Clark Forklift C152, P152, C232, P232, P455, P680 English OM-1045 Operator's Manual

INTERNAL COMBUSTION LIFT TRUCKS

[Do not remove this manual from the truck]

C 15/18/20s D,L C 15/18/20sC L C 20/25/30/35 D,L,G C 20/25/30/32C L,G Part No. 8136112 (Eng) Book No. OM 1045 (Rev 1.4) Feb. 2017

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Operator Daily Inspection — Safety and Operating Checks A lift truck should always be examined by the operator, before driving, to be sure it is safe to operate. The importance of this procedure is emphasized in this manual with a brief illustrated review and later with more detailed instructions. CLARK dealers can supply copies of a helpful “Drivers Daily Checklist.”

Planned Maintenance In addition to the daily operator inspection, CLARK recommends that a planned maintenance and safety inspection program (PM) be performed by a trained and authorized 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 procedures for a periodic planned maintenance program that covers inspections, operational checks, cleaning, lubrication, and minor adjustments are outlined in this manual. Your CLARK dealer is prepared to help you with a Planned Maintenance Program by trained service personnel who know your lift truck and can keep it operating safely and efficiently.

Modification of the truck prohibited Unauthorized modification of the truck is not permitted, and, in case that a problem has occurred due to a modification without permission, the warranty service shall not be provided.

For instance, the modifications which may void the warranty include those that may negatively affect the performance, durability and safety of the truck due to addition of unauthorized electrical devices (lamp, black box, electrical instrument, communication equipment, etc.), braking system, steering system, vision improvement system and detachable attachment device that were not mounted when the equipment was shipped out of the factory.

Introduction

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Daily Inspection

At the beginning of each shift, inspect your truck and fill out a daily inspection sheet.

Check for damage and maintenance problems.

Have repairs made before you operate the truck.

!

CAUTION DO NOT MAKE REPAIRS YOURSELF. Lift truck mechanics are trained professionals. They know how to make repairs safely. (See Section 5)

1-2

Daily Inspection

Section 1. General Safety Rules

Do’s and Don’ts

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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.

Don't use the similar fuel.

If forklift truck is to be operated outdoors during rainy conditions, make sure cab is in place to prevent damage to electrical components

Do’s and Don’ts

1-3

Seat Belts

ALWAYS BUCKLE UP

Seat belts can reduce injuries.

1-4

Seat Belts

Section 1. General Safety Rules

No Riders

The operator is the only one who should be on a truck.

Never transport personnel on the forks of a lift truck.

No Riders

1-5

Pedestrians

Watch where you are going. Look in the direction of travel. Pedestrians 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.

1-6

Pedestrians

Section 1. General Safety Rules

Operator Protection

Keep under the overhead guard.

Always keep your body within the confines of the truck.

Operator Protection

1-7

Fork Safety

Never allow anyone to walk under raised forks.

DANGER

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1-8

Fork Safety

There is special equipment to raise people for overhead work. DO NOT USE LIFT TRUCKS.

Section 1. General Safety Rules

Pinch Points

!

WARNING Keep hands, feet and legs out of the upright.

!

WARNING Don't use the upright as a ladder.

!

CAUTION Never try to repair the upright, carriage, chain, or attachment yourself! Always get a trained mechanic.

Pinch Points

1-9

Travel

Travel with the load near the floor/ground with upright tilted back to cradle the load 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.

Be sure to pivot in the seat to give maximum visibility.

Unstable loads are a hazard to you and to your fellow workers.

Always make certain that the load is well stacked and evenly positioned across both forks.

Right

Never attempt to lift a load with only one fork.

Wrong

1-10

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Section 1. General Safety Rules

Parking

• Never park on a grade.

• Always come to a complete stop before leaving truck.

• Be sure travel control is in NEUTRAL. • Lower forks fully to floor and tilt forward.

• Set parking brake.

• Turn key to OFF position.

Parking

1-15

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This Section shows some of the hazards that may cause you, or someone around you, 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.

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/RRVH RU XQEDODQFHG ORDGV DUH GDQJHURXV 2EVHUYH WKHVH SUHFDXWLRQV Never carry loose or uneven material.

Center wide loads.

Stack and band loose material.

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Section 2. Operating Hazards

Long and Wide Loads / Rear Swing

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WARNING With long or wide loads, you need more room. So slow down and watch your clearance.

A long load reduces the capacity of 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 endswing when turning.

!

WARNING When turning, be sure the rear end of the truck does not swing into racks, posts, etc. Watch for pedestrians beside the truck.

Long and Wide Loads / Rear Swing

2-3

Low Overhead Clearance· Fast Turns and High Loads

!

WARNING Know the height of your truck, with and without a load.

Check your clearances.

Keep the load low and tilted back.

!

WARNING Watch overhead clearance: Moving into overhead structures can tip a truck over, or spill a load.

!

WARNING Slow down before turning.

The truck can tip over.

Turn too sharp with a raised load and your truck can tip even at slow speeds.

Travel with a load raised only when removing or depositing a load.

2-4

Low Overhead Clearance· Fast Turns and High Loads

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Truck Description

6

1 2 3

7

4

8

9

5 1. Steering Handwheel 2. Overhead Guard 3. Seat and Seat Belt 4. Counterweight

5. Steer Axle, Wheels / Tires 6. Upright and Carriage 7. Load Backrest 8. Forks 9. Drive Axle, Wheels / Tires

The truck shown above is a typical representation of a CLARK internal combustion lift truck. Your model may vary slightly.

3-2

Truck Description

Section 3. Operator Compartment and Controls

Operator Compartment

1

8 10

16

3 12 13 14

2 11

15

17 9 4

5 6 7

(seat)

1. Steering Handwheel

10. Instrument Pod

2. Forward / Reverse Lever

11. Turn Signal Lever

3. Brake Fluid Reservoir

12. Lift Control Lever

4. Parking Brake Pedal

13. Tilt Control Lever

5. Inching Pedal

14. Auxiliary Control Lever

6. Service Brake Pedal

15. Accelerator Pedal

7. Seat Adjustment Lever

16. Key Switch

8. Horn Button

17. Steer Column Tilt Lever

9. Parking Brake Release

Operator Compartment

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Section 3. Operator Compartment and Controls

Operator Controls Key/Start Switch The Key/Start Switch: • Turns the truck electrical system on and off.

• Connects and tests the warning indicator lights.

• Connects the starter motor circuit when engine is to be started.

The Key/Start Switch has three positions.

