Clark S20 D Operator's Manual
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Clark S20 D Operator's Manual

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INTERNAL COMBUSTION LIFT TRUCKS
S 20/25/30/35 D,L,G
S 20/25/30/32C L,G
[Do not remove this manual from the truck]
Part No. 8140450 (Eng)
Book No. OM 1067 (Rev 1.9)
Nov. 2019

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  • Page 1 INTERNAL COMBUSTION LIFT TRUCKS [Do not remove this manual from the truck] S 20/25/30/35 D,L,G S 20/25/30/32C L,G Part No. 8140450 (Eng) Book No. OM 1067 (Rev 1.9) Nov. 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 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 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 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. Please check with your authorized CLARK dealer for information on possible updates or revisions.
  • 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 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 Contents ................1-1 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 ..............

  • 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. Don't use the similar fuel.

  • 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 The operator is the only one who should be on a truck. Never transport personnel on the forks of a lift truck. No Riders...

  • Page 18: Pedestrians

    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.

  • 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 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 the floor/ground with upright tilted back cradle 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 SAND GRAVEL WEAK FLOORS 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 combina- tion 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. Parking Brake Switch •...

  • 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: Carbon Monoxide And Fumes

    Section 1. General Safety Rules Carbon Monoxide and Fumes Be sure your employees understand that they must not use an internal combustion engine in a closed area such as a cold storage locker. Carbon monoxide is a colorless, odorless, poisonous gas which can overcome your employees without warning.

  • Page 31: Section 2. Operating Hazards

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

  • Page 32: Loose Loads

    Loose Loads 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 33: Long And Wide Loads / Rear Swing

    Section 2. Operating Hazards Long and 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 34: 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. WARNING Slow down before turning.

  • Page 35: Drop-Offs

    Section 2. Operating Hazards 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 36: Right-Angle Stacking

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

  • Page 37: 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. Chain Slack...

  • Page 38: 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 39: Section 3. Operator Compartment And Controls

    Section 3. Operator Compartment and Controls Operator Compartment and Controls Contents Truck Description ..........3-2 Operator Compartment ......... 3-3 Instrument Pod ............3-4 Display ..............3-6 Operator Controls ..........3-41 Contents...

  • Page 40: Truck Description

    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. Truck Description...

  • Page 41: Operator Compartment

    Section 3. Operator Compartment and Controls Operator Compartment SEAT S20330202 1. Forward / Reverse Lever 10. Tilt Control Lever 2. Steering Handwheel 11. Auxiliary Control Lever 3. Horn Button 12. Power Socket (12V) 4. Parking Brake Switch 13. USB Charger 5.

  • Page 42: Instrument Pod

    Instrument Pod 1. Turn Signal Indicator (Optional) 2. Date Indicator 3. Truck Model Indicator 4. Time Indicator 5. Head Light Indicator 6. Rear Work Light Indicator 7. Fuel Level Indicator 8. Mode Select Switch (Membrane Switch) 9. Coolant Temperature Gauge 10.
  • Page 43 IMPORTANT For safety reasons, every CLARK forklift truck is fitted with a neutral start device. The purpose of this is to pre- vent the engine from being started while the transmission is in gear.

