Clark S20 D Operator'S Manual Download

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A Message to CLARK Lift Truck Operators

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, Towing and Lowering ....6-1

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

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

Summary of Contents for S20 D

Page 1: ...Do not remove this manual from the truck S20 25 30 35 D L G S20 25 30 32C L G INTERNAL COMBUSTION LIFT TRUCKS Part No 8140450 Eng Book No OM 1067 Rev 1 9 Nov 2019...

Page 2: ......

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: ...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 corre...

Page 5: ...d in safe lift truck repair procedures and are authorized by your employer CAUTION This forklift burns fuel which will produce exhaust gases that are harmful to humans They include carbon monox ide ca...

Page 6: ...iv...

Page 7: ...ty 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...

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: ...nts details on how to perform the operator s daily safety inspection and refuel the lift truck Section 6 Emergency Starting Towing and Lowering gives instructions for towing your truck in an emergency...

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: ...atch for pedestrians Don t blocksafetyoremergency equipment Dowearsafetyequipment when required Don t smoke in NOSMOKING areas orwhen refueling XXX Don t use the similar fuel If forklift truckistobe o...

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 operatoristhe onlyone whoshould be on atruck Nevertransport personnel on the forksof alift 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 Never allow anyone to walk under raised forks 2372604 DANGER There is special equipment to raise people for overhead work DO NOT USE LIFT TRUCKS...

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: ...is even more likely with excessive forward tilt braking in for ward travel or accelerating rearward Longitudinal tip over can occur by driving with the load down slope on a steep grade Never travel wi...

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: ...rade 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 the parking brake by pressing the Parking Brake Switch For...

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...

Page 30: ......

Page 31: ...ce 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 IMPORTANT This section shows some of the hazards that may cause you or someone around you...

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: ...Section 3 Operator Compartment and Controls Contents 3 1 Operator Compartment and Controls Contents Truck Description 3 2 Operator Compartment 3 3 Instrument Pod 3 4 Display 3 6 Operator Controls 3 41...

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: ...d Reverse Lever 2 Steering Handwheel 3 Horn Button 4 Parking Brake Switch 5 Key Switch 6 Turn Signal Lever 7 Instrument Pod 8 Accelerator Pedal 9 Lift Control Lever 10 Tilt Control Lever 11 Auxiliary...

Page 42: ...or 5 Head Light Indicator 6 Rear Work Light Indicator 7 Fuel Level Indicator 8 Mode Select Switch Membrane Switch 9 Coolant Temperature Gauge 10 Hour Meter or Trip Distance Indicator 11 Direction Indi...

Page 43: ...ersists the truck will shut down again 3 Neutral start function and Anti restart function 1 Neutral start function The instrument pod will not allow the starter to be engaged if directional switches a...

Page 44: ...CD Standard Speed meter activated if speed more than 1 km h 0 6 mph 1 Time Indicator 2 Speed meter Optional Function activated like weight when speed is less 1 km h 0 6 mph 1 Weight Indicator Optional...

Page 45: ...enu 2 Save the values with this enter button pass word changing or adjusting value in sub menu Upper arrow button Turtle select button 1 At the menu mode this switch is used for mov ing to higher menu...

Page 46: ...witch function performed 3 At the menu mode if pushing for over 1 second the changing value speed will decrease 3 Indication of Display Turn on the key switch Key on 1 Show CLARK until main screen boo...

Page 47: ...6 117 C 110 111 C 106 107 C 120 122 C 2 113 115 C 100 109 C 104 105 C 117 119 C 1 110 112 C 98 99 C 100 103 C 115 116 C GREEN Middle 5 101 109 C 91 97 C 91 99 C 112 114 C 4 86 100 C 81 90 C 81 90 C 96...

Page 48: ...EMPTY red levels are indicated When the low fuel icon begins flashing the truck must be immediately parked and the fuel tank renewed before the engine shuts down 3 Zone specification Zone Gauge Step...