When the key is in the vertical "OFF" position, all truck electrical circuits are off, and the key can be removed. From the "OFF" position, the key can be turned clockwise to the "START" position, where the starter motor is engaged and part of the truck electrical system is energized. When the key is released from the "START" position, it automatically returns to the "ON" position, where the starter is disengaged and the entire truck electrical system is on.

OFF

ON

START

The key switch has a mechanical "anti-restart" feature, which prevents the engine starter from being engaged and damaged if the operator attempts to start the engine when it is already running. The key switch cannot be turned to the "START" position from the "ON" position without returning the key to the "OFF" position. If the engine stops running, the key switch must be turned to the "OFF" position before it can be restarted.

Cold Start Preheating (Diesel Only) With the switch in the "ON" position the warning indicator will light up then the glow plugs are pre-heating automatically. The engine can then be started. To repeat the preheating process turn the key to the "OFF" and then into the "ON" position.

Operator Controls

3-27

Engine Stop Run the engine at idling speed briefly before shutting it off.

Turn the key switch to the "OFF" position to shut the engine down.

Seat Adjustment Back declining adjustment

Fore and Aft Adjust 100 110 30 210 190 2 90 50

70 16300 50 110 50 8070 1 1

1 70 1 6 kg 370 3500 1 lb 33

130 140 290 270 120 0 50 3 1 2 0

The fore and aft adjustment lever is located on the front under the seat. To unlock, pull the lever to the left and adjust the seat, release the lever. Be sure that the seat locking mechanism is engaged. The back declining adjustment lever is located on the left side of seat cushion. Pull the lever up and adjust the back, release the lever. Be sure that the back locking mechanism is engaged.

Driver’s weight adjustment

!

CAUTION Never adjust driver's seat while truck is moving, to avoid the possibility of loss of control and of personal injury.

Parking Brake Activates brake operation.

Check the parking Brake To apply the parking brake, push the pedal down with your left foot until pedal stops. The parking brake release is located just above the brake pedal as shown. To release the parking brake, pull upward.

Parking Brake Release

Parking Brake Apply

!

CAUTION Always apply parking brake before leaving truck.

!

WARNING Never operate your lift truck with a defective parking brake.

Hour Meter Starting the engine also starts the operating hour meter. Use the hour meter reading to perform prescribed maintenance.

3-28

Operator Controls

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Hydraulic Control Levers The levers of the control valve activate the lift and tilt cylinders as well as any other hydraulic devices which are installed on the truck.

Lift Tilt Auxiliary

IMPORTANT The hydraulic levers shown are typical representations of a CLARK internal combustion lift truck. Your model may vary slightly.

Lift Control Function With the lift control lever, you are able to raise and lower the fork carriage on the upright. The lifting and lowering speeds are controlled through the main hydraulic valve by varying the lever position (from the center or neutral positions).

When the lift control lever is pushed forward, the fork carriage is lowered. When the lift control lever is pulled back the fork carriage is raised.

You can also lower the fork carriage even if the key switch is OFF.

Tilt Control Lever With the tilt control lever, you are able to control the tilting or vertical positioning of the upright and the angle of the forks. When the lever is pulled back, the upright and forks tilt backward. Push the lever forward to tilt the upright and forks forwards.

Auxiliary Control Lever (Optional) An auxiliary control lever is mounted to the right of the tilt control lever. If your lift truck is equipped with an optional attachment, this lever lets you control the flow and direction of the hydraulic oil to the attachment.

Auto Choke Control (Gasoline Only) Depending on the atmosphere temperature, the engine “Choke” valve plate in the carburetor works automatically rotating. At this time, engine may be higher than low setting and it goes down to normal when engine reach normal operating temperature.

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Most lift truck INJURIES are to other people near the lift truck.

Prevent Overturns!

AVOID : • slippery, sloping, or uneven surfaces • loads over capacity on nameplate • unstable or high loads • low tire pressure • poorly maintained lift truck • fast or sharp turns

In Case of Tip-Over: Don't jump

Hold on tight

Brace feet Lean away

2798235

Section 3. Operator Compartment and Controls

Upright Warning Decal This safety decal is on the upright to warn of the danger of injury from 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 between moving parts of the upright.

Keep Away from Forks Decal This safety decal is placed on the upright 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 sure that the forks are in the fully lowered position when they are not being used to handle a load.

2372604

Hot Surface Warning Decal The warning decals are attached to the engine, the tail pipe when vertical exhaust system is installed, and on the heater when cabin is installed.

The surface of decal is very hot by the heat generated during work.

If this surface is touched, serious burns may result.

Operator Controls

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SERIOUS OR FATAL INJURY MAY RESULT TO YOURSELF OR OTHERS IF NOT FOLLOWED This lift truck should not be operated by anyone who is not authorized and properly trained.

Read the Operators Manual carefully, and make yourself familiar with your lift truck.

Inspect and check your lift truck daily before and after use. Do not operate faulty or damaged lift trucks.

Repair work should be done by authorized and trained persons only.

To protect from falling objects, make sure that the Overhead Guard and Load Backrest are correctly mounted and in good condition.

Before starting engine, always set forward/reverse lever in neutral, with hand brake on.

Drive carefully, deeping forks and attachments as low as possible & fully tilted back.

Keep a careful lookout for people, obstructions and the path of travel. Watch clearance, especially overhead and tail swing.

Do not stick hands, feet and other parts of your body outside the Operators compartment.

Drive forward when you are climbing a slope with a load. Drive in reverse when you are descending with loads. Do not turn while on a slope.

Slow down before turning. Avoid any sudden start, stop or turning. Lateral tipover can occur if truck is improperly operated.

Do not load lift truck over capacity limit designated on the load chart. Do not lift unstable loads.

This lift truck is not designed for raising or transporting people. Do not use lift truck for those purposes under any circumstances.

Before you get off lift truck, make sure the hand brake is set, lower forks or attachments, put forward/reverse lever in neutral position and turn off key switch. Do not park on a slope.

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Section 4. Operating Procedures

Starting from a Safe Condition Always start from a safe condition. Before operating a lift truck, make sure that: 1. Parking brake is applied.

2. Forks are fully lowered to the floor or ground.

3. You are familiar with how all the controls function and have read the Operator Manual.

4. All controls are in neutral or other correct position.

5. Truck has received its daily inspection and is ready and safe to operate.

Parking

Forks are down

Put the direction control lever in the NEUTRAL position, before turning the key switch to ON.