  • Page 44: Display

    Display 1. TFT LCD Standard Speed meter activated if speed more than 1 km/h (0.6 mph) 1. Time Indicator 2. Speed meter Optional Function activated like weight when speed is less 1 km/h (0.6 mph) 2500 1. Weight Indicator (Optional) 2.
  • Page 45 Section 3. Operator Compartment and Controls 2. Mode Select Switch (Membrane Switch) Left arrow button (Mode button) 1. When pressing this button at normal condition, it will move to the Menu mode. 2. At menu mode, this switch is used for moving to left menu.
  • Page 46 3. At the menu mode, if pushing for over 1 second, the changing value speed will decrease. 3. Indication of Display (Turn on the key switch) Key on 1. Show “CLARK” until main screen booted. 2. Show the main screen with 1 time single beep.
  • Page 47 Section 3. Operator Compartment and Controls Coolant Temperature Indicator Show current truck coolant temperature. GREEN BLUE 3-Zone specification Truck Engine Type Gauge Zone Step YANMAR ISUZU FORD 118°C ~ 112°C ~ 108°C ~ 123°C ~ 116~117°C 110~111°C 106~107°C 120~122°C (Top) 113~115°C 100~109°C 104~105°C 117~119°C 110~112°C 98~99°C...
  • Page 48 3-4 Fuel Level Indicator (diesel and gasoline models) Accurately displays the remaining fuel for trucks using diesel or gasoline. If using LPG, only the FULL (blue) and EMPTY (red) levels are indicated. When the low fuel icon begins flashing, the truck must be immediately parked and the fuel tank renewed before the engine shuts down.
  • Page 49 Section 3. Operator Compartment and Controls Speed Meter Show truck speed. (Unit : km/h or MPH) Time Indicator Show current hour. Hour Meter or Trip Distance Indicator Show truck operating hours or distance. Trip distance must be configured with MENU setting for km and miles.
  • Page 50 Seat Warning / Seat Belt Warning (optional) The icon lights up when the driver does not sit on the seat. This also optionally functions as a seat belt reminder. If the seat belt is not worn, it will illuminate. Fault Icon When an error occurs this icon is displayed to distinguish the condition easily.
  • Page 51 Section 3. Operator Compartment and Controls Rear Work Light Icon There are three ways to turn ON/OFF the rear work light. 1. The rear work light is activated using the button. Push the rear work light button to turn the light ON. Push it again to turn the light OFF.
  • Page 52 When LED is on, the preset service time is approaching or has been reached, indicating that a PM(Planned Maintenance) is required. For service contact your responsible CLARK dealer. Battery Charging Warning Lamp This symptom indicates trouble on the batteries or improper charging of the batteries by the alternator.
  • Page 53 Section 3. Operator Compartment and Controls Engine Check Lamp When the engine has problem, this LED will be on. Contact your CLARK dealer. Glow Plug Preheat (Diesel Truck) Turn the starter key to "ON" position. The indicator light will illuminate indicating that an electrical operated glow wire is heating the air in the induction manifold.
  • Page 54 Weight Indicator (optional) Weight of load is measured and indicated on the display. 2500 The default unit of weight on the service menu mode 5500 is "kg." You can set the unit to pound (lb) on the menu when measuring load weight. A password is required, contact your dealer.
  • Page 55 REF No2. : 1 2 3 4 5 6 7 8 digit No. 2 are displayed as shown on the right figure. INPUT PW : * * * * * 3. Contact your dealer or CLARK Service Center with the numbers. Driver Menu Mode...
  • Page 56 (1) Date and Time Setting menu Current date and time are set. CLOCK SETUP Switching between 12- and 24-hour systems and between AM and PM is 30 MAR 2017 MON allowed. AM 09 : 27 • Make use of Plus (+) and Minus (-) buttons to change the current val- SAVE: ENTER ues.
  • Page 57 Section 3. Operator Compartment and Controls NOTICE The whole hour and Trip distance can increase but not decrease in the Service menu. Neither is changing 99999.9 to 00000.0 allowed. (3) Menu for Resetting Load Weight to '0' Operator can reset the default of the load weight gauge to "0"...
  • Page 58 (5) Error code In the drive menu mode, only error codes are displayed, and error codes can be deleted. In the service menu mode, you can delete error codes after entering the password. Contact your dealer, regarding your password. Alarm Setup Alarm can be set in service menu mode only.
  • Page 59 Section 3. Operator Compartment and Controls (4) Seat belt alarm setup SEAT BELT Used to set the seat belt warning function. SEAT BELT REMINDER HORN SMART INTERLOCK • Function of displaying message SMART INTERLOCK TIME only / Message displaying + buzzer sounding function Message...
  • Page 60 (9) Tilt Limit Warning Setup (only Korea option) Used to set the mast tilt angle limit alarm. • ON function / OFF function Lamp Setup • Setup path: Service Menu Mode, SETUP LIGHT CONTROL (1) Front or Rear Work Lamp Setup Used to set operation of the front and the rear work lamps.
  • Page 61 Section 3. Operator Compartment and Controls Display Setup Used to set options relevant to operation of the forklift truck. DISPLAY SETUP A password is required, contact your DISPLAY MODE HOUR dealer. LANGUAGE • Selecting operation hours and DRIVER MONITER DRIVER ALARMLOG mileage DEALER INFORMATION •...
