Download
Share
Print this page
Clark OSX 15 Operator's Manual
  1. Manuals
  2. Brands
  3. Clark Manuals
  4. Forklifts
  5. OSX 15
  6. Operator's manual

Clark OSX 15 Operator's Manual

Hide thumbs

Advertisement

Quick Links

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 ; May. 2020
Battery Powered Order Picker Truck
[Do not remove this manual from the truck]
OSX 15
Part No. 8083630
Book No. OM-842 (Rev 2.6)
Jun. 2022

Advertisement

loading
Need help?

Need help?

Do you have a question about the OSX 15 and is the answer not in the manual?

Questions and answers

Related Manuals for Clark OSX 15

Summary of Contents for Clark OSX 15

  • Page 1 Battery Powered Order Picker Truck Additional copies of this manual may be purchased from YOUR AUTHORIZED CLARK DEALER [Do not remove this manual from the truck] OSX 15 CLARK MATERIAL HANDLING COMPANY Part No. 8083630 700 Enterprise Drive Lexington, Kentucky 40510 [ www.clarkmhc.com ] ●...
  • Page 3 Operator’s Warning IMPORTANT NOTICE This is the “SAFETY ALERT SYMBOL” . This symbol is used to call your attention to items or operations that could be dangerous to you or other persons using this equipment. Please read these messages carefully. It is essential that you read the instructions and safety regulations before you attempt to assemble or use this truck.

  • Page 4: Foreword

    NOTICE: The descriptions and specifications in this man- ual were current at the time of printing. CLARK Material Handling reserves the right to make improvements and changes to specifications and /or design, without notice and without incurring obligation.The examples, illustra-...
  • Page 5 Foreword Standard Compliance This truck complies with the following standards and regulation in effect on the date the truck was manufactured: • American Society of Mechanical Engineers (ASME) B56.1 • Underwriters Laboratory (UL) # 583 • Occupational Safety and Health Administration (OSHA) Dimensions and capacities The dimensions and capacities shown in this manual have been converted from their original measurements and...

  • Page 6: Table Of Contents

    Contents of this Manual Foreword ................ii Section 1. Safety Regulations ......... 1-1 Section 2. Presentation Truck......... 2-1 Section 3. Control and instruments........ 3-1 Section 4. Driving ............4-1 Section 5. Maintenance ........... 5-1 Section 6. Transporting and Storing the Truck ..... 6-1 SAFETY STARTS WITH YOU (Safety Video) 2840951...

  • Page 7: Section 1. Safety Regulations

    Safety Regulations Warning symbols Always follow the warnings given in this Operator’s Man- ual and on the truck to avoid accidents from occurring. Warning levels Warning text is given in four levels and provides information on the risks, describe the consequences, and instruct how to avoid accidents.
  • Page 8 Safety Regulations General • Do NOT operate or work on this truck unless trained, qualified, and authorized to do so and have read the Operator's Manual. • Know the truck controls and what they do. • Do NOT operate truck if it needs repair or if it is in any way unsafe.
  • Page 9 Safety Regulations Operate truck from t • Operate truck from the posi- tion of the Operator. • Before working on this truck, always turn the key switch to OFF and disconnect truck’s battery connector (unless this manual states otherwise). • Do NOT wear watches, rings, or jewelry when working on the truck.
  • Page 10 Safety Regulations he position of the t • Follow exactly the safety and repair instructions this manual. Do NOT take "short- cuts". • Do NOT use an open flame near the truck. • Do NOT use gasoline or other flammable liquids for cleaning parts.
  • Page 11 Safety Regulations • Always operate and park truck indoors. • Do NOT wash truck with a hose. • Do NOT add to or modify truck without wrtten approval from the company.
  • Page 12 Safety Regulations Battery Safety WARNING As a battery is being charged, an explosive gas mixture forms within and around each cell. If the area is not prop- erly ventilated, this explosive gas can remain in or around the battery for several hours after charging. Be sure there are no open flames or sparks in the charging area.
  • Page 13 Safety Regulations • Make sure a shower and eye- wash station are nearby in case there is an accident. • A battery gives off explosive gases. Never smoke, use an open flame, or use anything that gives off sparks near a battery.
  • Page 14 Safety Regulations • Do NOT lay tools or metal objects on top of the battery. A short circuit or explosion could result. • Keep batteries clean. Corrosion causes shorts to the frame and possibly sparks. • Keep plugs, terminals, cables, and receptacles in good con- dition to avoid shorts and sparks.
  • Page 15 Safety Regulations • Never plug a battery charger into the truck’s battery con- nector. Plug battery charger into the battery con- nector from the battery. • Follow the charging proce- dures in the "Battery Instruc- tion Manual" and in the "Battery Charger Instruction Manual".
  • Page 16 Safety Regulations Alway Warning and information decals The figure below shows the position and significance of the decals location on the truck. 1. Decal - Fork Safety 7. Decal - Wiring Schematic 2. Decal - Hand Safety 8. Label - Warning 3.
  • Page 17 • You must replace a decal if the decal is damaged, missing, or cannot be read. • If a decal is on a part that is replaced, make sure you install a new decal on the new part. New warning decals can be obtained from your CLARK dealer. 1-11...

