Clark CER10 User manual

8024404
FORK LIFT

0 – 1
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 – 10
5.2 LOCATION OF MARKING PLATE .................................................................................. 0 – 10
5.3 NAME PLATE .................................................................................................................................. 0 – 11
[ SAFETY ]
6. BASIC PRECAUTIONS .......................................................................................................... 1–1
7. SAFETY TRAVELING ............................................................................................................... 1–6
8. HOW TO USE THE BATTERY AND CAUTIONS
FOR CHARGING ......................................................................................................................... 1 – 10
9. CAUTIONS WHEN OPERATING THE MACHINE ............................. 1 – 12
10. TRANSPOTATION
10.1 REACH CYLINDER PIN ....................................................................................................... 1 – 13
10.2 MAIN LIFT & TILT & RETURN HOSE ................................................................... 1 – 13
10.3 FORK & LOAD BACKREST ............................................................................................. 1 – 13

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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 – 11
13. DRIVING AND OPERATION
13.1 LCD DISPLAY PANEL AND CONTROLLER ....................................................... 2–21
13.2 OPERATING ................................................................................................................................... 2 – 14
14. BATTERY CHARGING
14.1 NORMAL CHARGING ............................................................................................................. 2 – 16
14.2 EQUAL CHARGING ................................................................................................................. 2 – 17
14.3 SUPPLEMENTARY CHARGING ..................................................................................... 2 – 18
14.4 CHARGING FOR LONG TERM STORAGE ......................................................... 2 – 18
14.5 CHARGING METHOD ............................................................................................................ 2 – 18
15. STATIONARY BATTERY
15.1 CHARGING METHOD (NORMAL CHARGING) .................................................. 2 – 19
16. BATTERY REPLACEMENT ............................................................................................ 2 – 20
17. LEVEL OF BATTERY ELECTROLYTE AND TEADING
GRAVIMETER
17.1 LEVEL OF BATTERY ELECTROLYTE ..................................................................... 2 – 21
17.2 HOW TO READ THE GRAVIMETER ........................................................................ 2 – 21
17.3 SPECIFIC GRAVITY OF ELECTORLYTE AND CONVERSION TABLE OF
TABLE OF TEMPERATURE COMPENSATION ................................................. 2 – 22
18. SOUND INFORMATION......................................................................................................... 2 – 23
18.1 SOUND LEVEL ............................................................................................................................ 2 – 23

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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 – 29
21. OPERATING AND UNLOADING
21.1 PREPARATION FOR STARTING .................................................................................. 2 – 31
21.2 OPERATING ................................................................................................................................... 2 – 31
21.3 LOADING .......................................................................................................................................... 2 – 32
21.4 UNLOADING ................................................................................................................................... 2 – 33
[ INSPECTION AND MAINTENANCE ]
22. INSPECTION AND MAINTENANCE
22.1 GENERAL CAUTIONS FOR INSPECTION AND MAINTENANCE ..... 3 – 11
22.2 INSPECTION EVERY WEEK (50HR) ........................................................................ 3 – 11
22.3 MEASURING SPECIFIC GRAVITY .............................................................................. 3 – 31
22.4 CLEANING BATTERY ............................................................................................................ 3 – 41
22.5 INSPECTION EVERY MONTH (200HR) .................................................................. 3 – 51
22.6 INSPECTION EVERY 2 MONTHS (400HR) ........................................................ 3 – 81
22.7 INSPECTION EVERY 3 MONTHS (600HR) ........................................................ 3 – 81
22.8 INSPECTION OF CARBON BRUSH .......................................................................... 3 – 81
23. LUBRICATION CHART
23.1 LUBRICATING POINT ............................................................................................................ 3 – 91
23.2 SPECIFIED LUBRICATION CHART ............................................................................ 3 – 10

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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 – 16
25.3 USAGE OF NO SLIP TIRE .............................................................................................. 3 – 16
26. SPECIFICATIONS
26.1 DIMENSIONS ................................................................................................................................. 4–10
26.2 TRUCK SPECIFICATION ..................................................................................................... 4–20
26.3 BATTERY SPECIFICATION ............................................................................................... 4–30
26.4 TIGHTENING TORQUE OF EACH PART ............................................................. 4–40

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1. PREFACE
This manual contains basic safety and operating and maintenance instructions.
Please read this manual carefully prior to operation.
Always pay strict attention to safe operation to prevent personal injury.
Some photographs or illustrations in this publication show details or attachments that
can be different from your machine. Guards and covers may have been removed
for illustrative purposes.
Continuing improvement and advancement of product design may have caused
changes to your machine which are not included in this publication.
Abnormal operation may result in serious injury or death.
Please read this manual carefully prior to operation and maintenance.
Be sure to keep this manual in the cab so that all the personnel can read
it.
• 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.
• The safety, operation, maintenance and repair information described in
this manual are applied to limit the machine to specified usage
WARNING
!
This manual is copyrighted with all rights reserved.
No part of this manual may be copied, in whole or in part, without written
consent from CLARK.

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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.
This manual contains the outlines of operation, inspection and maintenance. But all
of the information can not be described.
Therefore it is the responsibility of the operator to make sure that he operate, inspect
and maintain the equipment safely for the works not described in this manual.
Safety symbol Contents
DANGER
!
WARNING
!
CAUTION
!
IMPORTANT
Imminent danger resulting in death or serious injury.
Latent danger resulting in death or serious injury.
Latent danger resulting in less serious injury or equipment
damage.
Matters which are important in the correct handling of this
machine are indicated with an “IMPORTANT”.

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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.
It is the responsibility of the operator to make sure that he operates, inspects and
maintain the equipment safely for the works not described in this manual.
Do not perform the works prohibited in this operator’s manual.

