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6-1

Section 6. Planned Maintenance and Lubrication

Contents

Daily Inspection Points .............................................6.2
Typical Operating Conditions ...................................6.2
Maintenance and Lubrication Schedule ..................6.3
Safe Maintenance Practices .....................................6.4
Safety Standards .......................................................6.7
Battery Maintenance ..................................................6.8
Battery Handling ........................................................6.9
Battery Charging ......................................................6.10
Battery Removal ...................................................... 6.11
Battery Cleaning and Care ......................................6.12
Battery Service Records .........................................6.12
Battery Life ...............................................................6.13
Battery Installation ..................................................6.13

NOTICE

THIS SECTION IS FOR TRAINED SERVICE PERSON-

NEL to use as a reference for Planned Maintenance

(PM) procedures. Complete maintenance information

is located in the Service Manual (SM-743).

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Содержание WSTX33

Страница 1: ...Operator s Manual OM 743 Do not remove this manual from the truck Rev 1 1 WSTX33 NOV 2019 ...

Страница 2: ...________________________________ Customer Vehicle Identification No ________________________ Vehicle Weight Empty__________________________________ Vehicle Rated Capacity_________________________________ Vehicle Gross Weight__________________________________ Special Equipment or Attachments________________________ IMPORTANT Do not expose this manual to hot water or steam ...

Страница 3: ...and ask your supervisor for assistance Learn about the unit you operate Breaking these rules will cause serious or fatal injury to yourself and others Operator s Manual Then Practice operating your truck safely And Keep your truck in a safe operating condition with correct and timely maintenance You must be trained and authorized to operate a lift truck ...

Страница 4: ...Manual viii Safety Signs and Safety Messages x Section 1 General Safety Rules 1 1 Section 2 Operating Hazards 2 1 Section 3 Common Truck 3 1 Section 4 Operator Maintenance and Care 4 1 Section 5 Operating Procedures 5 1 Section 6 Planned Maintenance 6 1 Section 7 Towing 7 1 Section 8 Specifications 8 1 ...

Страница 5: ...iii ...

Страница 6: ...afety 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 safety rules and hazards of lift truck operation It describes...

Страница 7: ...u start operating this lift truck be sure you under stand all driving procedures It is your responsibility and it is important to you and your family to operate your lift truck safely and efficiently Be aware that the Federal Occupational Safety and Health Act OSHA and state laws require that operators be completely trained in the safe operation of lift trucks it is also an OSHA requirement that a...

Страница 8: ...ad back rest parking brake and horn are standard equipment Safe productiveoperationofalifttruckrequiresbothskillandknowledge on the part of the operator The operator must know understand and practice the safety rules and safe driving and load handling techniques describedinthismanual Todeveloptheskillrequired theoperatormust become familiar with the construction and features of the lift truck and ...

Страница 9: ...zed mechanic on a regular basis The PM will provide an opportunity to make a thorough inspection of the safety and operating condition of your lift truck Necessary adjustments and repairs can be done during the PM which will increase the life of components and reduce unscheduled downtime and increase safety The PM can be scheduled to meet your particular application and lift truck usage The proced...

Страница 10: ...tion 6 Planned Maintenance describes the PM program Section 7 Towing Provides information regarding towing a disabled truck Section 8 Specifications provides reference information and data on features components and maintenance items NOTICE The descriptions and specifications included in this manual wereineffectatthetimeofprinting CLARKMaterialHandlingCompany reserves the right to make improvement...

Страница 11: ...ly 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 pro cedures in this manual Understand how BDI gauge indicator lights and control functions Please contact your authorized CLARK dealer for the answers to any questions you may have about your lift truck s features operation or manu...

Страница 12: ...r 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 other special data IMPORTANT This message is used when s...

Страница 13: ...Section 1 General Safety Rules Daily Inspection 1 2 Do s and Don ts 1 3 No Riders 1 4 Pedestrians 1 4 Fork Safety 1 5 Pinch Points 1 6 Travel 1 7 Tip Over 1 8 Surface and Capacity 1 9 Parking 1 10 Contents ...

Страница 14: ...nting operation Steering loose binding leaks operation n o i t a r e p o e g a m a d s t n e m u r t s n I s e g u a G Service Brake linkage loose binding stops OK grab Operator Restraint damage mounting operation oily dirty Parking Brake loose binding operational adjustment Warning Decals Operator s Manual missing not readable Seat Brake if equipped loose binding operational adjustment g n i s s ...

