Clark GCS20I Operator's Manual

(
Operator's Manual
Do not remove this manual
from the truck.
GCS 20 I
Book No. 2779027

OM-520 3rd Rev.
(
Record the following information pertaining to your truck.
GCS 20 I
Model N o . - - - - - - - - - - - - - - - - - - -
Serial N o . - - - - - - - - - - - - - - - - - - -
Customer Truck Identification No. - - - - - - - - - - - -
Truck Weight, E m p t y - - - - - - - - - - - - - - - -
4,000 Lbs.
Truck Rated Capacity - - - - - - - - - - - - - - -
Truck Gross Weight, Loaded w / Rated Load _ _ _ _ _ _ __
None
Special Equipment _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
IMPORTANT
Do not expose this manual to hot water or steam.
©1990 Clark Equipment Company

(
Operator's Manual
You must be trained and authorized to operate a lift truck.
Follow these rules:

Read and understand your
Operator's Manual.
OVERHEAD
GUARD
PARKING
BRAKE
d~ Know your truck.
~i
STEER AXLE
AND WHEELS
MACHINE SERIAL DRIVE AXLE

NUMBER AND WHEELS
Learn safe operating rules

and practice operating
your truck.
Breaking these rules will cause serious or fatal injury to

yourself and others.
(
CONTENTS
This manual covers trucks with capacities from 3,000 pounds through 6,000 pounds.
A MESSAGE TO CLARK LIFT TRUCK OPERATORS ........ iii

TRUCK APPLICATION ................................. iv
OPERATOR MAINTENANCE ............................ 1
GENERAL SAFETY RULES ............................. 2
OPERA Tl NG HAZARDS ................................ 3
KNOW YOUR TRUCK .................................. 4
OPERATING PROCEDURES ............................ 5
EMERGENCY STARTING ............................... 6
EMERGENCY TOWING ................................ 7
PLANNED MAINTENANCE AND LUBRICATION ............ 8
SPECIFICATIONS ..................................... 9
ii
A Message To CLARK Lift Truck Operators )
Lift trucks are specialized machines with unique operating characteristics
designed to perform specific jobs. 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 ex-

perience with lift truck accidents has shown that when accidents happen
and people are killed or injured the causes are:
1. OPERATOR NOT PROPERLY TRAINED
2. OPERATOR NOT EXPERIENCED WITH LIFT TRUCK OPERATION
3. BASIC SAFETY RULES NOT FOLLOWED
4. LIFT TRUCK WAS NOT MAINTAINED IN A
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 learn how to operate your lift truck safe-
ly. This manual shows and tells you about operator maintenance and the im-
portant general safety rules and hazards of lift truck operation. It describes
the special components and features of the truck and their function. The
correct operating procedures are shown and explained. Illustrations and im-
portant safety messages are included for clear understanding. And, finally,
a section on maintenance and lubrication is included for the lift truck
mechanic.
The operator's manual is not a training manual. It is a guide to help autho-

rized operators safely operate their lift truck by illustrating the correct pro-
cedures. It cannot cover every possible situation which may result in an ac-
cident. You must watch for hazards in your work areas and correct them. It is
important that you learn the information in this manual and know your com-
pany safety rules! Be sure that your equipment is maintained in a safe con-
dition and do not operate a damaged truck. Practice safe operation every
time you use your lift truck. Let's join together to set new standards in
safety.
Remember, before you start operating this lift truck, be sure that you
understand all driving procedures. It is your responsibility, and it is impor-
tant to you and your family, to operate your lift truck safely and efficiently.
And be aware that the Federal Occupational Safety and Health Act and state
laws require that operators be completely trained in the safe operation of lift
trucks.
And let us make this point, 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 ef-
ficient as the operator and the persons responsible for maintaining them.
Do not make any repairs to this truck unless you have been trained in lift
truck repair procedures and authorized by your employer.
iii
( Truck Application
Each truck is designed for a specific application. Make sure
you are using the correct truck for the job.
Cushion (solid tires)
Cushion (solid) tire

trucks are designed for
use inside on smooth
dry surfaces.
Pneumatic (air-filled tires)
DD
Q__D
_.,, /
Use pneumatic (air) r
tire trucks on
-~
~-
~--
improved surface-
--- -~
....--~
---- ----
... inside or outside.
.... -
/"/__,.-__...... -
iv
( 1 Operator Maintenance
Daily Inspection
At the beginning of each

shift, fill out a daily
inspection sheet.
Do not make repairs your-

self. Lift truck mechanics
are trained professionals.
They know how to make
repairs safely.
1.1
Operator Maintenance )
Safety inspection
Check safety
equipment -
the overhead
guard, load
backrest
extension, horn,
and if present,
backup alarms,
Look at the upright, BUT KEEP .,.
YOUR HANDS OUT.
.,..,. and rotary
.,. lights .
fa
Backup Alarm
M
Warning Light
Other safety
devices are
available from
your Clark
dealer.
•
Make minor adjustments. Major
adjustments are made by trained
and authorized mechanics.
( Operator Maintenance
Tire inspection
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 fromJ_he side.
Low tires can effect the truck's stability

... but don't just add air! A damaged or
improperly installed split rim can come
apart under high pressure, resulting in
....:... severe injury or death. Check with a
mechanic; the tire may require removal or_
repair.
1.3
Operator Maintenance
Maintenance problem
DO NOT OPERATE A LIFT

TRUCK THAT HAS A
MAINTENANCE PROBLEM.
-
--
Remove the key and put

an "Out of Service" tag
on the truck.
1.4
(
Refuel gas or diesel
Refuel in designated
areas only.
RED CAN GREEN CAN
GASOLiNEI
FLAMMABLE
1
Use clean, properly Clean up spills. Use clean, properly

marked fuel cans. marked fuel cans.
Do not mix Use only clean,

gasoline and water-free diesel
diesel fuel. fuel. Check and
drain fuel bowl
daily if water
is present.
1.5
Refuel LPG tanks
When changing LPG tanks:
Follow these basic rules:
• Change only in well-ventilated areas.
• Turn the ignition off.
• Check for leaks.
• Never allow open flames.
• Store tanks following local fire codes.
If you refill LPG tanks:

Make sure someone explains all
procedures to you, and follow them.
LPG ... is heavier than air - it will settle

on your clothes and the ground where
you're working. Open flame can cause
flash fires.
Check all connections

for damage or leaks. If the truck
will not start after you change a
tank, get a mechanic to check it.
1.6
(
1. General Safety Rules
Follow the rules
Never mix drugs and

alcohol with your job.
Watch for
pedestrians.
Don't block safety or

emergency equipment.
Wear safety equipment

when required.
Watch those "No

Smoking" areas.
2.1
General Safety Rules
Surface and capacity
Avoid or slow
down on these
conditions ...
Know the weight of your truck and load.

Check capacities:
0 Elevators D Floors
2.2
( General Safety Rules
Seat belts
ALWAYS BUCKLE UP
011.~
Seat belts and wing seats can
reduce injuries.
2.3
No riders
The operator is the only one

who should be on a truck.
2.4
Pedestrians
Watch where you
are going.
Pedestrians may
use the same
roadway you do.
Sound your horn
at all inter-
sections.
Watch for people in your

work area even if your
truck has warning lights
or alarms. They may not
watch for you.
Make people
stand back, even
when you are
parked.
2.5
Stay in the confines of the truck
Keep under the

overhead guard.
Keep hands on the

wheel.
Keep arms and legs

inside.
2.6
Travel
Carry loads low

and tilted back.
If load blocks your

view, travel in
reverse.
Never turn on a
grade.
2.7
General Safety Rules J
Grades, ramps, slopes and inclines
Unloaded -
Forks Downgrade
Loaded -
Forks Upgrade
2.8
Don't jump
Your chances for survival in a tipover are better
if you stay with the truck.
TIP WITH THE TRUCK
2.9
....... ...
General Safety Rules )
Fork safety
There is special
equipment to raise __ _
people for overhead work. - _ -
DO NOT USE LIFT TRUCKS-.- -
Loading Dock
2.11
Pinch points
Keep hands, feet

and legs out of the
upright.
Don't use the

upright for a ladder.
Never try to repair the

upright, carriage, chain or
attachment yourself ...
...--------,
always get
a trained
mechanic.
2.12
Parking
Never park on a Lower forks fully to

grade. floor. Tilt forward until
forks are flat.
Put directional lever

in neutral.
Turn key off. Set parking brake.
2.13
(
3 Operating Hazards
This section shows 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 boss
to help identify and avoid those hazards.
3.1
Operating Hazards )
AWARNING:
Fast turns
An empty truck can tip
over easier than a loaded
truck because they are
rear-end heavy.
A WARNING:
High loads
Turn too sharp with a
raised load and your truck _.,,.,-&
can tip even at slow ~ ~~~A~
speeds.
3.2
( Operating Hazards
A WARNING:
Rear steering
A turn onto a soft
shoulder can tip a truck
over ... slow down on
turns. Watch the rear and
keep the steer wheels on
the road.
3.3
,.
Operating Hazards
AWARNING: Loose loads

Never carry loose or
uneven material.
Center wide loads.

Spread the forks to
fit the load.
DO THIS
Stack and band

loose material.
( Operating Hazards
A WARNING:
Long & wide loads
With long or wide loads you
need more room ... so ...
slow down and watch your
clearance.
Wide loads ... keep them low and

watch your balance.
Remember, a long load will reduce the capacity

of the truck.
3.5
Operating Hazards J
AWARNING:
Chain slack
...
-:~.....--
7/•.. _____.. I
Slack chains mean rail or

carriage hang-up. Raise
the upright before you
move.
( Operating Hazards
AWARNING: Right-angle stacking
When right-angle stacking, or moving with a

raised load to clear low objects, avoid sharp
turns and move slowly.
3.7
Operating Hazards
A WARNING:
Low overhead
Watch overhead:
moving into
overhead struc-
tures or tilting
heavy loads too far __
forward can tip a
truck over.
Know the height of your truck.