  • Page 19: Section 2. Presentation Truck

    Different speeds can be set. Application area for CLARK order picker trucks CLARK trucks are solely designed and manufactured to han- dle goods. This truck should be fitted with the appropriate accessories relevant to the application.
  • Page 20 Presentation of truck Truck Dimensions 1013mm Platform Width 1210...
  • Page 21 Presentation of truck 1 Manufacturer CLARK CLARK s ' r i t a y t i 4 Load Center Fork Face to Load CG in(mm) 24 (600) 24 (600) c i r t l o t l o 6 Operator Type...
  • Page 22 Presentation of truck Data plate Know the rated capacity on the data plate and understand areas 1 through 16 as shown in the illustration. 1. Truck model name 2. Truck type (E or EE) 3. Truck serial number 4. Attachment 5.
  • Page 23 Presentation of truck Main components...
  • Page 24 Presentation of truck 1. Driver controls: The steering wheel, instrument panel, and switches (key, emergency stop, and light/fan cluster) are on the console cover. The travel speed and direction, hydraulic function, and horn are controlled through the control handle. 2. Steering wheel: Steers the truck in the direction of travel.
  • Page 25 Presentation of truck 12. Travel speed / direction selection: To select direction, rotate in the desired direction to travel. The further you rotate in that direction the faster you travel. 13. Mast: The mast is a clear view model. 14. Hydraulic unit: Pump motor and pump are an integrated unit.

