brake. - continued 1023-2
R EV OCT 68 (FR ONT)
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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 dr,y.
8.
Handle LP gas cy) lnders with care.
9.
Brakes, steering mechanisms, control mechanisms, warning devices, I ights, governors, 1 ift 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 11drift 11 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 which affect capacity and safe truck operation should not be performed by the custooier 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
RE V OCT 68 (BACK)
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INDUSTRIAL TRUCK DIVISION N O T E
P L E A S E
I N S T R U C T I O N S
U S E
0 N
M A N U A L
0 F
This Operator's Manual is published as a service refer ence guide and includes Specifications, Operating Instructions, Lubrication and Preventive Maintenance Instructions, and Trouble Shooting Guide. The TABLE OF CONTENTS for this manual is printed on green paper and is placed at the front for easy reference. A separate INDEX (also printed on green paper) is placed in front of the Lubrication and Preventive ·Maintenance Section. listed The
TIME
Example: 002 a for
INTERVAL BH the
is
customer the
Maintenance Instructions are that they should be performed.
and Preventive TIME INTERVALS
Lubrication under the
is part BH
002-0; PAGE
NUMBER,
is
of
the
the and
disregard.
should
benefit
of
page
TIME
INTERVAL a CODE
is
-0
dash
The
the publisher
number
number
and
(8
code
number.
operating
NUMBER
you
as
number
is
that
code
or
hours),
only.
The INDEX is set up under the TIME INTERVALS that Lubrication and Preventive Maintenance should be performed. Example:
(B
Time Interval (H=Hours)
Hours)
Page Number (000-)
&
503 303.
BH BH
Hydraulic sump Tank, level check. .. Brake Pedal Free Travel, check .. .•.
the
The above states to check the sump tank fluid level every B operating hours and refer to page 503 for fluid recommendations etc. Also, to check brake pedal free travel at this interval and turn to page 303 for instructions. hour section (BH) and then to Turn to the eight (8) 503 or 303 etc. The instructions covered the page listed therein will pertain only to the checks or adjustments that should be performed at this TIME INTERVAL. If, for instance, the Brake Pedal Free Travel is incorrect, you would then refer to the INDEX for "Brake Pedal Free Travel, adjust" which would be listed in the TIME INTERVALS following the B hour section. Example:
Brake
(100
Pedal Free Turn
Time Interval (H=Hours)
Hours)
Travel,
to ·the
one
adjust.. .. hundred
hour
AOOl-3
Page Number (000-)
&
302
100H section
(lOOH)
and
then
to 27 JAN 64
INDUSTRIAL TRUCK DIVISION (continued) I N S T R U C T I O N S
U S E
0 N
page 302. Complete instructions as to free travel, the method to check and travel with illustrations are included
0 F
M A N UAL
the importance of pedal adjust for correct free therein.
N O T E YOU TION
WILL AND
LOCATION
NOTE
THAT
PREVENTIVE OF
THE
AT
THE
BEGINNING
MAINTENANCE
COMPONENTS
TO
OF
EVERY
ILLUSTRATION BE
IS
SECTION SHCMN
A
LUBRICA
GIVING
THE
SERVICED.
It is impossible to cover all types of machine operations in one manual. ·operating conditions should determine the lubrica tion and maintenance intervals. Common sense and a close observ ance can best determine the frequency with which you should service your machine. The care you give your machine will greatly determine the A satisfaction and service life that you will obtain from it. difinite maintenance program should be set up and followed. Haphazard maintenance will only lead to faulty performance and short lifP..