Check your clearance.
Keep loads
low and tilted
back.
3.8
( Operating Hazards
AWARNING:
Dock or trailer drop-offs
To avoid these hazards you must:

• Talk to the truck driver yourself, make sure he does not
move the trailer until you are done!
• Apply trailer brakes.
• Use wheel chocks.
• Use trailer-to-dock locking systems, if available.
AWARNING:
Trailer creep
The impact
of moving
3.9
Operating Hazards )
A WARNING:
Carbon monoxide
Internal Combustion engines emit a harmful toxic gas
(carbon monoxide) which can cause serious injury or death.
To avoid this hazard you must:
• Make sure there is enough ventilation.
• Avoid unnecessary extended idling.
• Never operate your engine in closed areas.
• Do not drive your truck into restricted areas.
3.10
(
4 Know Your Truck
Truck Model Illustrations
Truck Components & Features
Operator's Compartment & Controls
Truck Data and Safety Plates
Safety Decals
How Your Lift Truck Operates
How To Start Your Truck
4.1
Know Your Truck
Truck Model Illustration
84M411
CLARK
GCS/GCX 17-20-22-25-27-30
1. Cushion Drive Axle and wheels
2. Hydraullc Sump Tank
3. Cushion Steer Axle and Wheels
4. Overhead Guard
5. Safety Seat and Seat Belt
6. Steering Control Handwheel
7. Directional Control Lever
8. Upright
9. Load Back Rest Extension
1o. Fork carriage
4.2
11. Load Forks
( Know Your Truck
Truck Model Illustration
84M412
CLARK
G PS/G PX 20-22-25-27-30
12. Pneumatic Drive Axle and wheels
13. Side Door Latch (access to engine compartment)
14. Fuel Tank Enclosure
15. Machine Serial Number (on frame Inside door)
16. Pneumatic Steer Axle and Wheels
17. Fuel FIiier Opening
18. Counterweight
. 19. Seat Deck Latch
... See following pages for

general description of
truck components & features
4.3
•
Know Your Truck )
Things You May Need or Want to Know About the:
GCS/GPS 17 thru 30 and the GCX/GPX 20 thru 30
Series Lift Trucks.
Model Designation/Rated Load Capacity

rated load model designation
capacity GCS GCX GPS GPX
17 [1750 kg] 3500 lbs. X NIA

20 [2000 kg] 4000 lbs. X X
22 [2250 kg] 4500 lbs. X X
25 [2500 kg] 5000 lbs. X X
27 [2750 kg] 5500 lbs. X X
30 [3000 kg] 6000 lbs. X X
Available as: Standard models, Custom models, Industrial models, and X Series.
Each capacity model has its own counterweight.
Frame & Chassis

• Standardized styling and design
• Stamped and formed, welded construction, 10mm (except cowl 6mm)
• 2 wheel bases each model series (2 GCS, 2 GPS) Std. GCS has long
WBonly.
• Removable fuel and hydraulic tanks
• Basic design is to metric standard dimensions
• Components and hardware dimensions are combination USA inch and
metric.
Engines
Gasoline Mitsubishi 4G54 [2.6L] 156 cu.in.
and L.P.G. Continental TM27 [2.7L] 164 cu.in.
(Begin Lot 6200)
Waukensha 0176 GA [2.9L] 176 cu. in.
(Thru Lot 6086)
Diesel Continental TMD27 [2.7L] 164 cu.in.

(Begin Lot 6200)
Transaxle
model over all ratio truck model
11FHR500 1-spd. 15.710:1 GCS/GPS

11FHR600 1-spd. 13.703:1 GCS
11FHR600 1-spd. 12.727:1 GCS
11FHR600 1-spd. 16.248:1 GPS
11FHR600 2-spd. 26.966:1(1) GPS
13.703:1(2)
11FHR600 2-spd. 24.600:1 (1) GPS
15.185:1 (2)
TA18.01-2 1-spd. 15.875:1 GCX/GPX
4.4
( Know Your Truck
Drive Wheels & Tires

Std Cushion (2) 20 x (8)(9) x 16 Opt Cushion (2) 18 x (8)(9) x 12.12
Pneumatic (2) 7.00 x 12 - 14 ply 28 X 9 X 15 - 14 ply
Steer Wheels & Tires

Std Cushion (2) 17 x (5)(6) x 12.12 Opt 16 X (5)(6) X 10.5
Pneumatic 6.50 X 10 - 10 ply
Steer Axle
• Integral power steering cylinder
• Cast body w/attached 3.38-inch double-acting cylinder
• Straight kingpins in tapered roller bearings
• Cushion 1-piece hub/wheel 83-degree turn angle
• Pneumatic 2-piece hub/wheel 75-degree turn angle
Cooling System
• Automotive crossflow radiator
• Transmission oil cooler in radiator side tank
• Tempatrol fan drive (optional model trucks)
Air Intake - Dry-type replaceable-element air filter
Exhaust System - Muffler behind radiator, exhaust into air stream.
Fuel System
• Gasoline/diesel -
Metal fuel tank w/gauge sending unit, bolted
into LH side frame.
• LPG tank - Standard strap holder for 33.5# tank.
• LPG components - IMPCO
Filters
• Fuel - Paper element type • Hydraulic oil
• Engine air - Dry type 1 tank fill tube screen
• Engine oil - Spin on 2 tank breather cap
• Transaxle oil - Spin on 3 return line - spin on
4_5
---- T
Know Your Truck )

Power Steering System
All GCS/GPS-GCX/GPX 17-30 trucks are equipped with hydrostatic power
steering. Oil is supplied from main hydraulic pump through a priority-demand
valve to steer gear. Priority demand valve gives correct oil flow for steering. Oil
not used for steering is added to lift or tilt system. Steering hand wheel operates
a steering control valve which directs oil flow to a 2-way steering cylinder in the
steer axle. The steering control valve will act as a pump to provide manual
steering if main pump oil flow stops.
Directional Control "Forward"or "Reverse"

Direction of travel is selected with the direction control lever on left side of
steering column.
HR500/HR600 direction control lever is
linked mechanically to transmission
control valve, which engages the
"Forward" or "Reverse" clutch pack.
TA 18 direction control lever actuates

electrical circuits that engage the
"Forward" or "Reverse" clutch pack.
NEUTRAL
Speed Control "High" or "Low"

Some models have a speed control
lever below the directional control lever.
It is linked mechanically to the
transmission control valve, which
engages the "High" or "Low" range
clutch pack.
Accelerator Control Pedal

Travel speed and lift (pump) speed are controlled by engine speed. Engine
speed is controlled with a foot pedal suspended from the cowl and linked to
engine fuel system.
4.6
( Know Your Truck
HRSOO Brake System
Service Brake
Dual foot pedals are connected to a single master cylinder. Service brakes can
be applied with both pedals. Trucks have a manual (not powered) brake system.
The master cylinder applies pressure, through brake lines, to drum and shoe
brakes at drive wheels. Brakes are self adjusting. Service brakes are
mechanically actuated for parking. Brake system is a closed circuit using
conventional SAE automotive hydraulic brake fluid.
Inching Brake
Normal inching is controlled by both pedals. Pushing gradually on pedal will
smoothly disengage transmission. Pushing pedal further will apply service
brakes.
HR600 Brake System
Service Brake
Dual foot pedals are connected to a single master cylinder. Service brakes can
be applied with both pedals. Trucks have a manual (not powered) brake system.
The master cylinder applies pressure, through brake lines, to wet disk brakes
inside drive axle. Brakes are self adjusting. Service brakes are mechanically
actuated for parking. Brake system is supplied with transmission fluid. Overflow
from master cylinder is returned to transmission. Fluid in brake line circuit is
transmission fluid. Do not put brake fluid in master cylinder reservoir.
Inching Brake
Normal inching is controlled by both pedals. Pushing gradually on pedal will
smoothly disengage transmission. Pushing pedal further will apply service
brakes.
TA 18 Brake System
Service Brake
Dual foot pedals are connected to two master cylinders. Service brakes can be
applied with both pedals. Trucks have a manual (not powered) brake system.
The master cylinders apply pressure, through brake lines, to drum and shoe
brakes at drive wheels. Brakes are self adjusting. Service brakes are
mechanically actuated for parking. Brake system is a closed circuit using
conventional SAE automotive hydraulic brake fluid supplied from a separate
reservoir.
Inching Brake
Left pedal is for normal inching control. Pushing gradually on pedal will smoothly
disengage transmission. Pushing pedal further will apply service brakes.
4.7
. ;; . ~ ~..,,.........
Know Your Truck )

Parking Brake
\
A parking brake for all truck models is
provided by mechanical actuation of
the service brakes. On standard trucks,
a hand-operated parking brake lever
mounted at the dash is connected by
cables to the brake assemblies, one to
each drive wheel.
On optional model trucks, a similar
hand operated parking brake lever
mounted at the dash is connected by a
cable to an equalizing linkage bar at-
tached across the top of the drive axle
between the parking brake actuating
arms. These actuating arms, when
84M280
rotated, use a cam action to force the
brake discs together and apply the
brakes.
The main hydraulic pump is
Main Hydraulic System/Power mounted to an SAE pad on the
Steering System transmission driven by a silent
The parts of the main hydraulic system chain from the engine.
are the hydraulic sump tank, main
The main hydraulic control valve
hydraulic pump, priority demand valve,
features adjustable system
main control valve, hydraulic oil filter,
pressure· relief valves, counter-
and associated hydraulic lines and
balance valve in the tilt circuit
hoses.
with pressure compensated flow
The hydraulic sump is a separate, control valve to control tilt
removable tank bolted in the right side speeds. All ports and connecting
compartment of the truck frame where lines are on the bottom surface of
it is protected from damage. It has a the valve. When lift attachments
large opening at the top with a are used, single or double aux-
removable cover which includes the fill iliary sections may be added to
tube/breather, oil level dipstick, and oil the outer (RH) side of the stan-
filter return line. The cover is held on dard (lift/tilt only) main valve. The
with a V-clamp for positive sealing and optional aux sections also have
ease of servicing. The sump breather is an adjustable relief valve and can
a standard Clark part with a nominal 10 be assembled with optional flow
micron @ 98.5% efficiency rating. controls for 2.5, 4.0, 5.5, 7.0, or
10.0 gpm flow level.
Oil from the hydraulic sump tank is fed
by a gear pump through the priority de- The hydraulic system relief
mand valve to the main control valve. pressure level is "tuned" (ad-
At the priority demand valve the justed) to match the need of each
necessary flow may be diverted to the truck rated capacity. Maximum
steering system. From the main control pressure is [20,700 kPa] 3000 psi.
valve the oil is directed to either the lift A diagnostic fitting (quick-
cylinders or the tilt cylinders. Oil disconnect) at the priority de-
returns to the hydraulic sump tank mand valve allows access for
through the spin-on, full-flow return- checking main hydraulic and
line filter. steer system pressure.
4.8
( Know Your Truck
Tilt Cylinders
The tilt cylinders are mounted with self-aligning bearings at each end. All tilt
requirements are satisfied with a choice of two adjustable rod ends and a
variety of external tilt limit spacer sleeves.
Driver's Seat
The driver's seat is a new safety seat equipped with seat belt. It has protec-
tive wrap-around arms at each side designed to support and hold the
operator in the seat if the truck tips.
The seat is bolted to the center top of the engine compartment cover, which
is locked in place by the control latch. The seat mounting base allows a
6-inch fore-and-aft adjustment of its slide mechanism.
Electrical Components
• Electrical Wiring - Standard wiring harness is a one-piece assembly
with in-line fuse holders. Optional models have
two-piece wiring harness.
• Starter - all models: Reduction type, positive engagement drive
• Alternator - all models: Delco 37-amp rating.
• Ignition switch: Key switch, keyed alike.
• Diesel cold start heater: Actuated with a push button.
Instruments
• Fuel gauge (gasoline and diesel trucks only)
• Indicator lights w/lnternational symbols
1 Engine coolant over-temperature
2 Transmission oil over-temperature
3 Engine oil low-pressure
4 Battery discharge
• Hourmeter - solid-state activated by engine oil pressure switch
• Provision for two optional switches
Uprights
• HI-VIS STD w/LOW FREE LIFT (2 cylinders) • HI-VIS TSU
• HI-VIS STD w/HIGH FREE LIFT (Optional • HI-VIS HI-LO
w/field kit) • HI-VIS QUAD
Uprights for standard trucks have welded-on mounting trunnion brackets to
match either GCS or GPS requirements.
Uprights for optional trucks have separate bolt-on mounting trunnion
brackets.
4.9
... -- -· ---
Know Your Truck
.,.......
Operator's Compartment & Controls
84M413
1. Directional Control Lever 9. Lift Control Lever
2. Speed Control Lever 10. Tilt Control Lever
(Optional Pneumatic Tire
Trucks Only) 11. Aux Valve Control Lever
3. Horn Button
4. Steering Handwheel
5. Accelerator Pedal
6. Service Brake and Inching
Pedals Familiarize
7. Choke Control Knob
yourself with the controls
and follow
8. Parking Brake Lever safe operating rules.
( Know Your Truck
Operator's Compartment and Controls
84M414
12. Ignition Key Switch
13. Water Temperature Indicator
14. Battery Charge Indicator
15. Transmission 011 Temp
Indicator
16. Engine 011 Pressure Indicator
17. Fuel Gauge (Gasoline and
dlesel only)
18. Hourmeter
19. Fasten Seat Belt Light
20. Light Switch (0ptlonal)
21. Accessory Switch (0ptlonal)
22. Glow Plug Switch
4.11
Know Your Truck
84M415
1. Truck Data and Capacity Plate

(Truck Nameplate)
2. Operator Safety Warning Plate
A WARNING
NAMEPLATES & DECALS
DD NOT OPERATE A LIFT TRUCK
WITH DAMAGED OR LOST DECALS
AND NAMEPLATES. REPLACE THEM
IMMEDIATELY. THEY CONTAIN
IMPORTA~T INFORMATION.
4.12
A 1?
( Know Your Truck
Truck Data and Capacity Plate
24985
Know the location of your truck's . ..

