Table of Contents OM-1206 Information ..........................6 Overview........................... 7 A Message to Operators ......................8 Introduction ..........................9 How to Use this Manual ......................11 Safety Standards ........................12 Section 1. General Safety Rules................... 13 Do’s and Don’ts ....................... 14 Operator Protection ......................15 Pedestrians ........................
Information Lift Truck Information Model Type Serial No. Truck Weight Rated Capacity Gross Weight Component Serial Number Drive Axle (left) Drive Axle (right) Steer Axle Hydraulic Pump/Motor Controller(s) Lift Truck Information...
Overview YOU can prevent accidents First: Know the rules of safe lift truck operation and the safety rules specific to your work area. Next: Read the Operator's Manual. If you do not understand something, ask your supervisor. LEARN about the lift truck you operate! Know YOUR lift truck Then: Operate your lift truck safely.
All CLARK lift trucks are designed and built to handle hard work, but not abuse from an operator. They are designed and built to be dependable, but are only as safe and efficient as the operator(s) and person(s) responsible for using and maintaining them.
Foreword CLARK welcomes you to the growing group of professionals who own, operate, and maintain our lift trucks. We take pride in our tradition of quality product and superior value that the CLARK name represents. This operator's manual has been specially prepared to help you use and maintain your CLARK lift truck in a safe and correct manner.
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Your CLARK dealer can help with implementing a Planned Maintenance program and providing properly trained and authorized service technicians to keep your lift truck operating safely and efficiently.
If the lift truck you operate is not equipped with an Operator's Manual, tell your supervisor immediately. • Your authorized CLARK dealer is ready to help! They can provide you with any additional information about the features, operation, and maintenance of your lift truck.
IL 60062. IMPORTANT! Your CLARK lift truck has been built to meet all applicable mandatory design and construction requirements of the ANSI / ITSDF B56.1 Safety Standard for Low Lift and High Lift Trucks. No additions, omissions, or modifications should be made to the lift truck that affect compliance to the above requirements or in any way minimize the effectiveness of its safety devices.
Do’s and Don’ts DON’T mix drugs or alcohol with your job. DO watch for pedestrians. DON’T block safety equipment. DO wear personal protective equipment. DON’T smoke in NO SMOKING areas. DON’T operate or store the lift truck outdoors during rain or snow conditions. Do’s and Don’ts...
Section 1. General Safety Rules Operator Protection Seat Belt Always use the seatbelt. Overhead Guard WARNING • Stay under the overhead guard when operating the lift truck. • Keep arms and legs inside the operator’s compartment. • Be careful when traveling in reverse and in tight areas.
Pedestrians No Riders WARNING The operator is the only person allowed on the lift truck. WARNING Do not transport personnel with the lift truck. Nearby Personnel WARNING • Look in the direction you are traveling. • Slow down and operate the horn at every intersection or location where visibility is limited.
Section 1. General Safety Rules Upright Forks and Upright WARNING Do not walk or stand under raised forks. WARNING Do not raise personnel with the lift truck. WARNING Do not use the upright as a ladder. Pinch Points WARNING Keep hands, feet, and legs out of the upright. Upright...
Travel Forward Travel • Lower the forks to a safe height and tilt the upright back when traveling with a load. • Do not lift or lower a load while the lift truck is moving. Reverse Travel • Operate the lift truck in reverse when handling loads that restrict your view.
Section 1. General Safety Rules Parking Parking Rules • Do not park the lift truck on a ramp or grade. • Do not leave the lift truck before coming to a complete stop. • Park the lift truck in authorized areas only. •...
Tipover Side Tipover • Tipover can occur when a certain combination of travel speed and turn sharpness exceeds the stability of the lift truck. This is most likely to occur with an unloaded lift truck. • Tipover can occur while turning with the upright raised or braking in reverse with the upright raised or accelerating during a turn.
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Section 1. General Safety Rules What To Do in Case of a Tipover WARNING DO NOT JUMP! During a tipover, your best chance of survival is to stay in the seat. BRACE YOURSELF AS ILLUSTRATED BELOW! Step 2 Step 1 Step 3 Step 4 1.
Load Handling Unbalanced Loads Wide Loads Do not lift or move uneven loads. Center wide loads on the forks. Loose Material Right-Angle Stacking Stack and band loose material. Avoid sharp turns and move slowly. High Loads Long or Wide Loads Do not turn sharply with a raised load.