FORWARD NEUTRAL Position REVERSE

Starting from a Safe Condition

4-3

Adjusting the Seat Adjust the seat to a comfortable position for you. Adjust the seat by moving and holding the release lever at the front under of the seat. Put the seat in a position that will provide easy reach to all controls. Release the seat lever. Make sure that the seat locking mechanism is engaged.

Back declining adjustment

Fore and Aft Lever

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CAUTION Never adjust the driver's seat while the truck is moving, to avoid the possibility of loss of control and of personal injury.

Buckling Up Buckle up. Be sure that you put on the seat belt. Connect and adjust the seat belt strap to a snug, comfortable position.

!

WARNING Always wear your seat belt when operating a lift truck.

Starting the Truck Before you start the truck, make sure that you have taken all the above mentioned precautions and that the directional control is in NEUTRAL. To start the truck, turn the key switch clockwise to the ON position.

4-4

Starting from a Safe Condition

Section 4. Operating Procedures

Positioning Forks and Upright When driving, with or without a load, it is good practice to have the forks slightly raised and tilt the upright (forks) backward. Having the forks raised and tilting back prevents the fork tips from catching on possible obstructions and reduces the wear on the fork blades from striking or dragging on the floor or ground. See the NOTICE and CAUTION below.

Lift Control Lever

Tilt Control Lever

Pull back on the lift control lever and raise the forks 6 to 8 inches (152 to 203 mm) above the floor. Then, using the tilt control, tilt the upright back slightly to raise the fork tips.

NOTICE When the upright (carriage and/or load) is raised, the stability of the truck is reduced. Some of the other conditions that may affect stability are: ground and floor conditions, grade, speed, loading, dynamic and static forces and the judgement exercised by the operator. Trucks equipped with attachments behave as partially loaded trucks even when operated without a load on the attachment. Also, improper operation, faulty maintenance or poor housekeeping may contribute to a condition of instability.

!

CAUTION For stability reasons, do not travel with the load or carriage raised into a high (elevated) position. Travel with the lift mechanism raised only enough to clear the ground or obstacles.

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WARNING If your truck starts to tip over, DO NOT JUMP! Your chances for survival in a tip-over are better if you stay with the truck, in your seat. BRACE YOURSELF!. Make sure your seat belt is fastened securely. Stay in your seat.

Grip the wheel. Brace your feet. See page 1.14

Starting from a Safe Condition

4-5

Controlling Speed With the direction control in FORWARD or REVERSE, the parking brake released, put your foot on the accelerator pedal and push down smoothly until the truck is moving at the desired speed.

Braking To stop the truck, lift your foot from the accelerator pedal and put it on the brake pedal. Push down on the brake pedal in a smooth, firm motion until the truck is stopped.

IMPORTANT Stop a lift truck as gradually as practical. Hard braking and wheel sliding are dangerous and can cause tip-over or the truck could lose its load. Also, hard braking can increase wear and can be harmful to the lift truck.

4-6

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CAUTION Operate your lift truck only in areas that have been approved for your lift truck type designation. Certain areas contain flammable gases, liquids, dust, fibers, or other hazardous materials. Lift truck operations in these areas must have special approval. These areas must be designated to show the type of lift truck approval required for operation in the area. Be aware that changes to special equipment or poor maintenance can cause the lift truck to lose its special approval. Be sure that your truck is the correct fire safety type for the area in which you are working. The proper type designation for this truck is listed on the nameplate. In areas classified as hazardous, use only trucks approved for use in those areas. If you are unsure of the classification of the area you wish to enter, check before entering.

Adjusting the Load Forks The load forks are adjustable on the hanger shaft. Forks should be spaced as far apart as the load being carried will allow. Both forks should always be the same distance from the center of the fork carriage. To adjust the forks, raise the carriage slightly. Tilt the upright fully forward to reduce friction and make the forks slide easier. Unlock the fork locking pins.

Position the forks. Secure the fork locking pins.

Forks are heavy, keep fingers clear. Move forks by pushing with one foot while holding on to the load back rest with hands. Be sure to have firm footing before attempting to move forks. Do not attempt this where the floor is slippery or wet.

4-10

Starting from a Safe Condition

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After Operating the Truck Always leave your lift truck in a safe condition. When you leave your truck, or park it, follow these safety rules: • Park in a safe area away from normal traffic.

• Never park on a grade.

• Never park in areas that block emergency routes or equipment, access to fire aisles, or stairways and fire equipment.

Before leaving the operator's position: 1.

2.

3.

4.

5.

Bring truck to complete stop.

Put the directional control lever in the NEUTRAL position.

Apply the parking brake.

Lower the lift mechanism fully.

Turn the key switch to the OFF position.

If you are going to leave the truck unattended: 6. Remove the key.

7. Block the wheels if the truck has any possibility of moving.

4-16

Starting from a Safe Condition

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Daily Safety Inspection Before using a lift truck, it is the operator's responsibility to check its condition and be sure it is safe to operate.

Check for damage and maintenance problems; have repairs made before you operate the truck. Unusual noises or problems must be reported immediately to your supervisor or other designated authority.

Do not make repairs yourself unless you are trained in lift truck repair procedures and authorized by your employer. Have a qualified mechanic make repairs using genuine CLARK or CLARK-approved parts.

!

CAUTION Do not operate a truck if it is in need of repair. If it is in an unsafe condition, remove the key and report the condition to the proper authority. If the truck becomes unsafe in any 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 aid in carrying out this inspection, CLARK has prepared a form called the "Driver's Daily Checklist." We recommend that you use this form to make a daily record of your inspections and truck condition. You may obtain copies of this form from your CLARK dealer.

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WARNING Leaking hydraulic oil may be hot or under pressure. When inspecting a lift truck, wear safety glasses and do not check for leaks with bare hands.

5-2

Daily Safety Inspection

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OUT OF SERVICE

Section 5. Operator Maintenance and Care

Fuel Safety Practices Refueling Gasoline and Diesel Trucks

Use clean, properly marked fuel cans.

Clean up spills.

Fuel Safety Practices

5-5

Refueling LPG Tanks When changing liquefied petroleum gas (LPG), tanks follow these basic rules: • Change only in well ventilated areas.

• Never allow open flames.

• Turn the ignition switch to the OFF position.

• Check for leaks.

• Check condition of the O-ring.

• Make sure tank is on locating pin.

• Make sure tank latches are securely fastened.

• Store tanks according to local fire codes

Locating Pin

O-Ring

Relief Valve

Typical Illustration

If you refill LPG tanks: • Make sure you know and understand the proper procedure for filling an LPG tank.

• If you have any questions on refilling LPG tanks, please ask your supervisor.

!

