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Clark PWX30SE Operator's Manual

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Book No. 8057856
OM-781

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Summary of Contents for Clark PWX30SE

  • Page 1 Book No. 8057856 OM-781...
  • Page 2 Truck Gross Weight, Loaded w/Rated Load Special Equipment or Attachments IMPORTANT Do not expose this manual to hot water or steam. The following warnings are provided pursuant to California Health & Safety Code Sections 25249.5 et. seq: 1995 Clark Material Handling Company...
  • Page 3 Welcome to the growing group of professionals who own, operate, and maintain CLARK lift trucks. We take pride in the long tradition of quality products and superior value that the CLARK name represents. This manual will familiarize you with the safety, operation, and maintenance aspects of your lift truck.
  • Page 4 Before You Operate Your Lift Truck You must be trained and authorized to operate a lift truck. LEARN TO 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.
  • Page 5 Safety Standards Your CLARK lift truck is 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 B56.1 Safety Standard for Powered Industrial Trucks.
  • Page 6 In addition to the daily user inspection, CLARK recommends that a planned maintenance and safety inspection program (PM) be performed by trained and authorized personnel. Inspections, adjustments, and repairs done during the PM increase the life of components and reduce unscheduled downtime.
  • Page 7 About this Manual To operate a truck safely and productively, the operator must know and understand the appropriate safety practices, including safe operating and load handling techniques. To develop the skill required, the operator must become familiar with the construction and features of the lift truck.
  • Page 8 If the truck is not equipped with this manual, ask your supervisor to obtain one and have it attached to the truck. And remember, your CLARK dealer is pleased to answer questions about the operation and maintenance of your lift truck and will provide you with additional information should you require it.
  • Page 9 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 10 Truck Application Each model is designed for a specific set of work tasks and conditions. Be sure you are using the right truck for the job. PWX model lift trucks are designed for moving loads short distances. No riding is allowed on P model trucks. HWX model lift trucks are designed for moving loads longer distances.

  • Page 11: Table Of Contents

    Section 1. General Safety Rules General Safety Rules Contents Do’s and Don’ts............1.2 No Riders ..............1.3 Pedestrians.............. 1.4 Grades ..............1.5 Travel ............... 1.6 Pinch points ............1.7 Parking..............1.8 Contents...

  • Page 12: Do's And Don'ts

    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 required safety when equipment. Don't smoke in "NO SMOKING" areas or when recharging. Do’s and Don’ts...

  • Page 13: No Riders

    Section 1. General Safety Rules No Riders Always walk with PWX model trucks. Never attempt to ride. The operator must be the only rider on HWX model trucks. No Riders...

  • Page 14: Pedestrians

    Pedestrians Watch where you are going. Pedestrians may use the same roadway you do. Sound your horn at all intersections. Watch for people in your work area. They may not watch for you. Pedestrians...

  • Page 15: Grades

    Section 1. General Safety Rules Grades Always keep forks downgrade with or without a load and in the raised position when working on a grade. Do not ride HWX model on a grade. Trucks are designed to travel up a 5 % maximum grade with load.

  • Page 16: Travel

    Travel Always carry loads in the raised position. Enter confined areas such as semi-trailers, trucks, boxcars or elevators with load end of your truck first. This will minimize the maneuvering necessary to exit. If load blocks your view while traveling in reverse, make sure path is clear of personnel and obstructions.

  • Page 17: Pinch Points

    Section 1. General Safety Rules Pinch Points WARNING Never allow anyone to reach under or around the edge of the truck. Be especially careful not to put any portion of your body under the load forks. Keep your feet clear of the truck when traveling. WARNING When operating close to stationary objects do not attempt to stop the truck with your feet, or fend off...

  • Page 18: Parking

    Parking Park trucks in designated parking areas only. Do not obstruct traffic lanes or aisles. Lower forks to floor. Place control handle in full turn and raise handle to "up" position to apply brake. Turn key switch off and remove key. Unplug battery connector.
  • Page 19 Section 2. Operating Hazards Operating Hazards Contents Fast Turns..............2.2 Corner Cutting............2.2 Loose Loads............2.3 Long and Wide Loads..........2.3 Dock or Trailer Drop offs........2.4 Trailer Creep............2.4 Debris on Floor ............2.5 Damaged Pallets and Skids ........2.6 IMPORTANT The operation of lift trucks involves many hazardous situ- ations.

  • Page 20: Fast Turns

    Fast Turns • Corner Cutting Fast Turns WARNING Slow down on turns. An empty truck can tip over easier than a loaded truck. Corner-Cutting WARNING Always use caution when making a turn into an aisle. The load wheels do not follow the turn path of the drive wheel and will tend to "cut"...

