Om 1064 PDF

INTERNAL COMBUSTION LIFT TRUCKS
[Do not remove this manual from the truck]
GTS 20/25/30/33 D
GTS 20/25/30/33 L
Part No. 8140267 (Eng)

Book No. OM 1064 (Rev 1.3)
Jan, 2019
Operator’s Manual
You must be trained and authorized to operate a lift truck.
YOU can prevent accidents
First: Learn safe operating rules and your company rules.
Next: Read your Operator’s Manual. If you do not understand

it, ask your supervisor for help.
Learn about the unit you operate.
KNOW YOUR TRUCK
Then: Practice operating your

truck safely.
And: Keep your truck in safe

operating condition with
correct and timely
maintenance.
Breaking these rules will cause serious or fatal injury to

yourself and others.
i
A Message to CLARK Lift Truck Operators
Lift trucks are specialized machines with unique operating

characteristics, designed to perform a specific job. Their function and
operation is not like a car or ordinary truck. They require specific
instructions and rules for safe operation and maintenance.
Safe operation of lift trucks is of primary importance to CLARK. Our
experience with lift truck accidents has shown that when accidents
happen and people are killed or injured, the causes are:
• Operator not properly trained

• Operator not experienced with lift truck operation
• Basic safety rules not followed
• Lift truck not maintained in safe operating condition
For these reasons, CLARK wants you to know about the safe
operation and correct maintenance of your lift truck.
This manual is designed to help you operate your lift truck safely.
This manual shows and tells you about safety inspections and the
important general safety rules and hazards of lift truck operation. It
describes the special components and features of the truck and
explains their functions. The correct operating procedures are shown
and explained. Illustrations and important safety messages are
included for clear understanding. A section on maintenance and
lubrication is included for the lift truck mechanic.
ii A Message to CLARK Lift Truck Operators

The operator’s manual is not a training manual. It is a guide to help
trained and authorized operators safely operate their lift truck by
emphasizing and illustrating the correct procedures. However, it
cannot cover every possible situation that may result in an accident.
You must watch for hazards in your work areas and avoid or correct
them. It is important that you know and understand the information in
this manual and that you know and follow your company safety rules!
Be sure that your equipment is maintained in a safe condition. Do not
operate a damaged or malfunctioning truck. Practice safe operation
every time you use your lift truck. Let's join together to set high
standards in safety.
Remember, before you start operating this lift truck, be sure you
understand all driving procedures. It is your responsibility, and it is
important to you and your family, to operate your lift truck safely and
efficiently. Be aware that the Federal Occupational Safety and Health
Act (OSHA) and state laws require that operators be completely
trained in the safe operation of lift trucks; it is also an OSHA
requirement that a machine inspection be performed before every
shift. If you think you need training in operating or inspecting your lift
truck, ask your supervisor.
CLARK lift trucks are built to take hard work, but not abuse. They are
built to be dependable, but they are only as safe and efficient as the
operator and the persons responsible for maintaining them. Do not
make any repairs to this truck unless you have been trained in safe
lift truck repair procedures and are authorized by your employer.
! CAUTION
This forklift burns propane (LPG) which will produce exhaust gases that
are harmful to humans. They include carbon monoxide, carbon dioxide,
nitrogen oxides and hydrocarbons. The amounts of each of these gases
will vary, depending on a number of related factors. With the correct fuel,
proper tuning of the system by technicians and adequate ventilation, this
truck can produce emissions that are considered safe for indoor use. Of
the four gases, carbon monoxide poses the greatest threat. Carbon mon-
oxide symptoms may vary with individuals, depending on breathing rate,
the amount of work or exercise being performed at the time of exposure,
and the physical state of the subject. In case of working in an enclosed
area, the area should be well ventilated. We recommend the forklift not be
operated in a small enclosed area for long periods. To maintain the emis-
sion levels to a normal level, customers are requested to follow the mainte-
nance schedule. A truck using diesel fuel is not recommended indoor use.
A Message to CLARK Lift Truck Operators iii

iv
Contents of this Manual
A Message to CLARK Lift Truck Operators....................... ii
Introduction ......................................................................... vi
How to Use this Manual .................................................... viii
Safety Signs and Safety Messages .................................... x
Section 1. General Safety Rules ......................................1-1
Section 2. Operating Hazards ..........................................2-1
Section 3. Operator Compartment and Controls ...........3-1
Section 4. Operating Procedures ....................................4-1
Section 5. Operator Maintenance and Care ....................5-1
Section 6. Emergency Starting and Towing ...................6-1
Section 7. Planned Maintenance and Lubrication .........7-1
Section 8. Specifications ..................................................8-1
A Message to CLARK Lift Truck Operators v

Introduction
CLARK welcomes you 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 the CLARK
name represents. This manual familiarizes you with safety,
operating, and maintenance information about your new lift truck. It
has been specially prepared to help you use and maintain your
CLARK lift truck in a safe and correct manner.
Your CLARK lift truck has been designed and built to be as safe and
efficient as today’s technology can make it. As manufactured, it
meets all the applicable mandatory requirements of ANSI / ITSDF
B56.1 Safety Standard for Powered Industrial Trucks. Each truck is
also furnished with equipment to help you operate safely; for
example, load back rest, parking brake, safety restraint system, seat
belts and horn are standard equipment.
Safe, productive operation of a lift truck requires both skill and
knowledge on the part of the operator. The operator must know,
understand, and practice the safety rules and safe driving and load
handling techniques described in this manual. To develop the skill
required, the operator must become familiar with the construction
and features of the lift truck and how they function. The operator
must understand its capabilities and limitations, and see that it is kept
in a safe condition.
Routine Servicing and Maintenance

Regular maintenance and care of your lift truck are not only
important for economy and utilization reasons; it is essential for your
safety. A faulty lift truck is a potential source of danger to the
operator, and to other personnel working near it. As with all quality
equipment, keep your lift truck in good operating condition by
following the recommended schedule of maintenance.
vi Introduction
Operator Daily Inspection — Safety and Operating Checks
A lift truck should always be examined by the operator, before

driving, to be sure it is safe to operate. The importance of this
procedure is emphasized in this manual with a brief illustrated review
and later with more detailed instructions. CLARK dealers can supply
copies of a helpful “Drivers Daily Checklist.”
Planned Maintenance
In addition to the daily operator inspection, CLARK recommends

that a planned maintenance and safety inspection program (PM) be
performed by a trained and authorized mechanic on a regular basis.
The PM will provide an opportunity to make a thorough inspection of
the safety and operating condition of your lift truck. Necessary
adjustments and repairs can be done during the PM, which will
increase the life of components and reduce unscheduled downtime
and increase safety. The PM can be scheduled to meet your
particular application and lift truck usage.
The procedures for a periodic planned maintenance program that

covers inspections, operational checks, cleaning, lubrication, and
minor adjustments are outlined in this manual. Your CLARK dealer is
prepared to help you with a Planned Maintenance Program by
trained service personnel who know your lift truck and can keep it
operating safely and efficiently.
Modification of the truck prohibited

Unauthorized modification of the truck is not permitted, and, in case
that a problem has occurred due to a modification without permis-
sion, the warranty service shall not be provided.
For instance, the modifications which may void the warranty include
those that may negatively affect the performance, durability and
safety of the truck due to addition of unauthorized electrical devices
(lamp, black box, electrical instrument, communication equipment,
etc.), braking system, steering system, vision improvement system
and detachable attachment device that were not mounted when the
equipment was shipped out of the factory.
Introduction vii
How to Use this Manual
This manual is a digest of essential information about the safe

operation, the features and functions and explains how to maintain
your lift truck. This manual is organized into eight major parts:
Section 1, General Safety Rules, reviews and illustrates accepted
practices for safe operation of a lift truck.
Section 2, Operating Hazards, warns of conditions that could cause
damage to the truck or injury to the operator or other personnel.
Section 3, Operator Compartment and Controls, describes the
operating components, systems, controls, and other features of your
truck and tells how they function.
Section 4, Operating procedures, discusses specific instructions
on the safe, efficient operation of your lift truck.
Section 5, Operator Maintenance and Care, presents details on
how to perform the operator's daily safety inspection and refuel the
lift truck.
Section 6, Emergency Starting and Towing, gives instructions for
towing your truck in an emergency and for using battery jumper
cables to start your truck in an emergency.
Section 7, Planned Maintenance and Lubrication, describes the
PM program.
Section 8, Specifications, provides reference information and data
on features, components, and maintenance items.
NOTICE: The descriptions and specifications included in this manual

were in effect at the time of printing. CLARK Material Handling
Company reserves the right to make improvements and changes in
specifications or design. Please check with your authorized CLARK
dealer for information on possible updates or revisions.
The examples, illustrations, and explanations in this manual should
help you improve your skill and knowledge as a professional lift truck
operator and take full advantage of the capabilities and safety
features of your new lift truck.
viii How to Use this Manual

The first Section of the manual is devoted to a review, with
illustrations and brief messages, of general safety rules and the
major operating hazards you can encounter while operating a lift
truck. Next, you will find descriptions of the components of your
specific lift truck model and how the instruments, gauges, and
controls operate. Then, you will find a discussion of safe and efficient
operating procedures, followed by instructions on how to tow a
disabled lift truck. The later sections of the manual are devoted to
maintenance and truck specifications.
Take time to carefully read the “Operator Compartment and
Controls” section. By acquiring a good basic understanding of your
truck's features, and how they function, you are better prepared to
operate it both efficiently and safely.
In “Planned Maintenance and Lubrication,” you will find essential
information for correct servicing and periodic maintenance of your
truck, including charts with recommended maintenance intervals and
component capacities. Carefully follow these instructions and
procedures.
Each major Section has its own table of contents, so that you can
find the various topics more easily. If you cannot find a topic in the
table of contents, check the index at the back of the manual.
We urge you to first carefully read the manual from cover to cover.
Take time to read and understand the information on general safety
rules and operating hazards. Acquaint yourself with the various
procedures in this manual. Understand how all gauges, indicator
lights, and controls function. Please contact your authorized CLARK
dealer for the answers to any questions you may have about your lift
truck’s features, operation, or manuals.
Operate your lift truck safely; careful driving is your responsibility.
Drive defensively and think about the safety of people who are
working nearby. Know your truck’s capabilities and limitations. Follow
all instructions in this manual, including all IMPORTANT, CAUTION,
WARNING, and DANGER messages to avoid damage to your lift
truck or the possibility of any harm to yourself or others.
This manual is intended to be a permanently attached part of your lift
truck. Keep it on the truck as a ready reference for anyone who may
drive or service it. If the truck you operate is not equipped with a
manual, ask your supervisor to obtain one and have it attached to the
truck. And, remember, your CLARK dealer is pleased to answer any
questions about the operation and maintenance of your lift truck and
will provide you with additional information should you require it.
How to Use this Manual ix

Safety Signs and Safety Messages
Improper operation can cause accidents. Don’t take chances with

incorrect or damaged equipment. Read and understand the
procedures for safe driving and maintenance outlined in this manual.
Don't hesitate to ask for help. Stay alert! Follow safety rules,
regulations, and procedures. Avoid accidents by recognizing
dangerous procedures or situations before they occur. Drive and
work safely and follow the safety signs and their messages on the
truck and in this manual.
Safety signs and messages are placed in this manual and on the
truck to provide instructions and identify specific areas where
potential hazards exist and special precautions should be taken.
Know and understand the meaning of these instructions, signs, and
messages. 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-
tions or identification are required relating to procedures,
equipment, tools, pressures, capacities and other special
data.
IMPORTANT
This message is used when special precautions should
be taken to ensure a correct action or to avoid damage to
or malfunction of the truck or a component.
! CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
! WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
! DANGER
Indicates an imminently hazardous situation which, if not
avoided, will result in death or injury
x Safety Signs and Safety Messages

Section 1. General Safety Rules
General Safety Rules
Contents
Contents .......................................................................... 1-1
Daily Inspection .............................................................. 1-2
Do’s and Don’ts ............................................................... 1-3
Seat Belts ......................................................................... 1-4
No Riders ......................................................................... 1-5
Pedestrians ...................................................................... 1-6
Operator Protection ........................................................ 1-7
Fork Safety ...................................................................... 1-8
Pinch Points .................................................................... 1-9
Travel ............................................................................. 1-10
Grades, Ramps, Slopes, and lnclines ......................... 1-11
Surface and Capacity ................................................... 1-12
Tip-Over ......................................................................... 1-13
What to do in Case of a Tip-over ................................. 1-14
Parking ........................................................................... 1-15
General Tire Maintenance, Inspection, and Repair .... 1-16
Carbon monoxide and fumes ....................................... 1-17
Contents 1-1
Daily Inspection
At the beginning of each shift, inspect your truck and fill out a daily
inspection sheet.
Check for damage and maintenance problems.
Have repairs made before you operate the truck.
!
CAUTION
DO NOT MAKE REPAIRS YOURSELF. Lift truck mechanics
are trained professionals. They know how to make repairs
safely. (See Section 5)
1-2 Daily Inspection

Do’s and Don’ts
Don't mix drugs or alcohol with your job.

XXX
Do watch for pedestrians.
Don't block safety or emergency

equipment.
Do wear safety equipment

when required.
Don't smoke in "NO SMOKING" areas

or when refueling.
Don't use the similar fuel.
If forklift truck is to be operated outdoors

during rainy conditions, make sure cab is in
place to prevent damage to electrical
components.
Do’s and Don’ts 1-3

Seat Belts
ALWAYS BUCKLE UP
Seat belts can reduce injuries.
1-4 Seat Belts

No Riders
The operator is the only one who should be on a truck.
Never transport personnel on the forks of a lift truck.
No Riders 1-5
Pedestrians
Watch where you are going. Look in the direction of

travel. Pedestrians may use the same roadway you do.
Sound your horn at all intersections or blind spots.
Watch for people in your work area even if your truck has
warning lights or alarms. People may not watch for you.
Make people stand back, even when you are parked.
1-6 Pedestrians
Operator Protection
Keep under the overhead guard.

