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Section 5. Operator Maintenance and Care

Contents

5-1

Operator Maintenance and Care

Contents

Daily Safety Inspection .......................................... 5-2

Fuel Safety Practices ............................................. 5-5

Refueling LPG Tanks ............................................. 5-6

NOTICE

The Occupational Safety and Health Act (OSHA) requires
that truck users examine their trucks before each shift to
be sure they are in safe working order. Defects when
found shall be immediately reported and corrected. The
truck shall be taken out of service until it has been
restored to safe operating condition.

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Summary of Contents for C40D

Page 1: ... Do not remove this manual from the truck INTERNAL COMBUSTION LIFT TRUCKS Part No 8131796 Eng Book No OM 1038 Rev 2 4 Sep 2019 C 40 45 50s 55s D L C 60 70 75 80 D L ...

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Page 3: ...others YOU can prevent accidents First Learn safe operating rules and your company rules Next Read your Operator s Manual If you do not understand it ask your supervisor for help Learn about the unit you operate KNOW YOUR TRUCK Then Practice operating your truck safely And Keep your truck in safe operating condition with correct and timely maintenance ...

Page 4: ...d Operator not experienced with lift truck operation Basic safety rules not followed Lift truck not maintained in safe operating condition For these reasons CLARK wants you to know about the safe operation and correct maintenance of your lift truck This manual is designed to help you operate your lift truck safely This manual shows and tells you about safety inspections and the important general s...

Page 5: ...k you need training in operating or inspecting your lift truck ask your supervisor CLARK lift trucks are built to take hard work but not abuse They are built to be dependable but they are only as safe and efficient as the operator and the persons responsible for maintaining them Do not make any repairs to this truck unless you have been trained in safe lift truck repair procedures and are authoriz...

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Page 7: ...i Safety Signs and Safety Messages x Section 1 General Safety Rules 1 1 Section 2 Operating Hazards 2 1 Section 3 Operator Compartment and Controls 3 1 Section 4 Operating Procedures 4 1 Section 5 Operator Maintenance and Care 5 1 Section 6 Emergency Starting and Towing 6 1 Section 7 Planned Maintenance and Lubrication 7 1 Section 8 Specifications 8 1 ...

Page 8: ...ack rest parking brake safety restraint system seat belts and horn are standard equipment 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 th...

Page 9: ...M can be scheduled to meet your particular application and lift truck usage The procedures for a periodic planned maintenance program that covers inspections 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 by trained service personnel who know your lift truck and can keep it opera...

Page 10: ...presents details on how to perform the operator s daily safety inspection and refuel the lift truck Section 6 Emergency Starting and Towing gives instructions for towing your truck in an emergency and for using battery jumper cables to start your truck in an emergency Section 7 Planned Maintenance and Lubrication describes the PM program Section 8 Specifications provides reference information and ...

Page 11: ... you cannot find a topic in the table of contents check the index at the back of the manual We urge you to first carefully read the manual from cover to cover Take time to read and understand the information on general safety rules and operating hazards Acquaint yourself with the various procedures in this manual Understand how all gauges indicator lights and controls function Please contact your ...

Page 12: ...tructions signs and messages Damage to the truck death or serious injury to you or other persons may result if these messages are not followed If warning decals are damaged they must be replaced Contact your CLARK dealer for replacements NOTICE This message is used when special information instruc tions or identification are required relating to procedures equipment tools pressures capacities and ...

Page 13: ...3 Seat Belts 1 4 No Riders 1 5 Pedestrians 1 6 Operator Protection 1 7 Fork Safety 1 8 Pinch Points 1 9 Travel 1 10 Grades Ramps Slopes and lnclines 1 11 Surface and Capacity 1 12 Tip Over 1 13 What to do in Case of a Tip over 1 14 Parking 1 15 General Tire Maintenance Inspection and Repair 1 16 Carbon monoxide and fumes 1 17 ...

Page 14: ...ct your truck and fill out a daily inspection sheet Check for damage and maintenance problems Have repairs made before you operate the truck CAUTION DO NOT MAKE REPAIRS YOURSELF Lift truck mechanics are trained professionals They know how to make repairs safely See Section 5 ...

Page 15: ...tch for pedestrians Don t blocksafetyor emergency equipment Do wear safetyequipment when required Don t smoke in NOSMOKING areas or when refueling XXX Don t use the similar fuel If forklift truckisto be operated outdoors during rainyconditions make sure cab is in place to prevent damage to electrical components ...

Page 16: ...1 4 Seat Belts Seat Belts ALWAYS BUCKLE UP Seat belts can reduce injuries ...

Page 17: ...Section 1 General Safety Rules No Riders 1 5 No Riders The operatoristhe onlyone whoshould be on atruck Nevertransport personnel on the forksof alift truck ...

Page 18: ...ction of travel Pedestrians may use the same roadway you do Sound your horn at all intersections or blind spots Watch for people in your work area even if your truck has warning lights or alarms People may not watch for you Make people stand back even when you are parked ...

Page 19: ...Section 1 General Safety Rules Operator Protection 1 7 Operator Protection Keep under the overhead guard Always keep your body within the confines of the truck ...

Page 20: ...1 8 Fork Safety Fork Safety Neverallow anyone to walkunderraised forks There isspecial equipment toraise people foroverhead work DONOTUSE LIFTTRUCKS 2372604 DANGER ...

Page 21: ... Pinch Points 1 9 Pinch Points WARNING Keep hands feet and legs out of the upright WARNING Don t use the upright as a ladder CAUTION Never try to repair the upright carriage chain or attachment yourself Always get a trained mechanic ...

