Table of Contents OM-1205 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 / Motor Steer Axle Hydraulic Pump / Motor Traction Controller Pump Controller 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.
If you have not been certified (or need recertification) to operate or inspect your lift truck, tell your supervisor. 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/or maintain our lift trucks. We take pride in the tradition of high quality 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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Always Practice Safe Operation Incorrect lift truck operation can cause accidents. Do not operate an improperly setup, damaged, or malfunctioning lift truck. Read and understand the procedures for safe driving and maintenance described in this manual. If you have questions, ask for assistance. Stay alert and follow the rules, regulations, and procedures for safe lift truck operation.
If the lift truck you operate is not equipped with an Operator’s Manual, alert your supervisor immediately. • Your authorized CLARK dealer is ready to help and can provide you with additional information about the unique features, operation, and maintenance of your lift truck. How to Use this Manual...
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 it’s 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 while operating the lift truck and in NO SMOKING areas. DON’T operate the lift truck outdoors during poor weather conditions such as rain, snow, or ice.
Section 1. General Safety Rules Operator Protection Seat Belt Always use the seat belt. 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. Pedestrians...
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Section 1. General Safety Rules Nearby Personnel WARNING • Alway look in the direction of travel. • Always slow down and sound the horn at every intersection or area with limited visibility. • Always alert personnel to stand back while operating or parking the lift truck. •...
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...
Section 1. General Safety Rules 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 traveling. Reverse Travel •...
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 an authorized area only. • Do not block traffic. •...
Section 1. General Safety Rules 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. •...
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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. Always use your seat belt. 2.
Section 2. Operating Hazards Contents Load Handling ..................24 Collisions ....................27 Drop-Offs ....................28 Ramps and Grades .................. 29 Surface and Capacity ................30 WARNING • Always secure loose loads before handling. • Long loads decrease the capacity of your lift truck. Know and understand your lift truck’s specific load rating.
Load Handling Unbalanced Loads Do not handle uneven loads. Wide Loads Center wide loads on the forks. Loose Material Stack and band loose material. Load Handling...
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Section 2. Operating Hazards Right-Angle Stacking Avoid sharp turns and operate slowly. High Loads Do not turn sharply with a raised load. Long or Wide Loads Long or wide loads require more clearance. Load Handling...
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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, carriage, or forks hanging up. Raise the forks before moving, or damage to the chains may occur. Pallets and Skids WARNING Do not move or store material on damaged pallets or skids, this can lead to material...
Section 2. Operating Hazards Collisions Overhead Clearance WARNING • Know your overhead clearance and look for obstacles. • Colliding with an overhead structure can cause the lift truck to tipover or drop its load. • Keep the load low and tilted back. WARNING •...
Drop-Offs WARNING When operating on a dock or drop-off, do the following: • Tell the driver not to move the trailer and use the trailer brakes. • Install wheel chocks. • Use a trailer-to-dock system if available. The trailer may move unexpectedly while loading or unloading. Drop-Offs...
Section 2. Operating Hazards Ramps and Grades Unloaded Travel When Traveling Unloaded... Keep Forks Pointed Down Grade Loaded Travel When Traveling Loaded... Keep Forks Pointed Up Grade WARNING • Always look in the direction of travel. • Always ascend or descend grades slowly, and with caution. •...
Surface and Capacity SAND ROCKS WEAK FLOORS WARNING Poor conditions can cause the lift truck to lose traction when braking or traveling. WARNING Do not travel over a surface that cannot support the weight of a loaded lift truck. Know the combined (gross) weight of the lift truck and the load.
Section 3. Know Your Lift Truck Operator Controls Driving Controls The steering wheel controls Steering the position of the rear steer Wheel wheels and tires. The brake pedal controls the braking of the lift truck. Brake Pedal Press down on the brake pedal to slow or stop the lift truck.
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Driving Controls The parking brake pedal is used to engage the parking Parking brake. Brake Pedal Press down on the parking brake pedal to engage the parking brake. The release lever is used to disengage the parking brake. Release Lever Lift up on the lever to release the parking brake.
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Section 3. Know Your Lift Truck Hydraulic Controls - Standard The lift lever controls the raising and lowering of the upright. Lift Lever Pull the lever back to lift the upright. Push the lever forward to lower the upright. The tilt lever controls the vertical position of the upright.
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Hydraulic Controls - Optional The lift lever controls the raising and lowering of the upright. Lift Lever Pull the lever back to lift the upright. Push the lever forward to lower the upright. The tilt lever controls the vertical position of the upright. Pull the lever back to tilt the Tilt Lever upright backward.
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Section 3. Know Your Lift Truck Hydraulic Controls - Optional The directional switch is used to change the driving direction Directional of the lift truck. Control (If equipped) There are three positions: forward, neutral, and reverse. The emergency disconnect Emergency switch enables the operator Disconnect to immediately turn lift truck...
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Optional Controls The horn button is used to Horn Button alert nearby personnel while operating the lift truck. The directional control switch is used to change the driving Directional direction of the lift truck. Control (If equipped) There are three positions: forward, neutral, and reverse.
