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ELECTRIC RIDER LIFT TRUCKS [Do not remove this manual from the truck] GEX 40/45/50 Part No. 8106240 OM 899 (Rev 1.3) Jun. 2019…
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Operator’s Manual You must be trained and authorized to operate a lift truck. YOU can prevent accidents First: Learn safe operating rules and your company rules. Next: Read your Operator’s Manual. If you do not understand it, ask your supervisor for help. Learn about the unit you operate.
Page 4: A Message To Clark Lift Truck Operators

They require specific instructions and rules for safe operation and maintenance. Safe operation of lift trucks is of primary importance to CLARK. Our experience with lift truck accidents has shown that when accidents happen and people are killed or injured, the causes are: •…
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If you think you need training in operating or inspecting your lift truck, ask your supervisor. CLARK lift trucks are built to take hard work, but not abuse. They are built to be dependable, but they are only as safe and efficient as the operator and the persons responsible for maintaining them.
Page 7: Table Of Contents

Contents of this Manual A Message to CLARK Lift Truck Operators……. ii Introduction ……………. vi How to Use this Manual ……….viii Safety Signs and Safety Messages ……..x Section 1. General Safety Rules ……..1-1 Section 2. Operating Hazards ………. 2-1 Section 3.
Page 8: Introduction

CLARK lift truck in a safe and correct manner. Your CLARK lift truck has been designed and built to be as safe and efficient as today’s technology can make it. As manufactured, it meets all the applicable mandatory requirements of ANSI / ITSDF B56.1 Safety Standard for Powered Industrial Trucks.
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The procedures for a periodic planned maintenance program that covers inspections, operational checks, cleaning, lubrication, and minor adjustments are outlined in this manual. Your CLARK dealer is prepared to help you with a Planned Maintenance Program by trained service personnel who know your lift truck and can keep it operating safely and efficiently.
Page 10: How To Use This Manual

Also, the Index helps you locate information about various topics. NOTICE: The descriptions and specifications included in this manual were in effect at the time of printing. CLARK Material Handling Company reserves the right to make improvements and changes in specifications or design.
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If the truck you operate is not equipped with a manual, ask your supervisor to obtain one and have it attached to the truck. And, remember, your CLARK dealer is pleased to answer any questions about the operation and maintenance of your lift truck and will provide you with additional information should you require it.
Page 12: Safety Signs And Safety Messages

Damage to the truck, death, or serious injury to you or other persons may result if these messages are not followed. If warning decals are damaged, they must be replaced. Contact your CLARK dealer for replacements. NOTICE This message is used when special information, instruc-…
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Section 1. General Safety Rules General Safety Rules Contents Daily Inspection …………. 1-2 Do’s and Don’ts …………1-3 Seat Belts …………..1-4 No Riders …………..1-5 Pedestrians …………. 1-6 Operator Protection ……….1-7 Fork Safety …………. 1-8 Pinch Points …………1-9 Travel …………..
Page 14: Daily Inspection

Daily Inspection At the beginning of each shift, inspect your truck and fill out a daily inspection sheet. Check for damage and maintenance problems. Have repairs made before you operate the truck. CAUTION DO NOT MAKE REPAIRS YOURSELF. Lift truck mechanics are trained professionals.
Page 15: Do’s And Don’ts

Section 1. General Safety Rules Do’s and Don’ts Don’t mix drugs or alcohol with your job. Do watch for pedestrians. Don’t block safety or emergency equipment. Do wear safety equipment when required. Don’t smoke in «NO SMOKING» areas or when refueling. If forklift truck is to be operated outdoors during rainy conditions, make sure cab is in place to prevent damage to electrical…
Page 16: Seat Belts

Seat Belts ALWAYS BUCKLE UP Seat belts can reduce injuries. Seat Belts…
Page 17: No Riders

Section 1. General Safety Rules No Riders No Riders…
Page 18: Pedestrians

Pedestrians Estar atento cuando se maneja. Mirar en el sentido de marcha. Los peatones pueden estar usando la misma vía Watch where you are going. Look in the direction of que usted. Sonar la bocina en todas las intersecciones o travel.
Page 19: Operator Protection

Section 1. General Safety Rules Operator Protection Keep under the overhead guard. Always keep your body within the confines of the truck. Operator Protection…
Page 20: Fork Safety

Fork Safety Never allow anyone to walk under raised forks. DANGER There is special equipment to raise 2372604 people for overhead work. DO NOT USE LIFT TRUCKS. Fork Safety…
Page 21: Pinch Points

Section 1. General Safety Rules Pinch Points WARNING Keep hands, feet and legs out of the upright. WARNING Don’t use the upright as a ladder. CAUTION Never try to repair the upright, carriage, chain, or attachment yourself! Always trained mechanic. Pinch Points…
Page 22: Travel

Travel Travel with the load near floor/ground with upright tilted back to cradle the load whenever possible. Never lift or lower the load when the truck is in motion. When handling bulky loads that restrict your vision, operate your truck reverse improve visibility.
Page 23: Grades, Ramps, Slopes, And Lnclines

Section 1. General Safety Rules Grades, Ramps, Slopes, and lnclines Unloaded Forks Downgrade WARNING Never turn on a grade, either loaded or unloaded. Loaded Forks Upgrade Grades, Ramps, Slopes, and lnclines 1-11…
Page 24: Surface And Capacity

Surface and Capacity Avoid these conditions. They can cause a truck to tip over or lose traction for braking or driving. WARNING Know the weight of your truck and load. Especially when using elevators. Know the capacity of the elevator you intend to use.
Page 25: Tip-Over

Section 1. General Safety Rules Tip-Over Lateral Tip-over Lateral tip-over can occur with a com- • bination of speed and sharpness of turn. This combination will exceed the stability of the truck. This condition is even more likely with an unloaded truck.
Page 26: What To Do In Case Of A Tip-Over

What to do in Case of a Tip-over If your truck starts to tip over, WARNING DO NOT JUMP!!! IMPORTANT Your chances for survival in a tip-over are better if you stay with the truck, in your seat. Brace yourself as illustrated below! 1.
Page 27: Parking

Section 1. General Safety Rules Parking • Never park on a grade. • Always come to a complete stop before leaving truck. • Be sure travel control is in NEUTRAL. • Lower forks fully to floor and tilt forward. • Set parking brake. •…
Page 28: General Tire Maintenance, Inspection, And Repair

General Tire Maintenance, Inspection, and Repair 1. Park the truck as described on page 1-15 and check for correct tire inflation air pressure. See specifications in this OM for cor- rect tire pressure for your truck. CAUTION Check tire pressure from a position facing the tread of the tire, not the side.
Page 29: Section 2. Operating Hazards