Always keep your body within the confines of the truck.
Operator Protection 1-7

Fork Safety
Never allow anyone to

walk under raised forks.
DANGER
There is special
2372604 equipment to raise
people for overhead
work. DO NOT USE
LIFT TRUCKS.
1-8 Fork Safety

Pinch Points
! WARNING
Keep hands, feet and legs out of the upright.
! WARNING
Don't use the upright as a ladder.
! CAUTION
Never try to repair the upright, carriage, chain, or
attachment yourself! Always get a trained
mechanic.
Pinch Points 1-9

Travel
Travel with the load

near the floor/ground
with upright tilted back
to cradle the load
whenever possible.
Never lift or lower the
load when the truck is
in motion.
When handling bulky

loads that restrict your
vision operate your
truck in reverse to
improve visibility.
Be sure to pivot in the
seat to give maximum
visibility.
Unstable loads are a hazard

to you and to your fellow
workers.
Always make certain that the
load is well stacked and Right
evenly positioned across both
forks.
Never attempt to lift a load
with only one fork.
Wrong
1-10 Travel
Grades, Ramps, Slopes, and lnclines
Unloaded
Forks Downgrade
! WARNING
Never turn on a grade, either loaded or unloaded.
Loaded
Forks Upgrade
Grades, Ramps, Slopes, and lnclines 1-11

Surface and Capacity
ICE
OIL SAND
MUD
GRAVEL
WEAK
FLOORS
Avoid these conditions. They can cause a truck to tip over or lose
traction for braking or driving.
! WARNING
Know the weight of your truck and load. Especially when
using elevators. Know the capacity of the elevator you
intend to use. Do not overload.
IMPORTANT
Seat belts can reduce injuries.
ALWAYS BUCKLE UP
1-12 Surface and Capacity

Tip-Over
Lateral Tip-over
• Lateral tip-over can occur with a com-
bination of speed and sharpness of
turn. This combination will exceed the
stability of the truck. This condition is
even more likely with an unloaded
truck.
• With the load or upright raised, lateral tip-over can occur while
turning and/or braking when traveling in reverse or accelerating
and turning while traveling forward.
• Lateral tip-over can occur loaded or unloaded by turning on an
incline or ramp.
Longitudinal Tip-over
• Longitudinal tip-over can occur with a
combination of overloading and load
elevated also with capacity load and
elevated. This combination will exceed
the stability of the truck. This condition
is even more likely with excessive for-
ward tilt, braking in forward travel or
accelerating rearward.
• Longitudinal tip-over can occur by driving with the load down
slope on a steep grade.
Lateral and longitudinal tip-over can occur if the truck is driven over
objects on the floor or ground, off the edge of improved surfaces, or
into potholes in the road surface, or by running into overhead objects
or collisions.
An off dock type of tip-over can occur if the truck is steered too close
to the dock edge, driven off the edge of the dock or ramp, or if the
highway truck or trailer rolls away from the dock or is driven away
during loading.
! WARNING
The conditions listed above can be further aggravated by
overloading, excessive tilt, or off center loads.
IMPORTANT
Lift truck tip-over can cause serious injury or death if the
operator is trapped between the truck and the ground.
Tip-Over 1-13
What to do in Case of a Tip-over
If your truck starts to tip over,
! WARNING
DO NOT JUMP!!!
IMPORTANT
Your chances for survival in a tip-over are better if you
stay with the truck, in your seat.
Brace yourself as illustrated below!

1. Make sure your seat belt is fastened securely.
2. Stay in your seat.
3. Grip the wheel.
4. Brace your feet.
1
2
1-14 What to do in Case of a Tip-over

Parking
• Never park on a grade.

• Always come to a complete
stop before leaving truck.
• Be sure travel control is in

NEUTRAL.
• Lower forks fully to floor
and tilt forward.
• Set parking brake.
• Turn key to OFF position.
Parking 1-15
General Tire Maintenance, Inspection, and Repair
1. Park the truck as described on page 1-15 and check for correct
tire inflation air pressure. See specifications in this OM for cor-
rect tire pressure for your truck.
! CAUTION
Check tire pressure from a position facing the tread of the
tire, not the side. Use a long-handled gauge to keep your
body away from the side.
• If tires are low, do not add air. Have the tire and wheel inspected
by a person trained and authorized to do tire and wheel mainte-
nance. The tire may require removal and repair.
• Incorrect (low) tire pressure can reduce the stability of a lift truck
and cause it to tip over.
IMPORTANT
Check wheels and tires for damage every time you check
tire pressure. Make repairs when needed. Dirt can get
into cuts and cause damage to the tire cord and tread.
Remove debris from all cuts.
!CAUTION
Multiple wheel assemblies. Do not loosen or remove
wheel assembly nuts before fully deflating tire. Have only
a trained and authorized mechanic make repairs.
See Service Manual for more detailed information.
1-16 General Tire Maintenance, Inspection, and Repair

Carbon monoxide and fumes
Be sure your employees understand that they must not use an

internal combustion engine in a closed area such as a cold storage
locker. Carbon monoxide is a colorless, odorless, poisonous gas
which can overcome your employees without warning. This gas is
the product of incomplete burning of any material containing carbon,
such as gasoline, LP and natural gas, and diesel fuel.
Internal combustion engines that use these fuels are sources of
exposure in the workplace. Control of carbon monoxide levels in the
workplace is dependent on ventilation and proper maintenance of
carbon monoxide producers including internal combustion-powered
equipment.
Properly running internal combustion engines will still produce
carbon monoxide emissions and deplete the oxygen supply
sufficiently, affecting the quality of ambient air in the work
environment if the ambient air exchange is not adequate. Always use
ventilation as the primary means of control by providing necessary
air exchange capability.
Ventilation shall be provided in enclosed areas where internal
combustion-powered equipment is used to maintain an atmosphere
that shall not exceed the contamination levels specified by the
American Conference of Governmental Industrial Hygienists,
"Threshold Limit Values of Airborne Contaminants." (See 29 CFR
1910.1000 Table Z-1.) This includes the atmosphere within the truck
cab when a cab is provided.
Common symptoms of carbon monoxide exposure may include
headaches, dizziness, and nausea. If employees exhibit these
symptoms, move them into fresh air, seek medical attention as
required, and determine the source of carbon monoxide by
monitoring "threshold limit values" in areas of exposure.
Questions concerning degree of concentration and methods of
sampling to ascertain the conditions present should be referred to a
qualified professional. Users must follow applicable local, state, and
federal regulations that apply to their workplace.
Carbon monoxide and fumes 1-17

Section 2. Operating Hazards
Operating Hazards
Contents
Loose Loads ..................................................................... 2-2
Long and Wide Loads / Rear Swing ............................... 2-3
Low Overhead Clearance

Fast Turns and High Loads .......................................... 2-4
Drop-Offs .......................................................................... 2-5
Right-Angle Stacking ....................................................... 2-6
Chain Slack ....................................................................... 2-7
Pallets and Skids ............................................................. 2-8
This Section shows some of the hazards that may cause you, or
someone around you, to be killed or badly hurt. As the operator, you
must look for other hazards. Get your supervisor to help you identify
and avoid those hazards.
Contents 2-1
Loose Loads
Loose or unbalanced loads

are dangerous. Observe
these precautions.
Never carry loose or uneven

material.
Center wide loads.
Stack and band loose material.
2-2 Loose Loads

Long and Wide Loads / Rear Swing
!WARNING
With long or wide loads, you need more room. So slow
down and watch your clearance.
A long load reduces the capacity of the truck. Know and
understand your truck load rating.
When extra-long material makes it necessary to travel with the
load elevated, do so with extreme care and be alert to load end-
swing when turning.
! WARNING
When turning, be sure the rear end of the truck does not
swing into racks, posts, etc. Watch for pedestrians beside
the truck.
Long and Wide Loads / Rear Swing 2-3

Low Overhead Clearance½
Fast Turns and High Loads
! WARNING
Know the height of your
truck, with and without a
load.
Check your clearances.
Keep the load low and
tilted back.
! WARNING
Watch overhead clearance:
Moving into overhead structures
can tip a truck over, or spill a load.
! WARNING
Slow down before turning.
The truck can tip over.
Turn too sharp with a raised
load and your truck can tip
even at slow speeds.
Travel with a load raised only
when removing or depositing
a load.
2-4 Low Overhead Clearance½GFast Turns and High Loads

Drop-Offs
! WARNING
To avoid these hazards, you must:
• Talk to the truck driver yourself; make sure the driver
does not move the trailer until you are done!
• Apply trailer brakes.
• Use wheel chocks.
• Use trailer-to-dock locking system if available.
The impact of moving in and out of a trailer may
cause the trailer to creep or move.
Drop-Offs 2-5
Right-Angle Stacking
SLOWLY
When right-angle stacking or moving with a raised

load to clear low objects, avoid sharp turns and move
slowly.
2-6 Right-Angle Stacking

Chain Slack
! WARNING
Slack chains mean rail or carriage hang-up. Raise the
forks before you move, or broken chains can result.
Chain Slack 2-7

Pallets and Skids
! WARNING
Do not move or store materials on damaged pallets or skids.
Items can fall through them causing severe injury or death!
Be sure the pallet or skid you are using is in good condition

and does not have defective or missing components and
fasteners.
2-8 Pallets and Skids

Section 3. Operator Compartment and Controls
Operator Compartment and Controls
Contents
Truck Description .................................................. 3-2

Operator Compartment ......................................... 3-3
Instrument Pod ....................................................... 3-4
Pod Symbols and Functions ................................. 3-5
Operator Controls ................................................ 3-11
Contents 3-1
Truck Description
1
6
2
3
4
7
5 9
1. Steering Handwheel
2. Overhead Guard
3. Seat and Seat Belt
4. Counterweight
5. Steer Axle, Wheels / Tires
6. Upright and Carriage
7. Load Backrest
8. Forks
9. Drive Axle, Wheels / Tires
The truck shown above is a typical representation of a

CLARK internal combustion lift truck. Your model may vary
slightly.
3-2 Truck Description

Operator Compartment
2 1 6 10 8 7
9
11
12
13
3
14
4
1. Steering Handwheel 8. Turn Signal Lever

2. Forward/Reverse Lever 9. Accelerator Pedal
3. Inching Pedal 10. Key Switch
4. Brake Pedal 11. Lift Control Lever
5. Seat Adjustment Lever 12. Tilt Control Lever
6. Horn Button 13. Auxiliary Control Lever
7. Instrument Pod 14. Parking Brake Lever
Operator Compartment 3-3

Instrument Pod
1/2 90
0 4/4 50 130
LPG
1. Coolant Temperature Gauge

2. Fuel Gauge
3. Transmission Oil Temperature
4. Engine Oil Pressure
5. Engine check
6. Alternator Charging Status
7. Service Icon
8. Turn Signal
9. Hour Meter
10. Glow Plug Preheat
11. Seat Belt
12. Parking Brake
13. Work Lamp Icon
14. Rear Work Lamp Icon
15. LPG truck signal
16. Fuel warning lamp
17. Transmission Oil Pressure warning Icon
18. Coolant High-Temperature warning Icon
3-4 Instrument Pod

Pod Symbols and Functions
Functions
1. General function
The instrument pod consists of indicator lights, an hour meter, a
circuit board and attached gauges. The pod provides the
operator with important information about truck conditions and
can shut down the truck in the event that certain critical
conditions are present.
2. Engine shutdown function
The instrument pod circuit board receives signals from sensors
in various locations and shuts down the truck when
Transmission fluid temperature is excessive or engine oil
pressure is low. Before shutting down the truck, the instrument
pod sounds alarm for 20-30 seconds and flashes indicator lights.
After shutdown, the truck may be restarted, but if the fault
condition persists, the truck will shut down again.
3. Neutral start function and Anti-restart function
Neutral start function
The instrument pod will not allow the starter to be engaged if
directional switches are closed or key has been in start position
once. Key switch must always be turned OFF to restart engine.
Anti-restart function
When engine is already running, the start motor does not rotate
although the key switch is turned to the start position.
IMPORTANT
For safety reasons, every CLARK forklift truck is fitted
with a neutral start switch. The purpose of this is to pre-
vent the engine from being started while the transmission
is in gear. Thus the engine may only start when the direc-
tion control lever is in the neutral position.
4. Anti-drive and parking brake reminder function

When parking brake is engaged, the truck cannot be driven even
when the directional switch is closed. A parking brake alarm
shall be activated if key switch is turned to the OFF position
and the parking brake is not applied. Applying the park brake will
reset the alarm.
Pod Symbols and Functions 3-5

5. Gauges and indicators
• Coolant temperature gauge
90
50 130
• Fuel gauge
It displays the remaining fuel level in 1/2
0 4/4
fuel tank.
• Transmission oil temperature

Indicates that the Transmission oil
temperature is excessive. If the light is on,
shut down the truck and service it. The
truck will go into shut down mode after the
light flashes for 30 seconds. (the buzzer
sounds)
• Engine oil pressure

Indicates engine oil pressure is too low. If
the light is on, shut down the truck and
service it. The truck will go into shut down
mode after the light flashes for 30
seconds.(the buzzer sounds)
If during operation, while engine is running, oil pressure switch
closes to ground, the buzzer will sound immediately.
After 5 seconds, the engine will shutdown. The function that
has caused the shutdown will flash the corresponding icon
until the key is returned to the off position.
• LPG truck lamp

This symbol displays when the LPG truck.
3-6 Pod Symbols and Functions

• Fuel warning lamp

This symbol displays when the LPG fuel
empty.
• Engine check
When the engine has problem, this LED
will be on.
• Alternator charging status

Indicates that the alternator is not properly
charging the battery. Service is required to
correct the problem.
• Service icon
LED will illuminate when pre-set service
time is reached. When LED is on, the pre-
set service time has been reached
indicating that a PM is required. Refer to
Service Manual for proper PM procedures.
Pre-set service time setting method - initialized by “key on +
FWD + F1 + F2”, service time display at hour meter. Here, F1
is for up set, F2 is for down set (with interval times of 50
hours). When the key switch is turned OFF, the pre-set
service time setting time is saved. Pre-set service time counts
down opposite to operating time. To disable the Service Icon,
set the pre-set service time to “-1000” (display 1 0 0 0 ); If you
push the F2 switch when setting the pre-set service time, the
time will be adjusted to “-1000”.
• Turn signal
Indicates that the turn signal switch is
actuated.

• Glow plug Preheat (Diesel truck)
Indicates glow plugs are in the process of
preheating the diesel engine. When the
ignition switch is turned to the “ON”
position, a timer is set. This symbol
displays until the timer cycle is completed.
The engine may then be started.
• Seat belt
At start-up, this light and a buzzer come
on for three seconds to remind the
operator to fasten the seat belt. There is no
start interlock.
IMPORTANT
You should always have your seat belt
securely fastened when operating your lift truck.
• Parking brake
Indicates that the parking brake is
engaged. Anytime the parking brake is on,
the truck can’t be driven because the
Transmission solenoid valves switch is off.
When the parking brake is not set and the
key switch is turned to the OFF position,
the instrument pod will sound.
If the parking brake is set, buzzer and horn will not sound.

Speed Limit System (Option)
Switch Operation Method and Description

The switch can be found on the right side of the instrument panel.
1 2 3
Use the switch when setting and changing the speed limit system.
Go to the submenu.
Switch 1 Red
Change the setting and number.
If pressed for less than 2 seconds : Cancel
Switch 2 Green
If pressed for more than 2 seconds : Save
Switch 3 Black Move between menus. (Move to the right side.)
Speed limit display

When setting the speed limit system to ON, the following is displayed
on the instrument panel:
• When the truck speed is 0.5km/h or more, the speed is displayed.
• When the truck speed is less than 0.5km/h, the operation time is
displayed.
10.0km/h 1.0
0.5km/h or more Less than 0.5km/h
※ Refer to the service manual or contact the CLARK dealer

for how to setting the speed limit value.

Weight Measurement System (Option)
Switch Operation Method and Description

The switch can be found on the right side of the instrument panel.
1 2 3
Use the switch when setting or changing the weight measurement

system.
Go to the submenu.
Switch 1 Red
Change the setting and number.
If pressed for less than 2 seconds : Cancel
Switch 2 Green
If pressed for more than 2 seconds : Save
Switch 3 Black Move between menus. (Move to the right side.)
Weight measurement display

When the load weight is 100kg or more, the load weight is displayed
only when the truck speed is 0.5km/h or less.
• Weight measurement error range : ±100kg
1.0 100kg 0.5km
※ Refer to the service manual or contact the CLARK dealer for

how to setting the weight measurement.

