Clark GEX 40 Operator's Manual
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Clark GEX 40 Operator's Manual

Electric rider lift trucks
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ELECTRIC RIDER LIFT TRUCKS
[Do not remove this manual from the truck]
GEX 40/45/50
Part No. 8106240
OM 899 (Rev 1.3)
Jun. 2019

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Summary of Contents for Clark GEX 40

  • Page 1 ELECTRIC RIDER LIFT TRUCKS [Do not remove this manual from the truck] GEX 40/45/50 Part No. 8106240 OM 899 (Rev 1.3) Jun. 2019...
  • Page 3 Operator’s Manual You must be trained and authorized to operate a lift truck. YOU can prevent accidents First: Learn safe operating rules and your company rules. Next: Read your Operator’s Manual. If you do not understand it, ask your supervisor for help. Learn about the unit you operate.

  • Page 4: A Message To Clark Lift Truck Operators

    They require specific instructions and rules for safe operation and maintenance. Safe operation of lift trucks is of primary importance to CLARK. Our experience with lift truck accidents has shown that when accidents happen and people are killed or injured, the causes are: •...
  • Page 5 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.

  • Page 7: Table Of Contents

    Contents of this Manual A Message to CLARK Lift Truck Operators....... ii Introduction ................ vi How to Use this Manual ..........viii Safety Signs and Safety Messages ........x Section 1. General Safety Rules ........1-1 Section 2. Operating Hazards .......... 2-1 Section 3.

  • Page 8: Introduction

    CLARK lift truck in a safe and correct manner. Your CLARK lift truck has been designed and built to be as safe and efficient as today’s technology can make it. As manufactured, it meets all the applicable mandatory requirements of ANSI / ITSDF B56.1 Safety Standard for Powered Industrial Trucks.
  • Page 9 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.

  • Page 10: How To Use This Manual

    Also, the Index helps you locate information about various topics. NOTICE: The descriptions and specifications included in this manual were in effect at the time of printing. CLARK Material Handling Company reserves the right to make improvements and changes in specifications or design.
  • Page 11 If the truck you operate is not equipped with a manual, ask your supervisor to obtain one and have it attached to the truck. And, remember, your CLARK dealer is pleased to answer any questions about the operation and maintenance of your lift truck and will provide you with additional information should you require it.

  • Page 12: Safety Signs And Safety Messages

    Damage to the truck, death, or serious injury to you or other persons may result if these messages are not followed. If warning decals are damaged, they must be replaced. Contact your CLARK dealer for replacements. NOTICE This message is used when special information, instruc-...
  • Page 13 Section 1. General Safety Rules General Safety Rules Contents Daily Inspection ............. 1-2 Do’s and Don’ts ............1-3 Seat Belts ..............1-4 No Riders ..............1-5 Pedestrians ............. 1-6 Operator Protection ..........1-7 Fork Safety ............. 1-8 Pinch Points ............1-9 Travel ..............

  • Page 14: Daily Inspection

    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.

  • Page 15: Do's And Don'ts

    Section 1. General Safety Rules Do’s and Don’ts 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. If forklift truck is to be operated outdoors during rainy conditions, make sure cab is in place to prevent damage to electrical...

  • Page 16: Seat Belts

    Seat Belts ALWAYS BUCKLE UP Seat belts can reduce injuries. Seat Belts...

  • Page 17: No Riders

    Section 1. General Safety Rules No Riders No Riders...

  • Page 18: Pedestrians

    Pedestrians Estar atento cuando se maneja. Mirar en el sentido de marcha. Los peatones pueden estar usando la misma vía Watch where you are going. Look in the direction of que usted. Sonar la bocina en todas las intersecciones o travel.

  • Page 19: Operator Protection

    Section 1. General Safety Rules Operator Protection Keep under the overhead guard. Always keep your body within the confines of the truck. Operator Protection...

  • Page 20: Fork Safety

    Fork Safety Never allow anyone to walk under raised forks. DANGER There is special equipment to raise 2372604 people for overhead work. DO NOT USE LIFT TRUCKS. Fork Safety...