Page 22: ...otion When handling bulky loads that restrict your vision operate your truck in reverse to improve visibility Be sure to pivot in the seat to give maximum visibility Right Wrong Unstable loads are a hazard to you and to your fellow workers Always make certain that the load is well stacked and evenly positioned across both forks Never attempt to lift a load with only one fork ...

Page 23: ...Section 1 General Safety Rules Grades Ramps Slopes and lnclines 1 11 Grades Ramps Slopes and lnclines WARNING Never turn on a grade either loaded or unloaded Unloaded Loaded Forks Upgrade ...

Page 24: ... to tip over or lose traction for braking or driving WARNING Know the weight of your truck and load Especially when using elevators Know the capacity of the elevator you intend to use Do not overload IMPORTANT Seat belts can reduce injuries ALWAYS BUCKLE UP SAND MUD GRAVEL OIL WEAK FLOORS ICE ...

Page 25: ...of the truck This condition is even more likely with excessive for ward tilt braking in forward travel or accelerating rearward Longitudinal tip over can occur by driving with the load down slope on a steep grade Lateral and longitudinal tip over can occur if the truck is driven over objects on the floor or ground off the edge of improved surfaces or into potholes in the road surface or by running...

Page 26: ...starts to tip over WARNING DO NOT JUMP IMPORTANT Your chances for survival in a tip over are better if you stay with the truck in your seat Brace yourself as illustrated below 1 Make sure your seat belt is fastened securely 2 Stay in your seat 3 Grip the wheel 4 Brace your feet 3 4 2 1 ...

Page 27: ... Rules Parking 1 15 Parking Never park on a grade Always come to a complete stop before leaving truck Be sure travel control is in NEUTRAL Lower forks fully to floor and tilt forward Set parking brake Turn key to OFF position ...

Page 28: ...ave the tire and wheel inspected by a person trained and authorized to do tire and wheel mainte nance The tire may require removal and repair Incorrect low tire pressure can reduce the stability of a lift truck and cause it to tip over IMPORTANT Check wheels and tires for damage every time you check tire pressure Make repairs when needed Dirt can get into cuts and cause damage to the tire cord and...

Page 29: ...n the work environment if the ambient air exchange is not adequate Always use ventilation as the primary means of control by providing necessary air exchange capability Ventilation shall be provided in enclosed areas where internal combustion powered equipment is used to maintain an atmosphere that shall not exceed the contamination levels specified by the American Conference of Governmental Indus...

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Page 31: ...learance Fast Turns and High Loads 2 4 Drop Offs 2 5 Right Angle Stacking 2 6 Chain Slack 2 7 Pallets and Skids 2 8 This Section shows some of the hazards that may cause you or someone around you to be killed or badly hurt As the operator you must look for other hazards Get your supervisor to help you identify and avoid those hazards ...

Page 32: ...2 2 Loose Loads Loose Loads Loose or unbalanced loads are dangerous Observe these precautions Never carry loose or uneven material Center wide loads Stack and band loose material ...

Page 33: ... clearance A long load reduces the capacity of the truck Know and understand your truck load rating When extra long material makes it necessary to travel with the load elevated do so with extreme care and be alert to load end swing when turning WARNING When turning be sure the rear end of the truck does not swing into racks posts etc Watch for pedestrians beside the truck ...

Page 34: ...load Check your clearances Keep the load low and tilted back WARNING Watch overhead clearance Moving into overhead structures can tip a truck over or spill a load WARNING Slow down before turning The truck can tip over Turn too sharp with a raised load and your truck can tip even at slow speeds Travel with a load raised only when removing or depositing a load ...

Page 35: ...ds you must Talk to the truck driver yourself make sure the driver does not move the trailer until you are done Apply trailer brakes Use wheel chocks Use trailer to dock locking system if available The impact of moving in and out of a trailer may cause the trailer to creep or move ...

Page 36: ...2 6 Right Angle Stacking Right Angle Stacking SLOWLY When right angle stacking or moving with a raised load to clear low objects avoid sharp turns and move slowly ...

Page 37: ...Section 2 Operating Hazards Chain Slack 2 7 Chain Slack WARNING Slack chains mean rail or carriage hang up Raise the forks before you move or broken chains can result ...

Page 38: ...NG Do not move or store materials on damaged pallets or skids Items can fall through them causing severe injury or death Be sure the pallet or skid you are using is in good condition and does not have defective or missing components and fasteners ...

Page 39: ...ment and Controls Contents 3 1 Operator Compartment and Controls Contents Truck Description 3 2 Operator Compartment 3 3 Instrument Pod 3 4 Pod Symbols and Functions 3 5 Urea SCR System C60 80D Doosan 3 12 Operator Controls 3 20 ...

Page 40: ...eel 2 Overhead Guard 3 Seat and Seat Belt 4 Counterweight 5 Steer Axle Wheels Tires 6 Upright and Carriage 7 Load Backrest 8 Forks 9 Drive Axle Wheels Tires The truck shown above is a typical representation of a CLARK internal combustion lift truck Your model may vary slightly ...

Page 41: ... 6 7 8 9 10 11 12 13 14 1 Steering Handwheel 2 Forward Reverse Lever 3 Inching Pedal 4 Brake Pedal 5 Seat Adjustment Lever 6 Horn Button 7 Instrument Pod 8 Turn Signal Lever 9 Accelerator Pedal 10 Key Switch 11 Lift Control Lever 12 Tilt Control Lever 13 Auxiliary Control Lever 14 Parking Brake Lever ...

