OM-673

Additional copies of this manual may be purchased from
YOUR AUTHORIZED CLARK DEALER
Operator’s
Manual
ELECTRIC RIDER LIFT TRUCKS
700 Enterprise Drive

Lexington, KY 40510 Part No. 8039886 Do not remove this manual
Printed in Korea Book No. OM-673 from the truck.
Oct, 2005
Rev.3
Oct.2005
iv
Operator’s Manual
You must be trained and authorized to operate a lift truck.
YOU can prevent accidents
First: Learn safe operating rules and your company rules.
Next: Read your Operator’s Manual. If you do not understand

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

truck safely.
And: Keep your truck in safe

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

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

characteristics, designed to perform a specific job. Their function and
operation is not like a car or ordinary truck. They require specific
instructions and rules for safe operation and maintenance.
Safe operation of lift trucks is of primary importance to CLARK. Our
experience with lift truck accidents has shown that when accidents
happen and people are killed or injured, the causes are:
• Operator not properly trained
• Operator not experienced with lift truck operation
• Basic safety rules not followed
• Lift truck not maintained in safe operating condition
For these reasons, CLARK wants you to know about the safe
operation and correct maintenance of your lift truck.
This manual is designed to help you operate your lift truck safely.
This manual shows and tells you about safety inspections and the
important general safety rules and hazards of lift truck operation. It
describes the special components and features of the truck and
explains their functions. The correct operating procedures are shown
and explained. Illustrations and important safety messages are
included for clear understanding. A section on maintenance and
lubrication is included for the lift truck mechanic.
ii A Message to CLARK Lift Truck Operators

The operator’s manual is not a training manual. It is a guide to help
trained and authorized operators safely operate their lift truck by
emphasizing and illustrating the correct procedures. However, it
cannot cover every possible situation that may result in an accident.
You must watch for hazards in your work areas and avoid or correct
them. It is important that you know and understand the information in
this manual and that you know and follow your company safety rules!
Be sure that your equipment is maintained in a safe condition. Do not
operate a damaged or malfunctioning truck. Practice safe operation
every time you use your lift truck. Let's join together to set high
standards in safety.
Remember, before you start operating this lift truck, be sure you
understand all driving procedures. It is your responsibility, and it is
important to you and your family, to operate your lift truck safely and
efficiently. Be aware that the Federal Occupational Safety and Health
Act (OSHA) and state laws require that operators be completely
trained in the safe operation of lift trucks; it is also an OSHA
requirement that a machine inspection be performed before every
shift. If you think you need training in operating or inspecting your lift
truck, ask your supervisor.
CLARK lift trucks are built to take hard work, but not abuse. They are
built to be dependable, but they are only as safe and efficient as the
operator and the persons responsible for maintaining them. Do not
make any repairs to this truck unless you have been trained in safe
lift truck repair procedures and are authorized by your employer.
A Message to CLARK Lift Truck Operators iii

iv
Contents of this Manual
A Message to CLARK Lift Truck Operators....................... ii

Introduction ........................................................................ vi
How to Use this Manual ................................................. viii
Safety Signs and Safety Messages .................................. x
Section 1. General Safety Rules ...................................... 1-1
Section 2. Operating Hazards .......................................... 2-1
Section 3. Common Truck................................................ 3-1
Section 4. Operator Compartment and Controls .......... 4-1
Section 5. Operatoring Procedures................................. 5-1
Section 6. Operator Maintenance and Care.................... 6-1
Section 7. Emergency Towing ......................................... 7-1
Section 8. Planned Maintenance ..................................... 8-1
Section 9. Specifications.................................................. 9-1
Index........................................................................... Index-1
Contents of this Manual v

Introduction
CLARK welcomes you to the growing group of professionals who

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

Regular maintenance and care of your lift truck are not only
important for economy and utilization reasons; it is essential for your
safety. A faulty lift truck is a potential source of danger to the
operator, and to other personnel working near it. As with all quality
equipment, keep your lift truck in good operating condition by
following the recommended schedule of maintenance.
vi Introduction
Operator Daily Inspection — Safety and Operating Checks
A lift truck should always be examined by the operator, before
driving, to be sure it is safe to operate. The importance of this
procedure is emphasized in this manual with a brief illustrated review
and later with more detailed instructions. CLARK dealers can supply
copies of a helpful “Drivers Daily Checklist.”
Planned Maintenance
In addition to the daily operator inspection, CLARK recommends
that a planned maintenance and safety inspection program (PM) be
performed by a trained and authorized mechanic on a regular basis.
The PM will provide an opportunity to make a thorough inspection of
the safety and operating condition of your lift truck. Necessary
adjustments and repairs can be done during the PM, which will
increase the life of components and reduce unscheduled downtime
and increase safety. The PM can be scheduled to meet your
particular application and lift truck usage.
The procedures for a periodic planned maintenance program that
covers inspections, operational checks, cleaning, lubrication, and
minor adjustments are outlined in this manual. Your CLARK dealer is
prepared to help you with a Planned Maintenance Program by
trained service personnel who know your lift truck and can keep it
operating safely and efficiently.
Introduction vii
How to Use this Manual
This manual is a digest of essential information about the safe

operation, the features and functions and explains how to maintain
your lift truck. This manual is organized into nine major parts:
Section 1, General Safety Rules, reviews and illustrates accepted
practices for safe operation of a lift truck.
Section 2, Operating Hazards, warns of conditions that could cause
damage to the truck or injury to the operator or other personnel.
Section 3, Common Truck, describes the most common operating
components, systems, controls, and other features of your truck and
tells how they function.
Section 4, Operator Compartment and Controls, discribes the
operating components, system, controls, and other features of your
truck and tells how they function.
Section 5, Operating Procedures, discusses specific instructions
on the safe, efficient operation of your lift truck.
Section 6, Operator Maintenance and Care, presents details on
how to perform the operator’s daily safety inspection and refuel the
lift truck.
Section 7, Emergency Towing, gives instructions for towing your
truck in an emergency.
Section 8, Planned Maintenance, describes the PM program.
Section 9, Specifications, provides reference information and data
on features, components, and maintenance items.
Also, the Index helps you locate information about various topics.
NOTICE: The descriptions and specifications included in this manual
were in effect at the time of printing. CLARK Material Handling
Company reserves the right to make improvements and changes in
specifications or design. Please check with your authorized CLARK
dealer for information on possible updates or revisions.
The examples, illustrations, and explanations in this manual should
help you improve your skill and knowledge as a professional lift truck
operator and take full advantage of the capabilities and safety
features of your new lift truck.
viii How to Use this Manual

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

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

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

Section 1. General Safety Rules
General Safety Rules
Contents
Daily Inspection ..................................................... 1-2

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

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

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

equipment.
Do wear safety equipment

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

or when refueling.
Do’s and Don’ts 1-3

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

No Riders
The operator is the only one who should be on a truck.
No Riders 1-5
Pedestrians
Estar atento cuando se maneja. Mirar en el sentido de

marcha. Los peatones pueden estar usando la misma vía
Watch where
que usted. youlaare
Sonar going.
bocina Look las
en todas in the direction ofo
intersecciones
travel. Pedestrians may use the same roadway
puntos con visibilidad limitada. Estar atento youado.la
Sound your horn at all intersections or blind
presencia de las personas en la zona de trabajo, aun spots.
si el
Watch for people
montacargas in your
tiene luceswork area even if o
de advertencia your truck has
alarmas. Las
warning
demás personas pueden no estar atentas a lo for
lights or alarms. People may not watch queyou.
hace
Make people stand back, even when you are parked.
1-6 Pedestrians
Operator Protection
Keep under the overhead guard.

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

Fork Safety
Never allow anyone to

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

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

Travel
Travel with the load near

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

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

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

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

Tip-Over
Lateral Tip-over
• Lateral tip-over can occur with a com-
bination of speed and sharpness of
turn. This combination will exceed the
stability of the truck. This condition is
even more likely with an unloaded
truck.
• With the load or upright raised, lateral
tip-over can occur while turning and/or
braking when traveling in reverse or accelerating and turning
while traveling forward.
• Lateral tip-over can occur loaded or unloaded by turning on an
incline or ramp.
Longitudinal Tip-over
• Longitudinal tip-over can occur with a
combination of overloading and load
elevated also with capacity load and
elevated. This combination will exceed
the stability of the truck. This condition
is even more likely with excessive for-
ward tilt, braking in forward travel or
accelerating rearward.
• Longitudinal tip-over can occur by driving with the load down
slope on a steep grade.
Lateral and longitudinal tip-over can occur if the truck is driven over
objects on the floor or ground, off the edge of improved surfaces, or
into potholes in the road surface, or by running into overhead objects
or collisions.
An off dock type of tip-over can occur if the truck is steered too close
to the dock edge, driven off the edge of the dock or ramp, or if the
highway truck or trailer rolls away from the dock or is driven away
during loading.
! WARNING
The conditions listed above can be further aggravated by
overloading, excessive tilt, or off center loads.
IMPORTANT
Lift truck tip-over can cause serious injury or death if the
operator is trapped between the truck and the ground.
Tip-Over 1-13
What to do in Case of a Tip-over
If your truck starts to tip over,
! WARNING
DO NOT JUMP!!!
IMPORTANT
Your chances for survival in a tip-over are better if you
stay with the truck, in your seat.
Brace yourself as illustrated below!
1. Make sure your seat belt is fastened securely.
2. Stay in your seat.
3. Grip the wheel.
4. Brace your feet.
1
2
1-14 What to do in Case of a Tip-over

Parking
• Never park on a grade.

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

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

Section 2. Operating Hazards
Operating Hazards
Contents
Loose Loads ........................................................... 2-2

Long or Wide Loads / Rear Swing ........................ 2-3
Low Overhead Clearance
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
This Section shows some of the hazards that may cause you, or
someone around you, to be killed or badly hurt. As the operator, you
must look for other hazards. Get your supervisor to help you identify
and avoid those hazards.
Contents 2-1
Loose Loads
! WARNING
Loose or unbalanced loads
are dangerous. Observe
these precautions.
Never carry loose or uneven
material.
Center wide loads.
Stack and band loose material.
2-2 Loose Loads

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

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

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

Right-Angle Stacking
SLOWLY
! WARNING
When right-angle stacking or moving with a raised
load to clear low objects, avoid sharp turns and move
slowly.
2-6 Right-Angle Stacking

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

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

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

Section 3. Common Truck
Common Truck
Contents
Truck Description ................................................. 3-2

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

electric sit down rider lift truck. Your model may vary slightly.
3-2 Truck Description

Operator Controls
Key/Start Switch
• Connects the battery with all truck operating systems (drive, lift,
and steer electrical circuits) except the horn.
• Connects battery to the diagnostic display hourmeter and bat-
tery charge status.
The key switch must always be turned to the

ON position to operate the truck. When the
key is in the vertical OFF position,
instruments, drive and pump motor electrical
circuits are disconnected (shut-off), and the
key can be removed. The horn should operate
at all times if an adequately charged battery is
connected at the truck receptacle.
Seat Adjustment
The fore and aft adjustment lever is
located on the front under the seat.
To unlock, pull the lever to the left
and adjust the seat, release the Back declining
lever. Be sure that the seat locking adjustment
mechanism is engaged. The back
declining adjustment lever is
located on the right side of seat Fore and
cushion. Pull the lever up and Aft Adjust
adjust the back, release the lever.
Be sure that the back locking
mechanism is engaged.
! CAUTION
Never adjust driver’s seat while truck is moving, to avoid
the possibility of loss of control and of personal injury.
Operator Controls 3-3

Parking Brake
The parking brake pedal or lever (depending on your model)
mechanically operates the parking brake.
Parking Brake Pedal

To apply the parking brake, push the Parking Brake Release
pedal down with your left foot until
pedal stops. The parking brake release
is located just above the brake pedal as
shown. To release the parking brake
pull toward you.
Parking Brake Lever

Pull the lever toward the the operator to
apply the parking brake. The lever
should snap-lock easily into applied
position, when correctly adjusted.
Push the lever forward (away from the
operator) to release the parking brake.
! WARNING
Always apply parking brake before leaving truck.
! WARNING
Never operate your lift truck with a defective parking brake.
Hour Meter
With the key switch on, putting the directinal
control lever into forward or reverse positions
also starts the operating hour meter. Use the
hour meter reading to perform prescribed
maintenance.
3-4 Operator Controls

Steering System
The steering handwheel operates a
steering control valve that directs the oil
flow to the steering cylinder connected to
the steer axle. The steering control valve
can also act as a pump to provide manual
steering if the hydraulic pump stops.
Horn Button
The horn button is located in the center hub of the steering
handwheel.
Service Brake
Your truck has a manual service brake system with a single pedal
that actuates the master cylinder.
Direction Control Lever

This lever is typically on the left side
of the steering column.
Forward
! WARNING
Neutral
Never operate your lift truck
with the service or parking Reverse
brakes not working correctly.