Operator Controls
Key/Start Switch
The Key/Start Switch:
• Turns the truck electrical system on and off.
• Connects and tests the warning indicator lights.
• Connects the starter motor circuit when engine is to be
started.
The Key/Start Switch has three positions.
When the key is in the vertical "OFF" OFF ON
position, all truck electrical circuits are off,
and the key can be removed. From the
"OFF" position, the key can be turned
clockwise to the "START" position, where
the starter motor is engaged and part of the
truck electrical system is energized. When
the key is released from the "START" START
position, it automatically returns to the "ON"
position, where the starter is disengaged
and the entire truck electrical system is on.
The key switch has a mechanical "anti-restart" feature, which
prevents the engine starter from being engaged and damaged if the
operator attempts to start the engine when it is already running. The
key switch cannot be turned to the "START" position from the "ON"
position without returning the key to the "OFF" position. If the engine
stops running, the key switch must be turned to the "OFF" position
before it can be restarted.
Cold Start Preheating (Diesel Only)

With the switch in the "ON" position the warning indicator will light up
then the glow plugs are pre-heating automatically. The engine can
then be started. To repeat the preheating process turn the key to the
"OFF" and then into the "ON" position.
Operator Controls 3-11

Engine Stop
Run the engine at idling speed briefly before shutting it off.
Turn the key switch to the "OFF" position to shut the engine down.
Seat Adjustment
The fore and aft adjustment lever is located
on the front under the seat. To unlock, pull
Back
the lever to the left and adjust the seat, declining
adjustment
release the lever. Be sure that the seat
locking mechanism is engaged. The back
declining adjustment lever is located on the Fore and
left side of seat cushion. Pull the lever up and Aft Adjust
adjust the back, release the lever. Be sure

70 16300 50
50 110
8070 1
1
110 30 210 190

90
kg 370 3500 1
lb
that the back locking mechanism is engaged.
1 70 1 6
100
2
50
33
0
Driver’s weight
50 3 1 2
0 270 120
140 290
130
adjustment
! CAUTION
Never adjust driver's seat while truck is moving, to avoid
the possibility of loss of control and of personal injury.
Parking Brake
Activates brake operation.
Check the parking Brake Parking Brake

The brake is applied by pulling the lever Apply
uppers. It is released by pushing downs.
Parking Brake
Release
!
CAUTION
Always apply parking brake before leaving truck.
! WARNING
Never operate your lift truck with a defective parking brake.
Hour Meter
Starting the engine also starts the operating hour meter. Use the hour
meter reading to perform prescribed maintenance.
3-12 Operator Controls

Steering System
The steering handwheel operates a steering
control valve that directs the oil flow to the
steering cylinder connected to the steer axle. The
steering control valve can also act as a pump to
provide manual steering if the hydraulic pump
stops.
Horn Button
The horn button is located in the center hub of the steering
handwheel. Depressing the botton will sound the horn.
Brake Pedals
The left hand brake pedal (inching pedal) has two functions in order
to improve handling and efficiency. While pressing the inching pedal
the first part of its movement interrupts the power from the engine to
the transmission. The level of disengagement is dependent on the
movement of the pedal. The last part of the travel applies the brake
system.
In this way you are able to lift a load rapidly with full engine RPM
while controlling slow driving speed with the inching pedal like a
clutch. This is very useful in confined level working spaces.
On ramps or inclines the right hand brake pedal only should be used.
When using the inching pedal on slopes the lift truck could move
backwards or forwards unintentionally.
Direction Control Lever

This lever is typically on the left side of the steering column. When
changing the direction of travel, make sure that your lift truck has
come to a complete stop before moving the lever to the other
position.
! CAUTION
If the truck will start with the direction control lever in
either forward or reverse, there is a problem with the
neutral start switch and it must be repaired.
Traction Disable Function

When driver leaves seat over 3sec, transmission goes to
neutral(power of fwd/rev solenoides is shut off). When driver gets
back in seat, truck must not go into gear until he shifts to neutral,
then shifts into gear.

Hydraulic Control Levers
The levers of the control valve activate the
Lift
lift and tilt cylinders as well as any other
hydraulic devices which are installed on Tilt
the truck. Auxiliary
IMPORTANT
The hydraulic levers shown are typical representations
of a CLARK internal combustion lift truck. Your model
may vary slightly.
Lift Control Function

With the lift control lever, you are able to raise
and lower the fork carriage on the upright. The
lifting and lowering speeds are controlled through
the main hydraulic valve by varying the lever
position (from the center or neutral positions).
When the lift control lever is pushed forward, the
fork carriage is lowered. When the lift control
lever is pulled back the fork carriage is raised.
You can also lower the fork carriage even if the
key switch is OFF.
Tilt Control Lever

With the tilt control lever, you are able to control
the tilting or vertical positioning of the upright and
the angle of the forks. When the lever is pulled
back, the upright and forks tilt backward. Push the
lever forward to tilt the upright and forks forwards.
Auxiliary Control Lever (Optional)

An auxiliary control lever is mounted to the right of the tilt control lever. If
your lift truck is equipped with an optional attachment, this lever lets you
control the flow and direction of the hydraulic oil to the attachment.

Steering Column Pylon

The steering wheel can be tilted forwards
and backwards in small discrete movements.
Push and hold pylon lock, move the wheel to
the desired position and release lock.
Pylon Lock
Hood open
The hood release lever is located on the left
side of hood.
Unitrol Pedal(Optional)
With the CLARK Unitrol, the directional
control lever is no longer located on the
steering pylon. The direction of travel and
speed of truck is determined by the Unitrol
pedal.
Forward Reverse
• Forward : To select and move the truck
in the forward direction you must push
down on the(FWD arrow) left side of
the Unitrol pedal. The further the pedal is depressed the faster
the lift truck will go in forward.
• Reverse : To select and move the truck in the reverse direction
you must push down on the(REV arrow) right side of the Unitrol
pedal. The further the pedal is depressed the faster the lift truck
will go in reverse.
• Neutral : The unitrol pedal activates only FWD and REV. Neutral is
activated only when the parking brake is set.
IMPORTANT
For safety reasons, your CLARK forklift truck is fitted with
a neutral start switch. The purpose of this is to prevent the
engine from being started while the transmission is in
gear. Thus the engine may only start when the direction
control lever is in the neutral position.

! CAUTION
If the truck will start with the direction control in either
forward or reverse, there is a problem with the neutral
start switch and it must be repaired.
Truck Data and Capacity Plate

1. Truck model number or
registered name. 1 2
3
2. Truck serial number -An
identification number 4
assigned to this particular
truck and should be used
when requesting informa-
tion or ordering service 5
parts for this truck from your

authorized CLARK dealer.
The serial number is also stamped on the frame.
3. Attachment description (if any installed) - The user must see that
the truck is marked to identify the attachment(s), including the
weight of the truck/attachment combination and truck capacity
with the attachment.
4. Capacity rating, load center, and lifting height data - Shows the
maximum load capacity of this truck with relation to load centers
and fork heights (see diagram on plate). Personal injury and
damage to the truck can occur if these capacities are exceeded.
Do not exceed the maximum capacity specified.
5. Truck weight - The weight of the truck without a load on the
forks. This weight plus the weight of the load must be consid-
ered when operating on elevators, elevated floors, etc. to be
sure they are safe.
! CAUTION
When attachments are added or if the truck is modified,
the capacity of the truck may be affected. Contact your
authorized CLARK dealer for a new nameplate showing
the revised capacity.
IMPORTANT
OSHA requires prior written approval from the manufac-
turer before any modifications affecting capacity or safety
may be made.

Operator Safety Warning Decal

WARNING
Read the
manual
Buckle up!
Apply brake

when leaving
truck
Watch Out
For Other
People
Most lift truck

INJURIES
are to other
people near
the lift truck.
IMPORTANT
Prevent
Safety and warning decals are placed in conspicuous Overturns!
locations on the truck to remind you of essential

procedures or to prevent you from making an error
AVOID :
that could damage the truck or possibly cause • slippery,
sloping,
personal injury. You should know, understand, and or uneven
surfaces
follow these instructions. Safety and warning decals • loads over
capacity on
should be replaced immediately if missing or nameplate
• unstable or
defaced (damage or illegible). high loads
• low tire
pressure
• poorly
Operator/Tip-Over maintained
lift truck
• fast or
This decal is located on the front right hand leg of the sharp turns
drivers overhead guard. It is to remind the operator that In Case of

Tip-Over:
staying in the seat provides the best chance of avoiding Don't
jump
injury in the event of a tip-over or off the dock mishap.
Lift trucks can be tipped over if operated improperly.
Hold on
Analysis of lift truck accidents has shown that the driver tight
cannot react quickly enough to jump clear of the truck

and overhead guard as the truck tips. To protect Brace feet
operators from severe injury or death in the event of a tip- Lean

away
over, it is best to be held securely in the seat. So, please,

always buckle up when driving your lift truck. 2798235

Upright Warning Decal
This safety decal is on the upright to
warn of the danger of injury from
movement between rails, chains,
sheaves, fork carriage, and other parts
of the upright assembly. Do not climb on
or reach into the upright. Personal injury
will result if any part of your body is put
between moving parts of the upright.
Keep Away from Forks Decal

This safety decal is placed on the
upright to warn of the danger of injury
from forks when they are in the raised
position. Do not ride on or stand under
forks or attachments. The forks can fall
and cause injury or death. Always make
sure that the forks are in the fully
lowered position when they are not
being used to handle a load.
2372604
Hot Surface Warning Decal

The warning decals are attached to the
engine, the tail pipe when vertical
exhaust system is installed, and on the
heater when cabin is installed.
The surface of decal is very hot by the
heat generated during work.
If this surface is touched, serious burns
may result.

Attached position of safety decals
!
CAUTION
Do not operate a lift truck with damaged or missing decals
or data plates. Replace them immediately. They contain
important information. Contact your local CLARK dealer
to acquire new decals or data plates.
VIEW A VIEW B
250
2372604
DIESEL
VIEW C

Attached position of safety decals
CAUTION !
Do not operate a lift truck with damaged or missing decals
or data plates. Replace them immediately. They contain
important information. Contact your local CLARK dealer
to acquire new decals or data plates.
LPG FUEL CYLINDER REPLACEMENT PROCEDURE

-----------------------------------------------------------------------
1 .---------------------------------------------------
------------------------------------.
2 .----------------------------------------------------
----------------------------------------------------.
3 .---------------------------------------------------
--------------------------------------------------.
-----------------------------------------------
------------------------------------.
4 .----------------------------- -----------------------
---------------------------------------------------.
-----------------------------------------------------
-----------------------.
5 .--------------------------------------------------
-----------------------------------.
NOTE --------------------,-------------.
------------------.-----------------------------
-----.--------------------------------------------
--------------------------------------------------
------. P/NO.8009528
RECOMMENDED SAFETY MAINTENANCE PROCEDURE

FOR LP GAS FUELED FORKLIFT TRUCKS
----------------------------------------------
-------------------------------------------------
--------------------------------------------
--------
----------------------------------------
----------------------------------
---------------------------------------
--------------.
---------------------------------------
----------.
-------------------------------------------.
----------------------------------------------.
1 .---------------------------------------.
2 .-------------------------------------.
A .-----------------------------------
-----------.
B . ---------------------------------------
------------------------.
3 .-------------------------------------------
----.----------------------------------------
----------------------------------------------
---------------------------------------------
--.-----------------.--------------.----------
------------------------------.
-----------------------------------.-------
-------. ------------.---------------. +١‫ٵ‬1ٟ٪٠0٧( ٟ‫ٵ‬١/ ٟ٪٢ ٟ١ٰ( ) 1٠٠ٟ
NOTE --------------------,------------------ <;
------------------.-------------------------- 1 2
-----.----------------------------------. 3
NOTE --------------------------------------
-------------------------------------------------
----------------------------------------------
-----------.-----------------------------------. 4
SERVICE WORK SHOULD BE PERFORMED BY
QUALIFIED PERSONNEL ONLY.
P/No. 928847

Section 4. Operating Procedures
Operating Procedures
Contents
Before Operating the Truck .................................. 4-2

Starting from a Safe Condition ............................. 4-3
Contents 4-1
Before Operating the Truck
Be sure that you have read and

understand the information in this
Operator's Manual before operating
the lift truck.
The Operator's Manual Holder is
located on the back of the seat.
! WARNING
• This equipment can be dangerous if not used properly.
Safe operation is the responsibility of the operator.
• Do not start or operate the truck, or any of its functions
or attachments, from any place other than the
designated operator's position.
! CAUTION
• Inspect your lift truck before operating at the start of
the day or shift. Before putting your truck to use, check
the operation of the controls and all systems.
• Protect yourself. Do not operate truck without a
driver's overhead guard unless conditions prevent its
use. Do not remove overhead guard unless specifically
authorized. Use special care if operation without this
safety device is required.
4-2 Before Operating the Truck

Starting from a Safe Condition
Always start from a safe condition. Before operating a lift truck, make
sure that:
1. Parking brake is applied.
2. Forks are fully lowered to the floor or ground.
3. You are familiar with how all the controls function and have read
the Operator Manual.
4. All controls are in neutral or other correct position.
5. Truck has received its daily inspection and is ready and safe to
operate.
Parking
Forks are down
Put the direction control

lever in the NEUTRAL
position, before turning the
key switch to ON. FORWARD
NEUTRAL
Position
REVERSE
Starting from a Safe Condition 4-3

Adjusting the Seat
Adjust the seat to a comfortable
position for you. Adjust the seat
by moving and holding the
release lever at the front under of Back
declining
the seat. Put the seat in a adjustment
position that will provide easy

reach to all controls. Release the
seat lever. Make sure that the
seat locking mechanism is
Fore and
engaged. Aft Lever
! CAUTION
Never adjust the driver's seat while the truck is moving,
to avoid the possibility of loss of control and of personal
injury.
Buckling Up
Buckle up. Be sure that you put
on the seat belt. Connect and
adjust the seat belt strap to a
snug, comfortable position.
!
WARNING
Always wear your seat belt when operating a lift truck.
Starting the Truck

Before you start the truck, make sure that you have taken all the
above mentioned precautions and that the directional control is in
NEUTRAL. To start the truck, turn the key switch clockwise to the ON
position.
4-4 Starting from a Safe Condition

Positioning Forks and Upright

When driving, with or without a load, it is
good practice to have the forks slightly
raised and tilt the upright (forks) backward. Lift Control
Lever
Having the forks raised and tilting back
prevents the fork tips from catching on
possible obstructions and reduces the
wear on the fork blades from striking or
dragging on the floor or ground. See the
NOTICE and CAUTION below.
Pull back on the lift control lever and raise
the forks 6 to 8 inches (152 to 203 mm)
above the floor. Then, using the tilt
control, tilt the upright back slightly to Tilt Control
raise the fork tips. Lever
NOTICE
When the upright (carriage and/or load) is raised, the sta-
bility of the truck is reduced. Some of the other conditions
that may affect stability are: ground and floor conditions,
grade, speed, loading, dynamic and static forces and the
judgement exercised by the operator. Trucks equipped
with attachments behave as partially loaded trucks even
when operated without a load on the attachment. Also,
improper operation, faulty maintenance or poor house-
keeping may contribute to a condition of instability.
!CAUTION
For stability reasons, do not travel with the load or
carriage raised into a high (elevated) position. Travel with
the lift mechanism raised only enough to clear the ground
or obstacles.
! WARNING
If your truck starts to tip over, DO NOT JUMP! Your
chances for survival in a tip-over are better if you stay
with the truck, in your seat. BRACE YOURSELF!. Make
sure your seat belt is fastened securely. Stay in your seat.
Grip the wheel. Brace your feet. See page 1.14

Controlling Speed
With the direction control in FORWARD or REVERSE, the parking
brake released, put your foot on the accelerator pedal and push
down smoothly until the truck is moving at the desired speed.
Braking
To stop the truck, lift your foot
from the accelerator pedal and put
it on the brake pedal. Push down
on the brake pedal in a smooth,
firm motion until the truck is
stopped.
IMPORTANT
Stop a lift truck as gradually as practical. Hard braking
and wheel sliding are dangerous and can cause tip-over
or the truck could lose its load. Also, hard braking can
increase wear and can be harmful to the lift truck.