Page 42: ... display 4 Hourmeter Speed 5 Message display Travel direction icon 6 Parking brake LED 7 Seat belt LED 8 Error LED 9 Down arrow button Mode button 10 Up arrow button Enter button 11 Left arrow button 12 Right arrow button Power button 13 Plus button 14 Minus button 15 Glow Plug Preheat 16 Engine Oil Pressure 17 Transmission Oil Temperature 18 Alternator Charging Status 19 Engine check 20 Service I...

Page 43: ...t down again 3 Neutral start function and Anti restart function Neutral start function The instrument pod will not allow the starter to be engaged if directional switches are closed or key has been in start position once Key switch mustalways be turned OFF to restart engine Anti restart function When engine is already running the start motor does not rotate although the key switch is turned to the...

Page 44: ...il temperature Indicates that the Transmission oil temperature is excessive If the light is on shut down the truck and service it The truck will go into shut down mode after the light flashes for 30 seconds the buzzer sounds Engine oil pressure Indicates engine oil pressure is too low If the light is on shut down the truck and service it The truck will go into shut down mode after the light flashe...

Page 45: ... service time display at hour meter Here F1 is for up set F2 is for down set with interval times of 50 hours When the key switch is turned OFF the pre set service time setting time is saved Pre set service time counts down opposite to operating time To disable the Service Icon set the pre set service time to 1000 display 1 0 0 0 If you push the F2 switch when setting the pre set service time the t...

Page 46: ...se the Transmission solenoid valves switch is off When the parking brake is not set and the key switch is turned to the OFF position the instrument pod will sound If the parking brake is set buzzer and horn will not sound Date Time It displays current date and time Hourmeter Speed It displays the accumulated operating hour and traveling speed of truck When the traveling speed is less than 0 5km h ...

Page 47: ...curred the priority 2 Errors will be displayed The priority means Error number When failure and warning are caused at the same time the content of failure will be displayed on top row and the warning icon at below row Travel direction icon Function To display the traveling direction or gear selected condition of truck Receive the traveling direction data from the T M controller When it is in neutr...

Page 48: ...ide of LCD Each button has specific function and some have multiple functions Down arrow button Mode button Pressing this button in normal operating condition it will move to Menu mode Pressing it in Menu mode it will move to lower menu Pressing it in the lowest mode there will be no change Up arrow button Enter button Pressing this button it will move to upper menu It will also take role of Enter...

Page 49: ... OP selection function at normal mode It selects DR OP in turns whenever pressing the button The data for the selected mode will be trans ferred to T M controller Under S L mode DR OP does not change Minus button 1 Decrease the data as set value in the current Menu mode 2 It performs ML A1 A2 selection function at nor mal mode It selects ML A1 A2 in turns whenever pressing the button The data for ...

Page 50: ...f violation of regulations and laws regarding emission Please note that CLARK will not take any liability for an performance issue and or damages of a forklift derived from the modification of a forklift Urea solution gauge The urea gauge shows the current level of urea solution in the tank Check the remaining level regularly and refill as needed WARNING The engine warning light will be ON and the...

Page 51: ... gravely affect the forklift per formance and may cause a malfunction Make sure that the urea solution meets the specifications of ISO 22241 Urea solution of poor quality will gravely affect the forklift performance and may cause a malfunc tion Turn the cap of the tank clockwise and close it completely Wipe the area around the cap with a clean cloth after filling the tank Any remaining urea soluti...

Page 52: ...ution will contaminate the forklift Consumption of urea solution may vary per driving practices and conditions How to store urea solution 1 Make sure NOT to use the container of the following materials to store urea solution Aluminum Copper Copper alloy Non alloy metal Zinc coated metal Galvanized steel Storage of urea solution shall comply with the following 2 The container to store urea solution...

Page 53: ... imme diately if you come into contact with the water 2 The emission reduction system causes high heat thus make sure to work on the system after its surface is completely cooled down Otherwise you may suffer a burn on the skin WARNING 1 Make sure to use the urea solution of the designated specifications for the forklift with the SCR system 2 Adding urea solution of poor quality or any liquid not ...

Page 54: ...n tank The urea solution may get chemically dissolved if heated up to 50 C for extended time The dissolution will generate ammonia vapor 11 Opening the urea solution tank cap in hot weather may cause the ammonia vapor to leak from the tank The ammonia vapor has highly irritable odor and irritate skin mucous membrane and eyes You may suffer irritation in the eye nose and neck with some coughing and...

Page 55: ... Do NOT turn off the forklift during the automatic reset A task of high load is preferred for efficiency of the reset The icon will turn off when the automatic reset is complete WARNING There may be some odor similar to that of burning sulfur in the middle of the reset Make sure to run the reset in the well ventilated outdoor environment Move the forklift to a safe place if any flammable gas or pa...

Page 56: ...1 Move the forklift to an appropriate place 2 Set the gear at neutral without turning off the engine and engage the parking brake 3 Push and hold the forced reset switch on the right side of the dashboard in the direction of 1 for more than 3 seconds Take the hand off and the switch will return to the original place CAUTION Holding the forced reset switch for too long more than 30 seconds will fai...

Page 57: ...close to the forklift especially from behind or contact the exhaust system as the emission from the engine is hot 3 Indicator for reset blocking Pressing the reset blocking switch 2 for blocking or stopping the reset during automatic reset of the post processing device will turn on the indicator for reset blocking and the reset will be blocked IMPORTANT Engage the switch to block the resetting ope...

Page 58: ...entiretruckelectricalsystemison The key switch has a mechanical anti restart feature which prevents the engine starter from being engaged and damaged if the operator attempts to start the engine when it is already running The key switch cannot be turned to the START position from the ON position without returning the key to the OFF position If the engine stops running the key switch must be turned...