  • Page 62 (4) System time setting (not allowed to change) Time information from the engine ECU is displayed on the instrument panel. Setting and change of the information are not allowed. (5) Setting maintenance hours Setting maintenance hours of the forklift truck. A password is required, contact your dealer.
  • Page 63 Section 3. Operator Compartment and Controls • When entering correct password, "PASSWORD OK" message is displayed, the buzzer sounds once, and then the main screen is displayed. • When you enter wrong password, "PASSWORD ERROR" mes- sage is displayed, the buzzer sounds once, and Password Input screen is prompted again.
  • Page 64 Weight Function Setup • Setup path: Service Menu Mode, SETUP LOAD WEIGHT (1) Display Function ON/OFF You can set the weight function to ON or OFF. The value is displayed in ‘kg’ LOAD WEIGHT or ‘lbs’ upon unit setting. WEIGHT FUCTION Used to display the default value, and LOAD WEIGHT 1234...
  • Page 65 Section 3. Operator Compartment and Controls Rear Camera Function Setup (optional) You can set the rear camera function to ON or OFF. A password is REAR CAMERA required, contact your dealer. REAR CAMERA Images transmitted from the rear camera displayed instrument panel only when the gear lever is shifted to the forward position while the camera is kept turned on.
  • Page 66 (2) Decrease Shift Shock Delays transmission direction change shift until set speed. This is to reduce impact on the drive-line that occurs during rapid reverse to forward (and vice-versa) shifting. (The default is 25 km/h.) • The setting can be changed between 1 and 25 km/h in increments of 1 km/h.
  • Page 67 Section 3. Operator Compartment and Controls (1) Checking error on engine If an engine error takes place on the forklift truck, "Engine Fault Warning ALARM LOGBOOK Lamp" is displayed on the main ENGINE ERROR screen, and error message is shown. TRUCK CONTROLLER ERROR The screen displays two or three SPEED LIMIT ERROR...
  • Page 68 The specifics of an Error message number Activation/deactivation error are shown as the right to the figure. ERROR1 (ACTIVE) SPN/FMI SPN:190 / FMI: 14 Count of O.C: 3 occurrence DESCRIPTION: Description SENSOR ERROR HANDTHROTTLE SENSOR; SIGNAL RANGE CHECK LOW (2) Truck controller error If an error takes place on the forklift truck, "Fault Icon"...
  • Page 69 Section 3. Operator Compartment and Controls (4) Speed Limit controller error If an error takes place on the forklift truck, "Fault Icon" is turned on the main screen, and error message is displayed. Pressing "Down Arrow" on the right of the instrument panel displays error codes in sequence.
  • Page 70 Message Function Below are frequent warning messages : Detailed descriptions on following pages. Warning Message(English) Specifics of Warning INCORRECT START PUT Neutral position warning DIRECTIONAL LEVER IN NEUTRAL SEAT SWITCH OPEN. Seat warning SEAT BELT SWITCH OPEN. Seat belt warning REFASTEN SEAT BELT Smart interlock warning NEXT MAINTENANCE IN...
  • Page 71 Section 3. Operator Compartment and Controls Seat Switch Open Warning takes place when operator leaves the driver's seat. Warning message is displayed, "Seat Icon" blinks, and the buzzer sounds. Warning removed when operator sits on the seat. Seat Belt Switch Open (optional) Warning takes place...
  • Page 72 3. Operator wears the seatbelt. (Seat belt ON) 4. The forklift truck normally operates only when step 1 to 3 above are completed in sequence. (2) When smart interlock warning takes place: • Warning takes place when seat belt is latched before operator is in seat.
  • Page 73 Section 3. Operator Compartment and Controls CAUTION When pressing Parking Switch during operation, the parking brake immediately applies. Next Maintenance In: When setting maintenance hours on "Hour Setup" in page 3-23, remainder maintenance hours are displayed when turning the key on if defined maintenance hours are not exhausted.
  • Page 74 Engine Will Shut Down After 30 Seconds Shutdown of the engine is indicated. The engine stops 30 seconds after display of the engine shutdown warning alarm. 1. Popup window is prompted immediately after occur- rence of the shutdown warning. 2. The forward / backward solenoid valves are released.
  • Page 75 Section 3. Operator Compartment and Controls (2) Warning occurred • Forklift truck with Yanmar engine When engine oil pressure error persists for 3 seconds or longer while the engine is running : 1. Error is detected from the operating engine. 2.
  • Page 76 Engine Coolant Temperature High Engine coolant temperature warning. (1) Lamp turned on 1. "Coolant Overheat Warning Lamp, and Engine Fault Warning Lamp" icons are turned on, and warning message is displayed. (2) Warning occurred 1. "Coolant Overheat Warning Lamp, and Engine Fault Warning Lamp"...
  • Page 77 Section 3. Operator Compartment and Controls Transmission Oil Temperature High Transmission oil temperature warning. When the transmission oil temperature switch closes for 1 second or longer: (1) Lamp turned on 1. "Transmission Oil Temper- ature Warning Lamp" icon is turned on, warning mes- sage is displayed, and the buzzer sounds.
  • Page 78 Starter Interrupted To protect starter from overheating, when the key switch is kept turned to “Start” position for 15 seconds or longer, warning message is displayed and the buzzer sounds. Check Engine Controller Malfunction on engine controller Check error log messages. Check Truck Controller Malfunction on truck controller.

