Clark HWX 30-40, Operator'S Manual

Page 1: ...OM 746 Do not remove this manual from the truck Operator s Manual PWX 30 40 HWX 30 40 ...

Page 2: ...________ Vehicle Weight Empty_________________________________ Vehicle Rated Capacity ________________________________ Vehicle Gross Weight _________________________________ Special Equipment or Attachments _______________________ IMPORTANT Do not expose this manual to hot water or steam WARNING California Proposition 65 This product contains and emits chemicals known to the State of California of...

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

Page 4: ...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...

Page 5: ...ou 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 ...

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Page 7: ...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 ...

Page 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 ...

Page 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...

Page 10: ...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 Also the Index helps you locate information about various topics NOTICE The descriptions and specifications included in this manual wereineffectatthetimeofprinting CLARKMaterialHandlingCompany reserves t...

Page 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...

Page 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...

Page 13: ...1 1 Daily Inspection 1 2 Do s and Don ts 1 3 No Riders 1 4 Pedestrians 1 5 Grades 1 6 Travel 1 7 Pinch Points 1 8 Parking 1 9 General Safety Rules Contents ...

Page 14: ...rk Lights damage mounting operation Steering loose binding leaks operation Gauges Instruments damage operation 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 Data Plate not rea...

Page 15: ...M0005 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 General Safety Rules ...

Page 16: ...1 4 No Riders WARNING Always walk with PWX model truck Never attempt to ride WARNING The operator must be the only rider on the HWX model trucks Never carry passengers General Safety Rules ...

Page 17: ...ians 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 Pedestrians General Safety Rules ...

Page 18: ...orks downgrade with or without a load and in the raised position when working on a grade Do not ride HWX model on a grade Trucks designed to travel up a 5 maximum grade with load Grades WARNING Never turn on a grade either loaded or unloaded ...

Page 19: ...uck first This will minimize the maneuvering necessary to exit If load blocks your view while traveling in reverse make sure path is clear of personnel and obstructions CAUTION Always take extra care in any confined places Think ahead of your moves When moving in and out of confined space allow enough room for yourself between the truck and walls racks pallets etc Travel ...

Page 20: ...llow anyone to reach under or around the edge of the truck Be especially careful not to put any portion of your body under the load forks Keep your feet clear of the truck when traveling Pinch Points General Safety Rules ...

Page 21: ...ower forks to floor Place control handle in full turn and raise handle to up position to apply brake Turn key switch off and remove key Unplug battery connector Block drive wheel to prevent accidental roll Turn key in to proper authority General Safety Rules Wheel Block WARNING Never park on a grade ...

Page 22: ...1 10 General Safety Rules ...

Page 23: ...offs 2 4 Trailer Creep 2 4 Debris on Floor 2 5 Damaged Pallets and Skids 2 6 IMPORTANT The operation of lift trucks involves many hazardous situ ations This section describes some of the more common ones Your place of work may have hazards not described Be alert to those situations that can result in injury and possibly death ...

Page 24: ...RNING Slow down on turns An empty truck can tip over easier than a loaded truck WARNING Always use caution when making a turn into an aisle The load wheels do not follow the turn path of the drive wheel and will tend to cut the corner ...

Page 25: ...usly injure yourself or others Never carry uneven material Stack loose material evenly Long or Wide Loads WARNING Long or wide loads are less stable and may strike objects or per sons in their path Watch load clearance move slowly and turn carefully ...

Page 26: ...e he she does not move the trailer until you are done The lift truck operator must make sure the driver applies the trailer brakes and chocks trailer wheels The impact of moving in and out of a trailer may cause the trailer to move WARNING Usewheelchocks Usetrailer to docklockingsystems if available ...

Page 27: ...sand mud wood gravel and other materials will make the floor slippery uneven and dangerous Be careful when cross ing these areas 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 ...

Page 28: ...2 6 OM0011 Damaged Pallets and Skids WARNING Do not move or store materials on damaged or poorly maintained palletsandskids Itemscan fallthroughoroffthemcausingsevere injury or death ...

Page 29: ...2 Component Location HWX Model 3 3 Operator s Controls PWX Model 3 4 Operator s Controls HWX Model 3 5 Maintenance Component Location PWX Model 3 6 Maintenance Component Location HWX Model 3 7 System Description 3 8 Nameplate Description 3 10 Warning Decals 3 11 ...