Страница 15: ...001 OM0002 OM0003 OM0004 OM0005 Don t mix drugs or alcohol with your job Do watch for pedestrians Don t block safety or emergency equipment Do wear safety equipment when required Don t smoke in NO SMOKING areas or when refueling Do s and Don ts ...

Страница 16: ...s 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 No Riders WARNING Always walk the truck Never attempt to ride or allow passengers ...

Страница 17: ...5 Section 1 General Safety Rules 657006 657005 There is special equip ment to raise people for overhead work DO NOT USE LIFT TRUCKS Never allow anyone to walk under raised forks DANGER 2372604 Fork Safety ...

Страница 18: ...ING Keep hands feet and legs out of the upright Pinch Points WARNING Don t use the upright as a ladder CAUTION Never try to repair the upright carriage chain or attach ment yourself Only properly trained mechanics can repair or maintain lift trucks ...

Страница 19: ...s in motion Travel with the load near the floor ground whenever possible Never lift or lower the load when the truck is in motion When handling bulky loads that restrict your vision operate your truck in reverse to improve visibility Unstable loads are a hazard to you and to your fellow workers Always make certain that the load is well stacked and evenly po sitioned across both forks Never attempt...

Страница 20: ...raveling with this combination may exceed the stability of the truck This condition is even more likely when braking in forward travel or ac celerating rearward 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 into overhead objects or collisions An off dock typ...

Страница 21: ...y WSTX004 Avoid these conditions They can cause a truck to tip over or lose trac tion 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 ...

Страница 22: ...s Never park on a grade Alwayscometoacompletestop Be sure travel control is in NEUTRAL Lower forks fully to floor Place control handle in full turn andraisehandleto UP position to apply brake Turn key to OFF position Block drive wheel to prevent accidental roll Turn key in to proper authority ...

Страница 23: ...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 Loose Loads 2 2 Long and Wide Loads 2 3 Rear Swing 2 3 Low Overhead Clearance 2 4 Fast Turns and High Loads 2 4 Right Angle Stacking 2 5 Chain Slack 2 6 Pallets and Skids 2 7 Contents ...

Страница 24: ...on 2 Operating Hazards WARNING Looseorunbalancedloads are dangerous Observe these precautions Stack and band loose material Never carry loose or uneven material Loose Loads Center wide loads OM0008 OM0006 OM0007 ...

Страница 25: ... 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 Long and Wide Loads WARNING When turning be sure the truck does not swing into racks posts etc Watch for pedestrians beside the truck Extra Long Rear Swing ...

Страница 26: ...at slow speeds Travel with a load raised only when removing or depositing a load WARNING Know the height of your truck with and without a load Check your clearances Keep the load low as possible when traveling Watch overhead clearance Moving into overhead structures can tip a truck over or spill a load Low Overhead Clearance Fast Turns and High Loads ...

Страница 27: ...2 5 Section 2 Operating Hazards WARNING When right angle stacking or moving with a raised load to clear low objects avoid sharp turns and move slowly Right Angle Stacking S L O W L Y ...

Страница 28: ...t of the upright WARNING Don t use the upright as a ladder CAUTION Nevertrytorepairtheupright carriage chain or attachment yourself Always contact a trained mechanic WARNING Slack chains mean rail or carriage hang up Raise the forks before you move or broken chains and or hoses can result ...

Страница 29: ... 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 condi tion and does not have defective or missing components and fasteners Pallets and Skids OM0011 ...

Страница 30: ......

Страница 31: ...3 1 Section 3 Common Truck Truck Description 3 2 Operator Controls 3 3 Battery Discharge Indicator 3 4 Nameplate 3 5 Warning Decals 3 6 Contents ...

Страница 32: ...k Description 1 Chassis 2 Drive Wheel 3 Battery Discharge Indicator 4 Key Switch 5 Control Handle 6 Battery Disconnect 7 Controller 8 Mast 9 Back rest 10 Forks 11 Load Wheel 12 Hydraulic Pump 13 Battery 3 6 8 9 13 11 5 2 12 1 4 7 10 ...

Страница 33: ...ected shut off and the key can be removed The horn will not operate if the key switch is turned off Control Handle Controls travel direction and speed lift lower tilt horn braking and steering Twist grip or butterfly type speed control for left or right hand operation Up or down brake application Safety reversing switch on end of control handle 180º rotation for maneuverability Offset steering pro...