  • Page 79: Operator Controls

    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.
  • Page 80 Seat Adjustment The fore and aft adjustment lever is located on the front under the seat. To unlock, pull Back the lever to the left and adjust the seat, declining adjustment release the lever. Be sure that the seat locking mechanism is engaged. The back declining adjustment lever is Fore and located on the left side of seat cushion.
  • Page 81 Section 3. Operator Compartment and Controls Hour Meter Starting the engine also starts the operating hour meter. Use the hour meter reading to perform prescribed maintenance. Steering System The steering handwheel operates a steering control valve that directs the oil flow to the steering cylinder connected to the steer axle.
  • Page 82 IMPORTANT The hydraulic levers shown are typical representations of a CLARK internal combustion lift truck. Your model may vary slightly. 1) Lift Control Function With the lift control lever, you are able to raise and lower the fork carriage on the upright.
  • Page 83 Section 3. Operator Compartment and Controls 4) Control Function 1. Forward / Reverse Switch (optional) 2. Horn Button 3. Auxiliary Function (optional) Tilt - Vertical Mast Control Button control lever 4. Auxiliary Function (optional) - Clamp Lever Lock Button S20330277e (or Push Button) 5.
  • Page 84 Mini Lever (optional) 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. •...
  • Page 85 Section 3. Operator Compartment and Controls 3) Tilt Lever Tilt the mast forward and backward.  Forward : Push forward  Backward : Pull backward Forward or backward tilting speed can be adjusted by the extent of operating the lever. 4) Attachment Lever Operates the attachment.
  • Page 86 IMPORTANT Ground speed is controlled by the accelerator pedal only. For safety reasons, your CLARK forklift truck is fitted with a neutral start feature. The purpose of this is to prevent the engine from being started while the transmission is in gear.
  • Page 87 Section 3. Operator Compartment and Controls Fuse FUSE BOX The fuses are located at the inside of the foot well, on the right when looking forward. The fuse ratings are visible on the fuses. CAUTION The fuse box lid contains the legend list of what the fuses are for and what their ratings are.
  • Page 88 Truck Engine Type Fuse Specification ISUZU YANMAR FORD Heater/Aircon (option) Option Option Speed Limit Control (Dual) F19 Spare F20 Spare F21 Direction Switch F22 W/S Sensor F23 Display F24 Hyd Valve (ISO Relay) Aircon (option) Option (vcc) Power (option) EHL (option) F26 Heater F27 Wiper F29 Spare - 15A...
  • Page 89 Section 3. Operator Compartment and Controls Heater and Air Conditioner (Optional) Lay-out Windscreen defrost Foot room louver Drivers compartment louver Drivers compartment louver Control panel Recirculation grill Temperature control (2) Fan speed control (1) Air Conditioner On/Off (3) 1. Operating the Heater a) Turn the fan speed control knob(1) to set the fan speed to the desired setting.
  • Page 90 2. Operating the Air Conditioner Press the ac button (3), to turn on/off the air conditioner NOTICE To defrost the windscreen set the fan speed to the highest setting and point the louvers towards the windows. Activating the AC function during the windscreen defrost will improve the defrost performance.
  • Page 91 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 and international standards requires prior written approval from the manufacturer before any modifications affecting capacity or safety may be made.
  • Page 92 Operator Safety Warning Decal WARNING Read the manual Buckle up! Apply brake when leaving truck Watch Out For Other People Most lift truck INJURIES 2798233 are to other people near the lift truck. IMPORTANT Prevent Safety and warning decals are placed in conspicuous Overturns! locations on the truck to remind you of essential procedures or to prevent you from making an error...
  • Page 93 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.
  • Page 94 Do not operate a lift truck with damaged or missing decals or data plates. Replace them immediately. They contain important information. Contact your local CLARK dealer to acquire new decals or data plates. WARNING Read the manual Buckle up! Apply brake...