DANGER LPG IS HEAVIER THAN AIR. It settles on your clothes and the ground around you, displacing oxygen vital for breathing. Open flame can cause flash fires.

IMPORTANT Check all connections for damage or leaks. If the truck will not start after you change tanks, get a qualified mechanic to check the truck.

5-6

Refueling LPG Tanks

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The maintenance time intervals referred to in this manual relate to truck operating hours as recorded on the hourmeter, and are based on experience CLARK has found to be convenient and suitable under typical (normal or average) operating conditions. The periods and their designations are: PM Interval: A=8 - 10 hours or daily B=50 - 250 hours or every month (typical PM interval) C=450 - 500 hours or every 6 months D=900 - 1000 hours or every 12 months E=2000 hours or every year

Check truck visually and inspect components.

Test drive truck/check functional performance.

Air clean truck and radiator.

Check torque on critical fasteners.

Lubricate truck. (See component) Drain and replace engine oil.

Replace engine oil filter.

Clean and replace LPG/Gas engine air filter. (*) Clean and replace Diesel engine air filter. (*) Change Diesel fuel filter.

Change LPG/Gas fuel filter.

Drain heavy ends from vaporizer.

Inspect / adjust fan belts.

Drain / flush radiator coolant.

Check engine ignition and timing.

Engine tune-up.

Check battery.

Check transaxle fluid level.

Change transaxle fluid. (drain and replace) Change (replace) transaxle oil filter.

Clean drive axle air vent.

Check brake condition and wear.

Check drive axle mounting and fasteners.

Lubricate steer axle linkage.

Check / lubricate steer axle wheel bearings.

Change / replace hydraulic sump oil filter and breather. (**) Change / replace hydraulic sump fluid and oil filter. (**) Lubricate tilt cylinder rod ends.

Check lift chain adjustment and wear.

Check / lubricate lift chains.

Lubricate upright rollers.

7-10

Planned Maintenance Intervals

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Section 7. Planned Maintenance and Lubrication

NOTES: *

Air filter change interval may be determined by using an air restriction indicator.

** Hydraulic filter change interval may be determined by hydraulic filter restriction indicator.

A B C D E Check truck for obvious damage and leaks.

Check fuel system for leaks, etc.

Check capacity, warning plates and decals.

Check condition of tires and wheels. Remove embedded objects. Check air pressure.

Check for missing or loose wheel lugs nuts.

Check engine oil level.

Check engine coolant level (radiator and recovery tank) Check transaxle fluid level Check fuel level.

Check hydraulic sump oil level.

Check gauges and instruments.

Check warning lights and hour meter.

Check overhead guard condition and bolts.

Check horn operation and other warning devices.

Check steering operation.

Check service brake operation.

Check parking brake operation.

Check parking brake linkage for damage, broken parts.

Check directional and speed controls operation.

Check accelerator and engine speed operation.

Check lift, tilt and aux. operation.

Check upright, lift chains and fasteners.

Check carriage or attachments and forks.

Check seat deck hold-down latch for correct locking.

Check optional safety equipment. (alarms, lights etc.)

• • • • • • • • • • • • • • • • • • • • • • • • •

Planned Maintenance Intervals

7-11

PM Report Form Make and keep records of your PM inspections. Use these records to help establish the correct PM intervals for the truck application and to indicate maintenance required to prevent major problems from occurring during operation.

As an aid in performing and documenting your PM inspections, CLARK has prepared a Gasoline, LPG, or Diesel Planned Maintenance Report Form. Copies of this form may be obtained from your authorized CLARK dealer. We recommend that you use this form as a checklist and record of your inspection and truck condition.

The maintenance procedures outlined in this Section are intended to be used in conjunction with the PM Report Form. They are arranged in a logical and efficient sequence.

You make a check mark or entry on the PM Report Form when the PM is performed. A special coding system for indicating the importance of needed repairs and/or adjustments appears on the form.

When you have finished the PM inspections, be sure to give a copy of the report to the designated authority or person responsible for lift truck maintenance.

Do not make repairs or adjustments unless authorized to do so.

!

CAUTION For safety, it is good practice to: • Remove all jewelry (watch, rings, bracelets, etc.) before working on the truck.

• Disconnect the battery ground cable (-) from the battery before working on electrical components.

• Always wear safety glasses. Wear a safety (hard) hat in industrial plants and in special work areas where protection is necessary and required.

7-12

PM Report Form

Section 7. Planned Maintenance and Lubrication

PM Report Form

7-13

How to Perform Planned Maintenance Visual Inspection First, perform a visual inspection of the lift truck and its components.

Walk around the truck and take note of any obvious damage or maintenance problems.

Check to be sure all capacity, safety, and warning plates are attached and legible.

NOTICE NAME PLATES AND DECALS: Do not operate a lift truck with damaged or lost decals and nameplates. Replace them immediately. They contain important information.

Inspect the truck, before and after starting the engine, for any sign of external leakage of fuel, engine coolant, transmission fluid, etc.

Check for hydraulic oil leaks and loose fittings.

!

CAUTION HYDRAULIC FLUID PRESSURE: Do not use your hands to check for hydraulic leakage. Fluid under pressure can penetrate your skin and cause serious injury.

Overhead Guard Be sure that the driver's overhead guard and any safety devices are in place, undamaged, and attached securely.

Check the overhead guard for damage. Be sure that it is properly positioned and all mounting fasteners are in place and tight.

Load Handling Components Inspect the upright assembly, load backrest (LBR), rails, carriage rollers, lift chains, and lift and tilt cylinders. Look for obvious wear and maintenance problems and damaged or missing parts. Check for any loose parts or fittings. Check for leaks, damaged or loose rollers, and rail wear (metal flaking). Carefully check the lift chains for

7-14

How to Perform Planned Maintenance

Section 7. Planned Maintenance and Lubrication

wear, rust, corrosion, cracked or broken links, stretching, etc. Check that the lift and carriage chains are correctly adjusted to have equal tension. Check that the lift chain anchor fasteners and locking means are in place and tight. Inspect all lift line hydraulic connections for leaks.

IMPORTANT Uprights and lift chains require special attention and maintenance to remain in safe operating condition. Refer to “Lift Chain Maintenance” in this Section for additional information.

Forks Inspect the load forks for cracks, breaks, bending, and wear. The fork top surfaces should be level and even with each other. The height difference between both fork tips should be no more than 1.5% of the blade length.

A

10% of "A" is max. wear allowed

1.5% is max. height difference

!