Страница 34: ...attery The battery indicator shows the actual charge level of the trucks battery The battery discharge indicator BDI is used to indicate the degree the battery has been drained of charge The BDI is to be read when the unit is at rest with the key switch ON and with no motor running The hour meter displays the time the drive motor and or the pump motors are operating ...

Страница 35: ...r 4 Capacity data 5 Truck weight less load 6 Battery weight 7 Battery type 8 Battery voltage 9 Battery ampere hour rating Nameplate CAUTION When attachments are added or if the truck is modified the capacity of the truck may be affected Contact your authorized Clark dealer for a new nameplate showing the revised capacity IMPORTANT OSHA requires prior written approval from the manufac turer before ...

Страница 36: ... and understand these instructions and the other safety messages in this manual and on the lift truck Do not operate this motorized hand truck unless you are trained andauthorized Read andunderstand theoperator smanual before starting truck Do not operate damaged or faulty truck Do not attempt repairs unless you are trained and authorized Keep hands on designated grip and feet away from truck Do n...

Страница 37: ... the right covertogivewarningtodisconnect the battery before servicing and to maintain correct battery polarity Upright Warning Decal This safety decal is on the upright towarnofthedangerofinjuryfrom movement between rails chains sheaves fork carriage and other parts of the upright assembly Do not climb on or reach into the upright Personal injury will result if any part of your body is put be twe...

Страница 38: ...right 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 surethattheforksareinthefullylowered position when they are not being used to handle a load 2372604 ...

Страница 39: ...TION The Occupational Safety and Health Act OSHA re quires 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 tagged with a Out Of Service tag and taken out of service until it has been restored to safe operating condition ...

Страница 40: ...ondition removethekeyandreportthecondition totheproperauthority Ifthetruckbecomesunsafeinany 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 on the following pages As an...

Страница 41: ... not use bare hands to check Oil may be hot or under pressure 5 Be sure that the load back rest and all other safety devices are in place securely fastened and undamaged 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 ...

Страница 42: ...t code is not an operator fault code notify a service technician 3 Be sure all controls and systems operate freely and return to neutral properly Check the Brake system Hydraulic controls Control handle Direction Accelerator and Steering control Steering system When the functional checks are completed 1 Bring truck to complete stop 2 Lower the lift mechanism fully 3 Raise handle to the full up pos...

Страница 43: ... sure any unusual noises or problems are investigated immediately OUT OF SERVICE Donotoperatealifttruckthathas a maintenance problem or is not safe to operate Remove the key from the ignition switch and put an Out of Service tag on the truck BesuretoputthisOperator sManual back in the holder in the operator s compartment Read the manual again if you are not sure of all lift truck operating procedu...

Страница 44: ......

Страница 45: ...nts Before Operating the Truck 5 2 Starting from a Safe Condition 5 2 Travel Control 5 3 Emergency Reverse Switch 5 3 Lift and Lower Control 5 4 Horn 5 4 Braking 5 5 Plugging 5 5 Load Handling 5 6 Stacking 5 13 After Operating the Truck 5 15 ...

Страница 46: ...signated operator s position CAUTION Inspect your walkie stacker 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 Starting from a Safe Condition Always start from a safe condition Before operating a walkie stacker truck make sure The emergency disconnect switch is in the OFF position Unplug battery cha...

Страница 47: ...y reversal switchstrikesanobjectoraperson or is held in by the operator the truck automatically propels itself in the reverse direction reverse is defined as the direction in which the forks point When the switch no longer contacts the person or object the switch pops up and the truck resumes normal control Emergency reversal is disabled when the brake is ON or when the truck is in high speed mode...

Страница 48: ...on 5 Operating Procedures Raises and Lowers forks Tilts the forks forward and backwards Press horn button to sound horn Lift and Lower Control Tilt Control Horn Button Horn Lift Lower Tilt Lift and Lower Control ...

Страница 49: ...When the steering arm is in the upright position the brake acts as a parking brake Braking occurs when the handle is released and spring action raises steering arm to the upright position Plugging This electrical braking function consists of rotating the speed control lever in the opposite direction of travel and then releasing it when the truck stops Plugging is a convenient way to slow down the ...

Страница 50: ... forks enough to elevate the load before moving truck Avoid operating hazards and observe general safety rules while moving Always approach load deposit areas squarely and cautiously Be especially careful when placing loads near water pipes electrical wiring or outlets steampipes heaters andother dangerousorfragileequipment After placing load in position lower the forks completely Tilt forward Wit...