1. Model number 5. Capacity. Capacity, load center,
and lifting height data are
2. Truck type. The code letter(s) stamped in these areas. Do not
signifies type of the protection exceed the maximum specified.
construction. Check with proper
authority before entering areas Important: If the truck is modified
where flammable or explosive so as to affect capacity; or, if the
material may be present. plate is damaged or defaced, get
a new plate from your Clark
3. Serial number dealer.
4. Attachment description (If any). 6. Truck weight less load.
24986
Operator Safety Warning Plate

The operator's warning plate describes basic instructions for safe operation
of a lift truck. Read and understand these instructions and the other safety
messages in this manual and on the lift truck.
4.13
Know Your Truck
Safety Decals
Seat Belt Warning Decal AWARNING

This safety decal is placed on each
side of the operator's seat arms to re-
mind you to always wear your seat belt
when driving a lift truck. To help in call-
ing your attention to this important
safety item, a seat belt warning light
and a buzzer alarm are connected with
the ignition key switch.
24972
Lift trucks can be tipped over if

operated improperly. Experience with
lift truck accidents has shown that the
driver cannot react quickly enough to
jump clear of the truck and overhead
guard as the truck tips. To protect
operators from severe injury or death in
the event of a tip-over, it is best to be
held securely in the seat. The sides on
the seat help to keep your body and
arms safely within the confines of the
truck and overhead guard.
So, please, always buckle up when driv-
ing your lift truck.
84M419
Seat Deck Opening Decal

This safety decal describes the pro-
cedure for unlatching and opening the
seat deck. The seat deck must be lock-
ed down to make the seat belt effec-
tive. Make sure that the seat deck is
securely locked in place before
operating the truck.
83M404
4.14
( Know Your Truck
Safety Decals
Fan Warning Decal

This safety decal is displayed on the
cooling fan shroud of the radiator to
warn of the danger of injury from turn- WARNING FAN
ing fan blades when the engine is run-
ning. 25057
Make sure that you keep your hands,

fingers, arms and clothing away from a
spinning fan. Don't stand in line with a
spinning fan. Fan blades can break at
high speed and be thrown out of the
engine compartment.
84M271
Overhead Guard Conformance Plate

THIS OVERHEAD GUARD CONFORMS
This plate is permanently attached to TO AMERICAN NATIONAL STANDARD
the inside of the overhead guard top to B 56. 1. IT IS INTENDED TO PROTECT THE
DRIVl!R FROM SMAU FAUING OBJECTS
confirm that the overhead guard BUT NOT FROM FALLING CAPACITY LOADS.
assembly design has been tested and GUARDS OF THIS DESIGN HAVE ALSO
PI\SSED A VERTICAL 1111'1\CT TEST OF
conforms to the requirements of ANSI 16,DOD FOOT POUNDS.
856.1 safety standards.
22270
4.15
'
Know Your Truck

Safety Decals
Upright Warning Decal

This safety decal is placed 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.
83M408
19341
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 be-
83M407
ing used to handle a load.
A WARNING
FALLING FORKS
-~-----,
DO NOT ~ALK OR STAND UNDER
RAISEO FORKS. THE FORKS CAN
FALL AND CAUSE INJURY OR
DEATH.
19340 4.16
( Know Your Truck
The Instrument Panel includes the
1 ignition key switch
2 warning indicator lights
3 fuel gauge (gasoline and diesel
trucks only)
4 hourmeter
5 seat belt warning light
6 provision for optional LPG low fuel
warning light and optional light
switch
7 glow plug control button
The Ignition Key Switch
• turns the ignition circuit "on" and 84M276
"off" for gasoline and LPG engines

• connects and tests the warning
indicator lights
• connects the starter motor circuit
when engine is to be started
The key switch has three positions

• OFF
• RUN
• START
When the key is in the vertical "off"
position all engine and indicator light
electrical circuits are disconnected 84M277
(shut off), and the key can be removed.
From the "off" position the key can be The key switch has a mechanical
turned to the right (clockwise) to the "anti-restart" feature, which
"start" position, where the engine igni- prevents the engine starter from
tion and the starter motor are engaged. being engaged and damaged if
From the "start" position, when the key the key switch is accidentally
is released it will return automatically turned from the "run" position to
back to the left (countclockwise) for a the "start" position when the
part of its travel, to the "run" position engine is running. If the engine
where the engine starter is disengaged stops running, the key switch
and only the ignition circuit for must be turned to the "off" posi-
gasoline and LPG engines is "on". tion to restart the engine.
4.17
,.. ....... ........ .. ..
Know Your Truck
Warning indicator lights are provided
for protection of four important
systems of your lift truck
1 Ammeter (Battery charging system)
2 Engine oil pressure
3 Water temperature (Engine coolant)
4 Transmission oil temperature
84M417
The ammeter warning light indicates Turn the key switch clockwise to
when the battery is receiving no charg- the "run" position. The ammeter
ing current. The engine oil pressure and eng oil press lights should il-
light indicates if a problem causes oil luminate, and the fuel gauge nee-
pressure to drop below a safe level. The dle should indicate fuel level.
water temperature light indicates that
The water temp and trans oil
the engine is overheating for some
temp lights are also illuminated
reason. The transmission oil tempera-
for checking when the key switch
ture light warns that the transmission
is turned to the "start" position.
oil is too hot and damage can result if
Note: If you don't want to start
operation is not stopped until the
the engine when checking these
reason for high temperature is cor-
warning lights, move the direc-
rected.
tional control lever from "neutral"
The warning lights can be tested with briefly only, while turning the key
the key switch. switch to the "start" position.
After checking the lights, turn
key switch back to "off"_
The hourmeter is controlled by engine

oil pressure. It operates only if the
engine is running when the oil pressure
has built up (increased) above a level to
start the hourmeter. Operation of the
hourmeter can be checked by watching
for movement of the indicator as it
rotates.
84M418
4.18
A ~D
( Know Your Truck
The choke control is located conve-

niently near the dash on the steering
column support. It is required and fur-
nished only with gasoline engines. The
choke knob is connected by a wire con-
trol to the carburetor on the engine to
enrichen the fuel/air mixture to aid in
starting when the engine is cold.
84M278
With the accelerator pedal you control

the engine to select the required truck
travel speed and power, and the correct
speed for lifting a load. The accelerator
is mechanically connected to the
engine carburetor on gasoline and LPG
engines or the fuel control on diesel
engines.
84M269
The steering wheel is connected with a

hydrostatic steering gear. Power steer-
ing is provided by oil pressure from the
main hydraulic pump which flows to
the steering gear to be used in the
amount required for movement of the
steering cylinder on the steer axle.
Never operate a lift truck which has a
steering system fault.
83M409
4.19
Know Your Truck
Direction of travel is selected with the
direction control lever.
•FORWARD
• NEUTRAL
• REVERSE
NOTICE - For safety, always bring

truck to a complete stop before
shifting to opposite direction.
HR500/HR600 direction control lever

is held positively in each position by
spring detents in the transmission
control cover. Control lever position
may be checked by looking through the
hole in top of quadrant housing
83M417
TA18 direction control lever is held

positively in each position by spring
detents in the lever assembly.
Direction of travel may be noted by
visual check of lever position.
Some models have a speed control

lever. It is used to select (1) low or (2)
high speed for applications where a
greater range of performance is
required. (1) low range will give you
slower travel speed and more power
for climbing grades or slow
maneuvering, than (2) high speed.
4.20 83M421
( Know Your Truck
Service brakes can be applied by ~ 1'
pushing on right or left brake pedal.
Never operate your lift truck if the

service brakes are not working
properly.
84M244
HR500/HR600 Inching is controlled by

using left or right brake pedal. Pedal
will smoothly disengage transmission
as it is pressed. When the pedal is
pushed further the service brakes are
applied.
TA18 Inching is controlled by using left

brake pedal. Pedal will smoothly
disengage transmission as it is
pressed. When the pedal is pushed
further the service brakes are applied.
84M279
Parking brake lever mounted at right

of steering column mechanically
applies service brakes. Pull lever fully
to vertical upright position to apply
parking brake. Push lever forward to
release parking brake. (Shown in
released position).
84M280
4.21
Know Your Truck
How Your lift Truck Operates
With the lift control lever, you are able
to raise and lower the fork carriage on
the upright. The lifting speed is con-
trolled by varying engine speed and
lever position.
84M236
When the lift control lever is pushed

forwards, the fork carriage is lowered.
By varying the amount of movement of
the lever, you determine the lowering
speed. You can also lower the fork car-
riage when the engine is stopped.
84M237
With the tilt control lever, you are able

to control the tilting or vertical posi-
tioning of the upright. When the lever is
pulled back, the upright also tilts
backwards. If the lever is pushed for-
wards, the upright is tilted forward.
84M239
4.22
( Know Your Truck
The seat adjustment lever is located on

the left side under the seat. To unlock,
push the lever to the left and adjust the
seat so that all controls may be comfor-
tably reached. Then release the lever.
Make sure that the seat locking
mechanism is engaged.
84M238
Access to the Engine Compartment

The side doors of the engine compart-
ment are held closed by a spring latch
handle. Pull the latch handle towards
the outside of the door to unlatch and
open the door.
84M288
84M355
4.23
-- 1
Know Your Truck

Before starting a lift truck it is good

practice to always start from a safe
condition.
Check to see that:
1 Parking brake is applied
2 Forks are fully lowered to the floor
3 You are familiar with how all the
controls function
4 All controls in neutral or other
correct position
5 Truck has been checked and is
ready to operate
84M281
This is a good time to adjust the seat to

a comfortable position for you. Adjust
the seat by moving and holding the
release lever at the left front edge of
the seat. Put the seat in a position
which will provide easy reach to all
controls. Release the seat lever. Make
sure that the seat locking mechanism
is engaged.
84M238
Put the directional control lever in the

"N" (neutral) position. The truck should
start only in the "neutral" position.
4.24 83M416
) Know Your Truck
To start a cold gasoline engine pull the
choke control out half of its total travel.
_ _ _ _ _ _ NOTICE _ _ _ _ __
Climate conditions and other fac-

tors play a large part in how your
engine starts. You may have to make
adjustments in these procedures to
find a combination more suitable for
your situation and location.
84M367
Push the accelerator pedal down half

of its total travel and hold.
IMPORTANT
As soon as engine starts, release
the key switch from the "start" posi-
tion to avoid starter drive damage.
84M269
Turn the ignition key switch from the