WARNING If the fork blade at the heel is worn down by more than 10 %, the load capacity is reduced and the fork must be replaced.

Inspect the forks for twists and bends. Put a 2"-thick metal block, at least 4" wide by 24" long with parellel sides, on the blade of the fork with the 4" surface against the blade. Put a 24" carpenter's square on the top of the block and against the shank. Check the fork 20" above the blade to make sure it is not bent more than 1" maximum.

Shank 1" max

20"

Carpenter Square Blade Metal Block

How to Perform Planned Maintenance

7-15

If the fork blades are obviously bent or damaged, have them inspected by a trained maintenance person before operating the truck.

Inspect the fork locking pins for cracks or damage. Reinsert them and note whether they fit properly.

Wheels and Tires Check the condition of the drive and steer wheels and tires. Remove objects that are embedded in the tread. Inspect the tires for excessive wear and breaks or “chunking out.”

Check all wheel lug nuts or bolts to be sure none are loose or missing.

Replace missing bolts or lug nuts.

Torque loose or replaced items to specifications.

!

WARNING Check tire pressure from a position facing the tread of the tire, not from the side. Use a long-handled gauge to keep your body away from the side. If tires are low, do not operate and do not add air. Check with a mechanic. The tire may require removal and repair. Incorrect (low) tire pressure can reduce the stability of your lift truck. Do not operate truck with low tire pressure. Proper cold inflation is 100 psi.

7-16

How to Perform Planned Maintenance

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Section 7. Planned Maintenance and Lubrication

If the maximum fork height is not reached, this indicates there is an inadequate (low) oil level in the hydraulic sump tank or severe binding within the upright.

Push forward on the lift control lever. Watch the upright as it lowers.

When the forks reach the floor, release the lever.

All movements of the upright, fork carriage, and lift chains must be even and smooth, without binding or jerking. Watch for chain wobble or looseness; the chains should have equal tension and move smoothly without noticeable wobble.

Auxiliary Controls (Optional) If your lift truck is equipped with an attachment, test the control lever for correct function and briefly operate the attachment.

Steering System NOTICE The steering system, steer axle, and steering linkage on your truck should be inspected periodically for abnormal looseness and damage, leaking seals, etc. Also, be alert for any changes in steering action. Hard steering, excessive freeplay (looseness), or unusual sound when turning or maneuvering indicates a need for inspection or servicing.

Check the steering system by moving the steering handwheel in a full right turn and then in a full left turn. Return the handwheel to the straight-ahead position. The steering system components should operate smoothly when the handwheel is turned. Never operate a truck that has a steering system fault.

!

WARNING Fasten your seat belt before driving the truck.

Direction Control, Braking, and Inching Be sure that the travel area is clear in front of the truck.

1. Push firmly on the brake pedal. Release the parking brake.

Move the directional control lever from NEUTRAL to FORWARD. How to Perform Planned Maintenance

7-19

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Section 7. Planned Maintenance and Lubrication

Engine Accessories Inspect the engine coolant hoses and fan belt(s). Look for leaking and obvious damage, worn (frayed) condition, breaks, etc. that could cause failure during operation.

Engine Air Cleaner Check the engine air cleaner for damage and contamination (excessive dirt buildup and clogging). Be sure that the air cleaner hose is securely connected (not loose or leaking). Fan or cone shaped dust deposits on tube or hose surfaces indicate a leak.

Change or service the air cleaner element every 2000 operating hours for gas engine, every 1000 operating hours for diesel engine, depending upon your application. Service intervals may also be determined by the air restriction indicator.

Battery Inspect the battery for damage, cracks, leaking condition, etc. If the terminals are corroded, clean and protect them with CLARK Battery Saver (available from your CLARK dealer). If your battery has removable cell caps, check to be sure the cells are all filled. Refill them with distilled water.

!

WARNING EXPLOSIVE GASES: Do not smoke or have open flames or sparks near batteries. An explosion can cause injury or death.

Engine Cooling System To check engine coolant level open the hood to the engine compartment. Visually inspect the recovery bottle, locate the “HOT” and “COLD” marks. The “HOT” mark indicates maximum level at operating temperature. The “COLD” mark indicates additional coolant needs to be added to the system.

How to Perform Planned Maintenance

7-21

The recovery bottle shown is a typical illustration of overflow system. Your actual system may vary slightly.

A level anywhere between the HOT and COLD marks is normal.

Inspect the coolant level in the overflow bottle only.

!

WARNING Do not remove the radiator cap when the radiator is hot.

STEAM from the radiator will cause severe burns. Do not remove the radiator cap to check the coolant level.

!

WARNING Never remove the radiator cap while the engine is running. Stop the engine and wait until it has cooled.

Failure to do so could result in serious personal injury from hot coolant or steam blowout and/or damage to the cooling system or engine.

If the level is low, add a 50/50 mixture of specified coolant and water to the correct fill level. If you have to add coolant more than once a month or if you have to add more than one quart at a time, check the coolant system for leaks.

• Check engine oil for presence of coolant leaking into engine.

• Inspect the coolant for condition. Look for excessive contamination or rust or oil in the coolant solution.

• Check the PM time interval for need to change coolant.

• Check the condition of radiator cap rubber seal and radiator filler neck for damage. Be sure they are clean.

• Check overflow hose for clogging or damage.

7-22

How to Perform Planned Maintenance

Section 7. Planned Maintenance and Lubrication

NOTICE Your lift truck cooling system is filled with a factoryinstalled solution of 50% water and 50% permanent-type antifreeze containing rust and corrosion inhibitors. You should leave the solution in year around. Plain water may be used in an emergency, but replace it with the specified coolant as soon as possible to avoid damage to the system. Do not use alcohol or methanol antifreeze.

Engine Oil and Filter Locate the engine oil dipstick. Pull the dipstick out, wipe it with a clean wiper, and reinsert it fully into the dipstick tube. Remove the dipstick and check oil level.

It is normal to add some oil between oil changes. Keep the oil level above the ADD mark on the dipstick by adding oil as required. Do not overfill. Use the correct oil as specified under Lubricant Specifications.

It is recommended to: • Drain and replace the engine crankcase oil every 500 operating hours. (depending on application). Contact your nearest CLARK Dealer for further information.

• Engine Oil Filter must be changed at every PM when the oil is changed.

• Remove the oil pan drain plug to drain old oil after the truck has been in operation and the engine (oil) is at operating temperature.

!

WARNING Engine oil at operating temperature is hot and can cause burns. Beware of splashing oil.

• Carefully check for leaks after changing oil and installing new filter.