Page 49: ...etting for km and miles Direction Indicator Standard Show travel direction Warning Symbol and Lamp Status Indicator ICON lights displayed for recognition when errors or issues occur Parking Brake Icon...

Page 50: ...multaneously displayed Work Light Icon There are two ways to turn ON OFF the work light 1 The work light is activated using the button Push the work light button to turn the light ON Push it again to...

Page 51: ...rk light is deactivated 3 The rear work light is activated when the directional lever is placed in reverse and then deactivated when it is moved out of reverse If the operator turns the switch OFF the...

Page 52: ...ning Lamp 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...

Page 53: ...er the light goes out you may start the engine If the engine fails to start turn the key switch to ON and wait for 30 seconds before turning it to start Smart Interlock Icon optional Operating sitting...

Page 54: ...mation of setup 4 Display Monitoring Menu Mode Monitor Description 1 How to display Driver menu mode and Service menu mode 1 Pressing the Mode button displays the Menu mode without entering the passwo...

Page 55: ...n screen simul taneously for two seconds 2 8 digit Ref No 1 and 8 digit No 2 are displayed as shown on the right figure 3 Contact your dealer or CLARK Service Center with the numbers Driver Menu Mode...

Page 56: ...CLOCK SETUP 2 Reset Menu of Trip Hour Meter or Trip Distance When the forklift truck operates at speed higher than 0 5 km h Trip Hour Meter or Trip Distance is displayed when the truck operates at spe...

Page 57: ...e SETUP WEIGHT SET to ZERO WARNING When the default is not reset to zero after changing the attachment actual value of load weight may be different from measurement value 4 Monitor Alarm Logbook Menu...

Page 58: ...f displaying message only Message displaying buzzer sounding function Message displaying horn sounding function NOTICE See page 3 33 Seat Warning for further information 2 Seat Shutdown Setup When the...

Page 59: ...isplaying horn sounding function 6 Smart Interlock Time Setup When the hours set on the smart interlock setup conditions have elapsed the buzzer sounds Select and set value from 0 5 10 and 20 seconds...

Page 60: ...verse Setting Rear Work Lamp only activated when directional lever placed in reverse 2 Strobe Light Setup Used to set operation of the strobe light A password is required contact your dealer Key setti...

Page 61: ...Service Menu Mode SETUP HOUR SETUP 1 Operating hour Operation hours are set based on the engine operation of the forklift truck 2 KEY ON hour Setting key On hours of the forklift truck A password is r...

Page 62: ...panel until maintenance hours are reached If specified maintenance hours are exceeded such exceeded hours are displayed on the instrument panel Such exceeded hours are displayed until reset Password S...

Page 63: ...urtle Icon button is not capable of turning the speed limit function on or off Setup path Service Menu Mode SETUP SPEED SETUP 1 Speed Limit Function Setup for the forklift trucks mounted with Isuzu PS...

Page 64: ...ding upon unit setting Changing the value in the driver menu mode is not possible A password is required contact your dealer 3 Weight value indication Weight value sensor value is displayed Changing t...

Page 65: ...more than 0 km h the gear lever shifts to neutral position and the parking brake automatically applies A password is required contact your dealer CAUTION Make sure parking functions work correctly wh...

Page 66: ...els forward at speed of 10 km h with a setting of 8 km h and the direction lever is shifted from for ward to reverse direction the speed of the truck is reduced to 8 km h before the direction change s...

Page 67: ...splays two or three errors Pressing Mode button displays the menu mode If there is no error a submenu is not displayed It is possible to check error history from Parameter HISTORIC ERROR ALARM LOGBOOK...

Page 68: ...ini Lever controller error optional If an error takes place on the forklift truck Fault Icon is turned on the main screen and error message is displayed Pressing Down Arrow on the right of the instrum...

Page 69: ...g Engine Error on the previous page for activated error codes and specifics of errors 5 Parking Brake Counter Applications of the parking brake at forklift truck speeds of 5 km h or more are counted T...