"off" position to the "start" position.
Release the switch when the engine
starts. When the engine runs smoothly,
push in the choke control slowly.
If the engine stops running, you must
turn the ignition key switch back to the
"off" position before turning back to
the "start" position.
84M242
4.25
- :t; , f\ r ...
Know Your Truck
If the engine fails to start, pull the

choke control out fully and repeat the
previous starting procedure.
IMPORTANT
If the engine stalls or falters in
starting, wait 3 or 4 seconds
before re-engaging the starter.
This will prevent possible serious
damage to the starter or engine.
84M367
To start a warm gasoline engine push

the accelerator pedal down half of its
total travel and hold.
84M269
Turn the ignition key switch to the

"start" position. Release the switch as
soon as the engine starts.
If the engine fails to run, pull the choke
control out one-quarter of its total
travel. Turn the ignition key switch to
"off" and repeat the starting procedure.
When the engine runs smoothly, push
the choke control all the way in (off).
84M242
4.26
( Know Your Truck
To start a flooded gasoline engine,

push the choke control all the way in
(off). Push the accelerator pedal down
fully. Turn the ignition key switch to the
"off" position, then to the "start" posi-
tion. Release the key switch when the
engine is running.
84M269
Engines Using LPG Fuel

If your Iift truck uses LP Gas, the fuel
supply is stored in a special tank
mounted above the counterweight at
the rear of the truck. For safety, there is
a check valve and a shut-off valve at the
tank. The shut-off valve is operated
,
manually to control the flow of fuel
from the tank. This valve must be
closed when the engine is not running.
Close this valve by hand only to a firm
tightness. Do not overtighten.
r
84M258
Check the amount of LPG fuel in the

tank by the gauge near the shut-off
valve.
A WARNING
LPG FUEL IS HIGHLY FLAMMABLE.
NEVER SMOKE WHEN CHANGING
TANKS. NEVER CHANGE TANKS
WHEN THE ENGINE IS RUNNING.
84M416
4.27
Know Your Truck
)
Before starting an LPG engine, open
the tank shut-off valve slowly.
NOTICE - If this valve is opened too
quickly, the automatic safety check
valve will close. If this happens, close
the shut-off valve and wait 2-3 minutes.
Then, open the shut-off valve slowly.
-
r
84M258
To start an LPG fuel engine, follow the

starting procedure for a gasoline
engine truck, with the exception that
no choke control is required with LPG
engines.
83M430
To stop an LPG fuel engine safely,

follow this shut-down procedure:
1. Stop the truck with the service
brakes.
2. Apply the parking brake.
3. Let the engine run at low idle
speed.
4. Close the shut-off valve at the LPG
tank.
5. Wait until the engine uses (burns
up) the supply of LPG remaining in the
fuel system.
6. When the engine stops running, 84M259
turn the ignition key switch to the "off"
position. 4.28
- ·--,
Know Your Truck

Here are some Starting Tips:

• Turn off all optional equipment while Starting and Operating
you crank the engine. This will reduce Recommendations
the electrical load on your battery and
supply extra power to the starter motor. Avoid damage to your truck
• Avoid excessive starter cranking (in or possible harm to yourself.
excess of 30 seconds) with an intermit- Follow these recommenda-
tently firing or flooded engine. To avoid tions:
starter overheat or damage, do not • Avoid extended (in excess
crank the starter continuously for more of 10 minutes) and unneces-
than 30 seconds at a time. If the engine sary idling of the engine. If
fails to start within a period of 30 extended idling occurs or is
seconds, wait 2 minutes before again anticipated beyond 10 min-
attempting to start your lift truck. utes, turn off the engine.
• If your battery is "run down" CARBON MONOXIDE is col-
(discharged) or becomes discharged orless and odorless, but can
while trying to start your truck, please be present with all other
refer to the "Emergency Starting - exhaust fumes.
How To Use Battery Jumper Cables"
section of this manual.
A WARNING
EXHAUST GASES, PARTIC-
ULARLY CARBON MONOX-
A WARNING IDE, ARE HARMFUL AND
CAN CAUSE SERIOUS IN-
NEVER LEAVE YOUR LIFT JURY OR DEATH.
TRUCK UNATTENDED WHILE
NEVER IDLE YOUR LIFT
THE ENGINE IS RUNNING.
TRUCK ENGINE IN CLOSED
AREAS.
4.29
Know your truck (
How to start your truck
To start a diesel engine:
1. Press pre-heat (glow plug) control button and hold for the number of seconds as
shown in the chart.
Temp. Sec.
70 F. ( 21 C.) 10
32 F. ( 0 C.) 20
-4 F. (-20 C.) 25
The glow plug relay in the fast glow control system on the diesel engine must not be
bypassed for any reason. Jumping the relay to energize the glow plugs bypasses
the internal circuitry that controls the glow plug temperature. This action will cause
the glow plugs to prematurely burn out.
A Warning
STARTING FLUIDS OR AIDS SUCH AS ETHER OR GASOLINE MUST
NOT BE USED IN A DIESEL ENGINE. THE USE OF THESE FLUIDS CAN
CAUSE INJURY TO PERSONNEL AND DAMAGE TO THE ENGINE.
2. Turn the engine switch to the start position. Release the key as the engine starts,
to avoid starter damage.
3. If engine fails to start, turn the key to the "off" position and then repeat the
procedure. If the engine re-start is not done within 15-20 seconds, repeat the pre-
heat procedure in step one.
4. When the engine starts, make sure there is oil pressure indicated on the oil
pressure gauge. (0.5 box) 7-10 psi (idle), (2.8-4.1 box) 40-60 psi (max).
5. Operate engine at fast idle for one to two minutes to circulate and warm the oil
before operating the engine at maximum speeds.
To stop a dlesel engine:

1. Stop the truck with the service brake.
2. Put all controls in the neutral position.
3. Engage the parking brake.
4. If engine is hot, operate at idle speed for 1-2 minutes.
5. Turn ignition switch to the "off" position.
4.30
...... ..
5 Operating Procedures
Before Operation
How To Perform The Daily Inspection
Operation
How To Operate Your Truck
After Operation
When You Have Finished Using Your Truck
i;; 1
Before Operation
Before operating your lift truck you should check its condition. Be sure that
your truck is safe to operate.
Lift trucks should always be inspected daily, or at the start of each shift. The
following pages point out important areas to check during the daily inspec-
tion.
As an aid in carrying out this inspec-
tion, Clark has prepared a form called
"Driver's Daily Checklist". Copies of
this form may be obtained from your I '<
Clark dealer. We recommend that you \

use this form to make a daily record of
your inspections and truck condition.
A WARNING
PERSONAL INJURY
WEAR EYE GLASSES, SAFETY
SHOES AND CORRECT FITTING
CLOTHING WHEN WORKING ON
LIFT TRUCKS. INJURY CAN
RESULT IF YOU DO NOT WEAR
PROTECT! ON. 84M285
First, perform a visual inspection of the

truck and its components. Walk around
your lift truck and take note of obvious
damage which may have been caused
by operation during the last shift.
Check for leaks and loose fittings.
Then, check all of the critical com-
ponents that handle or carry the load.
84M289
Inspect the upright assembly, rails,

rollers, lift chains, and lift cylinders.
Look for any loose parts or fittings. The
lift and carriage chains must have
equal tension. Check the lift chain an-
chor fasteners.
.,
84M351
5.2
Before Operation
Check the condition of the drive and

steer wheels and tires. Remove objects
that are embedded in the tread. Inspect
the tires for excessive wear and breaks
or "chunking out".
12917
Check to make sure that all wheel lug

nuts or bolts are tight.
Please refer to "Specifications" for
torque and tire pressure values.
84M263
Check for the correct air pressure on

trucks with pneumatic tires.
CAUTION
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, don't 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 and cause it to tip over.
24964
5.3
Before Operation (
Inspect the lift forks for cracks, breaks, bending and wear. The fork
surfaces should be level and even with each other. The height
difference between both fork tips should be no more than (6 mm)
0.25 inch maximum. If the fork blade at the heel of the fork is worn
down by more than 1O percent, the load capacity of the forks is reduced
and they must be replaced.
max.
Inspect the forks for twists and

bends.Put a 2"x4"x24" block
on the blade of the fork with the
4" surface against the blade.
Put a carpenters square on the
top of the block and against the
shank. Check the fork 18"
above the blade to make sure
it is not bent more than specified
in the chart.
Fork Allowable •yw values for various blade lengths
cross - section 42" blade 48"blade 54" blade 60"blade
1-1t2x4 15/16 1-1/4 1-9/16 1-15/16
1-3/4x5 112 5/8 25/32 31/32
To prevent accidental shifting

of the forks inspect the fork
latches. Make sure they are not
damaged or broken, and that they
operate freely and lock correctly.
5.4
Before Operation
Check the load back rest for damage.

Make sure that the mounting fasteners
are all in place and tight.
84M350
Check the overhead guard for damage.

Make sure that it is properly positioned
and all mounting fasteners are in place
and tight.
84M349
Unlatch and open each side door for ac-

cess to the engine compartment.
Unlatch and lift the seat deck.
Inspect all components within the

engine compartment.
83M404
Before Operation (
Check fluid levels and air filters.
Locate the engine oil dipstick and

check the engine oil level.
A WARNING
STEAM
DO NOT REMOVE THE RADIATOR
CAP ..!1EN THE RADIATOR IS
HOT. STEAM FROM THE RADIATOR
WILL CAUSE SEVERE BURIC.
83M426
Check the engine coolant level.
Inspect the engine coolant hoses and

fan belts.
83M425
Check the engine air filter for con-

tamination (dirt build-up and clogging)
and damage.
83M428
5.6
Before Operation
Check the hydraulic sump tank fluid
level. Also, check the sump fill
cap/breather for contamination and
damage.
83M427
When you know that all of the com-
ponents within the engine compart-
ment are in satisfactory condition,
lower the seat deck and close the side
doors.
83M424
Now, make sure that all controls and
systems are functioning correctly. If
you are unfamiliar with the function of
each control or system, please refer to
previous descriptions titled under
"Know Your Truck", Truck Components
and Features, How Your Lift Truck
Operates, and How To Start Your Lift
Truck.
Press the horn button to check horn
function. If the horn does not operate,
report the failure and have it repaired
before the truck is put into operation.
84M243
Before Operation (
Test the warning indicator lights.
From the "off" position, turn the key
switch to the "run" position to check
ammeter and eng oil press indicator
lights. Turn the key switch to the
"start" position to check the water
temp and trans oil temp indicator
lights.
IMPORTANT
DAMAGE TO THE TRUCK CAN
RESULT IF ANY OF THE WARNING IN-
DICATORS ILLUMINATE WHEN THE
ENGINE IS RUNNING. STOP THE
84M242
ENGINE. DO NOT OPERATE THE
TRUCK.
Report the failure.
Start the engine and let it warm up until

it runs evenly and accelerates
smoothly when you push on the ac-
celerator pedal.
With the engine running, check the
hourmeter indicator for operation.
Check the service brake system. Push 84M276

down on the brake pedal and hold.
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
move downwards, report the failure im-
mediately. DO NOT OPERATE THE
TRUCK UNTIL THE BRAKES ARE
REPAIRED.
Note: A low pedal reserve (clearance at
floor plate) is normal.
Check the function of the parking
brake. Release, then apply the parking
brake with the lever.
84M244
5.8
...
) Before Operation
Check the function of the hydraulic
system with the hydraulic pump
(engine) running.
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 ver-
tical position. Release the lever.
CAUTION
MAKE SURE THAT THERE IS ADE-
QUATE OVERHEAD CLEARANCE 84M239
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 and fork
carriage must be even and smooth,
without binding or jerking motion.
Release the lever.
If the maximum fork height is not
reached, this indicates that there is an
inadequate (low) oil level in the
hydraulic sump tank, or severe binding
within the upright.
84M377
Push forward on the lift control lever.
Watch the upright ;i.s it lowers. When
the forks reach the floor, release the
lever.
84M237
5.9
5.9
Before Operation (
Move the steering handwheel in a full