Section 2. Operating Hazards Operating Hazards Contents Loose Loads …………2-2 Long or Wide Loads / Rear Swing ……2-3 Low Overhead Clearance Fast Turns and High Loads ……..2-4 Docks/Drop Offs …………. 2-5 Right-Angle Stacking ……….2-6 Chain Slack …………. 2-7 Pallets and Skids ………..
Page 30: Loose Loads

Loose Loads WARNING Loose or unbalanced loads dangerous. Observe these precautions. Never carry loose or uneven material. Center wide loads. Stack and band loose material. Loose Loads…
Page 31: Long Or Wide Loads / Rear Swing

Section 2. Operating Hazards Long or Wide Loads / Rear Swing WARNING With long or wide loads, you need more room. So slow down and watch your clearance. A long load reduces the capacity of the truck. Know and understand your truck load rating. When extra-long material makes it necessary to travel with the load elevated, do so with extreme care and be alert to load end- swing when turning.
Page 32: Low Overhead Clearance Fast Turns And High Loads

Low Overhead Clearance Fast Turns and High Loads WARNING Know the height of your truck, with and without a load. Check your clearances. Keep the load low and tilted back. WARNING Watch overhead clearance: Moving into overhead structures can tip a truck over, or spill a load.
Page 33: Docks/Drop Offs

Section 2. Operating Hazards Docks/Drop Offs WARNING To avoid these hazards, you must: • Talk to the truck driver yourself; make sure the driver does not move the trailer until you are done! • Apply trailer brakes. • Use wheel chocks. •…
Page 34: Right-Angle Stacking

Right-Angle Stacking SLOWLY WARNING When right-angle stacking or moving with a raised load to clear low objects, avoid sharp turns and move slowly. Right-Angle Stacking…
Page 35: Chain Slack

Section 2. Operating Hazards Chain Slack WARNING Slack chains mean rail or carriage hang-up. Raise the forks before you move, or broken chains can result. WARNING Keep hands, feet and legs out of the upright. WARNING Don’t use the upright as a ladder. CAUTION Never try to repair the upright, car- riage,…
Page 36: Pallets And Skids

Pallets and Skids WARNING Do not move or store materials on damaged pallets or skids. Items can fall through them causing severe injury or death! Be sure the pallet or skid you are using is in good condition and does not have defective or missing components and fasteners.
Page 37: Section 3. Common Truck

Section 3. Common Truck Common Truck Contents Truck Description ……….3-2 Operator Controls ……….3-3 Contents…
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5. Steer Axle, Wheels/Tires 6. Upright and Carriage 7. Load Backrest 8. Forks 9. Drive Axle, Wheels/Tires The truck shown above is a typical representation of a Clark electric sit down rider lift truck. Your model may vary slightly. Truck Description…
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Section 3. Common Truck Operator Controls Key/Start Switch • Connects the battery with all truck operating systems (drive, lift, and steer electrical circuits) except the horn. • Connects battery to the diagnostic display hourmeter and bat- tery charge status. The key switch must always be turned to the ON position to operate the truck.
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Parking Brake The parking brake pedal or lever (depending on your model) mechanically operates the parking brake. Parking Brake Pedal To apply the parking brake, push the Parking Brake Release pedal down with your left foot until pedal stops. The parking brake release is located just above the brake pedal as shown.
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Section 3. Common Truck Steering System steering handwheel operates steering control valve that directs the oil flow to the steering cylinder connected to the steer axle. The steering control valve can also act as a pump to provide manual steering if the hydraulic pump stops. Horn Button The horn button is located in the center hub of the steering handwheel.
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IMPORTANT Tilt The hydraulic levers shown are typical representations CLARK lift truck. Your model may vary slightly. Lift Control Function With the lift control lever, you are able to raise and lower the fork carriage on the upright. The lifting and lowering…
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CAUTION When attachments are added or if the truck is modified, the capacity of the truck may be affected. Contact your authorized CLARK dealer for a new nameplate showing the revised capacity. IMPORTANT OSHA requires prior written approval from the manufac- turer before any modifications affecting capacity or safety may be made.
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Operator Safety Warning Decal WARNING Read the manual Buckle up! Apply brake when leaving truck Watch Out For Other People Most lift truck 8009529 INJURIES are to other people near the lift truck. IMPORTANT Safety and warning decals are placed in conspicuous Prevent Overturns! locations on the truck to remind you of essential pro-…
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Section 3. Common Truck Upright Warning Decal This safety decal is on the upright to warn of the danger of injury from movement between rails, chains, sheaves, fork carriage, and other parts of the upright assembly. Do not climb on or reach into the upright.
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3-10…
Page 47: Section 4. Operator Compartment And Controls

Section 4. Operator Compartment and Controls Operator Compartment and Controls Contents GEX40-50 Operator Compartment …….. 4-2 Contents…
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GEX40-50 Operator Compartment 1. Steering Handwheel 2. Horn Button 3. Turn Signal Lever 4. Key Switch 5. Brake Pedal 6. Dash Display 7. Accelerator 8. Lift Control Lever 9. Tilt Control Lever 10. Auxiliary Control Lever 11. Forward/reverse lever 12. Parking brake release 13.
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Section 4. Operator Compartment and Controls GEX40-50 Dash Display The primary design of the Dash Display is to provide the operator with an easily understandable, visual feedback of the status of the truck and it’s system components. 08/01/12[WED] 1. Battery State of Charge 8.
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Seat Belt: At start up this symbol displays along with an audio alarm for 4 seconds. This display reminds you to fasten your seat belt. Parking Brake: The symbol is displayed when the parking brake is applied. Release parking brake to operate truck. Alarm Code: This symbol will be displayed anytime the inputs to the controls are missing, incorrect or anytime the controls sense a fault in the circuits or in the controls…
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Section 4. Operator Compartment and Controls Mode Selection Button 6 mode selection buttons are located on right side of LCD. Each button has specific function, and some have multiple functions. Down arrow button (Mode button): Pressing this button in normal operating condition will move to Menu mode. This button is used for programming and should be used by a trained technician only.
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Right arrow button (Power mode selection button): In normal operating condition, will change Power mode. −Power mode is composed of 3 steps and can be selected by pressing this Power Mode button. Economy: • Is Slow speed mode to save the battery consumption by minimizing the acceleration function.
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Section 5. Operating Procedures Operating Procedures Contents Before Operating the Truck ……… 5-2 Starting from a Safe Condition ……5-3 Contents…
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Section 5. Operating Procedures Before Operating the Truck sure that have read understand information this Operator’s Manual before operating the lift truck. The Operator’s Manual Holder is located on the back of the seat. WARNING • This equipment can be dangerous if not used properly. Safe operation is the responsibility of the operator.
Page 55: Section 5. Operatoring Procedures