Page 59: ... is engaged CAUTION Never adjust driver s seat while truck is moving to avoid the possibility of loss of control and of personal injury Parking Brake Activates brake operation Check the parking Brake The brake is applied by pulling the lever uppers It is released by pushing downs CAUTION Always apply parking brake before leaving truck WARNING Never operate your lift truck with a defective parking ...

Page 60: ...e able to lift a load rapidly with full engine RPM while controlling slow driving speed with the inching pedal like a clutch This is very useful in confined level working spaces On ramps or inclines the right hand brake pedal only should be used When using the inching pedal on slopes the lift truck could move backwards or forwards unintentionally Direction Control Lever This lever is typically on ...

Page 61: ...the center or neutral positions When the lift control lever is pushed forward the fork carriage is lowered When the lift control lever is pulled back the fork carriage is raised You can also lower the fork carriage even if the key switch is OFF Tilt Control Lever With the tilt control lever you are able to control the tilting or vertical positioning of the upright and the angle of the forks When t...

Page 62: ...he pedal is depressed the faster the lift truck will go in forward Reverse To select and move the truck in the reverse direction you must push down on the REV arrow right side of the Unitrol pedal The further the pedal is depressed the faster the lift truck will go in reverse Neutral The unitrol pedal activates only FWD and REV Neutral is activated only when the parking brake is set IMPORTANT For ...

Page 63: ...g load center and lifting height data Shows the maximum load capacity of this truck with relation to load centers and fork heights see diagram on plate Personal injury and damage to the truck can occur if these capacities are exceeded Do not exceed the maximum capacity specified 5 Truck weight The weight of the truck without a load on the forks This weight plus the weight of the load must be consi...

Page 64: ...nt of a tip over or off the dock mishap Lift trucks can be tipped over if operated improperly Analysis of lift truck accidents has shown that the driver cannot react quickly enough to jump clear of the truck and overhead guard as the truck tips To protect operators from severe injury or death in the event of a tip over it is best to be held securely in the seat So please always buckle up when driv...

Page 65: ...fety decal is placed on the upright to warn of the danger of injury from forks when they are in the raised position Do not ride on or stand under forks or attachments The forks can fall and cause injury or death Always make sure that the forks are in the fully lowered position when they are not being used to handle a load Hot Surface Warning Decal The warning decals are attached to the engine the ...

Page 66: ...rh ead G u ard an d Load Bac k rest are c orrec t ly mou n t ed an d in good c on dit ion Bef ore st art in g en gin e alw ays set f orw ard rev erse lev er in n eu t ral w it h h an d brak e on Driv e c aref u lly k eepin g f ork s an d at t ac h men t s as low as possible f u lly t ilt ed bac k Keep a c aref u l look ou t f or people obst ru c t ion s an d t h e pat h of t rav el Wat c h c leara...

Page 67: ...Section 4 Operating Procedures Contents 4 1 Operating Procedures Contents Before Operating the Truck 4 2 Starting from a Safe Condition 4 3 ...

Page 68: ...operator Do not start or operate the truck or any of its functions or attachments from any place other than the designated operator s position CAUTION Inspect your lift truck before operating at the start of the day or shift Before putting your truck to use check the operation of the controls and all systems Protect yourself Do not operate truck without a driver s overhead guard unless conditions ...

Page 69: ...ks are fully lowered to the floor or ground 3 You are familiar with how all the controls function and have read the Operator Manual 4 All controls are in neutral or other correct position 5 Truck has received its daily inspection and is ready and safe to operate Put the direction control lever in the NEUTRAL position before turning the key switch to ON Forks are down Parking NEUTRAL Position FORWA...

Page 70: ...ver s seat while the truck is moving to avoid the possibility of loss of control and of personal injury Buckling Up Buckle up Be sure that you put on the seat belt Connect and adjust the seat belt strap to a snug comfortable position WARNING Always wear your seat belt when operating a lift truck Starting the Truck Before you start the truck make sure that you have taken all the above mentioned pre...

Page 71: ... is reduced Some of the other conditions that may affect stability are ground and floor conditions grade speed loading dynamic and static forces and the judgement exercised by the operator Trucks equipped with attachments behave as partially loaded trucks even when operated without a load on the attachment Also improper operation faulty maintenance or poor house keeping may contribute to a conditi...

Page 72: ...he desired speed Braking To stop the truck lift your foot from the accelerator pedal and put it on the brake pedal Push down on the brake pedal in a smooth firm motion until the truck is stopped IMPORTANT Stop a lift truck as gradually as practical Hard braking and wheel sliding are dangerous and can cause tip over or the truck could lose its load Also hard braking can increase wear and can be har...

Page 73: ... a truck up to anyone standing in front of an object Protect yourself and those around you Operate the truck only from the designated operator s position Stay within the confines of the lift truck profile dimensions Keep arms legs and hands inside the operator s compartment and away from the danger of passing obstructions Keep under the overhead guard NOTICE An overhead guard is intended to offer ...

Page 74: ... path that may cause the truck to swerve or tip If these conditions are unavoidable slow down and carefully drive past them Slow down for wet or slippery surfaces Avoid any sudden movement Start stop travel steer and brake smoothly Operate your lift truck under all conditions at a speed that will permit it to be brought safely to a stop WARNING Travel slowly when turning Use special care when trav...

Page 75: ... do not indulge in stunt driving or horseplay Observe traffic rules Watch for people and hazards Slow down Be in full control of your lift truck at all times Follow the instructions in this manual to avoid damage to your truck or the possibility of injury to yourself or others During your work observe all functions of your lift truck This allows you to immediately recognize a problem or irregulari...

Page 76: ... on the nameplate In areas classified as hazardous use only trucks approved for use in those areas If you are unsure of the classification of the area you wish to enter check before entering Adjusting the Load Forks The load forks are adjustable on the hanger shaft Forks should be spaced as far apart as the load being carried will allow Both forks should always be the same distance from the center...