Operating Safely
IMPORTANT
Safe operation is the responsibility of the operator. Watch
where you are going. Don't go if you can't see.
Before driving, check all around

to be sure that your intended path
of travel is clear of obstructions
and pedestrians.
While driving, be alert for
pedestrians, other vehicles or
obstructions in your path of travel.
Watch people. Do not allow anyone to stand or pass under the load
or raised forks. Watch for people in your work area even if your truck
has warning lights or alarms. They may not watch for you.
Sound horn at intersections and wherever vision is obstructed.
Do not drive a truck up to anyone standing in front of an object.
Protect yourself and those around you...
Operate the truck only from the designated operator's position. Stay
within the confines of the lift truck profile dimensions. Keep arms,
legs and hands inside the operator's compartment and away from
the danger of passing obstructions. Keep under the overhead guard.
NOTICE
An overhead guard is intended to offer protection to the
operator from falling objects, but cannot protect against
every possible impact. Therefore, it should not be consid-
ered a substitute for good judgement and care in loading,
handling, storage, etc..
Keep clear of the upright and lift
mechanism. NEVER reach into or put
hands, arms, legs or head into or through
the upright structure or near the carriage
or lift chains. Never put any part of your
body between the upright and the truck.
Don't use the upright as a ladder.

Keep all other persons clear of the load and upright mechanism while
attempting to handle a load.
No riders...
Do not carry passengers. The operator is the only one who should
be on the truck.
Always be in full control of your lift truck...

Never operate a lift truck or its attachments if you are not in the
designated operator's position.
Never operate a lift truck when your hands are wet or greasy.
Always pick the smoothest travel route for your lift truck. Avoid
bumps, holes, slick spots, and loose objects or debris in your path
that may cause the truck to swerve or tip. If these conditions are
unavoidable, slow down and carefully drive past them. Slow down
for wet or slippery surfaces.
Avoid any sudden movement. Start, stop, travel, steer, and brake
smoothly.
Operate your lift truck under all conditions at a speed that will permit
it to be brought safely to a stop.
! WARNING
Travel slowly when turning. Use special care when
traveling without a load because the risk of tipping over is
greater with an empty truck, especially at high speed and
when cornering.
Travel with the fork carriage tilted back and raised only enough to
fully clear the ground or obstacles. When the carriage (load) is
elevated, the stability of the truck is reduced.
Do not elevate the load except during stacking.

Grades, ramps, and inclines...

Use special care when operating on ramps, inclines, and uneven
areas. Travel slowly. Travel straight up and down. Do not turn or
drive at an angle across an incline or ramp.
When the truck is loaded, travel with the load upgrade. When the
truck is empty, travel with lifting mechanism (upright) downgrade.
Practice safe operation every time you use your truck...
Careful driving and operation is your responsibility. Be completely
familiar with all the safe driving and load handling techniques in this
operator's manual. Use common sense. Drive carefully; do not
indulge in stunt driving or horseplay. Observe traffic rules. Watch for
people and hazards. Slow down. Be in full control of your lift truck at
all times.
Follow the instructions in this manual to avoid damage to your truck
or the possibility of injury to yourself or others.
During your work, observe all functions of your lift truck. This allows
you to immediately recognize a problem or irregularity that could
affect the safe operation of your truck.
Periodically check the gauges and warning indicator lights in the
instrument panel to be sure they indicate a normal condition. If an
abnormal condition appears, shut off the key switch immediately and
report the problem.
IMPORTANT
Do not continue to operate a truck that has a malfunction.
Stop and have it fixed.
IMPORTANT
Always wear your seat belt
when operating your lift
truck.

! CAUTION
Operate your lift truck only in areas that have been
approved for your lift truck type designation. Certain
areas contain flammable gases, liquids, dust, fibers, or
other hazardous materials. Lift truck operations in these
areas must have special approval. These areas must be
designated to show the type of lift truck approval required
for operation in the area. Be aware that changes to special
equipment or poor maintenance can cause the lift truck to
lose its special approval. Be sure that your truck is the
correct fire safety type for the area in which you are
working. The proper type designation for this truck is
listed on the nameplate. In areas classified as hazardous,
use only trucks approved for use in those areas. If you are
unsure of the classification of the area you wish to enter,
check before entering.
Adjusting the Load Forks

The load forks are adjustable on the
hanger shaft. Forks should be spaced
as far apart as the load being carried
will allow. Both forks should always
be the same distance from the center
of the fork carriage. To adjust the
forks, raise the carriage slightly. Tilt
the upright fully forward to reduce
friction and make the forks slide easier. Unlock the fork locking pins.
Position the forks. Secure the fork locking pins.
Forks are heavy, keep fingers
clear. Move forks by pushing
with one foot while holding on to
the load back rest with hands. Be
sure to have firm footing before
attempting to move forks. Do not
attempt this where the floor is
slippery or wet.

Load Handling
Handle only loads that are within the truck rated capacity as shown on
the nameplate. This rating specifies the maximum load that should be
lifted. However, other factors such as special load handling
attachments, loads having a high center of gravity, or uneven terrain
may dictate that the safe working load be less than the rated capacity.
Under these conditions, the operator must reduce the load carried so
that the lift truck remains stable.
Handle only stable or safely arranged loads. Do not handle loads
made up of loose, unevenly stacked or unstable items that can easily
shift and fall. Take the time to correctly stack and band loose items.
Center the load on the forks.
Do not lift anything that might fall on the operator or a bystander.
Do not handle loads that are higher than the fork carriage unless the
load is secured so that no part of it can fall backwards.
Keep the load back against the carriage. Loads placed out on the
ends of the forks can make the lift truck less stable and more likely to
tip up.
Lift and lower with the upright must vertical or tilted slightly back —
never tilted forward.
Operate lift and tilt controls slowly and smoothly. Never tilt forward
when carriage (load) is raised, except to pick up or deposit a load
over a rack or stack.
! WARNING
Slack chains mean rail or carriage hang-up. Raise the
upright before you move. If the upright malfunctions in
any way or becomes stuck in a raised position, operate
the lift control to eliminate any slack chains. DO NOT go
under a raised upright or forks to attempt repairs. DO NOT
reach into or climb on upright to free hang-up.
Remember, your lift truck is designed to carry loads forward of the
front wheels so that the weight of the load is counter-balanced by the
weight of the truck.
The farther the load is carried from the pivot point (center of front
wheels), the greater will be the uplift at the rear of the truck.
Therefore, always carry the load as close to the front wheels as
possible (back and flush against the face of the forks).

The capacity load shown on the nameplate is represented by a cube
in which the weight is evenly distributed, with the center of gravity
located a standard distance from the face of the forks. If the weight of
the actual load to be handled is not evenly distributed, put the
heaviest part closest to the carriage.
Traveling with a Load

Travel with load or carriage as low as possible and tilted back. Never
travel with the load or carriage raised (elevated) in a high position.
Do not elevate the load except during stacking.
Observe all traffic regulations and watch for other traffic, pedestrians,
and safe clearances. Always look in the direction of travel. Keep a
clear view of the path of travel, and when the load blocks your
visibility, travel in reverse with load trailing (except when climbing an
incline).
Avoid sudden movements when carrying a load—start, stop, travel,
steer, and brake smoothly. Steer clear of bumps, holes, and loose
materials or debris on the ground. Lift and tilt slowly and smoothly.
Go slowly when turning. Cross railroad tracks slowly at an angle
wherever possible.
Use special care when handling and traveling with long, high, or wide
loads—to avoid losing the load, striking bystanders or obstructions,
or tipping the truck.
Watch clearances around the truck and load as you travel. Raise the
forks or attachment only to pick up or stack a load. Look out for
obstructions, especially overhead.
Be aware that exaggerated tail swing, when turning while traveling
forward, is a characteristic of lift trucks that are steered by the rear
wheels. Accordingly, you need to become accustomed to tail swing
and always check the tail swing area of the counterweight to be sure
it is clear before you turn.
Always be concerned about the stability of your lift truck. When
attachments are used, extra care should be taken in securing,
manipulating, positioning, and transporting the load. Because
attachments generally add extra weight and complexity to the truck,
operate trucks equipped with attachments as partially-loaded trucks
when not handling a load.

Picking Up and Moving Loads

When picking up a load from the ground,
approach the load slowly and carefully
align the truck square with the load. The
forks should be adjusted to fit the load or
pallet being handled and spread as wide
as possible to provide good stability and
balance. Before lifting, be sure the load is
centered and the forks are fully under and supporting the load. Fork
length should be at least 2/3 of load length. With the lift and tilt
controls, adjust the forks to the correct height and angle for freely
engaging the load pallet. Move forward until the forks are squarely
and completely under the load.
NOTICE
Be sure that the forks do not extend beyond the load,
causing damage or tipping of other adjacent loads or
materials behind the load being moved.
If the forks are longer than the load, move the tips partially under the
load without extending beyond the load. Raise the load to clear the
floor. Back out several inches, or whatever distance is necessary,
then set the load down and move forward until the load is positioned
against the carriage.
Raise the load from the floor or stack by tilting the upright back just
enough to lift the load from the surface. When stacking or tiering, use
only enough backward tilt to stabilize the load.
Then raise the load to traveling height and tilt fully back to travel
(except for loads that must be transported as level as possible).
Unloading
To deposit a load on the floor after being moved into the correct
position, tilt the upright forward to a vertical position and lower the
load.
Adjust the fork height and tilt the upright forward slightly, as
necessary, for smooth removal of the forks from the load (pallet).
Carefully back away to clear the forks from the load.
Raise the forks to traveling height and tilt fully back.

Stacking
To put a load on a stack:
1. Approach slowly and align the lift
truck and load squarely with the
stack.
2. Raise (elevate) the load as the lift

truck is nearing the stack.
3. Move forward, slowly, until the load is

almost touching the stack. The lead-
ing edge and sides of the load pallet
should be lined up exactly with the
near edge and side of the load or
rack on which you are stacking.
4. Stop close to the stack and further lift

(raise) the load high enough to clear
the top surface of the stack. Slowly
move the load into position. Be care-
ful not to damage or move adjacent
loads.
5. When the load is aligned with the stack beneath it, tilt the upright
to the vertical position and carefully lower the load onto the top
surface of the stack.

6. Lower (drop) the forks slightly to clear

(disengage) the load pallet. Tilt the forks
forward slightly, if necessary.
7. Check your travel path, then carefully

back away until the forks are clear of the
stack. Stop and lower the forks to the
travel position (6 to 8 inches above the
ground), then tilt back to travel.
To move a load from a stack:

Approach the stack carefully, truck lined up squarely with the load.
With the truck just in front of the stack and the upright must vertical,
raise the forks to the correct height for freely engaging the load
pallet. Adjust fork angle as necessary to fit squarely under the load.
Move forward until the forks are under the load.
Be sure that the forks do not extend beyond the load, causing
damage or tipping of other adjacent loads or materials behind the
load being moved. If the forks are longer than the load, move the tips
partially under the load without extending beyond the load. Raise the
load to clear the undersurface. Back out several inches, then set the
load down and move forward until the front face of the forks contacts
the load.
Raise the load from the stack by tilting the upright back just enough
to lift the load from the surface. Or, with the mast still vertical, raise
the forks until they begin to lift the load. At this point, apply the
minimum back tilt that will stabilize the load.
Check your travel path, slowly back off until clear of the stack, stop,
and then lower the load to the travel position (6 to 8 inches off the
ground). Tilt full back to travel (except for certain loads that may have
to be transported as level as possible). Be sure the load is back flush
against the carriage or front face of the forks.
NOTICE
Certain loads may have to be transported as level as pos-
sible.

After Operating the Truck
Always leave your lift truck in a safe condition. When you leave
your truck, or park it, follow these safety rules:
• Park in a safe area away from normal traffic.
• Never park on a grade.
• Never park in areas that block emergency routes or equipment,
access to fire aisles, or stairways and fire equipment.
Before leaving the operator's position:

1. Bring truck to complete stop.
2. Put the directional control lever in the NEUTRAL position.
3. Apply the parking brake.
4. Lower the lift mechanism fully.
5. Turn the key switch to the OFF position.
If you are going to leave the truck unattended:

6. Remove the key.
7. Block the wheels if the truck has any possibility of moving.

Section 5. Operator Maintenance and Care
Operator Maintenance and Care
Contents
Daily Safety Inspection .......................................... 5-2

Fuel Safety Practices ............................................. 5-5
Refueling LPG Tanks ............................................. 5-6
NOTICE
The Occupational Safety and Health Act (OSHA) requires
that truck users examine their trucks before each shift to
be sure they are in safe working order. Defects when
found shall be immediately reported and corrected. The
truck shall be taken out of service until it has been
restored to safe operating condition.
Contents 5-1
Daily Safety Inspection
Before using a lift truck, it is the operator's responsibility to check

its condition and be sure it is safe to operate.
Check for damage and maintenance problems; have repairs made
before you operate the truck. Unusual noises or problems must be
reported immediately to your supervisor or other designated
authority.
Do not make repairs yourself unless you are trained in lift truck repair
procedures and authorized by your employer. Have a qualified
mechanic make repairs using genuine CLARK or CLARK-approved
parts.
! CAUTION
Do not operate a truck if it is in need of repair. If it is in an
unsafe condition, remove the key and report the condition
to the proper authority. If the truck becomes unsafe in any
way while you are operating it, stop operating the truck,
report the problem immediately, and have it corrected.
Lift trucks should be inspected every eight hours, or at the start of

each shift. In general, the daily inspection should include the visual
and functional checks described on the following pages.
As an aid in carrying out this inspection, CLARK has prepared a form
called the "Driver's Daily Checklist." We recommend that you use
this form to make a daily record of your inspections and truck
condition. You may obtain copies of this form from your CLARK
dealer.
! WARNING
Leaking hydraulic oil may be hot or under pressure. When
inspecting a lift truck, wear safety glasses and do not
check for leaks with bare hands.
5-2 Daily Safety Inspection