Section 5. Operating Procedures Starting from a Safe Condition Always start from a safe condition. Before operating a lift truck, make sure that: 1. Parking brake is applied. 2. Forks are fully lowered to the floor or ground. 3. You are familiar with how all the controls function and have read the Operator Manual.
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Section 5. Operating Procedures Adjusting the Seat Adjust the seat to a comfortable position for you. Adjust the seat moving holding Back declining release lever at the front under of Adjustment seat. Put the seat in a position that will provide easy reach to all controls.
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Section 5. Operating Procedures Starting the Truck Before you start the truck, make sure that you have taken all the above-mentioned precautions and that the directional control is in NEUTRAL. To start the truck, turn the key switch clockwise to the ON position.
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Section 5. Operating Procedures Diagnostic Display Code Condition Likely Corrective Action -001 Seat switch open Sit on seat -061, -065 ,-140, Overheat of motor and Restart after cooling down -203, -207 controller Replace with charged bat- -066, -208 Low battery voltage tery Before starting, place the Forward/Reverse lever to…
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Section 5. Operating Procedures Positioning Forks and Upright When driving, with or without a load, it is good practice to have the forks slightly raised and tilt the upright (forks) backward. Having the forks raised and tilting back prevents the fork tips from catching on possible obstructions and reduces the wear on the fork blades from striking or dragging on the floor or…
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Section 5. Operating Procedures Mini lever (Option) 1) Forward and Reverse switch Switch for shifting between forward and reverse. − Forward….. Push forward − Reverse….. Push backward The speed of forward and backward traveling can be adjusted by pressing the accelerator pedal. NOTICE •…
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Section 5. Operating Procedures 3) Tilt lever Tilt the mast forward and backward. − Forward….. Push forward − Backword..Pull backward Forward or backward tilting speed can be adjusted by the extent of operating the lever. NOTICE • After the system has been activated, return the accelera- tor pedal and all of the levers to their neutral positions and return to the seat before recommencing operations.
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Section 5. Operating Procedures ATTENTION Attachments not supplied with the truck may only be employed if an authorized distributor ascertains that a safe operation is assured in respect to load capacity and stability. Controlling Speed With the direction control in FORWARD or REVERSE, the parking brake released, put your foot on the accelerator pedal and push down smoothly until the truck is moving at the desired speed.
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Section 5. Operating Procedures Operating Safely IMPORTANT Safe operation is the responsibility of the operator. Watch where you are going. Don’t go if you can’t see. Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.
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Section 5. Operating Procedures Keep all other persons clear of the load and upright mechanism while attempting to handle a load. No riders… Do not carry passengers. The operator is the only one who should be on the truck. Always be in full control of your lift truck… Never operate a lift truck or its attachments if you are not in the designated operator’s position.
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Section 5. Operating Procedures Grades, ramps, and inclines… Use special care when operating on ramps, inclines, and uneven areas. Travel slowly. Travel straight up and down. Do not turn or drive at an angle across an incline or ramp. When the truck is loaded, travel with the load upgrade. When the truck is empty, travel with lifting mechanism (upright) downgrade.
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Section 5. Operating Procedures CAUTION Operate your lift truck only in areas that have been approved for your lift truck type designation. Certain areas contain flammable gases, liquids, dust, fibers, or other hazardous materials. Lift truck operations in these areas must have special approval. These areas must be designated to show the type of lift truck approval required for operation in the area.
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Section 5. Operating Procedures Load Handling Handle only loads that are within the truck rated capacity as shown on the nameplate. This rating specifies the maximum load that should be lifted. However, other factors such as special load handling attachments, loads having a high center of gravity, or uneven terrain may dictate that the safe working load be less than the rated capacity.
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Section 5. Operating Procedures The capacity load shown on the nameplate is represented by a cube in which the weight is evenly distributed, with the center of gravity located a standard distance from the face of the forks. If the weight of the actual load to be handled is not evenly distributed, put the heaviest part closest to the carriage.
Page 69
Section 5. Operating Procedures Picking Up and Moving Loads When picking up a load from the ground, approach the load slowly and carefully align the truck square with the load. The forks should be adjusted to fit the load or pallet being handled and spread as wide as possible to provide good stability and balance.
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Section 5. Operating Procedures Stacking To put a load on a stack: 1. Approach slowly and align the lift truck and load squarely with the stack. 2. Raise (elevate) the load as the lift truck is nearing the stack. 3. Move forward, slowly, until the load is almost touching the stack.
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Section 5. Operating Procedures Lower (drop) the forks slightly to clear (disengage) the load pallet. Tilt the forks forward sli ghtly, if nece ssary. Check your travel path, then carefully back away until the forks are clear of the stack. Stop and lower the forks to the travel position (6 to 8 inches above the ground), then tilt back to travel.
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Section 5. Operating Procedures After Operating the Truck Always leave your lift truck in a safe condition. When you leave your truck, or park it, follow these safety rules: • Park in a safe area away from normal traffic. • Never park on a grade. •…
Page 73: Section 6. Operator Maintenance And Care

Section 6. Operator Maintenance and Care Operator Maintenance and Care Contents Inspecting Your Truck ……….. 6-2 Visual Checks …………6-3 Functional Checks ……….6-4 Concluding the Inspection ……..6-5 NOTICE The Occupational Safety and Health Act (OSHA) requires that truck users examine their trucks before each shift to be sure they are in safe working order.
Page 74: Inspecting Your Truck

In general, the daily inspection should include the visual and functional checks described on the following pages. As an aid in carrying out this inspection, CLARK has prepared a form called the «Driver’s Daily Checklist.» We recommend that you use this form to make a daily record of your inspections and truck condition.
Page 75: Visual Checks

Section 6. Operator Maintenance and Care Visual Checks First, perform a visual in- spection of the truck and its major components: 1. Walk around your lift truck and take note of obvious damage that may have been caused by operation during the last shift.
Page 76: Functional Checks

Functional Checks Check the operation of the truck as follows: NOTICE Before performing these checks, familiarize yourself with the operating procedures. Be sure there is enough over- head clearance to fully raise the upright. 1. With key switch off, be sure all controls and systems operate freely and return to neutral properly.
Page 77: Concluding The Inspection

Section 6. Operator Maintenance and Care Concluding the Inspection Make a record on the “Driver’s Daily Checklist” of all the operating and truck problems that you find. Review the checklist to be sure it has been completed and turn it in to the person responsible for lift truck mainte-nance.
Page 79: Section 7. Emergency Towing