  • Page 21: Pinch Points

    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 trained mechanic. Pinch Points...

  • Page 22: Travel

    Travel Travel with the load near 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 reverse improve visibility.

  • Page 23: Grades, Ramps, Slopes, And Lnclines

    Section 1. General Safety Rules Grades, Ramps, Slopes, and lnclines Unloaded Forks Downgrade WARNING Never turn on a grade, either loaded or unloaded. Loaded Forks Upgrade Grades, Ramps, Slopes, and lnclines 1-11...

  • Page 24: Surface And Capacity

    Surface and Capacity Avoid these conditions. They can cause a truck to tip over or lose traction for braking or driving. WARNING Know the weight of your truck and load. Especially when using elevators. Know the capacity of the elevator you intend to use.

  • Page 25: Tip-Over

    Section 1. General Safety Rules Tip-Over Lateral Tip-over Lateral tip-over can occur with a com- • bination of speed and sharpness of turn. This combination will exceed the stability of the truck. This condition is even more likely with an unloaded truck.

  • Page 26: What To Do In Case Of A Tip-Over

    What to do in Case of a Tip-over If your truck starts to tip over, WARNING DO NOT JUMP!!! IMPORTANT Your chances for survival in a tip-over are better if you stay with the truck, in your seat. Brace yourself as illustrated below! 1.

  • Page 27: Parking

    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. •...

  • Page 28: General Tire Maintenance, Inspection, And Repair

    General Tire Maintenance, Inspection, and Repair 1. Park the truck as described on page 1-15 and check for correct tire inflation air pressure. See specifications in this OM for cor- rect tire pressure for your truck. CAUTION Check tire pressure from a position facing the tread of the tire, not the side.

  • Page 29: Section 2. Operating Hazards

    Section 2. Operating Hazards Operating Hazards Contents Loose Loads ............2-2 Long or Wide Loads / Rear Swing ......2-3 Low Overhead Clearance Fast Turns and High Loads ........2-4 Docks/Drop Offs ............. 2-5 Right-Angle Stacking ..........2-6 Chain Slack ............. 2-7 Pallets and Skids ...........

  • Page 30: Loose Loads

    Loose Loads WARNING Loose or unbalanced loads dangerous. Observe these precautions. Never carry loose or uneven material. Center wide loads. Stack and band loose material. Loose Loads...

  • Page 31: Long Or Wide Loads / Rear Swing

    Section 2. Operating Hazards Long or Wide Loads / Rear Swing 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 end- swing when turning.

  • Page 32: Low Overhead Clearance Fast Turns And High Loads

    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.

  • Page 33: Docks/Drop Offs

    Section 2. Operating Hazards Docks/Drop Offs WARNING To avoid these hazards, you must: • Talk to the truck driver yourself; make sure the driver does not move the trailer until you are done! • Apply trailer brakes. • Use wheel chocks. •...

  • Page 34: Right-Angle Stacking

    Right-Angle Stacking SLOWLY WARNING When right-angle stacking or moving with a raised load to clear low objects, avoid sharp turns and move slowly. Right-Angle Stacking...

  • Page 35: Chain Slack

    Section 2. Operating Hazards Chain Slack WARNING Slack chains mean rail or carriage hang-up. Raise the forks before you move, or broken chains can result. 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, car- riage,...

  • Page 36: Pallets And Skids

    Pallets and Skids 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.

  • Page 37: Section 3. Common Truck

    Section 3. Common Truck Common Truck Contents Truck Description ..........3-2 Operator Controls ..........3-3 Contents...
  • Page 38 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 electric sit down rider lift truck. Your model may vary slightly. Truck Description...
  • Page 39 Section 3. Common Truck Operator Controls Key/Start Switch • Connects the battery with all truck operating systems (drive, lift, and steer electrical circuits) except the horn. • Connects battery to the diagnostic display hourmeter and bat- tery charge status. The key switch must always be turned to the ON position to operate the truck.
  • Page 40 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 Parking Brake Release pedal down with your left foot until pedal stops. The parking brake release is located just above the brake pedal as shown.
  • Page 41 Section 3. Common Truck Steering System steering handwheel operates 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.
  • Page 42 IMPORTANT Tilt The hydraulic levers shown are typical representations CLARK 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...
  • Page 43 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 manufac- turer before any modifications affecting capacity or safety may be made.
  • Page 44 Operator Safety Warning Decal WARNING Read the manual Buckle up! Apply brake when leaving truck Watch Out For Other People Most lift truck 8009529 INJURIES are to other people near the lift truck. IMPORTANT Safety and warning decals are placed in conspicuous Prevent Overturns! locations on the truck to remind you of essential pro-...
  • Page 45 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.
  • Page 46 3-10...