Visual Checks
First, perform a visual inspection of the truck and its major
components:
1. Walk around your lift truck and take note of obvious damage that
may have been caused by operation during the last shift.
2. Check that all capacity, safety, and warning plates or decals are
attached and legible.
3. Check before and after starting engine for leaking fuel, engine
coolant, transmission fluid, etc.
4. Check for hydraulic oil leaks and loose fittings.
!
CAUTION
Do not use bare hands to check. Oil may be hot or under
pressure.
5. Be sure that the driver's overhead guard, load back rest and all
other safety devices are in place, securely fastened and undam-
aged. Inspect for damaged or missing parts, corrosion, cracks,
breaks etc.
6. Check all of the critical components that handle or carry the
load.
7. Look the upright and lift chains over. Check for obvious wear
and maintenance problems such as damaged or missing parts,
leaks, slack or broken chains, rust, corrosion, bent parts, cracks,
etc.
8. Carefully inspect the load forks for cracks, breaks, bending,
twists, and wear. Be sure that the forks are correctly installed
and locked in their proper position.
9. Inspect the wheels and tires for safe mounting, wear condition,
and air pressure.
10. Check the hydraulic sump oil level, engine oil level, and fuel
level.
Daily Safety Inspection 5-3

Functional Checks
Check the operation of the truck as follows.
NOTICE
Before performing these checks, familiarize yourself with
the starting, operating, and shutdown procedures in Sec-
tion 4 of this manual. Also, know the safety rules given in
Section 1 of this manual.
1. Test warning devices, horn, lights, and other safety equipment
and accessories.
2. Start the engine and be sure all controls and systems operate
freely and return to neutral properly. Check the:
• Gauges, meters, and indicator lights
• Service brakes, inching pedal, and parking brakes
• Hydraulic controls: lift, tilt, and auxiliary (if installed)
• Accelerator
• Directional control
• Steering system
• Lift mechanism and any attachments.
When the functional checks are completed, follow the standard
shutdown procedures given in Section 4, “Operating Procedures.”
Concluding the Inspection

Make a record on the “Driver's Daily Checklist” of all the problems
that you find. Review the checklist to be sure it has been completed
and turn it in to the person responsible for lift truck maintenance. Be
sure any unusual noises or problems are investigated immediately.
Do not operate a lift truck that has a maintenance problem or is
not safe to operate.
Instead, remove the key from the
ignition switch and put an “Out of
Service” tag on the truck.
If all of the Daily Inspection checks
were normal or satisfactory, the
truck can be operated.
5-4 Daily Safety Inspection

Fuel Safety Practices
Refueling Gasoline and Diesel Trucks
Use clean, properly marked fuel

cans.
Clean up spills.
Fuel Safety Practices 5-5

Refueling LPG Tanks
When changing liquefied petroleum gas (LPG), tanks follow these

basic rules:
• Change only in well ventilated
areas.
• Never allow open flames.
• Turn the ignition switch to the
OFF position.
• Check for leaks.
• Check condition of the O-ring.
• Make sure tank is on locating
pin. Locating
Pin O-Ring
• Make sure tank latches are
securely fastened. Relief Valve
• Store tanks according to local Typical Illustration
fire codes
If you refill LPG tanks:

• Make sure you know and understand the proper procedure for
filling an LPG tank.
• If you have any questions on refilling LPG tanks, please ask your
supervisor.
!DANGER
LPG IS HEAVIER THAN AIR. It settles on your clothes and
the ground around you, displacing oxygen vital for
breathing. Open flame can cause flash fires.
IMPORTANT
Check all connections for damage or leaks. If the truck
will not start after you change tanks, get a qualified
mechanic to check the truck.
5-6 Refueling LPG Tanks

RECOMMENDED SAFETY MAINTENANCE PROCEDURES

FOR LPG FUELED LIFT TRUCKS
!WARNING
LPG is a combustible fuel that is heavier than air. Escaping gas
may accumulate in low areas. The fuel cylinder should be
mounted so that it does not extend outside the truck and should
also be properly positioned by using the locating pin or key
way.
The fuel valve should be turned off when the machine is not in
service. Cast fittings should not be used in the LPG system. Use only
Underwriters Laboratories or Factory Mutual listed LPG hose
assemblies where pressure fuel lines are required. All pipe threaded
fittings should be installed using an approved sealing compound.
Fuel lines should be supported by clamps to minimize chafing and
wear. The LPG solenoid valve should be wired to an automatic shut
off switch (oil pressure or vacuum) to prevent leakage of gas in the
event the ignition is on without the engine running. Check the LPG
solenoid or vacuum shutoff valve for leakage as follows:
1. Turn fuel tank valve off, start and run engine until it stops.
2. Install a 0 to 30 psi pressure gauge per instruction A or B:
A. To primary test port of single units consisting of primary and
secondary regulators.
B. Between the primary and secondary stage regulators when
the LPG system consists of two regulators.
3. Turn the tank fuel valve on. The pressure gauge should maintain
a zero reading. If it does not, the solenoid valve or vacuum shut-
off valve must be repaired or replaced. An odor is added to LPG
to help indicate leaks. If you detect gas odor, you should turn off
the fuel tank supply valve and engine. Remove all sources of
ignition, and ventilate the area. Make all of the necessary repairs
before you turn the fuel supply on. The complete LPG system
should be inspected periodically. Check all hoses for wear, con-
nections for leaks, and all parts for damage.
NOTE: Fuel hoses have a limited life expectancy. They should be
checked for cracking and drying due to age. Hoses with visible signs
of age should be replaced. Use only Underwriters Laboratories or
Factory Mutual listed LPG parts for replacements.
NOTE: The above information is provided as a guide. Consult the
National Fire Protection Association Pamphlet 58 for the safe
storage and handling of liquefied petroleum gases. Governmental
safety regulations in your locality could vary. Check with the authority
having jurisdiction to be sure that you meet all of their requirements.
Contact the manufacturer for detailed service information.
Refueling LPG Tanks 5-7

Section 6. Emergency Starting and Towing
Emergency Starting and Towing
Contents
How to Tow a Disabled Truck ............................... 6-2

How to Use Battery Jumper Cables ..................... 6-4
Contents 6-1
How to Tow a Disabled Truck
If your lift truck becomes disabled but it can be moved freely on its
own wheels without further damage, use the following procedures to
tow it safely to a repair area.
IMPORTANT
It is important for your safety and the care of your lift truck
to use the proper equipment and carefully follow these
recommendations for safe towing.
! WARNING
DO NOT tow a lift truck if there is a problem with the brakes
or tires or the steering cannot be operated. DO NOT tow up
or down ramps and steep inclines. DO NOT attempt to tow
a lift truck if traction or weather conditions are poor.
1. Be sure to apply the parking brake or block the drive wheels on
the disabled truck while working around it.
2. When possible, raise the carriage (forks) on the disabled truck
about 12 inches (300 mm) from the floor or ground. Secure the
carriage with a chain.
3. Obtain another lift truck of equal or larger size carrying a partial
load for traction.
4. Check that the counterweight bolts are in place and properly
torqued. (This bolt is made of a special high-tensile steel and is
not commercially available. Replace it, when necessary, only with
a genuine CLARK replacement part).
5. Use an approved, solid metal tow bar with towing couplers that
connect to the towing pins in the counterweights.
6. Release the parking brake on the towed vehicle.
7. Transmission control is in neutral.
NOTICE
DOT approved towing equipment may be available from
your Clark dealer.
8. Tow the disabled truck backward. An operator must be on the
towed truck. Tow the truck slowly. Careful towing is necessary
to prevent injury to personnel or damage to the truck. The truck
should be towed at a speed of less than 5 m.p.h. (8 kph) with a
driver in the seat. Do not lift the truck or any wheels off the floor
or ground while the truck is being towed.
6-2 How to Tow a Disabled Truck

!
CAUTION
The power steering and brakes will not operate on the
disabled truck when the engine is not running. Manual
operation of the handwheel and brakes will be difficult to
operate. More manual effort will be required to perform
these functions.
9. Park the disabled truck in authorized areas only. Fully lower the
forks to the floor, put the directional control lever in the NEU-
TRAL position and turn the ignition switch to the OFF position.
Engage the parking brake. Remove the ignition key and, when
necessary, block the wheels to prevent the truck from rolling.
!
WARNING
Always engage the parking brake when parking a lift
truck. The truck can move and cause injury or death to
personnel near it.
How to Tow a Disabled Truck 6-3

How to Use Battery Jumper Cables
! CAUTION
If the fork lift truck is laid off for more than 1 month, the (-)
cable of battery should be disconnected. Otherwise, the
starting of engine will be impossible due to discharge of
battery.
If your lift truck battery is discharged (“dead”), you can start your lift
truck by “jumping” it from another lift truck that has a 12-volt,
negative-ground electrical system. The “booster” battery must be
fully charged and in good condition. This section explains how to
perform this procedure safely. To avoid damage to your lift truck and
your battery or the possibility of harm to yourself, follow the
instructions and warnings carefully. If you have any doubts, ask for
help from an experienced mechanic.
If your truck has a battery with terminals on the side, you will need a
set of jumper cables with matching connector clamps or cable
adapters for side-mounted battery terminals.
! CAUTION
USE ONLY A 12-VOLT, NEGATIVE GROUND SYSTEM to
jump your truck. You can injure yourself and permanently
damage your truck’s 12-volt starting motor and ignition
system by connecting it to a 24-volt power supply (two 12-
volt batteries in series or a 24-volt generating set) or to a
positive-ground system.
!
WARNING
BATTERIES CONTAIN SULFURIC ACID. Avoid acid
contact with skin, eyes, or clothing. If acid contacts your
eyes or skin, flush immediately with water and get
medical assistance. Wear safety glasses when working
near the battery to protect against possible splashing of
the acid solution.
1. If the discharged battery has filler caps, check the fluid level. Do
not use an open flame to check and do not smoke. If low, add
distilled water to the correct level. Be sure to install the caps
before jump starting.
Do not jump start, charge, or test a sealed-type battery if the test
indicator looks illuminated or has a bright color. Install a new
battery.
6-4 How to Use Battery Jumper Cables

! WARNING
BATTERIES EMIT EXPLOSIVE GAS. Do not smoke or have
open flames or sparks in battery charging areas or near
batteries. An explosion can result and cause injury or
death. Hydrogen gas is produced during normal battery
operation. Hydrogen can explode if flames, sparks, or
lighted tobacco are brought near the battery. When
charging or using a battery in an enclosed space, always
provide ventilation and shield your eyes. Wear safety
glasses when working around batteries.
2. Put the truck with the booster battery as near to the other truck
as necessary for the jumper cables to reach both batteries.
Check and make sure that the trucks do not touch each other.
Use particular care when connecting a booster battery to
prevent sparks.
3. On both trucks:
a. Apply the parking brake.
b. Put the directional control lever in the NEUTRAL position.
c. Turn the key/start switch to the OFF position.
d. Turn all accessories to the OFF position and leave them off
until after the engine has been started and the jumper cables
have been removed.
! WARNING
To avoid SHORT CIRCUITS, remove all jewelry and do not
permit any metal tools to make contact between the
positive battery terminal and other metal on the truck.
When you connect jumper cable clamps to the positive
terminals of the two batteries, make sure that neither
clamp contacts any other metal. Injury can occur from
electrical shock or explosion.
How to Use Battery Jumper Cables 6-5

4. Connect the jumper cables in the
following sequence:
a. Connect a jumper cable from
the positive (+; red) terminal on
one battery to the positive (+;
red) terminal on the other bat-
tery. Never connect positive (+;
red) to negative (-; black), or
negative to positive.
b. Connect one end of the second
cable to the grounded negative
(-;black) terminal of the “Jumper
Vehicle” battery.
c. Connect the other end of the
second cable to a stationary,
solid metallic point on the
engine of the “Stalled Vehicle,”
not to the negative (-;black)
terminal of its battery. Make
this connection at a point at
least 18 inches (450 mm) away
from the battery, if possible. Do
not connect it to pulleys, fans or
other parts that move. Do not
touch hot manifolds that can
cause severe burns.
5. Start the engine on the “Jumper Vehicle” and run the engine at a
moderate speed for a minimum of five minutes.
6. Start the engine on the “Stalled Vehicle.” Follow the starting
instructions in Section 4, “Operating Procedures” in this manual.
Be sure that the engine is at idle speed before disconnecting the
jumper cables.
7. Remove the jumper cables by reversing the installation
sequence exactly. Start by removing the last jumper cable from
the stalled vehicle first. Remove the cable end from the engine
block first, then the other end of the negative (-; black) cable.
8. Remove both ends of the positive (+; red) cable.
6-6 How to Use Battery Jumper Cables

Section 7. Planned Maintenance and Lubrication
Planned Maintenance and Lubrication
Contents
Introduction ............................................................ 7-2

Safe Maintenance Practices .................................. 7-3
Major Component Locations ................................ 7-8
Planned Maintenance Intervals ............................ 7-9
PM Report Form ................................................... 7-12
How to Perform Planned Maintenance .............. 7-14
NOTICE
THIS SECTION IS FOR TRAINED SERVICE PERSONNEL
to use as a reference for Planned Maintenance proce-
dures. Complete maintenance information is in the Ser-
vice Manuals.
Contents 7-1
Introduction
NOTICE
ONLY TRAINED AND AUTHORIZED PERSONNEL should
perform Planned Maintenance. Local CLARK dealers are
prepared to help customers put in place a Planned Main-
tenance program for checking and maintaining their lift
trucks according to applicable safety regulations.
!CAUTION
Powered industrial trucks may become hazardous If
maintenance is neglected.
The operator should make a safety inspection of the lift truck before
operating it. The purpose of this daily examination is to check for any
obvious damage and maintenance problems, and to have minor
adjustments and repairs made to correct any unsafe condition.
In addition to the operator’s daily inspection, CLARK recommends

that the owner set up and follow a periodic planned maintenance (PM)
and inspection program. Performed on a regular basis by trained
personnel, the program provides thorough inspections and checks of
the safe operating condition of the lift truck. The “PM” identifies
needed adjustments, repairs, or replacements so they can be made
before failure occurs. The specific schedule (frequency) for the PM
inspections depends on the particular application and lift truck usage.
This Section recommends typical Planned Maintenance and
Lubrication Schedules for items essential to the safety, life, and
performance of the truck. It also outlines safe maintenance practices
and gives brief procedures for inspections, operational checks,
cleaning, lubrication, and minor adjustments.
Specifications for selected components, fuel, lubricants, critical bolt
torques, refill capacities, and settings for the truck are found in
Section 8.
If you have need for more information on the care and repair of your
truck, see your CLARK dealer.
7-2 Introduction
Safe Maintenance Practices
The following instructions have been prepared from current industry

and government safety standards applicable to industrial truck
operation and maintenance. These recommended procedures
specify conditions, methods, and accepted practices that aid in the
safe maintenance of industrial trucks. They are listed here for the
reference and safety of all workers during maintenance operations.
Carefully read and understand these instructions and the specific
maintenance procedures before attempting to do any repair work.
When in doubt of any maintenance procedure, please contact your
local CLARK dealer.
1. Powered industrial trucks can become hazardous if mainte-
nance is neglected. Therefore, suitable maintenance facilities
and trained personnel and procedures shall be provided.
2. Maintenance and inspection of all powered industrial trucks shall
be performed in conformance with the manufacturer's recom-
mendations.
3. Follow a scheduled planned maintenance, lubrication, and
inspection system.
4. Only trained and authorized personnel are permitted to maintain,
repair, adjust, and inspect industrial trucks and must do so in
accordance with the manufacturer’s specifications.
5. Always wear safety glasses. Wear a safety (hard) hat in indus-
trial plants and in special work areas where protection is neces-
sary and required.
6. Properly ventilate work area, vent exhaust fumes, and keep
shop clean and floors dry.
7. Avoid fire hazards and have fire protection equipment present in
the work area. Do not use an open flame to check for leakage.
Do not use open pans of fuel or flammable cleaning fluids for
cleaning parts.
8. Before starting work on truck:
a. Raise drive wheels free of floor and use oak blocks or other
positive truck positioning devices.
b. Remove all jewelry (watches, rings, bracelets, etc.).
c. Put oak blocks under the load-engaging means, innermasts,
or chassis before working on them.
d. Disconnect the battery ground cable (-) before working on the
electrical system.
Safe Maintenance Practices 7-3

