Clark Forklift TMX250, ECX360, GEX162, GEX230, GTX162 English OM-1040 Operator's Manual -,PDF DOWNLO

ELECTRIC RIDER LIFT TRUCKS

[Do not remove this manual from the truck]

ECX 20/25/30/32 TMX 12/15s/15/17/20/25 GEX 16/18/20s/20/25/30s/30/32 GTX 16/18/20s Part No. 8131797 (Eng) Book No. OM 1040 (Rev 1.4) Oct. 2020

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The operator’s manual is not a training manual. It is a guide to help trained and authorized operators safely operate their lift truck by emphasizing and illustrating the correct procedures. However, it cannot cover every possible situation that may result in an accident.

You must watch for hazards in your work areas and avoid or correct them. It is important that you know and understand the information in this manual and that you know and follow your company safety rules!

Be sure that your equipment is maintained in a safe condition. Do not operate a damaged or malfunctioning truck. Practice safe operation every time you use your lift truck. Let's join together to set high standards in safety.

Remember, before you start operating this lift truck, be sure you understand all driving procedures. It is your responsibility, and it is important to you and your family, to operate your lift truck safely and efficiently. Be aware that the Federal Occupational Safety and Health Act (OSHA) and state laws require that operators be completely trained in the safe operation of lift trucks; it is also an OSHA requirement that a machine inspection be performed before every shift. If you think you need training in operating or inspecting your lift truck, ask your supervisor.

CLARK lift trucks are built to take hard work, but not abuse. They are built to be dependable, but they are only as safe and efficient as the operator and the persons responsible for maintaining them. Do not make any repairs to this truck unless you have been trained in safe lift truck repair procedures and are authorized by your employer.

A Message to CLARK Lift Truck Operators

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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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Section 1. General Safety Rules

Do’s and Don’ts

Don't mix drugs or alcohol with your job.

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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.

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

No Riders

1-5

Pedestrians

Estar atento cuando se maneja. Mirar en el sentido de Watch where you are pueden going. estar Look usando in the direction of marcha.

Los peatones la misma vía travel.

Pedestrians may use the same roadway you do. que usted. Sonar la bocina en todas las intersecciones o Sound at all intersections or blind puntos your con horn visibilidad limitada. Estar atentospots. a la Watch for people in your work area even if your presencia de las personas en la zona de trabajo,truck aun has si el warning lights tiene or alarms. may not watch for you. montacargas lucesPeople de advertencia o alarmas.

Las demás personas pueden no estar atentas a lo que hace

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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Fork Safety

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

Section 1. General Safety Rules

Pinch Points

Keep hands, feet and legs out of the upright.

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WARNING Don't use the upright as a ladder.

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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

Travel

Section 1. General Safety Rules

Grades, Ramps, Slopes, and lnclines

Unloaded Forks Downgrade

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WARNING Never turn on a grade, either loaded or unloaded.

Loaded Forks Upgrade

Grades, Ramps, Slopes, and lnclines

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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

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Pallets and Skids

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WARNING Do not move or store materials on damaged pallets or skids.

Items can fall through them causing severe injury or death!

Be sure the pallet or skid you are using is in good condition and does not have defective or missing components and fasteners.

2-8

Pallets and Skids

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Parking Brake The parking brake pedal or lever (depending on your model) mechanically operates the parking brake.

Parking Brake Pedal 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 toward you.

Parking Brake Release

Parking Brake Lever Pull the lever toward the the operator to apply the parking brake. The lever should snap-lock easily into applied position, when correctly adjusted.

Push the lever forward (away from the operator) to release the parking brake.

!

WARNING Always apply parking brake before leaving truck.

!

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

Hour Meter With the key switch on, putting the directional control lever into forward or reverse positions also starts the operating hour meter. Use the hour meter reading to perform prescribed maintenance.

3-4

Operator Controls

Section 3. Common Truck

Steering System The steering handwheel operates a steering control valve that directs the oil flow to the steering cylinder connected to the steer axle. The steering control valve can also act as a pump to provide manual steering if the hydraulic pump stops.

Horn Button The horn button is located in the center hub of the steering handwheel.

Service Brake Your truck has a manual service brake system with a single pedal that actuates the master cylinder.

