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Safety Signs and Safety Messages

Improper operation can cause accidents. Don’t take chances with incor-
rect 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 specifi c 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 identifi cation 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

Safety Signs and Safety Messages

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Summary of Contents for ESX Series

Page 1: ...657028 Book No 2827061 OM 718 Do not remove this manual from the truck Operator s Manual ESX Stand Up Counterbalanced Trucks ...

Page 2: ...______ Customer Truck Identification No ________________________ Truck Weight Empty __________________________________ Truck Rated Capacity _________________________________ Truck Gross Weight___________________________________ Truck Gross Weight Loaded w Rated Load________________ Special Equipment or Attachments _______________________ IMPORTANT Do not expose this manual to hot water or steam ...

Page 3: ...NOW YOUR TRUCK 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 Breaking these rules will cause serious or fatal injury to yourself and others Operator s Manual You must be trained and authorized to operate a lift truck 657028 ...

Page 4: ...ck 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 op...

Page 5: ...tandards in safety Remember before you start operating this lift truck be sure you under stand 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 ...

Page 6: ...iv ...

Page 7: ...ii Safety Signs and Safety Messages x Section 1 General Safety Rules 1 1 Section 2 Operating Hazards 2 1 Section 3 Common Truck 3 1 Section 4 Operator Maintenance and Care 4 1 Section 5 Operating Procedures 5 1 Section 6 Planned Maintenance 6 1 Section 7 Specifications 7 1 Index Index 1 Contents of this Manual ...

Page 8: ...st parking brake and horn are standard equipment Safe productiveoperationofalifttruckrequiresbothskillandknowledge on the part of the operator The operator must know understand and practice the safety rules and safe driving and load handling techniques describedinthismanual Todeveloptheskillrequired theoperatormust become familiar with the construction and features of the lift truck and how they f...

Page 9: ...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...

Page 10: ...n features components and maintenance items Also the Index helps you locate information about various topics NOTICE The descriptions and specifications included in this manual wereineffectatthetimeofprinting CLARKMaterialHandlingCompany reserves the right to make improvements and changes in specifica tions or design without notice and without incurring obligation Please check with your authorized ...

Page 11: ...afety rules and operating hazards Acquaint yourself with the various pro cedures 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 defensivelyandthink...

Page 12: ...he 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 messag...

Page 13: ...and Don ts 1 3 No Riders 1 4 Pedestrians 1 5 Operator Protection 1 6 Fork Safety 1 7 Pinch Points 1 8 Travel 1 9 Surface and Capacity 1 10 Grades Ramps Slopes and Inclines 1 11 Tip Over 1 12 What to do in Case of a Tip Over 1 13 Parking 1 14 General Safety Rules Contents ...

Page 14: ... inspection sheet Check for damage and maintenance problems Have repairs made before you operate the truck Daily Inspection Daily Inspection CAUTION DO NOT MAKE REPAIRS YOURSELF Lift truck mechanics are trained professionals They know how to make repairs safely See Section 4 ...

Page 15: ...02 OM0003 OM0004 OM0005 Do s and Don ts Don t mix drugs or alcohol with your job Do watch for pedestrians Don t block safety or emergency equipment Do wear safety equipment when required Don t smoke in NO SMOKING areas or when refueling Do s and Don ts ...

Page 16: ...1 4 No Riders 718001 657028 The operator is the only one who should be on a truck WARNING Never transport personnel on the forks of a lift truck No Riders ...

Page 17: ... 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 Pedestrians ...

Page 18: ...RTANT Keep under the overhead guard Always keep your body within the confines of the truck Be especially careful when traveling in reverse and ma neuvering in tight areas Operator Protection Keep arms and legs in the operator compartment ...

Page 19: ...1 General Safety Rules 1 7 657006 657005 There is special equip ment to raise people for overhead work DO NOT USE LIFT TRUCKS Never allow anyone to walk under raised forks DANGER Fork Safety Fork Safety 2372604 ...

Page 20: ... 2791862 WARNING Keep hands feet and legs out of the upright Pinch Points WARNING Don t use the upright as a ladder CAUTION Never try to repair the upright carriage chain or attach ment yourself Always get a trained mechanic ...