Page 30: ...onent Location PWX 1 Steering and Brake 2 Truck Data Plate 3 Load Wheels 4 Drive Wheel 5 Load Forks 6 Covers 7 Battery 8 Hour Meter 9 Operator s Manual 10 Warning Decals 11 Key Switch 1 2 11 6 9 10 7 3 5 8 10 4 ...

Page 31: ... Operator Hand Rail 4 Truck Data Plate 5 Load Wheels 6 Drive Wheel 7 Load Forks 8 Covers 9 Rider Platform 10 Battery 11 Stability Casters 12 Hour Meter 13 Coast Control option 14 Operator s Manual 15 Warning Decals 16 Key Switch 1 4 8 9 6 11 12 14 3 2 16 13 5 7 15 10 ...

Page 32: ...r Controls PWX 1 4 5 3 6 2 2 7 3 1 Steering and Brake Control Handle 2 Lower Control Button 3 Lift Control Button 4 Speed Button Rabbit 5 Horn Button 6 Emergency Reverse Switch 7 Forward Reverse Control Butterfly ...

Page 33: ...X 1 Steering and Brake Control Handle 2 Lower Control Button 3 Lift Control Button 4 Speed Button Rabbit 5 Horn Button 6 Emergency Reverse Switch 7 Forward Reverse Control Twist Grip 8 Coast Control 1 4 5 3 6 2 2 7 5 4 2 3 8 3 ...

Page 34: ...3 6 Maintenance Component Location PWX 1 2 3 4 5 7 6 7 7 1 Battery 2 Traction Control Panel 3 Hydraulic Unit 4 Brake 5 Drive Motor 6 Drive Unit 7 Lubrication Fittings ...

Page 35: ...3 7 Maintenance Component Location HWX 1 Battery 2 Traction Control Panel 3 Hydraulic Unit 4 Brake 5 Drive Motor 6 Drive Unit 7 Lubrication Fittings 7 7 7 7 4 3 2 1 5 6 ...

Page 36: ... Unit Double reduction helical spur and spiral bevel gears Totally enclosed with lubricating oil bath Vertical mount drive motor Five bolt drive wheel mounting for simple removal and replace ment Brake Double acting Electromagnetic type brake Easy service accessibility Electrical 24 volt electrical system U L listed type E Inverter type control features cool and quiet operation cold switching for ...

Page 37: ...0Arms HWX or ACE2_400Arms PWX Control System ZAPI MDI CAN display bat tery discharge indicator full 6 lift height horn key switch 24 volt electrical system cushion rubber drive tire poly load wheels 7 or 13 6 wide battery compartments SB 175 amp grey connector high visibility Clark green and black finish Additional HWX features include spring loaded stability casters operator platform with non ski...

Page 38: ...ere flammable or explosive material may be present Truck serial number Capacity data Truck weight less load Battery weight Battery identification number System voltage Battery ampere hour rating IMPORTANT When attachments are added or if the truck is modified the ca pacity of the truck may be affected Contact your authorized Clark dealer for a new nameplate showing the revised capacity 1 2 3 4 5 6...

Page 39: ...reas with load and first Be very careful when operating in confined area to avoid being pinned Avoid uneven or slippery surfaces and loose materials Travel slowly and with caution on slopes and do not turn Always travel with load down grade Do not load truck over capacity on nameplate Do not handle shaky loads be very careful when handling long high and wide loads Do not exceed floor weight limits...

Page 40: ...tempting to ride as a passenger on HWX model trucks The operator must be the only rider on HWX model trucks Battery Warning Decal This decal is located on the right cover to give warning to discon nect the battery before servicing and to maintain correct battery polarity Coast Control Decal This decal is located on the con trol handle base cover to give warning when the brake is deac tivated on th...

Page 41: ...Operation 4 2 Travel Control 4 3 HWX High Speed Control 4 3 Emergency Reversal Switch 4 4 Horn Control 4 4 Lift Lower Control PWX Model 4 5 Lift Lower Control HWX Model 4 5 Braking 4 6 Plugging 4 6 Load Handling 4 7 Coast Control Option 4 8 Parking 4 9 ...

Page 42: ... clockwise to on position Check to make sure your path of travel is clear of people or obstructions Make sure HWX model are completely stopped before you get on or off Keep one hand on control handle and other hand on operator hand rail Keep your feet back from edge of operator s platform while oper ating truck Do not ride HWX model trucks while traveling on ramps picking up or depositing loads or...