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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.
•The position and descriptions of the troubles are displayed in characters and codes
at the same time by using various self-diagnostic functions, which make the process
of maintenance and inspection simple. The controller can limit and reduce the
functions automatically according to the condition of troubles to improve machine
safety.
•The complex control function of travel and hydraulic prevents the instant over
discharging in order to achieve the maximization of service time.
•Suspension system with impact absorption springs is installed in order to reduce
operator’s fatigue and to improve durability of machine.
•Big LCD display panel with high brightness is installed in order to check almost
all contents related to the machine conditions.
•Operators can fix a certain speed in advance, and can travel under static speed
traveling mode in order to carry the important load safely.
•The working performance of mast is improved by increasing free lift height with
helps of free bar system.

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4. DRIVING LICENSE
The operator must obtain the driving license for the fork lift operation according to
the related regulations.

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5. NAME PLATE
5.1 LOCATION OF NAME PLATES
The name plates are located on the upper
part of left side on the frame.
5.2 LOCATION OF MARKING PLATE
Remarks
FX946
Serial No. :
Service center :
Address : Tel No. :
Serviceman in charge :

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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.
4. Which tire type (dimension, ply-rating)
to be used.
The type of tire (pneumatic/elastic)
influences the static stability of the
forklift-truck.
For this reason only the tire types approved by the manufacturer may be used.
Column 4 shows the tire types which are approved by the manufacturer.
Tire code:
E = cushion
L = pneumatic
S = super elastic
Z = twin tires
R = radial
5. The year of build.
6. The capacity of the forklift-truck with forks.
In this space the capacity, the load centre and the lift height are stated. The
specified maximum values must not be exceeded.
Attention:
For additional attachments there must be mounted an additional load capacity
plate beside the type plate, which gives the permissible load capacity of your
forklift-truck for a CENTRAL LOAD in conjunction with additional attachments.
These load capacities must not be exceeded.
The subsequent mounting (not supplied by the manufacturer) of one or more
additional attachments requires immediate mounting of a new capacity plate for
the combination forklift-truck /additional attachments. The customer must obtain
this from the manufacturer or local dealer.
7. The forklift-truck weight less battery.
A damaged type plate or capacity plate must to be replaced.

Read the safety cautions carefully and observe
them.
Serious injury may result if not followed.
SAFETY
EX396
WARNING
!

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6. BASIC PRECAUTIONS
•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.
• Keep this manual and the safety decals in a legible state. Please contact
our local dealer in the event that this manual or any safety decal is
missing or damaged.
For safety decal, refer to “10. Attached position of safety decals”.
OBSERVE USER’S MANUAL AND SAFETY DECAL
•Only qualified operators are permitted to operate this machine. (Refer to “4.
Driving license”.)
• Operators under 18 years old are not permitted to operate this machine.
• Be sure to carry your fork lift driver’s licence.
• Abnormal operation can result in injury to the operator or other personnel.
Therefore, read this manual carefully prior to operation or maintenance.
• Have hard practice to be familiar with the machine.
Be sure to operate carefully after being trained.
Otherwise, personnel injury or physical damage can result.
•Rudimentary drivers shall be trained in the operating and unloading methods
by experienced and trained personnel.
•When an operator operates multi-machines, the operator shall grasp each
machine characteristics such as brake, accelerator or unloading device.
Specially make sure to know the braking effort.
•The operator shall be trained for this machine by experienced and trained
personnel, although the operator has experience operating other machines.
• The operator shall be specifically trained for high place working.
OPERATING QUALIFICATION

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6. BASIC PRECAUTIONS
•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.
CLOTHING
• Do not operate the machine which is not mounted with overhead guard and
load backrest. (*The best suitable overhead guard for the machine is
mounted at shipment.)
OVERHEAD GUARD
•Unauthorized modification is not permitted without prior notice in writing.
Additional counterweight or the other modification can affect safety and stability.
•Do not attach obstacles that obstruct the view of the operator.
NEVER MODIFY
• Be sure to perform the inspectin before working and periodic inspection
(once a month).
• Never operate the machine if the recommend inspections are not performed.
INSPECTION AND MAINTENANCE
EX048

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6. BASIC PRECAUTIONS
•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.
•Note the telephone numbers of the nearest
hospital, first-aid station, ambulance service
and related facilities.
• Keep a first-aid kit on a specified place.
•Be sure to engage the parking brake, lower
the forks to the ground and remove the start
key when you get off the machine.
PREPARE FOR EMERGENCIES
EX036
•Do not operate the machine when in poor physical condition or under the
influence of alcohol, drugs or medicine.
•Always obey safety rules, procedures or precautions when the machine is
operated, inspected or maintained.
• Always pay strict attention to safety when operating this machine.
SAFETY RULES
•The overhead guard protects the operator from falling objects. However it is
not designed to withstand the impact of heavy object.
Pay strict attention to the danger falling objects
SAFETY DEVICE

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•Prepare a suitable working plan according to the conditon of work area,
machinr type and capacity, and load type and shape.
• Use a signal person when operating the machine in a narrow area.
SAFETY PLAN
6. BASIC PRECAUTIONS
•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.
• Use “KEEP AWAY” signs in dangerous areas.
• Travel the fork lift only on the specified road.
•Use “NO THOROUGHFARE” signs to keep unauthorized vehicles out of the
unloading area.
• lluminate the work area to improve visibility.
ACCIDENT PREVENTION
•Always keep the around of operator’s seat clean. Spilled oil or mud can cause
wrong operationg of the machine to result in personnel injury.
•Do not place parts, tools or other objects near the operator’s seat. They could
hinder or prevent the safe operation of the machine.
CLEAR OPERATOR’S SEAT