Direction Control Lever This lever is typically on the left side of the steering column.

!

WARNING Never operate your lift truck with the service or parking brakes not working correctly.

Forward Neutral Reverse

Operator Controls

3-5

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.

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

Lift

Auxiliary

Tilt

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.

3-6

Operator Controls

Section 3. Common Truck

Truck Data and Capacity Plate 1. Truck model number or registered name.

1

3 2. Truck serial number— An identification number assigned to this particular truck and should be used when requesting information or ordering ser5 vice parts for this truck from your authorized CLARK dealer.

The serial number is also stamped on the frame.

2

4

3. Attachment description (if any installed). The user must see that the truck is marked to identify the attachment(s), including the weight of the truck/attachment combination and truck capacity with the attachment.

4. Capacity rating, load center, and lifting height data—Shows the maximum load capacity of this truck with relation to load centers and fork heights (see diagram on plate). Personal injury and damage to the truck can occur if these capacities are exceeded.

Do not exceed the maximum capacity specified.

5. Truck weight—The approximate weight of the truck without a load on the forks. This weight plus the weight of the load must be considered when operating on elevators, elevated floors, etc. to be sure they are safe.

!

CAUTION When attachments are added or if the truck is modified, the capacity of the truck may be affected. Contact your authorized CLARK dealer for a new nameplate showing the revised capacity.

IMPORTANT OSHA requires prior written approval from the manufacturer before any modifications affecting capacity or safety may be made.

Operator Controls

3-7

. $ < WARNING Read the manual

Buckle up!

Apply brake when leaving truck

Watch Out For Other People

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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

31:

'

Section 3. Common Truck

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

Battery Connector Warning Decal This decal is placed next to the battery connector to warn of the danger of the truck starting in motion.

Operator Controls

3-9

31/C

Section 4. Operator Compartment and Controls

Operator Compartment and Controls Contents ECX Operator Compartment .......................................... 4-2 TMX Operator Compartment ..................................... 4-3 GEX,GTX Operator Compartment ............................ 4-4

Contents

4-1

ECX Operator Compartment

1

2

3

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4

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7 10 5 11

13

8

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

4-2

Steering Handwheel Horn Button Directional Control Lever Pylon Release Lever Brake Pedal Seat Key Switch Parking Brake Pedal Lift Control Lever Tilt Control Lever Accelerator Standard Display/Command System Parking Brake Release

ECX Operator Compartment

Section 4. Operator Compartment and Controls

TMX Operator Compartment

1

2 12

3, 8 4

7

6

10

9

5 11

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Steering Handwheel Horn Button Directional Control Lever Pylon Release Lever Brake Pedal Seat Key Switch Parking Brake Lever Lift Control Lever Tilt Control Lever Accelerator Standard Display/Command System

TMX Operator Compartment

4-3

GEX,GTX Operator Compartment

3

2

1

7

9 4

10

6 12 5 11

8

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2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Steering Handwheel Horn Button Directional Control Lever Pylon Release Lever Brake Pedal Seat Key Switch Parking Brake Lever Lift Control Lever Tilt Control Lever Accelerator Standard Display/Command System Armrest for driver’s seat (Optional) Control lever (joystick) for working hydraulic (Optional) 15. Control lever (joystick) for auxiliary hydraulic (Optional)

4-4

GEX,GTX Operator Compartment

Section 4. Operator Compartment and Controls

TMX Dash Display The primary design of the Dash Display is to provide the operator with an easily understandable, visual feedback of the status of the truck and it's system components.

1 2 5 11

3

10

4

6 9

7

8

Standard Display 1. Pump controller & Motor overheat warning indicator lamp 2. Drive controller & Motor overheat warning indicator lamp 3. Seat Belt Alert 4. Park Brake

5.

6.

7.

8.

9.

10.

11.

Planned Maintenance Numeric Display Hour Meter Service Status Battery Status Head light Switches Speed change switch (Optional)

GEX,GTX Operator Compartment

4-5

ECX Dash Display The primary design of the Dash Display is to provide the operator with an easily understandable, visual feedback of the status of the truck and it's system components.