Page 21: ... truck is in motion Unstable loads are a hazardtoyouandtoyour fellow workers Alwaysmakecertainthat the load is well stacked and evenly positioned across both forks Never attempt to lift a load with only one fork Travel When handling bulky loads that restrict your vision operate your truck in reverse to improve vis ibility Be sure to pivot in the operator compartment to give maximum visibility Righ...

Page 22: ...itions They can cause a truck to tip over or lose trac tion 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 Surface and Capacity ...

Page 23: ...ithout a load travel up or down with the forks pointing downgrade see illustration WARNING Never turn on grades ramps slopes or inclines wait until you are back on level sur face 4 With a load travel up or down with the load pointing upgrade see illustration 5 Theloadshouldbetiltedback andraisedonlyhighasneces sary to clear the surface Without Load With Load Grade Ramps Slopes and Inclines 657014 ...

Page 24: ...fthetruck This condition is even more likely with excessiveforwardtilt brakinginforward travel or accelerating rearward Longitudinal tip over can occur by driv ing with the load down slope on a steep grade Tip over 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 runni...

Page 25: ...truck Tip over What to do in Case of a Tip over IMPORTANT If you tip an electric stand up lift truck over you can be seriously injured or killed no matter what you do Your best chance of surviving a tip over is to get away from the falling truck and load You must step out and away from the driver s compartment NOTE This only applies to a stand up rider type truck with a large rear opening in the d...

Page 26: ... and tilt forward Turn key to OFF position When you step from the truck or turn the key switch to OFF the brake will set itself Never step from the truck while it is motion Always come to a complete stop before leaving the truck Doing so is not only dangerous but will cause ac celerated wear of the brake components Parking Parking RUN Tilt 718019 657020 OFF ...

Page 27: ...s the operator you must look for other hazards Get your supervisor to help you identify and avoid those hazards Loose Loads 2 2 Long and Wide Loads 2 3 Rear Swing 2 3 Low Overhead Clearance 2 4 Fast Turns and High Loads 2 4 Docks Drop offs 2 5 Right Angle Stacking 2 6 Chain Slack 2 7 Pallets and Skids 2 8 Contents Operating Hazards Contents ...

Page 28: ... 2 Loose Loads WARNING Looseorunbalancedloads are dangerous Observe these precautions Stack and band loose material Never carry loose or uneven material Loose Loads Center wide loads OM0008 OM0006 OM0007 ...

Page 29: ...rstand your truck load rating When extra long material makes it neces sary to travel with the load elevated do so with extreme care and be alert to load end swing when turning Long and Wide Loads Rear Swing Long and Wide Loads Rear Swing WARNING When turning be sure the rear end of the truck does not swing into racks posts etc Watchforpedes triansbesidethe truck 718022 718066 ...

Page 30: ...eds Travel with a load raised only when removing or depositing a load Low Overhead Clearance Fast Turns 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 Low Overhead Clearance Fast Turns and High Loads 718064 718065 657017 657016 ...

Page 31: ...ou 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 657026 657027 ...

Page 32: ...2 6 Right Angle Stacking WARNING When right angle stacking or moving with a raised load to clear low objects avoid sharp turns and move slowly Right Angle Stacking S L O W L Y OM0009 ...

Page 33: ...s out of the upright WARNING Don t use the upright as a ladder CAUTION Nevertrytorepairtheupright carriage chain or attachment yourself Always get a trained mechanic OM0010 WARNING Slack chains mean rail or carriage hang up Raise the forks before you move or broken chains and or hoses can result ...

Page 34: ...e 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 condi tion and does not have defective or missing components and fasteners Pallets and Skids OM0011 ...

Page 35: ...ostic Display 3 5 Multi Function Control Handle 3 6 Lift Control 3 6 Tilt Control 3 7 Horn Button 3 7 Function Change Button 3 7 Variable Tilt Feature 3 8 Tilt Restriction Indicator 3 8 Vertical Mast Forks Level 3 9 Auxiliary Valve Control optional 3 9 Plugging 3 10 Parking Brake System 3 10 Truck Data Plate and Capacity Plate 3 11 Operator Safety Warning Decals 3 12 Common Truck Contents ...