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

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

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

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

Truck Data and Capacity Plate

1. Truck model number or regis-
tered name.
2. Truck serial number—An ide- 1
2
ntification number assigned to 3
this particular truck and sho-
uld be used when requesting
information or ordering ser- 4
vice parts for this truck from
your authorized CLARK deal-
er. The serial number is also
stamped on the frame.
3. Attachment description (if any
installed)—The user must see
that the truck is marked to
identify the attachment(s), in-
cluding the weight of the 5
truck/attachment combination
and truck capacity with the
attachment.
4. Capacity rating, load center, and lifting height data—Shows the
maximum load capacity of this truck with relation to load centers
and fork heights (see diagram on plate). Personal injury and
damage to the truck can occur if these capacities are exceeded.
Do not exceed the maximum capacity specified.
5. Truck weight—The approximate weight of the truck without a
load on the forks. This weight plus the weight of the load must
be considered when operating on elevators, elevated floors, etc.
to be sure they are safe.
! CAUTION
When attachments are added or if the truck is modified,
the capacity of the truck may be affected. Contact your
authorized CLARK dealer for a new nameplate showing
the revised capacity.
IMPORTANT
OSHA requires prior written approval from the manufac-
turer before any modifications affecting capacity or safety
may be made.

Operator Safety Warning Decal
WARNING
Read the
manual
Buckle up!
Apply brake
when leaving
truck
Watch Out
For Other
People
Most lift truck

8009529
INJURIES
are to other
people near
the lift truck.
IMPORTANT
Safety and warning decals are placed in conspicuous Prevent
Overturns!
locations on the truck to remind you of essential pro-
cedures or to prevent you from making an error that
could damage the truck or possibly cause personal AVOID :
injury. You should know, understand, and follow these • slippery,
sloping,
instructions. Safety and warning decals should be or uneven
surfaces
replaced immediately if missing or defaced (damage or • loads over
illegible). Refer to your Service Manual for location of capacity on
nameplate
all decals. • unstable or
high loads
• low tire
pressure
Operator/Tip-Over • poorly
maintained
lift truck
This decal is located on the front right hand leg of the • fast or
sharp turns
drivers overhead guard. It is to remind the operator that
In Case of
staying in the seat provides the best chance of avoiding Tip-Over:
injury in the event of a tip-over or off the dock mishap. Don't
jump
Lift trucks can be tipped over if operated improperly.

Analysis of lift truck accidents has shown that the driver
Hold on
cannot react quickly enough to jump clear of the truck and tight
overhead guard as the truck tips. To protect operators from

Brace feet
severe injury or death in the event of a tip-over, it is best to
Lean
be held securely in the seat. So, please, always buckle up away
when driving your lift truck. (see page 1-13)

2798235

Upright Warning Decal

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

to warn of the danger of injury from forks
when they are in the raised position. Do
not ride on or stand under forks or
attachments. The forks can fall and cause
injury or death. Always make sure that the
forks are in the fully lowered position when
they are not being used to handle a load.
2372604
Battery Connector Warning

Decal
This decal is placed next to the battery
connector to warn of the danger of the
truck starting in motion.

3-10
Section 4. Operator Compartment and Controls
Operator Compartment and Controls
Contents
EPG 20-30, ECG 20-32, ECX20-32

Operator Compartment .................................................. 4-2
TMG12-25,TMX12-25 Operator Compartment ......... 4-3
Contents 4-1
EPG 20-30, ECG 20-32,ECX 20-32 Operator Compartment
1
2
12
3 9
4 10
7 5
13 11
8 6
2. Horn Button
3. Directional Control Lever
4. Pylon Release Lever
5. Brake Pedal
6. Seat
7. Key Switch
8. Parking Brake Pedal
9. Lift Control Lever
10. Tilt Control Lever
11. Accelerator
12. Standard Display/Command System
13. Parking Brake Release
4-2 EPG 20-30, ECG 20-32,ECX 20-32 Operator Compartment

TMG12-25, TMX12-25 Operator Compartment
12
1
2
3, 8 7
4 10
9 5
6 11
2. Horn Button
3. Directional Control Lever
4. Pylon Release Lever
5. Brake Pedal
6. Seat
7. Key Switch
8. Parking Brake Pedal
9. Lift Control Lever
10. Tilt Control Lever
11. Accelerator
12. Standard Display/Command System
TMG12-25, TMX12-25 Operator Compartment 4-3

EPG, ECG and TMG Dash Display
The primary design of the Dash Display is to provide the operator
with an easily understandable, visual feedback of the status of the
truck and it’s system components.
3 5
10
6
4
9
7
Standard Display
1. Pump Motor Brush 6. Numeric Display

Wear Indicator 7. Hour Meter
(optional) 8. Service Status
2. Drive Motor Brush Wear 9. Battery Status
Indicator (optional) 10. Accessory Switches
3. Seat Belt Alert (lights, etc.)
4. Park Brake
5. Planned Maintenance
4-4
TMX Dash Display

truck and it’s system components.
6
11 3
4 9
10
7
8
Standard Display
1. Pump controller & 5. Planned Maintenance

Motor overheat warn- 6. Numeric Display
ing indicator lamp 7. Hour Meter
2. Drive controller & Motor 8. Service Status
overheat warning indi- 9. Battery Status
cator lamp 10. Head light Switches
3. Seat Belt Alert 11. Speed change switch
4. Park Brake (Optional)

ECX Dash Display
truck and it's system components.
1 2 3 4 5
7
6
km/h 10
9
11
Standard Display
1. Park Brake 6. Battery Discharging

2. Seat Belt Alert Indicator
3. Drive controller & Motor 7. Display Setted Speed
overheat warning indi- limit
cator lamp 8. Activating Speed limit
4. Pump controller & function
Motor overheat warn- 9. Hour Meter
ing indicator lamp 10. Display Travel Speed
5. Planned Maintenance 11. Service Status
4-6 TMG12-25, TMX12-25 Operator Compartment

ECG and TMG Command System Display (Option)

The primary design of the Command System is to provide the
operator with an easily understandable, visual feedback of the status
of the truck and it's system components.The operator can also select
/change vehicle operating characteristics.
5 1 2 3 4 14
15
16
13
6 9 17 18
24 10 19
7 22
11
8 21
12 20
23
Command System
1. Pump Motor Tempera- 12. Performance Mode 4
ture (Opt) 13. Performance Selector
2. Pump Motor Brush Wear Button
(Opt) 14. Battery Level (high)
3. Pump Control Tempera- 15. Battery Level (med)
ture 16. Battery Level (low)
4. Planned Maintenance 17. Seat Belt Alert
5. Drive Motor Temperature 18. Park Brake
(Opt) 19. Numeric Display
6. Drive Motor Brush Wear 20. Hour Meter
(Opt) 21. Service Status
7. Traction Control Temper- 22. Battery Status
ature (Opt) 23. Stored Status Code
8. Drive Motor Overload Button
9. Performance Mode 1 24. Accessory Switches
10. Performance Mode 2 (Lights, etc.)
11. Performance Mode 3

Pump Motor Temperature(For DC truck Only): (Optional)
The symbol is dis-played to "alert" of pump motor
temperature exceeding the design limits. Do not use truck.
Allow pump motor to cool until after symbol turns "OFF".
Pump Motor Brush Wear(For DC truck Only): (Optional)
The symbol is displayed to warn one or more of the pump
motor brushes are worn beyond allowable length. Do not
use truck. Call service to replace brushes.
Drive Motor Brush Wear(For DC truck Only): (Optional)
The symbol is displayed to warn one or more of the drive
motor brushes are worn beyond allowable length. Do not
use truck. Call service to replace brushes.
Seat Belt: At start up this symbol displays along with an
audio alarm for 4 seconds. This display reminds you to
fasten your seat belt.
Parking Brake: The symbol is displayed and "-01" status
code appears on the numeric display when parking brake is
applied. Release parking brake to operate truck.
Planned Maintenance: This symbol is displayed and "-99"
status code appears on the numeric display when the key
switch is turned "ON" and trucks operating hours exceed pre-
programmed hours for planned maintenance. The symbol is
a reminder only and will turn "OFF" after 4 seconds and
display will return to normal operation. The truck shall be
inoperative while this symbol is displayed. Call Service.
Hour Meter(ECG/EPG/TMG/TMX): This symbol identifies
the number displayed on numeric display as truck and/or
pump motor (optional) operating hours. The symbol is
displayed for 2 seconds to 6 seconds when the key switch
is turned "OFF".
(ECX): This indicating lamp shows that the working hour is
counted. It flickers in a second cycle when the fork lift truck
is working.

Service Status(For DC truck ONLY): "-01 through -03", "-

06”, “-8” and “-11" are usually operator fault codes, and can
be corrected by as explained in "Section 5, Operating
Procedures." If you see any other codes displayed, the
truck needs to be serviced.
(For TMX/ECX ONLY) : "-001”, “-066", "-079”, “-217”, “-
245” and “-255” are usually operator fault codes, and can
be corrected by as explained in "Section 5, Operating
Procedures." If you see any other codes displayed, the
truck needs to be serviced.
Battery Status: If this symbol displays, the numeric display
shows the percentage of usable charge remaining on the
battery.
Pump Control Temperature(For DC truck ONLY):

(Optional) The symbol is dis-played and "-141" status code
appears on numeric display to "alert" of main transistor
temperature on pump control exceeding allowable design
limits. Do not use truck. Allow control to cool until symbol
turns "OFF". Call Service.
Traction Control Temperature(For DC truck ONLY):
(Optional) The symbol is displayed and "-41" status code
appears on numeric display to "alert" of main transistor
temperature on traction control exceeding allowable design
limits. Do not use truck. Allow control to cool until symbol
turns "OFF". Call Service.
Drive Motor Overload(For DC truck ONLY): This symbol
will come on when the drive motor is stalled or overloaded.
The numeric display will show a status code "-82" or "-83"
when this occurs.
Drive Motor Temperature(For DC truck ONLY):
(Optional) The symbol is displayed to "alert" of drive motor
temperature exceeding the design limits. Do not use truck.
Allow motor to cool until after symbol turns "OFF".
Performance Selector Button(For DC truck ONLY):
Used in conjunction with stored status code access button
to select one of the four available pre-programmed sets of
performance characteristics of the truck. (see page 5-5)

Stored Status Code Button(For DC truck ONLY): Used in
conjunction with performance selector button to retrieve the
failure history. (upto 16 status codes with associated state
of battery and truck operating hours). (see page 5-5)
Battery Level(For DC truck ONLY):
Graphical display showing state of
charge.
Performance Mode Levels(For DC

truck ONLY): Selected level of operating
characteristic of the truck from the 4
available sets of pre-programmed
operating characteristic.
Pump controller & Motor overheat warning indicator
lamp(For AC Only):This indicator lamp is to warn the
conditions that the temperature of pump motor and
controller exceeds the limited value. If this lamp turns on,
reduce the output to half.
Pump motor warning code: "-207"
Pump controller warning code: "-203"
Drive controller & Motor overheat warning indicator
lamp(For AC Only):This indicator lamp is to warn the
conditions that the temperature of drive motor and controller
exceeds the limited value. If this lamp turns on, reduce the
output to half.
Drive motor warning code: "-65"
Drive controller warning code: "61(Master), -140(Slave)"

Battery discharge indicator (ECX) :

This indicating lamp shows that the charging
rate that can be usable by the using battery
One chamber will turn off when the charging
rate is reduced in 10%. Warning Code:" 66:BAT
LOW"
Speed limit rate indicator (ECX)

This indicating lamp shows that the traveling
speed limit rate. One chamber will turn off when
the speed limit rate is reduced in 10%.
Speed limit function indicator (ECX) : This indicating

lamp shows that the traveling speed limit. It will turn on
when the traveling speed limit function of fork lift truck is
working.
Traveling speed indicator (ECX) : This indicating lamp
shows that the traveling speed of fork lift truck. It will turn
on when the current traveling speed is indicated.