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Section 2. Operating Hazards Chain Slack WARNING Check for chain slack before attempting to lower a load or when withdrawing the forks after placing a load. Chain slack is caused by the upright rails, carriage, or forks hanging up. Raise the forks before moving, or damage to the chains may occur. Pallets and Skids WARNING Possibility of crushing injury or death.
Collisions Overhead Clearance WARNING • Know your overhead clearance and look for obstacles. • Hitting an overhead structure can cause the lift truck to tipover or drop its load. • Keep the load low and tilted back. WARNING • Know the total height of your lift truck, with and without load.
Section 2. Operating Hazards Drop-Offs WARNING When operating on a dock or drop-off, do the following: • Tell the driver not to move the trailer. • Use the trailer brakes. • Install wheel chocks. • Use a trailer-to-dock system if available. The trailer may move unexpectedly while loading or unloading.
Ramps and Grades Unloaded Travel When Traveling Unloaded... Keep Forks Pointed Down Grade WARNING WARNING Always look in the direction of travel. Do not turn on a grade. Loaded Travel When Traveling Loaded... Keep Forks Pointed Up Grade WARNING When operating the lift truck, ascend or descend grades slowly, and with caution. •...
Section 2. Operating Hazards Surface and Capacity SAND ROCKS WEAK FLOORS WARNING Do not travel over poor surface conditions which can cause the lift truck to tipover or lose traction when braking or traveling. WARNING Do not travel over a surface that cannot support the weight of a fully loaded lift truck. Know the combined weight of the load and the lift truck.
Section 3. Know Your Lift Truck Operator Controls Driving Controls Name Description View The steering wheel controls the Steering position of the rear steer tires. Wheel The position of the steer tires is shown on the dash display. The brake pedal controls the Brake braking of the lift truck.
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Driving Controls Name Description View The horn to used to alert nearby Horn personnel while operating the lift truck. The emergency disconnect switch enables the operator Emergency to immediately turn lift truck Disconnect power off. Only use this in an emergency situation.
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Section 3. Know Your Lift Truck Driving Controls Name Description View The accessory switches control Accessory electrical options such as Switches headlights, work lights, and hazard lights. The rear horn button enables Rear Horn the operator to operate the horn Button when traveling in reverse.
Seat The standard operator's seat offers three types of adjustment for optimal operator comfort. The seat can be adjusted for recline angle, front-to-rear position, and suspension firmness. Adjusting the Seat Recline: • Pull back on the side lever (1) and lean backward or forward to position the seat back cushion.
Section 3. Know Your Lift Truck Steering Column The steering column offers two-way tilt adjustment for optimal operator comfort. Adjusting the Steering Column: • Loosen the locking lever (1) to release the steering column. • Rotate the steering column (2) up or down to adjust the tilt angle. •...
Armrest The operator armrest offers four-way adjustment for optimal operator comfort. The armrest can be adjusted by recline angle, front-to-rear position, and height. Adjusting the Armrest: • Loosen the knob (1) to release the armrest. Adjust the armrest to the desired height. Tighten the knob to secure the armrest.
Section 3. Know Your Lift Truck Parking Brake The lift truck is equipped with a Self-Activating Parking Brake (SAPB) system which consists of an electromagnetic (EM) brake attached to each drive motor. They are controlled by the traction controller. During normal operation, the EM brakes are disengaged to allow the drive motors to turn freely.
Operator Presence System The Operator Presence System (OPS) consists of a safety switch located in the bottom of the operator's seat. It determines if the operator is seated correctly while operating the lift truck. The operator must sit in the seat to travel or use the hydraulic controls. If the operator is not in a correct seating position, both travel and hydraulic operations are interrupted.
A new data plate is required whenever modifications are made to the lift truck that may affect capacity, such as adding an attachment. Contact your authorized CLARK dealer for an updated data and capacity plate showing the correct capacity.
Decals Decal Locations ASSEMBLED IN BATTERY MAXIMUM HOUR AMP HOUR CAPACITY RATE BATTERY COMPARTMENT DIMENSIONS Do not operate this truck unless you have been Travel with lifting mechanism as low as possible and Do not handle loads which are higher than the load authorized and trained to do so, and have read all tilted back.