Page 36: ...3 2 657028 Truck Description ESX 1 Overhead Guard 2 Operator Compartment 3 Battery Compartment 4 Battery Retainer 5 Steer Wheels 6 Upright 7 Load Backrest 8 Forks 9 Drive wheels 1 2 3 4 5 6 7 8 9 ...

Page 37: ...7041 Operator Compartment 1 Key Switch 2 Diagnostic Display 3 Steering Tiller 4 Warning Decal 5 Nameplate and Data Plates 6 Parking Brake 7 Multi Function Control Handle 8 Battery Disconnect 9 Control Handle Decal 1 2 3 4 5 6 7 8 9 Operator Compartment ...

Page 38: ... steering tiller has a soft grip knob to control the hydraulically as sisted power steering The tiller is oriented for maximum ease of use in forward or reverse travel 657042 Parking Brake System Emer gency Brake Consists of spring applied electro magnetic release disc brakes The parking brakes are activated by allowing the brake pedal to rise This brake should never be used as the normal stopping...

Page 39: ...tly reduced At this point the battery will be 80 discharged Charge or replace the battery immediately If you see an alarm code use the table below as a guide The codes listed below are usually the operator alarm codes faults Any other code is a service code Code Condition Likely Corrective Action AL001 Parking brake switch open Release parking brake AL079 Incorrect Start SRO Put direction control ...

Page 40: ...t togoforward To moveinthereversedirection move the handle toward the rear of the truck tothedriversleft Thefarther you move the multi function handle the faster the truck will travel NOTICE The direction control handle must be in neutral position prior to turning the key to the ON position Lift Lower Control To lift or lower the upright you must also use the multi function control lever Pull back...

Page 41: ...nve niently on the front face of the multi function control handle where your index finger typically rests The horn should be sounded before entering all intersections to help reduce the likelihood of a collision withotherlifttrucksorpedestrians This is for your safety and the safety of others The key switch must be turned ON before the horn will operate 718076 Function Change Button The function ...

Page 42: ...ed Back Tilt Position V Vertical RF Restricted Forward Tilt Posi tion FF Full Forward Tilt Position 1 Fast tilt speeds when forks are low 2 Full range of tilt when forks are low and restricted limited range of tilt when forks are high 3 Fork Level See full description on following page 4 Lift is disabled above free lift if tilt is outside of Restricted Range TILT RESTRICTION INDICATOR 718068 Tilt ...

Page 43: ...xample If Aux 1 is used for sideshifter moving the joystick forwards will sideshift the forks to the left Moving the joystick backwards will sideshift the forks to the right 718078 718077 Fork Level The Fork Level function operates byholdingthefunctionchangebut ton in located on the multi function controllever andusingyourthumb to operate the mini joystick up or down While holding the function cha...

Page 44: ...p the truck in an emergency as long as the key switch is turned ON and the battery is stillconnected Thisbrakeshouldneverbeusedasthenormalstopping device for the truck The parking brake will automatically be applied after the truck has come to a complete stop and will not release until the multi function control lever is moved into the forward or reverse direction The parking brake pedal must be d...

Page 45: ...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 attach ment 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 d...

Page 46: ...uck or possibly cause personal injury You should know understand and follow these instructions Safety and warning decals should be replaced immediately if missing or defaced damaged or illegible Refer to your Service Manual for location of all decals Leg Crushing Warning Decal This decal is located to the left of the steer tiller and warns of the danger of not keeping your arms and legs within the...

Page 47: ...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 attach ments The forks can fall and cause injury or death Always make sure that the forks are in the fully lowered position ...

Page 48: ...3 14 ...

Page 49: ...nd Care Contents CAUTION The Occupational Safety and Health Act OSHA re quires 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 tagged with a Out Of Service tag and taken out of service until it has been restored to safe operating condition ...

Page 50: ...dition totheproperauthority Ifthetruckbecomesunsafeinany 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...