  • Page 27: Section 3. Control And Instruments

    Controls and instruments Controls and instruments Guards and shields have been provided on the unit for your protection. WARNING DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place. Decals are also provided to warn of potential danger as well as to display special operating procedures.
  • Page 28 Controls and instruments The primary design of the Dash Display is to provide the oper- ator with an easily understandable, visual feedback of the sta- tus of the truck and it's system components. 1. Battery discharge Indicator 2. Slow-speed icon (Turtle shaped) 3.
  • Page 29 Controls and instruments Seat Belt : At start up this symbol displays along with an audio alarm for 4 seconds. This display reminds you to fasten your seat belt. Parking Brake : The symbol is displayed and "-01" status code appears on the numeric display when parking brake is applied.
  • Page 30 Controls and instruments Message display The model name, POWER selection, OSX15 Normal travel direction, warning and error mes- Error sage are displayed. OSX15 Warning BATTERY LOW • In normal operating condition: Model name / POWER / Travel direction. When several messages are simultaneously displayed, they will be displayed in the order of Error, Warning and Normal condition.
  • Page 31 Controls and instruments MODE SELECTION BUTTON • 6 mode selection buttons are located on the right side of the LCD. • Each button has a specific function, and some have multiple functions. Down arrow button (Mode button) 1. Pressing this button in normal operating condition, it will move to Menu mode.
  • Page 32 Controls and instruments Up arrow button (Enter button) 1. Pressing this button, it will move to the upper menu. 2. It will also take the role of an "Enter" button when confirming a changed password or main parameter. Left arrow button (Left selection button) 1.
  • Page 33 Controls and instruments Plus(+) button 1. Increase the data value in the current Menu mode. Minus(-) button 1. Decrease the data value in the current Menu mode. Controls and instruments Code Condition Likely Corrective Action -061 -065 Overheat of -140 motor and con- Restart after cooling down -203...
  • Page 34 Controls and instruments Emergency Stop Switch Key Switch Lamp Switch Lift and Lower Spinner Control Handle (travel speed / direction) Steering Wheel Display Panel Horn Switch Emergency stop The truck is fitted with an emergency stop button which is located to the right of the key switch on the control console. Pressing the emergency stop will cut the control power supply.
  • Page 35 Controls and instruments Battery disconnect In an emergency, first push the emergency stop to OFF. This will disable electrical controls. Then disconnect the battery connector, this will cut all electrical power to the truck. Perform all repairs before reconnecting the battery. Key switch The key switch is the main power switch for the control circuit.
  • Page 36 Controls and instruments Stopping is accomplished by two methods. The preferred method, plugging, is achieved by moving the control handle through neutral to the opposite direction of travel. The further the control handle is moved in the opposite direction, the faster the truck will slow.
  • Page 37 Controls and instruments Hydraulic controls Forward Lift Lower Reverse Horn The lift and lower forks thumb knob is on the end of the control handle. Rotating the thumb knob up will lift the forks and rotat- ing the thumb knob down will lower the forks. NOTE No hydraulic functions can be used if the key switch is in the OFF position or if the operator has not...
  • Page 38 Controls and instruments Switches - Lamps and fans Switches for the lights and fan are located on the control con- sole for easy operator access. Reading Work Lamp Lamp Switch Switch Switch Reading Lamp Work Lamp 3-12...
  • Page 39 Controls and instruments Brake pedal Place your foot on the brake pedal to release the brake. Brake pedal WARNING Risk of crushing exists if any part of the body is out- side of the operator’s compartment. Always have your entire body inside the operator’s comparaat- ment.
  • Page 40 Controls and instruments Hydraulic manual release valve NOTE The operator should stay on the platform. Another qualified person in the area should manually release the valve. This truck is equipped with a hydraulic manual release valve located on the hydraulic control valve. When electrical functions do not operate, the platform can be lowered man- ually.
  • Page 41 Controls and instruments Pallet clllet clamp foot pedal controls This pallet clamp only works on pallets with a center brace. The pallet clamp control is used to secure a pallet to the plat- form. The pallet clamp jaws are physically located between the forks on the platform.