Section 3. Know Your Lift Truck Seat Adjusting the Seat Recline: • Pull back on the side lever (1) and lean backward or forward to position the seat back cushion. Release the lever to lock into place. Adjusting the Seat Position: •...
Steering Column Adjusting the Steering Column: • Press and hold the lock button (1) to release the steering column. • Rotate the steering column (2) up or down to the desired tilt angle. • Release the lock button (1) to secure the steering column in place. WARNING Do not attempt to adjust the steering column while operating the lift truck.
Section 3. Know Your Lift Truck Hood Raising the Hood: • Rotate the steering column fully forward. • Pull the latch (1) out to release the hydraulic controls, and then rotate the lever assembly fully forward. • Push the release lever (2) up to release the hood. •...
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 plate showing the correct capacity.
Decals Decals IMPORTANT Read the manual Buckle up! Apply brake when leaving truck Watch Out For Other People IMPORTANT Most lift truck INJURIES are to other people near the lift truck. Prevent Overturns! AVOID : • slippery, sloping, or uneven surfaces •...
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Section 3. Know Your Lift Truck Safety Decals The operator warning Operator decal describes how to Warning safely operate and park the lift truck. Prevent Overturns! In Case of Tip-Over: Don't WARNING Watch Out jump For Other Read the AVOID : People manual The tipover safety decal...
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Safety Decals The fork safety decals show the risk of serious Fork injury or death when Safety the forks are in a raised position. The upright safety decal warns of the risk of serious injury when Upright placing body parts Safety between the moving components of the...
Section 4. Operating the Display Contents Overview....................48 Icons and Indicators................50 Menu ......................54 Contents...
Overview Dash Display Battery Level Fault Indicator Model Menu Buttons Travel Speed Hour Meter Speedometer Travel Direction Parking Brake Indicator Clock Seat Indicator Performance Mode Battery Type Overview...
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Section 4. Operating the Display Menu Buttons Press the MENU button to enter Menu MENU Mode. (DOWN) When Menu Mode, press the MENU Button button to return to the previous screen. ENTER Press the ENTER button to enter a menu. (UP) When in Menu Mode, press the ENTER button to enter a menu or save a value.
T221: PARK BRAKE Alarm name are shown in a new window. IMPORTANT! If a controller service alarm occurs continuously, stop operation of the lift truck and contact your CLARK dealer for assistance. Icons and Indicators...
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Section 4. Operating the Display Icons The battery level icon shows the remaining battery charge. Each increment on the icon Battery Level is equal to 10% of total (NORMAL) battery charge. The battery charge level is considered NORMAL when it is greater than 20%.
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Icons This clock icon shows the Clock current time. km/h The speedometer icon Speedometer shows the lift truck's travel speed. 2345 kg The load weight icon Load Weight displays the weight of the (If Equipped) current load. 12345 The hour meter icon shows Hour Meter the total operating hours of the lift truck.
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Section 4. Operating the Display Indicators The parking brake indicator is Parking Brake illuminated when the parking brake is engaged. The fault indicator is illuminated if a Fault controller alarm has occurred. The seat switch indicator is Seat illuminated when the lift truck is Switch ON and the operator is improperly sitting in the seat.
STATUS submenu. The remaining submenus are accessed using the service password and are intended for technician use only. If the service password is required, then refer to the Service Manual or contact the CLARK Service Department for assistance. Menu Descriptions •...
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Section 4. Operating the Display Menu Level Name Description STATUS-TRACTION BATT. VOLT. Battery voltage level. BATT. CHARGE Battery charge level. MOTOR VOLT. Traction motor voltage. FREQUENCY Traction motor frequency. MEASURED SPEED Traction motor speed. CURRENT RMS Traction motor current. CONTROL TEMP. Traction controller temperature.
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Menu Level Name Description 2.14 B5-AUX3 CLL PB Clamp lever lock push button switch status. 2.15 SEAT FROM TRAC. Speed limit switch status. 2.16 B11-MAST SWITCH High mast switch status. 2.17 B3-PRESS. SENSOR Load weight sensor voltage. 2.18 B4-SEAT BELT SW Seat belt switch status.
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Section 4. Operating the Display Menu Level Name Description 3.2.5 LOWER ADDER Adjust lower adder value. DISPLAY PARAMETER 3.3.1 TURTLE BUTTON Enable or disable the low speed (turtle) button. PERFORMANCE 3.3.2 Enable or disable the performance mode button. BUTTON MODEL SETUP EPX FL SEC20/35 4.2.1...
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Menu Level Name Description CLARK LOGO Enable or disable the logo at startup. LOAD WEIGHT SETUP LOAD WEIGHT View the current weight of the load. SET REF. WEIGHT Adjust the reference load weight. UNLOADED-1ST Adjust the base point weight when in free lift.
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 raised slightly and the upright tilted back. This helps prevent the fork tips from catching on the ground or debris while traveling.
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Section 5. Operating Your Lift Truck Adjusting the Forks The forks are adjustable on the carriage. When carrying a load, the forks should be spaced as far apart as possible. Position each fork an equal distance from the center of the carriage. Raise the carriage so that the forks do not contact the ground.