4-12
Section 5. Operating Procedures
Operating Procedures
Contents
Before Operating the Truck ................................. 5-2

Starting from a Safe Condition ............................ 5-3
Contents 5-1
Before Operating the Truck
Be sure that you have read and

understand the information in this
Operator’s Manual before operating the lift
truck.
The Operator’s Manual Holder is located
on the back of the seat.
! WARNING
• This equipment can be dangerous if not used properly.
Safe operation is the responsibility of the operator.
• Do not start or operate the truck, or any of its functions or
attachments, from any place other than the designated
operator's position.
! CAUTION
• Inspect your lift truck before operating at the start of
the day or shift. Before putting your truck to use, check
the operation of the controls and all systems.
• Protect yourself. Do not operate truck without a
driver's overhead guard unless conditions prevent its
use. Do not remove overhead guard unless specifically
authorized. Use special care if operation without this
safety device is required.
5-2 Before Operating the Truck

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

in the NEUTRAL position,
before turning the key switch to
FORWARD
ON.
NEUTRAL
Position
REVERSE
Starting from a Safe Condition 5-3

Adjusting the Seat
Adjust the seat to a comfortable
position for you. Adjust the seat
by moving and holding the
release lever at the front under of Back declining
the seat. Put the seat in a adjustment
position that will provide easy
reach to all controls. Release the Fore
seat lever. Make sure that the and Aft
Lever
seat locking mechanism is
engaged.
! CAUTION
Never adjust the driver’s seat while the truck is moving,
to avoid the possibility of loss of control and of personal
injury.
Buckling Up
Buckle up. Be sure that you put
on the seat belt. Connect and
adjust the seat belt strap to a
snug, comfortable position.
! WARNING
Always wear your seat belt when operating a lift truck.
Starting the Truck

Before you start the truck, make sure that you have taken all the
above-mentioned precautions and that the directional control is in
NEUTRAL. To start the truck, turn the key switch clockwise to the ON
position.
5-4 Starting from a Safe Condition

Selecting Performance Level on Command System

(ECG/TMG only)
Depress and hold green and white
push button switches for two (2)
seconds with key on and truck in
neutral. Release switches when Performance
"wrench" symbol starts flashing. Selector Button
Cycle (push/release) white switch to Stored Status
choose desired performance level Code Button
between turtle and rabbit icons as
shown by lit LED. Depress and hold green switch for (2) seconds till
selected level LED start flashing. Release green switch and "wrench”
symbol will turn off.
Using the Display
LCD Back Light (ECX)
• LCD back light is working linked with Key switch.
"- When the start key turns on, power is applied to display.
Whenever the power is applied, LCD back light will turn on."
DISPLAY Initial Start-up(ECX)
• KEY ON
- All the Icons and Buzzers will be ON for 1second to check the
indicating conditions.
- Seat belt warning mode (5seconds) after Icon turns of for
1second: It is always indicated regardless of communication
conditions; When this mode is working, all the indicating data
should be in normal conditions.
"(Working hour/speed, Battery discharging rate, Speed limit rate,
Parking)"
• After seat belt warning mode is working, the data supplied from
controller will be indicated.
The display should turn "ON" all symbols and "8888" appears on
numeric display for about 2 seconds when the key switch is turned
"ON". After 2 seconds, all displays should return to normal operating
conditions except seat belt reminder symbol which will continue to be
displayed for 2 additional (4 seconds total) while the seat belt buzzer
(alarm) sounds.
If the battery symbol light comes on, the digital readout shows the
percentage of charge remaining on the battery. When the remaining
charge registers as 20% or less, the readout flashes. At 10%
remaining charge, the lift and tilt functions become inoperable.

If the wrench symbol comes on, a status code appears on the digital
readout. The status code may indicate an easily correctable
"operator fault" or it may indicate that you need to have the truck
serviced. If you see a status code, use the table below as a guide.
Codes -01 through -06 are usually the operator errors. Any other
code is a service code
Working hour/speed indicating algorithm (ECX)
• Working hour/speed will be indi-
cated at the same portion. Hour Meter
• The indicating data is decided
on the base of traveling speed.
• If the traveling speed exceeds Speed Meter
0.5km/h, the current traveling
speed will be indicated "km/h" km/h
icon turn on. When the speed

gets lower than 0.5km/h, travel-
ing speed indicator will be released "km/h" icon turn off.
• The current working hour is indicated when the traveling speed is
lower than 0.5km/h, and the "sandglass" icon flickers in a second
cycle.
When the traveling speed is more than 0.5km/h, the working hour
indicator is released (converted to speed indicator), and the "sand-
glass" icon will turn off.
Character indicator (ECX)
• Error code indicator (#37
error)

Diagnostic Display ECG, EPG, TMG

Code Condition Likely Corretive Action
Parking brake or seat switch
-01 Release parking brake.
open.
Direction control in FOR- Put direction control in NEU-
-02
WARD when key turned ON. TRAL before starting.
Direction control in REVER- Put direction control in NEU-
-03
SE when key turned ON. TRAL before starting.
Brake and accelerator
-05 Use only one at a time.
depressed at same time.
Accelerator depressed with
-06 Select direction first.
NEUTRAL selected.
Accelerator depressed with Remove foot from acce- lera-
-11
when key is turned on. tore before starting.
Other Truck needs service. Call service technician.
Diagnostic Display ECX, TMX

Code Condition Likely Corretive Action
-001 Seat switch open Take a seat
-061, -065 ,-140, Overheat of motor and
Restart after cooling down
-203, -207 controller
Replace with charged bat-
-066, -208 Low battery voltage
tery
Before starting, place the
Forward/Reverse lever to
Started with wrong N position
-079
sequence
Before starting, release the
accelerator pedal.
Replace the battery with a
-217,-245 Wrong set battery
correct battery
Accelerator depressed
-255 Select direction first.
with NEUTRAL selected.
Other Truck needs service. Call service technician.

Positioning Forks and Upright
When driving, with or without a load, it
is good practice to have the forks
slightly raised and tilt the upright (forks)
backward. Having the forks raised and
tilting back prevents the fork tips from
catching on possible obstructions and
reduces the wear on the fork blades
from striking or dragging on the floor or
ground. See the NOTICE and
CAUTION below.
Lift Control
Pull back on the lift control lever and Lever
raise the forks 6 to 8 inches (152 to Tilt Control
203 mm) above the floor. Then, using Lever
the tilt control, tilt the upright back
slightly to raise the fork tips.
NOTICE
When the upright (carriage and/or load) is raised, the sta-
bility of the truck is reduced. Some of the other conditions
that may affect stability are: ground and floor conditions,
grade, speed, loading, dynamic and static forces and the
judgement exercised by the operator. Trucks equipped
with attachments behave as partially loaded trucks even
when operated without a load on the attachment. Also,
improper operation, faulty maintenance or poor house-
keeping may contribute to a condition of instability.
! CAUTION
For stability reasons, do not travel with the load or
carriage in a highly elevated position. Travel with the lift
mechanism raised only enough to clear the ground or
obstacles.
! WARNING
If your truck starts to tip over, DO NOT JUMP! Your
chances for survival in a tip-over are better if you stay
with the truck, in your seat. BRACE YOURSELF!. Make
sure your seat belt is fastened securely. Stay in your seat.
Grip the wheel. Brace your feet. See page 1-14

Controlling Speed
With the direction control in FORWARD or REVERSE, the parking
brake released, put your foot on the accelerator pedal and push
down smoothly until the truck is moving at the desired speed.
Braking
To stop the truck, lift your foot
from the accelerator pedal and
put it on the brake pedal. Push
down on the brake pedal in a
smooth, firm motion until the
truck is stopped.
IMPORTANT
Stop a lift truck as gradually as practical. Hard braking
and wheel sliding are dangerous and can cause tip-over
or the truck could lose its load. Also, hard braking can
increase wear and can be harmful to the lift truck.
Plugging
You can change direction, without braking, by "plugging." As you are
traveling, move the direction control lever to the opposite direction
and keep the accelerator pedal depressed. The truck should slow to
a smooth, controlled stop and then accelerate in the opposite
direction.
You can control the plugging distance with the accelerator pedal:
The farther the accelerator is depressed, the shorter the reversal
distance.
By lifting your foot from the accelerator pedal as the truck comes to a
stop (before going in the opposite direction) the truck can be stopped
without use of the brakes.
! CAUTION
Be careful when plugging. Any sudden change in
direction can cause the load to move or fall off the forks.

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

Keep all other persons clear of the load and upright mechanism while
attempting to handle a load.
No riders...
Do not carry passengers. The operator is the only one who should
be on the truck.
Always be in full control of your lift truck...
Never operate a lift truck or its attachments if you are not in the
designated operator's position.
Never operate a lift truck when your hands are wet or greasy.
Always pick the smoothest travel route for your lift truck. Avoid
bumps, holes, slick spots, and loose objects or debris in your path
that may cause the truck to swerve or tip. If these conditions are
unavoidable, slow down and carefully drive past them. Slow down
for wet or slippery surfaces.
Avoid any sudden movement. Start, stop, travel, steer, and brake
smoothly.
Operate your lift truck under all conditions at a speed that will permit
it to be brought safely to a stop.
! WARNING
Travel slowly when turning. Use special care when
traveling without a load because the risk of tipping over is
greater with an empty truck, especially at high speed and
when cornering.
Travel with the fork carriage tilted back and raised only enough to
fully clear the ground or obstacles. When the carriage (load) is
elevated, the stability of the truck is reduced.
Do not elevate the load except during stacking.

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

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

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

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

The capacity load shown on the nameplate is represented by a cube

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

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

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

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

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

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

(raise) the load high enough to clear
the top surface of the stack. Slowly
move the load into position. Be care-
ful not to damage or move adjacent
loads.
5. When the load is aligned with the

stack beneath it, tilt the upright to the
vertical position and carefully lower
the load onto the top surface of the
stack.