  • Page 95: Section 4. Operating Procedures

    Section 4. Operating Procedures Operating Procedures Contents Before Operating the Truck ........4-2 Starting From a Safe Condition ......4-3 Contents...
  • Page 96 Before Operating the Truck Be sure that you have read and Operator's Manual understood the information in 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 97 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.
  • Page 98 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 bottom Back declining of the seat. Put the seat in a adjustment position that will provide easy reach to all controls.
  • Page 99 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 tilt 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 Lift Control...
  • Page 100 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.
  • Page 101 Section 4. 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 102 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 103 Section 4. 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 104 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 105 Section 4. 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 106 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 107 Section 4. 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 108 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 109 Section 4. Operating Procedures 6. Lower (drop) the forks slightly to clear (disengage) the load pallet. Tilt the forks forward slightly, if necessary. 7. 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 110 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 111: Section 5. Operator Maintenance And Care

    Section 5. Operator Maintenance and Care Operator Maintenance and Care Contents Daily Safety Inspection .......... 5-2 Fuel Safety Practices ..........5-5 Refueling LPG Tanks ..........5-6 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 112 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 113 Section 5. Operator Maintenance and Care Visual Checks First, perform a visual inspection 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. 2.
  • Page 114 Functional Checks Check the operation of the truck as follows. NOTICE Before performing these checks, familiarize yourself with the starting, operating, and shutdown procedures in Sec- tion 4 of this manual. Also, know the safety rules given in Section 1 of this manual. 1.
  • Page 115 Section 5. Operator Maintenance and Care Fuel Safety Practices Refueling Gasoline and Diesel Trucks Clean up spills. Use clean, properly marked fuel cans. On Isuzu Diesel Engine equipped trucks: • Using fuel other than ultra-low-sulfur (sulfur content of 15 ppm or lower) diesel fuel may have a harmful effect on the engine, pos- sibly resulting in a breakdown.
  • Page 116 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. •...
  • Page 117 Section 5. Operator Maintenance and Care RECOMMENDED SAFETY MAINTENANCE PROCEDURES FOR LPG FUELED LIFT TRUCKS WARNING LPG is a combustible fuel that is heavier than air. Escaping gas may accumulate in low areas. The fuel cylinder should be mounted so that it does not extend outside the truck and should also be properly positioned by using the locating pin or key way.