Section 7. Emergency Towing Emergency Towing Contents Towing Precautions ……….7-2 Towing Procedures ……….7-3 Contents…
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Towing Precautions If your lift truck becomes disabled but can be moved freely on its own wheels without further damage, use the following procedures to tow it safely to a repair area. IMPORTANT It is important for your safety and to the care of your lift truck to use the proper equipment and carefully follow these recommendations for safe towing.
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(This bolt is made of a special high tensile steel and is not commercially available. Replace it, when necessary, only with a genuine Clark replacement part). 5. Use an approved, solid metal tow bar with towing couplers that connect to the towing pins in the counterweight or that connect to the frame or chassis through the counterweight of each truck.
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8. Park the disabled truck in authorized areas only. Fully lower the forks to the floor, put directional control lever in the NEUTRAL position and turn the key switch to the OFF position. Engage the parking brake. Remove the key and, when necessary, block the wheels to prevent the truck from rolling.
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Section 8. Planned Maintenance Planned Maintenance Contents Lift truck Maintenance ……….8-2 Contents…
Page 84
In addition to the daily inspection, CLARK recommends that you set up and follow a periodic planned maintenance (PM) and inspection program. PM inspections should only be performed by a trained and authorized fork lift mechanic.
Page 85
Your local CLARK dealer is prepared to help you with your Planned Maintenance Program, if you want assistance. Your CLARK dealer has specially trained service personnel who are authorized to check your lift truck according to the applicable safety regulations.
Page 86
The maintenance time intervals referred to in this manual relate to truck operating hours as recorded by the diagnostic system (or hourmeter) and based on experience which CLARK has found to be convenient and suitable under typical (normal or average) operating…
Page 87: Section 8. Planned Maintenance

Section 8. Planned Maintenance Periodic Maintenance Checks PM Interval: A = 8-10 hours or daily B = 50-250 hours or every month C = 450-500 hours or every 3 months D = 900-1000 hours or every 6 months E = 2000 hours or every year PERIODIC CHECKS and A B C D E PLANNED MAINTENANCE (PM)
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Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please contact your local CLARK dealer. 1. Powered industrial trucks can become hazardous if mainte- nance is neglected. Therefore, suitable maintenance facilities, trained personnel, and procedures shall be provided.
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Section 8. Planned Maintenance 9. Before starting to drive the truck: a. Be seated in a safe operating position and fasten your seat belt. b. Make sure parking brake is applied. c. Put directional control in NEUTRAL. d. Turn the key switch to the ON position. e.
Page 90
Parts, including tires, are to be installed per the manufacturer’s procedures. Always use genuine CLARK or CLARK-approved parts. 21. Use special care when removing heavy components from the truck, such as counterweight, upright, etc., the truck can become…
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Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20210. IMPORTANT Your new CLARK lift truck has been built to meet all appli- cable mandatory requirements of ANSI/ITSDF B56.1 Safety Standard for Powered Industrial Trucks. Each truck also includes certain safety devices, e.g., horn and over- head guard, safety restraint system, seat belt as standard equipment.
Page 92
CLARK prepared an Electric Truck Planned Maintenance Report Form (PM Report Form). Copies of this form may be obtained from your authorized CLARK dealer. We recommend that you use this form as a checklist and a record of your inspection and truck condition.
Page 93
Section 8. Planned Maintenance Visual Inspection Begin the PM routine with a visual inspection of the lift truck and its components. 1. Walk around the truck and take note of any obvious damage and maintenance problems. Check for loose fasteners and fittings. 2.
Page 94
Check for any loose parts or fittings. Check for leaks, any damaged or loose rollers, and rail wear (metal flaking). Inspect all lift line hydraulic connections for leaks Load Backrest Check load backrest damage. Inspect the welds on the carriage and load backrest for cracks.
Page 95
The lift chains operate under heavy load- ings and function more safely and have longer life if they are regularly and correctly lubricated. CLARK chain lubricant is recommended; it is easily sprayed on and provides superior lubrication. Heavy motor oil may also be used as a lubricant and corrosion inhibitor.
Page 96
WARNING Uprights and lift chains require special attention to main- tain them in safe operating condition. • Uprights can drop suddenly. Look at the upright, but keep hands out. • Lift chain repairs and adjustments should be made by trained service personnel. Forks Inspect the load forks for cracks, breaks, bending and wear.
Page 97
Section 8. Planned Maintenance Wheels and Tires Check the condition of the drive and steer wheels and tires. Remove objects that are embedded in the tire. Inspect the tires for excessive wear and breaks or «chunking out» and bond failure between the tire and the rim. Check all wheel lug nuts or bolts to be sure none are loose or missing.
Page 98
Service and Parking Brakes Operate service and parking brakes; all hydraulic controls—lift, tilt, and auxiliary (if installed); accelerator; directional controls; and steering system. Be sure all controls operate freely and return to neutral properly. Check the service brake system. Push the brake pedal fully down and hold.
Page 99
Section 8. Planned Maintenance Lift Mechanisms and Controls Check the function of the lift system and controls. Pull back on the tilt control lever and hold until the upright reaches the full back tilt position. Push forward on the lever to return the upright to the vertical position.
Page 100
Steering System NOTICE The steering system, steer axle, and steering linkage on your truck should be inspected periodically for abnormal looseness and damage, leaking seals, etc.. Also, be alert for any changes in steering action. Hard steering, exces- sive freeplay (looseness), or unusual sound when turning or maneuvering indicates a need for inspection or servic- ing.
Page 101
Section 8. Planned Maintenance Transistorized Traction Control Test for correct function of the traction control. Check creep speed, high speed, and plugging. CAUTION Check and make sure the travel area is clear before each movement and before each change of direction. 1.
Page 102
Checking the Hydraulic Fluid Check the hydraulic sump tank fluid level. Correct fluid level is important for proper system operation. Low fluid level can cause pump damage. Hydraulic fluid expands as its temperature rises. Therefore, it is preferable to check the fluid level at operating temperature (after approximately 30 minutes of truck operation).
Page 103
Section 8. Planned Maintenance Air Cleaning the Truck Always maintain a lift truck in a clean condition. Do not allow dirt, dust, lint, or other contaminants to accumulate on the truck. Keep the truck free from leaking oil and grease. Wipe up all oil spills. Keep the controls and floorboards clean, dry, and safe.
Page 104
Electric Truck Battery Maintenance BATTERY BATTERY SERVICE SERVICE AREA AREA SMOKING SMOKING Battery charging installations must be located in areas designated for that purpose. These areas must be kept free of all non-essential combustible materials. Facilities must be provided for: •…
Page 105
Section 8. Planned Maintenance Battery Handling 1. Change (remove) or service storage batteries only in an area designated for this purpose. 2. Be sure this area has provisions to flush and neutralize spillage, to ventilate fumes from gassing batteries, and for fire protection. 3.
Page 106
7. Keep all tools and other metallic objects away from the terminals. WARNING BATTERY SERVICE: Battery service must be done by trained and authorized personnel. Battery acid can cause severe burns and injury. Battery Charging 1. Persons maintaining storage batteries must wear protective clothing such as face shield, long sleeves, and gloves.
Page 107
Section 8. Planned Maintenance 3. When charging batteries, the vent caps must be kept in place to avoid electrolyte spray. Care must be taken to assure that vent caps are open (clean) and functioning. The battery (or compart- ment) cover(s) must be open to dissipate heat and gas. IMPORTANT If batteries discharge rapidly during normal operation or do not charge to the correct specifications, contact a…
Page 108
Refer to the battery manufacturer or supplier for their recommended battery maintenance and care procedures. BATTERY SAVER and CLEANER, CLARK Part No. 886398, may be used to clean and protect the truck battery. New Truck Batteries: Apply a light coat of BATTERY SAVER and CLEANER to entire surface of battery.
Page 109
Section 8. Planned Maintenance How to Get Maximum Battery Life 1. Follow normal battery maintenance procedures, re-charging before 80% discharged and with periodic equalizing charges. Let cool eight hours after charging before using. 2. Don’t add acid to a battery. Only a person trained and qualified to do battery maintenance should determine if this is necessary.
Page 110
Checking the traction and hydraulic cables • Check up the damage of cables and terminal at every sched- uled PM(250 hours) • During inspection, check the following cable condition − Terminal for loosing or corrosion − Insulation for hardening and cracking −…
Page 111: Section 9. Specifications