Page 77: ...ackwards Keep the load back against the carriage Loads placed out on the ends of the forks can make the lift truck less stable and more likely to tip up Lift and lower with the upright must vertical or tilted slightly back never tilted forward Operate lift and tilt controls slowly and smoothly Never tilt forward when carriage load is raised except to pick up or deposit a load over a rack or stack ...

Page 78: ...f bumps holes and loose materials or debris on the ground Lift and tilt slowly and smoothly Go slowly when turning Cross railroad tracks slowly at an angle wherever possible Use special care when handling and traveling with long high or wide loads to avoid losing the load striking bystanders or obstructions or tipping the truck Watch clearances around the truck and load as you travel Raise the for...

Page 79: ...load being moved If the forks are longer than the load move the tips partially under the load without extending beyond the load Raise the load to clear the floor Back out several inches or whatever distance is necessary then set the load down and move forward until the load is positioned against the carriage Raise the load from the floor or stack by tilting the upright back just enough to lift the...

Page 80: ...ng edge and sides of the load pallet should be lined up exactly with the near edge and side of the load or rack on which you are stacking 4 Stop close to the stack and further lift raise the load high enough to clear the top surface of the stack Slowly move the load into position Be care ful not to damage or move adjacent loads 5 When the load is aligned with the stack beneath it tilt the upright ...

Page 81: ... tipping of other adjacent loads or materials behind the load being moved If the forks are longer than the load move the tips partially under the load without extending beyond the load Raise the load to clear the undersurface Back out several inches then set the load down and move forward until the front face of the forks contacts the load Raise the load from the stack by tilting the upright back ...

Page 82: ...areas that block emergency routes or equipment access to fire aisles or stairways and fire equipment Before leaving the operator s position 1 Bring truck to complete stop 2 Put the directional control lever in the NEUTRAL position 3 Apply the parking brake 4 Lower the lift mechanism fully 5 Turn the key switch to the OFF position If you are going to leave the truck unattended 6 Remove the key 7 Bl...

Page 83: ...5 5 Refueling LPG Tanks 5 6 NOTICE The Occupational Safety and Health Act OSHA requires that truck users examine their trucks before each shift to be sure they are in safe working order Defects when found shall be immediately reported and corrected The truck shall be taken out of service until it has been restored to safe operating condition ...

Page 84: ...n an unsafe condition remove the key and report the condition to the proper authority If the truck becomes unsafe in any way while you are operating it stop operating the truck report the problem immediately and have it corrected Lift trucks should be inspected every eight hours or at the start of each shift In general the daily inspection should include the visual and functional checks described ...

Page 85: ... pressure 5 Be sure that the driver s overhead guard load back rest and all other safety devices are in place securely fastened and undam aged Inspect for damaged or missing parts corrosion cracks breaks etc 6 Check all of the critical components that handle or carry the load 7 Look the upright and lift chains over Check for obvious wear and maintenance problems such as damaged or missing parts le...

Page 86: ...liary if installed Accelerator Directional control Steering system Lift mechanism and any attachments When the functional checks are completed follow the standard shut down procedures given in Section 4 Operating Procedures Concluding the Inspection Make a record on the Driver s Daily Checklist of all the problems that you find Review the checklist to be sure it has been completed and turn it in t...

Page 87: ...Section 5 Operator Maintenance and Care Fuel Safety Practices 5 5 Fuel Safety Practices Refueling Gasoline and Diesel Trucks Use clean properly marked fuel cans Clean up spills ...

Page 88: ...ccording to local fire codes If you refill LPG tanks Make sure you know and understand the proper procedure for filling an LPG tank If you have any questions on refilling LPG tanks please ask your supervisor DANGER LPG IS HEAVIER THAN AIR It settles on your clothes and the ground around you displacing oxygen vital for breathing Open flame can cause flash fires IMPORTANT Check all connections for d...

Page 89: ...o primary test port of single units consisting of primary and secondary regulators B Between the primary and secondary stage regulators when the LPG system consists of two regulators 3 Turn the tank fuel valve on The pressure gauge should maintain a zero reading If it does not the solenoid valve or vacuum shut off valve must be repaired or replaced An odor is added to LPG to help indicate leaks If...

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Page 91: ...Section 6 Emergency Starting and Towing Contents 6 1 Emergency Starting and Towing Contents How to Tow a Disabled Truck 6 2 How to Use Battery Jumper Cables 6 4 ...

Page 92: ...es 300 mm from the floor or ground Secure the carriage with a chain 3 Obtain another lift truck of equal or larger size carrying a partial load for traction 4 Check that the counterweight bolts are in place and properly torqued This bolt is made of a special high tensile steel and is not commercially available Replace it when necessary only with a genuine CLARK replacement part 5 Use an approved s...

Page 93: ...to perform these functions 9 Park the disabled truck in authorized areas only Fully lower the forks to the floor put the directional control lever in the NEU TRAL position and turn the ignition switch to the OFF position Engage the parking brake Remove the ignition key and when necessary block the wheels to prevent the truck from rolling WARNING Always engage the parking brake when parking a lift ...

Page 94: ...r cables with matching connector clamps or cable adapters for side mounted battery terminals CAUTION USE ONLY A 12 VOLT NEGATIVE GROUND SYSTEM to jump your truck You can injure yourself and permanently damage your truck s 12 volt starting motor and ignition system by connecting it to a 24 volt power supply two 12 volt batteries in series or a 24 volt generating set or to a positive ground system W...