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

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

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

After Operating the Truck

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

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

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

5-20
Section 6. Operator Maintenance and Care
Operator Maintenance and Care
Contents
Inspecting Your Truck ........................................... 6-2

Visual Checks ......................................................... 6-3
Functional Checks ................................................. 6-4
Concluding the Inspection .................................... 6-5
NOTICE
The Occupational Safety and Health Act (OSHA) requires
that truck users examine their trucks before each shift to
be sure they are in safe working order. Defects when
found shall be immediately reported and corrected. The
truck shall be taken out of service until it has been
restored to safe operating condition.
Contents 6-1
Inspecting Your Truck
Before using a lift truck, it is the operator’s responsibility to check

its condition and be sure it is safe to operate.
Check for damage and maintenance problems; have repairs made
before you operate the truck. Unusual noises or problems must be
reported immediately to your supervisor or other designated
authority.
Do not make repairs yourself unless you are trained in lift truck repair
procedures and authorized by your employer. Have a qualified
mechanic make repairs using genuine CLARK or CLARK-approved
parts.
Do not operate a truck if it is in need of repair. If it is in an unsafe
condition, remove the key and report the condition to the proper
authority. If the truck becomes unsafe in any way while you are
operating it, stop operating the truck, report the problem
immediately, and have it corrected.
Lift trucks should be inspected every eight hours, or at the start of
each shift. In general, the daily inspection should include the visual
and functional checks described on the following pages.
As an aid in carrying out this inspection, CLARK has prepared a form
called the "Driver’s Daily Checklist." We recommend that you use
this form to make a daily record of your inspections and truck
condition. You may obtain copies of this form from your CLARK
dealer.
! WARNING
Leaking hydraulic oil may be hot or under pressure. When
inspecting a lift truck:
• Wear safety glasses
• Do not check for leaks with bare hands.
6-2 Inspecting Your Truck

Visual Checks
First, perform a visual in-

spection of the truck and its
major components:
1. Walk around your lift
truck and take note of
obvious damage that
may have been caused
by operation during the
last shift.
2. Check that all capacity,
safety, and warning
plates or decals are
attached and legible.
3. Check that the battery is
installed and secured in
position correctly. Check
battery connector for safe
condition.
4. Look for any external leakage around drive axle.
5. Check for hydraulic oil leaks and loose fittings. Do not use bare-
hands.
6. Be sure that the driver’s overhead guard and any other safety
devices are in place, undamaged, and attached securely.
7. Check all of the critical components that handle or carry the
load.
8. Check the upright and lift chains. Check for obvious wear and
maintenance problems such as damaged or missing parts,
leaks, slack or broken chains, bent parts, and so on.
9. Carefully inspect the load forks for cracks, breaks, bending,
twists, and wear. Be sure that the forks are correctly installed
and locked in their proper position.
10. Inspect the wheels and tires for safe mounting and wear condi-
tion.
11. Check the hydraulic sump oil level.
Visual Checks 6-3

Functional Checks
Check the operation of the truck as follows:

NOTICE
Before performing these checks, familiarize yourself with
the operating procedures. Be sure there is enough over-
head clearance to fully raise the upright.
1. With key switch off, be sure all controls and systems operate
freely and return to neutral properly. Check the:
• Service and parking brakes
• Hydraulic controls: lift, tilt, and aux functions (if installed)
• Accelerator control
• Directional control
• Steering system
2. Test warning devices, horn, lights, and other safety equipment
and accessories.
3. With the truck on, check the dash display. The display should
show the charge remaining on the battery or a fault code. If the
fault code is not an operator fault code, call a service technician.
4. Check hydraulic fluid level: With the truck parked on a level sur-
face, lift the carriage to maximum height while listening for a
high-pitched squeal. This sound, called “cavitation”, indicates
the fluid is low. Add fluid just enough to stop the cavitation.
When the functional checks are completed:
1. Bring truck to complete stop.
2. Put the directional control lever in the NEUTRAL position.
3. Apply the parking brake.
4. Turn the key switch to the OFF position.
5. Lower the lift mechanism fully.
If you are going to leave the truck unattended:
6. Remove the key.
7. Block the wheels if the truck has any possibility of moving.
6-4 Functional Checks

Concluding the Inspection
Make a record on the “Driver's Daily Checklist” of all the operating

and truck problems that you find. Review the checklist to be sure it
has been completed and turn it in to the person responsible for lift
truck mainte-nance. Be sure any unusual noises or problems are
investigated immediately.
Do not operate a lift truck that has a maintenance problem, or is
not safe to operate.
RVICE
Remove the key from the ignition
switch and put an “Out of Service”
tag on the truck.
OUTOF
OUT OF
SERVICE
SERVICE
If all of the Daily Inspection checks were normal or satisfactory,

the truck can be operated.
Concluding the Inspection 6-5

6-6
Section 7. Emergency Towing
Emergency Towing
Contents
Towing Precautions .............................................. 7-2

Towing Procedures ............................................... 7-3
Contents 7-1
Towing Precautions
If your lift truck becomes disabled but can be moved freely on its own
wheels without further damage, use the following procedures to tow it
safely to a repair area.
IMPORTANT
It is important for your safety and to the care of your lift
truck to use the proper equipment and carefully follow
these recommendations for safe towing.
! WARNING
DO NOT tow a lift truck if there is a problem with the
brakes or tires, or the steering cannot be operated.
DO NOT tow up or down ramps and steep inclines.
DO NOT attempt to tow a lift truck if traction or weather
conditions are poor.
DO NOT tow with truck in either "Forward" or "Reverse".
Always tow with the truck in "Neutral".
7-2 Towing Precautions

Section 7. Emergency Towing
Towing Procedures
1. Be sure to apply the parking brake or block the drive wheels on

the disabled truck while working around it.
2. When possible, raise the carriage (forks) on the disabled truck
about 12 inches (300 mm) from the floor or ground. Secure the
carriage with a chain.
3. Obtain another lift truck of equal or larger size carrying a partial
load for traction.
4. Check that the counterweight bolts are in place and properly
torqued. (This bolt is made of a special high tensile steel and is
not commercially available. Replace it, when necessary, only
with a genuine Clark replacement part).
5. Use an approved, solid metal tow bar with towing couplers that
connect to the towing pins in the counterweight or that connect
to the frame or chassis through the counterweight of each truck.
6. Release the parking brake on the towed vehicle.
NOTICE
Dot approved towing equipment maybe available from
your CLARK dealer.
7. Tow the disabled truck backward. An operator must be on the
towed truck wearing a seat belt.
Tow the truck slowly. Careful towing is necessary to prevent
injury to personnel or damage to the truck. The truck should be
towed at a speed of less than 5 m.p.h. (8 kph) with a driver in the
seat. Do not lift the truck or any wheels off the floor or ground
while the truck is being towed.
!
CAUTION
The power steering does not operate on the disabled
truck when the power steer motor is not running, which
makes the steering handwheel difficult to turn.
Towing Procedures 7-3

8. Park the disabled truck in authorized areas only. Fully lower the
forks to the floor, put directional control lever in the NEUTRAL
position and turn the key switch to the OFF position. Engage the
parking brake. Remove the key and, when necessary, block the
wheels to prevent the truck from rolling.
LIFT TRUCK PARKING
! WARNING
Always engage the parking brake when parking a lift
truck.
The truck can move and cause injury or death to
personnel near it.
7-4 Towing Procedures

Section 8. Planned Maintenance
Planned Maintenance
Contents
Lift truck Maintenance ................................................ 8-2
Contents 8-1
CLARK shall have obligation under this warranty in the following cases.(This
warranty shall exist for the period per the below column, whichever occurs
first.)
Period 1 year or 2000 hours 2 years or 4000 hours
12 months 12 months plus an additional 12
months on major components
All parts (excluding : All electric motors (excluding :
bulbs, glass, grease fit- brushes)
tings, filters, fuses, linings, Solid state control panel
Contents lubricants, tires, Contac- components
tor tips, fan or other nor-
Contactor panels (excluding :
mal wearing and aging
contactor tips)
parts.)
Drive Axle (excluding : brake
assemblies)
(Naturally, this warranty does not apply to damage arising from

accident, misuse or negligence, use of non-CLARK parts, or from
alterations not authorized by CLARK.)
8-2 Contents
Lift truck Maintenance
Regular maintenance and care of your lift truck is not only important
for full and efficient truck life; it is essential for your safety. The
importance of maintaining your lift truck in a safe operating condition
by servicing it regularly and, when necessary, repairing it promptly
cannot be emphasized too strongly. Experience has shown that
powered industrial trucks can cause injury if improperly used or
maintained. In the interest of promoting safety, several current
industry and government safety standards specify that any powered
industrial truck not in safe operating 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 done at regular intervals. This planned approach is
considered essential to the life and safe performance of your truck.
It is your responsibility to be alert for any indication that your truck
may need service and have it attended to promptly. You play an
important part in maintenance. Only you can make sure that your lift
truck regularly receives the care it needs.
!
CAUTION
Powered industrial trucks may become hazardous if
maintenance is neglected.
Planned Maintenance
As outlined previously, you should always make a safety inspection
of your lift truck before operating it. The purpose of this daily
examination is to check for any obvious damage and maintenance
problems, and to have minor adjustments and repairs made to
correct any unsafe condition.
In addition to the daily inspection, CLARK recommends that you set
up and follow a periodic planned maintenance (PM) and inspection
program. PM inspections should only be performed by a trained and
authorized fork lift mechanic. Performed on a regular basis, the
program provides thorough inspections and checks on the safe
operating condition of your lift truck. The need for major adjustments,
repairs, or replacements is found and corrections made as required,
not after failure has occurred. The specific schedule (frequency) for
these PM inspections depends on the conditions of your particular
application and lift truck usage.
Lift truck Maintenance 8-3

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
reference.
Your local CLARK dealer is prepared to help you with your Planned
Maintenance Program, if you want assistance. Your CLARK dealer
has specially trained service personnel who are authorized to check
your lift truck according to the applicable safety regulations.
"Section 9, Specifications," contains some useful information for se-
lected components, fuel and lubricants, critical bolt torques, refill
capacities, and settings for your truck.
If you have the need for more information on the care and repair of
your truck, see your CLARK dealer.
Planned Maintenance Intervals

Typical Operating Conditions
Time intervals between maintenances are largely determined by
operating conditions. For example, operation in sandy, dusty
locations requires shorter maintenance intervals than operation in
clean warehouses.
The indicated intervals are intended for normal operation. The
following operating conditions are defined:
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 as: cement plants, lumber
mills, and coal dust or stone crushing sites
• High-temperature locations, such as: steel mills, foundries, etc.
• Sudden temperature changes, such as: constant trips from
buildings into the open air, refrigeration plants, etc..
If your fork lift truck is used in severe or extreme operating
conditions, you must shorten the maintenance intervals accordingly.
NOTICE
Since the operating environment of lift trucks varies
widely, the above descriptions are highly generalized and
should be applied as actual conditions dictate.
8-4 Lift truck Maintenance

Daily Maintenance Checks

Recommended PM Intervals
The maintenance time intervals referred to in this manual relate to
truck operating hours as recorded by the diagnostic system (or
hourmeter) and based on experience which CLARK has found to be
convenient and suitable under typical (normal or average) operating
conditions, as follows:
A = 8-10 hours or daily
B = 50-250 hours or every month
C = 450-500 hours or every 3 months
D = 900-1000 hours or every 6 months
E = 2000 hours or every year
DAILY MAINTENANCE CHECKS A B C D E

Check truck for obvious damage and leaks.
Check/clean battery terminals.
Check electrolyte level.
Check capacity, warning plates and decals.
Check condition of tires and wheels, remove
embedded objects.
Check wheel lug nuts.
Check hydraulic sump oil level.
Check gauges and instruments.
Check warning lights and hour meter.
Check overhead guard condition and bolts.
Check horn operation and other warning devices.
Check steering operation.
Check service brake operation.
Check parking brake operation.
Check directional and speed control operation.
Check accelerator.
Check lift, tilt and auxiliary operation.
Check upright, lift chains and fasteners.
Check load backrest extension and forks.

Periodic Maintenance Checks
PM Interval:
A = 8-10 hours or daily
B = 50-250 hours or every month
C = 450-500 hours or every 3 months
D = 900-1000 hours or every 6 months
E = 2000 hours or every year
Notes:
* Replace as required.
PERIODIC CHECKS and

PLANNED MAINTENANCE (PM) A B C D E
Check truck visually and inspect components.
Test drive truck/check functional performance.
Air clean truck.
Check torque on critical fasteners.
Lubricate truck. (See component)
Clean/check battery terminals, electrolyte level.
Check battery cables/truck receptacle.
Perform battery load test.
Check drive motor brushes.*
Check lift motor brushes.*
Check steer motor brushes.*
Test ground.
Clean drive axle air vent.
Check drive axle fluid level.
Drain and replace drive axle fluid.
Check brake condition and wear.
Check drive axle mounting and fasteners.
Lubricate steer axle linkage.
Check/lubricate steer axle wheel bearings.
Replace hydraulic sump fluid and filter.
Clean/replace hydraulic sump breather.
Lubricate tilt cylinder rod ends.
Check lift chain adjustement and wear.
Check/lubricate lift chains.
Lubricate upright rollers.