Page 70: ...EN Seat belt warning 4 REFASTEN SEAT BELT Smart interlock warning 5 NEXT MAINTENANCE IN Maintenance hour warning 6 MAXIMUM TILT ACHIEVED Tilt limit warning 7 ENGINE WILL SHUT DOWN AFTER 30 SECONDS Eng...

Page 71: ...r releases the seat belt with the gear lever shifted out of the neutral position Warning message is displayed Seat Icon and Seat belt Icon blink and the buzzer sounds three times The warning is remove...

Page 72: ...km h B ON 3km h or lower a C over 3km h a D Truck status Description of operation Remark A 1 Warning displayed 2 Trans shifts into neutral 3 Delay time 1 sec 4 Auto parking brake applied B 1 Warning d...

Page 73: ...ed when turning the key on if defined maintenance hours are not exhausted When defined maintenance hours are exhausted hours exceeding the maintenance hours are displayed on the screen when turning th...

Page 74: ...g is automatically performed 30 seconds later 4 Move the forklift truck to safe place before auto shutdown and turn the engine off NOTICE When the warning is reset during shutdown mode shut down mode...

Page 75: ...engine oil pressure error persists for 8 seconds or longer while the engine is running 1 Error is detected from the operating engine 2 Warning message popup window is prompted on the display the buzze...

Page 76: ...ard solenoid valves are released 20 seconds later 3 The engine is shut down and the parking brake applies 30 sec ond later 3 The warning takes place also when coolant temperature does not vary for 10...

Page 77: ...idle mode 2 If shutdown warning alarm is indicated on the display move the forklift truck to safe place before auto shutdown and turn the engine off Low Level Fuel Warning Warning takes place if fuel...

Page 78: ...ontroller Malfunction on truck controller Check error log messages Check CAN Bus Line Malfunction in the CAN BUS system Check error log messages Engine Running Key in Start Position While Engine Runni...

Page 79: ...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 position it automatically returns to the ON position...

Page 80: ...rking brake automatically applies when the truck is turned OFF or when the operator leaves the seat The parking brake will also automatically apply during certain functions ex Anti Roll Back CAUTION N...

Page 81: ...essing 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 t...

Page 82: ...wering 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 lowe...

Page 83: ...n 5 Auxiliary Function optional Clamp Lever Lock Button or Push Button 1 Vertical Mast Control Function optional When pressing this button and operating the tilt control lever the mast will be stop wh...

Page 84: ...tween forward and backward traveling Always operate the control switch from a properly seated posi tion 2 Lift Lever Raise and lower the forks for loading Raise Pull backward Lower Push forward Raisin...

Page 85: ...n be adjusted by the extent of operating the lever 5 Emergency Disconnect Activating this will disable all hydraulic functions It must be pulled out to reset and re enable hydraulic functions 6 Attach...

Page 86: ...and lower hood until latched IMPORTANT Ground speed is controlled by the accelerator pedal only For safety reasons your CLARK forklift truck is fitted with a neutral start feature The purpose of this...

Page 87: ...d fuse in Fuse Specification Truck Engine Type ISUZU YANMAR FORD PSI F1 Sub Controller 10A F2 Sub Controller 10A F3 Parking 5A F4 Turn signal 10A F5 Horn 10A F6 Speed Limit Control 15A F7 Brake 5A F8...

Page 88: ...A Option 20A F18 Option 20A Speed Limit Control Dual 15A F19 Spare 10A F20 Spare 5A F21 Direction Switch 10A F22 W S Sensor 10A F23 Display 10A F24 Hyd Valve ISO Relay 10A F25 Aircon option 10A Option...

Page 89: ...Medium fan speed III High fan speed b Turn the temperature control 2 to the right to increase or to the left to decrease the cabin temperature NOTICE To defrost the windscreen set the fan speed to th...

Page 90: ...side air temperature Keep the doors and windows closed when the air condi tioning system is switched on There should be no draft effect Replacement of the air filters a Loosen the screws on the sides...