  • Page 47: Section 4. Operator Compartment And Controls

    Section 4. Operator Compartment and Controls Operator Compartment and Controls Contents GEX40-50 Operator Compartment ........ 4-2 Contents...
  • Page 48 GEX40-50 Operator Compartment 1. Steering Handwheel 2. Horn Button 3. Turn Signal Lever 4. Key Switch 5. Brake Pedal 6. Dash Display 7. Accelerator 8. Lift Control Lever 9. Tilt Control Lever 10. Auxiliary Control Lever 11. Forward/reverse lever 12. Parking brake release 13.
  • Page 49 Section 4. Operator Compartment and Controls GEX40-50 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. 08/01/12[WED] 1. Battery State of Charge 8.
  • Page 50 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 when the parking brake is applied. Release parking brake to operate truck. Alarm Code: This symbol will be displayed anytime the inputs to the controls are missing, incorrect or anytime the controls sense a fault in the circuits or in the controls...
  • Page 51 Section 4. Operator Compartment and Controls Mode Selection Button 6 mode selection buttons are located on right side of LCD. Each button has specific function, and some have multiple functions. Down arrow button (Mode button): Pressing this button in normal operating condition will move to Menu mode. This button is used for programming and should be used by a trained technician only.
  • Page 52 Right arrow button (Power mode selection button): In normal operating condition, will change Power mode. −Power mode is composed of 3 steps and can be selected by pressing this Power Mode button. Economy: • Is Slow speed mode to save the battery consumption by minimizing the acceleration function.
  • Page 53 Section 5. Operating Procedures Operating Procedures Contents Before Operating the Truck ......... 5-2 Starting from a Safe Condition ......5-3 Contents...
  • Page 54 Section 5. Operating Procedures Before Operating the Truck sure that have read understand information this Operator's Manual before operating the lift truck. The Operator's Manual Holder is located on the back of the seat. WARNING • This equipment can be dangerous if not used properly. Safe operation is the responsibility of the operator.