1

2

3

4

5

8 7 6 10

9 11

Standard Display 1. Park Brake 2. Seat Belt Alert 3. Drive controller & Motor overheat warning indicator lamp 4. Pump controller & Motor overheat warning indicator lamp 5. Planned Maintenance

4-6

6. Battery Discharging Indicator 7. Display Set Speed limit 8. Activating Speed limit function 9. Hour Meter 10. Travel speed & Error code display 11. Service Status

GEX,GTX Operator Compartment

Section 4. Operator Compartment and Controls

GEX,GTX Dash Display The primary design of the Dash Display is to provide the operator with an easily understandable, visual feedback of the status of the truck and it's system components.

1

2

3

4

6

7

8

9 10 05/8/10 [WED]

11 12 13 14

5

1. Battery indicator 2. Slow speed indicator (Turtle mark) 3. Date and time display 4. Hour meter and speed display 5. Massage area and truck direction indicator 6. Parking brake LED 7. Seat belt LED 8. Fault LED

9. Down arrow switch (Mode switch) 10. Up arrow switch (Enter switch) 11. Left arrow switch (Slow speed switch) 12. Right arrow switch (Power select switch) 13. Plus switch 14. Minus switch

GEX,GTX Operator Compartment

4-7

Seat Belt: At start up this symbol displays along with an audio alarm for 4 seconds. This display reminds you to fasten your seat belt.

Parking Brake: The symbol is displayed and "-01" status code appears on the numeric display when parking brake is applied. Release parking brake to operate truck.

Planned Maintenance: This symbol is displayed and "-99" status code appears on the numeric display when the key switch is turned "ON" and trucks operating hours exceed preprogrammed hours for planned maintenance. The symbol is a reminder only and will turn "OFF" after 4 seconds and display will return to normal operation. The truck shall be inoperative while this symbol is displayed. Call Service.

Hour Meter(TMX): This symbol identifies the number displayed on numeric display as truck and/or pump motor (optional) operating hours. The symbol is displayed for 2 seconds to 6 seconds when the key switch is turned "OFF".

(ECX): This indicating lamp shows that the Operating hours are being counted. It blinks once each second.

Service Status : "-001”, “-066", "-079”, “-217”, “-245” and “255” are usually operator fault codes, and can be corrected by as explained in "Section 5, Operating Procedures." If you see any other codes displayed, the truck needs to be serviced.

Battery Status: If this symbol displays, the numeric display shows the percentage of usable charge remaining on the battery.

4-8

GEX,GTX Operator Compartment

Section 4. Operator Compartment and Controls

Pump controller & Motor overheat warning indicator lamp & ICON(For AC Only) : This indicator lamp is to warn of conditions where the temperature of pump motor and controller exceeds the limited value. If this lamp turns on, pump motor output is reduce in half.

Pump motor warning code: "-207" Pump controller warning code: "-203" Drive controller & Motor overheat warning indicator lamp & ICON(For AC Only) : This indicator lamp is to warn of conditions where the temperature of drive motor and controller exceeds the limited value. If this lamp turns on, drive motor output is reduce in half.

Drive motor warning code: "-65" Drive controller warning code: "61(Master), -140(Slave)" Travel direction ICON (GEX,GTX) : It is display on the screen.

Battery discharge indicator (ECX) :This display shows the remaining charge in the battery. One segment will turn off with each 10% reduction in charge. Warning Code:" 66:BAT LOW", it occurs at 10% remaining battery charge.

Blue color

Red color

Battery discharge indicator (GEX,GTX) : It displays the battery discharge condition of forklift truck.

The one bar indicates 10% charging condition. If the battery is charged more than 20% (8 bars or more), blue LED is displayed, but it is less than 20% (2 bars or less), red LED is displayed. If it is less than 10% (1 bar), it will flicker and buzzer sound.

GEX,GTX Operator Compartment

4-9

Speed limit rate indicator (ECX) This indicating lamp shows the traveling speed limit rate. One segment will turn off when the speed limit rate is reduced by 10%.

Displays the maximum allowable travel speed.

When all segments are lit, no restriction is present. If the speed is limited, the appropriate number of segments will be lit.

Speed limit function indicator (ECX): This indicating lamp shows traveling speed is limited. It will turn on when the traveling speed limit function of fork lift truck is working.

Slow-speed indicator (GEX,GTX): The traveling speed of truck is limited to set speed.