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Section 3. Know Your Lift Truck Safety Decals Name Description View The operator safety Do not operate this truck unless you have been Travel with lifting mechanism as low as possible and Do not handle loads which are higher than the load authorized and trained to do so, and have read all tilted back.
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Safety Decals Name Description View The battery cleaning decal warns the operator Battery to not allow the battery Cleaning to be exposed to pressurized water when cleaning or operating. The fork safety decals show the risk of serious Fork injury or death when Safety the forks are in a raised position.
Display Overview Dash Display – 1. Menu Buttons 11. Battery Status 2. Speedometer 12. Braking Level 3. Brake Pedal 13. Lift Limit (NOT USED) 4. Accelerator 14. Accelerator Position 5. Truck Position 15. Travel Direction 6. Steer Position 16. Fault Information 7.
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Section 4. Operating the Display Menu Buttons Name Function Button Press the UP button to change the operating mode (default) or the speed mode (if enabled). Up Button When in the menu, press the UP button to move to a higher menu level. Press the DOWN button to change the acceleration mode (if enabled).
Icons Icons Name Description Icon The speed icon shows the lift truck's Speed travel speed. The battery icon shows the remaining Battery battery charge percentage. The battery charge icon shows the remaining battery charge level. Each increment on the icon is equal to approximately 10% of total battery charge.
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Section 4. Operating the Display Icons Name Description Icon The truck position icon shows the Truck Position direction of travel in 360 degrees while operating the lift truck. The fault icon is shown when a controller Fault fault has occurred. The fault information icon is displayed when an alarm (error) has occurred.
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Icons Name Description Icon The low battery icon is displayed when the battery charge level is low and the lift truck is in battery protection mode. Mode L1: hydraulic lift function is disabled. Mode L2: hydraulic lift function is Low Battery disabled, travel speed is limited to the primary cutback.
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Section 4. Operating the Display Icons Name Description Icon The brake pedal position icon shows the position (not engaged to fully engaged) when the operator presses on the brake pedal. Brake Pedal Grey: no braking amount applied Position Green: low braking amount applied Orange: medium brake amount applied Red: high brake amount applied The hydraulic speed icons show the...
Traction Controller (left) WARNING If a service alarm (controller error) occurs, immediately stop operation of the lift truck and contact your supervisor or CLARK dealer. Do not operate a faulty or damaged lift truck. Entering the Menu • Press the ENTER button twice (2x) to show the password screen.
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Section 4. Operating the Display Main Menu Descriptions Name Description View DISPLAY EP 5.4 >> DISPLAY EP 5.4 >> The display menu allows for a Parameter Set Record technician to adjust dash display Set Password and other operating features. Display Refer to the Service Manual for additional information.
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Main Menu Descriptions Name Description View A0MP2BCPTVEP1.11 >> A0MP2BCPTVEP1.11 >> Parameter Change Set Options Set Model Adjustment The pump controller menu allows Special Adjust the technician to adjust settings, Hardware Setting enable and disable options, teach Program VACC (learn) sensors, and view real-time Tester Pump readings related to the hydraulic...
Section 4. Operating the Display Operator Settings Operator Settings Name Description Menu Operation Allows for adjustment of the display brightness level, use Brightness Adjusted Using Menu Buttons the PLUS (3) and MINUS (4) buttons. Allows for the acceleration Adjust Performance Mode mode and speed mode to be Performance adjusted separately by the...
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Operator Settings Name Description Menu Operation Adjust Password Enable If enabled, requires a password Password to be entered before operating DISPLAY → PARAMETER SET → Enable the lift truck. PASSWORD ENABLE → OFF or ON Allows the technician to adjust Adjust Charge Soon Mode Charge at what battery charge level...
Before Operating the Lift Truck IMPORTANT! Read the Operator’s Manual before operating the lift truck. WARNING • Safe operation is always the responsibility of the operator! • The operator must be trained and authorized to operate this lift truck. • Only operate the lift truck in a safe and controlled manner.
Section 5. Operating Your Lift Truck Safe Operation Look where you are going... Check that your intended path of travel is clear of obstacles and pedestrians. Watch for other personnel, lift trucks, and any other obstructions in your path of travel and work area. Do not rely on your lift trucks warning lights or alarms to alert others while operating your lift truck.