  • Page 119: Section 6. Emergency Starting, Towing And Lowering

    Section 6. Emergency Starting, Towing and Lowering Emergency Starting, Towing and Lowering Contents How to Tow a Disabled Truck ....... 6-2 How to Use Battery Jumper Cables ..... 6-5 Emergency Lowering of Upright ......6-8 Contents...
  • Page 120 (These bolts are made of a special high-tensile steel and are not commercially available. Replace, 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 counterweights.
  • Page 121 7. Transmission control is in neutral. NOTICE Department of Transportation approved towing equipment may be available from your CLARK dealer. 8. Tow the disabled truck backward. An operator must be on the towed truck. Tow the truck slowly. Careful towing is necessary to prevent injury to personnel or damage to the truck.
  • Page 122 Solid metal tow bar CAUTION The power steering and brakes will not operate on the disabled truck when the engine is not running. Manual operation of the handwheel and brakes will be difficult to operate. More manual effort will be required to perform these functions.
  • Page 123 Section 6. Emergency Starting, Towing and Lowering How to Use Battery Jumper Cables CAUTION If the fork lift truck is out of service for more than 1 month, the (-) cable of battery should be disconnected. Otherwise, the starting of engine will be impossible due to discharge of battery.
  • Page 124 WARNING BATTERIES EMIT EXPLOSIVE GAS. Do not smoke or have open flames or sparks in battery charging areas or near batteries. An explosion can result and cause injury or death. Hydrogen gas is produced during normal battery operation. Hydrogen can explode if flames, sparks, or lighted tobacco are brought near the battery.
  • Page 125 Section 6. Emergency Starting, Towing and Lowering 4. Connect the jumper cables in the following sequence: a. Connect a jumper cable from the positive (+; red) terminal on one battery to the positive (+; red) terminal on the other bat- tery.
  • Page 126 Emergency Lowering of Upright CAUTION In the event the lift truck loses total power, it may be necessary to use the following procedure to lower the lifting mechanism and load to the ground. If the following procedure must be followed, you must ensure that it is done safely, and you must remain in a safe position where the load or lifting mechanism can not strike you or anyone else.

  • Page 127: Section 7. Planned Maintenance And Lubrication

    Section 7. Planned Maintenance and Lubrication Planned Maintenance and Lubrication Contents Introduction ............7-2 Safe Maintenance Practices ........7-3 Major Component Locations ........ 7-8 Planned Maintenance Intervals ......7-9 PM Report Form ........... 7-12 How to Perform Planned Maintenance ....7-14 NOTICE THIS SECTION IS FOR TRAINED SERVICE PERSONNEL to use as a reference for Planned Maintenance proce-...

  • Page 128: Introduction

    In addition to the operator’s daily inspection, CLARK recommends that the owner set up and follow a periodic planned maintenance (PM) and inspection program. Performed on a regular basis by trained personnel, the program provides thorough inspections and checks of the safe operating condition of the lift truck.

  • Page 129: Safe Maintenance Practices

    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 and trained personnel and procedures shall be provided.
  • Page 130 CAUTION CAUTION Refer to the “Jacking and Blocking” section in the Service Manual for proper procedures. Never lift the truck by the counterweight. 9. Operation of the truck to check performance must be conducted in an authorized, safe, clear area. 10.
  • Page 131 Section 7. Planned Maintenance and Lubrication 14. Fuel systems must be checked for leaks and condition of parts. Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected.
  • Page 132 Be sure that lifting and handling equipment is of the correct capacity and in good condition. 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—such as horn, over-...
  • Page 133 Section 7. Planned Maintenance and Lubrication NOTICE You should be familiar with additional operating and maintenance safety instructions contained in the follow- ing publications: ANSI / ITSDF B56.1: Safety Standard for Low Lift and High Lift Trucks (Safety Code For Powered Industrial Trucks). NFPA 505:Fire Safety Standard for Powered Industrial Trucks: Type Designations, Areas of Use, Maintenance and Operation.

  • Page 134: Major Component Locations

    12. Sheet Metal 6. Transmission 13. Upright and Carriage 7. Drive Axle and Wheel 14. Drive Shaft The truck shown above is a typical representation of a CLARK internal combustion lift truck. Your model may vary slightly. Major Component Locations...