  • Page 21: Loose Loads

    Section 2. Operating Hazards Loose Loads • Long or Wide Loads Loose Loads WARNING Falling loads can seriously injure yourself or others. Never carry uneven material. Stack loose material evenly. Long or Wide Loads WARNING Long or wide loads are less stable and may strike objects or persons in their path.
  • Page 22 Drop Offs • Trailer Creep WARNING Talk to the truck driver yourself and make sure he does not move the trailer until you are done! Make sure the driver applies the trailer brakes and chocks trailer wheels. The impact of moving in and out of a trailer may cause the trailer to move.

  • Page 23: Debris On Floor

    Section 2. Operating Hazards Debris on Floor WARNING Oil, water, sand, mud, wood, gravel and other materials will make the floor slippery, uneven and dangerous. Be careful when crossing these areas. WARNING Know the weight of your truck and load. Especially when using elevators.

  • Page 24: Damaged Pallets And Skids

    Damaged Pallets and Skids WARNING Do not move or store materials on damaged or poorly maintained pallets and skids. Items can fall through or off them them causing severe injury or death. Damaged Pallets and Skids...
  • Page 25 Section 3. Know Your Truck Know Your Truck Contents Component Location (PWX Model) ....... 3.2 Component Location (HWX Model)....... 3.3 Operator's Controls (PWX Model) ......3.4 Operator's Controls (HWX Model) ......3.5 Maintenance Component Location (PWX Model) 3.6 Maintenance Component Location (HWX Model) 3.7 System Description ..........
  • Page 26 Component Location PWX 1. Steering and Brake 8. Battery Connector Control Handle 9. Hour Meter (optional) 2. Truck Data Plate 10. Hour Meter (optional 3. Load Wheels location) 4. Drive Wheel 11. Operator's Manual 5. Load Forks 12. Warning Decals 6.

  • Page 27: Component Location (Hwx Model)

    Section 3. Know Your Truck Component Location HWX 1. Steering and Brake 9. Battery Control Handle 10. Battery Connector 2. Operator Hand Rail 11. Stability Casters 3. Truck Data Plate 12. Hour Meter (option) 4. Load Wheels 13. Coast Control (option) 5.

  • Page 28: Operator's Controls (Pwx Model)

    Operator's Controls PWX 1. Steering and Brake Control Handle 2. Lift Control Button 3. Emergency Reversal Switch 4. Forward/Reverse Control (Butterfly) 5. Key Switch 6. Speed Control Switch 7. Horn Button 8. Lower Control Button Operator's Controls PWX...

  • Page 29: Operator's Controls (Hwx Model)

    Section 3. Know Your Truck Operator's Controls HWX 1. Steering and Brake Control Handle 2. Emergency Reversal Switch 3. Forward/Reverse Control (Twist Grip) 4. Speed Control Switch 5. Lift Control Button 6. Lower Control Button 7. Horn Button 8. Key Switch 9.

  • Page 30: Maintenance Component Location (Pwx Model)

    Maintenance Component Location PWX 1. Battery 2. Traction Control Panel 3. Hydraulic Unit 4. Brake 5. Drive Motor 6. Drive Unit 7. Lubrication Fittings Maintenance Component Location PWX...

  • Page 31: Maintenance Component Location (Hwx Model)

    Section 3. Know Your Truck Maintenance Component Location HWX * * * * * 1. Battery 2. Traction Control Panel 3. Hydraulic Unit 4. Brake 5. Drive Motor 6. Drive Unit 7. Lubrication Fittings Maintenance Component Location HWX...

  • Page 32: System Description

    System Description Control Handle • Controls travel direction and speed, lift and lower, horn, braking and steering. • Twist grip or butterfly type speed control for left or right hand operation. • Up or down brake application. • Safety reversing switch on end of control handle. •...
  • Page 33 7" or 13.6" wide battery compartments, SB-175 amp grey connector, high visibility Clark green and black finish. Additional HWX features include spring loaded stability casters, operator platform with non- skid metal surface, and operator hand rail with center mounted control buttons.

  • Page 34: Nameplate Description

    9. Battery ampere-hour rating. IMPORTANT When attachments are added or if the truck is modi- fied, the capacity of the truck may be affected. Con- tact your authorized Clark dealer for a new nameplate showing the revised capacity. 3-10 Nameplate Description...

