CONTENTS 1. PREFACE 0 – 5 ..............................2. SAFETY 0 – 6 ..............................3. GENERAL 3.1 DESIGNATED WORKS 0 – 7 ....................... 3.2 CHARACTERISTICS OF THE MACHINE 0 – 8 ..............4. DRIVING LICENSE 0 – 9 ........................5. NAME PLATE 5.1 LOCATION OF NAME PLATES 0 –...
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11. ATTACHED POSITION OF SAFETY DECALS 11.1 ATTACHED POSITION OF SAFETY DECALS 1 – 14 ..........11.2 CONTENTS OF SAFETY DECALS 1 – 15 ................[ OPERATION ] 12. GENERAL LOCATIONS 2 – ..................... 13. DRIVING AND OPERATION 13.1 LCD DISPLAY PANEL AND CONTROLLER 2 –...
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19. CHECK BEFORE WORKING 19.1 CHECKING POINTS 2 – 24 ........................ 19.2 CHECKING METHODS BEFORE STARTING OPERATION 2 – 25 ....20. LOAE AND STABILITY OF MACHINE 20.1 STANDARD LOAD CENTER AND LOAD CURVE 2 – 28 ......... 20.2 STABILITY OF MACHINE 2 –...
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24. GUIDE TO REPLACE AND REPAIR PARTS 24.1 HOW TO REPLACE THE CONTACTOR 3 – 12 ............... 24.2 HOW TO ADJUST THE BRAKE 3 – 14 .................. 25. REFRIGERATING SPECIFIED VEHICLE 25.1 COUNTERMEASURE FOR ANTICORROSION 3 – 15 ..........25.2 COUNTERMEASURE FOR LOW TEMPERATURE 3 –...
• Never operate the machine prior to reading and understanding this manual fully. • Read this manual repeatedly. • Please contact your local CLARK dealer in the event that this manual is missing or damaged. • Transfer this manual with the machine.
2. SAFETY Most accidents are the result of abnormal operation, inspection or maintenance. Always pay strict attention to safe operation to prevent personal injury. Please read this manual carefully prior to operation, inspection and maintenance. Note the caution nameplates provided on this machine. Following safety symbols are used.
3. GENERAL 3.1 DESIGNATED WORKS This fork lift truck is electric reach type. The main working purposes are as follows. • Llifting the load materials • Piling the load materials • Carrying the load materials in a short distance For details of operation, refer to “21. OPERATING AND UNLOADING”. The cautions for operation, inspection and maintenance depicted in this manual are limited to the designated works.
3. GENERAL 3.2 CHARACTERISTICS OF THE MACHINE • It is possible to reduce the cost for maintenance through imporved working performance and less usage of contactors as SEM(Separately Excited Motor) type travel motor is used. • Excellent working performance by installing high-output and high-efficient motor, and geatly improved durability by installing Traveling and hydraulic motor with H type of insulating class.
5. NAME PLATE 5.1 LOCATION OF NAME PLATES The name plates are located on the upper part of left side on the frame. FX946 5.2 LOCATION OF MARKING PLATE Serial No. : Service center : Address : Tel No. : Serviceman in charge : Remarks 0 –...
5. NAME PLATE 5.3 Name plate What you should know about your forklift-truck: 1. The location of the model name. 2. The location of the serial number. 3. The description of the additional attachments (if any). Take note of the additional capacity load plate.
6. BASIC PRECAUTIONS OBSERVE USER’S MANUAL AND SAFETY DECAL • Please read this manual and all safety decals on this machine carefully. Abnormal operation can result in physical personnel injury or damage. • Understand the operating and maintenance methos for safety operation. •...
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6. BASIC PRECAUTIONS CLOTHING • Do not wear a loose clothing when you operate this machine. These items may be caught by levers or pedals, so severe injury could result. • Wear a helmet and safety shoes. • Wear other safety equipment appropriate to the job.
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6. BASIC PRECAUTIONS PREPARE FOR EMERGENCIES • Park the machine in a safe place and notify the supervisor when the machine has any abnormality or malfunction. • Insure a fire extinguisher is installed and know how to use it. • Always be prepared for emergencies. •...
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6. BASIC PRECAUTIONS ACCIDENT PREVENTION • Always keep the working area level, and remove all spilled grease, oil or other materials. • Avoid operating the machine near criffs, platforms or docks. Use safety blocks if it is unavoidable to work in that place. •...