The upper mark is slow speed operating icon, and the figure shows the limited max. speed. (In upper example, the limited max. speed is 2MPH) Traveling speed indicator (ECX): This icon is shown when the truck is moving.

Seat switch (ECX): If the operator leaves the seat without setting the park brake regardless of key switch position (IGN. ON or OFF) for more than two (2) seconds, the ICON shall flash during the complete procedure. At first the internal beeper shall beep 5 times and after that the horn shall beep 5 times. Setting the park brake will reset the alarm.

Mode Selection Button (GEX,GTX) 6 mode selection buttons are located on right side of LCD. Each button has specific function, and some have multiple functions.

4-10

GEX,GTX Operator Compartment

Section 4. Operator Compartment and Controls

Down arrow button (Mode button): Pressing this button in normal operating condition, it will move to Menu mode.

Up arrow button (Enter button): Pressing this button, it will move to upper menu.

Left arrow button (Slow speed button) : In normal operating condition, it will select/release Slow speed. −When pressing, the following figure will be displayed and Slow speed selected. − Press once more to release. − The figure will be disappeared and Slow speed released. − Chang of slow speed Use "+/-" buttons to change the set speed while the Slow speed is selected. After adjusting the speed, press "Enter" (Up arrow) button to store it.

The speed can be set from 2 km/h to 9km/h with unit of 1km/h.

Right arrow button (Power selection button): In normal operating condition, it will select/release Power. −Power mode is composed of 3 steps, and it can be adjusted by use of "+/-" buttons. After adjusting the speed, press "Enter" (Up arrow) button to store it. − Power mode In the order of Economy → Normal → Power; Pressing "+" button to move right, and "-" left.

• Economy: It is Slow speed mode to save the battery consumption as minimizing the acceleration function.

•

Normal: It is normal operating mode, and smooth acceleration can be done.

•

Power: Powerful acceleration is possible and the work ability will be improved.

Plus(+) button: Increase the data as set value in the current Menu mode.

Minus(-) button : Decrease the data as set value in the current Menu mode.

GEX,GTX Operator Compartment

4-11

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Section 5. 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 Brake is Set 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

5-3

Adjusting the Seat Adjust the seat to a comfortable position for you. Adjust the seat by rotating the release lever upward 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 Adjustment

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. Fasten seat belt by pushing the flat end into the buckle until you hear a click.

Connect and adjust the seat belt strap to a snug, comfortable position.

Adjust seat belt snuggly across your lap and pelvis area, never across your stomach.

Always wear seat belt low and snug.

!

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.

5-4

Starting from a Safe Condition

Section 5. Operating Procedures

Adjusting the armrest of the driver's seat • Loosen the armrest adjustment clamping screw (1).

• Move the armrest (2) to the desired position.

• Tighten the clamping screw (1) again.

!

WARNING The clamping screw must be tight.

1

2

Central control lever (joystick) operation of mast (1) and attachments (2) ATTENTION Use the lifting device and attachments only for authorized applications. The operator must be instructed in the handling of the lifting device and attachments.

Observe the maximum lift height.

1

2

ATTENTION Do not put your hands or any other part of the body into the lift mast or the space between the mast and truck.

Always operate the control levers smoothly; do not jerk.

The speed of lifting, lowering and tilting is determined by how far the lever is moved. The lever is designed to return to the neutral position when released.

NOTICE Note the operating symbols with arrows.

NOTICE On the single lever model both functions are operated simultaneously (e.g. lifting and tilting) when the control lever is moved to an intermediate position (about 45 ˚ ).

Starting from a Safe Condition

5-5

Tilting the mast forward • Push the control lever (1) forward.

Tilting the mast back • Pull the control lever (1) back.

Raising the fork carriage

!

1

WARNING Do not step on the raised forks.

Increased danger of falling and being squeezed.

• Push control lever (1) to the right.

Lowering the fork carriage • Push control lever (1) to the left.

Operating the attachments (Optional) Attachments (e.g. sideshift, clamp, etc.) can be fitted on the lift truck as optional equipment.

Observe the operating pressure and instructions for the attachment. One additional control lever is fitted for its operation.