!
CAUTION
Refer to the “Jacking and Blocking” section in the Service
Manual for proper procedures.
9. Operation of the truck to check performance must be conducted

in an authorized, safe, clear area.
10. Before starting to operate the truck:
a. Be seated in a safe operating position and fasten your seat
belt.
b. Make sure parking brake is applied.
c. Put the direction control in NEUTRAL.
d. Start the engine.
e. Check functioning of lift and tilt systems, direction and speed
controls, steering, brakes, warning devices, and load han-
dling attachments.
11. Before leaving the truck:
a. Stop the truck.
b. Fully lower the load-engaging means: upright, carriage, forks
or attachments.
c. Put the directional control in NEUTRAL.
d. Apply the parking brake.
e. Stop the engine.
f. Turn the key switch to the OFF position.
g. Put blocks at the wheels if the truck must be left on an incline.
12. Brakes, steering mechanisms, control mechanisms, warning
devices, lights, governors, lift overload devices, lift and tilt mech-
anisms, articulating axle stops, load back rest, overhead guard
and frame members must be carefully and regularly inspected
and maintained in a safe operating condition.
13. Special trucks or devices designed and approved for hazardous-
area operation must receive special attention to insure that
maintenance preserves the original approved safe operating
features.
7-4 Safe Maintenance Practices

14. Fuel systems must be checked for leaks and condition of parts.
Extra special consideration must be given in the case of a leak in
the fuel system. Action must be taken to prevent the use of the
truck until the leak has been corrected.
15. All hydraulic systems must be regularly inspected and main-
tained in conformance with good practice. Tilt and lift cylinders,
valves, and other parts must be checked to assure that "drift" or
leakage has not developed to the extent that it would create a
hazard.
16. When working on the hydraulic system, be sure the engine is
turned off, upright is in the fully-lowered position, and hydraulic
pressure is relieved in hoses and tubing.
!WARNING
Always put oak blocks under the carriage and upright
rails when it is necessary to work with the upright in an
elevated position.
17. The truck manufacturer's capacity, operation, and maintenance

instruction plates, tags, or decals must be maintained in legible
condition.
18. Batteries, limit switches, protective devices, electrical conduc-
tors, and connections must be maintained in conformance with
good practice. Special attention must be paid to the condition of
electrical insulation.
19. To avoid injury to personnel or damage to the equipment, con-
sult the manufacturer's procedures in replacing contacts on any
battery connection.
20. Industrial trucks must be kept in a clean condition to minimize
fire hazards and help in detection of loose or defective parts.
21. Modifications and additions that affect capacity and safe truck
operation must not be done without the manufacturer's prior writ-
ten approval. Capacity, operation, and maintenance instruction
plates, tags, or decals must be changed accordingly.

22. Care must be taken to assure that all replacement parts, includ-
ing tires, are interchangeable with the original parts and of a
quality at least equal to that provided in the original equipment.
Parts, including tires, are to be installed per the manufacturer's
procedures. Always use genuine CLARK or CLARK-approved
parts.
! WARNING
When removing tires follow industry safety practices. Most
importantly, deflate pneumatic tires completely prior to
removal. Following assembly of tires on multi-piece rims,
use a safety cage or restraining device while inflating.
23. Use special care when removing heavy components, such as

counterweight, upright, etc. Be sure that lifting and handling
equipment is of the correct capacity and in good condition.
IMPORTANT
Your new CLARK lift truck has been built to meet all appli-
cable mandatory requirements of ANSI / ITSDF B56.1
Safety Standard for Powered Industrial Trucks. Each truck
also includes certain safety devices—such as horn, over-
head guard, safety restraint system, seat belt and load
back rest—as standard equipment. No additions, omis-
sions, or modifications should be made that affect compli-
ance to the above requirements or in any way minimize
the effectiveness of the safety devices.
7-6 Safe Maintenance Practices

NOTICE
You should be familiar with additional operating and
maintenance safety instructions contained in the follow-
ing publications:
ANSI / ITSDF B56.1: Safety Standard for Low Lift and High Lift
Trucks (Safety Code For Powered Industrial Trucks).
NFPA 505:Fire Safety Standard for Powered Industrial Trucks: Type

Designations, Areas of Use, Maintenance and Operation. Available
from National Fire Protection Association, Inc., Batterymarch Park,
Quincy, MA 02169.
General Industrial Standards, OSHA 2206: OSHA Safety and Health

Standards (929 CFR 1910), Subpart N-Materials Handling and
Storage, Section 1910.178 Powered Industrial Trucks. For sale by:
Superintendent of Documents, US Government Printing Office,
Washington, DC 20210.

Major Component Locations
Use the illustration below to help locate components included in the

PM procedures.
9 11
10 12
13
4 5 3 6 14 7
1. Radiator 8. Counterweight
2. Transmission Cooler 9. Overhead Guard
3. Frame 10. Exhaust
4. Steer Axle 11. Carburetion
5. Engine 12. Sheet Metal
6. Transmission 13. Upright and Carriage
7. Wheels and Tires 14. Drive axle
The truck shown above is a typical representation of a CLARK

internal combustion lift truck. Your model may vary slightly.
7-8 Major Component Locations

Planned Maintenance Intervals
Time intervals between maintenances are largely determined by

operating conditions. For example, operation in sandy, dusty
locations requires shorter maintenance intervals than operation in
clean warehouses. The indicated intervals are intended for normal
operation. The operating condition classifications are:
Normal Operation
Eight-hour material handling, mostly in buildings or in clean, open air
on clean paved surfaces.
Severe Operation
Prolonged operating hours or constant usage.
Extreme Operation
• In sandy or dusty locations, such as cement plants, lumber
mills, and coal dust or stone crushing sites.
• High-temperature locations, such as steel mills and found-
ries.
• Sudden temperature changes, such as constant trips from
buildings into the open air, or in refrigeration plants.
If the lift truck is used in severe or extreme operating conditions, you
must shorten the maintenance intervals accordingly.
NOTICE
Since the operating environment of lift trucks varies
widely, the above descriptions are highly generalized and
should be applied as actual conditions dictate.
Planned Maintenance Intervals 7-9

The maintenance time intervals referred to in this manual relate to
truck operating hours as recorded on the hourmeter, and are based
on experience CLARK has found to be convenient and suitable
under typical (normal or average) operating conditions. The periods
and their designations are:
PM Interval:
A=8 - 10 hours or daily
B=50 - 250 hours or every month (typical PM interval)
C=450 - 500 hours or every 6 months
D=900 - 1000 hours or every 12 months
E=2000 hours or every year
Check truck visually and inspect components. •

Test drive truck/check functional performance. •
Air clean truck and radiator. •
Check torque on critical fasteners. •
Lubricate truck. (See component) •
Replace LPG engine oil and filter. •
Replace Diesel engine oil and filter. •
Clean and replace LPG engine air filter. (*) •
Clean and replace Diesel engine air filter. (*) •
Change Diesel fuel filter. •
Change LPG fuel filter. •
Inspect / adjust fan belts. •
Drain / flush radiator coolant. (5000 hours)
Check engine ignition and timing. •
Engine tune-up. •
Check battery. •
Check transmission fluid level. •
Change transmission fluid. •
Change transmission oil filter. •
Clean drive axle air vent. •
Check brake condition and wear. •
Check drive axle mounting and fasteners. •
Lubricate steer axle linkage. •
Check / lubricate steer axle wheel bearings. •
Change / replace hydraulic sump oil filter and breather. (**) •
Change / replace hydraulic sump fluid and oil filter. (**) •
Lubricate tilt cylinder rod ends. •
Check lift chain adjustment and wear. •
Check / lubricate lift chains. •
Lubricate upright rollers. •
7-10 Planned Maintenance Intervals

NOTES:
* Air filter change interval may be determined by using an air
restriction indicator.
** Hydraulic filter change interval may be determined by hydraulic
filter restriction indicator.
A B C D E
Check truck for obvious damage and leaks. •
Check fuel system for leaks, etc. •
Check capacity, warning plates and decals. •
Check condition of tires and wheels. Remove embedded •
objects. Check air pressure.
Check for missing or loose wheel lugs nuts. •
Check engine oil level. •
Check engine coolant level (radiator and recovery tank) •
Check transmission fluid level •
Check fuel level. •
Check hydraulic sump oil level. •
Check gauges and instruments. •
Check warning lights and hour meter. •
Check overhead guard condition and bolts. •
Check horn operation and other warning devices. •
Check steering operation. •
Check service brake operation. •
Check parking brake operation. •
Check parking brake linkage for damage, broken parts. •
Check directional and speed controls operation. •
Check accelerator and engine speed operation. •
Check lift, tilt and aux. operation. •
Check upright, lift chains and fasteners. •
Check carriage or attachments and forks. •
Check seat deck hold-down latch for correct locking. •
Check optional safety equipment. (alarms, lights etc.) •
Planned Maintenance Intervals 7-11

PM Report Form
Make and keep records of your PM inspections. Use these records to

help establish the correct PM intervals for the truck application and to
indicate maintenance required to prevent major problems from
occurring during operation.
As an aid in performing and documenting your PM inspections,
CLARK has prepared a Gas, LPG, or Diesel Planned Maintenance
Report Form. Copies of this form may be obtained from your
authorized CLARK dealer. We recommend that you use this form as
a checklist and record of your inspection and truck condition.
The maintenance procedures outlined in this Section are intended to
be used in conjunction with the PM Report Form. They are arranged
in a logical and efficient sequence.
You make a check mark or entry on the PM Report Form when the
PM is performed. A special coding system for indicating the
importance of needed repairs and/or adjustments appears on the
form.
When you have finished the PM inspections, be sure to give a copy
of the report to the designated authority or person responsible for lift
truck maintenance.
Do not make repairs or adjustments unless authorized to do so.
! CAUTION
For safety, it is good practice to:
• Remove all jewelry (watch, rings, bracelets, etc.) before
working on the truck.
• Disconnect the battery ground cable (-) from the battery
before working on electrical components.
• Always wear safety glasses. Wear a safety (hard) hat in
industrial plants and in special work areas where pro-
tection is necessary and required.
7-12 PM Report Form

PM Report Form 7-13

How to Perform Planned Maintenance
Visual Inspection
First, perform a visual inspection of the lift truck and its components.
Walk around the truck and take note of any obvious damage or
maintenance problems.
Check to be sure all capacity, safety, and warning plates are
attached and legible.
NOTICE
NAME PLATES AND DECALS: Do not operate a lift truck
with damaged or lost decals and nameplates. Replace
them immediately. They contain important information.
Inspect the truck, before and after starting the engine, for any sign of
external leakage of fuel, engine coolant, transmission fluid, etc.
Check for hydraulic oil leaks and loose fittings.
!
CAUTION
HYDRAULIC FLUID PRESSURE: Do not use your hands to
check for hydraulic leakage. Fluid under pressure can
penetrate your skin and cause serious injury.
Overhead Guard
Be sure that the driver's overhead
guard and any safety devices are in
place, undamaged, and attached
securely.
Check the overhead guard for
damage. Be sure that it is properly
positioned and all mounting fasteners
are in place and tight.
Load Handling Components

Inspect the upright assembly, load backrest (LBR), rails, carriage
rollers, lift chains, and lift and tilt cylinders. Look for obvious wear
and maintenance problems and damaged or missing parts. Check
for any loose parts or fittings. Check for leaks, damaged or loose
rollers, and rail wear (metal flaking). Carefully check the lift chains for
7-14 How to Perform Planned Maintenance

wear, rust, corrosion, cracked or broken links, stretching, etc. Check

that the lift and carriage chains are correctly adjusted to have equal
tension. Check that the lift chain anchor fasteners and locking means
are in place and tight. Inspect all lift line hydraulic connections for
leaks.
IMPORTANT
Uprights and lift chains require special attention and
maintenance to remain in safe operating condition. Refer
to “Lift Chain Maintenance” in this Section for additional
information.
Forks
Inspect the load forks for cracks,
breaks, bending, and wear. The
fork top surfaces should be level
and even with each other. The
height difference between both A
fork tips should be no more than

10% of "A" is
1.5% of the blade length. max. wear
allowed 1.5% is max.
height difference
! WARNING
If the fork blade at the heel is worn down by more than 10
%, the load capacity is reduced and the fork must be
replaced.
Inspect the forks for twists and

bends. Put a 2"-thick metal block, 1"max
at least 4" wide by 24" long with
parellel sides, on the blade of the
fork with the 4" surface against
the blade. Put a 24" carpenter's 20"
square on the top of the block
and against the shank. Check the
fork 20" above the blade to make
sure it is not bent more than 1"
maximum.
How to Perform Planned Maintenance 7-15

If the fork blades are obviously bent or damaged, have them
inspected by a trained maintenance person before operating the
truck.
Inspect the fork locking pins for cracks or damage. Reinsert them
and note whether they fit properly.
Wheels and Tires

Check the condition of the drive and
steer wheels and tires. Remove
objects that are embedded in the
tread. Inspect the tires for excessive
wear and breaks or “chunking out.”
Check all wheel lug nuts or bolts to
be sure none are loose or missing.
Replace missing bolts or lug nuts.
Torque loose or replaced items to
specifications.
! WARNING
Check tire pressure from a position facing the tread of the
tire, not from the side. Use a long-handled gauge to keep
your body away from the side. If tires are low, do not
operate and do not add air. Check with a mechanic. The
tire may require removal and repair. Incorrect (low) tire
pressure can reduce the stability of your lift truck. Do not
operate truck with low tire pressure. Proper cold inflation
is 100 psi.

Disassembling the split rim wheel

When you disassemble the split-rim wheel,
NEVER remove the tire before you deflate
the tire pressure. First, deflate the tire
pressure and then loosen the wheel bolts
and nuts. Failure to do so could result in
serious personal injury. This work should be
performed only by a trained and authorized
mechanic.
Functional Tests
You will start the engine to complete the functional tests, so be sure
that:
• The parking brake is applied.
• Directional control is in NEUTRAL.
• Forks are fully lowered to the floor or ground
• All controls are in neutral or other correct position
• You are familiar with the safety procedures given in Section
4, “Operating Procedures,” in this manual.
As you test the following components, be sure they are properly
mounted and working correctly.
Horn
Press the horn button to check horn function. If the horn or any other
part does not operate, report the failure and have it repaired before
the truck is put into operation.
Neutral Start Switch

Check the operation of the neutral start switch by placing the
direction control lever in FORWARD or REVERSE and turning the
key switch to START position. The starter must not engage until the
direction control lever is moved to the NEUTRAL position.
Hour Meter
Start the engine and let it warm up until it runs evenly and
accelerates smoothly when you push on the accelerator pedal.
Check the hour meter for operation with the engine running. Write
the hour meter reading on the PM report form. Report any
malfunction or damage.