  • Page 55: Section 5. Operatoring Procedures

    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.
  • Page 56 Section 5. Operating Procedures Adjusting the Seat Adjust the seat to a comfortable position for you. Adjust the seat moving holding Back declining release lever at the front under of Adjustment seat. Put the seat in a position that will provide easy reach to all controls.
  • Page 57 Section 5. Operating Procedures 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.
  • Page 58 Section 5. Operating Procedures Diagnostic Display Code Condition Likely Corrective Action -001 Seat switch open Sit on seat -061, -065 ,-140, Overheat of motor and Restart after cooling down -203, -207 controller Replace with charged bat- -066, -208 Low battery voltage tery Before starting, place the Forward/Reverse lever to...
  • Page 59 Section 5. 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...
  • Page 60 Section 5. Operating Procedures Mini lever (Option) 1) Forward and Reverse switch Switch for shifting between forward and reverse. − Forward..... Push forward − Reverse..... Push backward The speed of forward and backward traveling can be adjusted by pressing the accelerator pedal. NOTICE •...
  • Page 61 Section 5. Operating Procedures 3) Tilt lever Tilt the mast forward and backward. − Forward..... Push forward − Backword..Pull backward Forward or backward tilting speed can be adjusted by the extent of operating the lever. NOTICE • After the system has been activated, return the accelera- tor pedal and all of the levers to their neutral positions and return to the seat before recommencing operations.
  • Page 62 Section 5. Operating Procedures 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. 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.
  • Page 63 Section 5. Operating Procedures 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.
  • Page 64 Section 5. Operating Procedures Keep all other persons clear of the load and upright mechanism while attempting to handle a load. No riders... Do not carry passengers. The operator is the only one who should be on the truck. Always be in full control of your lift truck... Never operate a lift truck or its attachments if you are not in the designated operator's position.
  • Page 65 Section 5. Operating Procedures Grades, ramps, and inclines... Use special care when operating on ramps, inclines, and uneven areas. Travel slowly. Travel straight up and down. Do not turn or drive at an angle across an incline or ramp. When the truck is loaded, travel with the load upgrade. When the truck is empty, travel with lifting mechanism (upright) downgrade.
  • Page 66 Section 5. Operating Procedures 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.
  • Page 67 Section 5. Operating Procedures Load Handling Handle only loads that are within the truck rated capacity as shown on the nameplate. This rating specifies the maximum load that should be lifted. However, other factors such as special load handling attachments, loads having a high center of gravity, or uneven terrain may dictate that the safe working load be less than the rated capacity.
  • Page 68 Section 5. Operating Procedures The capacity load shown on the nameplate is represented by a cube in which the weight is evenly distributed, with the center of gravity located a standard distance from the face of the forks. If the weight of the actual load to be handled is not evenly distributed, put the heaviest part closest to the carriage.
  • Page 69 Section 5. Operating Procedures Picking Up and Moving Loads When picking up a load from the ground, approach the load slowly and carefully align the truck square with the load. The forks should be adjusted to fit the load or pallet being handled and spread as wide as possible to provide good stability and balance.
  • Page 70 Section 5. Operating Procedures Stacking To put a load on a stack: 1. Approach slowly and align the lift truck and load squarely with the stack. 2. Raise (elevate) the load as the lift truck is nearing the stack. 3. Move forward, slowly, until the load is almost touching the stack.
  • Page 71 Section 5. Operating Procedures Lower (drop) the forks slightly to clear (disengage) the load pallet. Tilt the forks forward sli ghtly, if nece ssary. Check your travel path, then carefully back away until the forks are clear of the stack. Stop and lower the forks to the travel position (6 to 8 inches above the ground), then tilt back to travel.
  • Page 72 Section 5. Operating Procedures 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. •...

  • Page 73: Section 6. Operator Maintenance And Care

    Section 6. Operator Maintenance and Care Operator Maintenance and Care Contents Inspecting Your Truck ........... 6-2 Visual Checks ............6-3 Functional Checks ..........6-4 Concluding the Inspection ........6-5 NOTICE The Occupational Safety and Health Act (OSHA) requires that truck users examine their trucks before each shift to be sure they are in safe working order.

  • Page 74: Inspecting Your Truck

    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.

  • Page 75: Visual Checks

    Section 6. Operator Maintenance and Care Visual Checks First, perform a visual in- spection of the truck and its major components: 1. Walk around your lift truck and take note of obvious damage that may have been caused by operation during the last shift.

  • Page 76: Functional Checks

    Functional Checks Check the operation of the truck as follows: NOTICE Before performing these checks, familiarize yourself with the operating procedures. Be sure there is enough over- head clearance to fully raise the upright. 1. With key switch off, be sure all controls and systems operate freely and return to neutral properly.

  • Page 77: Concluding The Inspection

    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.