Forks and Upright Positioning the Forks for Traveling When traveling with or without a load, it is recommended to have the forks slightly raised and the upright tilted back. This helps prevent the fork tips from catching on the ground or debris while traveling.
Section 5. Operating Your Lift Truck Load Handling Overview • Always handle loads that are at or below the lift truck’s rated capacity. The rated capacity can be found on the capacity and data plate. This rating specifies the maximum load that should be lifted.
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Traveling with a Load • Always travel with the load as low as possible and the upright tilted back. Do not travel with a raised load. Do not attempt to raise the load except when stopped or stacking. • Know and follow all traffic rules and regulations for your work area. Look and be aware of other vehicles, personnel, and other obstacles.
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Section 5. Operating Your Lift Truck Stacking a Load Step Procedure View Drive forward slowly while aligning the load squarely with the stack Raise the load as the lift truck approaches the stack. Drive forward slowly until the load is almost touching the stack. The leading edge and sides of the load pallet should be lined up with the near edge and side of the load or...
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Stacking a Load Step Procedure View Lower the forks slightly to disengage the load pallet. Tilt the forks slightly forward, if needed to clear the pallet. Check for nearby personnel and obstructions, then carefully move backward until the forks are clear of the stack.
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Section 5. Operating Your Lift Truck Unstacking a Load Slowly approach the stack with the lift truck lined up squarely with the load. When near the stack, tilt the upright to the vertical position. Raise the forks high enough to freely engage the load pallet. Adjust fork angle as necessary to position the forks squarely under the load.
Braking Normal Braking The braking system for the lift truck is electronically controlled. When the brake pedal is depressed while traveling, the drive motor direction is reversed and the lift truck slows down. Stopping the Lift Truck Push down firmly on the brake pedal until the lift truck comes to a stop.
Section 5. Operating Your Lift Truck Parking Parking the Lift Truck Step Procedure View Stop the lift truck. Put the directional control in neutral. Lower the upright to the ground. The lift truck is equipped with a Self-Activating Parking Brake. Turn the key switch OFF.
Section 6. Maintaining Your Lift Truck Contents Safe Maintenance ..................70 Operator's Daily Checklist ..............71 Daily Inspection ..................72 Cleaning ....................74 Planned Maintenance ................75 Forks and Lift Chain ................77 Wheels and Tires ..................79 Lithium-Ion Battery .................. 80 WARNING THIS SECTION IS INTENDED FOR SERVICE TECHNICIANS ONLY! The following information is to be used as a reference for determining your lift truck's...
13. All batteries, motors, controllers, switches, protective devices, electrical conductors and connections must be inspected and maintained. 14. Refer to the manufacturer's (CLARK) procedures for replacing battery contacts to avoid injury or damage to the equipment. 15. Lift trucks must be kept clean to minimize the risk of fire and to aide in the detection of damaged or defective parts.
Engine (IC) (rough idle, noisy, leaking) Auxiliary (loose, binding, operation) Description of Problem(s): 59-770-2937 NOTE CLARK has prepared an Operator's Daily Checklist to assist you in performing and documenting your daily inspections. This form is available from your CLARK dealer. Operator's Daily Checklist...
Daily Inspection Every 8-10 Daily Inspection Overview Explanation Hours (Daily) CHECK Obvious damage ● Fluid leaks ● Drive and steer tires ● Capacity plate and warning decals ● Load backrest and attachment ● Upright and lift chains ● Overhead guard ●...
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Section 6. Maintaining Your Lift Truck Visual and Operational Inspections Lift Truck Exterior • Check for obvious damage, fluid leaks, or other maintenance issues. • Check that all safety, capacity, and warning plates and decals are attached and legible. Wheels and Tires •...
Cleaning Cleaning Rules Always maintain a clean lift truck. Do not allow debris or contaminants to accumulate on the lift truck. Clean any excess or leaking grease and oil before operating the lift truck. Before attempting to clean the lift truck, all efforts to prevent shorting (arcing) of the electric circuits must be completed.
PM table are for normal operation. For severe or extreme operation, the maintenance intervals should be shortened to ensure optimal lift truck performance and reliability. Contact your authorized CLARK dealer if you have questions regarding the recommended service intervals for your specific application.