Page 91: ...nd 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 capa...

Page 92: ...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 can rarely react quick...

Page 93: ...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 da...

Page 94: ...E PROCEDURE FOR LP GAS FUELED FORKLIFT TRUCKS SERVICE WORK SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY P No 928847 1 2 3 4 5 NOTE P NO 8009528 LPG FUEL CYLINDER REPLACEMENT PROCEDURE Most lift tru...

Page 95: ...Section 4 Operating Procedures Contents 4 1 Operating Procedures Contents Before Operating the Truck 4 2 Starting From a Safe Condition 4 3...

Page 96: ...rt 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...

Page 97: ...re 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 rece...

Page 98: ...ver 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 str...

Page 99: ...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 100: ...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 101: ...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 102: ...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...

Page 103: ...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 104: ...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 105: ...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 106: ...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 107: ...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 108: ...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 109: ...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 110: ...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 t...

Page 111: ...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 112: ...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 113: ...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 114: ...d 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 S...

Page 115: ...diesel fuel may have a harmful effect on the engine pos sibly resulting in a breakdown If truck is filled with the wrong type of fuel drain it completely It is dangerous to start the engine with the...

Page 116: ...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 117: ...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...

Page 118: ......

Page 119: ...n 6 Emergency Starting Towing and Lowering Contents 6 1 Emergency Starting Towing and Lowering Contents How to Tow a Disabled Truck 6 2 How to Use Battery Jumper Cables 6 5 Emergency Lowering of Uprig...

Page 120: ...1 Be sure to block the drive wheels on the disabled truck while working around it 2 When possible raise the carriage forks on the disabled truck about 300 mm 12 inches from the floor or ground Secure...

Page 121: ...wise with 27mm socket wrench the parking brake will be released Preparing the truck to return to service a A trained forklift technician must reset the brake and prepare the truck to return to service...

Page 122: ...s to the floor put the directional control lever in the NEU TRAL position and turn the ignition switch to the OFF position Block the wheels to prevent the truck from rolling With parking brake disenga...

Page 123: ...u 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 inju...

Page 124: ...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...

Page 125: ...Make this connection at a point at least 450 mm 18 inches 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...

Page 126: ...ood of truck and locate the emergency lowering valve on the lift lower section of the hydraulic valve 2 Using a 4mm allen wrench loosen the valve 1 4 turn 3 Operate the lift lower lever carefully to l...

Page 127: ...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 128: ...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 129: ...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 130: ...efore 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 automatically oc...

Page 131: ...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 de...

Page 132: ...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 133: ...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 134: ...ve is a typical representation of a CLARK internal combustion lift truck Your model may vary slightly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 Radiator 2 Transmission Cooler 3 Frame 4 Steer Axle and Wheel 5...

Page 135: ...pen air on clean paved surfaces Severe Operation Prolonged operating hours or constant usage or heavy loading cycles Extreme Operation In sandy or dusty locations such as cement plants lumber mills an...

Page 136: ...Replace engine oil filter Clean and replace LPG Gas engine air filter Clean and replace Diesel engine air filter Change Diesel fuel filter Change LPG Gas fuel filter Drain heavy ends from vaporizer I...

Page 137: ...coolant level radiator and recovery tank Check transaxle fluid level Check fuel level Check hydraulic sump oil level Check gauges and instruments Check warning lights and hour meter Check overhead gua...

Page 138: ...junction 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 indicat...

Page 139: ...PM Report Form 7 13 Section 7 Planned Maintenance and Lubrication...

Page 140: ...tarting the engine for any sign of external leakage of fuel engine coolant transmission fluid etc Check for hydraulic oil leaks and loose fittings CAUTION CAUTION HYDRAULIC FLUID PRESSURE Do not use y...

Page 141: ...ck for leaks damaged or loose rollers and rail wear metal flaking Carefully check the lift chains for wear rust corrosion cracked or broken links stretching etc Check that the lift and carriage chains...