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6. BASIC PRECAUTIONS REDUCTION OF ALLOWABLE LOAD FOR MACHINE WITH ATTACHMENTS • Allowable load of the machine with any attachments is reduced against the standard machine. Reason 1) Load is reduced due to attachment weight. 2) The center of gravity is moved forward due to attachment weight. •...
7. SAFETY TRAVELING Operator must read and observe the followings for safety For driving fork lift above 1 ton, the operator must trained authorized person or fork lift. For driving fork lift below 1 ton, the person who had a special training coursefor fork lift can operate the machine.
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7. SAFETY TRAVELING Before carrying the load, make sure that the load is on the pallet safely. FX922 Follow specified ways to put in and out the fork. Do not load unevenly. FX923 When lifting up the load, must stop traveling.
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7. SAFETY TRAVELING While unloading, do not stop the machine suddenly, otherwise cause overturn. Pay attention to the conditions of the ground. If the machine is tilted, do not lift up the load. Do not unload on the slope. Do not let a person be under the lifted FX926 load.
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7. SAFETY TRAVELING When ascending on the slope with load, drive forward slowly, when descending from the slope, drive in reverse slowly. FX929 On the contrary, when ascending on the slope without load, drive in reverse, and when descending from the slope, drive forward.
8. HOW TO USE THE BATTERY AND CAUTIONS FOR CHARGING Do not over discharge. If the equipment is used until it is not moving, the battery life is shortened. Charge immediately when the green lamp in the volumeter is off and the red lamp flickers.
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8. HOW TO USE THE BATTERY AND CAUTIONS FOR CHARGING Keep away from flammable. Around battery, never flammable (because explosive gas is generated). Avoid overcharging. Charge according instructive manual of charger. Do not disconnect the plug while charging. If you have to disconnect the plug while charging, surely push the stop button and pull out the plug body after the charging lamp is off.
9. CAUTIONS WHEN OPERATING THE MACHINE a Do not overdischarge. b Do not lift up or push the load with the fork tip. c Do not load the fork lift over capacity limit (allowable load). d Avoid a sudden start, stop, or turn. e Do not operate the valve suddenly with the mast raised and the luggage loaded.
10. TRANSPOTATION When a truck can't be loaded in a container because of a high-MAST. The MAST shall be disassembled. •Disassembly method is following below. 10.1 REACH CYLINDER PIN No Part name Qty Remarks Washer Pin split FX1169 10.2 MAIN LIFT & TILT & RETURN HOSE No Part name Qty Remarks 1 Cover...
11. ATTACHED POSITION OF SAFETY DECALS Always keep safety decals clean, if the decals are damaged or lost, replace it. Several decals except for the followings are attached on the machine, treat them in the same way as the following one 11.1 ATTACHED POSITION OF SAFETY DECALS VIEW A FX942...
11. ATTACHED POSITION OF SAFETY DECALS 11.2 CONTENTS OF SAFETY DECALS 1 Safety cautions for forks FX060 2 Safety warning for hands FX059 3 Warning for safety WARNING FX943 1 – 15...
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11. ATTACHED POSITION OF SAFETY DECALS 4 Safety caution for battery FX944 5 Warning for the machine for refrigerating WARNING specified vehicle FX945 1 – 16...
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OPERATION WARNING The most important thing is safety. Concentrate on your operation only.
13. DRIVING AND OPERATING 13.1 LCD DISPLAY PANEL AND CONTROLLER TRAVEL HYD STEER CHARGE Km/h Km/h FX902 1. Battery level display 8. Trouble display 2. Travel power display 9. Safety monitor 3. Hydraulic power display 10. Function selection switch 4. Regenerative braking display 11.
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13. DRIVING AND OPERATING 13.1.1 BATTERY LEVEL DISPLAY It displays the status of charging. When the key is ON, the status of battery level is displayed according to the charging condition. When charging is completed, all lamps light up, and according to the degree of discharging, lamps are distinguished downwards from the top.
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13. DRIVING AND OPERATING 13.1.4 REGENERATIVE BRAKING DISPLAY The system that increase service hour of the machine by recharging the battery with electric energy, which is produced when electric braking is applied. When the battery is recharged with the energy successfully, main display lamp lights up.
