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Section 7. Planned Maintenance and Lubrication

Contents

7-1

Planned Maintenance and Lubrication

Contents

Introduction ............................................................ 7-2

Safe 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.

Содержание CGC40 L

Страница 1: ...Do not remove this manual from the truck INTERNAL COMBUSTION LIFT TRUCKS CGC40 50 55 60 70 L Part No 8058502 eng Book No OM 764 Rev 1 2 Jun 2019...

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Страница 3: ...thers 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 y...

Страница 4: ...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 opera...

Страница 5: ...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...

Страница 6: ...iv...

Страница 7: ...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 Ma...

Страница 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 op...

Страница 9: ...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...

Страница 10: ...m 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...

Страница 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 infor...

Страница 12: ...ructions 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 Contac...

Страница 13: ...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...

Страница 14: ...t 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 ar...

Страница 15: ...owatch forpedestrians Don t blocksafetyoremergency equipment Dowearsafetyequipment when required Don t smoke in NOSMOKING areas orwhen refueling XXX Don t use the similarfuel If forklift truckistobe o...

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

Страница 17: ...Section 1 General Safety Rules No Riders 1 5 No Riders The operator is the only one who should be on a truck Never transport personnel on the forks of a lift truck...

Страница 18: ...tion 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...

Страница 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...

Страница 20: ...1 8 Fork Safety Fork Safety Never allow anyone to walk under raised forks There is special equipment to raise people for overhead work DO NOT USE LIFT TRUCKS 2372604 DANGER...

Страница 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 yoursel...

Страница 22: ...tion 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 ha...

Страница 23: ...ction 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 Forks Downgrade Loaded Forks Upgrad...

Страница 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 I...

Страница 25: ...f 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...

Страница 26: ...tarts 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 bel...

Страница 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...

Страница 28: ...ve 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 l...

Страница 29: ...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...

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Страница 31: ...earance 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...

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

Страница 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...

Страница 34: ...oad 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 t...

Страница 35: ...s 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...

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

Страница 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...

Страница 38: ...G 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...

Страница 39: ...trols Contents 3 1 Operator Compartment and Controls Contents Truck Description 3 2 Operators Compartment 3 3 Dash Pod Display 3 4 Dash Pod Symbols 3 5 Hydrostatic Operators Compartment 3 6 Hydrostati...

Страница 40: ...el 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 represent...

Страница 41: ...heel to the desired position and release lock 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 Steering Handwheel 2 Dash Display 3 Forward Reverse Lever 4 Parking Brake Release 5 Hood Release 6 Parking Bra...

Страница 42: ...ourself with the dash display and its warning indicators Make viewing the indicators part of your normal operating routine If any of these indicator lights show an irregularity or when they are not wo...

Страница 43: ...asten your seat belt IMPORTANT You should always have your seat belt securely fastened when operating your lift truck Air Filter This symbol displays when the restriction level in the air cleaner reac...

Страница 44: ...iary Control Lever 6 Brake Pedal 7 Accelerator Pedal 8 Pylon Lock 9 Horn Button 10 Dash Display 11 Direction Control standard 12 Parking Brake Release 13 Hood Release 14 Parking Brake Pedal 15 Seat Ad...

Страница 45: ...e truck in the forward direction you must push down on the FWD arrow left side of the Unitrol pedal The farther the pedal is depressed the faster the lift truck will go in forward Reverse To select an...

Страница 46: ...ck to decelerate and stop The preferred method of braking is to lift your foot from the direction or ground speed pedal the truck will then come to a stop IMPORTANT The Clark Hydrostatic Lift Truck us...

Страница 47: ...pedal should be used to hold the truck on a ramp or incline Preferred Method of Inching Hydraulic lever functions lift tilt and aux when actuated will automatically raise the engine RPM This feature h...

Страница 48: ...ents 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 RUN positi...

Страница 49: ...ange is 50 kg 170 kg 110 lb 374 lb CAUTION Never adjust driver s seat while truck is moving to avoid the possibility of loss of control and of personal injury Parking Brake The parking brake pedal or...

Страница 50: ...erator to release the parking brake CAUTION Always apply parking brake before leaving truck WARNING Never operate your lift truck with a defective parking brake Hour Meter Starting the engine also sta...

Страница 51: ...e backwards or forwards unintentionally Direction Control Lever This lever is typically on the left side of the steering column When changing the direction of travel make sure that your lift truck has...

Страница 52: ...ng and lowering speeds are controlled through the main hydraulic valve by varying the lever position from the center or neutral positions When the lift control lever is pushed forward the fork carriag...

Страница 53: ...control lever If your lift truck is equipped with an optional attachment this lever lets you control the flow and direction of the hydraulic oil to the attachment Steering Column Pylon The steering w...

Страница 54: ...ng 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 a...

Страница 55: ...he best chance of avoiding injury in the event 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 can...

Страница 56: ...t 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...

Страница 57: ...Section 4 Operating Procedures Contents 4 1 Operating Procedures Contents Before Operating the Truck 4 2 Starting from a Safe Condition 4 3...

Страница 58: ...perator 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 st...

Страница 59: ...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 receive...

Страница 60: ...er 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 stra...

Страница 61: ...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 equip...

Страница 62: ...e 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 IMPORT...

Страница 63: ...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 prof...

Страница 64: ...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 t...

Страница 65: ...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 a...

Страница 66: ...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...

Страница 67: ...ckwards 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...