Page 43: ...vel forward Rotate the direction speed in the opposite direction to travel in reverse Re verse is defined as the direction in which the forks point Truck speed increases the further you rotate the direction speed control When you release the control it rotates back to the neutral position HWX High Speed Control When riding HWX model trucks for long distances you can use the high speed control on t...

Page 44: ...verse direction Reverse is defined as the direc tion in which the forks point When the switch no longer con tacts the person or object the switch pops up and the truck re sumes normal control Emergen cy reversal is disabled when the brake is on or when the truck is in high speed ride mode CAUTION Be careful not to activate Emergency Reversal Switch when pulling down the handle from the parked posi...

Page 45: ... the lower control to lower the load forks Press the lift con trol to raise the load forks Press the lower control to lower the load forks PWX Lift Lower Control HWX Lift Lower Control IMPORTANT Always travel with the load forks fully elevated to provide maximum floor clearance ...

Page 46: ...oth stop CAUTION When operating a HWX rider truck always bring the truck to a complete stop before getting on or off Plugging optional braking You can change direction and stop the truck without braking by plug ging As you are traveling move the travel control to the opposite direction The truck should slow to a smooth controlled stop and then accelerate in the opposite direction You can control t...

Page 47: ...ely before moving truck Avoid operating hazards and observe general safety rules while moving load Always approach load deposit areas squarely and cautiously Be especially careful when placing loads near water pipes elec trical wiring or outlets steam pipes heaters and other danger ous or fragile equipment After placing load in position lower the forks completely Withdraw the forks squarely from t...

Page 48: ...play alarm light will start flashing To deactivate coast place control arm in the vertical position twist the directional control to Forward Hold coast buttons for two 2 seconds The dash display alarm light will turn off CAUTION Be aware that the electromagnetic brake is deactivated when the coast function is active Coast Buttons NOTE When coast function is activated the red alarm LED on the dash ...

Page 49: ...ea 2 Lower forks to floor 3 Place control handle in full turn and raise handle to up position to apply brake 4 Turn key switch to off position and remove key 5 Unplug battery connector 6 Block drive wheel to prevent accidental roll 7 Turn key in to proper authority ...

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Page 51: ...rol 4 4 Travel Control 5 4 Lift and Lower Controls 5 5 Brake 5 6 Coast Control Option 5 6 Wheels and Tires 5 7 Maintenance Problems 5 7 NOTICE OSHArequires inspection before starting each shift to keep lift trucks in safe operating condition The following information points out important areas to check during these inspections ...

Page 52: ...quipped mounting operation Load Back Rest bent cracked loose missing Warning Lights if equipped mounting operation Forks bent worn stops OK Lift Lower loose binding excessive drift leaks Engine Oil level dirty leaks Tilt loose binding excessive drift chatters leaks Hydraulic Oil level dirty leaks Attachments mounting damaged operation leaks Radiator level dirty leaks Battery Test electric trucks o...

Page 53: ...WX Check the emergency reversal switch It should depress easily and pop back out on its own Position the control handle to release the brake Then with the truck in neutral or forward depress the emer gency reversal switch The truck should move away from you until you take your hand off the switch or apply the brake ...

Page 54: ...l position when released Operator Hand Rail HWX model only On the HWX test the high speed control While riding the truck ro tate the direction speed control to full forward speed Depress the high speed control button The truck goes into higher speed and stays there until you return the throttle to neutral High Speed Control PWX Lift and Lower Controls ...

Page 55: ...WX Lift and Lower Controls Check the lift lower control buttons The control buttons must return to the off position when released The hydraulic lift pump motor should stop when maximum lift height is reached ...

Page 56: ...jogged with coast buttons It is not necessary to move the control handle from the vertical position To activate coast press the two coast buttons at the same time Hold for two 2 seconds The dash display alarm light will start flashing To deactivate coast place control arm in the vertical position twist the directional control to Forward Hold coast buttons for two 2 seconds The dash display alarm l...

Page 57: ...t excessive wear breaks chunking out or bond failure Check lug nuts for proper torque Watch for loose wheel bearings Do not operate a truck that has a maintenance problem Park the truck properly and remove the key if equipped Put an Out of Service tag on the truck Report the truck problem to the proper authority ...