27 JAN 64
A002-0
INDUSTRIAL TRUCK DIVISION T A B L E Page AOOI A003 BOO! B003 B031
0 F
C O NT E NT S
D:Dm
�
Description Instructions On Use Of Manual Table Of Contents Illustration Of Machine Specifications New Machine 50 Hour Inspection OP ERA TION S
C002 C003 coos coo6 c303 C401
LU B R Time Interval (H=Hours)
&
Overall Controls Instrument Indicators Starting and OperatingInstructions Fuel TankReserve Manual Cut-in Valve To Move, Stack and Lo11er Loads. Safety and Operating Suggestions Proper Handling of L.P . Fuel
CA TI ON
Page Number (000D-)
H
001
8H
002
8H 8H SH 8H 8H 8H 8H 8H
003 103 203 303 403 503 602 703
!OOH
002
!OOH
003
!OOH !OOH lOOH !OOH !OOH
103 203 302 303 403
!OOH !OOH lOOH
503 603 702
500H
002
500H
003
500H 500H 500H
103 202 302
500H
403
A N D
PREV EN T I V E
M A I N T E NA N C E
Description Index
8 Hour Lubrication & Preventive MaintenanceIllustration Horn, Fuel Tank and System Fuses Crankcase Oil Level check; Recommended Lub�icants Cooling System check Instrument Indicators, check BrakePedal Free Travel check;Parking Brake Operation check Engine Air Cleaner service Hydraulic Sump Tank Level check; Hydraulic Control Lever Operation check TiresInspect Power SteeringReservoir level check 100 Hour Lubrication &Preventive Maintenance Illustration Converter, Transmission &Axle Adaptor Level check; Fuel Tank and Lines inspect Engine Crankcase drain & refi 11; Crankcase Ventilation inspect; Engine 0 i 1 Fi I ter change Cooling System inspect; clean radiator fins Fan and Generator Belt adjustment BrakePedal Free Travel check Brake Pedal Free Travel adjust; Master Cylinder level check Lift and TiIt Cylinders inspect; Lift Chains check and adjust; visually inspect all 1·1iring and hydraulic piping; lubricate all miscellaneous linkage Hydraulic Sump Tank Breather inspect or replace Steering Gear verify lubricant level; Battery inspect Lubrication Charts 500H Hour Lubrication &Preventive Maintenance Illustration Fuel Pump Strainer clean; FuelPump Operation check Converter, Transmission and Axle Adaptor drain & refill; Transmission Oil Filter change Hydraulic Sump Tank drain & refill; Hydraulic Sump Tank Oil Filter change Steering Gear adjust SteeringAxle and Linkage adjust (LessPower Steering - WhitePaper) (Power Steering Equipped - TangerinePaper) Manifolds check security of mounting; Nuts, Bolts and Cap Screws security check
A003-3
REV 8 OCT 64
INDUSTRIAL TRUCK DIVISION T A B L E L U B R 1 C A T I 0 N Time Interval & (H=Hours) 1000H
Page Number (0000-) 002
lOOOH
003
lOOOH IOOOH IOOOH IOOOH lOOOH 1000H lOOOH IOOOH IOOOH 1 000H lOOOH lOOOH lOOOH IOOOH IOOOH IOOOH lOOOH 1000H 1000H
004 1 03 203 204 303 403 503 603 703 803 805 912 1002 1103 1202 1503 1703 1793 1803
A N D
MA I N T E N A N C E
PR E VE N TI VE
Description 1000 Hour lubrication & Preventive Maintenance I 1 1ustration Engine Tune Up; Air Cleaner, Fuel Pump Engine Tune Up; Cylinder Head Stud Nuts Intake andExhaust Manifolds, Crankcase Ventilation; Intake and Exhaust Valve Clearance adjustments Engine Tune Up; Intake andExhaust Valve Clearance adjustments Engine Tune Up; Compression test, Spark Plugs Engine Tune Up; Distributor Engine Tune Up; Tach Dwell Meter Engine Tune Up; Contact Point Adjustment; Ignition Timing Engine Tune Up; Vacuum Test and Carburetor adjustment Engine Tune Up; Governor Adjustment S tarting MotorInspect Generator inspect Wheel Bearings clean and repack; adjust AxleEnds clean and repack Bleeding Brake System Brake Adjus ters Hand Brake adjustment Cooling System inspect and clean Main Hydraulic System Pressure checks Transmission Pressure checks Neutral Star ting Switch adjustment UprightR oller lubrication and adjustments
TR 0 U B LE Page TS TS TS TS TS TS TS TS TS TS TS TS
REV 8 OCT 64
C 0 N T E N T S
0 F
001 251 321 341 361 381 401 483 521 541 653 963
s
H O O T I N G
G UI D E
Deserie tion Engine Fuel System Cooling System Ignition Sys tan Starter Generator Battery & Horn Drive Axle Steering Axle Brake System Hydraulic Systan Hydratork Drive (Transmfssion)
A008-0
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INDUSTRIAL TRUCK DIVISION
� �
ILLUSTRATION OF MACH !NE B 001-3
16 JUL 63
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INDUSTRIAL TRUCK DIVISION SPECIFICA TIONS
DISTRIBUTOR (All FOUR and SIX Cyli nder Engines}
H e o v_y__D u t l.__ P o i n t s When conn ecting leads, terminals m u s t bebock tobock(fl a t s i d es t og et h e r ). Push into slot between insulator and spring. ( DO NO T p u s h I e v e r s p r i n g . ) T hen push other termi n al in place between fi rst termi n al and insulator. See followin g i 11 u stroti on.