right turn, and then in a full left turn to
check the steering. Return the hand-
wheel (steer wheels) to the straight-
ahead position.
WARNING
Fasten your seat belt before driving the
truck.
Check and make sure that the travel

area is clear in front of the truck.
83M409
Push firmly on brake pedal. Release the
parking brake. Move the directional
control lever from "N" (neutral) to "for-
ward" 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.
Make sure that the travel area is clear 84M283

behind the truck.
"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.
"N" (neutral) position.
Apply the parking brake.
Turn the ignition key switch to the "off"
position.
84M284
5.10
) Before Operation
Make a record on the "Driver's Daily
Checklist" of all the operating and
truck problems that you find. Review
the checklist to make sure it has been
completed. Give the checklist to the
person responsible for lift truck
maintenance.
If all of the "Before Operation" checks

were normal or satisfactory, the truck
can be operated.
84M286
Do not operate a lift truck that has a

maintenance problem, or is not safe to
operate.
Remove the key from the ignition key
switch and put an "Out of Service" tag
on the truck.
Be sure to put this Operator's Manual

back in the holder behind the seat.
Read the manual again if you are not
sure of all lift truck operating pro-
cedures.
83M412
5.11
Operation (
Be sure that you read and understand

the information in the Operator's
Manual before operating a lift truck.
The Operator's Manual is stored in a
holder in the back of the driver's seat.
84M287
Before operating a lift truck each

operator must check his truck and
complete the "Driver's Daily Check-
list". Please refer to the previous sec-
tion "Before Operation" for information
on "How To Perform The Daily Inspec-
tion".
15197
Remember, before starting and
operating a lift truck it is good practice
to always start from a safe condition.
Check to see that:
• Parking brake is applied
• Forks are fully lowered
• You are familiar with how all the
controls function
• All controls are in neutral or other
correct position
• Truck has been checked and is
ready to operate
5.12
Operation
Buckle up. Make sure that you put on
the seat belt. Connect and adjust the
seat belt strap to a snug, comfortable
position.
Always wear your seat belt when !lliiii...
operating a lift truck. r""'
If your truck is equipped with two

speeds, put the speed control lever in
the correct position for the expected
speed and grade operation.
(Provided on optional Industrial Option
Package pneumatic tire trucks only)
83M421
Be sure that the directional control

lever is in the "N" (neutral) position.
83M416
5.13
Operation (
Start the engine.

Turn the ignition key switch to the
"start" position. When engine is run-
ning, release the key. The key will
return to the "run" position.
If you are unfamiliar with this pro-
cedure, please refer to the section,
"How To Start Your Truck".
Be sure that your truck won't move

unexpectedly before you are ready to
drive.
Put your foot on the brake pedal and
push down to apply the service brakes.
83M410
Release the parking brake.
\
84M281
5.14
)
-
Operation
I
correct position for the desired direc-
tion of travel.
83M417
Check all around to make sure that
your intended path of travel is clear of
obstructions and pedestrians.
83M431
Pull back on the lift control lever and
raise the forks approximately [50 mm] 2
inches above the floor.
83M422
5.15
Operation (
Using the tilt control, tilt the upright

back slightly to raise the fork tips
above the floor.
Raising the forks and tilting them back
prevents the forks from catching on
possible obstructions and reduces the
wear on the fork blades if they strike or
drag on the floor.
83M420
Put your foot on the accelerator pedal

and push down smoothly until the
truck is moving at the desired speed.
84M269
Be alert for pedestrians, other vehicles

or obstructions in your path of travel.
83M432
5.16
) Operation
Always bring your truck to a complete

stop before shifting to the opposite
direction.
Any sudden change in direction can
cause the load being carried to move or
fall off the forks. Also, many com-
ponents of the truck can be overloaded
when a shift in direction is made
without first slowing and stopping the
truck.
83M418
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.
84M244
5.17
i:; 17
Operation (
When picking up a load, enter the load

carefully. The forks must be fully under
the load and spread as wide as possi-
ble to provide good stability and
balance.
13203
If the forks need adjusting, lift the fork
lock lever. Slide the forks on the fork
bar of the lift carriage to get the correct ·,
width for the load. Make sure the fork
lock pin fits into a locking notch on the
fork carriage.
,I
84M252
Lower the lever to lock the forks after
they are in the correct position.
10759
5.18
~ ·~ - - y ~ - - - --~ - - --------~--------
) Operation
When driving, always raise the forks

slightly [50 - 100 mm] 2-4 inches above
the floor and tilt the upright (forks)
backward slightly.
83M422
Practice safe operation every time you

use your lift truck.
During your work, observe all functions
of your lift truck. This will allow you to
immediately recognize a problem or ir-
regularity that could affect the safe
operation of your truck. Do not con-
tinue to operate a truck that has a
malfunction. Stop and have it fixed.
Operate your lift truck safely. Careful
driving and operation is your respon-
sibility. Follow the instructions in this
manual to avoid damage to your truck
or the possibility of injury to yourself.
84M372
WARNING
ALWAYS WEAR YOUR SEAT BELT
WHEN OPERATING YOUR LIFT
TRUCK.
A WARNING
CARBON MONOXIDE
INTERNAL CIJ1BUST ION ENGINES
GENERATE TOXIC GASES Ioli !CH
CAN CAUSE SERIOUS INJURY OR
OEATH loliEN INHALED. BE SURE
THERE IS mourn VENTILATION. 83M406
5.19
After Operation (
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 nor-
mal traffic.
• Never park on a grade.
• Never park in areas which block
emergency routes or equipment.
83M396
• Put the directional control lever in

the "N" (neutral) position.
83M416
• Lower the forks or attachment to

the floor.
84M237
5.20
) After Operation
• Tilt the upright forward until the

forks are level or flat on the floor.
84M240
• Apply the parking brake.

Block the wheels if you have any
doubt about the truck moving from a
safe position.
,
\
84M281
• Turn the ignition key switch to the

"off" position and remove the key.
LPG Fuel Engines

1. Close the shut-off valve at the LPG
tank.
2. Wait until the engine stops.
3. Turn the ignition key switch to the
"off" position and remove the key.
5.21 84M241
)
.. ---
6 Emergency Starting
Emergency Starting (
How To Use Battery Jumper Cables
These instructions apply to the use of a similar-model lift truck with a fully-
charged "booster" battery to start the engine of a lift truck with a dis-
charged battery.
To avoid damage to your lift truck and your battery or the possibility of harm
to yourself follow these instructions and warnings. If you have any doubts,
ask for help from an experienced mechanic.
1. This truck has a 12-volt battery and a IMPORTANT

negative ground electrical system.
Make sure that the other truck also Use only a 12-volt jumper system.
has a 12-volt battery and negative You can permanently damage a
ground system. If not sure of the 12-volt starting motor and igni-
voltage, or if the ground is different, tion system by connecting it to a
do not try to jump start, as personal 24-volt power supply (two 12-volt
injury or damage to the electrical batteries in series, or a 24-volt
system can result. generating set).
NOTICE
If your truck has a battery with ter- A WARNING
SULFURIC ACID
minals on the side, you will need a THE BATTERY CONTAINS CORROSIVE
set of jumper cables with matching AC IO WHICH CAN CAUSE INJURY.
IF ACID CONTACTS YOUR EYES OR
connector clamps, or cable adapters SKIN, FLUSH IMMEDIATELY WITH
for side-mounted battery terminals. WATER AND GET MEDICAL ASSIS-
TANCE.
2. If the discharged battery has filler Batteries contain sulfuric acid.

caps, check the fluid level. Do not Avoid acid contact with skin,
use an open flame to check and do eyes or clothing. Also, shield
not smoke. If low, add distilled water your eyes when working near the
to the correct level. Be sure to install battery to protect against possi-
the caps before jump starting. ble splashing of the acid solu-
Do not jump start, charge or test a tion.
sealed-type battery if the test in-
dicator looks illuminated or has a
bright color. Install a new battery.
A WARNING
3. Put the truck with the booster bat- EXPLOSIVE GASES
tery as near to the other truck as DO NOT SMOKE OR HAVE OPEN
FLAMES OR SPARKS IN BATTERY
necessary for the jumper cables to CHARGING AREAS OR NEAR BAT-
reach both batteries. Check and TERIES.AN EXPLOSION CAN RESULT
AND CAUSE INJURY OR DEATH.
make sure that the trucks do not
touch each other.
Hydrogen and oxygen gases are
Use particular care when connect- produced during normal battery
ing a booster battery to prevent operation. This gas mixture can
sparks. explode if flames, sparks or
lighted tobacco are brought near
the battery. When charging or us-
ing a battery in an enclosed
space, always provide ventilation
and shield your eyes. Wear safety
glasses when working around
batteries.
6.2
•· ...... .,. rr ,,. • • • ---.,.....,
Emergency Starting
How To Use Battery Jumper Cables
4. On both trucks:
• Turn all accessories to the
A WARNING
"off" position and leave them SHORT CIRCUITS
off until after the engine has
been started and the jumper REMOVE ALL JEWELRY. DO
NOT PERMIT ANY METAL
cables removed. TOOLS TO MAKE CONTACT
WITH THE POSITIVE BATTERY
• Turn the ignition key switch to TERMINAL AND OTHER
the "off" position. METAL ON THE TRUCK. MAKE
SURE WHEN CONNECTING
• Apply the parking brake. JUMPER CABLE CLAMPS TO
THE POSITIVE TERMINALS OF
• Put the directional control THE BATTERIES THAT
lever in the "N" (neutral) posi- NEITHER CLAMP CONTACTS
tion. ANY OTHER METAL. INJURY
CAN OCCUR FROM ELEC-
5. Connect the jumper cables in the TRICAL SHOCK OR EXPLO-
following sequence: SION.
(Also refer to Figure 24871)

a. Connect the first jumper Make Connecti.ons in Numerical Order
cable from the positive ( +) 0 First Jumper Cablt1
(Red) terminal on one battery

Discha,ged
to the positive ( +) (REAi) ter- Battery
minal on the other battery. __ .. nd Jumper Cable
Never connect ( +) (Red\ to
( - ) (Black), or ( - ) to ( + ).
b. Next, connect one end of the
second cable to the grounded
( - ) (Black) terminal of the
booster battery.
c. Last, connect the other end of 24871
the second jumper cable to a 7. Start the engine of the truck
stationary solid metallic point with the discharged battery.
on the engine of the truck Follow the starting instruc-
with the discharged battery. tions in the "Know Your Truck"
(Not to negative ( - ) terminal section of this manual. Make
of the battery.) Make this con- sure that the engine is at idle
nection at a point at least [450 speed before disconnecting
mm) 18 inches away from the the jumper cables.
battery, if possible. Do not
connect it to pulleys, fans, or 8. Remove the jumper cables by
other parts that move. Be sure reversing the above sequence
not to touch hot manifolds exactly. Start by removing the
which can cause severe last jumper cable, from the
burns. truck with the discharged bat-
tery, first. Remove the cable
6. Start the engine on the truck with end from the engine block
the booster battery, and run the first, then the other end of the
engine at a moderate speed. negative ( - ) cable.
9. Remove both ends of the
6.3 positive ( +) cable.
7 Emergency Towing
7.1
Emergency Towing (
How To Tow a Disabled Truck
If your lift truck becomes disabled but

can be moved freely on its own wheels
without further damage, use the follow-
ing procedures to tow it safely to a
repair area.
It is important for your safety and to
the care of your lift truck to use the pro-
per equipment and carefully .follow
these recommendations for safe tow-
ing.
Use an approved towing coupler that

bolts to the axle through the
24172
counterweight.
Towing equipment is optional equip-
ment available from your Clark dealer.
1. Engage the parking brake.