  • Page 135: Planned Maintenance Intervals

    Section 7. Planned Maintenance and Lubrication Planned Maintenance Intervals Time intervals between maintenances are largely determined by operating conditions. For example, operation in sandy, dusty locations requires shorter maintenance intervals than operation in clean warehouses. The indicated intervals are intended for normal operation.
  • Page 136 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...
  • Page 137 Section 7. Planned Maintenance and Lubrication NOTES: * Air filter change interval may be determined by using an air restriction indicator. CAUTION CAUTION Breather interval for very dirty environment : every 500 operating hours, at least twice a year. B C D E Check truck for obvious damage and leaks.

  • Page 138: Pm Report Form

    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.
  • Page 139 Section 7. Planned Maintenance and Lubrication PM Report Form 7-13...

  • Page 140: How To Perform Planned Maintenance

    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.
  • Page 141 Be sure that it is properly positioned and all mounting fasteners are in place and tight. The overhead guard must not be modified from CLARK specification. 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.
  • Page 142 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 Shank bends. Put a 50mm(2") - thick 25mm (1") max metal block, at least 100mm(4") wide by 600mm(24") long with parallel sides, on the blade of the...
  • Page 143 Incorrect (low) tire pressure can reduce the stability of your lift truck. Do not operate truck with low tire pressure. For proper cold inflation pressure, check the CLARK specifications. Disassembling the Split Rim Wheel When you disassemble the split-rim wheel, NEVER remove the tire before you deflate the tire pressure.
  • Page 144 Functional Tests You will start the engine to complete the functional tests, so be sure that: • The automatic parking brake is applied. • Directional control is in NEUTRAL. • Forks are fully lowered to the floor or ground • All controls are in neutral or other correct position •...
  • Page 145 Section 7. Planned Maintenance and Lubrication Service Brakes and Inching Pedal With the direction control in NEUTRAL and the engine running, push the service brake pedal fully down and hold. The brakes should apply before the pedal reaches the floorplate. If the pedal continues to creep downward, report the failure immediately.
  • Page 146 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;...
  • Page 147 Section 7. Planned Maintenance and Lubrication 2. Remove your right foot from the service brake pedal and put it on the accelerator pedal. Push down until the truck moves slowly forward. Remove your foot from the accelerator pedal and push down on the service brake pedal to stop the truck. The brakes should apply smoothly and equally.
  • Page 148 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.
  • Page 149 Section 7. Planned Maintenance and Lubrication The recovery bottle shown is a typical illustration of overflow system. Your actual system may vary slightly. A level anywhere between the FULL and LOW marks is nor- mal. Inspect the coolant level in the overflow bottle only.
  • Page 150 • Drain and replace the engine crankcase oil every 500 oper- ating hours. (depending on application). Contact your near- est CLARK Dealer for further information. • Engine Oil Filter must be changed at every PM when the oil is changed.
  • Page 151 Section 7. Planned Maintenance and Lubrication 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.
  • Page 152 NEUTRAL and the drive wheels blocked, check the fluid on the dipstick. Fill, if necessary, to the FULL mark on the dipstick, using CLARK transmission fluid (Mobil 424, US market). If unable to determine actual oil temperature, use this alternate check method:...
  • Page 153 Section 7. Planned Maintenance and Lubrication Park the forklift truck on level ground, incline the mast forward to the largest extent, and check oil level of the drive axle. When the oil temperature is same as the ambient temperature, makeup the oil up to "LOW"...
  • Page 154 Lift Chains Lubricate the entire length of the upright rail lift and carriage chains with CLARK Chain and Cable Lube. IMPORTANT Do not lubricate the carriage roller rails. Air Cleaning Always maintain a lift truck in a clean condition. Do not allow dirt, dust, lint, or other contaminants to accumulate on the truck.
  • Page 155 Section 7. Planned Maintenance and Lubrication Air clean the upright assembly, drive axle, radiator—from both counterweight and engine side, engine and accessories, driveline and related components, and steer axle and cylinder. Critical Fastener Torque Checks Fasteners in highly loaded (critical) components can quickly fail if they become loosened.
  • Page 156 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.
  • Page 157 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.