2

NOTICE For each attachment, affix a load capacity label for the truck with attachment to the battery cover and affix a symbol label at the rear of the appropriate control lever.

Operating the sideshift (Optional) • Push control lever (2) to the left (this will move the sideshift to the left).

• Push control lever (2) to the right (this will move the sideshift to the right).

Operating the clamp (Optional) • Push control lever (2) forward (this will open the clamp).

• Pull control lever (2) back (this will close the clamp).

ATTENTION Attachments not supplied with the truck may only be employed if an authorized distributor ascertains that a safe operation is assured in respect to load capacity and stability.

5-6

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• Speed (MPH) is shown when the truck is moving.

Message display (GEX,GTX) The model name, POWER Normal selection, travel direction, warning and error message Error are displayed.

In normal operating condition: Warning Model name/POWER/Travel BATTERY LOW direction.

When several messages are simultaneously displayed, it will be displayed in the order of Error, Warning and Normal condition.

If many error conditions are simultaneously occurred, the priority 2 Errors will be displayed. (The priority means Error number)

23 : FUSE ERROR 56 : FET SHORT

Travel direction icon (GEX,GTX) It displays the traveling direction or angle of steering wheel.

The direction icon rotates in 10 degrees. (Total 36 icon) Error icon (GEX,GTX) : When error occurs this icon is displayed to distinguish the condition easily. When the error message is displayed, this icon is simultaneously displayed.

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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.

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.

Lift Control Lever Tilt Control Lever

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 judgment 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.

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CAUTION For stability reasons, do not travel with the load or carriage in a highly 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

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Operating Safely IMPORTANT Safe operation is the responsibility of the operator. Watch where you are going. Don't go if you can't see.

Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.

While driving, be alert for pedestrians, other vehicles or obstructions in your path of travel.

Watch people. Do not allow anyone to stand or pass under the load or raised forks. Watch for people in your work area even if your truck has warning lights or alarms. They may not watch for you.

Sound horn at intersections and wherever vision is obstructed. Do not drive a truck up to anyone standing in front of an object.

Protect yourself and those around you...

Operate the truck only from the designated operator's position. Stay within the confines of the lift truck profile dimensions. Keep arms, legs and hands inside the operator's compartment and away from the danger of passing obstructions. Keep under the overhead guard.

NOTICE An overhead guard is intended to offer protection to the operator from falling objects, but cannot protect against every possible impact. Therefore, it should not be considered a substitute for good judgment and care in loading, handling, storage, etc..

Keep clear of the upright and lift mechanism. NEVER reach into or put hands, arms, legs or head into or through the upright structure or near the carriage or lift chains. Never put any part of your body between the upright and the truck. Don't use the upright as a ladder.

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Section 6. Operator Maintenance and Care

Concluding the Inspection Make a record on the “Driver's Daily Checklist” of all the operating and truck problems that you find. Review the checklist to be sure it has been completed and turn it in to the person responsible for lift truck mainte-nance. Be sure any unusual noises or problems are investigated immediately.

Do not operate a lift truck that has a maintenance problem, or is not safe to operate.

RVICE Remove the key from the ignition switch and put an “Out of Service” tag on the truck.

OUT OF OUT SERVICE SERVICE

If all of the Daily Inspection checks were normal or satisfactory, the truck can be operated.

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Daily Maintenance Checks Recommended PM Intervals The maintenance time intervals referred to in this manual relate to truck operating hours as recorded by the diagnostic system (or hourmeter) and based on experience which CLARK has found to be convenient and suitable under typical (normal or average) operating conditions, as follows: A = 8-10 hours or daily B = 50-250 hours or every month C = 450-500 hours or every 6 months D = 900-1000 hours or every 12 months E = 2000 hours or every year

DAILY MAINTENANCE CHECKS Check truck for obvious damage and leaks.

Check/clean battery terminals.

Check electrolyte level.

Check capacity, warning plates and decals.

Check condition of tires and wheels, remove embedded objects.

Check wheel lug nuts.

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 directional and speed control operation.

Check accelerator.

Check lift, tilt and auxiliary operation.

Check upright, lift chains and fasteners.

Check load backrest extension and forks.