  • Page 35: Warning Decals

    Section 3. Know Your Truck Warning Decal Here are examples of decals which give important information about operation and safety. OSHA and ANSI require you to replace them if they are missing or unreadable. Get familiar with them and follow the instructions.
  • Page 36 No Riding Decal This safety decal is placed on the top cover to warn of the danger of injury by attempting to ride PWX model trucks. Always walk with PWX model truck. No Passenger Decal This safety decal is placed on the top cover to warn of the danger of injury by attempting to ride as a passenger on HWX model trucks.
  • Page 37 Section 4. Operating Procedures Operating Procedures Contents Beginning Truck Operation........4.2 Travel Control............4.3 Emergency Reversal Switch........4.4 Lift & Lower Control (PWX Model) ......4.4 Lift & Lower Control (HWX Model) ......4.5 Horn Control............4.6 Braking..............4.7 Plugging..............4.7 Load Handling ............
  • Page 38 Beginning Operation Remove chocks from drive wheel. Plug in battery connector. Lower control handle to comfortable operating position and swing handle in line with intended path of forward or reverse travel. Insert key and turn clockwise to "on" position. Check to make sure your path of travel is clear of people or obstructions.

  • Page 39: Travel Control

    Section 4. Operating Procedures Travel Control PWX Travel Control Rotate the direction/speed control as shown to travel forward. Rotate the direction/speed in the opposite direction to travel in reverse. ("Reverse" defined direction in which the forks point.) Truck speed increases the further you rotate the direction/ speed Travel control.

  • Page 40: Emergency Reversal Switch

    Emergency Reversal Switch • Lift/Lower Contol Emergency Reversal Switch Emergency Reversal Switch Emergency Reversal Switch When the emergency reversal switch strikes an object or a person, or is held in by the operator, the truck automatically propels itself in the "reverse" direction. ("Reverse" is defined as the direction in which the forks point.) When the switch no longer contacts the person or object, the switch pops up and the truck resumes normal control.
  • Page 41 Section 4. Operating Procedures Lift/Lower Control • Hand Rail HWX Lift /Lower Control • Press the "lift" control to raise the load forks. • Press the "lower" control to lower the load forks. Operator Hand Rail Lift and Lower Control (HWX Model) •...
  • Page 42 Horn Button Horn Button • Press either horn button to sound horn. Horn Button...

  • Page 43: Braking

    Section 4. Operating Procedures Braking • Plugging Braking Brake On Brake Off Brake On Lowering the control handle to the operating position disengages the brake. Pushing the control handle to the "up" position or pulling the control handle to the "down" position applies the brake and shuts off the drive motor.

  • Page 44: Load Handling

    Load Handling • Lower forks completely before entering load. • Center forks with load as you approach. • Enter load as far as possible. • Make sure the lifting area is clear before lifting load. • Raise forks completely before moving truck. •...

  • Page 45: Parking

    Section 4. Operating Procedures Parking Optional Coast Control (HWX Models) The coast control deactivates the brake and enables the truck to be "jogged" with the travel control and coasted for order picking. • Press the two order picking switches at the same time for 1 sec to activate the coast control function.
  • Page 46 4-10...
  • Page 47 Section 5. Daily Inspection Daily Inspection Contents Daily Inspection Sheet..........5.2 Operator Repairs............. 5.2 Horn................5.3 Emergency Reversal Switch ........5.3 Travel Control............5.4 Lift and Lower Controls.......... 5.5 Brake ................ 5.6 Coast Control (Option) ........... 5.6 Wheels and Tires ............ 5.7 Maintenance Problems...........

  • Page 48: Daily Inspection Sheet

    Explanation of problems marked above: 59-770-2937 Jan 1996 As an aid in carrying out this inspection, Clark has prepared a form called "Driver’s Daily Check List." Copies of this form may be obtained from your Clark dealer. We recommend that you use this form to make a daily record of your inspection and truck condition.

  • Page 49: Horn

    Section 5. Daily Inspection Horn • Emergency Reversal Switch Horn PWX Model HWX Model Check the horn. Make sure the horn works properly using both buttons. Emergency Reversal Switch HWX Model PWX Model Check the emergency reversal switch. It should depress easily and pop back out on its own.

  • Page 50: Travel Control

    Travel Control Direction/Speed Control PWX Model HWX Model Check travel control. Operate truck in both forward and reverse directions. The direction/speed control must return to neutral position when released. Operator Hand Rail (HWX model High Speed only) On the HWX, test the high- Control speed control: While riding the truck, rotate the direction/speed...
  • Page 51 Section 5. Daily Inspection Lift Controls HWX Lift and Lower Control Check the lift/lower control buttons. The control buttons must return to the "off" position when released. The hydraulic lift pump motor should stop when maximum lift height is reached. Lift Controls...

  • Page 52: Brake

    Brake • Coast Control Brake Brake On Brake Off Brake On Check the brake. The brake should be applied with the control handle in the fully raised and fully lowered positions. The drive motor should stop when the brake is applied. Optional Coast Control (HWX Models) The coast control deactivates the brake and enables the truck to be "jogged"...

