CLARK FORKLIFT SM.638 CMP1511S1202 SERVICE MANUAL

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CLARK FORKLIFT SM 638 CMP1511S1202 SERVICE MANUAL – PDF DOWNLOAD

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CLARK FORKLIFT SM 638 CMP1511S1202 SERVICE MANUAL – PDF DOWNLOAD

• Operation of the truck to check performance must be conducted in an authorized, safe, clear area. Before starting to drive truck: a. Be in operating position. b. Be sure parking brake is engaged. c. Put direction control in neutral. d. Start engine. e. Check functioning of direction and speed controls, steering, brakes, warning devices, and any load handling attachments. Before leaving truck a. Stop truck. b. Put directional control in neutral. c. Apply the parking brake. d. Stop the engine by turning off the ignition circuit. e. Put blocks at the wheels if truck is on an incline.
• Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, guards, safety devices, and frame members must be carefully and regularly inspected and maintained in a safe operating condition. 19. 20. 21. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturer’s prior written approval.
• Capacity, operation and maintenance instruction plates, tags, or decals must be changed accordingly. This is an OSHA requirement. 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 procedures.
• Always use genuine CLARK or CLARK-approved parts. Use special care when removing heavy components from the truck, such as counterweight, seat deck, upright, etc. Be sure that lifting and handling equipment is of the correct capacity and in good condition. Also, this removal may upset the stability of the truck. The frame must always be safely blocked for major component removal. NOTE Special trucks or devices designed and approved for hazardous area operation must receive special attention to ensure that maintenance preserves the original, approved, safe-operating features. You should also be familiar with additional operating and maintenance safety instructions contained in the following publications: Fuel systems must be checked for leaks and condition of parts.
• Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected. The truck manufacturer’s capacity, operation, and maintenance instruction plates, tags, or decals must be maintained in legible condition. ANSI/ASME B56.1- 1988 Operator Control-Industrial Tow Tractors (Safety Standard For Powered Industrial Trucks). Published by: Society of Mechanical Engineers, United Engineering Center, 345 E. 47th Street, New York, NY 10017. NFPA 505-1982: Fire Safety Standard for Powered Industrial Trucks: Type Designations, Areas of Use, Maintenance and Operation. Available from: National Fire Protection
• Assoc., Inc., Batterymarch Park, Quincy, MA 02269. Batteries, motors, controllers, limit switches, protec- General Industrial Standards, OSHA 2206: OSHA Safety tive devices, electrical conductors, and connections and Health Standards (29 CFR 19 lo), Subpart N-Materials must be inspected and maintained in conformance Handling and Storage, Section 1910.178 Powered Induswith good practice. Special attention must be paid to trial Trucks. For sale by: Superintendent of Documents, the condition of electrical insulation.
• U.S. Government Printing Office, Washington, DC 20402. To avoid injury to personnel or damage to the equipment, consult the manufacturer’s procedures in replacing contacts on any battery connection. Industrial trucks must be kept in a clean condition to minimize fire hazards and help in the detection of loose or defective parts.

Table Of Contents:

CLARK FORKLIFT SM 638 CMP1511S1202 SERVICE MANUAL – PDF DOWNLOAD

SAFE MAINTENANCE
1. Safety
2. Lifting, Jacking, and Blocking
3. Towing
PERIODIC SERVICE
1. Maintenance Schedules
2. Planned Maintenance
3. PM Inspection Form
ENGINE
1. Specifications and Description
2. Troubleshooting
3. Engine Oil
4. Tune-Up
5. RPM, Vacuum, and Stall Checks
6. Compression Checks
7. Removal and Replacement
8. Overhaul
COOLING SYSTEM
1. Specifications and Description
2. Troubleshooting
FUEL SYSTEM
1. LPG Fuel System
2. Gasoline Fuel System
TRANSAXLE
1. Specifications and Description
2. Checks and Troubleshooting
3. Removal and Replacement
3. Overhaul
IGNITION SYSTEM
1. Specifications and Description
2. Troubleshooting
3. Ignition Timing
4. Distributor Overhaul
ELECTRICAL
1. Circuit Diagram
2. Starter
3. Alternator
4. Instrument Pod
16 WHEELS AND TIRES
1. Specifications and Description
2. Cushion Wheels and Tires
3. Pneumatic Wheels and Tires
23 BRAKE SYSTEM
1. Specifications
2. Service Brake
3. Parking Brake
25126 STEER SYSTEM
1. Specifications and Description
2. Troubleshooting
3. Steering System Pressure Check
4. Steering System Removals & Installations
5. Steering Unit Overhaul
6. Priority Valve Overhaul
7. Steer Cylinder Overhaul
29/30 HYDRAULIC SYSTEM
1. Specifications and Description
2. Troubleshooting
3. Hydraulic Pump Overhaual
4. Control Valve Overhaul
34 UPRIGHTS
1. Specifications and Description
2. Upright Checks and Adjustments
3. Lift Chain Service
4. Removals and Replacements
5. Lift and Tilt Cylinder Overhaul
38 COUNTERWEIGHT
1. Specifications
2. Inspection
3. Removal and Replacement
40 SPECIFICATIONS
1. Specifications

Please Note:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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