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 lift truck’s data plate. This rating specifies the maximum load that should be lifted. However, other factors such as using a special attachment, handling loads with a high center of gravity, or traveling over uneven surfaces may reduce the safe working load to be less than the rated capacity.
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Section 5. Operating Your Lift Truck 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. •...
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Stacking a Load Drive forward slowly while Step 1 aligning the load squarely with the stack Raise the load as the lift truck Step 2 approaches the stack. Drive forward slowly until the load is almost touching the stack. Step 3 The leading edge and sides of the load pallet should be lined up with the near edge...
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Section 5. Operating Your Lift Truck Stacking a Load Stop close to the stack and raise the load high enough to clear the top surface of the stack. Position the load slowly so that it aligns with the load or rack beneath it.
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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.
Section 5. Operating Your Lift Truck Braking Normal Braking The service braking system for the lift truck is both mechanically and electronically controlled. When the brake pedal is depressed while traveling, the drive motor torque direction is reversed and the lift truck slows down. The service drum brakes are also engaged and slow the rotation of the front drive wheels.
Parking Parking the Lift Truck Stop the lift truck and put the directional control in neutral. Step 1 Lower the upright to the ground, and then tilt the upright fully forward. Press down on the parking brake pedal until fully depressed. Step 2 The icon on the dash display will illuminate when the parking...
Fuses ......................82 Battery ...................... 84 WARNING The following information is intended as a reference when determining your lift truck's specific planned maintenance (PM) schedule. For complete maintenance and service information, refer to the service manual or your CLARK dealer. Contents...
13. All batteries, motors, controllers, switches, protective devices, electrical conductors, and connections must be inspected and maintained. 14. Refer to the OEM manufacturer's (CLARK) procedures for replacing battery connections 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, make sure to prevent shorting (arcing) of the electric circuits. Your specific operating environment determines the amount and extent of cleaning required for your lift truck.
Operator's Manual are for normal operation only. For severe or extreme operation, the maintenance interval 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 lift truck 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 axle fluid level ■ Hydraulic fluid level ■ Brake fluid level ■ Battery electrolyte level ■ Drive and pump motors ■...
Section 6. Maintaining Your Lift Truck Forks and Lift Chain Fork Inspection Inspect the 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. •...
Fuses The lift truck is equipped with two fuse boxes and two main fuses. The front fuse box is located behind the cowl and is accessed by removing a cover plate labeled FUSE BOX. The rear fuse box is located in the rear of the lift truck and is accessed by removing the rear counterweight cover.
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Section 6. Maintaining Your Lift Truck Rear Fuse Box Rear Fuse Box Number Description Rating Number Description Rating FR-1 Traction - Positive In FR-6 Accelerator FR-2 Pump - Positive In FR-7 Backup / Travel Relay FR-3 Controller Fans (if equipped) FR-4 Power Jack / USB FR-8...
Battery Battery Service Area The industrial battery service area must be in a location dedicated for that purpose. The area must be free of all nonessential combustible materials. The battery service area must have the following: • Ability to clean and properly dispose of spilled electrolyte solution. •...
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Section 6. Maintaining Your Lift Truck Battery Handling When removing or installing 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 Care Cleaning The recommended method of cleaning a lead-acid industrial battery is to use a solution of baking soda dissolved in water and rinsed using a low pressure spray of cool, clean water. After cleaning, apply an appropriate protectant to the terminals and cable connections to prevent corrosion.
Emergency Towing 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. Disabled Lift Truck If the lift truck becomes disabled... •...
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Section 7. Towing and Lowering Safe Towing Rules: • Do not tow on a grade or if ground conditions are poor. • If using another lift truck to tow, make sure it is of equal or greater size and carrying a partial load to ensure adequate traction.
Emergency Lowering Lowering the Upright (Standard) The lift section of the hydraulic control valve is equipped with an override release which, during an emergency or failure situation, can be used to safely lower the upright. Loosen the lock nut securing the release screw. Loosen the release screw approximately one-half (1/2) a turn.
Section 7. Towing and Lowering Transporting Transporting the Lift Truck The lift truck is equipped with four (4) integrated tie down points that are to be used whenever shipping or transporting the truck. IMPORTANT! In accordance with USDOT 49 CFR § 393.130, when transporting a lift truck that weighs 10,000 lb (4536 kg) or more, it must be restrained using the four (4) tie down points specifically designed for that purpose.
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.
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21 x 7 x 15 16 x 6 x 10.5 Electric / Non-Marking SEC20-32 21 x 8 x 15 16 x 6 x 10.5 Electric / Non-Marking SEC35 22 x 9 x 16 16 x 7 x 10.5 Electric / Non-Marking SEC20-35...
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VV70202 Recommended Lubricants Type Part Number Specification Component CLARK Innerslide 886396 Upright rails Lubricant CLARK Chain & 886399 Lift chains Cable Lubricant Upright and carriage rollers, tilt NLGI #2 EP General cylinder pins, upright trunnion VV608 CLARK MS-107C Purpose Grease...
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Scan Link Below Safety Starts with You! OM-1205 700 Enterprise Drive Lexington KY 40510 Additional copies of this manual are available from your CLARK dealer.
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