Section 9. Specifications Specifications Contents GEX40-50 …………..9-2 Contents…
Page 112
GEX 40-50 CLARK products and specification are subject to improvements and changes without notice or obligation. Model Designation — Rated Load Capacity GEX 40 4,000kg @ 500mm load center [8,000lbs @ 24in] GEX 45 4,500kg @ 500mm load center [9,000lbs @ 24in]…
Page 113
Fill Capacities—Fluid Volumes Drive Axle : each 1.4L ~ 1.6 L Hydraulic Sump Tank (Useable Volume) : — GEX 40~50 : MFH ~5000 : 22 L MFH 5001~ : 30 L Hydraulic Fluid Recommendation Normal application — CLARK Specification MS-68 Hydraulic oil (CLARK # 1802155).
Page 115: Index

Fastener Checks, Critical ..8-19 After Operating the Truck ..5-20 Forks ……..8-14 Air Cleaning the Truck ….. 8-21 Forks Positioning……5-10 A Message to CLARK Lift Fork Safety ……..1-8 Truck Operators ……ii Functional Checks……6-4 Auxiliary Control Lever Functional Tests …….8-15 (Optional) ……..
Page 116
Long and Wide Loads ….2-3 Seat Belt……..1-4 Loose Loads ……2-2 Service and Parking Brakes ..8-16 Low Overhead Clearance ..2-4 Service Brake ……3-5 Skids ……….2-8 Stacking ……..5-18 No Riders ……..1-5 Starting from a Safe Condition …5-3 Starting the Truck …….5-4 Steering System ……3-5 Operator Controls ……
Page 120
Additional copies of this manual may be purchased from YOUR AUTHORIZED CLARK DEALER CLARK MATERIAL HANDLING COMPANY 700 Enterprise Drive Lexington, Kentucky 40510 [ www.clarkmhc.com ] ● Printed Date ; Jun. 2019…

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Clark, which was founded in 1903, began its history as a manufacturer of spare parts for automobiles.

This continued until 1917, when the company invented the world’s first industrial loader, thereby setting the standard for a modern prototype.

Since then, for more than 80 years, the company has been a technological trendsetter in the global industry of lifting and transport equipment.

In 1917, the company designed the first tractor tractor in Buchanan, Michigan. A year after the debut, eight saw the lightl. By the way, in the same year the first Tructractor
was sent to France.

Thus, the beginning of the export was laid.

1921 was marked by the release of the model Trucklift, whose carrying capacity was from 2 to 5 tons. Using the success of its predecessor, a year later, a new model
Trucklift was released.

After 2 years, the Duat was introduced to the market: a three-wheeler capable of lifting a 750-kg load. In addition, Tructractor and Trucklift models are now
being produced at the company’s new plant in Battle Creek, Michigan.

In 1926, a new model was introduced: the Clark towing vehicle, capable of withstanding a weight of up to 1,200 kg. It became a
replacement for the Duat, which could carry only 700 kg. By the way, a year later the market was supplemented by a new towing tractor Clark.
It was used to tow planes and trailers.

1928 became famous for the release of Tructier, the world’s first forklift truck with an internal combustion engine.

10 years later, Carloader, the world’s first compact forklift, was released.

The year 1939 was marked by the development of Utilitruc, a new high-performance, high-reliability forklift truck that was used in the
engineering industry.

Despite the war, in 1942, the new models Electric Clipper, Carloader and Utilitrus were released, and in 1943 — the first forklift on the pneumatic
course Planeloader.

In the first post-war year, the Yardlift 40 was released. It became the first of a line of loaders with pneumatic tires. It could be
used both in open areas and indoors.

1948 became famous for the release of innovative Dynatork parts. It is an electromagnetic transmission device between an internal
combustion engine and a transmission. It replaced the dry clutch that was previously used in the design of forklifts. In addition, this year Clark
Equipment entered into a licensing agreement with Tutt-Bryant Limited in Sydney, Australia, and two years later with
the German Schultz-Stinnes of Essen.

By 1951, the Hydrolift and Electrolift forklift trucks entered the market
for the first time. Released later under the name Powrworker, the Electrolift loaders were electric battery-powered loaders.

1956 marked the development of a new line of forklifts Clarklift. It produced models with both pneumatic tires and tires with rubberized
rims, as well as models operating on either gasoline or electricity.

After 8 years, Clark was recognized as the first manufacturer of loaders, which produces absolutely all of its models with a closed cab
and driver’s seat back. Also, the production of loaders was organized at a plant in Canada.

Three years later, a new model TW15 / 20 was produced. She became the first electric three-wheel loader in the United States. This
easy-to-operate loader became immediately in demand in many areas: when working in warehouses, transporting goods, etc.

A new development was the release in 1968 of the C500 line — electric and gasoline trucks with tires of any kind.

In 1972, forklifts appeared that were equipped with a dual power system.