NOTICE The time interval for changing engine oil depends upon your application and operating conditions. To determine the correct schedule for your truck, it is suggested that you periodically submit engine oil samples to a commercial laboratory for analysis of the condition of the oil.

How to Perform Planned Maintenance

7-23

ENGINE OIL PERFORMANCE DESIGNATION : Refer to the “Engine Oil” in Section 8.

Hydraulic Sump Tank Check the hydraulic sump tank fluid level. Correct fluid level is important for proper system operation. Low fluid level can cause pump damage. Overfilling can cause loss of fluid or lift system malfunction.

Hydraulic fluid expands as its temperature rises. Therefore, it is preferable to check the fluid level at operating temperature (after approximately 30 minutes of truck operation). To check the fluid level, first park the truck on a level surface and apply the parking brake. Put the upright in a vertical position and lower the fork carriage fully down. Pull the dipstick out, (attached to the sump breather) wipe it with a clean wiper, and reinsert it. Remove dipstick and check oil level. Keep the oil level above the LOW mark on the dipstick by adding recommended hydraulic fluid only, as required. Do not overfill.

Check the condition of the hydraulic fluid (age, color or clarity, contamination). Change (replace) the oil as necessary.

Hydraulic Fluid and Filter Change Drain and replace the hydraulic sump fluid every 2000 operating hours. (Severe service or adverse conditions may require more frequent fluid change). Replace the hydraulic oil filter elements at every oil change. Remove, clean, and reinstall the hydraulic and steer system suction line screens at first PM and every 1000 hours thereafter. Check for leaks after installation of the filters. Also, check that the hydraulic line connections at the filter adapter are tightened correctly. The procedure for draining hydraulic sump tank is in your Service Manual.

7-24

How to Perform Planned Maintenance

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Lift Chain Inspection and Measurement Inspect and lubricate the lift chains every PM (50-250 hours). When operating in corrosive environments, inspect the chains every 50 hours. During the inspection, check for the following conditions: • Rust and corrosion, cracked plates, raised or turned pins, tight joints, wear, and worn pins or holes.

• When the pins or holes become worn, the chain becomes longer. When a section of chain is 3% longer than a section of new chain, the chain is worn and must be discarded.

• Chain wear can be measured by using a chain scale or a steel tape measure. When checking chain wear, be sure to measure a segment of chain that moves over a sheave. Do not repair chains by cutting out the worn section and joining in a new piece. If part of a chain is worn, replace all the chains on a truck.

Lift Chain Lubrication Lift chain lubrication is an important part of your maintenance program. The lift chains operate under heavy loadings and function more safely and have longer life if they are regularly and correctly lubricated. CLARK chain lubricant is recommended; it is easily sprayed on and provides superior lubrication. Heavy motor oil may also be used as a lubricant and corrosion inhibitor.

Lift Chain Wear and Replacement Criteria: 1. (NEW CHAIN LENGTH) The distance from the first pin counted to the last pin counted in a span while the chains are lifting a small load.

2. (WORN CHAIN LENGTH) The distance from the first pin counted to the last pin counted in a span while the chains are lifting a small load.

2 1

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How to Perform Planned Maintenance

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C15-35, C15C-32C CLARK products and specifications are subject to improvements and changes without notice or obligation.

Model Designation - Rated Load Capacity C15 1360kg @600mm load center C18 1590kg @600mm load center C20s 1810kg @600mm load center C20 1810kg @600mm load center C25 2270kg @600mm load center C30 2720kg @600mm load center C35 3175kg @600mm load center C15C 1360kg @600mm load center C18C 1590kg @600mm load center C20sC1810kg @600mm load center C20C 1810kg @600mm load center C25C 2270kg @600mm load center C30C 2720kg @600mm load center C32C 2950kg @600mm load center

[3000lbs@24in] [3500lbs@24in] [4000lbs@24in] [4000lbs@24in] [5000lbs@24in] [6000lbs@24in] [7000lbs@24in] [3000lbs@24in] [3500lbs@24in] [4000lbs@24in] [4000lbs@24in] [5000lbs@24in] [6000lbs@24in] [6500lbs@24in]

[1500kg@500mm] [1800kg@500mm] [2000kg@500mm] [2000kg@500mm] [2500kg@500mm] [3000kg@500mm] [3500kg@500mm] [1500kg@500mm] [1800kg@500mm] [2000kg@500mm] [2000kg@500mm] [2500kg@500mm] [3000kg@500mm] [3200kg@500mm]

Note: Rated capacity applies when using standard upright and standard forks. [C15-20s(C) :3085mm, C20-30(C):3300mm, C32C:3225mm, C35:3165mm MFH]

Engine

Specifications for EPA Tier4 engine (C15-20sC,C15-20s)

Model : Cylinders : Displacement cubic inches : liters : Idle RPM : Governed RPM High idle : Rated RPM : Rated kW :

8-2

Diesel (Tier4)

LPG (Tier4)

LPG (Tier4)

Yanmar 4TNV88 4

PSI 4G63 4

HMC Theta 2.4 4

133 2.2 800

122 2.0 800

143 2.3 750

2600 2400 29.5

2650 2650 36.8

2800 2600 37.6

C15-35, C15C-32C

Section 8. Specifications

Specifications for EPA Tier4 engine (C20-32C,C20-35)

Model : Cylinders : Displacement cubic inches : liters : Idle RPM : Governed RPM High idle : Rated RPM : Rated kW :

Diesel (Tier4)

LPG/Gas (Tier4)

LPG/Gas (Tier4)

LPG/Gas (Tier4)

ISUZU 4LE2X 4

HMC Theta 2.4 4

GM 3.0

FORD 2.5

4

4

133 2.2 800

143 2.3 750

180 3.0 800

152 2.5 750

2650 2400 46

2800 2600 52.5

2650 2650 51.6

2550 2500 48.5

Cooling System Automotive type crossflow radiator.