2. Put blocks against the drive wheels.
23057
7.2
Emergency Towing
Connect an approved solid metal tow
bar to the tow vehicle and to the truck
to be towed. With a driver in the seat,
push down on the foot brake pedal to
prevent the truck from moving. Have
the blocks removed from the drive
wheels.
83M410
Push forward on the parking brake han-

dle to release the brake.
\
84M281
Correct towing is necessary to prevent RK

injury to personnel or damage to the
truck. The truck is to be towed at a
speed of less than [8 kph] 5 mph with a
driver in the seat. Do not lift the truck
or any wheels off the floor while the
truck is being towed.
7.3 24174
Emergency Towing
(
Power steering will not operate on the

disabled truck when the engine will not
run. The handwheel will be difficult to
turn.
24175
Park the disabled truck in authorized

areas only. Fully lower the forks to the
floor, put directional control lever in
"N" (neutral) position and turn the igni-
tion switch to the "off" position.
Engage the parking brake. Remove the
ignition key and put blocks behind the
wheels to prevent the truck from roll-
ing.
24176
A CAUTION
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
.. ''fl-
8 Planned Maintenance
and Lubrication
A WARNING
LIFT TRUCK MAINTENANCE
DO NOT WORK ON THIS TRUCK
UNLESS YOU ARE TRAINED AND
AUTHORIZED AND KNOW THE
CORRECT MAINTENANCE PROCE-
DURES.
Planned Maintenance and Lubrication (
Regular maintenance and care of your lift truck is essential for economy
and utilization reasons, but most important for your safety. A faulty lift truck
is a potential source of danger to the operator, and to other personnel work-
ing near it.
Lift trucks should be inspected daily, or at the start of each shift. This daily
inspection should include a visual check for leaks and any obvious damage
which may have been caused by operation during the last shift. Check the
tires and wheel bolts. Look the upright and lift chains over. Check the forks
and load backrest extension. Look for loose bolts and fittings. Make sure
that the overhead guard is in good condition. Check all of the controls. Make
sure that all systems are functioning correctly. Check the engine oil, fuel
and coolant levels as well as the hydraulic sump oil level. And make sure
that all instruments, warning lights and the horn are operating correctly and
that your truck is safe to operate. Use the daily inspection sheet as a check
list and record of your findings.
In addition, Clark recommends that you set up and follow a planned
maintenance and inspection program. Performed on a regular basis, the pro-
gram will provide the opportunity to make thorough inspections and checks
on the safe operating condition of your lift truck. Necessary adjustments
and repairs are made as needed. The schedule for these planned
maintenance (PM) inspections will depend on the conditions of your par-
ticular application and lift truck use. Recommended periodic inspection and
maintenance items are listed in the Maintenance and Lubrication section.
Also shown is the PM inspection and report form which may be obtained
from your local Clark dealer. He is also prepared to help you with your Plan-
ned Maintenance and Inspection Program if you want assistance. He has
specially trained service personnel who are authorized to check your lift
truck according to the respective safety regulations.
Also, in the Maintenance and Lubrication section, you will find a listing of
useful specifications for 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.
8.2
)
'}
•
Planned Maintenance and Lubrication
Recommended Planned Maintenance Intervals
Operating conditions
Time intervals between maintenances
are largely determined by operating Ensure
conditions. For example, operation in
sandy, dusty locations requires shorter
operational
maintenance intervals than operation safety
in clean warehouses. The indicated in-
tervals are intended for normal opera-
tion. To allow better understanding of
this aspect, the following clarification
should be made:
NORMAL OPERATION:
Basically, eight-hour material handling,
mostly in buildings or in the open air.
SEVERE OPERATION:
Prolonged operating hours or constant
usage.
EXTREME OPERATION:
1. In sandy or dusty locations, i.e. ce-
ment plant, lumber or flour mills,
coal dust or stone crushing sites.
2. High-temperature locations, i.e.
steel mills, foundries, etc.
3. Sudden temperature changes (con-
stant trips from buildings into the
open air), e.g. refrigeration plant.
If your fork-lift truck is used in extreme
operating conditions, you must
shorten the maintenance intervals ac-
cordingly.
8.3
Recommended Planned Maintenance
and Lubrication Schedule
For: GCS / GPS / DPS 17-30
PM Interval: *Oil change intervals may be
8 = 8 - 10 hours determined by laboratory
50-250 = 50 - 250 hours analysis.
500 = 450 - 500 hours
1 = 900 - 1000 hours or every *·Air filter change interval may
6 months be determined by using air
2 = 2000 hours or every year cleaner gauge.
Nominal
6~~; t
Maintenance Interval
Find 8 50-250 500 1 2
01 LUBRICATION Air Clean Truck/Radiator # •
Steer axle linkages (8) fittings 1 •
Upright trunnion bushings (2) fittings 2 •
Tilt cylinder rod ends @ upr (2) fittings 3 •
Lift chains 4 •
Carriage chains 5 •
00 ENGINE OIL*
Drain and replace Gasoline 6 •
LPG •
Diesel •
Replace filter 7 •
01 COOLING SYSTEM
Check coolant condition/protect level 8 •
Drain/flush radiator 8 •
Inspect/adjust belts 9 •
02 FUEL SYSTEM
Replace fuel filter Gasoline 10 •
LPG •
Diesel •
Clean tank I filler screen 11 •
02 AIR INTAKE**
Replace air filter 12 •
06 TRANSAXLE
Clean transmission oil strainer screen 13 •
Replace transmission oil filter 14 •
11 IGNITION
Engine tuneup 15 •
Check engine/ignition timing •
Replace spark plugs Gasoline •
LPG
12 BATTERY
Clean/check terminals, electrolyte level 16 •
20 DRIVE AXLE (TRANSAXLE)
Check fluid level/condition 17 •
Drain and replace fluid 17 •
Check brake wear 18 •
Check air vent 19 •
Lubricate wheel end gearing/bearings 20 •
23 BRAKES
Check brake fluid level (Std Only) 21 •
Replace brake fluid (Std Only) 21 •
26 STEER AXLE
Lubricate wheel bearings 22 •
29 HYDRAULIC SUMP & FILTER
Check fluid level/condition - sample 23 •
Change fluid 23 •
Replace fluid filter 24 •
Replace tank breather cap 23 •
8.4
- - - - ,..-----...--- d Lubrication
Maintenance an
Planned . Chart
Planne d Maintenance an d Lubrication
GCS/GPS 17-30
LEGEND:
Engine oil
EO . coolant
CO Engine . sion fluid
TF Transm1_s brake fluid
Hydraulic .
BF draulic oil
HO ~~ain lubrica_nt t
CL I
DL Dry -nm lubricangrease NLGI 1
MP1 Multipurpose grease NLGI 2
MP2 Multipurpose
*** Refer
t uck only
Standard r le specs
to transax
8.5
Engine Oil Level Check

Check the engine oil level at left side of
engine. Pull the dipstick out, wipe it
with a clean wiper and push it back into
the dipstick tube. Remove the dipstick
again and check the oil level.
84M390
Engine Oil and Filter Change

It is recommended to:
* • Drain and replace the engine crank-
case oil every 50 to 250 operating
hours.
• Replace the engine oil filter every
oil change.
•NOTICE - The time interval for changing
engine oil will depend upon your application
and operating conditions. To determine the
correct schedule for your truck, it is recom-
mended that you periodically submit engine
oil samples to a commercial laboratory for
analysis of the condition of the oil. 84M392
Engine Air Cleaner

Change the engine air filter every 50 to
250 operating hours, depending upon
your application and operating condi-
tions.
• STANDARD MODELS - Remove
and replace the complete air filter unit.
• CUSTOM AND INDUSTRIAL OP-
TION PACKAGE - Remove and
replace the filter element (shown).
84M362
a_s
ri:· -
) Planned Maintenance and Lubrication
Engine Coolant Check

On standard trucks the engine coolant
level is checked by removing the
radiator cap. Remove the cap only
when the engine is cold. Turn the cap
slowly to release any pressure that may
be in the radiator. Then push the cap
fully down and turn to release and
remove the cap.
A WARNING
STEAM
DD NOi REMOVE THE RADIATOR
CAP ,MEN THE RADIATOR IS
HOT. STEAM FROM THE RADIATOR
~ILL CAUSE SEVERE BURIIS.
On custom and industrial option

package trucks, inspect the coolant
level in the overflow bottle only. Do not
remove the cap.
The coolant level should be at the
"Cold Level" line on the coolant
recovery bottle.
NOTICE: Your lift truck cooling system
is filled with a factory-installed solu-
tion of 50% permanent-type anti-freeze
and 50% water, containing rust and
corrosion inhibitors. You should leave
it in the truck year around. 83M425
Battery - Water-Fill Type

Check the battery to be sure the cells
are all filled. Inspect for cracks. If the
terminals are corroded, clean and pro-
tect them with Battery Saver.
84M356
8.7
(
Brake Master Cyllnder Fluld Level
Check
Standard Model w/HRS00 Transaxle
1. Remove floorboards
2. Check brake fluid level on standard

trucks by opening inspection/fill plug on
brake master cylinder top.
IMPORTANT
WITH STANDARD MODEL SERVICE
BRAKE SYSTEMS, USE SAE
AUTOMOTIVE HYDRAULIC BRAKE
FLUID ONLY. D.O.T 3
84M399
3. Replace floorboards.
IMPORTANT
HR600 Transaxle
DO NOT OPEN MASTER CYLINDER TO CHECK FLUID LEVEL. DO NOT PUT
STANDARD SAE AUTOMOTIVE BRAKE FLUID IN THIS SYSTEM.
NOTICE
HR600 Transaxle
Service brake system on these models uses transaxle fluid. Brake master
cylinder fluid level is supplied (replenished) automatically.
NOTICE
TA18 Transaxle
Has reservoir on dash for D.O.T. 3 brake fluid.
8.8
Hydraulic Fluid Level Check

Check the hydraulic sump tank oil level
with:
1. Truck on a level surface.
2. Upright in a vertical position.
3. Fork carriage fully down.
4. Oil at operating temperature.
Pull the dipstick out, wipe it with a
clean wiper, and push it back into the
dipstick tube. Pull the dipstick out
again and check the oil level.
84M397
The hydraulic sump tank oil level

should be up to the "F" (full) mark on
the dipstick.
Approximately [3,8 L] 1.0 gal. of
hydraulic oil is required to fill the
hydraulic tank from the "L" (low) mark
to the "F" (full) mark. Do not overfill.
24917
Hydraulic Sump Tank Fluid &

Filter Change
• Drain and replace the hydraulic
fluid every 2000 operating hours.
• Replace the hydraulic oil filter at
every oil change.
• Replace the hydraulic sump tank
breather/fill cap every 1000 operating
hours.
IMPORTANT
Use recommended fluid only 84M398
Use genuine Clark parts

Access to the Drive Axle

The best method to use for reaching
the drive axle check points (oil
level/filler plug and brake inspection
plugs) is dependent upon the style of
upright, carriage and attachments on
your truck. One method is to raise the
upright carriage to provide easy access
to the drive axle.
• Apply the parking brake and block
the wheels.
• Be sure to put blocking under the
carriage and upright rails.
A WARNING 84M255
FALLING FORKS
DO NOT ~ALK OR STAND UNDER

RAISED FORKS. THE FORKS CAN
FALL AND CAUSE INJURY OR
DEATH.
Transaxle Fluid Level Check