  • Page 79: Section 7. Emergency Towing

    Section 7. Emergency Towing Emergency Towing Contents Towing Precautions ..........7-2 Towing Procedures ..........7-3 Contents...
  • Page 80 Towing Precautions If your lift truck becomes disabled but can be moved freely on its own wheels without further damage, use the following procedures to tow it safely to a repair area. IMPORTANT It is important for your safety and to the care of your lift truck to use the proper equipment and carefully follow these recommendations for safe towing.
  • Page 81 (This bolt is made of a special high tensile steel and is not commercially available. Replace it, when necessary, only with a genuine Clark replacement part). 5. Use an approved, solid metal tow bar with towing couplers that connect to the towing pins in the counterweight or that connect to the frame or chassis through the counterweight of each truck.
  • Page 82 8. Park the disabled truck in authorized areas only. Fully lower the forks to the floor, put directional control lever in the NEUTRAL position and turn the key switch to the OFF position. Engage the parking brake. Remove the key and, when necessary, block the wheels to prevent the truck from rolling.
  • Page 83 Section 8. Planned Maintenance Planned Maintenance Contents Lift truck Maintenance ..........8-2 Contents...
  • Page 84 In addition to the daily inspection, CLARK recommends that you set up and follow a periodic planned maintenance (PM) and inspection program. PM inspections should only be performed by a trained and authorized fork lift mechanic.
  • Page 85 Your local CLARK dealer is prepared to help you with your Planned Maintenance Program, if you want assistance. Your CLARK dealer has specially trained service personnel who are authorized to check your lift truck according to the applicable safety regulations.
  • Page 86 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...

  • Page 87: Section 8. Planned Maintenance

    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 3 months D = 900-1000 hours or every 6 months E = 2000 hours or every year PERIODIC CHECKS and A B C D E PLANNED MAINTENANCE (PM)
  • Page 88 Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please contact your local CLARK dealer. 1. Powered industrial trucks can become hazardous if mainte- nance is neglected. Therefore, suitable maintenance facilities, trained personnel, and procedures shall be provided.
  • Page 89 Section 8. Planned Maintenance 9. Before starting to drive the truck: a. Be seated in a safe operating position and fasten your seat belt. b. Make sure parking brake is applied. c. Put directional control in NEUTRAL. d. Turn the key switch to the ON position. e.
  • Page 90 Parts, including tires, are to be installed per the manufacturer's procedures. Always use genuine CLARK or CLARK-approved parts. 21. Use special care when removing heavy components from the truck, such as counterweight, upright, etc., the truck can become...
  • Page 91 Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20210. IMPORTANT Your new CLARK lift truck has been built to meet all appli- cable mandatory requirements of ANSI/ITSDF B56.1 Safety Standard for Powered Industrial Trucks. Each truck also includes certain safety devices, e.g., horn and over- head guard, safety restraint system, seat belt as standard equipment.
  • Page 92 CLARK prepared an Electric Truck Planned Maintenance Report Form (PM 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 a record of your inspection and truck condition.
  • Page 93 Section 8. Planned Maintenance Visual Inspection Begin the PM routine with a visual inspection of the lift truck and its components. 1. Walk around the truck and take note of any obvious damage and maintenance problems. Check for loose fasteners and fittings. 2.
  • Page 94 Check for any loose parts or fittings. Check for leaks, any damaged or loose rollers, and rail wear (metal flaking). Inspect all lift line hydraulic connections for leaks Load Backrest Check load backrest damage. Inspect the welds on the carriage and load backrest for cracks.
  • Page 95 The lift chains operate under heavy load- ings 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.
  • Page 96 WARNING Uprights and lift chains require special attention to main- tain 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.
  • Page 97 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.
  • Page 98 Service and Parking Brakes Operate service and parking brakes; all hydraulic controls—lift, tilt, and auxiliary (if installed); accelerator; directional controls; and steering system. Be sure all controls operate freely and return to neutral properly. Check the service brake system. Push the brake pedal fully down and hold.
  • Page 99 Section 8. Planned Maintenance Lift Mechanisms and Controls Check the function of the lift system and controls. Pull back on the tilt control lever and hold until the upright reaches the full back tilt position. Push forward on the lever to return the upright to the vertical position.
  • Page 100 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, exces- sive freeplay (looseness), or unusual sound when turning or maneuvering indicates a need for inspection or servic- ing.
  • Page 101 Section 8. Planned Maintenance Transistorized Traction Control Test for correct function of the traction control. Check creep speed, high speed, and plugging. CAUTION Check and make sure the travel area is clear before each movement and before each change of direction. 1.
  • Page 102 Checking the Hydraulic Fluid Check the hydraulic sump tank fluid level. Correct fluid level is important for proper system operation. Low fluid level can cause pump damage. 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).
  • Page 103 Section 8. Planned Maintenance Air Cleaning the Truck Always maintain a lift truck in a clean condition. Do not allow dirt, dust, lint, or other contaminants to accumulate on the truck. Keep the truck free from leaking oil and grease. Wipe up all oil spills. Keep the controls and floorboards clean, dry, and safe.
  • Page 104 Electric Truck Battery Maintenance BATTERY BATTERY SERVICE SERVICE AREA AREA SMOKING SMOKING Battery charging installations must be located in areas designated for that purpose. These areas must be kept free of all non-essential combustible materials. Facilities must be provided for: •...
  • Page 105 Section 8. Planned Maintenance Battery Handling 1. Change (remove) or service storage batteries only in an area designated for this purpose. 2. Be sure this area has provisions to flush and neutralize spillage, to ventilate fumes from gassing batteries, and for fire protection. 3.
  • Page 106 7. Keep all tools and other metallic objects away from the terminals. WARNING BATTERY SERVICE: Battery service must be done by trained and authorized personnel. Battery acid can cause severe burns and injury. Battery Charging 1. Persons maintaining storage batteries must wear protective clothing such as face shield, long sleeves, and gloves.
  • Page 107 Section 8. Planned Maintenance 3. When charging batteries, the vent caps must be kept in place to avoid electrolyte spray. Care must be taken to assure that vent caps are open (clean) and functioning. The battery (or compart- ment) cover(s) must be open to dissipate heat and gas. IMPORTANT If batteries discharge rapidly during normal operation or do not charge to the correct specifications, contact a...
  • Page 108 Refer to the battery manufacturer or supplier for their recommended battery maintenance and care procedures. BATTERY SAVER and CLEANER, CLARK Part No. 886398, may be used to clean and protect the truck battery. New Truck Batteries: Apply a light coat of BATTERY SAVER and CLEANER to entire surface of battery.
  • Page 109 Section 8. Planned Maintenance How to Get Maximum Battery Life 1. Follow normal battery maintenance procedures, re-charging before 80% discharged and with periodic equalizing charges. Let cool eight hours after charging before using. 2. Don’t add acid to a battery. Only a person trained and qualified to do battery maintenance should determine if this is necessary.
  • Page 110 Checking the traction and hydraulic cables • Check up the damage of cables and terminal at every sched- uled PM(250 hours) • During inspection, check the following cable condition − Terminal for loosing or corrosion − Insulation for hardening and cracking −...