Page 51: ...o 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...

Page 52: ... service technician 3 Be sure all controls and systems operate freely and return to neutral properly Check the Parking brake system Hydraulic controls lift tilt and side shift if equipped Multi function handle Direction Accelerator control Steering system When the functional checks are completed 1 Bring truck to complete stop 2 Make sure the multi function handle has returned to NEUTRAL 3 Lower th...

Page 53: ... noises or problems are investigated immediately OUT OF SERVICE OUT OF SERVICE 718080 Do not operate a lift truck that has a maintenance problem or is not safe to operate Remove the key from the ignition switch and put an Out of Service tag on the truck Be sure to put this Operator s Manual back in the holder in the operator s compartment Read the manual again if you are not sure of all lift truck...

Page 54: ...4 6 ...

Page 55: ...e Condition 5 3 Using the Diagnostic Display 5 4 Positioning Forks and Upright 5 5 Controlling Speed 5 6 Plugging 5 6 Parking Brake 5 6 Operating Safely 5 7 Adjusting the Load Forks 5 10 Load Handling 5 10 Traveling with a Load 5 11 Picking Up and Moving Loads 5 12 Unloading 5 13 Stacking 5 14 After Operating the Truck 5 16 ...

Page 56: ...rt or operate the truck or any of its functions orattachments fromanyplaceotherthanthedesignated 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 overheadguardunlessconditionspreventitsuse Donot remove ove...

Page 57: ...e in neutral or other correct position 5 Truck has received its daily inspection and is ready to operate When turning the key switch to ON with the multi fuction handle re leased the handle will be in the NEUTRAL position the truck should start only in the NEUTRAL position Starting the Truck Before you start the truck make sure that you have taken all the above mentioned precautions and that the d...

Page 58: ...At this point the battery will be 80 discharged Charge or replace the battery immediately If you see an alarm code use the table below as a guide The codes listed below are usually the operator alarm codes faults Any other code is a service code Code Condition Likely Corrective Action AL001 Parking brake switch open Release parking brake by de pressing brake pedal AL079 Incorrect Start SRO Putdire...

Page 59: ... the tips Theamountofforwardandrearward tilt to be used is governed by the application NOTICE When the upright carriage and or load is raised into a high el evated position the stability 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 judgment exercised by the operator Trucks equipp...

Page 60: ... of the drive motor to slow the truck to a stop As you are traveling move the multi function control handle towards neutral or into the opposite direction The amount of movement of the handle in the opposite direction controls the distance required for the truck to slow to a smooth controlled stop The maximum handle movement will result in the shortest stopping distance CAUTION Becarefulwhenpluggi...

Page 61: ...perate the truck only from the designated operator s position Stay within the confines of the lift truck profile dimensions Keep arms legs feet and hands inside the operator s compartment and away from the danger of passing obstructions Stay under the overhead guard CAUTION An overhead guard is intended to offer protection to the operator from falling objects but cannot protect against every possi...

Page 62: ...nturning Usespecialcarewhentraveling without a load because the risk of tipping over is greater with an empty truck especially at high speed and when turning Travel with the fork carriage tilted back and raised only enough to fully clear the ground or obstacles When the carriage load is in an elevated position the stability of the truck is reduced Do not elevate the load except during stacking CAU...

Page 63: ...anual Use common sense Drive carefully do not indulge in stunt driving or horseplay Observe traffic rules Watch for people and haz ards 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 immedi...

Page 64: ... 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 being 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 ...

Page 65: ...ht 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 except during ...

Page 66: ... 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 andcarefullyalignthetrucksquare with the load The forks should be adjusted to fit the load or pal let being handled and spread as wide as possible to provide good stability and balance With the lift an...

Page 67: ...ft 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 special 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 A...

Page 68: ...ion Fig 2 Lift raise the load high enough to clear the top surface of the stack Fig 3 Slowly move the load into position Be careful not to damage or move adjacent loads Fig 4 When the load is aligned with the stack beneath it carefully lower the load onto the top surface of the stack Fig 5 Lower drop the forks slightly to clear disen gage the load pallet Tilt the forks forward slightly if necessar...