Indicator Lights
Check that all lights are functioning and indicate normal truck
operation as described in Section 3, “Operator Compartment and
Controls,” in this manual.
Service Brakes and Inching Pedal
With the direction control in NEUTRAL and the engine running, push
the service brake pedal fully down and hold. The brakes should apply
before the pedal reaches the floorplate. If the pedal continues to
creep downward, report the failure immediately. Do not operate the
truck until the brakes are repaired. Perform the same check with
the inching pedal. (Additional braking/inching checks will follow.)
Parking Brake
Check the function of the parking brake.
Pushing down, then pulling the lever
upwards. To check parking brake holding
capability, park the lift truck on a grade and
apply the parking brake. The parking brake
should hold a lift truck with rated load on a
15% grade.
! CAUTION
Do not operate a lift truck if the service or parking brakes
are not operating properly.
Lift Mechanisms and Controls

Pull back on the tilt control lever and hold until the upright reaches
the full back tilt position. Push forward on the lever to return the
upright to the vertical position. Release the lever.
!
CAUTION
Be sure that there is adequate
overhead clearance before raising
the upright.
Pull back on the lift control lever and raise
the fork carriage to full height. Watch the
upright assembly as it rises. Release the
lever.

If the maximum fork height is not reached, this indicates there is an

inadequate (low) oil level in the hydraulic sump tank or severe
binding within the upright.
Push forward on the lift control lever. Watch the upright as it lowers.
When the forks reach the floor, release the lever.
All movements of the upright, fork carriage, and lift chains must be
even and smooth, without binding or jerking. Watch for chain wobble
or looseness; the chains should have equal tension and move
smoothly without noticeable wobble.
Auxiliary Controls (Option)

If your lift truck is equipped with an attachment, test the control lever
for correct function and briefly operate the attachment.
Steering System
NOTICE
The steering system, steer axle, and steering linkage on
your truck should be inspected periodically for abnormal
looseness and damage, leaking seals, etc. Also, be alert
for any changes in steering action. Hard steering, exces-
sive freeplay (looseness), or unusual sound when turning
or maneuvering indicates a need for inspection or servic-
ing.
Check the steering system by moving the steering handwheel in a
full right turn and then in a full left turn. Return the handwheel to the
straight-ahead position. The steering system components should
operate smoothly when the handwheel is turned. Never operate a
truck that has a steering system fault.
!
WARNING
Fasten your seat belt before driving the truck.
Direction Control, Braking, and Inching

Be sure that the travel area is clear in front of the truck.
1. Push firmly on the brake pedal. Release the parking brake.
Move the directional control lever from NEUTRAL to FOR-
WARD.

2. Remove your right foot from the service brake pedal and put it
on the accelerator pedal. Push down until the truck moves
slowly forward. Remove your foot from the accelerator pedal
and push down on the service brake pedal to stop the truck. The
brakes should apply smoothly and equally.
Be sure the travel area is clear behind the truck.

3. Put the directional control lever in the REVERSE travel position.
Release the service brake and push down on the accelerator
pedal until the truck moves slowly in the reverse direction.
Remove your foot from the accelerator pedal and push down on
the service brake pedal to stop the truck. The brakes should
apply smoothly and equally.
4. Put the directional control in FORWARD. Press the inching
pedal fully down and hold. Depress the accelerator. The truck
should not move. Now, with the accelerator still depressed,
slowly release the inching pedal until the truck “inches” forward
smoothly and slowly.
Report any problems.
When you have completed the operational tests, park and leave
the truck according to standard shut down procedure as
described in Section 4 of this manual. Be sure to make a record of
all maintenance and operating problems you find.
Fluids, Filters, and Engine Accessories

To check fluid levels and other components within the engine
compartment, unlatch and open the hood to access the engine
compartment.
! CAUTION
To avoid the possibility of personal injury, never work in
the engine compartment with the engine running, except
when it is absolutely necessary to check or make
adjustments. Take extreme care to keep hands, tools,
loose clothing, etc., away from fan and drive belts. Also
remove watches, bracelets, and rings.

Engine Accessories
Inspect the engine coolant hoses and fan belt(s). Look for leaking
and obvious damage, worn (frayed) condition, breaks, etc. that could
cause failure during operation.
Engine Air Cleaner

Check the engine air cleaner for damage and contamination
(excessive dirt buildup and clogging). Be sure that the air cleaner
hose is securely connected (not loose or leaking). Fan or cone
shaped dust deposits on tube or hose surfaces indicate a leak.
Change or service the air cleaner element every 1000 operating
hours for LPG engine and Diesel engine, depending upon your
application. Service intervals may also be determined by the air
restriction indicator.
Battery
Inspect the battery for damage, cracks, leaking condition, etc. If the
terminals are corroded, clean and protect them with CLARK Battery
Saver (available from your CLARK dealer). If your battery has
removable cell caps, check to be sure the cells are all filled. Refill
them with distilled water.
! WARNING
EXPLOSIVE GASES: Do not smoke or have open flames
or sparks near batteries. An explosion can cause injury or
death.
Engine Cooling System

To check engine coolant level open the hood to the engine
compartment. Visually inspect the recovery bottle, locate the “HOT”
and “COLD” marks. The “HOT” mark indicates maximum level at
operating temperature. The “COLD” mark indicates additional
coolant needs to be added to the system.

The recovery bottle shown is a
typical illustration of overflow
system. Your actual system
may vary slightly.
A level anywhere between the
HOT and COLD marks is nor-
mal.
Inspect the coolant level in the
overflow bottle only.
!WARNING
Do not remove the radiator cap when the radiator is hot.
STEAM from the radiator will cause severe burns. Do not
remove the radiator cap to check the coolant level.
!WARNING
Never remove the radiator cap while the engine is
running. Stop the engine and wait until it has cooled.
Failure to do so could result in serious personal injury
from hot coolant or steam blowout and/or damage to the
cooling system or engine.
If the level is low, add a 50/50 mixture of specified coolant and water
to the correct fill level. If you have to add coolant more than once a
month or if you have to add more than one quart at a time, check the
coolant system for leaks.
• Check engine oil for presence of coolant leaking into
engine.
• Inspect the coolant for condition. Look for excessive con-
tamination or rust or oil in the coolant solution.
• Check the PM time interval for need to change coolant.
• Check the condition of radiator cap rubber seal and radiator
filler neck for damage. Be sure they are clean.
• Check overflow hose for clogging or damage.

NOTICE
Your lift truck cooling system is filled with a factory-
installed solution of 50% water and 50% permanent-type
antifreeze containing rust and corrosion inhibitors. You
should leave the solution in year around. Plain water may
be used in an emergency, but replace it with the specified
coolant as soon as possible to avoid damage to the sys-
tem. Do not use alcohol or methanol antifreeze.
Engine Oil and Filter

Locate the engine oil dipstick. Pull the dipstick out, wipe it with a
clean wiper, and reinsert it fully into the dipstick tube. Remove the
dipstick and check oil level.
It is normal to add some oil between oil changes. Keep the oil level
above the ADD mark on the dipstick by adding oil as required. Do not
overfill. Use the correct oil as specified under Lubricant Specifications.
It is recommended to:
• Drain and replace the engine crankcase oil every 500 oper-
ating hours. (depending on application). See NOTICE
• Engine Oil Filter must be changed at every PM when the oil
is changed.
• Remove the oil pan drain plug to drain old oil after the truck
has been in operation and the engine (oil) is at operating
temperature.
!
WARNING
Engine oil at operating temperature is hot and can cause
burns. Beware of splashing oil.
• Carefully check for leaks after changing oil and installing
new filter.
NOTICE
The time interval for changing engine oil depends upon
your application and operating conditions. To determine
the correct schedule for your truck, it is suggested that
you periodically submit engine oil samples to a commer-
cial laboratory for analysis of the condition of the oil.

ENGINE OIL PERFORMANCE DESIGNATION
: Refer to the “Engine Oil” in Section 8.
Hydraulic Sump Tank

Check the hydraulic sump tank fluid level. Correct fluid level is
important for proper system operation. Low fluid level can cause
pump damage. Overfilling can cause loss of fluid or lift system
malfunction.
Hydraulic fluid expands as its temperature rises. Therefore, it is
preferable to check the fluid level at operating temperature (after
approximately 30 minutes of truck operation). To check the fluid
level, first park the truck on a level surface and apply the parking
brake. Put the upright in a vertical position and lower the fork
carriage fully down. Pull the dipstick out, (attached to the sump
breather) wipe it with a clean wiper, and reinsert it. Remove dipstick
and check oil level. Keep the oil level above the LOW mark on the
dipstick by adding recommended hydraulic fluid only, as required. Do
not overfill.
Check the condition of the hydraulic fluid (age, color or clarity,
contamination). Change (replace) the oil as necessary.
Hydraulic Fluid and Filter Change

Drain and replace the hydraulic sump fluid every 2000 operating
hours. (Severe service or adverse conditions may require more
frequent fluid change). Replace the hydraulic oil filter elements at
every oil change. Remove, clean, and reinstall the hydraulic and
steer system suction line screens at first PM and every 1000 hours
thereafter. Check for leaks after installation of the filters. Also, check
that the hydraulic line connections at the filter adapter are tightened
correctly. The procedure for draining hydraulic sump tank is in your
Service Manual.

Sump Tank Breather Maintenance and Inspection

Remove the sump tank fill cap/breather and inspect for excessive
(obvious) contamination and damage. Replace the fill cap/breather,
per recommended PM schedule or as required by operating
conditions.
Transaxle Fluid Check

Before checking, run the engine until the unit is at operating
temperature. This is important since transmission oil temperature
should be minimum of 150°F to 250°F of maximum, the engine
should also be at operating temperature. Apply the parking brake.
With the engine operating at idle and the transmission in NEUTRAL,
and the parking brake set, check the fluid on the dipstick. Fill, if
necessary, to the FULL mark on the dipstick, using CLARK
transmission fluid. If unable to determine actual oil temperature, use
this alternate check method: With the unit cold, start and run the
engine at idle for 30 seconds then check the level and fill only to the
add mark.
NOTICE
Check the planned maintenance interval (operating hours)
or the condition of the oil to determine if the transaxle
fluid needs to be changed.
Lubrication
Truck Chassis Inspection and Lubrication
Lubrication and inspection of truck chassis components, including
steer wheels, steer axle linkage, steering cylinder, and wheel
bearings are easier if the truck is raised and blocked up under the
frame. Refer to your Service Manual for additional information on
machine blocking and jacking. Also refer to your Service Manual for
the location of grease fittings.
! WARNING
Do not raise the truck by lifting under the counterweight.
Inspect the steering cylinder piston rods, seals, and fasteners for
damage, leaks, and looseness. Lubricate the steer axle linkage rod
ends and linkage pivot points. Be sure to clean the grease fittings
before lubricating, and remove the excess grease from all points
after lubricating. Lubricate miscellaneous linkage as needed.

Upright and Tilt Cylinder Lubrication
Clean the fittings and lubricate the tilt cylinder rod end bushings
(forward end) and both the base rod-end bushings (rear end). Clean
and lubricate the upright trunnion bushingsU
Lift Chains
Lubricate the entire length of the upright rail lift and carriage chains
with CLARK Chain and Cable Lube.
IMPORTANT
Do not lubricate the carriage roller rails.
Air Cleaning
Always maintain a lift truck in a clean condition. Do not allow dirt,
dust, lint, or other contaminants to accumulate on the truck. Keep the
truck free from leaking oil and grease. Wipe up all oil spills. Keep the
controls and floorboards clean, dry, and safe. A clean truck makes it
easier to see leakage and loose, missing, or damaged parts, and
helps prevent fires. A clean truck runs cooler. The environment in
which a lift truck operates determines how often and to what extent
cleaning is necessary.
For example, trucks operating in manufacturing plants that have a
high level of dirt, dust, or lint (for example, cotton fibers or paper
dust) in the air or on the floor or ground, require more frequent
cleaning. The radiator especially may require daily air cleaning to
ensure correct cooling. If air pressure does not remove heavy
deposits of grease, oil, etc., it may be necessary to use steam or
liquid spray cleaner.
IMPORTANT
Lift trucks should be air cleaned at every PM interval, or
more often if necessary.
Use an air hose with special adapter or extension, a control valve,
and a nozzle to direct the air properly. Use clean, dry, low pressure,
compressed air. Restrict air pressure to 30 psi (207 kPa), maximum.
(OSHA requirement.)

!
CAUTION
Wear suitable eye protection and protective clothing
when air cleaning. Never point the air nozzle at anyone.
Air clean the upright assembly, drive axle, radiator—from both
counterweight and engine side, engine and accessories, driveline
and related components, and steer axle and cylinder.
Critical Fastener Torque Checks

Fasteners in highly loaded (critical) components can quickly fail if
they become loosened. Also, loose fasteners can cause damage or
failure of the component. For safety, it is important that the correct
torque be maintained on all critical fasteners of components that
directly support, handle, or control the load and protect the operator.
Critical items include:
• Drive axle mounting
• Overhead guard
• Drive and steer wheel mounting
• Tilt cylinder mounting and yokes
• Counterweight mounting
• Upright mounting and components
Torque specifications are in your Service Manual.
Lift Chain Maintenance

The chain system on the upright was designed for safe, efficient, and
reliable transmission of lifting force from hydraulic cylinder to the
forks. Safe use of your truck with minimum down-time depends on
the correct care and maintenance of the lift chains. Most complaints
of unacceptable chain performance are a result of poor maintenance.
Chains need periodic maintenance to give maximum service life.
!
WARNING
Do not attempt to repair a worn chain. Replace worn or
damaged chains. Do not piece chains together.

Lift Chain Inspection and Measurement
Inspect and lubricate the lift chains every PM (50-250 hours). When
operating in corrosive environments, inspect the chains every 50
hours. During the inspection, check for the following conditions:
• Rust and corrosion, cracked plates, raised or turned pins,
tight joints, wear, and worn pins or holes.
• When the pins or holes become worn, the chain becomes
longer. When a section of chain is 3% longer than a section
of new chain, the chain is worn and must be discarded.
• Chain wear can be measured by using a chain scale or a
steel tape measure. When checking chain wear, be sure to
measure a segment of chain that moves over a sheave. Do
not repair chains by cutting out the worn section and joining
in a new piece. If part of a chain is worn, replace all the
chains on a truck.
Lift Chain Lubrication

Lift chain lubrication is an important part of your maintenance
program. The lift chains operate under heavy loadings and function
more safely and have longer life if they are regularly and correctly
lubricated. CLARK chain lubricant is recommended; it is easily
sprayed on and provides superior lubrication. Heavy motor oil may
also be used as a lubricant and corrosion inhibitor.
Lift Chain Wear and Replacement Criteria:

1. (NEW CHAIN LENGTH) The
distance from the first pin
counted to the last pin counted
in a span while the chains are
lifting a small load.
2. (WORN CHAIN LENGTH) The 1 2 3
1
distance from the first pin
counted to the last pin counted
in a span while the chains are
lifting a small load.