Page 95: ...for the jumper cables to reach both batteries Check and make sure that the trucks do not touch each other Use particular care when connecting a booster battery to prevent sparks 3 On both trucks a Apply the parking brake b Put the directional control lever in the NEUTRAL position c Turn the key start switch to the OFF position d Turn all accessories to the OFF position and leave them off until aft...

Page 96: ... a point at least 18 inches 450 mm away from the battery if possible Do not connect it to pulleys fans or other parts that move Do not touch hot manifolds that can cause severe burns 5 Start the engine on the Jumper Vehicle and run the engine at a moderate speed for a minimum of five minutes 6 Start the engine on the Stalled Vehicle Follow the starting instructions in Section 4 Operating Procedure...

Page 97: ...afe Maintenance Practices 7 3 Major Component Locations 7 8 Planned Maintenance Intervals 7 9 PM Report Form 7 12 How to Perform Planned Maintenance 7 14 NOTICE THIS SECTION IS FOR TRAINED SERVICE PERSONNEL to use as a reference for Planned Maintenance proce dures Complete maintenance information is in the Ser vice Manuals ...

Page 98: ...c planned maintenance PM and inspection program Performed on a regular basis by trained personnel the program provides thorough inspections and checks of the safe operating condition of the lift truck The PM identifies needed adjustments repairs or replacements so they can be made before failure occurs The specific schedule frequency for the PM inspections depends on the particular application and...

Page 99: ...ustrial trucks shall be performed in conformance with the manufacturer s recom mendations 3 Follow a scheduled planned maintenance lubrication and inspection system 4 Only trained and authorized personnel are permitted to maintain repair adjust and inspect industrial trucks and must do so in accordance with the manufacturer s specifications 5 Always wear safety glasses Wear a safety hard hat in in...

Page 100: ...ving the truck a Stop the truck b Fully lower the load engaging means upright carriage forks or attachments c Put the directional control in NEUTRAL d Apply the parking brake e Stop the engine f Turn the key switch to the OFF position g Put blocks at the wheels if the truck must be left on an incline 12 Brakes steering mechanisms control mechanisms warning devices lights governors lift overload de...

Page 101: ...under the carriage and upright rails when it is necessary to work with the upright in an elevated position 17 The truck manufacturer s capacity operation and maintenance instruction plates tags or decals must be maintained in legible condition 18 Batteries limit switches protective devices electrical conduc tors and connections must be maintained in conformance with good practice Special attention...

Page 102: ... rims use a safety cage or restraining device while inflating 23 Use special care when removing heavy components such as counterweight upright etc Be sure that lifting and handling equipment is of the correct capacity and in good condition IMPORTANT Your new CLARK lift truck has been built to meet all appli cable mandatory requirements of ANSI ITSDF B56 1 Safety Standard for Powered Industrial Tru...

Page 103: ...r Powered Industrial Trucks NFPA 505 Fire Safety Standard for Powered Industrial Trucks Type Designations Areas of Use Maintenance and Operation Available from National Fire Protection Association Inc Batterymarch Park Quincy MA 02169 General Industrial Standards OSHA 2206 OSHA Safety and Health Standards 929 CFR 1910 Subpart N Materials Handling and Storage Section 1910 178 Powered Industrial Tru...

Page 104: ...hown above is a typical representation of a CLARK internal combustion lift truck Your model may vary slightly 1 2 3 4 5 6 14 7 8 9 10 11 12 13 1 Radiator 2 Transmission Cooler 3 Frame 4 Steer Axle 5 Engine 6 Transmission 7 Wheels and Tires 8 Counterweight 9 Overhead Guard 10 Exhaust 11 Carburetion 12 Sheet Metal 13 Upright and Carriage 14 Drive axle ...

Page 105: ...or in clean open air on clean paved surfaces Severe Operation Prolonged operating hours or constant usage Extreme Operation In sandy or dusty locations such as cement plants lumber mills and coal dust or stone crushing sites High temperature locations such as steel mills and found ries Sudden temperature changes such as constant trips from buildings into the open air or in refrigeration plants If ...

Page 106: ...ruck See component Replace LPG engine oil and filter Replace Diesel engine oil and filter Clean and replace LPG engine air filter Clean and replace Diesel engine air filter Change Diesel fuel filter KUBOTA IVECO Change Diesel fuel filter DEUTZ Change LPG fuel filter Inspect adjust fan belts Drain flush radiator coolant Check engine ignition and timing Engine tune up Check battery Check transmissio...

Page 107: ...l Check engine coolant level radiator and recovery tank Check transmission fluid level Check fuel level Check hydraulic sump oil level Check gauges and instruments Check warning lights and hour meter Check overhead guard condition and bolts Check horn operation and other warning devices Check steering operation Check service brake operation Check parking brake operation Check parking brake linkage...

Page 108: ...unction with the PM Report Form They are arranged in a logical and efficient sequence You make a check mark or entry on the PM Report Form when the PM is performed A special coding system for indicating the importance of needed repairs and or adjustments appears on the form When you have finished the PM inspections be sure to give a copy of the report to the designated authority or person responsi...

Page 109: ...PM Report Form 7 13 Section 7 Planned Maintenance and Lubrication ...

Page 110: ...etc Check for hydraulic oil leaks and loose fittings CAUTION CAUTION HYDRAULIC FLUID PRESSURE Do not use your hands to check for hydraulic leakage Fluid under pressure can penetrate your skin and cause serious injury Overhead Guard Be sure that the driver s overhead guard and any safety devices are in place undamaged and attached securely Check the overhead guard for damage Be sure that it is prop...

Page 111: ... information Forks Inspect the load forks for cracks breaks bending and wear The fork top surfaces should be level and even with each other The height difference between both fork tips should be no more than 1 5 of the blade length WARNING If the fork blade at the heel is worn down by more than 10 the load capacity is reduced and the fork must be replaced Inspect the forks for twists and bends Put...