  • Page 43: Section 4. Driving

    Driving Driving There are certain hazards that cannot avoided solely by mechanical means in the everyday use of mate- Travel rial handling trucks. Only intelligence, good sense, and care of the operator, along with proper mainte- nance, will assure that the trucks are operated properly.
  • Page 44 Driving Starting the truck • Make sure both battery stops are securely in place and the battery cannot move more then 0.5 inch (12.7 mm) in any horizontal direction. • Connect the battery to the truck. • Put the safety harness on and adjust the straps per the man- ufacturers instructions.
  • Page 45 Driving WARNING Always complete the daily operator’s checks before starting the day’s work. WARNING Accidents can occur. Always drive with care, good judgment, and responsibility. • To stop the lift truck in an emergency, release the brake pedal immediately. Releasing the pedal disables travel and applies the parking brake to stop the lift truck in the shortest possible distance.
  • Page 46 Driving Refer to “Travel / Direction control handle” on page 3.10 for detailed information on this method. The second stopping method is achieved by releasing the brake pedal. Refer to “Brake pedal” on page 3.14 for detailed information. Steering The steering signal is transmitted to an electric steering motor mounted in the motor compartment.
  • Page 47 CS type Hydraulic oil EQUMS46 III (S-OIL) Gear oil 75W-90 class oil Also, hydraulic hoses have excellent performance in low tem- peratures. When replacing then, please used genuine CLARK parts for optimum operation.
  • Page 48 Driving Electrical components and rust proofs specs Due to the temperature difference, moisture in the connectors of all wiring can cause corrosion. To prevent this, electrical grease has been applied. In addition, in the cable connection unit, silicon is applied to prevent corrosion caused by the same moisture.
  • Page 49 Driving CAUTION 1. Prior to the works in a freezing storage, operate your vehi- cle outside for more than 10 minutes. 2. A charger must be installed outside a freezing storage. 3. Do not exceed the max permitted hours of operation in a cold / freezer storage area.
  • Page 50 Driving Transporting loads General The weight of the load should be within the truck’s permitted lifting capacity. See “Data plate” on page 2.4 WARNING Risk of overturning. The lifting capacity is reduced if additional equipment is attached to the truck. Always check the truck data plate for the truck’s overall lifting capacity.
  • Page 51 Driving WARNING Risk of overturning. A truck can overturn when attempting to turn on an incline. Never operate a truck on an incline. Use of Pallets on Lift Trucks When a pallet is used for order picking, the attached pallet is not a work platform, but rather a place to temporarily set mate- rials being retrieved or stored.
  • Page 52 Driving Wire Guidance System(WG) - Option LED Indicator Backward (Load) Smart Antenna Front (Drive) Smart Antenna 4-10...
  • Page 53 Driving Wire Guidance system description 1. The system is Automatically configured as the truck passes over the in-floor rail (wire) along which the vehicle is to be guided. The antenna installation will recognize the wire at the beginning and end. Rail (travel area) Wire Guidance system truck with smart antenna...
  • Page 54 Driving Wire Guidance system operating component description. Operator Truck Control Action Response Foot Switch ON/OFF Foot Switch OFF (With Optional wire guidance) Guide Location of Switch Wire Foot Switch ON Truck “Alignment” on guide wire – steering is automatic. LED Indicator LED indicator is (Flashing or Always ON) Flashing :...
  • Page 55 Driving Operator Truck Control Action Response Front (Drive) Smart Antenna Backward (Load) Smart Antenna Refer to 4.14 page Refer to 4.14 page “Wire Guidance “Wire Guidance system operat- system operat- ing description” ing description” Smart Antenna (Drive and Load) 4-13...
  • Page 56 Driving Wire Guidance system operating description 1. This is the “Approach” condition view. FORWARD (DRIVE) Rail (travel area) BACKWARD (LOAD) Guide wire 45 deg. Approach angle. Figure 1 1). Forward conditions.  Wire guidance Foot Switch : Closed (ON)  Truck Speed : Max 1.0 mph (0.45 m/s) Truck speed controlled by operator.
  • Page 57 Driving 2. This is the “Inside Wire Guidance Field” condition view. FORWARD (DRIVE) Rail (travel area) BACKWARD (LOAD) Guide wire 45 deg. Approach angle. Figure 2 1). Forward conditions.  Wire guidance Foot Switch : Closed (ON)  Truck Speed : Max 1.0 mph (0.45 m/s) Truck speed controlled by operator.
  • Page 58 Driving 3. This is the “Rotate to Alignment” condition view. Rail (travel area) FORWARD (DRIVE) BACKWARD (LOAD) Guide wire 45 deg. Approach angle. Figure 3 1). Forward conditions.  Wire guidance Foot Switch : Closed (ON)  Truck Speed : Max 1.0 mph (0.45 m/s) Truck speed controlled by operator.
  • Page 59 Driving 4. This is the “Alignment” condition view. Rail (travel area) FORWARD (DRIVE) BACKWARD (LOAD) Guide wire Figure 4 1). Forward conditions.  Wire guidance Foot Switch : Closed (ON)  Truck Speed : Full speed (Max) defined as truck full speed in aligned position.
  • Page 60 Driving Wire Guidance system error condition. ERROR TRUCK DESCRIPTION STEERING CODE CONDITION Manual control by operator or Opera- When the truck is tor has no control Continue entering wire. (According to truck position) When the truck has been taken away Truck stop (smart antenna after Manual control...