Page 69: ...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 upright still vertical raise the forks until they begin to lift the ...

Page 70: ...n 1 Bring truck to complete stop 2 Put the multi function handle in the NEUTRAL position 3 Lower the lifting mechanism carriage and forks or attach ment fully to the floor 4 Apply the parking brake In addition when leaving the truck unattended 5 Tilt the upright forward until the forks are level and flat on the floor 6 Turn the key switch to the OFF position 7 Block the wheels if the truck must be...

Page 71: ...t Location 6 7 Daily Maintenance Checks 6 8 Periodic Maintenance Checks 6 9 PM Report Form 6 10 Visual Inspection 6 11 How to Perform PM 6 12 Functional Tests 6 15 SCR Traction Control 6 20 Checking the Hydraulic Fluid 6 21 Air Cleaning the Truck 6 22 Electric Truck Battery Maintenance 6 23 Battery Handling 6 24 Planned Maintenance ...

Page 72: ... powered industrial truck not in safe operat ing condition be removed from service and that all repairs be made by trained and authorized persons To assist you in keeping your lift truck in service and in good operating condition this section outlines maintenance procedures that should be doneatregularintervals Thisplannedapproachisconsideredessential to the life and safe performance of your truck...

Page 73: ...ed in conformance with the manufacturer s recommenda tions 3 Followascheduledplannedmaintenance lubrication andinspec tion 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 industrial plants and in special work...

Page 74: ...e wheels if the truck must be left on an in cline 12 Brakes steering mechanisms control mechanisms warning devices lights lift overload devices lift and tilt mechanisms load back rest overhead guard and frame members must be carefully and regularly inspected and maintained in a safe operating condi tion 13 Special trucks or devices designed and approved for hazard ous area operation must receive s...

Page 75: ...aintained in conformance with good practice Special attention must be paid to the condition of electrical insulation 18 To avoid injury to personnel or damage to the equipment consult the manufacturer s procedures in replacing contacts on any bat tery connection 19 Industrial trucks must be kept in a clean condition to minimize fire hazards and help in detection of loose or defective parts 20 Modi...

Page 76: ... inspections depends on the conditions of your particular application and lift truck usage The recommended planned maintenance and lubrication schedule lists those items considered essential to the safety life and performance of your truck with typical recommended service intervals Brief procedures for inspections operational checks cleaning lubrication and minor adjustments are included for your ...

Page 77: ... Motors 7 Sump Tank 8 Battery 9 Steer Axle and Housing 10 Steer Actuator 11 Steer Handle Use the illustration below to help you locate components included in the PM procedures 1 2 3 4 5 6 7 Component Locations Major Component Location The truck shown above is a typical representation of a CLARK electric counterbalanced stand up lift truck Your model may very slightly ...

Page 78: ...als Check condition of tires and wheels remove embedded objects Check wheel lug nuts Check diagnostic display Check overhead guard condition and bolts Check horn operation and other warning devices Check steering operation Check parking brake operation Check directional and speed control operations Check lift tilt and auxiliary operation Check upright lift chains and fasteners Check load backrest ...

Page 79: ...ther Lubricate tilt cylinder rod ends Lubricate upright and fittings Check lift chain adjustment and wear Check Lubricate lift chains Lubricate upright rollers 718053 Normal Operation Basically 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 ...

Page 80: ...l Controls i Seat Switch Operation c Air Clean All Motors j S R O a Condition d Lubricate Truck k P M T a Check for Leakage b Security of Mounting l Speed Limit Switches b Oil Level Condition m Steering Transducer c Security of Mounting a Cable Condition n Hydraulic Valve Switches d Tilt Column Operation a Decals Missing Condition b Electrolyte Level o Lift Valve Transducer b Data Plate Condition ...

Page 81: ...The maintenance procedures outlined in this section are intended to be used in conjunction with the PM Report Form They are arranged in groupings of maintenance work that are done in a logical and efficient sequence You make check marks or entries on the PM Report Form when you perform the PM Please notice on the form a special coding system for indicating the importance of needed repairs and or a...