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13. DRIVING AND OPERATING 13.1.7 FIXED TRAVEL SPEED DISPLAY This machine has the function to travel at the fixed speed in advance. There are 5 steps, such as 3, 4, 5, 6, 7km/hr, selectable. This function is displayed by operating Function selection switch. If this function is selected, the turtle mark is displayed, correspond speed is displayed on letter information display.
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13. DRIVING AND OPERATING 13.1.10 FUNCTION SELECTION SWITCH 1. Mode selection switch 2. Enter switch 3. Travel speed set switch MODE ENTER 4. Hydraulic power switch 5. Travel power-up switch 6. Travel power-down switch POWER FX912 2 – 6...
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13. DRIVING AND OPERATING 1) Mode selection switch The switch is to shift onto the LCD screen which operator desires. mode switch usage is as follows. Each time the mode switch is pressed, the mode moves to the arrow directions as shown below. ERROR DISTANCE PARAMETER...
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13. DRIVING AND OPERATING (1) MODEL NAME & READY OK These characters are displayed when the machine runs in the normal condition. In case that an abnormal condition occurs while running, the trouble message appears immediately. When the trouble message is shown on the screen, immediately stop operating and solve the problem, and then run equipment again.
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13. DRIVING AND OPERATING (4) PARAMETER DISPLAY? This mode confirms the basic control parameters of equipment as well as input and output of each part. If pressing the Enter key at (PARAMETER DISPLAY?), it moves to the lower mode. Then, whenever press the mode switch it moves as follows: (SENSOR INPUTS [ENTER]) ®...
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13. DRIVING AND OPERATING 2 DIGITAL INPUTS : It shows the digital input values. 1. DRIVE DIGITAL INPUTS. It indicates the driving ON/OFF.(It contains lower modes) FORWARD : It indicates the forward ON/OFF. REVERSE : It indicates the reverse ON/OFF. iii.
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13. DRIVING AND OPERATING 4 SYSTEM PARAMETERS: It shows all the parameters set on the controller. 1. VEHICLE PARAMETERS : It shows the parameters set on the vehicle. VEHICLE MAX SPEED : It indicates the maximum speed of vehicle. BDI WARNING LEVERL : It indicates the warning value of battery. iii.
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13. DRIVING AND OPERATING 2) ENTER SWITCH This switch is to select a mode that operator desires. Refer to “1) Mode switch” for usage. 3) TRAVEL SPEED SET SWITCH The switch is to travel constantly at a preset speed, which consists of 5 levels;...
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13. DRIVING AND OPERATING 13.1.11 HORN BUTTON If this button is pressed, the horn will sound and then stop automatically when it released. 13.1.12 HEAD LIGHTS SWITCH When this switch is in lower part, it is OFF. If it is moved upwards, it will be 13.1.13 TURN SIGNAL SWITCH When this switch is in neutral part, it is OFF.
13. DRIVING AND OPERATING 13.2 OPERATING FX913 1. Brake pedal 5. Tilt Lever 2. Steering wheel knob 6. Reach Lever 3. Steering wheel 7. Travel Control Lever 4. Lift Lever 8. Emergency Lever 13.2.1 BRAKE PEDAL When depressing the brake pedal, brake is set and travel circuit is connected. When taking off your foot from the pedal, the pedal is returned to the original position, the brake is set and travel circuit is disconnected at the same time.
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13. DRIVING AND OPERATING 13.2.2 STEERING WHEEL KNOB, 13.2.3 STEERING WHEEL When operating the steering wheel, hold the steering wheel knob with your left hand (Standard machine with electric power steering) 13.2.4 LIFT LEVER When you pull this lever backward, the fork goes up and push forward, the fork goes down.
14. BATTERY DHARGING 14.1 NORMAL CHARGING Note This is all about battery charger designated by CMHA. if you want to use a different charger, please refer to the operation manual of the charger which is included the charger. It depends on the discharging condition or capacity of battery, but generally it takes 8 or 10 hours continuously to charge.
14. BATTERY DHARGING 7 Never pull the plug out while charging. If you want to plug out while charging, press stop button first, and then pull out the plug while holding the body. 8 When charging is completed, the lamp on the top of charging sequence display will light up.
14. BATTERY DHARGING 14.3 SUPPLEMENTARY CHARGING If it is impossible to complete the day’s work by charging once, carry out supplementary charging during the break time. The supplementary charging method is the same with the normal charging. When you want to stop charging, push the stop button.