Safe Maintenance Practices

The following instructions have been prepared from current industry
and government safety standards applicable to industrial truck
operator and maintenance. These recommended procedures specify
conditions, methods, and accepted practices that aid in the safe
maintenance of industrial trucks. They are listed here for the
reference and safety of all workers during maintenance operations.
Carefully read and understand these instructions and the specific
maintenance procedures before attempting to do any repair work.
When in doubt of any maintenance procedure, please contact your
local CLARK dealer.
1. Powered industrial trucks can become hazardous if mainte-
nance is neglected. Therefore, suitable maintenance facilities,
trained personnel, and procedures shall be provided.
2. Maintenance and inspection of all powered industrial trucks shall
be done in conformance with the manufacturer’s recommenda-
tions.
3. A scheduled planned maintenance, lubrication, and inspection
system shall be followed.
4. Only trained and authorized personnel shall be permitted to
maintain, repair, adjust, and inspect industrial trucks—and in
accordance with the manufacturer's specifications.
5. Properly ventilate work area, and keep shop clean and floor dry.
6. Avoid fire hazards and have fire protection equipment present in
the work area. Do not use an open flame to check fluid or elec-
trolyte levels. Do not use open pans of fuel or flammable clean-
ing fluids for cleaning parts.
7. Before starting work on truck:
a. Raise drive wheels free of floor and use blocks or other posi-
tive truck positioning devices.
b. Put blocks under the load-engaging means, innermasts, or
chassis before working on them.
c. Disconnect battery before working on the electrical system.
NOTICE
Refer to the "Jacking and Blocking" section in the Service
Manual for proper procedures.
8. Operation of the truck to check performance must be conducted
in an authorized, safe, clear area.

9. Before starting to drive the truck:
a. Be seated in a safe operating position and fasten your seat belt.
b. Make sure parking brake is applied.
c. Put directional control in NEUTRAL.
d. Turn the key switch to the ON position.
e. Release the parking brake.
f. Check functioning of lift and tilt systems, directional and
speed controls, steering, brakes, warning devices, and any
load handling attachments.
10. Before leaving the truck:
a. Stop truck.
b. Fully lower the load-engaging means; upright, carriage, forks
or attachments. Tilt upright forward.
c. Put directional control in NEUTRAL.
d. Apply the parking brake.
e. Turn the key switch to the OFF position.
f. Disconnect battery.
g. Put blocks at the wheels if truck must be left on an incline.
11. Brakes, steering mechanisms, control mechanisms, warning de-
vices, lights, lift overload devices, lift and tilt mechanisms,
articulating axle stops, and frame members must be carefully
and regularly inspected and maintained in a safe operating
condition.
12. Special trucks or devices designed and approved for hazardous
area operation must receive special attention to insure that
maintenance preserves the original approved safe operating
features.
13. All hydraulic systems must be regularly inspected and
maintained in conformance with good practice. Tilt and lift
cylinders, valves, and other parts must be checked to assure
that "drift" or “leakage” has not developed to the extent that it
would create a hazard.
14. When working on hydraulic system, be sure the battery is
disconnected, upright is in the fully-lowered position, and
hydraulic pressure is relieved in hoses and tubing. Do not check
for hydraulic leaks with bare hands.
! WARNING
Always put blocks under the carriage and upright rails
when necessary to work with upright in an elevated
position.

15. The truck manufacturer’s capacity, operation, and maintenance
instruction plates, tags, or decals must be maintained in legible
condition.
16. Batteries, limit switches, protective devices, electrical
conductors, and connections must be maintained in
conformance with good practice. Special attention must be paid
to the condition of electrical insulation.
17. To avoid injury to personnel or damage to the equipment,
consult the manufacturer’s procedures in replacing contacts on
any battery connection.
18. Industrial trucks must be kept in a clean condition to minimize
fire hazards and help in detection of loose or defective parts.
19. Modifications and additions that affect capacity and safe truck
operation must not be done without the manufacturer’s prior
written approval. Capacity, operation, and maintenance
instruction plates, tags, or decals must be changed accordingly.
20. Care must be taken to assure that all replacement parts,
including tires, are interchangeable with the original parts and of
a quality at least equal to that provided in the original equipment.
Parts, including tires, are to be installed per the manufacturer’s
procedures. Always use genuine CLARK or CLARK-approved
parts.
21. Use special care when removing heavy components from the
truck, such as counterweight, upright, etc.., the truck can
become unstable and tipover. Be sure that lifting and handling
equipment is of correct capacity and in good condition.

NOTICE
You should also be familiar with additional operating and
maintenance safety instructions contained in the follow-
ing publications:
ASME B56.1: Safety Standard for Low Lift and High Lift Trucks
(Safety Code For Powered Industrial Trucks). Published by: Society
of Mechanical Engineers, Three Park Avenue, New York, NY10016.
NFPA 505: Fire Safety Standard for Powered Industrial Trucks:Type
Designations, Areas of Use, Maintenance and Operation. Available
from National Fire Protection Assoc., Inc., Batterymarch Park,
Quincy, MA 02169.
General Industrial Standards, OSHA 2206: OSHA Safety and Health
Standards (929 CFR 1910), Subpart N-Materials Handling and
Storage, Section 1910.178 Powered Industrial Trucks. For sale by:
Superintendent of Documents, U.S. Government Printing Office,
Washington, DC 20210.
IMPORTANT
Your new CLARK lift truck has been built to meet all appli-
cable mandatory requirements of ASME B56.1 Safety
Standard for Powered Industrial Trucks. Each truck also
includes certain safety devices, e.g., horn and overhead
guard, safety restraint system, seat belt as standard
equipment.
No additions, omissions, or modifications should be
made that affect compliance to the above requirements or
in any way minimize the effectiveness of the safety
devices.

PM Report Form
A planned maintenance CUSTOMER
ELECTRIC TRUCK
PLANNED MAINTENACE REPORT
C
O
D
E
O.K.
POTENTIAL
URGENT
/ = O.K
x = Adjust (Not P.M.)
r = Repair or replace
s = Requires shop year
(PM) program of regular,

DATE HOUR METER
DATE LUST P.M. HRS. LAST P.M.
routine inspections and

MODEL & SERIAL NO. CUST. P.O. NO.
ATTACHMENT NO.
AUTHORIZED SIGNATURE INSPECTOR SPECIAL INSTRUCTIONS
lubrication is important for
COMMENTS
A. TEST DRIVE MACHINE 16 MOTORS 23 BRAKE SYSTEM 34 UPRIGHT - CARRIAGE
a. Drive Train Noise a. Drive Train Noise a. Drive Train Noise a. Security of Mounting
b. Steering Operation Steering Operation b. Steering Operation b. Roller Condition/Clearance
c. Service Brake Operation Steering Operation c. Service Brake Operation

e. Chain Adjustment
long life and troublefree d. Speed Control c. Service Brake Operation d. Speed Control g. Latch and Stop Condition
Creep Speed Creep Speed e. Plugging & Direction Control 34 LOAD BACK REST
1A Operation 1A Operation 26 STEER AXLE a. Conditon
e. Plugging & Direction Control c. Service Brake Operation a. Drive Train Noise b. Steering Operation
operation of your lift truck. f. Return to Neutral
g. Hydraulic System Operation
e. Plugging & Direction Control

Air Clean Truck
Air Clean Electrical Truck
19 ELECTRICAL TESTS
b. Steering Operation
c. Service Brake Operation
d. Speed Control
35 LIFT LINKAGE (POW)
a. Drive Train Noise
Make and keep records of

01. CLEANING & LUBRICATION a. Drive Train Noise f. Return to Neutral b. Steering Operation
a. Air Clean Truck b. Steering Operation e. Plugging & Direction Control c. Service Brake Operation
b. Air Clean Electrical Truck c. Service Brake Operation 26 STEERING SYSTEM
12. BATTERY AND CABLES d. Speed Control a. Drive Train Noise 38 SHEET METAL & CWT
your inspections. a. Drive Train Noise
d. Speed Control
f. Return to Neutral
g. Hydraulic System Operation
h. Plugging & Direction Control

d. Speed Control
29/30 HYDRAULIC SYSTEM

a. Check for Leakage
b. Fluid Level - Condition
c. Clean/Replace Breather
d. Replace Filter
Use these records to help e. Drive Train Noise
f. Steering Operation
g. Service Brake Operation 20 DRIVE AXLE

b. Fluid Level - Condition
c. Clean/Replace Breather
e. Linkage Adjustment
f. Hose Condition
g. Lift Speed (in/Sec)
establish the correct PM

h. Speed Control a. Drive Train Noise d. Replace Filter Full Load
i. Drive Train Noise b. Steering Operation e. Linkage Adjustment h. Drift Test (in/mIn)
j. Steering Operation c. Service Brake Operation f. Hose Condition 39 OVERHEAD GUARD

k. Service Brake Operation g. Lift Speed (in/Sec) a. Check for Leakage
intervals for your appli- 13. GAUGES -LIGHTS-INDICATORS

23 WHEELS AND TIRES

Full Load
h. Drift Test (in/mIn)
Lift Cylinder
Tilt Cylinder
b. Cylinder Rod Condidtion
53 ATTACHMENTS
cation and to indicate d. Drive Train Noise
e. Steering Operation
f. Service Brake Operation

d. Speed Control
f. Return to Neutral
32 TILT CYLINDER

c. Mounting Security/Torque
maintenance required to
g. Drive Train Noise g. Hydraulic System Operation c. Mounting Security/Torque
h. Steering Operation e. Plugging & Direction Control d. Tilt Cylinder Adjustment (Racking)
prevent major problems

from occurring during operation.
As an aid in performing and documenting your PM inspections,
CLARK prepared an Electric Truck Planned Maintenance Report
Form (PM Report Form). Copies of this form may be obtained from
your authorized CLARK dealer. We recommend that you use this
form as a checklist and a record of your inspection and truck
condition.
The maintenance procedures outlined in this manual 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 adjustments.
When you have finished the PM inspections, be sure to give a copy
of the report to the designated authority responsible for lift truck
maintenance.
Do not make repairs or adjustments unless authorized to do so.
For safety, it is good practice to:
• Remove all jewelry (watch, rings, bracelets, etc.) before work-
ing on the truck.
• Disconnect the battery before working on electrical compo-
nents.
• Always wear safety glasses. Wear a safety (hard) hat in indus-
trial plants and in special work areas where protection is neces-
sary and required.

Visual Inspection
Begin the PM routine with a visual inspection of the lift truck and its
components.
1. Walk around the truck and take note of any obvious damage and
maintenance problems. Check for loose fasteners and fittings.
2. Check to be sure all capacity, safety, and warning plates or
decals are attached and legible.
NOTICE
NAMEPLATES AND DECALS: Do not operate a lift truck
with damaged or lost decals and nameplates. Replace
them immediately. They contain important information.
3. Inspect the truck for any sign of external leakage: transmission
fluid, brake oil, electrolyte, etc..
4. 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.
5. Be sure that the driver’s overhead guard, load backrest exten-
sion, and safety devices are in place, undamaged, and attached
securely.
Then check all of the critical components that handle or carry the
load.
Overhead Guard
Check the overhead guard for dam- Overhead Guard
age. Be sure that it is properly posi-
tioned and all mounting fasteners
are in place and tight. Make sure no Upright
cracks have developed.
Upright Assembly
Load
Inspect the upright assembly: rails, Backrest
carriage rollers, lift chains, and lift
and tilt cylinders. Look for obvious
wear and maintenance problems,
damaged or missing parts.
IMPORTANT
Make sure that no structural members have developed
any cracks.

Check for any loose parts or fittings. Check for leaks, any damaged
or loose rollers, and rail wear (metal flaking). Inspect all lift line
hydraulic connections for leaks
Load Backrest
Check the load backrest for
damage. Inspect the welds on the
carriage and load backrest for
cracks. Be sure that the mounting
fasteners are all in place and tight.
! CAUTION
If the load backrest extension
has been removed, a bolt and
washer must be in place on
each end of the top fork bar to
act as a fork stop.
Lift Chain Maintenance

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

Inspect and lubricate the lift chains every PM (50-250 hours). When
operating in corrosive environments, inspect the chains every 50
hours. During the inspection, check for the following conditions:
• Rust and corrosion, cracked plates, raised or turned pins,
tight joints, wear, and worn pins or holes.
• When the pins or holes become worn, the chain becomes
longer. When a section of chain is 3% longer than a section
of new chain, the chain is worn and must be discarded.