Two years later, the plant in Georgetown, Kentucky, began the production of strong, narrow-passage electric lift trucks.

1976 became famous for the release of the firm’s 500,000th creation. They became a four-wheel forklift C500-50 with an internal
combustion engine. It was donated to West Michigan University in 1977, where it is still in operation.

In 1981, the new comfortable ergonomic electric four-wheeled ECA17-30 and EPA
20-30 entered the market. At the same time, ECA evolved in 1987 into a model in ECS17-30, which, in turn, became a
model ECG20-32 in 1996.

Two years later, the company launched a program to improve work safety. A patent for this innovation was received by all manufacturers of forklift trucks absolutely free of charge.

1985 entered the history of the company with the release of the new GCS / GPS System series. The concept of this model range was that
the buyer himself could choose which engine, transmission and other details he wanted.

The year 1991 became important for the company, since Clark was the first manufacturing company to offer, at the request of the buyer,
the installation of an engine running on natural gas. This saved money and reduced harmful emissions.

In 1994, the market saw a four-wheel model range.

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INTERNAL COMBUSTION LIFT TRUCKS

GTS 20/25/30/33 D

GTS 20/25/30/33 L

[Do not remove this manual from the truck]

Part No. 8140267 (Eng)

Book No. OM 1064 (Rev 1.3)

Jan, 2019

Related Manuals for Clark GTS D Series

Summary of Contents for Clark GTS D Series

Page 1
INTERNAL COMBUSTION LIFT TRUCKS [Do not remove this manual from the truck] GTS 20/25/30/33 D GTS 20/25/30/33 L Part No. 8140267 (Eng) Book No. OM 1064 (Rev 1.3) Jan, 2019…
Page 3
Operator’s Manual You must be trained and authorized to operate a lift truck. YOU can prevent accidents First: Learn safe operating rules and your company rules. Next: Read your Operator’s Manual. If you do not understand it, ask your supervisor for help. Learn about the unit you operate.
Page 4
They require specific instructions and rules for safe operation and maintenance. Safe operation of lift trucks is of primary importance to CLARK. Our experience with lift truck accidents has shown that when accidents happen and people are killed or injured, the causes are: •…
Page 5
If you think you need training in operating or inspecting your lift truck, ask your supervisor. CLARK lift trucks are built to take hard work, but not abuse. They are built to be dependable, but they are only as safe and efficient as the operator and the persons responsible for maintaining them.
Page 7
Contents of this Manual A Message to CLARK Lift Truck Operators……. ii Introduction …………….. vi How to Use this Manual ………… viii Safety Signs and Safety Messages ……..x Section 1. General Safety Rules ……..1-1 Section 2. Operating Hazards ……….2-1 Section 3.
Page 8
CLARK lift truck in a safe and correct manner. Your CLARK lift truck has been designed and built to be as safe and efficient as today’s technology can make it. As manufactured, it meets all the applicable mandatory requirements of ANSI / ITSDF B56.1 Safety Standard for Powered Industrial Trucks.
Page 9
The procedures for a periodic planned maintenance program that covers inspections, operational checks, cleaning, lubrication, and minor adjustments are outlined in this manual. Your CLARK dealer is prepared to help you with a Planned Maintenance Program by trained service personnel who know your lift truck and can keep it operating safely and efficiently.
Page 10
NOTICE: The descriptions and specifications included in this manual were in effect at the time of printing. CLARK Material Handling Company reserves the right to make improvements and changes in specifications or design. Please check with your authorized CLARK dealer for information on possible updates or revisions.
Page 11
If the truck you operate is not equipped with a manual, ask your supervisor to obtain one and have it attached to the truck. And, remember, your CLARK dealer is pleased to answer any questions about the operation and maintenance of your lift truck and will provide you with additional information should you require it.
Page 12
Damage to the truck, death, or serious injury to you or other persons may result if these messages are not followed. If warning decals are damaged, they must be replaced. Contact your CLARK dealer for replacements. NOTICE This message is used when special information, instruc-…
Page 13: Table Of Contents

Section 1. General Safety Rules General Safety Rules Contents Contents …………….1-1 Daily Inspection ………….. 1-2 Do’s and Don’ts …………… 1-3 Seat Belts …………….. 1-4 No Riders …………….. 1-5 Pedestrians …………..1-6 Operator Protection …………1-7 Fork Safety …………..1-8 Pinch Points …………..
Page 14: Daily Inspection

Daily Inspection At the beginning of each shift, inspect your truck and fill out a daily inspection sheet. Check for damage and maintenance problems. Have repairs made before you operate the truck. CAUTION DO NOT MAKE REPAIRS YOURSELF. Lift truck mechanics are trained professionals.
Page 15: Do’s And Don’ts

Section 1. General Safety Rules Do’s and Don’ts Don’t mix drugs or alcohol with your job. Do watch for pedestrians. Don’t block safety or emergency equipment. Do wear safety equipment when required. Don’t smoke in «NO SMOKING» areas or when refueling. Don’t use the similar fuel.
Page 16: Seat Belts

Seat Belts ALWAYS BUCKLE UP Seat belts can reduce injuries. Seat Belts…
Page 17: No Riders

Section 1. General Safety Rules No Riders The operator is the only one who should be on a truck. Never transport personnel on the forks of a lift truck. No Riders…
Page 18: Pedestrians

Pedestrians Watch where you are going. Look in the direction of travel. Pedestrians may use the same roadway you do. Sound your horn at all intersections or blind spots. Watch for people in your work area even if your truck has warning lights or alarms.
Page 19: Operator Protection

Section 1. General Safety Rules Operator Protection Keep under the overhead guard. Always keep your body within the confines of the truck. Operator Protection…
Page 20: Fork Safety

Fork Safety Never allow anyone to walk under raised forks. DANGER There is special equipment to raise 2372604 people for overhead work. DO NOT USE LIFT TRUCKS. Fork Safety…
Page 21: Pinch Points

Section 1. General Safety Rules Pinch Points WARNING Keep hands, feet and legs out of the upright. WARNING Don’t use the upright as a ladder. CAUTION Never try to repair the upright, carriage, chain, or attachment yourself! Always trained mechanic. Pinch Points…
Page 22: Travel

Travel Travel with the load near the floor/ground with upright tilted back cradle load whenever possible. Never lift or lower the load when the truck is in motion. When handling bulky loads that restrict your vision operate your truck in reverse to improve visibility.
Page 23: Grades, Ramps, Slopes, And Lnclines

Section 1. General Safety Rules Grades, Ramps, Slopes, and lnclines Unloaded Forks Downgrade WARNING Never turn on a grade, either loaded or unloaded. Loaded Forks Upgrade Grades, Ramps, Slopes, and lnclines 1-11…
Page 24: Surface And Capacity