Страница 51: ...enturning Usespecialcarewhentraveling withoutaloadbecausetheriskoftippingoverisgreaterwith an empty truck especially at high speed and when turning Travel with the forks tilted back and raised only enough to fully clear the ground or obstacles When the carriage load is in an elevated position the stability of the truck is reduced IMPORTANT Your speed will be restricted when the forks are raised to...

Страница 52: ...e carefully do not indulge in stunt driving or horseplay Observe traffic rules Watch for people and haz ards 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 walkie stacker lift truck This allows you to immediately recogn...

Страница 53: ...dhandlingattachments loads having a high center of gravity or uneven terrain may dictate that the safe working load be less than the rated capacity Under these conditions the operator must reduce the load being carried so that the lift truck remains stable Handle only stable or safely arranged loads Do not handle loads made up of loose unevenly stacked or unstable items that can easily shift and f...

Страница 54: ...ge raised elevated in a high position except during stacking Observe all traffic regulations and watch for other traffic pedestrians and safe clearances Always look in the direction of travel Keep a clear view of the path of travel and when the load blocks your visibility travel in reverse with load trailing Avoid sudden movements when carrying a load start stop travel steer and brake smoothly Ste...

Страница 55: ...enerally add extra weight and complexity to the truck operate trucks equipped with attachments as partially loaded trucks when not handling a load Picking Up and Moving Loads When picking up a load from the ground approach the load slowly andcarefullyalignthetrucksquare with the load The forks should be adjusted to fit the load or pallet being handled and spread as wide aspossibletoprovidegoodstab...

Страница 56: ... the correct position lower the load to the floor Adjust the fork height as necessary for smooth removal of the forks from the load pallet Carefully back away to clear the forks from the load Raise the forks to traveling height Stacking To put a load on a stack Approach slowly and align the lift truck and load squarely with the stack Level the load as the lift truck is nearing the stack using the ...

Страница 57: ...n the load is aligned with the stack beneath it carefully lower the load onto the top surface of the stack Fig 5 Lower drop the forks slightly to clear disen gage the load pallet Tilt the forks forward slightly if necessary Fig 6 Checkyourtravelpath then carefully back awayuntiltheforksare clear of the stack Stop and lower the forks to the travel position 6 to 8 inches above the ground then tilt b...

Страница 58: ...the load to clear the under surface 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 just enough to lift the load from the surface Or with the upright still vertical raise the forks until they begin to lift the load At this point apply the minimum back tilt that will stabili...

Страница 59: ...at block emergency routes or equipment access to fire aisles or stairways and fire equipment Lower forks to the floor Tilt the upright forward until the forks are level and flat on the floor Place control handle in full turn and raise handle to UP position to apply brake Turn key switch to the OFF position and remove key Block drive wheel to prevent accidental roll Turn key in to proper authority ...

Страница 60: ......

Страница 61: ...ety Standards 6 7 Battery Maintenance 6 8 Battery Handling 6 9 Battery Charging 6 10 Battery Removal 6 11 Battery Cleaning and Care 6 12 Battery Service Records 6 12 Battery Life 6 13 Battery Installation 6 13 NOTICE THIS SECTION IS FOR TRAINED SERVICE PERSON NEL to use as a reference for Planned Maintenance PM procedures Complete maintenance information is located in the Service Manual SM 743 ...

Страница 62: ...nal and speed control operation Check lift and lower operation Check emergency disconnect switch Typical Operating Conditions Time intervals between maintenance are largely determined by op erating conditions The intervals specified in the following table are for normal operation For more severe operation the maintenance intervals should be shortened accordingly Contact you CLARK dealer for recomm...

Страница 63: ... truck check functional performance Air clean truck including all motors Check torque on critical fasteners Lubricate truck Clean Check battery terminals electrolyte level Check battery cables truck receptacle Perform battery load test Test for shorts and grounds Clean drive motor air vent Drain and replace drive unit fluid Check hydraulic fliud level Drain and replace hydraulic fluid Check emerge...

Страница 64: ...bricationandinspectionsystem shall be followed 4 Onlytrainedandauthorizedpersonnelshallbepermittedtomaintain repair adjust and inspect industrial trucks and in accordance with the manufacturer s specifications 5 Properly ventilate work area vent exhaust fumes keep shop clean and floor dry 6 Avoid fire hazards and have fire protection equipment present in the work area Do not use an open flame to c...

Страница 65: ...lift mechanisms and frame members must be carefully and regularly inspected and maintained in a safe operating condition 12 Specialtrucksordevicesdesignedandapprovedforhazardousarea operationmustreceivespecialattentiontoensurethatmaintenance preserves the original approved safe operating features 13 All hydraulic systems must be regularly inspected and maintained in conformance with good practices...