Cooling system pressure (radiator cap): 88 kPa nominal, 12.8psi Thermostat: Diesel, 82°C (180°F), fully open 95°C (203°F), Gas/LPG 82°C (180°F), fully open 95°C (203°F)

Powershift Transaxle CLARK Model TA-12A1 Transaxle(C15-20s) Speed : Overall Ratios : Convertor Stall Ratio :

1 Forward / 1 Reverse FWD/15.38:1 REV/15.67:1 11″ (3.3:1) for LPG/Gas/Diesel

CLARK Model TA-12CA1 Transaxle(C15-20sC) Speed : Overall Ratios : Convertor Stall Ratio :

1 Forward / 1 Reverse FWD/13.07:1 11″ (3.3:1) for LPG

REV/12.93:1

CLARK Model TA-30 Transaxle(C20-35) Speed : Overall Ratios : Convertor Stall Ratio :

1 Forward / 1 Reverse FWD/15.78:1 11″ (3.3:1) for LPG/Gas, 12″ (3.9:1) for Diesel

REV/16.06:1

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Section 8. Specifications

Fill Capacities (fluid volumes-liters, quarts, gallons,kilogram,pound) Cooling system C15-20sD 6.0L [6.3Q]

Eng.oil,w/ Transaxle filter

Hydraulic sump

5.8L[6.1Q] 15.0L[15.8Q] 34L[9.0G]

Fuel tank 42.0L[44.4Q]

C20-25D

9.6L [10.1Q] 7.5L[7.9Q] 18.5L[19.5Q] 40L[10.6G] 46.1L[48.7Q]

C30-35D

9.6L [10.1Q] 7.5L[7.9Q] 18.5L[19.5Q] 44L[11.6G] 51.9L[54.8Q]

C15-20sL 6.0L [6.3Q]

4.8L[5.1Q] 15.0L[15.8Q] 34L[9.0G]

C20-25L

8.5L [9.0Q]

4.8L[5.1Q] 18.5L[19.5Q] 40L[10.6G] 15kg[33 lb]

C30-35L

8.5L [9.0Q]

4.8L[5.1Q] 18.5L[19.5Q] 44L[11.6G] 15kg[33 lb]

C20-25G

8.5L [9.0Q]

4.8L[5.1Q] 18.5L[19.5Q] 40L[10.6G] 46.1L[48.7Q]

C30-35G

8.5L [9.0Q]

4.8L[5.1Q] 18.5L[19.5Q] 44L[11.6G] 51.9L[54.8Q]

C15-20sCL 6.0L [6.3Q]

15kg[33 lb]

4.8L[5.1Q] 15.0L[15.8Q] 24L[6.3G]

15kg[33 lb]

C20-32CL 10.5L[11.1Q] 4.8L[5.1Q] 18.5L[19.5Q] 37L[9.8G]

15kg[33 lb]

Engine Coolant Recommendation Use a mixture of 50% ethylene glycol permanent-type anti-freeze containing rust and corrosion inhibitor only.

Note: This mixture provides anti-freeze protection level of -37°C (-34°F), approximately.

Transmission Fluid Recommendation Use CLARK Specification MS-276A CLARK Part number 2776236.

Hydraulic Fluid Recommendation Use CLARK Specification MS-68 CLARK Part number 2776239 Hydraulic Oil, with anti-wear additives, or equivalent only.

C15-35, C15C-32C

8-5

Truck Weights - with standard upright. [C15-20s(C):3085mm, C20-30(C):3300mm, C32C:3225mm, C35:3165mm MFH] Gross Vehicle Empty Vehicle Loaded Drive Weight(kg[lbs]) Weight (kg[lbs]) Axle (kg[lbs])

Empty Drive Axle (kg[lbs])

C15-20sC Cushion LPG C15C

4246[9361]

2746[6054]

3740[8245]

1164[2566]

C18C

4762[10498]

2962[6530]

4210[9282]

1094[2412]

C20sC

5104[11252]

3104[6843]

4507[9936]

1044[2302]

C20-32C Cushion LPG C20C

5479[11670]

3479[7670]

4764[10146]

1484[3272]

C25C

6352[13492]

3852[8492]

5475[11624]

1375[3031]

C30C

7278[15431]

4278[9431]

6210[13155]

1290[2844]

C32C

7639[16286]

4439[9786]

6555[14045]

1268[2795]

C15-20s Pneumatic LPG & DSL C15

4285[9447]

2785[6140]

3733[8230]

1277[2815]

C18

4809[10602]

3009[6634]

4166[9185]

1219[2687]

C20s

5156[11367]

3156[6958]

4449[9808]

1175[2590]

C20-35 Pneumatic GAS & LPG C20

5301[11687]

3301[7277]

4817[10619]

1638[3611]

C25

6145[13745]

3645[8035]

5538[12209]

1565[3450]

C30

7079[15606]

4078[8990]

6332[13959]

1647[3631]

C35

8016[17672]

4516[9956]

7005[15443]

1656[3651]

C20-35 Pneumatic Diesel C20

5411[11929]

3411[7519]

4854[10701]

1675[3693]

C25

6255[13790]

3755[8278]

5576[12293]

1602[3532]

C30

7188[15847]

4189[9235]

6372[14048]

1687[3719]

C35

8126[17914]

4626[10198]

7069[15584]

1697[3741]

8-6

C15-35, C15C-32C

Section 8. Specifications

Engine Oil Engine Oil Recommendation LPG / GAS truck : HMC - in accordance with API classification more than a class SM or in accordance with ILSAC classification more than a class GF-4 / SAE 10W-30 GM - in accordance with API classification CF-5 grade and SAE 10W-30 full synthetic FORD - in accordance with ILSAC classification more than a class GF-5 grade and SAE 5W-30 full synthetic Diesel truck : Yanmar - in accordance with API classification CD or higher / SAE 10W-30 in accordance with ACEA classification E-3, E-4, E5 / SAE 10W-30 in accordance with JASO classification DH-1 / SAE 10W-30 ISUZU - in accordance with API classification CJ-4 and ACEA E6,E9, JASO DH-2 / SAE 10W-30

-40

-30

-20

-10

0

+10

+20

+30

+40

+50

SAE 0W-30 SAE 5W-30 SAE 5W-40 SAE 10W-30 SAE 10W-40 SAE 15W-40 SAE 20W-50 SAE 10W SAE 20W SAE 30 SAE 40

Engine Oil

8-7

IMPORTANT Do not extend oil change intervals from those specified when using synthetic lubricants.

Fill crankcase with correct amount of oil. When adding oil between oil changes, it is preferable to use the same brand as various oils may be incompatible. Refer to the Maintenance and Lubrication Section for recommended oil change intervals.

IMPORTANT Do not overfill crankcase. Excess oil causes foaming and can cause loss of lubrication and higher operating temperatures, resulting in engine damage.