  • Page 53: Wheels And Tires

    Section 5. Daily Inspection Wheels and Tires • Maintenance Problems Wheels and Tires Check condition of wheels and tires. Remove any embedded objects. Report excessive wear, breaks, "chunking out", or bond failure. Check lug nuts for proper torque. Watch for loose wheel bearings.

  • Page 55: Notice

    Section 6. Planned Maintenance and Lubrication Planned Maintenance and Lubrication Contents Daily Inspection Points .......... 6.2 Typical Operating Conditions........ 6.2 Maintenance and Lubrication Schedule ....6.3 Safe Maintenance Practices........6.4 Safety Standards............. 6.7 Battery Maintenance..........6.8 Battery Handling ............. 6.9 Battery Charging...........

  • Page 56: Daily Inspection Points

    Time intervals between maintenance are largely determined by operating conditions. The intervals specified in the following table are for normal operation. For more severe operation, the maintenance intervals should be shortened accordingly. Contact you CLARK dealer for recommendations. Normal Operation: Basically, eight hour material handling in clean buildings with smooth level floors and clean, open air.

  • Page 57: Maintenance And Lubrication Schedule

    Section 6. Planned Maintenance and Lubrication Maintenance and Lubrication Schedule Recommended Planned Maintenance Intervals: A = 8-10 hours 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 Planned Maintenance and Lubrication Check truck for obvious damage and leaks...

  • Page 58: Safe Maintenance Practices

    / maintenance operations. When in doubt of any inspection / maintenance procedures, 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 59 Section 6. Planned Maintenance and Lubrication 9. Before Starting to Drive the Truck: a. Remove drive wheel chocks. b. Plug-in battery connector. c. Lower and turn control handle to operating position. d. Insert key (if equipped) and turn to "on" position. e.
  • Page 60 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 and overhead guard-as standard equipment.

  • Page 61: Safety Standards

    General Industry Standards, OSHA 2206: OSHA Safety and Health Standards (29 CFR 1910), Subpart N - Materials Handling and Storage, Section 1910.178 Powered Industrial Trucks. For sale by: Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 or contact your CLARK dealer. Safety Maintenance Practices...

  • Page 62: Battery Maintenance

    Battery Maintenance BATTERY SERVICE AREA SMOKING Battery charging installations must be located in areas designated for that purpose. These areas must be kept free of all nonessential combustible materials. Facilities must be provided for: • Flushing spilled electrolyte. • Fire protection. •...

  • Page 63: Battery Handling

    Section 6. Planned Maintenance and Lubrication 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.

  • Page 64: Battery Charging

    Battery Charging 6. Chain hoists or power battery hoists must be equipped with load chain containers to accu- mulate the excess lifting chain. 7. Keep all tools and other metal- lic objects away from termi- nals. WARNING BATTERY SERVICE must be done trained authorized personnel.
  • Page 65 Section 6. Planned Maintenance and Lubrication Battery Removal from Truck 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 compartment) cover(s) must be open to dissipate heat and gas.

  • Page 66: Battery Cleaning And Care

    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 67 Section 6. Planned Maintenance and Lubrication Maximum Life • Battery Installation How to Get Maximum Battery Life 1. Follow normal battery maintenance procedures, re-charging before 80% discharged and with periodic equalizing charges. 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 68 6-14...
  • Page 69 Section 7. Towing Towing IMPORTANT Pull a disabled truck by hand to a service area. CAUTION CAUTION Do not tow or push the truck with another vehicle. Towing...
  • Page 71 Hydraulic Unit MS-68 Hydraulic fluid CLARK P/N 1800236 Drive Unit MS-276A CLARK P/N 2776236 Fluid Capacities Hydraulic Unit 1.5 qts (nominal) Drive Unit 2 -2.5 qts (nominal) General Purpose Grease Clark Specification MS-107C, use grade NLGI #2 per MS-107C Specifications...
  • Page 73 Index Frame and Forks ......3.9 Application ........viii General Purpose Grease ... 8.1 Battery Grades ........1.5 Charging....... 6.10 Cleaning and care ....6.12 Horn ........... 5.3 Installation ......6.13 How to Get Maximum Battery Maximum battery life .... 6.13 Life ...........
  • Page 74 Parking........1.8 Pedestrians ........ 1.4 Pinch Points....... 1.7 Planned Maintenance and Lubrication ......... 6.1 Publications, related Service ..vi PWX Lift and Lower Controls..5.4 Rated Load Capacity ....8.1 Safe Maintenance Practices ..6.4 Safety..........iii Safety messages ......vii Safety signs .........
  • Page 75 Serial Number: Truck Control Panel Drive Motor Hydraulic Unit...
  • Page 76 700 Enterprise Drive Lexington, KY 40510 Printed in Korea Feb, 2006...

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