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Clark GTS 20 D Operator'S Manual Download Page 89

Section 7.  Planned Maintenance and Lubrication

Contents

7-1

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. 

Summary of Contents for GTS 20 D

Page 1: ...Do not remove this manual from the truck INTERNAL COMBUSTION LIFT TRUCKS Part No 8140267 Eng Book No OM 1064 Rev 1 3 Jan 2019 GTS 20 25 30 33 D GTS 20 25 30 33 L...

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Page 3: ...thers 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 y...

Page 4: ...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 opera...

Page 5: ...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...

Page 6: ...iv...

Page 7: ...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 Oper...

Page 8: ...ck 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 ope...

Page 9: ...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...

Page 10: ...resents 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...

Page 11: ...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 infor...

Page 12: ...ructions 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 Contac...

Page 13: ...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...

Page 14: ...t 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 ar...

Page 15: ...tch for pedestrians Don t blocksafetyor emergency equipment Do wear safetyequipment when required Don t smoke in NOSMOKING areas or when refueling XXX Don t use the similar fuel If forklift truckisto...

Page 16: ...1 4 Seat Belts Seat Belts ALWAYS BUCKLE UP Seat belts can reduce injuries...

Page 17: ...Section 1 General Safety Rules No Riders 1 5 No Riders The operator is the only one who should be on a truck Never transport personnel on the forks of a lift truck...

Page 18: ...tion 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...

Page 19: ...Section 1 General Safety Rules Operator Protection 1 7 Operator Protection Keep under the overhead guard Always keep your body within the confines of the truck...

Page 20: ...1 8 Fork Safety Fork Safety Neverallow anyone to walkunderraised forks There isspecial equipment toraise people foroverhead work DONOTUSE LIFTTRUCKS 2372604 DANGER...

Page 21: ...Pinch Points 1 9 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 yoursel...

Page 22: ...tion 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 Right Wrong Unstable loads are a ha...

Page 23: ...ction 1 General Safety Rules Grades Ramps Slopes and lnclines 1 11 Grades Ramps Slopes and lnclines WARNING Never turn on a grade either loaded or unloaded Unloaded Forks Downgrade Loaded Forks Upgrad...

Page 24: ...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 I...

Page 25: ...f 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...

Page 26: ...tarts 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 bel...

Page 27: ...Rules Parking 1 15 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...

Page 28: ...ve 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 l...

Page 29: ...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...

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Page 31: ...earance 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...

Page 32: ...2 2 Loose Loads 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...

Page 33: ...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...

Page 34: ...oad 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 t...

Page 35: ...s 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...

Page 36: ...2 6 Right Angle Stacking Right Angle Stacking SLOWLY When right angle stacking or moving with a raised load to clear low objects avoid sharp turns and move slowly...

Page 37: ...Section 2 Operating Hazards Chain Slack 2 7 Chain Slack WARNING Slack chains mean rail or carriage hang up Raise the forks before you move or broken chains can result...

Page 38: ...G 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...

Page 39: ...Operator Compartment and Controls Contents 3 1 Operator Compartment and Controls Contents Truck Description 3 2 Operator Compartment 3 3 Instrument Pod 3 4 Pod Symbols and Functions 3 5 Operator Cont...

Page 40: ...el 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 represent...

Page 41: ...6 7 8 9 10 11 12 13 14 1 Steering Handwheel 2 Forward Reverse Lever 3 Inching Pedal 4 Brake Pedal 5 Seat Adjustment Lever 6 Horn Button 7 Instrument Pod 8 Turn Signal Lever 9 Accelerator Pedal 10 Key...

Page 42: ...re 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 Ic...

Page 43: ...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...

Page 44: ...r 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...

Page 45: ...en 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...

Page 46: ...e 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 Parki...

Page 47: ...g 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 Refer to the service man...

Page 48: ...ad 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 Refer to the service manual or contact the CLARK dealer for ho...

Page 49: ...TART position it automatically returns to the ON position where the starter is disengaged andtheentiretruckelectricalsystemison The key switch has a mechanical anti restart feature which prevents the...

Page 50: ...er 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 The brake is applied by...

Page 51: ...em 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 O...

Page 52: ...ositions 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...

Page 53: ...ion 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 rever...

Page 54: ...n 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...

Page 55: ...voiding injury in the event of a tip over or off the dock mishap Lift trucks can be tipped over if operated improperly Analysis of lift truck accidents has shown that the driver cannot react quickly e...

Page 56: ...d 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...

Page 57: ...ition 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...

Page 58: ...tely They contain important information Contact your local CLARK dealer to acquire new decals or data plates 1 2 3 4 5 1 0 1 1 2 A B 3 NOTE NOTE RECOMMENDED SAFETY MAINTENANCE PROCEDURE FOR LP GAS FUE...