• Check the transaxle fluid level with
the:
1. Truck on a level surface
2. Transmission in "NEUTRAL"
3. Engine idling
4. Oil at operating temperature
• Remove the fluid level inspection
plug located in the front surface of the
drive axle center housing (all models).
• The oil level is correct (full) when
the oil reaches the lower edge of the
plug opening, or can be measured on
the dipstick portion of the plug.
• After adding oil to the transaxle,
wait a few minutes until the oil has
distributed evenly throughout the unit,
keep the oil level at the lower edge of
the inspection opening. Do not overfill.
• Be sure to inspect the seal on the
inspection plug. Replace as needed.
84M233
8.10
Transaxle (Transmission) Oil

Filter Change
The transaxle oil filter is located
in a horizontal position on the top
left front (towards drive axle) side
of the transmission, and mounted
on the charging pump.
1. Remove the floorboards. You
wiU see the transmission oil
filter near the bottom of the
steering column.
2. Remove the oil filter. Take

84M421
special care when removing
this filter to avoid the draining
onto the floor of any oi I re-
maining in the filter. It is
recommended that you first
loosen the filter using a stan-
dard filter wrench. Then,
remove the filter while holding
a pad of shop cloths, or other
absorbent material, under the
open end of the filter to absorb
any excess oil that may drain
out of the filter.
3. Install a new filter. Be sure to

follow the installation instruc-
tions printed on the outside
surface of the filter.
IMPORTANT
Always Use Genuine Clark Parts.
4. Inspect and clean the trans-

axle breather (air vent), located
on the top of the converter
housing near the charging
pump.
5. Install the floorboards.
8.13
HR600 Transaxle
HR600 transaxle has four inspection
and service plug openings in drive axle
section.
1. Fill/oil level dipstick plug.
2. Drain plug.
3. Inspection/fill plug
4. Brake inspection plugs
In addition, HR600 transaxle has a

transmission housing drain plug (5), 24984
located on lower left side from corner of
transmission case sump, and a
transmission oil strainer screen access
plug (6) in lower left rear side corner
(towards engine) of housing.
Transaxle Fluld Replacement/Refill

HR600 Transaxle
After drive axle and transmission
housing has drained completely,
1. Install drain plug in drive axle.
2. Install drain plug in transmission

housing.
24990
3. Remove large inspection/filter plug in

top center of axle.
4. Fill transaxle to bottom edge of fill/oil

level plug opening on from of axle
with recommended fluid noted below.
Please refer to previous instructions
on "Transaxle Fluld Level Check".
5. Install fill/level plug.
6. Install inspection/filter plug.
7. Remove drain pan. Remove blocking

from under upright (if used) and
84M256
lower carriage and forks to floor.
IMPORTANT
HR600 use only Texaco 8570 ATF, or
Clark Part No. 962669 in HR600
transaxles.
DO NOT USE A SUBSTITUTE.
8.14
)
...... 1
-IT~-
Transaxle Fluid & Filter Change

NOTICE
Frequent changes of lubricant and
• Drain and replace the trans- filters is an inexpensive way to pro-
axle fluid every 1000 operating tect and prolong the safe opera-
hours. ting life of an essential and rela-
*• Replace the transmission oil
filter every 500 operating hours.
tively more valuable major compon-
ent such as the transaxle.
·when the transaxle is new or Extending the recommended inter-
rebuilt, it is recommended to change vals at which transaxle fluid and
the oil filter after the first 50 hours filters are changed should be con-
and again after 100 operating hours. sidered only after careful evalua-
The reason for this is to be sure that tion of your operating conditions
the oil is cleaned of all harmful par- and/or analysis of the condition of
ticles of material which may be the oil. Because the oil is heated
loosened or flushed off new parts as to very high temperatures when a
they wear in. troque converter and transmission
are operated under heavy or sus-
tained working conditions, it will
To change oil in the transaxle: "wear put" (break down) and lose
its lubricating ability due to oxida-
1. The oil should be drained tion. When this happens, it will cause
when it is warmed to operating rapid wear and damage to seals,
temperature. bearings, and clutch plates, result-
2. Put the truck in a level posi- ing in the need for a much more
tion. costly transmission rebuild.
3. Apply the parking brake and

block the wheels to prevent
the truck from moving.
NOTICE: When suitable equip-

ment is available, the truck may
be raised or hoisted up and
placed in a level position on
wheel cradles to allow access
under the axle. Otherwise, raise
the fork carriage only high
enough to provide access to the
axle. Please refer to procedure
described above in "Access to
the Drive Axle".
8.11
Transaxle Fluid & Filter Change

The transaxle oil must be drained from
two places (all models),
1. The drive axle drain plug, and
2. The transmission housing drain
plug, located at the lower left side
(front corner) of the transmission
case sump (below the control valve).
Place one flat drain pan of [15 L] 32

pints minimum capacity under both
drain openings, or separate drain pans
under each opening.
24991
Remove the drain plugs.
NOTICE: Please refer to the descrip-
tion of standard and optional model
transaxle features on following pages.
Transmission Sump Oil Strainer Screen

• Remove and clean the transmis-
sion sump oil strainer screen each time
the transmission fluid is changed.
1. Remove the access cover and the
transmission sump strainer screen.
2. Use an approved cleaning solvent to
clean the screen. Dry with com- 12171
pressed air.
A WARNING
AIR PRESSURE
WEAR EYE PROTECTION & PROTEC-
TIVE CLOTHING WHEN CLEANING
OR ORYING WITH AIR PRESSURE.
REDUCE PRESSURE TO [207 kPa]
30 PSI. DEBRIS REMOVED WITH
AIR PRESSURE CAN CAUSE INJURY.
3. Inspect the screen for damage.

Replace as necessary.
4. Install the screen and cover.
8.12
HRSOO Transaxle
HRS00 transaxle has two openings in
drive axle section.
1. Fill/oil level dipstick plug.
2. Drain plug, in lower front surface of

axle center housing.
In addition, HRS00 transaxle has a

transmission housing drain plug (3), and
a transmission oil strainer screen
access plug (4) located similarly to
HR600 transaxle.
Transaxle Fluld
Replacement/Ref Ill Fig. 24992
HRSOO transaxle
After drive axle and transmission
housing has drained completely,
1. Install drain plug in drive axle.
2. Install drain plug in transmission

housing.
3. Remove inspection/filler plug in from

center surface of drive axle housing.
4. Fill transaxle to bottom edge of fill/oil

level plug opening with recommend-
ed fluid noted below. Please refer to
previous instruction on "Transaxle
Fluld Level Check".
Fig. 24994
5. Install fill/level plug.
6. Remove drain pan. Remove

blocking from under upright (if
used). Lower carriage and forks to
floor.
IMPORTANT
HRS00 use only API Class CC,SC, SE,
SF Motor Oil
SAE30@32°F-110°F
SAE10@ 32°F-(-30°F)
DO NOT SUBSTITUTE.
IMPORTANT
TA18 use only AMOCO 1000 or
TEXACO 1893 TOH CLARK # 2776236 8.15
DO NOT SUBSTITUTE.
(
HR600 TRANSAXLE - BRAKE DISC WEAR CLEARANCE CHECK

The purpose of this check is to determine the "worn" thickness of the inner
(friction) brake discs. The remaining thickness of the inner plates is readily
determined by measuring the space (clearance) between two steel outer
discs. The minimum allowab'e "worn" thickness of the inner friction discs
is [2,6 mm] 0.104 inch. Measurable wear of the steel outer discs is normally
not expected. The brakes must be fully applied during this check to make
sure that all of the operating running clearance is removed.
Please refer to the procedure described

previously in "Access To The Drive
Axle".
PUT POSTS UNDER THE UPRIGHT AND

CARRIAGE AS SHOWN IN FIGURE 84M255
TO KEEP IT FROM FALLING AND
CAUSING PERSONAL INJURY.
3. Remove the brake inspection plugs

(4) from top of drive axle housing.
24984
4. Apply parking brake or push down on

the brake pedal and maintain [445N]
100 lbf. force on the pedal while
checking the brake discs.
84M244
8.16
5. Brake disc gauge (6) dimensions are

shown by Figure 20716.
Fig. 20716
6. Insert the gauge into the axle through

the brake inspection plug opening (5).
Try to put the brake disc clearance
gauge (6) between two steel discs
(8), Figure 24982. Minimum disc clear-
ance is [2,6 mm] 0.104 inch.
Fig. 21977
7. The gauge (6) should go between the

outer discs (8). If it does not, the
brake inner (friction) discs (7) are
worn and require replacement. Refer
to Overhaul Manual OH-522, GROUP
20, for drive axle overhaul.
Fig. 24982
8.17
Lift Chain Lubrication

Lift chain lubrication is an important
part of your maintenance program. The
lift chains operate under heavy
loadings and will function more safely
and have longer life if they are regularly
correctly lubricated. Clark chain lubri-
cant is recommended. It is easily
sprayed on and provides superior
lubrication.
21460
Lift Chain Adjustment Check

The lift chains are correctly adjusted if
the lower fork carriage rollers reach
their end (lowest) position approx-
imately (13 mm] 0.50 inch from the
lower edge of the inner rail. This also
positions the bottom of the forks the
same (equal) distance above the floor.
To check this dimension, raise the car-
riage to a height that exposes several
inches of the inner rail at the roller
path. Apply a layer of grease to the
roller path on the inner rail. Lower the
carriage and pick up a rated capacity
load, (tilt the upright back slightly) and 17643
raise the load until the carriage rollers
have passed over the greased area. NOTICE: It is important to make
Lower the load completely and remove the lift chain adjustment check
the load from the forks. Raise the car- with a rated load to make sure
riage again to expose the inner rail. You that the chains are stretched to
can now check the roller path pattern their maximum length.
in the grease and determine the correct If the chains show slack due to an
adjustment of the chains. increase in length they should be
The lift chains can be adjusted by measured for wear. When chains
loosening or tightening of the chain an- have stretched by wear more than
chor nuts. 3% of their original length they
are not safe and must be re-
placed.
8.18
Truck Lubrication
Raise the rear of the truck and place
blocking under the frame for safety.
Lubricate the steer axle linkage - tie
rod ends and kingpin bearings. Be sure
to clean the grease fittings before
lubricating and remove the excess
grease from all points after lubrication.
Inspect the steering cylinder piston
rod, seals and fasteners for damage,
leaks and looseness.
Remove the blocking and lower the rear
of the truck.
83M480
Lubricate the tilt cylinder rod ends (at

the forward end) and the upright trun-
nion bushings.
84M274
Your cLqRK Dealer

keeps all lubricant
available for you
8.19
Wheel and Tire Inspection
Federal and State laws require persons
to be fully trained and qualified before
doing maintenance on wheels and
A DANGER
RIM SEPARATION
tires. Injury or death can result from the
explosive separation of rim com- REMOVE THE AIR FROM TIRES
ponents if service procedures are not BEFORE DOING ANY WORK ON
done correctly. TIRES OR RIMS. MULTI-PIECE
RIMS CAN SEPARATE WITH
ENOUGH FORCE TO CAUSE
INJURY OR DEATH

facing the tread of the tire, not the side.
Use a long handled gauge to keep your
body away from the trajectory path of
multi-piece rims and wheels.
24964
If tires are low, do not add air. Check
with a mechanic. The tire may need to
be removed and repaired.
24308
8.20
..
Wheel and Tire Inspection
Remove air from the tire before remov-
ing wheel clamping nuts (two piece
wheels) or rim locking rings on multi-
piece rims.
18631
Always use a safety cage to inflate
tires after servicing.
24306
Trained and qualified mechanics
should refer to information in the GROUP
Planned Maintenance Manual before 22
working on pneumatic tires and rims. SECTION
1
PNEUMATIC
TIRE
AND WHEEL
l,\AINTENANCE
24309
8.21
...
)
9 Specifications
NOTICE
Clark products and specifications are
subject to improvements and changes
without notice or obligation.
9.1
(
Specifications
Truck Specifications
Fuel recommendations:
Gasoline Regular Grade, 85 Octane Minimum (Motor