Page 142: ...to make sure it is not bent more than 25mm 1 maximum If the fork blades are obviously bent or damaged have them inspected by a trained maintenance person before operating the truck Inspect the fork lo...

Page 143: ...and repair Incorrect low tire pressure can reduce the stability of your lift truck Do not operate truck with low tire pressure For proper cold inflation pressure check the CLARK specifications Disass...

Page 144: ...te 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...

Page 145: ...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 CAUTION Do not operate a lift truck if the service or parking brakes are...

Page 146: ...ur 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 so...

Page 147: ...y 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 an...

Page 148: ...ending 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...

Page 149: ...it 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...

Page 150: ...e 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 Contact your near est...

Page 151: ...ull 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 recomm...

Page 152: ...ne operating at idle the transmission in NEUTRAL and the drive wheels blocked check the fluid on the dipstick Fill if necessary to the FULL mark on the dipstick using CLARK transmission fluid Mobil 42...

Page 153: ...er 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 Service Manual for the location of grease...

Page 154: ...t 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 gr...

Page 155: ...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...

Page 156: ...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 c...

Page 157: ...f 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 n...

Page 158: ......

Page 159: ...Section 8 Specifications Contents 8 1 Specifications Contents S20 35 S20 32C 8 2 Engine Oil 8 6...

Page 160: ...G 2720kg 600mm load center 6000lbs 24in 3000kg 500mm S35 D L G 3175kg 600mm load center 7000lbs 24in 3500kg 500mm S20C L G 1810kg 600mm load center 4000lbs 24in 2000kg 500mm S25C L G 2270kg 600mm load...

Page 161: ...ar Ratio Pneumatic truck 1 16 Cushion truck 0 9818 Drive Axle 14 2 Total Pneumatic truck 16 472 Cushion truck 13 942 Torque Converter Stall Ratio 3 3 Differential 4 Pinion Brake Service Parking Wet di...

Page 162: ...protection level of 37 C 34 F approximately Transmission Fluid Recommendation Use CLARK Specification TEXTRAN TDH CLARK Part number 2776236 Drive Axle Fluid Recommendation Use CLARK Specification MOB...

Page 163: ...47L 12 4G 15kg 33 lb S30 35L 8 5L 9 0Q 5 4L 5 7Q 10 0L 10 6Q 4 1L 4 3Q 47L 12 4G 15kg 33 lb S20 25G 8 5L 9 0Q 5 4L 5 7Q 10 0L 10 6Q 4 1L 4 3Q 47L 12 4G 64L 67 6Q S30 35G 8 5L 9 0Q 5 4L 5 7Q 10 0L 10...

Page 164: ...de SAE 10W 30 long drain 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 in accordance with JASO classifi...

Page 165: ...the previous page 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...

Page 166: ......

Page 167: ...spection 5 2 Direction Control Lever 3 43 Direction Control Braking and Inching 7 20 Disassembling the split rim wheel 7 17 Display 3 6 Display monitoring 3 16 Do s and Don ts 1 3 Drop Offs 2 5 E Engi...

Page 168: ...ar Swing 2 3 Longitudinal Tip over 1 13 Loose Loads 2 2 Low Overhead Clearance Fast Turns and High Loads 2 4 Lubrication 7 26 M Major Component Locations 7 8 Message Function 3 32 Mini Lever 3 46 Mode...

Page 169: ...face and Capacity 1 12 T TFT LCD 3 6 Tilt Control Lever 3 44 Tip Over 1 13 Traction Disable Fuction 3 44 Transmission and Drive axle Fluid Recommendation 8 4 Transmission Fluid Check 7 26 Travel 1 10...

Page 170: ...CLARK MATERIAL HANDLING COMPANY 700 Enterprise Drive Lexington Kentucky 40510 www clarkmhc com Printed Date Nov 2019 Additional copies of this manual may be purchased from YOUR AUTHORIZED CLARK DEALER...

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