  • Page 61: Section 5. Maintenance

    Maintenance Daily service / safety checks • The operator is responsible for the daily service and care of the truck. • Carry out the daily service at the start of the each day or shift, before the truck is used. The daily service is a simple safety and function control check indicated in the list below.
  • Page 62 Your truck may have been fitted with Special equip- optional or special equipment that ment (i.e. travel requires a routine check to ensure alarm, lights, wire safe operation. Consult with your guidance, etc.) supervisor and CLARK representative about routine checks.
  • Page 63 • Only use CLARK approved spare parts when service and repair work are carried out. • Contact your CLARK dealer to setup a service and mainte- nance agreement to ensure the truck is operating properly. Safety regulations with maintenance work •...
  • Page 64 Maintenance WARNING Short-circuiting/burns. When working with truck’s electrical system, short circuiting/ burns can occur if a metal object comes into contact with live electrical connections. Remove watches, rings, or other types of metal jewelry. • Always switch OFF the truck’s power supply before opening the covers on the drive unit or electrical systems.
  • Page 65 Maintenance Only fill the hydraulic system with new, clean oil which meets cleanliness specification See "Lubrication chart" on page 5.15. Contact your CLARK representative for assistance or more information. STEEL TANK PUMP VALVE BREATHER FILTER WARNING The hydraulic system and hydraulic components can be damaged if the oil is contaminated.
  • Page 66 Maintenance Maintenance work that can be carried out by the driveronnel The Daily service / Safety checks as set out in the check list. Maintenance points with intervals 1 day, 1 week, and 1 month as set out in the Maintenance chart may be carried out by the driver without more knowledge than that provided by the Oper- ator’s Manual.
  • Page 67 Maintenance Cleaning and washing General Cleaning and washing of the truck is important to ensure the truck will operate safely and reliability. NOTICE Risk of short circuiting. The electrical system can be damaged. Disconnect the battery before washing by pulling out the battery connector. Do not spray water directly into the electrical compartments of the truck.
  • Page 68 Manitenance NOTICE Risk of short-circuiting. The electrical system can be damaged. Electrical components must not be cleaned with a high pressure washing unit. Electrical components • Blow electric motors dry using compressed air. WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi (206 kPa) and then only with effec- tive chip-guarding and personal protective equip- ment.
  • Page 69 Maintenance Maintenance chart Picture for maintenance chart...
  • Page 70 Maintenance Planed Maintenance Interval: A=10 Hours or 1 Day E=1000 Hours or 6 Months B=50 Hours or 1 Week F=2000 Hours or 12 Months C=150 Hours or 1 Month G=4000 Hours or 36 Months D=500 Hours or 3 Month Action A B C D E F G Chassis Check that truck’s data plate is leg-...
  • Page 71 Maintenance Action A B C D E F G Check for noises Check the mounting bolts Change oil (Initial 150-350 hours) Wheels Remove string and debris Check drive wheel wear and nuts Check that the support arm wheels rotate and axles are fitted correctly Check support arm wheels for wear Dismantle and lubricate the sup-...
  • Page 72 Maintenance Action A B C D E F G Check connections and routing of harness Warning light Battery Check the electrolyte level 1/4 inch [10-15 mm] above cell plate Check the connections on battery, truck and charger Check cell and pole guard Check the fluid density and tem- perature Check power cables are not cut or...
  • Page 73 Maintenance Action A B C D E F G 10.0 Upright and platform 10.1 Check for damage and cracks Check upright mounting bolt 10.2 torque 10.3 Check for play on the rollers Check the electrical limit switch 10.4 function Check for wear and stretch on the 10.5 chains and sheaves Check hoses and couplings for...
  • Page 74 Maintenance Action A B C D E F G 14.0 Safety harness and tether 14.1 Check for wear or damage 15.0 Decals 15.1 Check that all decals are readable X 5-14...
  • Page 75 Maintenance Lubrication chart Interval/Running hours Lubr- Pos. Service point icant 1000 h 2000 h 4000 h Wheel bearings Upright Beam Lifting chains Hydraulic system Brake Steering bearings Gear ring Drive Motor shaft,spline 5-15...
  • Page 76 C=Check O=Oil change Approved oils and grease 1) Grease - Bearong and bushing ; CLARK spec. MS-6 or MS-107C (Lubricant A) - Mast rails ; In accordance with CLARK #3762516 (Lubricant E) - Drive motor shaft, spline ; Kluberflex BEM34-132...
  • Page 77 Maintenance Environmental Definitions Trucks parked in ambient temperature Standard area when not in use and charging and maintenance work. Where a damp, wet, or corrosive condition Corrosion exits. Trucks completely dry prior to entering the continuous-stay in the cold store. Park inside cold storage for operator Cold Storage breaks.

  • Page 79: Section 6. Transporting And Storing The Truck

    Transporting and Storing the Truck Moving a disabled truck WARNING Be sure to remove the brake release bolts from the brake and return to their storage location before operating truck again. To safely move a disabled truck. Brake 1. Lower the operator plat- form and remove any load.
  • Page 80 Transporting and Storing the Truck Hydraulic system Change the oil in the hydraulic system when stored for peri- ods longer than 1 year, see the oil specification in the “Lubrication chart” on page 5.15 Drive unit Block up the truck’s drive section to take the load off the drive wheel and load wheels when storing for periods longer than one week.