8-8

Engine Oil

Index A A Message to CLARK Lift Truck Operators ..................................... ii Adjusting the Load Forks ........ 4-10 Adjusting the Seat .................... 4-4 After Operating the Truck ....... 4-16 Air Cleaning ............................ 7-26 Attached position of safety decals........................... 3-36 Auto Choke Control (Gasoline Only) ...................... 3-30 Auxiliary Control Lever (Optional) ................................ 3-30 Auxiliary Controls (Option) ...... 7-19 B Battery .................................... 7-21 Before Operating the Truck ...... 4-2 Below are Short Circuit Error codes that will display on Dash LCD when tripped........... 3-26 Brake Pedals .......................... 3-29 Braking ..................................... 4-6 Buckling Up .............................. 4-4 C C15-35, C15-32C ..................... 8-2 Chain Slack .............................. 2-7 Checks ................................... 7-27 Cold Start Preheating (Diesel Only) ........................... 3-27 Concluding the Inspection ........ 5-4 Controlling Speed ..................... 4-6 Cooling System ........................ 8-3 Critical Fastener Torque Checks .................................... 7-28 D Daily Inspection ........................ 1-2 Daily Safety Inspection ............. 5-2 Direction Control Lever ........... 3-29 Direction Control, Braking, and Inching ............................. 7-19

Disassembling the split rim wheel .......................................7-17 Do’s and Don’ts .........................1-3 Drop-Offs ..................................2-5 E Emergency open .....................3-31 Engine .......................................8-2 Engine Accessories ................7-21 Engine Air Cleaner ..................7-21 Engine Coolant Recommendation ......................8-4 Engine Cooling System ...........7-22 Engine Oil .................................8-7 Engine Oil Filter ......................7-24 Engine Oil Recommendations ..8-7 Engine Stop ............................3-28 Error indication ........................3-23 Extreme Operation ....................7-9 F Fill Capacities ............................8-5 Fluids, Filters, and Engine Accessories .............................7-20 Fork Safety ................................1-8 Forks .......................................7-15 Fuel Recommendations ............8-4 Fuel Safety Practices ................5-5 Functional Checks ....................5-4 Functional Tests ......................7-17 G General Tire Maintenance, Inspection, and Repair ............1-16 Grades, Ramps, Slopes, and lnclines .............................1-11 H Hood open ..............................3-31 Horn ........................................7-17 Horn Button .............................3-29 Hot Surface Warning Decal..... 3-35 Hour Meter ..............................3-28 Hour Meter ..............................7-17 Index-1

How to Perform Planned Maintenance ........................... 7-14 How to Tow a Disabled Truck ... 6-2 How to Use Battery Jumper Cables ...................................... 6-4 How to Use this Manual ............. viii Hydraulic Control Levers ........ 3-30 Hydraulic Fluid and Filter Change ................................... 7-24 Hydraulic Sump Tank ............. 7-24 , Indicator Lights ....................... 7-18 Instrument Pod ......................... 3-4 Introduction ..................................vi Introduction ............................... 7-2 .

Keep Away from Forks Decal ...................................... 3-35 Key/Start Switch ..................... 3-27 / Lateral Tip-over ...................... 1-13 Lift Chain Inspection and Measurement .......................... 7-28 Lift Chain Lubrication .............. 7-28 Lift Chain Maintenance ........... 7-27 Lift Chains ............................... 7-26 Lift Control Function ............... 3-30 Lift Mechanisms and Controls .................................. 7-18 Load Handling ........................ 4-11 Load Handling Components ... 7-14 Long and Wide Loads / Rear Swing ............................. 2-3 Longitudinal Tip-over .............. 1-13 Loose Loads ............................. 2-2 Low Overhead Clearance Fast Turns and High Loads ...... 2-4 Lubrication .............................. 7-25 Lift Chain wear and Replacement Criteriai ............. 7-28 0 Major Component Locations ..... 7-8

,QGH[

1 Neutral Start Switch ................7-17 No Riders ..................................1-5 Normal Operation ......................7-9 2 Operating Safely .......................4-7 Operator Compartment .............3-3 Operator Daily Inspection ...........vii Operator Protection ...................1-7 Operator Safety Warning Decal .......................................3-34 Operator/Tip-Over ...................3-34 Overhead Guard .....................7-14 Operator Controls ...................3-27 3 Pallets and Skids ......................2-8 Parking ....................................1-15 Parking Brake .........................7-18 Parking Brake .........................3-28 Parking Brake Pedal ...............3-27 Password operation ................3-21 Pedestrians ...............................1-6 Picking Up and Moving Loads ......................................4-13 Pinch Points ..............................1-9 Planned Maintenance .................vii Planned Maintenance Intervals ....................................7-9 PM Report Form .....................7-12 Pod Symbols and Functions .....3-5 Positioning Forks and Upright ...4-5 Powershift Transaxle ................8-3 5 Refueling Gasoline and Diesel Trucks ............................5-5 Refueling LPG Tanks ................5-6 Right-Angle Stacking ................2-6 Right-Angle Stacking ................2-6 Routine Servicing and Maintenance ............................... vi

6 Safe Maintenance Practices ..... 7-3 Safety Signs and Safety Messages .....................................x Seat Adjustment ..................... 3-28 Seat Belts ................................. 1-4 Service Brakes and Inching Pedal ...................................... 7-18 Stacking .................................. 4-14 Starting from a Safe Condition ... 4-3 Starting the Truck ..................... 4-4 Steering Column Pylon ........... 3-31 Steering System ..................... 3-29 Severe Operation ..................... 7-9 Steering System ..................... 7-19 Sump Tank Breather Maintenance and Inspection ........................ 7-25 Surface and Capacity ............. 1-12

: What to do in Case of a Tip-over ...................................1-14 Wheels and Tires ......................8-4 Wheels and Tires ....................7-16

7 TA-12/TA-30 Drive Axle ........... 8-4 Tilt Control Lever .................... 3-30 Tip-Over ................................. 1-13 Traction Disable Fuction ........ 3-29 Transaxle Fluid Check ............ 7-25 Travel ..................................... 1-10 Traveling with a Load ............. 4-12 Truck Chassis Inspection and Lubrication .............................. 7-25 Truck Data and Capacity Plate ....................................... 3-32 Truck Description ..................... 3-2 Truck Weights .......................... 8-6 Unitrol Pedal ........................... 3-31 Unloading ............................... 4-13 Upright and Tilt Cylinder Lubrication .............................. 7-26 Upright Warning Decal ........... 3-35 9 Visual Checks ........................... 5-3 Visual Inspection .................... 7-14

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Additional copies of this manual may be purchased from YOUR AUTHORIZED CLARK DEALER

CLARK MATERIAL HANDLING COMPANY 700 Enterprise Drive ● Lexington, Kentucky 40510 [ www.clarkmhc.com ] Printed Date ; Jul. 2018