15 STATIONARY BATTERY Install the charger in the place that is well ventilated and covers the rain. There must be no flammable around the charger. 15.1 CHARGING METHOD (NORMAL CHARGING) The charger has an automatic charging system. The charging method is as follows. 1 Turn the key switch to OFF and pull out the battery plug.
16. BATTERY REPLACEMENT When using the machine continuously by turns, replace with the charged battery during break. Immediately charge the battery which is taken off. Conform to the following method. Battery sensor Battery 1 Disconnect the battery plug. 2 Open the battery cover and fix with the stopper.
17. LEVEL OF BATTERY ELECTROLYTE AND READING GRAVIMETER 17.1 LEVEL OF BATTERY ELECTROLYTE Check the level of electrolyte. If the level is low, replenish with distilled water. When checking the lever of electrolyte, inspect the float condition through the electrolyte cover from outside. If the float isn’t seen, replenish with distilled water. Appropriate level Appropriate...
17. LEVEL OF BATTERY ELECTROLYTE AND READING GRAVIMETER 17.3 SPECIFIC GRAVITY OF ELECTROLYTE AND CONVERSION TABLE OF TEMPERATURE COMPENSATION Temperature °C Ex) When the scale mark is 1.250 at 5°C, it will be 1.240 (20°C). 2 – 22...
18. SOUND INFORMATION 18.1 SOUND LEVEL The sound pressure level (LpA) at the operator’s ear emitted by this machine is 66.7dB (A). The above measurements are obtained on a representative machine, by applying the procedures described in the standard of prEN12053. This figure can be changed as the condition of the road and tire.
19. CHECK BEFORE WORKING The operator never fail to inspect the following items before the day’s working for safe operation and optimum performance of the fork lift. 19.1 CHECKING POINTS Class. Item Check contents Brake system Brake pedal Operating distance of pedal, performance of brake Steeringl Clearance of steering wheel Loose, rattle, gap...
• When pressing brake pedal, check that micro switch is operated at 1.5~2cm from the floor plate. • When releasing brake pedal, check that it is operated normally. • Check mechanical conditions of brake. CER10~13 below 1.2m ····················································· CER15~18 below 1.5m ·····················································...
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In case of CER10-CER18, Check if you see the surface of the oil In case of CER20-CER25, Check the oil level with a deep stick.
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19. CHECK BEFORE WORKING 10 Operate the switches for headlight, back light and tail light (option), and turn signal light (option) in order to check that the lamp is ON and OFF. Press the horn button to check that it is sounds. 11 Checking Monitor In normal operating condition, when the key switch is ON, <System check>...
20. LOAD AND STABILITY OF MACHINE The fork lift can be regarded as a seesaw where the front wheels act as a fulcrum upon which the counter weight load on the rear wheels is counterbalanced by the load on the forks.
20. LOAD AND STABILITY OF MACHINE 1 Push the load so as that the load is surely loaded inside of the fork. 2 If the load is too much leaned to the Tilt front of fork even under max. load, backward unexpected force is applied to the mast fork...
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20. LOAD AND STABILITY OF MACHINE a Do not overdischarge b Do not lift up or pull the load with the tip end of the fork. c Do not load fork lift over capacity limit( allowable load). d Avoid a sudden start, stop, or turn, otherwise it may cause dangers. f Do not operate the valve suddenly when the mast is raised with load.
21. OPERATING AND UNLOADING Check the safety around the machine and sit down on the operator’s seat. Reach out Tilt forward Reach in Forward Lower Tilt down backward Lift up Reverse Left turn Right turn Stop Start FX934 21.1 PREPARATION FOR STARTING a Hold the steering wheel knob lightly with your left hand and turn the start switch ON position.
21. OPERATING AND UNLOADING • You must decelerate in following cases. • When turning suddenly, or approaching the load and pallet (without load) • When approaching the place to unload (with load) • When driving a place where excessively narrow, or uneven road 21.2.2 TURNING The forklift has rear wheel steering system apart from other general vehicles.
21. OPERATING AND UNLOADING * If the loading position is bad because the size of pallet or load is not fitted well, carry out in the following method. Control the reach operation in order to pull out the fork about 1/4 of the length and lift up again (5~10cm) to insert to the safe loading position and then lower down.
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INSPECTION·MAINTENANCE WARNING • When inspecting or maintaining, make sure to disconnect the battery plug.