  • Page 159: Section 8. Specifications

    Section 8. Specifications Specifications Contents S20-35, S20-32C ............. 8-2 Engine Oil ............... 8-6 Contents...
  • Page 160 S20-35, S20-32C CLARK products and specifications are subject to improvements and changes without notice or obligation. Model Designation - Rated Load Capacity S20 D/L/G 1810kg@600mm load center [4000lbs@24in] [2000kg@500mm] S25 D/L/G 2270kg@600mm load center [5000lbs@24in] [2500kg@500mm] S30 D/L/G 2720kg@600mm load center [6000lbs@24in] [3000kg@500mm]...
  • Page 161 Section 8. Specifications 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 (200°F), Gas/LPG 82°C (180°F), fully open 95°C (200°F) Power Train (Transmission / Drive Axle) • Gear Ratio −...
  • Page 162 Use CLARK Specification TEXTRAN TDH CLARK Part number 2776236. Drive Axle Fluid Recommendation* Use CLARK Specification MOBIL Fluid #424 CLARK Part number 1809371. *On US market trucks with forced cooling, the Drive Axle and the Transmission share common fluid and Mobil 424 must be used.
  • Page 163 Section 8. Specifications Fill Capacities (fluid volumes-liters, quarts, gallons,kilogram,pound) Eng.oil, Drive Cooling Hydraulic Model T/Mission* Fuel tank system sump w/filter** axle* S20-25D 9.6L[10.1Q] 8.4L[8.8Q] 10.0L[10.6Q] 4.1L[4.3Q] 47L[12.4G] 64L[67.6Q] S30-35D 9.6L[10.1Q] 8.4L[8.8Q] 10.0L[10.6Q] 4.1L[4.3Q] 47L[12.4G] 68L[71.9Q] S20-25L 8.5L[9.0Q] 5.4L[5.7Q] 10.0L[10.6Q] 4.1L[4.3Q] 47L[12.4G] 15kg[33 lb] S30-35L 8.5L[9.0Q] 5.4L[5.7Q] 10.0L[10.6Q] 4.1L[4.3Q] 47L[12.4G] 15kg[33 lb]...
  • Page 164 Engine Oil Engine Oil Recommendations LPG / GAS truck : Ford - in accordance with ILSAC classification more than a class GF-5 grade and SAE 5W-30 full synthetic PSI 4G64 - in accordance with API classification more than a class SM grade / SAE 10W-30, long drain. Diesel truck : Yanmar - in accordance with API classification CD or higher /...
  • Page 165 Section 8. Specifications IMPORTANT Do not extend oil change intervals from those specified when using synthetic lubricants. The Ford engine must be filled with full synthetic motor oil as specified on the previous page. 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.
  • Page 167 Index Display monitoring ....3-16 A Message to CLARK Lift Truck Do’s and Don’ts ......1-3 Operators ........ii Drop-Offs ........2-5 Adjusting the Load Forks ..4-10 Adjusting the Seat ....4-4 Engine ........8-2 After Operating the Truck ..4-16 Engine Accessories ....7-22 Air Cleaning ......
  • Page 168 How to Perform Planned Maintenance ......7-14 Major Component Locations ..7-8 How to Tow a Disabled Truck ... 6-2 Message Function ....3-32 How to Use Battery Jumper Mini Lever .......3-46 Cables ........6-4 Mode Select Switch ....3-7 How to Use this Manual ..... viii Hydraulic Control Levers ..
  • Page 169 Safe Maintenance Practices ..7-3 What to do in Case of a Safety Signs and Safety Tip-over .........1-14 Messages ........x Wheels and Tires ....7-16 Seat Adjustment ..... 3-42 Wheels and Tires ......8-3 Seat Belts ......... 1-4 Service Brakes and Inching Pedal ........
  • Page 170 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 ; Nov. 2019...

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