Страница 66: ...ed accordingly 20 Care must be taken to assure that all replacement parts including tires are interchangeable with the original parts and of a quality at leastequaltothatprovidedintheoriginalequipment Parts including tires are to be installed per the manufacturer s procedures Always use genuine CLARK or CLARK approved parts 21 Use special care when removing heavy components from the truck such as ...

Страница 67: ...ent Foundation 1750 K Street NW Suite 460 Washington DC 20009 www itsdf org NFPA 505 Fire Safety Standard for Powered Industrial Trucks Type Designations Areas of Use Maintenance and Operation Available from National Fire ProtectionAssoc Inc Batterymarch Park Quincy MA 02269 General Industry Standards OSHA 2206 OSHA Safety and Health Standards 29 CFR 1910 Subpart N Materials Handling and Storage S...

Страница 68: ...sing batteries When handling acid concentrates greater than 50 acid above 1 400 specific gravity an eye wash fountain must be provided A conveyor overhead hoist or equivalent material handling equipment must be provided for handling batteries IMPORTANT Electric truck batteries are heavy and awkward to handle They are filled with a very hazardous chemical solution On charge they give off hydrogen w...

Страница 69: ...pecial lifting device such as an insulted spreader bar to attach the hoist to the battery The width of the spreader bar must be the same as the lifting eyes of the battery to prevent damage to the battery If the spreader bar hooks are movable carefully adjust the position width of the hooks so that the pull is directly upward vertical and no side load or force pressure is exerted on the battery ca...

Страница 70: ...earprotectiveclothing such as face shield long sleeves and gloves 2 Hydrogen emissions from charging batteries are explosive No smoking is allowed in the charging area Do not check the electro lyte level with an open flame Do not allow open flame sparks or electric arcs in battery charging area WARNING SULFURIC ACID The battery contains corrosive acid that can cause injury If acid contacts your ey...

Страница 71: ... serviced be sure there are provisions to flush and neutralize spillage and to disperse ventilate fumes from gassing batteries on charge And be sure there are provisions for handling electrolyte 2 Before attempting to remove or charge a storage battery the truck should be positioned in the designated battery service area and the parking brake applied so the truck cannot move 3 Disconnect the batte...

Страница 72: ...used to clean and protect the truck battery New Truck Batteries Apply a light coat of BATTERY SAVER and CLEANER to entire surface of battery Allow to set for approximately 30 seconds then wipe thoroughly with a wiping cloth or rag Chemical action will dissolve rust and corrosion After cleaning apply a second coating for protection This will prevent the start and growth of corrosion on battery term...

Страница 73: ...e visible Do not overfill 7 Keep the battery clean and dry Wash down as needed 8 Keep battery service records Battery Installation 1 Useonlyalead acidbatterywiththevoltageandampere hourrating specified for the truck Use only the type of battery as indicated on the truck nameplate 2 When changing batteries on battery electric trucks replacement batteries must be of the service weight that falls wit...

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Страница 75: ...rvice area CAUTION Do not tow or push the truck with another vehicle IMPORTANT The WSTX33 walkie stacker counterbalanced lift truck has an electromagnetic emergency brake that must be disabled prior to towing see your Service Manual SM 743 If your truck becomes disabled contact a trained and authorized me chanic ...

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Страница 77: ...H 825 x 332 mm Grades Travel 5 loaded Variable from 0 to 3 1 mph loaded 8 empty Variable from 0 to 3 4 mph empty Tilt Lift 3 Forward Up to 20 ft min loaded 7 Backward Up to 27 ft min empty Drive Wheel Load Wheel 10 x 4 1 polyurethane 10 x 4 polyurethane Fluid Recommendations Hydraulic Unit AW ISO32 Hydraulic Fluid CLARK Part No 1800236 AW ISO22 Hydraulic Fluid Cold Storage Transmission SAE 80W 90 ...

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Страница 79: ... Traction Motor _______________________________________ Steer Motor __________________________________________ Pump Controller ______________________________________ Traction Controller ____________________________________ Expansion Controller Module ____________________________ Steer Unit ___________________________________________ Drive Unit ___________________________________________ ...

Страница 80: ...700 Enterprise Drive Lexington KY 40510 Printed in the USA Additional copies of this manual may be purchased from YOUR AUTHORIZED CLARK DEALER ...

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