3. (SPAN) The number of pins in the length (segment) of chain to

be measured.
4. (PITCH) The distance from the center of one pin to the center of
the next pin.
All chains must be replaced if any link has wear of 3% or more, or if
any of the damaged conditions noted above are found during
inspection. Order replacement chains from your CLARK dealer.
Replace all chains as a set. Do not remove factory lubrication or
paint new chains. Replace anchor pins and worn or broken anchors
when installing new chains. Adjust tension on new chains. Lubricate
chains when they are installed on the upright.
NOTICE
Please refer to your Service Manual for additional infor-
mation on lift chain measurement and maintenance.

Section 8. Specifications
Specifications
Contents
GTS20-33 ................................................................ 8-2

Engine Oil ............................................................... 8-5
Contents 8-1
GTS20-33
CLARK products and specifications are subject to improvements and

changes without notice or obligation.
Model Designation - Rated Load Capacity

GTS20 2000 kg @500mm load center [4409 lbs @20in]
Note: Rated capacity applies when using standard upright.
[GTS20-30 : 3195mm. GTS33 : 3165mm MFH]
Engine
Diesel Diesel LPG LPG
Yanmar Yanmar PSI HMC

Model : 4TNE98 4TNE94L 4G64 THETA 2.4
Cylinders : 4 4 4 4
Displacement
cubic inches : 202 186 143 143
liters : 3.3 3.0 2.3 2.3
Idle RPM : 850 810 700 750
Rated RPM : 2300 2200 2650 2650
Rated kW : 44.3 34.3 51.6 52.5
Cooling System
Automotive type crossflow radiator.
Cooling system pressure (radiator cap): 88 kPa nominal, 12.8psi
Thermostat: Diesel & LPG, 82°C (180°F), fully open 95°C (203°F)
Powershift Transmission
Speed : 1 Forward / 1 Reverse
Overall Ratios : FWD/REV 1:1 (Diesel)
1.23:1 (LPG)
Convertor Stall Ratio : 2.87:1
8-2 GTS20-33
Drive Axle
Full floating straight drive axle. 4 pinion differential with wet disk
brakes
Wheels and Tires

Drive GTS20-25 Single : 7.00×12-14PR...............1000kpa (145psi)
GTS30-33 Single : 28×9×15-14PR..............1000kpa (145psi)
GTS20-33 Dual : 7.00×12-14PR...............1000kpa (145psi)
Steer GTS20-25 6.00×9-10PR...................883kpa(128psi)
GTS30-33 6.50×10-12PR.................883kpa(128psi)
Standard Electrical System

Type: 12 volt DC, negative ground Fuses: 10, 20 amps
Batteries: BCI Group 45
Fuel Recommendations
Diesel: D-2 with cetane rating of 45 or higher.
D-1 and Jet A-1 also acceptable.
LPG: HD-5 propane
Fill Capacities (fluid volumes-liters, quarts, gallons,kilogram,pound)

Cooling Eng.oil,w/ Transmis- Hydraulic Fuel tank
system filter sion sump
GTS20-25D 14L[14.8Q] 9.0L[9.5Q] 11L[11.6Q] 50L[13.2G] 52L[13.7G]
GTS30-33D 14L[14.8Q] 9.0L[9.5Q] 11L[11.6Q] 55L[14.5G] 56L[14.8G]
GTS20-25L 8.5L[9.0Q] 5.5L[5.5Q] 11L[11.6Q] 50L[13.2G] 15kg[33 lb]
GTS30-33L 8.5L[9.0Q] 5.5L[5.5Q] 11L[11.6Q] 55L[14.5G] 15kg[33 lb]
Engine Coolant Recommendation

Use a mixture of 50% ethylene glycol permanent-type anti-freeze
containing rust and corrosion inhibitor only.
Note: This mixture provides anti-freeze protection level of -37°C
(-34°F), approximately.
Transmission Fluid Recommendation

Use CLARK Specification MS-276A CLARK Part number 2776236.
GTS20-33 8-3
Hydraulic Fluid Recommendation
Use CLARK Specification MS-68 CLARK Part number 2776239
Hydraulic Oil, with anti-wear additives, or equivalent only.
Truck Weights
- with standard upright.
[GTS20-30 : 3195mm, GTS33 : 3165mm MFH]
Gross Vehicle Empty Vehicle Loaded Drive Empty Drive
Weight(kg[lbs]) Weight (kg[lbs]) Axle (kg[lbs]) Axle (kg[lbs])
Pneumatic Diesel
GTS20 5396[11895] 3396[7486] 4579[10094] 1489[3282]
GTS25 6200[13667] 3700[8156] 5381[11862] 1330[2931]
GTS30 7070[15585] 4070[8972] 6240[13756] 1479[3260]
GTS33 7576[16701] 4276[9426] 6712[14796] 1588[3500]
Pneumatic LPG
GTS20 5327[11743] 3327[7334] 4639[10226] 1460[3218]
GTS25 6182[13628] 3682[8116] 5308[11701] 1335[2943]
GTS30 7036[15510] 4036[8897] 6148[13553] 1445[3185]
GTS33 7550[16643] 4250[9369] 6561[14463] 1387[3057]
8-4 GTS20-33
Engine Oil
Engine Oil Recommendation

LPG truck
PSI 4G64 - in accordance with API classification more than a class
SM grade / SAE 10W-30
HMC - in accordance with API classification more than a class SM
/ SAE 10W-30 (in accordance with ILSAC classification
more than a class GF-4 / SAE 10W-30)
Diesel truck
Yanmar - in accordance with API classification CD or higher / SAE
10W-30 (in accordance with ACEA classification E-3,
E-4, E5 / SAE 10W-30)
-40 -30 -20 -10 0 +10 +20 +30 +40 +50
SAE 0W-30
SAE 5W-30
SAE 5W-40
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-50
SAE 10W
SAE 20W
SAE 30
SAE 40
Engine Oil 8-5

IMPORTANT
Do not extend oil change intervals from those specified
when using synthetic lubricants.
Fill crankcase with correct amount of oil. When adding oil between oil
changes, it is preferable to use the same brand as various oils may
be incompatible. Refer to the Maintenance and Lubrication Section
for recommended oil change intervals.
IMPORTANT
Do not overfill crankcase. Excess oil causes foaming and
can cause loss of lubrication and higher operating tem-
peratures, resulting in engine damage.
8-6 Engine Oil

Index
A Disassembling the split rim

A Message to CLARK wheel ......................................7-17
Lift Truck Operators ..................... ii Do’s and Don’ts ........................1-3
Adjusting the Load Forks ....... 4-10 Drop-Offs ..................................2-5
Adjusting the Seat ................... 4-4
E
After Operating the Truck ...... 4-16
Engine ......................................8-2
Air Cleaning ........................... 7-26
Engine Accessories ................7-21
Attached position of
safety decals.......................... 3-18 Engine Air Cleaner .................7-21
Auxiliary Control Lever Engine Coolant
(Optional) ............................... 3-12 Recommendation .....................8-3
Auxiliary Controls (Option) ..... 7-19 Engine Cooling System ..........7-21
Engine Oil .................................8-5
B Engine Oil and Filter ...............7-23
Battery ................................... 7-21 Engine Stop ............................3-10
Before Operating the Truck ..... 4-2 Extreme Operation ...................7-9
Brake Pedals ......................... 3-11
Braking .................................... 4-6 F
Buckling Up ............................. 4-4 Fill Capacities ...........................8-3
Fluids, Filters, and Engine
C Accessories ............................7-20
Chain Slack ............................. 2-7 Fork Safety ...............................1-8
Cold Start Preheating Forks ......................................7-15
(Diesel Only) ............................ 3-9 Fuel Recommendations ...........8-3
Concluding the Inspection ....... 5-4 Fuel Safety Practices ...............5-5
Controlling Speed .................... 4-6 Functional Checks ....................5-4
Cooling System ....................... 8-2 Functional Tests .....................7-17
Critical Fastener Torque
Checks ................................... 7-27 G
General Tire Maintenance,
D Inspection, and Repair ...........1-16
Daily Inspection ....................... 1-2 Grades, Ramps, Slopes,
Daily Safety Inspection ............ 5-2 and lnclines ............................1-11
Direction Control Lever .......... 3-11 GTS20-33 .................................8-2
Direction Control, Braking,
H
and Inching ............................ 7-19
Hood open ..............................3-13
Horn .......................................7-17
Index-1
Horn Button ........................... 3-11 Longitudinal Tip-over ..............1-13
Hot Surface Warning Decal ... 3-16 Loose Loads .............................2-2
Hour Meter ............................. 3-10 Low Overhead Clearance
Hour Meter ............................. 7-17 Fast Turns and High Loads ......2-4
How to Perform Planned Lubrication ..............................7-25
Maintenance .......................... 7-14 Lift Chain wear and
How to Tow a Disabled Truck .. 6-2 Replacement Criteriai .............7-28
How to Use Battery Jumper
M
Cables ..................................... 6-4
How to Use this Manual ............ viii Major Component Locations ....7-8
Hydraulic Control Levers ....... 3-12 N
Hydraulic Fluid and Filter
Neutral Start Switch ...............7-17
Change .................................. 7-24
No Riders .................................1-5
Hydraulic Sump Tank ............ 7-24
Normal Operation .....................7-9
I
O
Indicator Lights ...................... 7-18
Operating Safely ......................4-7
Instrument Pod ........................ 3-4
Operator Compartment ............3-3
Introduction .................................vi
Operator Daily Inspection ...........vii
Introduction .............................. 7-2
Operator Protection ..................1-7
K Operator Safety Warning
Keep Away from Forks Decal ......................................3-15
Decal ..................................... 3-16 Operator/Tip-Over ..................3-15
Key/Start Switch ...................... 3-9 Overhead Guard ....................7-14
Operator Controls .....................3-9
L
Lateral Tip-over ...................... 1-13 P
Lift Chain Inspection and Pallets and Skids ......................2-8
Measurement ......................... 7-28 Parking ...................................1-15
Lift Chain Lubrication ............. 7-28 Parking Brake .........................7-18
Lift Chain Maintenance .......... 7-27 Parking Brake .........................3-10
Lift Chains .............................. 7-26 Parking Brake Pedal ..............3-10
Lift Control Function ............... 3-12 Pedestrians ..............................1-6
Lift Mechanisms and Picking Up and Moving
Controls ................................. 7-18 Loads .....................................4-13
Load Handling ....................... 4-11 Pinch Points .............................1-9
Load Handling Components .. 7-14 Planned Maintenance ................vii
Long and Wide Loads Planned Maintenance
/ Rear Swing ............................ 2-3 Intervals ....................................7-9
Index-2
PM Report Form .................... 7-12 Traveling with a Load .............4-12
Pod Symbols and Functions .... 3-5 Truck Chassis Inspection
Positioning Forks and Upright . 4-5 and Lubrication .......................7-25
Powershift Transmission ......... 8-2 Truck Data and Capacity
Plate .......................................3-14
R Truck Description .....................3-2
Refueling Gasoline and Truck Weights ..........................8-4
Diesel Trucks ........................... 5-5
Refueling LPG Tanks .............. 5-6 U
Right-Angle Stacking ............... 2-6 Unitrol Pedal ...........................3-13
Right-Angle Stacking ............... 2-6 Unloading ...............................4-13
Routine Servicing and Upright and Tilt Cylinder
Maintenance ............................... vi Lubrication ..............................7-26
Upright Warning Decal ...........3-16
S
Safe Maintenance Practices .... 7-3 V
Safety Signs and Safety Visual Checks ..........................5-3
Messages ....................................x Visual Inspection ....................7-14
Seat Adjustment .................... 3-10
W
Seat Belts ................................ 1-4
Service Brakes and Inching What to do in Case of a
Pedal ..................................... 7-18 Tip-over ..................................1-14
Stacking ................................. 4-14 Wheels and Tires .....................8-3
Starting from a Wheels and Tires ...................7-16
Safe Condition ......................... 4-3
Starting the Truck .................... 4-4
Steering Column Pylon .......... 3-13
Steering System .................... 3-11
Severe Operation .................... 7-9
Steering System .................... 7-19
Sump Tank Breather Maintenance
and Inspection ....................... 7-25
Surface and Capacity ............ 1-12
T
Tilt Control Lever ................... 3-12
Tip-Over ................................. 1-13
Traction Disable Fuction ....... 3-11
Transaxle Fluid Check ........... 7-25
Travel ..................................... 1-10
Index-3
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 ; Feb. 2019

Om 1064 PDF

Uploaded by

Copyright:

Available Formats

Om 1064 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Om 1064 PDF

Uploaded by

Copyright:

Available Formats

INTERNAL COMBUSTION LIFT TRUCKS

[Do not remove this manual from the truck]

Part No. 8140267 (Eng)

YOU can prevent accidents

First: Learn safe operating rules and your company rules.

Next: Read your Operator’s Manual. If you do not understand

Learn about the unit you operate.

KNOW YOUR TRUCK

Then: Practice operating your

And: Keep your truck in safe

Breaking these rules will cause serious or fatal injury to

Lift trucks are specialized machines with unique operating

• Operator not properly trained

ii A Message to CLARK Lift Truck Operators

A Message to CLARK Lift Truck Operators iii

A Message to CLARK Lift Truck Operators....................... ii

How to Use this Manual .................................................... viii

Safety Signs and Safety Messages .................................... x

Section 1. General Safety Rules ......................................1-1

Section 2. Operating Hazards ..........................................2-1

Section 3. Operator Compartment and Controls ...........3-1

Section 4. Operating Procedures ....................................4-1

Section 5. Operator Maintenance and Care ....................5-1

Section 6. Emergency Starting and Towing ...................6-1

Section 7. Planned Maintenance and Lubrication .........7-1

Section 8. Specifications ..................................................8-1

A Message to CLARK Lift Truck Operators v

CLARK welcomes you to the growing group of professionals who

Routine Servicing and Maintenance

A lift truck should always be examined by the operator, before

In addition to the daily operator inspection, CLARK recommends

The procedures for a periodic planned maintenance program that

Modification of the truck prohibited

This manual is a digest of essential information about the safe

NOTICE: The descriptions and specifications included in this manual

viii How to Use this Manual

How to Use this Manual ix

Improper operation can cause accidents. Don’t take chances with

x Safety Signs and Safety Messages

General Safety Rules

Contents .......................................................................... 1-1

Daily Inspection .............................................................. 1-2

Do’s and Don’ts ............................................................... 1-3

Seat Belts ......................................................................... 1-4

No Riders ......................................................................... 1-5

Pedestrians ...................................................................... 1-6

Operator Protection ........................................................ 1-7

Fork Safety ...................................................................... 1-8

Pinch Points .................................................................... 1-9

Travel ............................................................................. 1-10

Grades, Ramps, Slopes, and lnclines ......................... 1-11

Surface and Capacity ................................................... 1-12

Tip-Over ......................................................................... 1-13

What to do in Case of a Tip-over ................................. 1-14

Parking ........................................................................... 1-15

General Tire Maintenance, Inspection, and Repair .... 1-16

Carbon monoxide and fumes ....................................... 1-17

1-2 Daily Inspection

Do’s and Don’ts