Страница 68: ...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 handl...

Страница 69: ...oad 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 dis...

Страница 70: ...g 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...

Страница 71: ...ge or 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...

Страница 72: ...reas 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...

Страница 73: ...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 fo...

Страница 74: ...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 immed...

Страница 75: ...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 brea...

Страница 76: ...iary 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...

Страница 77: ...Section 5 Operator Maintenance and Care Fuel Safety Practices 5 5 Fuel Safety Practices Use clean properly marked fuel cans Clean up spills...

Страница 78: ...cording 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 supe...

Страница 79: ...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 fu...

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Страница 81: ...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...

Страница 82: ...s 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...

Страница 83: ...rking brake when parking a lift truck The truck can move and cause injury or death to personnel near it Towing a Disabled Hydrostatic Truck Clark does not recommend towing a disabled Hydrostatic lift...

Страница 84: ...TION 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 p...

Страница 85: ...or 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 Appl...

Страница 86: ...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...

Страница 87: ...fe 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 PERS...

Страница 88: ...nned 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...

Страница 89: ...rial trucks shall be performed in conformance with the manufacturer s recom mendations 3 Follow a scheduled or planned maintenance lubrication and inspection system 4 Only trained and authorized perso...

Страница 90: ...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 k...

Страница 91: ...nder 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 deca...

Страница 92: ...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...

Страница 93: ...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...

Страница 94: ...ruck shown above is a typical representation of a CLARK internal combustion lift truck Your model may vary slightly 1 2 3 4 5 6 7 11 12 8 9 10 1 Engine Cooling 2 Transmission Cooling 3 Steer Axle 4 En...

Страница 95: ...r 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...

Страница 96: ...k torque on critical fasteners Lubricate truck See component Drain and replace engine oil Replace LPG engine oil filter Clean and replace LPG engine air filter Change LPG fuel filter Inspect adjust fa...

Страница 97: ...r loose wheel lugs nuts Check engine oil level Check engine coolant level radiator and recovery tank Check transaxle fluid level Check fuel level Check hydraulic sump oil level Check gauges and instru...

Страница 98: ...onjunction 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 indic...

Страница 99: ...PM Report Form 7 13 Section 7 Planned Maintenance and Lubrication...

Страница 100: ...id etc Check for hydraulic oil leaks and loose fittings CAUTION HYDRAULIC FLUID PRESSURE Do not use your hands to check for hydraulic leakage Fluid under pressure can penetrate your skin and cause ser...

Страница 101: ...rmation 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 th...

Страница 102: ...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 WAR...

Страница 103: ...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 butto...

Страница 104: ...hing checks will follow Parking Brake Check the function of the parking brake Release then reapply To check parking brake holding capability park the lift truck on a grade and apply the parking brake...

Страница 105: ...achment 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...

Страница 106: ...D Press 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...

Страница 107: ...pending 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 corrode...

Страница 108: ...as cooled 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...

Страница 109: ...il level 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...

Страница 110: ...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 re...

Страница 111: ...te 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 t...

Страница 112: ...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 nec...

Страница 113: ...teners 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 mo...

Страница 114: ...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 lubricatio...

Страница 115: ...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 p...

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Страница 117: ...Section 8 Specifications Contents 8 1 Specifications Contents CGC40 70 8 2 Engine Oil 8 4...

Страница 118: ...tat Diesel 82 C 185 F fully open 95 C 203 F Gas LPG 88 C 190 F fully open 96 C 205 F CGC 40 3630kg 600mm load center 8 000lbs 24in 4000kg 500mm CGC 50 4540kg 600mm load center 10 000lbs 24in 5000kg 50...

Страница 119: ...C negative ground Fuses 5 15 amps Batteries BCI Group 45 Cold cranking current 12 volt DC 420 amps 0qF total Filters Engine air Dry type replaceable element Engine oil Spin on Transmission Spin on Hyd...

Страница 120: ...propane Fill Capacities fluid volumes Engine Coolant Recommendation Use a mixture of 50 ethylene glycol permanent type antifreeze containing rust and corrosion inhibitors only NOTICE This mixture prov...

Страница 121: ...correct amount of oil When adding oil between oil changes it is preferable to use the same brand as various oils may be incompatible Refer to the Maintenance and Lubrication Section for recommended oi...

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Страница 123: ...ing and Inching 7 19 Disassembling the split rim wheel 7 17 Do s and Don ts 1 3 Drop Offs 2 5 E Engine Accessories 7 21 Engine Air Cleaner 7 21 Engine Cooling System 7 21 Engine Oil 8 4 Engine Oil and...

Страница 124: ...l Shift Function 3 13 Neutral Start Switch 7 17 No Riders 1 5 Normal Operation 7 9 O Operating Safely 4 7 Operator Daily Inspection vii Operators Compartment 3 3 Optional Hydraulic Control Levers Deck...

Страница 125: ...Tank Breather Maintenance and Inspection 7 25 Surface and Capacity 1 12 T Tilt Control Lever 3 14 Tip Over 1 13 Transaxle Fluid Check 7 25 Transmission Flued Travel 1 10 Traveling with a Load 4 12 Tr...

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Страница 128: ...CLARK MATERIAL HANDLING COMPANY 700 Enterprise Drive Lexington Kentucky 40510 www clarkmhc com Printed Date Jun 2019 Additional copies of this manual may be purchased from YOUR AUTHORIZED CLARK DEALER...

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