Page 112: ...r excessive wear and breaks or chunking out Check all wheel lug nuts or bolts to be sure none are loose or missing Replace missing bolts or lug nuts Torque loose or replaced items to specifications WARNING Check tire pressure from a position facing the tread of the tire not from the side Use a long handled gauge to keep your body away from the side If tires are low do not operate and do not add ai...

Page 113: ... with the safety procedures given in Section 4 Operating Procedures in this manual As you test the following components be sure they are properly mounted and working correctly Horn Press the horn button to check horn function If the horn or any other part does not operate report the failure and have it repaired before the truck is put into operation Neutral Start Switch Check the operation of the ...

Page 114: ...l follow Parking Brake Check the function of the parking brake Pushing down then pulling the lever upwards To check parking brake holding capability park the lift truck on a grade and apply the parking brake The parking brake should hold a lift truck with rated load on a 15 grade CAUTION CAUTION Do not operate a lift truck if the service or parking brakes are not operating properly Lift Mechanisms...

Page 115: ...tachment Steering System NOTICE The steering system steer axle and steering linkage on your truck should be inspected periodically for abnormal looseness and damage leaking seals etc Also be alert for any changes in steering action Hard steering exces sive freeplay looseness or unusual sound when turning or maneuvering indicates a need for inspection or servic ing Check the steering system by movi...

Page 116: ...ress the inching pedal fully down and hold Depress the accelerator The truck should not move Now with the accelerator still depressed slowly release the inching pedal until the truck inches forward smoothly and slowly Report any problems When you have completed the operational tests park and leave the truck according to standard shut down procedure as described in Section 4 of this manual Be sure ...

Page 117: ...rs for diesel engine depending upon your application Service intervals may also be determined by the air restriction indicator Battery Inspect the battery for damage cracks leaking condition etc If the terminals are corroded clean and protect them with CLARK Battery Saver available from your CLARK dealer If your battery has removable cell caps check to be sure the cells are all filled Refill them ...

Page 118: ... Failure to do so could result in serious personal injury from hot coolant or steam blowout and or damage to the cooling system or engine If the level is low add a 50 50 mixture of specified coolant and water to the correct fill level If you have to add coolant more than once a month or if you have to add more than one quart at a time check the coolant system for leaks Check engine oil for presenc...

Page 119: ...evel above the ADD mark on the dipstick by adding oil as required Do not overfill Use the correct oil as specified under Lubricant Specifications It is recommended to Drain and replace the engine crankcase oil every 500 oper ating hours depending on application See NOTICE Engine Oil Filter must be changed at every PM when the oil is changed Remove the oil pan drain plug to drain old oil after the ...

Page 120: ... the sump breather wipe it with a clean wiper and reinsert it Remove dipstick and check oil level Keep the oil level above the LOW mark on the dipstick by adding recommended hydraulic fluid only as required Do not overfill Check the condition of the hydraulic fluid age color or clarity contamination Change replace the oil as necessary Hydraulic Fluid and Filter Change Drain and replace the hydraul...

Page 121: ...check method With the unit cold start and run the engine at idle for 30 seconds then check the level and fill only to the add mark NOTICE Check the planned maintenance interval operating hours or the condition of the oil to determine if the transaxle fluid needs to be changed Lubrication Truck Chassis Inspection and Lubrication Lubrication and inspection of truck chassis components including steer...

Page 122: ... see leakage and loose missing or damaged parts and helps prevent fires A clean truck runs cooler The environment in which a lift truck operates determines how often and to what extent cleaning is necessary For example trucks operating in manufacturing plants that have a high level of dirt dust or lint for example cotton fibers or paper dust in the air or on the floor or ground require more freque...

Page 123: ...l fasteners of components that directly support handle or control the load and protect the operator Critical items include Drive axle mounting Overhead guard Drive and steer wheel mounting Tilt cylinder mounting and yokes Counterweight mounting Upright mounting and components Torque specifications are in your Service Manual Lift Chain Maintenance The chain system on the upright was designed for sa...

Page 124: ...s over a sheave Do not repair chains by cutting out the worn section and joining in a new piece If part of a chain is worn replace all the chains on a truck Lift Chain Lubrication Lift chain lubrication is an important part of your maintenance program The lift chains operate under heavy loadings and function more safely and have longer life if they are regularly and correctly lubricated CLARK chai...

Page 125: ... 3 or more or if any of the damaged conditions noted above are found during inspection Order replacement chains from your CLARK dealer Replace all chains as a set Do not remove factory lubrication or paint new chains Replace anchor pins and worn or broken anchors when installing new chains Adjust tension on new chains Lubricate chains when they are installed on the upright NOTICE Please refer to y...

Page 126: ......

Page 127: ...Section 8 Specifications Contents 8 1 Specifications Contents C40 55s 8 2 C60 80 8 5 Engine Oil 8 8 ...

Page 128: ... LPG 82 C 180 F fully open 95 C 203 F Powershift Transmission C40 4000 kg 500mm load center 8810 lbs 20in C45 4500 kg 500mm load center 9920 lbs 20in C50s 5000 kg 500mm load center 11020 lbs 20in C55s 5500 kg 500mm load center 12120 lbs 20in Diesel Diesel LPG LPG Model KUBOTA V3800T DEUTZ TD3 6 GM V6 PSI 4X Cylinders 4 4 6 6 Displacement cubic inches 230 219 262 262 liters 3 8 3 6 4 3 4 3 Idle RPM...