Surface and Capacity SAND GRAVEL WEAK FLOORS Avoid these conditions. They can cause a truck to tip over or lose traction for braking or driving. WARNING Know the weight of your truck and load. Especially when using elevators. Know the capacity of the elevator you intend to use.
Page 25: Tip-Over

Section 1. General Safety Rules Tip-Over Lateral Tip-over • Lateral tip-over can occur with a com- bination of speed and sharpness of turn. This combination will exceed the stability of the truck. This condition is even more likely with an unloaded truck.
Page 26: What To Do In Case Of A Tip-Over

What to do in Case of a Tip-over If your truck starts to tip over, WARNING DO NOT JUMP!!! IMPORTANT Your chances for survival in a tip-over are better if you stay with the truck, in your seat. Brace yourself as illustrated below! 1.
Page 27: Parking

Section 1. General Safety Rules Parking • Never park on a grade. • Always come to a complete stop before leaving truck. • Be sure travel control is in NEUTRAL. • Lower forks fully to floor and tilt forward. • Set parking brake. •…
Page 28: General Tire Maintenance, Inspection, And Repair

General Tire Maintenance, Inspection, and Repair 1. Park the truck as described on page 1-15 and check for correct tire inflation air pressure. See specifications in this OM for cor- rect tire pressure for your truck. CAUTION Check tire pressure from a position facing the tread of the tire, not the side.
Page 29: Carbon Monoxide And Fumes

Section 1. General Safety Rules Carbon monoxide and fumes Be sure your employees understand that they must not use an internal combustion engine in a closed area such as a cold storage locker. Carbon monoxide is a colorless, odorless, poisonous gas which can overcome your employees without warning.
Page 31
Section 2. Operating Hazards Operating Hazards Contents Loose Loads …………..2-2 Long and Wide Loads / Rear Swing ……. 2-3 Low Overhead Clearance Fast Turns and High Loads ………. 2-4 Drop-Offs …………….2-5 Right-Angle Stacking …………2-6 Chain Slack …………… 2-7 Pallets and Skids ………….
Page 32: Loose Loads

Loose Loads Loose or unbalanced loads dangerous. Observe these precautions. Never carry loose or uneven material. Center wide loads. Stack and band loose material. Loose Loads…
Page 33: Long And Wide Loads / Rear Swing

Section 2. Operating Hazards Long and Wide Loads / Rear Swing WARNING With long or wide loads, you need more room. So slow down and watch your clearance. A long load reduces the capacity of the truck. Know and understand your truck load rating. When extra-long material makes it necessary to travel with the load elevated, do so with extreme care and be alert to load end- swing when turning.
Page 34: Low Overhead Clearance Fast Turns And High Loads

Low Overhead Clearance Fast Turns and High Loads WARNING Know the height of your truck, with and without a load. Check your clearances. Keep the load low and tilted back. WARNING Watch overhead clearance: Moving into overhead structures can tip a truck over, or spill a load. WARNING Slow down before turning.
Page 35: Drop-Offs

Section 2. Operating Hazards Drop-Offs WARNING To avoid these hazards, you must: • Talk to the truck driver yourself; make sure the driver does not move the trailer until you are done! • Apply trailer brakes. • Use wheel chocks. •…
Page 36: Right-Angle Stacking

Right-Angle Stacking SLOWLY When right-angle stacking or moving with a raised load to clear low objects, avoid sharp turns and move slowly. Right-Angle Stacking…
Page 37: Chain Slack

Section 2. Operating Hazards Chain Slack WARNING Slack chains mean rail or carriage hang-up. Raise the forks before you move, or broken chains can result. Chain Slack…
Page 38: Pallets And Skids

Pallets and Skids WARNING Do not move or store materials on damaged pallets or skids. Items can fall through them causing severe injury or death! Be sure the pallet or skid you are using is in good condition and does not have defective or missing components and fasteners.
Page 39
Section 3. Operator Compartment and Controls Operator Compartment and Controls Contents Truck Description ……….3-2 Operator Compartment ……… 3-3 Instrument Pod …………3-4 Pod Symbols and Functions ……… 3-5 Operator Controls ……….3-11 Contents…
Page 40: Truck Description

5. Steer Axle, Wheels / Tires 6. Upright and Carriage 7. Load Backrest 8. Forks 9. Drive Axle, Wheels / Tires The truck shown above is a typical representation of a CLARK internal combustion lift truck. Your model may vary slightly. Truck Description…
Page 41: Operator Compartment

Section 3. Operator Compartment and Controls Operator Compartment 1. Steering Handwheel 8. Turn Signal Lever 2. Forward/Reverse Lever 9. Accelerator Pedal 3. Inching Pedal 10. Key Switch 4. Brake Pedal 11. Lift Control Lever 5. Seat Adjustment Lever 12. Tilt Control Lever 6.
Page 42: Instrument Pod

Instrument Pod 1. Coolant Temperature Gauge 2. Fuel Gauge 3. Transmission Oil Temperature 4. Engine Oil Pressure 5. Engine check 6. Alternator Charging Status 7. Service Icon 8. Turn Signal 9. Hour Meter 10. Glow Plug Preheat 11. Seat Belt 12.
Page 43: Pod Symbols And Functions

IMPORTANT For safety reasons, every CLARK forklift truck is fitted with a neutral start switch. The purpose of this is to pre- vent the engine from being started while the transmission is in gear.
Page 44
5. Gauges and indicators • Coolant temperature gauge • Fuel gauge It displays the remaining fuel level in fuel tank. • Transmission oil temperature Indicates that Transmission temperature is excessive. If the light is on, shut down the truck and service it. The truck will go into shut down mode after the light flashes for 30 seconds.
Page 45
Section 3. Operator Compartment and Controls • Fuel warning lamp This symbol displays when the LPG fuel empty. • Engine check When the engine has problem, this LED will be on. • Alternator charging status Indicates that the alternator is not properly charging the battery.
Page 46
• Glow plug Preheat (Diesel truck) Indicates glow plugs are in the process of preheating the diesel engine. When the ignition switch is turned to the “ON” position, a timer is set. This symbol displays until the timer cycle is completed. The engine may then be started.
Page 47
1 . 0 1 0 . 0 k m / h 0.5km/h or more Less than 0.5km/h ※ Refer to the service manual or contact the CLARK dealer for how to setting the speed limit value. Pod Symbols and Functions…
Page 48
• Weight measurement error range : ±100kg 1 . 0 1 0 0 k g 0 . 5 k m ※ Refer to the service manual or contact the CLARK dealer for how to setting the weight measurement. 3-10 Pod Symbols and Functions…
Page 49: Operator Controls