N O T E
Di stributo rs are equi pped with either Standard or
Heavy Duty Points . Heavy Duty Points are thicker
(hove more con toct moteri cl)than Standa rd Poi nts.
WHEN
Heavy Duty Points - All £91.l.B Cylinderlngin s 5 Set Dwell Angle at •..............•31 - 34
CONNECTING
T E R MINALS
MUST
LE A DS,
BE
BACK
BACK ( flat sides together) ...........
Heavy Duty Points - All ..S1X.Cylinder tngineb Set DwelI An gle at.•...•..••.•..•.22 - 26
a THE
TO
:' ..;�
ilff._� _
- FOUR ( 4 ) CYLINDER ENGINES, ONLY Point O ni g (i� _ r
Dwell 1
I
--r-I
Centrifugal Advance
�:� -)
�----START------i-- INTERMEDIATE
31-34 31-34
l1
INTERMEDIATE
-r--
MAXIMUM ---
�--------�--------➔-------r------�------r------,-------,------�------r---.022* . 2i•• o
l
I1
!
I 1
Eng.rpm.I Eng.adv, j Eng.rpm.I Eng.adv. 600 600
i I 1
1-5 1-5
I I I
800 800
I 6-10 6-10
!I
I
I i
- S IX ( 6 ) CYLI NDE R ENG I NES,
I
·
Eng.rpm. !Eng.adv. Eng.rpm, Eng.adv j
I
1600 1600
I
11-15 I 11-15 I
2200
I 15-19
I . 22oo !I 15- 19
ONLY -
I�-------------- -------------Centrifugal Advance r---------------t-----------r INTERMEDIATE I INTERMEDIATE I MAXIMUM START I I �--------�--------;-------i-------�-------r------;--------1-------i-------r---- · I I En .rpm.I Eng.adv, I Eng.rpm.I Eng.adv, I Eng.rpm. I Eng.adv.I En .rpm. I Eng.adv . Point Opening (in.)
.020* .021**
Dwell Angle (deg.)
I
I
I
28-32 22-26
g
1
1
i
I
600 600
I
i
1-5 1-5
I
1
I
800 800
I 6-10 6-10 I I
I
I
I
I 11-15 I 11-15 1
1600 1600
I
I I
2200 2200
N O T E
en g i n e �J..!.b._ t i m i n g__l i g ht ��:!, __t:__0c h_o_�1:._t:_e_s __ �!.. __ e n i g en _!_b.� __<:._���1:... s p ec i f i c a ___o__: __ _!,!'...t:,'i ±QQ_I i i�--±�Q_:__5_8 _ 0 _. i r a n g e __!._ _c>_!l�__: ___I,b,� __ _!lJ_!_i__<:._ __ !_.!__�=-
!:=.!.��--t:__o__
D i s t r ib u t o r
a d v a nce
�����-=-=--���at
600
en g i n e
RPM
s h o u ld
D i s t r ib u t o r _r ot a t i o n __ 1 ° _ t o _5 ( a s _v i e w ed e n d )_J� -�<:._��t:..e.I.=l����i�I:...·
° .___
be
f r a m _c a_p
W h en c h ec k i n g D i st r ibu to r on o test s t a n d, t h e ab o v e sp e c i f i c a t i on s o r e 1/2 t h a t s h o w n . *.. . . . • . . . • • Four (4)or Six (6) Cylinder Engine STANDARD Points. *". . . • • . • . . • Four (4)or Six (6) Cylinder Eng ine HEAVY DUTY Poi nts. 1066-Z
REV 7 DEC 67
g
I 15-19
lI 15-19