22. INSPECTION AND MAINTENANCE If the inspecting and maintenance is surely carried out, an accident can be prevented and the life of machine becomes long. Even if you are busy, fix the date and carry out the periodic inspection so as to increase the working ratio of machine and to reduce the maintenance cost of machine.
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22. INSPECTION AND MAINTENANCE After filling up, close the electrolyte cover completely. Be careful when filling up the electrolyte because if the electrolyte is excessively filled up, it can overflow. Lack (Float isn’t seen.) (Replenish with water) 2) How to feed distilled water a Put the container filled with distilled water on the place higher than the battery position.
22. INSPECTION AND MAINTENANCE d When starting to fill up distilled water, loosen the pinch cork and push the center of distilled water container with Distilled your hand several times to make water distilled water come out by syphon container action.
22. INSPECTION AND MAINTENANCE 22.4 CLEANING BATTERY a To prevent the connecting part of battery and the environs from rusting, clean up with wet towel and keep those parts always dry. b The inside of the electrolyte cover can get dirty easily. Therefore, clean it with Battery neutral detergent sometimes so that it is Electrolyte...
22. INSPECTION AND MAINTENANCE 22.5 INSPECTION EVERY MONTH (200HR) Inspect the following items addition to the items to be inspected before working. (Report the inspecting results.) If there are items to require adjusting or replacing, contact to your local dealer. Item and content Check The whole machine...
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22. INSPECTION AND MAINTENANCE Item and content Check Clearance, operation Steering wheel Steering joint Vibration, noise Gear case Volume, leakage, abnormal noise Hub bolt of drive wheel Loose Drive wheel, caster wheel, load wheel Damage, worn part Upper spring Damage Cast spring Damage Lift chain...
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22. INSPECTION AND MAINTENANCE FX935 3 – 7...
22. INSPECTION AND MAINTENANCE 22.6 INSPECTION EVERY 2 MONTHS (400 HR) Inspecting the contactor When inspecting the contact points, if there are damages, repair and replace the items according to the degree of damage. (For details, refer to “21 GUIDE TO REPLACE AND REPAIR PARTS”) 22.7 INSPECTON EVERY 3 MONTHS (600 HR) Inspect the following items addition to the items to be inspected per every month...
23.2 SPECIFIED LUBRICATION CHART • Recommened specification and oil filling capacity (Unit : liter) Ambient temperature Filling capacity Division –22 –4 104 122°F CER10-13 CER14-18 CER20-25 –30 –20 –10 40 50°C ISO VG22 ou VG15 Hydraulic 13.5 15.6 ISO VG32 ISO VG46 SAE 80W–90...
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24. GUIDE TO REPLACE AND REPAIR PARTS If following failures occur while using the machine, check according to the checking point. (If there are any problems, make contact to your local dealer.) When checking, surely turn off the start switch and disconnect the battery plug. Failure Checking items LCD is not turned on...
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24. GUIDE TO REPLACE AND REPAIR PARTS 24.1 HOW TO REPLACE THE CONTACTOR WARNING Surely disconnect the battery plug and then replace it. When replacing the whole of contactor assembly, dissemble the relevant connector and put a new contactor in the original position. The followings are how to replace the contact points of contactor.
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24. GUIDE TO REPLACE AND REPAIR PARTS 2) Replacing contact point of steering EPS contactor a Separate the contactor installation bolt from the contactor assembly. Screw b Pull the contact points and the coils of contactor with hands in order to separate.
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Lever Brake pad Adjusting bolt Adjusting spring (A) Spring CER10–25 115mm FX941 <How to adjust> a Adjust the gap between the adjusting bolt and the cam to be 1.5mm b Adjust to meet the indicated numbers in the above table by loosening the nuts for adjusting brake spring.
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25. REFRIGERATING SPECIFIED VEHICLE This machine is the type of refrigerating specified vehicle. Therefore, it is a counter balance battery type forklift designed and manufactured to load and unload in the refrigerator warehouse with hard condition. The refrigerating specified vehicle can be used in the refrigerator warehouse of -35°C.
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25. REFRIGERATING SPECIFIED VEHICLE 25.2 COUNTERMEASURE FOR LOW TEMPERATURE 1) Hydraulic oil and grease For hydraulic oil, the oil with excellent performance in low temperature is used. Therefore, use the oil in the following table when changing oil. Also, the grease which has high performance of filling in low temperature is used.
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