8-4

Lift truck Maintenance

A B C D E

Section 8. Planned Maintenance

Periodic Maintenance Checks PM Interval: A = 8-10 hours or daily B = 50-250 hours or every month C = 450-500 hours or every 6 months D = 900-1000 hours or every 12 months E = 2000 hours or every year

PERIODIC CHECKS and PLANNED MAINTENANCE (PM) Check truck visually and inspect components.

Test drive truck/check functional performance.

Air clean truck.

Check torque on critical fasteners.

Lubricate truck. (See component) Clean/check battery terminals, electrolyte level.

Check battery cables/truck receptacle.

Perform battery load test.

Check drive motor.

Check lift motor.

Check steer motor.

Test ground.

Clean drive axle air vent.

Check drive axle fluid level. (First : 50 hours) Drain and replace TMX, ECX drive axle fluid.

GEX, GTX Check brake condition and wear.

Check drive axle mounting and fasteners.

Lubricate steer axle linkage.

Check/lubricate steer axle wheel bearings.

Replace hydraulic sump fluid and filter.

Clean/replace hydraulic sump breather.

Lubricate tilt cylinder rod ends.

Check lift chain adjustement and wear.

Check/lubricate lift chains.

Lubricate upright rollers.

A B C D E

Lift truck Maintenance

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Section 8. Planned Maintenance

• 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.

3

2 1

4

3. (SPAN) The number of pins in the length (segment) of chain to be measured.

4. (PITCH) The distance from the center of one pin to the center of the next pin.

All chains must be replaced if any link has wear of 3% or more, or if any of the damaged conditions noted above are found during inspection. Order replacement chains from your CLARK dealer.

Replace all chains as a set. Do not remove factory lubrication or paint new chains. Replace anchor pins and worn or broken anchors when installing new chains. Adjust tension on new chains. Lubricate chains when they are installed on the upright.

NOTICE Please refer to your Service Manual for additional information on lift chain measurement and maintenance.

Lift truck Maintenance

8-13

!

WARNING Uprights and lift chains require special attention to maintain them in safe operating condition.

• Uprights can drop suddenly. Look at the upright, but keep hands out.

• Lift chain repairs and adjustments should be made by trained service personnel.

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.

!

WARNING If the fork blade heel is worn down by more than 10 percents, 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, 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"(2.5 cm) maximum.

A

10% of "A" is max. wear

1.5% is max. height difference 2.5 cm (1 in)

50 cm (20 2in) 0"

Carpenter Carpenter square Square

5 x2"10Xcm 4" (2 x 4 in) Blade

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

Inspect the fork locating pins. Be sure they are not damaged or broken and operate freely and lock correctly. Check the fork stop pins for secure condition.

8-14

Lift truck Maintenance

Section 8. Planned Maintenance

Wheels and Tires Check the condition of the drive and steer wheels and tires. Remove objects that are embedded in the tire. Inspect the tires for excessive wear and breaks or "chunking out" and bond failure between the tire and the rim.

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

Have missing bolts replaced and loose bolts tightened to the correct torque before operating truck.

!

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.

Functional Test Now, check that all controls and systems are functioning correctly.

Test horn, lights, and all other safety equipment and accessories. Be sure they are properly mounted and working correctly.

Press the horn button to check horn function. If the horn or any other part does not operate, report the failure, and have it repaired before the truck is put into operation.

Horn

Lift truck Maintenance

8-15

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6

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Section 9. Specifications

Fill Capacities—Fluid Volumes Drive Axle : 2.4gal (9.0L) Hydraulic Sump Tank (Useable Volume) : 7.4 gal (28L) Hydraulic Fluid Recommendation Normal application - CLARK Specification MS-68 Hydraulic oil Drive Axle Fluid Recommendation : CLARK #2776236 Power Steering Fluid Recommendation : Uses main hydraulic sump oil supply.

Brake Reservoir : DOT 3 Brake Fluid.

Multi-Purpose Grease Axle Ends, Wheel Bearings :

NLGI Grade No. 1 Lithium soap base grease CLARK Specification MS-9B and MS-107B

Steering linkage, upright mast & carriage rollers, trunnion bushings, tilt cylinder rod ends, brake pedal shaft :

NLGI Grade No. 2 Lithium soap base grease, CLARK Specification MS-107C.

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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 ; Oct. 2020