• Chain wear can be measured by using a chain scale or a
steel tape measure. When checking chain wear, be sure to
measure a segment of chain that moves over a sheave. Do
not repair chains by cutting out the worn section and joining
in a new piece. If part of a chain is worn, replace all the
chains on a truck.
Lift Chain Lubrication
• Lift chain lubrication is an important part of your mainte-
nance program. The lift chains operate under heavy load-
ings and function more safely and have longer life if they are
regularly and correctly lubricated. CLARK chain lubricant is
recommended; it is easily sprayed on and provides superior
lubrication. Heavy motor oil may also be used as a lubricant
and corrosion inhibitor.
Lift Chain Wear and Replacement Criteria:
1. (NEW CHAIN LENGTH) The
distance from the first pin
counted to the last pin counted
in a span while the chains are
lifting a small load.
2. (WORN CHAIN LENGTH) The 2 3
distance from the first pin 1
counted to the last pin counted
in a span while the chains are
lifting a small load.
4
3. (SPAN) The number of pins in the length (segment) of chain to
be measured.
4. (PITCH) The distance from the center of one pin to the center of
the next pin.
All chains must be replaced if any link has wear of 3% or more, or if
any of the damaged conditions noted above are found during
inspection. Order replacement chains from your CLARK dealer.
Replace all chains as a set. Do not remove factory lubrication or
paint new chains. Replace anchor pins and worn or broken anchors
when installing new chains. Adjust tension on new chains. Lubricate
chains when they are installed on the upright.
NOTICE
Please refer to your Service Manual for additional infor-
mation on lift chain measurement and maintenance.

! WARNING
Uprights and lift chains require special attention to main-
tain them in safe operating condition.
• Uprights can drop suddenly. Look at the upright, but
keep hands out.
• Lift chain repairs and adjustments should be made by
trained service personnel.
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 than 6mm
(0.25in).
! WARNING
If the fork blade heel is
worn down by more than
10 percents, the load
capacity is reduced and the A
fork must be replaced.
6mm(1/4in) is
10% of "A" is max. height
max. wear difference
Inspect the forks for twists
and bends. Put a 2"-thick 14.5mm(0.6 in)
metal block, at least 4" wide
by 24" long, on the blade of
the fork with the 4" surface
against the blade. Put a 24"
50 cm
carpenter’s square on the top 0"
(20 2in) Carpenter
Carpenter
of the block and against the square
Square
shank. Check the fork 20"
above the blade to make sure
5 x2"10Xcm
4"
it is not bent more than (2 x 4 in)
0.6"(14.5mm) maximum. Blade
If the fork blades are obviously bent or damaged, have them

inspected by a trained maintenance person before operating the
truck.
Inspect the fork locating pins. Be sure they are not damaged or
broken and operate freely and lock correctly. Check the fork stop
pins for secure condition.

Wheels and Tires
Check the condition of the drive and steer
wheels and tires. Remove objects that are
embedded in the tire. Inspect the tires for
excessive wear and breaks or "chunking out"
and bond failure between the tire and the rim.
Check all wheel lug nuts or bolts to be sure
none are loose or missing.
Have missing bolts replaced and loose bolts
tightened to the correct torque before
operating truck.
! WARNING
Check tire pressure from a position facing the tread of the
tire, not from the side. Use a long-handled gauge to keep
your body away from the side. If tires are low, do not
operate and do not add air. Check with a mechanic. The
tire may require removal and repair. Incorrect (low) tire
pressure can reduce the stability of your lift truck. Do not
operate truck with low tire pressure. Proper cold inflation
is 100 psi.
Functional Test
Now, check that all controls and systems are functioning correctly.
Test horn, lights, and all other safety equipment and accessories. Be
sure they are properly mounted and working correctly.
Press the horn button to check horn
Horn
function. If the horn or any other part
does not operate, report the failure, and
have it repaired before the truck is put
into operation.

Service and Parking Brakes

Operate service and parking brakes; all hydraulic controls—lift, tilt,
and auxiliary (if installed); accelerator; directional controls; and
steering system. Be sure all controls operate freely and return to
neutral properly.
Check the service brake system. Push the brake pedal fully down
and hold. The brakes should be applied before the pedal reaches the
floorplate. Check for a feeling of solid resistance when the pedal
stops.
The pedal must feel firm and not move down farther after it stops. If
the pedal continues to creep downward, report the failure
immediately. Do not operate the truck until the brakes are repaired.
Parking Brake
Check the function of the parking brake.
Release, then reapply. To check parking
brake holding capability, park the lift truck
on a grade and apply the parking brake.
The parking brake should hold a lift truck
with rated load on a 15% grade.
! CAUTION
Do not operate a lift truck if the
service or parking brakes are not
operating properly.

Lift Mechanisms and Controls
Check the function of the lift system and controls.
Pull back on the tilt control lever and hold until the upright reaches
the full back tilt position. Push forward on the lever to return the
upright to the vertical position. Release the lever. It should spring
back to the neutral position freely without assistance.
! CAUTION
Be sure that there is adequate overhead clearance before
raising the upright.
Pull back on the lift control lever and
raise the fork carriage to full height.
Watch the upright assembly as it
rises. All movements of the upright,
fork carriage, and lift chains must be
even and smooth, without binding or
jerking. Watch for chain wobble or
looseness; the chains should have
equal tension and move smoothly
without noticeable wobble. Release
the lever.It should spring back to the
center position.
If the maximum fork height is not
reached, this indicates there is an
inadequate (low) oil level in the hy-
draulic sump tank or severe binding
within the upright.
Push forward on the lift control lever. Watch the upright as it lowers.
Movement should be smooth and even. When the forks reach the
floor, release the lever. It should spring back to the center position.
Auxiliary Controls
If your lift truck is equipped with an attachment, test the control lever
for correct function and briefly operate the attachment.

Steering System
NOTICE
The steering system, steer axle, and steering linkage on
your truck should be inspected periodically for abnormal
looseness and damage, leaking seals, etc.. Also, be alert
for any changes in steering action. Hard steering, exces-
sive freeplay (looseness), or unusual sound when turning
or maneuvering indicates a need for inspection or servic-
ing.
Check the steering system by
moving the steering handwheel in a
full right turn and then in a full left
turn. Return the handwheel (steer
wheels) to the straightahead
position. The steering system com-
ponents should operate smoothly
when the steering wheel is turned.
IMPORTANT
Never operate a truck with a malfunctioning steering
sytem.
! WARNING
Fasten your seat belt before driving the truck.
Direction Control and Brakes

Check and make sure that the travel area is clear in front of the truck.
Push firmly on the brake pedal. Release the parking brake. Move the
direction control lever from NEUTRAL to FORWARD travel position.
Remove your right foot from the brake pedal and put it on the
accelerator pedal. Push down until the truck moves slowly forward.
Remove your foot from the accelerator pedal and push down on the
brake pedal to stop the truck. The brakes should apply smoothly and
equally. Be sure the travel area is clear behind the truck.
Put the directional control lever in the REVERSE travel position.
Push down on the accelerator pedal until the truck moves slowly in
the reverse direction. Remove your foot from the accelerator pedal
and push down on the brake pedal to stop the truck. The brakes
should apply smoothly and equally.

Transistorized Traction Control
Test for correct function of the traction control. Check creep speed,
1A range, and plugging.
!
CAUTION
Check and make sure the travel area is clear before each
movement and before each change of direction.
1. Check creep speed and 1A range while driving the truck in a
straight line in both forward and reverse directions. All speed
changes should be smooth while increasing and decreasing
speed. Notice any unusual drive train noise or action of the con-
trols and drive train components.
Stop the truck with the service brakes. Note any unusual reac-
tions in driving or braking performance. Note any need for
adjustment.
2. Check the plugging function first at a slow speed. If operating
correctly, then test at full speed.
First, drive the truck in the FORWARD direction. Push the accel-
erator pedal and allow the truck to accelerate to the desired
travel speed. Then, move the direction control to the REVERSE
position while your foot is still depressing the accelerator pedal.
The truck should slow to a smooth, controlled stop and acceler-
ate in the opposite direction.
Repeat the test by moving the direction control back to the for-
ward position.
Check the accelerator control while conducting the speed range
tests. It must move easily and smoothly throughout the acceleration
stroke and return without binding.
Test the service brake (drive motor cut-off) switch.
Drive the truck in FORWARD (or in REVERSE) at creep speed.
While holding the accelerator pedal steady, push on the brake pedal
with your left foot. The braking action should interrupt power to the
drive motor and stop the truck. Release the brake pedal. The drive
motor should start moving the truck again.
IMPORTANT
When you have completed the operational tests, park and
leave the truck according to standard shut down proce-
dures.
Be sure to make a record of all maintenance and opera-
ting problems you find.

Checking the Hydraulic Fluid

Check the hydraulic sump tank fluid level. Correct fluid level is
important for proper system operation. Low fluid level can cause
pump damage.
Hydraulic fluid expands as its temperature rises. Therefore, it is
preferable to check the fluid level at operating temperature (after
approximately 30 minutes of truck operation). To check the fluid
level, first park the truck on a level surface and apply the parking
brake. Put the upright in a vertical position and lower the fork
carriage fully down. Pull the dipstick out (under the sump breather),
wipe it with a clean wiper, and reinsert it. Remove dipstick and check
oil level. Keep the oil level above the LOW mark on the dipstick by
adding recommended hydraulic fluid only, as required. Do not
overfill.
IMPORTANT
When checking hydraulic oil, make sure you use a clean
wiper and do not let contaminants get on the dipstick or in
the sump.
Check the condition of the hydraulic fluid (age, color or clarity,
contami-nation). 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 safety, it is important that the correct
torque be maintained on all critical fasteners of components that
directly support, handle, or control the load and protect the operator.
Check critical items, including:
• Drive axle mounting
• Drive and steer wheel mounting
• Counterweight mounting
• Load backrest extension
• Overhead guard
• Tilt cylinder mounting & yokes
• Upright mounting & components

Air Cleaning the Truck
Always maintain a lift truck in a clean condition. Do not allow dirt,
dust, lint, or other contaminants to accumulate on the truck. Keep the
truck free from leaking oil and grease. Wipe up all oil spills. Keep the
controls and floorboards clean, dry, and safe. A clean truck makes it
easier to see leakage and loose, missing, or damaged parts. A clean
condition helps prevent fires and helps the truck run cooler.
The environment in which a lift truck operates determines how often
and to what extent cleaning is necessary. For example, trucks
operating in manufacturing plants with a high level of dirt, dust, or
lint, (e.g., cotton fibers, paper dust, etc.) in the air or on the floor
require more frequent cleaning. If air pressure does not remove
heavy deposits of grease, oil, etc., it may be necessary to use steam
or liquid spray cleaner.
IMPORTANT
Do not steam, Pressure wash, or use liquid spray cleaner
on Electronic control panel. Lift trucks should be air
cleaned at every PM interval, or more often if necessary.
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 compressed air. Restrict air pressure to 30 psi (207 kPa),
maximum (OSHA requirement).
!
CAUTION
Wear suitable eye protection and protective clothing.
Air clean: upright assembly; drive axle; battery; cables; switches and
wiring harness; transistor traction controls and wiring; drive, lift, and
steer motors; and steer axle, steer cylinder, and linkage.

Electric Truck Battery Maintenance
BATTERY
BATTERY
SERVICE
SERVICE
NO AREA
AREA
SMOKING
SMOKING
Battery charging installations must be located in areas designated for

that purpose. These areas must be kept free of all non-essential
combustible materials.
Facilities must be provided for:
• Flushing spilled electrolyte
• Eye wash facility
• Fire protection
• Protecting charging apparatus from damage by trucks
• Adequate ventilation 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 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 hazardous chemical solution.
On charge, they give off hydrogen and oxygen which, in
certain concentrations, are explosive. And they are costly.
Before you remove, service, or install a truck battery,
carefully read the following recommendations and in-
structions.