  • Page 111: Section 9. Specifications

    Section 9. Specifications Specifications Contents GEX40-50 ..............9-2 Contents...
  • Page 112 GEX 40-50 CLARK products and specification are subject to improvements and changes without notice or obligation. Model Designation — Rated Load Capacity GEX 40 4,000kg @ 500mm load center [8,000lbs @ 24in] GEX 45 4,500kg @ 500mm load center [9,000lbs @ 24in]...
  • Page 113 Fill Capacities—Fluid Volumes Drive Axle : each 1.4L ~ 1.6 L Hydraulic Sump Tank (Useable Volume) : - GEX 40~50 : MFH ~5000 : 22 L MFH 5001~ : 30 L Hydraulic Fluid Recommendation Normal application - CLARK Specification MS-68 Hydraulic oil (CLARK # 1802155).

  • Page 115: Index

    Fastener Checks, Critical ..8-19 After Operating the Truck ..5-20 Forks ........8-14 Air Cleaning the Truck ..... 8-21 Forks Positioning......5-10 A Message to CLARK Lift Fork Safety ........1-8 Truck Operators ......ii Functional Checks......6-4 Auxiliary Control Lever Functional Tests .......8-15 (Optional) ........
  • Page 116 Long and Wide Loads ....2-3 Seat Belt........1-4 Loose Loads ......2-2 Service and Parking Brakes ..8-16 Low Overhead Clearance ..2-4 Service Brake ......3-5 Skids ..........2-8 Stacking ........5-18 No Riders ........1-5 Starting from a Safe Condition ...5-3 Starting the Truck .......5-4 Steering System ......3-5 Operator Controls ......
  • Page 120 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 ; Jun. 2019...

This manual is also suitable for:

Gex 50Gex 60

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