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Every 450-500 Every 900- Every 2000 PM Service Intervals Hours 1000 Hours Hours (6 Months) (12 Months) (Yearly) CHECK Wheel fastener torque ■ Drive and steer axle oil level ■ Hydraulic fluid level ■ Drive and pump motors ■ Lift chain stretch and wear ■...
Section 6. Maintaining Your Lift Truck Forks and Lift Chain Fork Inspection Inspect the load forks for bending and wear: • The top surfaces of the forks should be level with each other. • If the height difference between the fork tips is greater than 1.5% of the blade length (A), then the forks must be replaced.
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Lift Chain Inspection and Lubrication During normal operation, inspect and lubricate the lift chains every 450 to 500 hours. If operating in a corrosive or extreme working condition, inspect the lift chains more frequently. Be sure to check for the following: corrosion, cracked plates, raised or turned pins, tight joints, excessive wear, and worn pins and holes.
Section 6. Maintaining Your Lift Truck Wheels and Tires Inspect the drive and steer wheels and tires every day before operating the lift truck. Do the following when inspecting the wheels and tires: • Inspect the tires for excessive wear. Replace if needed. •...
Lithium-Ion Battery Battery Safety DANGER Do not keep a battery in service that has been damaged or submerged in water. DANGER Do not allow the battery near any open flames, sparks, or electrical arcs. If a lithium-ion battery fire occurs, immediately evacuate the work area. Only use Class D, CO , dry chemical, or foam-type fire extinguishers that are intended for lithium-type battery fires.
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Section 6. Maintaining Your Lift Truck Battery Handling When moving, installing, or removing the battery, do the following: • Ensure the service area is equipped with the proper tools designed for moving industrial batteries, such as a conveyor or overhead hoist. •...
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Battery Removal and Installation Removing and Installing the Battery: Park the lift truck. Turn the lift truck OFF. Remove the left side panel (1). Remove the bracket (2) and the two bolts (3). Disconnect the power cables (4) and the communication cables (5).
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Battery Care Cleaning CLARK recommends to only use compressed air at less than 207 kPa (30 psi) or a slightly damp towel to clean the battery. The battery, or its charging station, may be equipped with fans, heat sinks, or other cooling devices that require periodic cleaning. Always know and follow the battery manufacturer's recommendations for cleaning and service.
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The storage area should have a temperature range of 0-40°C (32-104°F), and a maximum humidity of 85%. CLARK also recommends storing lithium-ion batteries in a raised rack or shelf that allows for protection from possible collision damage.
Section 7. Towing Contents Emergency Towing .................. 86 WARNING THIS SECTION IS INTENDED FOR SERVICE TECHNICIANS ONLY! The following information is to be used as a reference. For complete maintenance and service information, refer to the Service Manual. Contents...
Emergency Towing Disabled Lift Truck If your lift truck becomes disabled... • Safely park the lift truck and remove the key. • Attach an OUT OF SERVICE tag. • Report the issue to your supervisor or certified lift truck technician. DANGER EQUIPMENT LOCKED OUT...
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Section 7. Towing and Lowering Towing a Disabled Lift Truck: Raise and secure the upright 300 mm (12 in) off the ground. Check that the counterweight is securely mounted. Block the drive wheels. Tighten the bolts until each brake is fully released.
If the data plate is missing, damaged, or modifications have been made to the lift truck that may affect the rated load capacity or weight of the lift truck, then it must be replaced. Contact your CLARK dealer if you require a new or updated data plate. CAUTION CLARK products and their specifications are subject to improvements and change without obligation of prior notice.
TWLi20 IMPORTANT! The rated load capacities shown below are based on lift trucks equipped with a standard upright (STD) with a maximum fork height (MFH) of 3000 mm (118 in), standard forks, and a standard weight battery. Rated Load Capacity...
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15x4.5-8 Recommended Lubricants Type Part Number Specification Component CLARK Innerslide 886396 Upright Rails Lubricant CLARK Chain & 886399 Lift Chains Cable Lubricant NLGI #2 EP Upright and Carriage Rollers, Tilt General Purpose VV608 CLARK MS-107C Cylinder Ends, Upright Mounting Grease...
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Scan Link Below Safety Starts with You! OM-1206 700 Enterprise Drive Lexington KY 40510 Additional copies of this manual are available from your CLARK dealer.
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