Battery Handling
1. Change (remove) or service storage batteries only in an area
designated for this purpose.
2. Be sure this area has provisions to flush and neutralize spillage,
to ventilate fumes from gassing batteries, and for fire protection.
3. This area should be equipped with material-handling tools de-
signed for removing and replacing batteries, including a con-
veyor or overhead hoist. Use lift hooks that have safety latches.
4. Always use a special 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 battery case. Be sure
the lift hooks are the correct size to fit the lifting eyes of the bat-
tery.
5. If the battery does not have a cover of its own or has exposed
terminals and connectors, cover the top with a non-conductive
(insulating) material, e.g., a sheet of plywood or heavy card-
board, prior to attaching the lifting device.
6. Chain hoists or power battery hoists must be equipped with
load-chain containers to accumulate the excess lifting chain.
Insulated-
Spreader Bar
Lifting Eye
Non-Conductive
Material
Lifting Eye Battery

7. Keep all tools and other metallic objects away from the
terminals.
! WARNING
BATTERY SERVICE: Battery service must be done by
trained and authorized personnel. Battery acid can cause
severe burns and injury.
Battery Charging
1. Persons maintaining storage batteries must wear protective
clothing such as face shield, long sleeves, and gloves.
2. Hydrogen emissions from charging batteries are flammable. No
smoking is allowed in the charging area. Do not check the elec-
trolyte level with an open flame. Do not allow open flame,
sparks, or electric arcs in battery charging area.
! WARNING
SULFURIC ACID: The battery
contains corrosive acid that can
cause injury. If acid contacts your
eyes or skin, flush immediately
with water and get medical
assistance.
! WARNING
EXPLOSIVE GASES: Do not
smoke or have open flames or
sparks on battery charging areas
or near batteries. An explosion
can cause injury or death.

3. When charging batteries, the vent caps must be kept in place to
avoid electrolyte spray. Care must be taken to assure that vent
caps are open (clean) and functioning. The battery (or compart-
ment) cover(s) must be open to dissipate heat and gas.
IMPORTANT
If batteries discharge rapidly during normal operation or
do not charge to the correct specifications, contact a
qualified battery service technician to check the battery
for you. Do not add electrolyte or attempt to service the
battery.
Battery Removal from Truck

1. Check the designated service and charging area for fire protec-
tion, and be sure all sources of ignition are cleared from the
area. Do not smoke. Be sure all previous 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 elec-
trolyte.
2. Before attempting to remove or charge a storage battery, the
truck should be positioned in the designated battery service area
and the parking brake applied so the truck cannot move.
3. If the battery to be handled is not equipped with its own cover,
cover the battery when handling with a non-conductive (insulat-
ing) material, e.g., plywood or heavy cardboard, before attaching
the lifting device.
4. Use an approved lifting device with an insulated spreader bar, to
remove and transport a truck battery. Be sure the hoist and lifting
chains are equipped with safety hooks.
5. Remove the battery and move it to a
safe storage location. Store batteries
either on an approved battery rack or
on a wooden pallet.

Battery Cleaning and Care

Never wash the battery when it is in the truck. The easiest and most
satisfactory method of cleaning a battery is to wash it occasionally
with a low-pressure cold-water spray. The top can also be washed
off with a solution of baking soda and water (add a box of baking
soda to a pail of water and stir until dissolved) and rinsed with clean
water. It is good practice to have this solution in a battery room at all
times.
IMPORTANT
During cleaning, the battery vent caps must be tightly in
place.
Refer to the battery manufacturer or supplier for their recommended
battery maintenance and care procedures.
BATTERY SAVER and CLEANER, CLARK Part No. 886398, may be
used to clean and protect the truck battery.
New Truck Batteries: Apply a light coat of BATTERY SAVER and
CLEANER 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 obtain the best
service life from your battery and truck. Select a pilot cell, take
readings of specific gravity and temperature before and after
charging, and record the readings with the date. It is best to change
the location of the pilot cell occasionally to distribute any electrolyte
loss over the battery.
Every 2 or 3 months, take complete battery readings (specific gravity,
temperature, and voltage) and make a record of them.

How to Get Maximum Battery Life
1. Follow normal battery maintenance procedures, re-charging
before 80% discharged and with periodic equalizing charges.
Let cool eight hours after charging before using.
2. Don’t add acid to a battery. Only a person trained and qualified
to do battery maintenance should determine if this is necessary.
3. Lift battery only with a correctly-constructed lifting device that will
not put pressure on the battery case.
4. Keep open flames, tools, and metal objects away from the top of
battery to prevent short circuits and explosions.
5. Do not overcharge.
6. Check the battery electrolyte level after each charging. Add
water if the top of the separator or plates are visible. Do not
overfill!
7. Keep the battery clean and dry. Wash down as needed.
8. Keep battery service records.
Battery Installation
1. Use only a lead-acid battery with the voltage and ampere-hour
rating specified for the truck.
2. When changing batteries on battery electric trucks, replacement
batteries must be of the service weight that falls within the
minimum/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.
5. Install the battery correctly in the truck and secure it in position.
NOTICE
Some trucks are equipped with battery stops or blocks.
Others do not require them. If the truck being serviced
has battery stops or blocks, be sure none are missing or
damaged. Replace them as necessary. If they are an ad-
justable type, be sure they are correctly adjusted and
tightened. There should be no more than 1/2" total clear-
ance around the battery. The battery weight must be
within the range specified on the truck nameplate.

Section 9. Specifications
Specifications
Contents
ECG 20-32 ............................................................... 9-2

EPG 20-30 ............................................................... 9-4
TMG 12-25................................................................ 9-6
TMX 12-25 ................................................................ 9-8
ECX 20-32 ............................................................. 9-10
Contents 9-1
ECG 20-32
Clark products and specification are subject to improvements and

changes without notice or obligation.
Model Designation — Rated Load Capacity
ECG 20 1810kg @ 600mm load center [4,000lbs @ 24in] [2000kg @ 500mm]
Note: Specifications are given with triple stage upright, standard
battery compartment size and minimum battery weight.
Truck Weights (approximate, with TSU upright, Min. battery wt., 30.4"
compartment)
Gross Vehicle Empty Vehicle Loaded Drive Empty Drive
Weight(kg[lbs]) Weight(kg[lbs]) Axle(kg[lbs]) Axle(kg[lbs])
ECG 20 6,019[13,270] 4,200[9,270] 5,400[11,910] 2,190[4,830]
ECG 25 7,025[15,490] 4,760[10,490] 6,110[13,470] 2,095[4,620]
ECG 30 7,740[17,070] 5,020[11,070] 6,920[15,250] 2,095[4,620]
ECG 32* 8,300[18,300] 5,350[11,800] 7,550[16,640] 2,385[5,260]
* ECG 32 spec is for a 34.4" battery compartment.
Wheels & Tires
Drive Tire Size: (Cushion) Steer Tire Size: (Cushion)
ECG 20 21 × 7 × 15 16 × 6 × 10.5
ECG 25 21 × 8 × 15 16 × 6 × 10.5
ECG 30 21 × 8 × 15 16 × 6 × 10.5
ECG 32 21 × 9 × 15 16 × 6 × 10.5
Battery Capacity Range
30.4" Battery Compartment
36 volt 48 volt
18 cells, 25 plates 24 cells, 19 plates
900-1320 amp hour @ 6 hr rate 675-990 amp hour @ 6 hr rate
31.3-45.9 kWh 31.4-45.8 kWh

36 volt 48 volt
18 cells, 27 or 29 plates 24 cells, 21 plates
33.8-53.5 kWh 35.0-50.9 kWh
Battery, fully charged: 1.275 specific gravity (1.310 Exide Load Hog)
Discharged: 1.140 specific gravity
9-2 ECG 20-32

Fill Capacities—Fluid Volumes

Drive Axle: 3.4gal (13L)
Hydraulic Sump Tank (Useable Volume): 5.5 gal (21L)
Hydraulic Fluid Recommendation

Normal application - Clark Specification MS-68 Hydraulic oil
Drive Axle Fluid Recommendation: AMOCO 1000
Power Steering Fluid Recommendation Uses main hydraulic

sump oil supply.
Brake Reservoir: DOT 3 Brake Fluid.
Multi-Purpose Grease
Axle Ends, Wheel Bearings: NLGI Grade No. 1 Lithium soap base grease
CLARK Specification MS-9B and MS-107B
Steering linkage, upright NLGI Grade No. 2 Lithium soap base grease,
mast & carriage rollers, trun- CLARK Specification MS-107C.
nion bushings, tilt cylinder
rod ends, brake pedal shaft:
Use genuine CLARK parts. See your CLARK dealer.
ECG 20-32 9-3

EPG 20-30

EPG 20 1810kg @ 600mm load center [4,000lbs @ 24in] [2000kg @ 500mm]
Truck Weights (approximate, with TSU upright 170in (4320mm), Min. bat-
tery wt., EPG20/25 31.0", EPG 30 39.0" compartment)
EPG 20 6000[13227] 4000[8818] 5360[11816] 2065[4552]
EPG 25 6970[15366] 4470[9854] 6145[13547] 2025[4464]
EPG 30 7875[17361] 4875[10747] 6905[15222] 2115[4662]
Wheels & Tires

Drive
EPG 20 7.00 × 12 − 14PR...................................1000kpa(145 psi)
EPG 25 7.00 × 12 − 14PR...................................1000kpa(145 psi)
EPG 30 28 × 9 × 15 − 14PR or
8.15 × 15 − 14PR .................................. 965kpa(140 psi)
Steer
EPG 20 18 × 7 × 8 - 16PR...................................1000kpa(145 psi)
EPG 25 18 × 7 × 8 - 16PR...................................1000kpa(145 psi)
EPG 30 18 × 7 × 8 - 16PR...................................1000kpa(145 psi)
48 volt
600-715 amp hour @ 5 hr rate

48 volt
9-4 EPG 20-30



Normal application - Clark Specification MS-68 Hydraulic oil:RANDO HD 32
Cold Storage: RANDO HD CZ
Drive Axle Fluid Recommendation: AMOCO 1000, EXXON

TORQUE FLUID 56.

sump oil supply.
EPG 20-30 9-5

TMG 12-25

TMG 12 1130kg @ 600mm load center [2,500 lbs @ 24in] [1250kg @ 500mm]
TMG 15S 1360kg @ 600mm load center [3,000 lbs @ 24in] [1500kg @ 500mm]
Truck Weights(approximate, with TSU upright and minimum battery weight)

TMG 12 4510[9948] 3380[7448] 4085[9005] 2000[4411]
TMG 15S 5000[11022] 3640[8022] 4490[9903] 1990[4390]
TMG 15 4885[10771] 3525[7771] 4325[9534] 1970[4341]
TMG 17 5260[11597] 3670[8097] 4720[10407] 1972[4348]
TMG 20 5740[12671] 3930[8671] 5105[11255] 1965[4330]
TMG 25 6660[14684] 4390[9684] 5870[12949] 1935[4268]
Wheels & Tires
Drive Tire Size: Steer Tire Size: Dual Steer
(Cushion/Pneumatic) (Cushion/Pneumatic) Tire Size:
(Cushion/solid)
TMG 12 18×7×12.12/18×7×8 16PR 18×7×12.12/18×7×8 16PR 15×5×11.25/15x4.5-8
TMG 15S 18×7×12.12/18×7×8 16PR 18×7×12.12/5-8/4.5(solid) 15×5×11.25/15x4.5-8
TMG 15 18×7×12.12/18×7×8 16PR 18×7×12.12/18×7×8 16PR 15×5×11.25/15x4.5-8
TMG 17 18×8×12.12/18×9×8 16PR 18×7×12.12/N/A 15×5×11.25/15x4.5-8
TMG 20 18×8×12.12/18×9×8 16PR 18×7×12.12/N/A 15×5×11.25/15x4.5-8
TMG 25 18×9×12.12/ N/A 18×6×12.12/N/A 15×5×11.25/N/A
36 Volt Battery
13.75" Battery Compartment 20.5" Battery Compartment
20.9-27.0 kWh 27.7 - 43.0 kWh