Page 82: ... external leakage 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 Be sure that the driver s overhead guard loadbackrestextension and safety devices are in place undam aged and attached securely Then check all of the critical com ponents that h...

Page 83: ...r loose rollers and rail wear metal flaking Inspect all lift line hydraulic connections for leaks Lift Chain Carefully check the lift chains for wear rust and corrosion cracked or broken links stretching etc Check that the lift and carriage chains are adjusted to have equal tension Check that the lift chain anchor fasteners and locking means are in place and tight WARNING Uprights and lift chains ...

Page 84: ...or twists and bends Put a 2 thick wood block at least 4 wide by 24 long on the blade of the fork with the 4 surface against the blade Put a 24 carpenter s 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 If the fork blades are obviously bent or damaged have them inspected by a trained maintenance person before op...

Page 85: ... and systems are functioning correctly Test horn lights and all other safety equipment and accessories Be sure they are properly mounted and working correctly 718070 Check all wheel lug bolts to be sure none are loose or missing Have missing bolts replaced and loose bolts tightened to the correct torque before operating truck Press the horn button to check horn function Ifthehornoranyotherpart doe...

Page 86: ...truck has a Diagnostic Display 88888 should display on the digital readout for about one second after you turn the key switch to ON This indicates that the digital readout is OK After one second either the hour glass symbol or the wrench symbol should come on If the hour glass symbol comes on the digital readout shows the truck operating hours If the wrench symbol comes on an alarm code ap pears o...

Page 87: ...eriodic checks to ensure it is work ing properly To check brake holding capability and adjustment park the lift truck at the bottom of a grade and release the parking brake pedal The brake should hold a lift truck with rated load on a 15 grade When the pedal is released the truck should not move If you find a brake problem report it immediately Do not operate the truck until the brakes are repaire...

Page 88: ...g or jerking Watch for chain wobble or looseness the chains should have equal tension and move smoothly without notice able wobble 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 multi function control handle Watch the upright as it lowers When the for...

Page 89: ...traight ahead position The steeringsystemcomponentsshould operatesmoothlywhenthesteering tiller is turned Neveroperateatruckwithasteer ing system fault Direction Control Check and make sure that the travel area is clear in front of the truck Depress the parking brake pedal and move the control handle from NEUTRALtoFORWARDtravelposi tion The truck should move in the forward direction The travel spe...

Page 90: ...ed travel speed Then move the multi function handle to the REVERSE position The truck should slow to a smooth controlled stop and accelerate in the opposite direction Repeat the test by moving the direction control back to the forward position Check the multi function control while conducting the speed range tests It must move easily and smoothly throughout the acceleration stroke and return witho...

Page 91: ... You should have a trained and authorized mechanic check the fluid level for you Do not overfill Check the condition of the hydraulic fluid age color or clarity contamina tion Change replace the oil as necessary Critical Fastener 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 safet...

Page 92: ...e does not remove heavy deposits of grease oil etc it may be necessary to use liquid spray cleaner CAUTION Do not steam clean the Control Panel motors or electrical com ponents Lift trucks should be air cleaned at every PM interval and more often if needed Use an air hose with special adapter or extension having a control valve and nozzle to direct the air properly Use clean dry low pressure compr...

Page 93: ...on for dispersal of fumes from gassing batteries When handling acid concentrates greater than 50 percent acid above 1 400 specific gravity an eye wash fountain and deluge shower must be provided A conveyor overhead hoist or equivalent material handling equipment must be provided for handling batteries IMPORTANT Electric truck batteries are heavy and awkward to handle They are filled with a very ha...

Page 94: ...ial lifting device such as an insulated spreader bar to attach the hoist to the battery The width of the spreader bar hooks must be the same as the lifting eyes of the battery to prevent damage to the battery If the spreader bar hooks are movable carefully adjust the position width of the hooks so that the pull is directly upward vertical and no side load or force pressure is exerted on the batter...