Page 129: ...te This mixture provides anti freeze protection level of 37 C 34 F approximately Transmission Fluid Recommendation Use CLARK Specification MS 276A CLARK Part number 2776236 Drive C40 Single 8 25 15 14PR 820kpa 119psi C45 Single 8 25 15 16PR 951kpa 138psi C50s Single 300 15 18PR 820kpa 119psi C55s Single 300 15 20PR 951kpa 138psi C40 55s Dual 7 50 15 12PR 820kpa 119psi Steer C40 55s 7 50 12 14PR 10...

Page 130: ...07 6188 DEUTZ 11108 24489 6608 14568 9844 21702 2840 6261 C50s KUBOTA 12129 26739 7129 15717 10798 23805 3183 6918 DEUTZ 12205 26907 7205 15884 10848 23916 3217 7092 C55s KUBOTA 13069 28812 7569 16687 11487 25324 3112 6860 DEUTZ 13149 28988 7645 16854 11657 25699 3143 6929 Pneumatic LPG C40 GM 9833 21678 5833 12859 8153 17974 2548 5617 PSI 4X 9833 21678 5833 12859 8749 19288 2548 5617 C45 GM 10879...

Page 131: ...on C60 80 Diesel New type C60 6000kg 600mm load center 13200lbs 24in C70 7000kg 600mm load center 15400lbs 24in C75 7500kg 600mm load center 16500lbs 24in C80 8000kg 600mm load center 17600lbs 24in Diesel Diesel LPG LPG Diesel Model IVECO F4GE9454C DEUTZ TD3 6 GM V6 PSI 4X DOOSAN D43P Cylinders 4 4 6 6 4 Displacement cubic inches 274 219 262 262 208 liters 4 5 3 6 4 3 4 3 3 4 Idle RPM 750 850 700 ...

Page 132: ...volumes liters quarts gallons kilogram pound Speed 3 Forward 3 Reverse Overall Ratios 1st 5 02 1 2nd 2 56 1 3rd 1 00 1 Convertor Stall Ratio 2 1 Drive C60 75 Dual 8 25 15 14PR 820kpa 119psi C80 Dual 8 25 15 18PR 1000kpa 145psi Steer C60 75 8 25 15 14PR 820kpa 119psi C80 8 25 15 18PR 1000kpa 145psi Batteries BCI Group 45 Cooling system Eng oil w filter Transmission Hydraulic sump Fuel tank C60 75D ...

Page 133: ...rt number 2776239 Hydraulic Oil with anti wear additives or equivalent only Truck Weights with standard upright C60 75 3000mm C80 2800mm MFH Gross Vehicle Weight kg lbs Empty Vehicle Weight kg lbs Loaded Drive Axle kg lbs Empty Drive Axle kg lbs Pneumatic Diesel C60 15260 33642 9260 20415 13926 29313 4050 8928 C70 16630 36663 9630 21230 14717 32445 3931 8666 C75 17144 37796 9644 21261 15555 34292 ...

Page 134: ... 15W 40 IVECO in accordance with API classification CI 4 and ACEA E3 SAE 15W 40 DEUTZ in accordance with API classification CI 4 and ACEA E9 E7 E6 SAE 10W 40 DOOSAN in accordance with API classification CJ 4 and ACEA E9 SAE 15W 40 IMPORTANT Do not extend oil change intervals from those specified when using synthetic lubricants 40 30 20 10 0 10 20 30 40 50 SAE 10W SAE 0W 30 SAE 5W 30 SAE 15W 40 SAE...

Page 135: ... it is preferable to use the same brand as various oils may be incompatible Refer to the Maintenance and Lubrication Section for recommended oil change intervals IMPORTANT Do not overfill crankcase Excess oil causes foaming and can cause loss of lubrication and higher operating tem peratures resulting in engine damage ...

Page 136: ......

Page 137: ...Critical Fastener Torque Checks 7 27 D Daily Inspection 1 2 Daily Safety Inspection 5 2 Direction Control Lever 3 22 Direction Control Braking and Inching 7 19 Disassembling the split rim wheel 7 17 Do s and Don ts 1 3 Drop Offs 2 5 E Engine 8 2 Engine Accessories 7 21 Engine Air Cleaner 7 21 Engine Coolant Recommendation 8 3 Engine Cooling System 7 21 Engine Oil 8 8 Engine Oil and Filter 7 23 Eng...

Page 138: ...nce 7 27 Lift Chains 7 26 Lift Control Function 3 23 Lift Mechanisms and Controls 7 18 Load Handling 4 11 Load Handling Components 7 14 Long and Wide Loads Rear Swing 2 3 Longitudinal Tip over 1 13 Loose Loads 2 2 Low Overhead Clearance Fast Turns and High Loads 2 4 Lubrication 7 25 Lift Chain wear and Replacement Criteriai 7 28 M Major Component Locations 7 8 N Neutral Start Switch 7 17 No Riders...

Page 139: ...he Truck 4 4 Steering Column Pylon 3 24 Steering System 3 22 Severe Operation 7 9 Steering System 7 19 Sump Tank Breather Maintenance and Inspection 7 25 Surface and Capacity 1 12 T Tilt Control Lever 3 23 Tip Over 1 13 Traction Disable Fuction 3 22 Transaxle Fluid Check 7 25 Travel 1 10 Traveling with a Load 4 12 Truck Chassis Inspection and Lubrication 7 25 Truck Data and Capacity Plate 3 25 Tru...

Page 140: ...ATERIAL HANDLING COMPANY 700 Enterprise Drive Lexington Kentucky 40510 www clarkmhc com Printed Date Sep 2019 Additional copies of this manual may be purchased from YOUR AUTHORIZED CLARK DEALER OM 1038 C40 80 ...

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