18 cells, 21 plates
34.77-53.8 kWh
9-6 TMG 12-25

48 Volt Battery
17.3-21.6 kWh 29.0 - 36.0 kWh
25.0" Battery Compartme
24 cells, 15 plates
40.6-50.2 kWh
Battery, fully charged:1.275 specific gravity (1.310 Exide Load Hog)


2 Drive Axle: 1.7gal (6.5L) each side.
Hydraulic Sump Tank: 4 gal. (15L)

Power Steering Fluid Recommendation: Uses main hydraulic

sump oil supply.
Brake Reservior: DOT 3 Brake Fluid

TMG 12-25 9-7

TMX 12-25

TMX 12 1130kg @ 600mm load center [2,500 lbs @ 24in] [1250kg @ 500mm]
TMX 15S 1360kg @ 600mm load center [3,000 lbs @ 24in] [1500kg @ 500mm]
Truck Weights(With TSU upright and minimum battery weight)

TMX 12 4418[9749] 3288[7249] 3947[8701] 1866[4114]
TMX 15S 4947[10908] 3587[9708] 4352[9594] 1855[4090]
TMX 15 4953[10921] 3593[7921] 4443[9796] 2091[4610]
TMX 17 5357[11805] 3767[8305] 4907[10819] 2163[4769]
TMX 20 5881[12964] 4066[8964] 5303[11692] 2167[4777]
TMX 25 6848[15093] 4578[10093] 6078[13401] 2158[4758]
Wheels & Tires
Drive Tire Size: Steer Tire Size: Dual Steer
(Cushion/Pneumatic) (Cushion/Pneumatic) Tire Size:
(Cushion/solid)
TMX 12 18×7×12.12/18×7×8 16PR 18×7×12.12/18×7×8 16PR 15×5×11.25/N/A
TMX 15S 18×7×12.12/18×7×8 16PR 18×7×12.12/5-8/4.5(solid) 15×5×11.25/N/A
TMX 15 18×7×12.12/18×7×8 16PR 18×7×12.12/18×7×8 16PR 15×5×11.25/N/A
TMX 17 18×8×12.12/18×9×8 16PR 18×7×12.12/N/A 15×5×11.25/N/A
TMX 20 18×8×12.12/18×9×8 16PR 18×7×12.12/N/A 15×5×11.25/N/A
TMX 25 18×9×12.12/ N/A 18×6×12.12/N/A N/A/N/A
36 Volt Battery
20.9-27.0 kWh 27.7 - 43.0 kWh

18 cells, 21 plates
34.77-53.8 kWh
9-8 TMX 12-25

48 Volt Battery
17.3-21.6 kWh 29.0 - 36.0 kWh
25.0" Battery Compartme
24 cells, 15 plates
40.6-50.2 kWh
Battery, fully charged:1.275 specific gravity (1.310 Exide Load Hog)


2 Drive Axle: 1.7gal (6.5L) each side.
Hydraulic Sump Tank: 4 gal. (15L)

Power Steering Fluid Recommendation: Uses main hydraulic

sump oil supply.
Brake Reservior: DOT 3 Brake Fluid

TMX 12-25 9-9

ECX 20-32

ECX 20 1810kg @ 600mm load center [4,000lbs @ 24in] [2000kg @ 500mm]
Truck Weights (approximate, with TSU upright, Min. battery wt., 30.4"
compartment)
ECX 20 6,070[13,390] 4,260[9,390] 5,359[11,815] 2,164[4,770]
ECX 25 7,090[15,625] 4,820[10,625] 6,090[13,425] 2,098[4,625]
ECX 30 7,800[17,200] 5,080[11,200] 6,888[15,185] 2,086[4,600]
ECX 32* 8,330[18,370] 5,385[11,870] 7,447[16,420] 2,573[5,672]
* ECX 32 spec is for a 34.4" battery compartment.
Wheels & Tires
Drive Tire Size: (Cushion) Steer Tire Size: (Cushion)
ECX 20 21 × 7 × 15 16 × 6 × 10.5
ECX 25 21 × 8 × 15 16 × 6 × 10.5
ECX 30 21 × 8 × 15 16 × 6 × 10.5
ECX 32 21 × 9 × 15 16 × 6 × 10.5
36 volt 48 volt
31.3-45.9 kWh 31.4-45.8 kWh

36 volt 48 volt
18 cells, 27 or 29 plates 24 cells, 21 plates
33.8-53.5 kWh 35.0-50.9 kWh
9-10 ECX 20-32




sump oil supply.
ECX 20-32 9-11

9-12
Index
A Maintenance.............................8-23
Adjusting the Load Forks ......... 5-13 ECG 20-32 .................................9-2
Adjusting the Seat...................... 5-4 ECG and TMG Command
After Operating the Truck ........ 5-19 System Display (Option) ...........4-7
Air Cleaning the Truck ............. 8-22 ECX 20-32................................9-10
A Message to CLARK Lift ECX Dash Display .....................4-6
Truck Operators ............................ ii EPG 20-30 .................................9-4
Auxiliary Control Lever EPG 20-30, ECG 20-32
(Optional) ................................... 3-6 Operator Compartment .............4-2
EPG, ECG and TMG Dash
B Display ......................................4-4
Before Operating the Truck ....... 5-2
Battery Charging ..................... 8-25
Battery Cleaning and Care ...... 8-27 F
Battery Connector Warning Fast Turn and High Loads..........2-4
Decal.......................................... 3-9 Fastener Checks, Critical .........8-20
Battery Handling ...................... 8-24 Forks .......................................8-15
Battery Installation ................... 8-28 Forks Positioning......................5-10
Battery Removal from Truck .... 8-26 Fork Safety ................................1-8
Battery Service Records .......... 8-27 Functional Checks......................6-4
Brake Pedals ............................. 3-5 Functional Tests .......................8-16
Braking....................................... 5-9
G
Buckling Up................................ 5-4
Grades, Ramps, Slopes,
C and lnclines ..............................1-11
Controlling Speed ...................... 5-9 General Tire Maintenance,
Chain Slack................................ 2-7 Inspection, and Repair .............1-16
Command System
H
ECG 20-32................................. 4-5
Horn Button ................................3-5
TMG 12-25................................. 4-5
Hour Meter .................................3-4
Concluding the Inspection ......... 6-5
How to Get Maximum
D Battery Life ..............................8-28
Daily Inspection ......................... 1-2 Hydraulic Control Lever..............3-6
Daily Maintenance Checks ........ 8-5 How to Use this Manual .............viii
Diagnostic Display ECG/TMG ... 5-7
I
Diagnostic Display ECX/TMX .... 5-7
Inspecting Your Truck ................6-2
Direction Control and Brakes... 8-19
Introduction ................................. vi
Direction Control Lever .............. 3-5
Do's and Don'ts.......................... 1-3 K
Docks/Drop Offs ........................ 2-5 Keep Away From Forks Decal....3-9
Key/Start Switch ........................3-3
E
Electric Truck Battery L
Index-1
Lift Control Function .................. 3-6 R
Lift Chain Inspection and Ramps ......................................1-11
Measurement........................... 8-14 Rear Swing................................ 2-3
Lift Chain Maintenance ............ 8-13 Right-Angle Stacking..................2-6
Lift Chain Wear and Routine Servicing and
Replacement Criteria: ............. 8-14 Maintenance................................. vi
Lift Mechanisms and
Controls .................................. 8-18 S
Lift truck Maintenance ............... 8-3 Safe Maintenance Practices.......8-7
Load Backrest ......................... 8-13 Safety Signs and Safety
Load Handling ......................... 5-14 Messages ..................................... x
Long and Wide Loads ............... 2-3 Seat Adjustment .........................3-3
Loose Loads .............................. 2-2 Selecting Performance Level on
Low Overhead Clearance .......... 2-4 Command System
(ECG/TMG only).........................5-5
N Seat Belt.....................................1-4
No Riders .................................. 1-5 Service and Parking Brakes ....8-17
Service Brake .............................3-5
O
Skids ..........................................2-8
Operator Controls ...................... 3-3
Stacking .................................. 5-17
Operator Protection ................... 1-7
Starting from a Safe Condition ...5-3
Operator Safety Warning
Starting the Truck .......................5-4
Decal.......................................... 3-8
Steering System .........................3-5
Operator/Tip-Over...................... 3-8
Steering System ......................8-19
Operating Safely ...................... 5-10
Surface and Capacity ...............1-12
Operator Daily Inspection ............ vii
T
P
Tilt Control Function .................. 3-6
Parking..................................... 1-15
Tip-Over .................................. 1-13
Parking Brake ............................ 3-4
Tire Maintenance......................1-16
Parking Brake Lever ................. 3-4
TMG 12-25 .................................9-6
Parking Brake Pedal ................. 3-4
TMX 12-25..................................9-8
Parking Brake ......................... 8-17
TMG12-25, TMX12-25 Operator
Pallets and Skids ....................... 2-8
Compartment..............................4-3
Pedestrians ................................ 1-6
TMX Dash Display......................4-5
Periodic Maintenance Checks ... 8-6
Towing Precautions................... 7-2
Picking Up and Moving
Towing Procedures ....................7-3
Loads ....................................... 5-16
Transistorized Traction
Pinch Points............................... 1-9
Control......................................8-20
Planned Maintenance .................. vii
Travel .......................................1-10
Planned Maintenance ................ 8-3
Traveling with a Load ...............5-15
Planned Maintenance Intervals . 8-4
Truck Data and Safety Plate ......3-7
Plugging..................................... 5-9
Truck Description .......................3-2
Positioning Forks and Upright.... 5-8
PM Report Form ...................... 8-11
Index-2
U
Unloading ................................ 5-16
Upright Warning Decal .............. 3-9
V
Visual Checks ............................ 6-3
Visual Inspection ..................... 8-12
W
What to do in Case of
a Tip-over................................. 1-14
Wheels and Tires..................... 8-16
Index-3
Additional copies of this manual may be purchased from
YOUR AUTHORIZED CLARK DEALER
Operator’s
Manual
ELECTRIC RIDER LIFT TRUCKS
700 Enterprise Drive

Lexington, KY 40510 Part No. 8039886 Do not remove this manual
Printed in Korea Book No. OM-673 from the truck.
Oct, 2005
Rev.3
Oct.2005

OM-673

Uploaded by

Copyright:

Available Formats

OM-673

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

OM-673

Uploaded by

Copyright:

Available Formats

Additional copies of this manual may be purchased from

YOUR AUTHORIZED CLARK DEALER

700 Enterprise Drive

YOU can prevent accidents

First: Learn safe operating rules and your company rules.

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

Learn about the unit you operate.

KNOW YOUR TRUCK

Then: Practice operating your

And: Keep your truck in safe

Breaking these rules will cause serious or fatal injury to

Lift trucks are specialized machines with unique operating

ii A Message to CLARK Lift Truck Operators

A Message to CLARK Lift Truck Operators iii

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

Contents of this Manual v

CLARK welcomes you to the growing group of professionals who

Routine Servicing and Maintenance

This manual is a digest of essential information about the safe

viii How to Use this Manual

How to Use this Manual ix

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

x Safety Signs and Safety Messages

General Safety Rules

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

1-2 Daily Inspection

Do’s and Don’ts

Don't mix drugs or alcohol with your job.

Do watch for pedestrians.

Don't block safety or emergency

Do wear safety equipment

Don't smoke in "NO SMOKING" areas

Do’s and Don’ts 1-3

Seat belts can reduce injuries.

1-4 Seat Belts

The operator is the only one who should be on a truck.

Estar atento cuando se maneja. Mirar en el sentido de

Make people stand back, even when you are parked.

Keep under the overhead guard.

Operator Protection 1-7

Never allow anyone to

1-8 Fork Safety

Pinch Points 1-9

Travel with the load near

When handling bulky

Unstable loads are a hazard

Grades, Ramps, Slopes, and lnclines

Grades, Ramps, Slopes, and lnclines 1-11

1-12 Surface and Capacity

If your truck starts to tip over,

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

• Never park on a grade.

• Be sure travel control is in

• Set parking brake.

• Turn key to OFF position.

1-16 General Tire Maintenance, Inspection, and Repair

Loose Loads ........................................................... 2-2

Center wide loads.

Stack and band loose material.

2-2 Loose Loads