Page 95: ... and injury Battery Charging 1 Personsmaintainingstoragebatteriesmustwearprotectivecloth ing such as face shield long sleeves rubber apron and gloves 2 Hydrogen emissions from charging batteries are flammable No smoking is allowed in the charging area Do not checktheelectrolytelevelwithanopen flame Donotallowopenflame sparks orelectricarcsinbatterychargingarea WARNING SULFURIC ACID The battery con...

Page 96: ...ious noted equipment is in the area in good repair and working properly If the battery is to be serviced be sure there are provisions to flush and neutralize spillage and to disperse ventilate fumes from gassing batteries on charge And be sure there are provisions for handling electrolyte 2 Before attempting to remove or charge a storage battery the truck should be positioned in the designated bat...

Page 97: ...LEANER to entire surface of battery Allow to set for approximately 30 seconds then wipe thoroughly with a wiping cloth or rag Chemical action will dissolve rust and corrosion After cleaning apply a second coating for protection This will prevent the start and growth of corrosion on battery terminals and cable connections Battery Service Records Keep a record of battery service and maintenance to o...

Page 98: ... specified for the truck 2 When changing batteries on battery electric trucks replacement batteries must be of the service weight that falls within the mini mum maximum range specified on truck nameplate 3 Be sure truck is properly positioned and parking brake applied 4 Handle battery only with approved lifting device Ensure that the opposite battery side gate battery stop is in place before slidi...

Page 99: ...Section 7 Specifications 7 1 Contents ESX 12 25 7 2 Specifications Contents ...

Page 100: ...1886kg 2014 914kg ESX15S 8735 3962kg 4404 1998kg 9975 4525kg 4331 1965kg 1757 797kg ESX15 9055 4107kg 4527 2053kg 9987 4530kg 4528 2054kg 2068 938kg ESX17 9417 4271kg 4659 2113kg 10878 4934kg 4758 2158kg 2040 925kg ESX20 9752 4423kg 4779 2168kg 11731 5321kg 4973 2256kg 2021 917kg ESX22 10071 4568kg 4814 2184kg 12507 5673kg 5257 2385kg 2064 936kg ESX25 10686 4847kg 5106 2316kg 13673 6202kg 5580 253...

Page 101: ...x5x5 2 per truck Battery Capacity Range 36 volt 18 cells 20 9 43 0 kWh 600 1240 amp hr 6 hr rating Battery fully charged 1 275 specific gravity 1 310 Exide Load Hog Discharged 1 160 to 1 120 specific gravity Battery Capacity Range 48 volt 24 cells 20 9 43 0 kWh 600 1240 amp hr 6 hr rating Battery fully charged 1 275 specific gravity 1 310 Exide Load Hog Discharged 1 160 to 1 120 specific gravity F...

Page 102: ...7 4 ...

Page 103: ...ecals Keep away from forks 3 13 Safety warning 3 12 Upright warning 3 13 Diagnostic display using 5 4 Diagnostic display 6 16 Do s and Don ts 1 3 Driver s Daily Checklist 1 2 Index F Fault codes operator 3 5 Forks 6 14 Forks and upright positioning 5 5 5 10 Fork wear and damage 6 14 Function change button 3 7 Functional checks 4 4 Functional tests 6 15 G General Safety Rules 1 1 H Horn button 3 7 ...

Page 104: ...tervals 6 8 Reporting problems 4 2 Riders 1 4 5 7 Right angle stacking 2 6 Routine Servicing vi S Safety inspection daily 1 2 Safety operating safely 5 7 Safety plates and decals See Decals and safety plates Safety Sign and Messages x Safety rules 1 1 Skids 2 8 Specifications 7 1 Stability 5 5 5 8 5 10 Stacking 5 14 Starting from a safe condition5 3 Surface and Capacity 1 10 Surface hazards 1 10 T...

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Page 106: ...iv ...

Page 107: ... Truck ______________________________________________ Control Panel _______________________________________ Drive Motor _________________________________________ Hydraulic Motor _____________________________________ ...

Page 108: ...Lexington Ky 40510 Printed in USA Additional copies of this manual may be purchased from YOUR AUTHORIZED CLARK DEALER ...

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