Page 59: ...Section 4 Operating Procedures Contents 4 1 Operating Procedures Contents Before Operating the Truck 4 2 Starting from a Safe Condition 4 3...

Page 60: ...perator 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 st...

Page 61: ...s 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 r...

Page 62: ...er 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 stra...

Page 63: ...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 equip...

Page 64: ...e 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 IMPORT...

Page 65: ...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 prof...

Page 66: ...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 t...

Page 67: ...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 a...

Page 68: ...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...

Page 69: ...ckwards 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...

Page 70: ...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 handl...

Page 71: ...oad 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 dis...

Page 72: ...g 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...

Page 73: ...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 t...

Page 74: ...reas 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...

Page 75: ...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 fo...

Page 76: ...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 immed...

Page 77: ...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 brea...

Page 78: ...nd auxiliary if installed Accelerator Directional control Steering system Lift mechanism and any attachments When the functional checks are completed follow the standard shut down procedures given in...

Page 79: ...Section 5 Operator Maintenance and Care Fuel Safety Practices 5 5 Fuel Safety Practices Refueling Gasoline and Diesel Trucks Use clean properly marked fuel cans Clean up spills...

Page 80: ...cording to local 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 supe...

Page 81: ...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 fu...

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Page 83: ...Section 6 Emergency Starting and Towing Contents 6 1 Emergency Starting and Towing Contents How to Tow a Disabled Truck 6 2 How to Use Battery Jumper Cables 6 4...

Page 84: ...s 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...

Page 85: ...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 igniti...

Page 86: ...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...

Page 87: ...or 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 Appl...

Page 88: ...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...

Page 89: ...fe 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 PERS...

Page 90: ...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...

Page 91: ...strial 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 person...

Page 92: ...ing 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 t...

Page 93: ...nder 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 deca...

Page 94: ...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...

Page 95: ...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...

Page 96: ...own above is a typical representation of a CLARK internal combustion lift truck Your model may vary slightly 1 2 3 4 5 6 14 7 10 8 13 12 11 9 1 Radiator 2 Transmission Cooler 3 Frame 4 Steer Axle 5 En...

Page 97: ...r 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...

Page 98: ...ners 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 Dies...

Page 99: ...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 C...

Page 100: ...nction 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 indicatin...

Page 101: ...PM Report Form 7 13 Section 7 Planned Maintenance and Lubrication...

Page 102: ...tc Check for hydraulic oil leaks and loose fittings CAUTION CAUTION HYDRAULIC FLUID PRESSURE Do not use your hands to check for hydraulic leakage Fluid under pressure can penetrate your skin and cause...

Page 103: ...rmation 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 fork tips should be no more th...

Page 104: ...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 WAR...

Page 105: ...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 butto...

Page 106: ...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...

Page 107: ...achment 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...

Page 108: ...ess 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 smo...

Page 109: ...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 ar...

Page 110: ...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 an...

Page 111: ...vel 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 crank...

Page 112: ...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 req...

Page 113: ...eck 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 co...

Page 114: ...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 nec...

Page 115: ...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 cylinde...

Page 116: ...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 lubricatio...

Page 117: ...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 p...

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Page 119: ...Section 8 Specifications Contents 8 1 Specifications Contents GTS20 33 8 2 Engine Oil 8 5...

Page 120: ...G 82 C 180 F fully open 95 C 203 F Powershift Transmission GTS20 2000 kg 500mm load center 4409 lbs 20in GTS25 2500 kg 500mm load center 5511 lbs 20in GTS30 3000 kg 500mm load center 6613 lbs 20in GTS...

Page 121: ...or 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 Drive GTS20 25 Si...

Page 122: ...ht kg lbs Loaded Drive Axle kg lbs Empty Drive 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 6...

Page 123: ...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...

Page 124: ...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 IMP...

Page 125: ...27 D Daily Inspection 1 2 Daily Safety Inspection 5 2 Direction Control Lever 3 11 Direction Control Braking and Inching 7 19 Disassembling the split rim wheel 7 17 Do s and Don ts 1 3 Drop Offs 2 5...

Page 126: ...ion 3 12 Lift Mechanisms and Controls 7 18 Load Handling 4 11 Load Handling Components 7 14 Long and Wide Loads Rear Swing 2 3 Longitudinal Tip over 1 13 Loose Loads 2 2 Low Overhead Clearance Fast Tu...

Page 127: ...g 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 Le...

Page 128: ...CLARK MATERIAL HANDLING COMPANY 700 Enterprise Drive Lexington Kentucky 40510 www clarkmhc com Printed Date Feb 2019 Additional copies of this manual may be purchased from YOUR AUTHORIZED CLARK DEALER...

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