Method)
LP Gas HD-5 Propane
Diesel Fuel Oil ASTM Grade No. 1D and 2D, 45 Cetane
Minimum, 50 Cetane Preferred
Engine oil recommendations:
(Gas - LPG) API Service Classification CC, SC, SE, SF, MIL-8 Motor Oil,
MIL-L-46152
(Diesel) -API Service Classification CD/SE MIL-451998
Ambient Temperature (Average) Viscosity
32°F to 110°F [0°C to 43°C] SAE 30
70°F to 0°F [21 °C to -17°C] SAE 20W
0°F to -30°F [-17°C to -34°C] SAE 10W
Engine coolant recommendation:

50% water and 50% ethylene glycol permanent-type antifreeze containing
rust and corrosion inhibitors. (Antifreeze protection level [ - 37°CJ - 34°F)
Tire inflation pressure:

Drive Tires (7.00 x 12 - 14 Ply, 28 x 9 x 15-14 Ply) [965 kPa] 140 psi
Steer Tires (6.50 x 1O - 1O Ply) [792 kPa] 115 psi
9.2
Specifications
FIii capacltles/fluld volumes:
Fuel Tank -- Gasoline/Diesel .................................................. (30,0 L] 8 gal
LPG [ICC Horiz Tank] ....................................... [15 kg] 33.5 lb
Cooling System:
Mitsubishi 2.6L Gasoline/LPG .............................................(8,5 L] 9 qt
Waukesha 2.9L Gasoline/ LPG ........................................(10,4 L] 11 qt
Continental 2.7L Gasoline/Diesel ........................................(8,5 L] 9 qt
Engine Oil, w/Filter
Mitsubishi 2.6L Gasoline/LPG .......................................... (4,5 L] 4.8 qt
Waukesha 2.9L Gasoline/LPG ......................................... (4,7 L] 5.0 qt
Continental 2.7L Gasoline/LPG ......................................(6.65 L] 7.0 qt
Continental 2.7L Diesel ..................................................(6.65 L] 7.0 qt
Transaxle [Transmission & Drive Axle]
HR500 .........................................................................(15, 1 L] 32 pints
HR600 ........................................................................(12, 8 L] 27 pints
TA18 ............................................................................(15,1 L] 32 pints
Hydraulic Sump Tank [Useable Volume] ............................ (20, 8 L] 5.5 gal
Hydraulic system rellef pressure setting:

Lift and Tilt Model 17,20 .............................. (16200 kPa] 2350 psi
[Adjustable] 22,35 .............................. (18270 kPa] 2650 psi
27,30 ............................... (20685 kPa]3000 psi
Steering system rellef pressure setting: ............................ (8615 kPa]1250 psi
Engine speed settings:[+][·] 50 rpm

Engine 2.6 L 2.7 L 2.9 L 2.6 L
Transaxle HR500 HR600 HR600 HR600 TA18
*Idle Speed, 600 600 600 550 600
rpm Max.
No-Load
Governed
Speed,
rpm 2300-2600 2350-2650 2350-2650 2350 2300-2600
Electrical system: ................................................. 12 volt DC, Negative Ground

Alternator: .......................................................................................37 amp
Battery Rating [Cold-Crank]:
Gasoline/LPG -- Water-Fill Type .................... 12v DC -295 amps @ 0°F
Gasoline/LPG --Maintenance-Free ................ 12 v DC -- 320 amps @ 0°F
Diesel -- Maintenance-Free ........................... 12 v DC --625 amps @ 0°F
Idle speed must be adjusted so truck has adequate oil supply to steer correctly.
*Idle speed must be adjusted so truck (when empty) does not have excessive
creep speed. Creep speed should be limited to 2 ft. per second. 9.3
Specifications (
Engine crankcase oll
Gasoline/LPG Engines API CC/SE Mil-2104B,
MIL-45199B
Transmission fluid
Powershift Transmission, (HR600) - TEXACO 8570 ATF
Torque Converter and or Clark #962669
Drive Axle
(HR500)- AMOCO 300 Motor Oil
SAE 20W
(TA18) AMOCO 1000

or TEXACO 1893 TOH
Hydraulic fluid
Hydraulic Sump Clark Specification
Normal Application MS-68
Multi-purpose grease
Axle Ends, Wheel Bearings, NLGI Grade No.1
Steer Axle Linkageme Rod Lithium soap base grease,
Ends, Steer Axle Knuckle Clark Specification MS-9B and
Bearings MS-107B, or equivalent.
Upright Mast Rollers, MLGI Grade No.2
Trunnion Bushings, Lithium soap base grease,
lilt Cylinder Rod Ends Clark Specification
MS-107C, or equivalent.
Chain lube
Upright Lift Chains
Clark #8 86399 Chain and
Cable Lube, or equivalent.
Dry-FIim lubricant
Side Shifter, Attachments
Clamp Slides Bonded Lubricant, Dow Corning Milykote 321
Graph-O-Kote
#220, Molub-Alloy #369 Dry
Battery
Lube, or equivalent.
(Unsealed-type)
FIiters Distilled Water.

Engine Fuel
Engine Oil - 990937
Engine Air - 2373789 Use Genuine Clark parts.
Transmission Oil - 247050/246262 See your Clark dealer.
BT8830
Hydraulic System Oil 2366807
Hydraulic Sump Breather - BT8386
Brake Fluld
HR500/TA18 D .O .T 3 Brake Fluid
HR600 Trucks Hydraulic System Fluid.
9.4
) Specifications
Critical Fastener Torque Specifications
• Drive Wheel Lug Nuts (GCS/GPS) ........ [640- 720 N · m] 470- 530 lbf. ft.
• Steer Wheel Lug Nuts (GPS) ............. [359 - 438 N · m] 265 - 323 lbf. ft.
• Steer Wheel Spindle Nut (GCS/G PS) . . . . . [230 - 244 N · m] 170 - 180 lbf. ft.
See Note (2) below
• Steer Axle Mounting Bolts @ Silent Block [570 - 650 N · m] 420 - 480 lbf. ft.
• Drive Axle Mounting Bolts .............. [542 - 596 N · m] 400 - 440 lbf. ft.
• Overhead Guard Mounting Bolts ......... [ 65 - 75 N · m] 50 - 55 lbf. ft.
• Counterweight Mounting Bolts
(Outside Rear) .......................... [320 - 360 N · m] 240 - 265 lbf. ft.
• Counterweight Mounting Bolts
(Inside Front) ........................... [320- 360 N · m] 240 - 265 lbf. ft.
• Steering Handwheel Retaining Nut ...... ( 47 - 54 N · m] 35 - 40 lbf. ft.
• Control Lever Knob Mounting Bolts ...... [ 8 - 10 N · m] 75 - 85 lbf. in.
• Upright Mounting Trunnion-to-
Upright Bolts ........................... [370-410 N · m] 273 -302 lbf. ft.
• Upright Mounting Trunnion Cap Bolts .... [ 75 - 80 N · m] 55 - 59 lbf. ft.
• Upright Cylinder Retaining/Holddown
Bolts .................................. [ 65 - 75 N · m] 50 - 55 lbf. ft.
• Tilt Cylinder Yoke Clamp Bolts .......... (170 -190 N · m] 125-140 lbf. ft.
• Tilt Cylinder Pin Retainer Bolts - Front ... [ 9- 10 N · m] 80- 90 lbf. in.
• Tilt Cylinder Pin Retainer Bolts - Rear .... [ 29- 31 N · m] 260 - 275 lbf. in.
• Load Backrest Extension Mounting Bolts (240-270 N · m] 177-199 lbf. ft.
• Axle End To Differential Housing Bolts .. [114-142 N · m] 84-105 lbf. ft.
• Seat Mounting Bolts .................... [18.1 - 20.6 N · m] 160 -183 lbf. in.
• Steering Column Mounting Bolts
Column to Bracket ................. [ 8 - 10 N · m] 70 - 85 lbf. in.
Bracket to Cowl .................... [ 20 - 25 N · m] 180 - 220 lbf. in.
NOTES: (1) When checking tightness of major fasteners on new trucks,

the values may be less than the recommended specifica-
tion due to metal deformation and fastener stretch. This is
a normal occurrence and does not indicate that the fasten-
ers were not correctly tightened during assembly. Tighten
to recommended specifications.
(2) Steer Wheel Spindle Nut Bearing Adjustment (For steer

axles with castellated nut and cotter pin).
Tighten spindle nut (bearing adjustment nut) until bearings
bind slightly when rotated, then back off to nearest slot
in nut and lock with cotter pin.
9.5
For Handy Reference (
Record the following information

pertaining to your truck:
Model No .......................... _ _ _ _ _ _ _ __
Serial No ........................... _ _ _ _ _ _ _ __
Attachments ....................... _ _ _ _ _ _ _ __
Truck Weight - Empty .............. _ _ _ _ _ _ _ __
Truck Rated Capacity ................ _ _ _ _ _ _ _ __
Gross Truck Weight (W/Rated Load) .... _ _ _ _ _ _ _ __
Customer Truck Identification No...... _ _ _ _ _ _ _ __
9.6
(
Additional copies of this manual may be purchased from
YOUR AUTHORIZED CLARK DEALER.
.,
,,
Material Handling
CIJARK (a)
Company Lexington, KY 40507

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Book No. 2779027

Record the following information pertaining to your truck.

Customer Truck Identification No. - - - - - - - - - - - -

Truck Gross Weight, Loaded w / Rated Load _ _ _ _ _ _ __

©1990 Clark Equipment Company

Follow these rules:

d~ Know your truck.

MACHINE SERIAL DRIVE AXLE

Learn safe operating rules

Breaking these rules will cause serious or fatal injury to

A MESSAGE TO CLARK LIFT TRUCK OPERATORS ........ iii

Safe operation of lift trucks is of primary importance to CLARK. Our ex-

The operator's manual is not a training manual. It is a guide to help autho-

Cushion (solid tires)

Cushion (solid) tire

Pneumatic (air-filled tires)

At the beginning of each

Do not make repairs your-

Check tire pressure from a position

Low tires can effect the truck's stability

DO NOT OPERATE A LIFT

Remove the key and put

RED CAN GREEN CAN

Use clean, properly Clean up spills. Use clean, properly

Do not mix Use only clean,

If you refill LPG tanks:

LPG ... is heavier than air - it will settle

Check all connections

Never mix drugs and

Don't block safety or

Wear safety equipment

Watch those "No

Know the weight of your truck and load.

The operator is the only one

Watch for people in your

Keep under the

Keep hands on the

Keep arms and legs

Carry loads low

If load blocks your

TIP WITH THE TRUCK

Keep hands, feet

Don't use the

Never try to repair the

Never park on a Lower forks fully to

Put directional lever

Turn key off. Set parking brake.

This section shows hazards that may

AWARNING: Loose loads

Center wide loads.

Stack and band

Wide loads ... keep them low and

Remember, a long load will reduce the capacity

Slack chains mean rail or

AWARNING: Right-angle stacking

When right-angle stacking, or moving with a

Know the height of your truck.

To avoid these hazards you must:

4 Know Your Truck