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Page 59: ...es 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 NOTICE THIS SECTION IS FOR TRAINED SERVICE PERSONNEL to use as a reference for Planned Maintenance procedures Complete maintenance information is in the Service Manual ...

Page 60: ...control operation Check lift and lower operation Typical Operating Conditions Time intervals between maintenance are largely determined by oper ating conditions The intervals specified in the following table are for normal operation For more severe operation the maintenance inter vals should be shortened accordingly Contact you CLARK dealer for recommendations Normal Operation Basically eight hour...

Page 61: ...d leaks Test drive truck Check functional performance Air clean truck Check torque on critical fasteners Lubricate truck Clean check battery terminals electrolyte level Check battery cables truck receptacle Perform battery load test Check motors Check lift pump motor brushes Test truck ground Clean drive motor air vents Check drive unit fluid level Drain and replace drive unit fluid Check hydrauli...

Page 62: ...ction system shall be followed 4 Only trained and authorized personnel shall be permitted to main tain 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 check e...

Page 63: ...isms and frame members must be carefully and regularly inspected and maintained in a safe oper ating condition 12 Special trucks or devices designed and approved for hazardous area operation must receive special attention to ensure that main tenance preserves the original approved safe operating features 13 All hydraulic systems must be regularly inspected and maintained in conformance with good p...

Page 64: ...prior written approval Capacity operation and maintenance instruction plates tags or decals must be changed 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 least equal to that provided in the original equipment Parts including tires are to be installed per the manufacturer s proce dures Always us...

Page 65: ...Fire Safety Standard for Powered Industrial Trucks Type Designations Areas of Use Maintenance and Operation Available from National Fire Protection Assoc Inc Battery march Park Quincy MA 02269 General Industry Standards OSHA 2206 OSHA Safety and Health Standards 29 CFR 1910 Subpart N Materials Handling and Storage Section 1910 178 Powered Industrial Trucks For sale by Superintendent of Documents U...

Page 66: ...teries 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 equip ment 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 which in...

Page 67: ...sulted 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 case Be sure the lift hooks are the c...

Page 68: ...moking is allowed in the charging area Do not check the elec trolyte level with an open flame Do not allow open flame sparks or electric arcs in battery charging area When charging batteries the vent caps must be kept in place to avoid electrolyte spray Care must be taken to assure that vent caps are open clean and functioning The battery or compartment cover s must be open to dissipate heat and g...

Page 69: ... be sure there are provisions for handling electro lyte 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 Disconnect battery before handling electrical components Polarity must be correct to prevent damage WARNING 3 Disconnect the battery connector 4 If the battery t...

Page 70: ... 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 corro sion on battery terminals and cable ...

Page 71: ...ator or plates are visible Do not overfill 7 Keep the battery clean and dry Wash down as needed 8 Keep battery service records Battery Installation 1 Use only a lead acid battery with the voltage and ampere hour rating specified for the truck 2 When changing batteries on battery electric trucks replacement batteries must be of the service weight that falls within the mini mum maximum range specifi...

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Page 73: ...7 1 TOWING IMPORTANT Pull a disabled truck by hand to a service area CAUTION Do not tow or push the truck with another vehicle ...

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Page 75: ...SE 7 1800 lbs 816 kg HWX 30SE 13 6 2030 lbs 920 kg HWX 40SE 7 1860 lbs 843 kg HWX 40SE 13 6 2280 lbs 1034 kg Battery 24 Volt Lead Acid 12 cells Minimum Wgt Capacity Battery 6 hr rate max Compartment 456 lbs 10 8 KW h 7 821 lbs 21 5 KW h 13 6 Specific Gravity Minimum Fully Charged 1 160 1 315 Fluid Recommendations Hydraulic Unit MS 68 Hydraulic fluid CLARK P N 1800236 Drive Unit MS 276A CLARK P N 2...

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Page 77: ..._________ Traction Motor ______________________________________ Steer Motor _________________________________________ Pump Controller _____________________________________ Traction Controller ___________________________________ Expansion Controller Module ___________________________ Steer Unit __________________________________________ Drive Unit __________________________________________ ...

Page 78: ...700 Enterprise Drive Lexington KY 40510 Printed in USA Additional copies of this manual may be purchased from YOUR AUTHORIZED CLARK DEALER ...