Section 3. Operator Compartment and Controls Operator Controls Key/Start Switch The Key/Start Switch: • Turns the truck electrical system on and off. • Connects and tests the warning indicator lights. • Connects the starter motor circuit when engine is to be started.
Page 50
Engine Stop Run the engine at idling speed briefly before shutting it off. Turn the key switch to the «OFF» position to shut the engine down. Seat Adjustment The fore and aft adjustment lever is located on the front under the seat. To unlock, pull Back the lever to the left and adjust the seat, declining…
Page 51
Section 3. Operator Compartment and Controls Steering System The steering handwheel operates a steering control valve that directs the oil flow to the steering cylinder connected to the steer axle. The steering control valve can also act as a pump to provide manual steering if the hydraulic pump stops.
Page 52
Auxiliary IMPORTANT The hydraulic levers shown are typical representations of a CLARK internal combustion lift truck. Your model may vary slightly. Lift Control Function With the lift control lever, you are able to raise and lower the fork carriage on the upright. The…
Page 53
IMPORTANT For safety reasons, your CLARK forklift truck is fitted with a neutral start switch. The purpose of this is to prevent the engine from being started while the transmission is in gear.
Page 54
CAUTION When attachments are added or if the truck is modified, the capacity of the truck may be affected. Contact your authorized CLARK dealer for a new nameplate showing the revised capacity. IMPORTANT OSHA requires prior written approval from the manufac- turer before any modifications affecting capacity or safety may be made.
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Section 3. Operator Compartment and Controls Operator Safety Warning Decal WARNING Read the manual Buckle up! Apply brake when leaving truck Watch Out For Other People Most lift truck INJURIES are to other people near the lift truck. IMPORTANT Prevent Safety and warning decals are placed in conspicuous Overturns! locations on the truck to remind you of essential…
Page 56
Upright Warning Decal This safety decal is on the upright to warn of the danger of injury from movement between rails, chains, sheaves, fork carriage, and other parts of the upright assembly. Do not climb on or reach into the upright. Personal injury will result if any part of your body is put between moving parts of the upright.
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Attached position of safety decals CAUTION Do not operate a lift truck with damaged or missing decals or data plates. Replace them immediately. They contain important information. Contact your local CLARK dealer to acquire new decals or data plates. VIEW A VIEW B…
Page 58
CAUTION Do not operate a lift truck with damaged or missing decals or data plates. Replace them immediately. They contain important information. Contact your local CLARK dealer to acquire new decals or data plates. LPG FUEL CYLINDER REPLACEMENT PROCEDURE ———————————————————————— .—————————————————…
Page 59
Section 4. Operating Procedures Operating Procedures Contents Before Operating the Truck ……..4-2 Starting from a Safe Condition ……4-3 Contents…
Page 60
Before Operating the Truck Be sure that you have read and understand the information in this Operator’s Manual before operating the lift truck. The Operator’s Manual Holder is located on the back of the seat. WARNING • This equipment can be dangerous if not used properly. Safe operation is the responsibility of the operator.
Page 61
Section 4. Operating Procedures Starting from a Safe Condition Always start from a safe condition. Before operating a lift truck, make sure that: 1. Parking brake is applied. 2. Forks are fully lowered to the floor or ground. 3. You are familiar with how all the controls function and have read the Operator Manual.
Page 62
Adjusting the Seat Adjust the seat to a comfortable position for you. Adjust the seat by moving and holding the release lever at the front under of Back declining seat. Put the seat in a adjustment position that will provide easy reach to all controls.
Page 63
Section 4. Operating Procedures Positioning Forks and Upright When driving, with or without a load, it is good practice to have the forks slightly Lift Control raised and tilt the upright (forks) backward. Lever Having the forks raised and tilting back prevents the fork tips from catching on possible obstructions and reduces the wear on the fork blades from striking or…
Page 64
Controlling Speed With the direction control in FORWARD or REVERSE, the parking brake released, put your foot on the accelerator pedal and push down smoothly until the truck is moving at the desired speed. Braking To stop the truck, lift your foot from the accelerator pedal and put it on the brake pedal.
Page 65
Section 4. Operating Procedures Operating Safely IMPORTANT Safe operation is the responsibility of the operator. Watch where you are going. Don’t go if you can’t see. Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.
Page 66
Keep all other persons clear of the load and upright mechanism while attempting to handle a load. No riders… Do not carry passengers. The operator is the only one who should be on the truck. Always be in full control of your lift truck… Never operate a lift truck or its attachments if you are not in the designated operator’s position.
Page 67
Section 4. Operating Procedures Grades, ramps, and inclines… Use special care when operating on ramps, inclines, and uneven areas. Travel slowly. Travel straight up and down. Do not turn or drive at an angle across an incline or ramp. When the truck is loaded, travel with the load upgrade. When the truck is empty, travel with lifting mechanism (upright) downgrade.
Page 68
CAUTION Operate your lift truck only in areas that have been approved for your lift truck type designation. Certain areas contain flammable gases, liquids, dust, fibers, or other hazardous materials. Lift truck operations in these areas must have special approval. These areas must be designated to show the type of lift truck approval required for operation in the area.
Page 69
Section 4. Operating Procedures Load Handling Handle only loads that are within the truck rated capacity as shown on the nameplate. This rating specifies the maximum load that should be lifted. However, other factors such as special load handling attachments, loads having a high center of gravity, or uneven terrain may dictate that the safe working load be less than the rated capacity.
Page 70
The capacity load shown on the nameplate is represented by a cube in which the weight is evenly distributed, with the center of gravity located a standard distance from the face of the forks. If the weight of the actual load to be handled is not evenly distributed, put the heaviest part closest to the carriage.
Page 71
Section 4. Operating Procedures Picking Up and Moving Loads When picking up a load from the ground, approach the load slowly and carefully align the truck square with the load. The forks should be adjusted to fit the load or pallet being handled and spread as wide as possible to provide good stability and balance.
Page 72
Stacking To put a load on a stack: 1. Approach slowly and align the lift truck and load squarely with the stack. 2. Raise (elevate) the load as the lift truck is nearing the stack. 3. Move forward, slowly, until the load is almost touching the stack.
Page 73
Section 4. Operating Procedures 6. Lower (drop) the forks slightly to clear (disengage) the load pallet. Tilt the forks forward slightly, if necessary. 7. Check your travel path, then carefully back away until the forks are clear of the stack. Stop and lower the forks to the travel position (6 to 8 inches above the ground), then tilt back to travel.
Page 74
After Operating the Truck Always leave your lift truck in a safe condition. When you leave your truck, or park it, follow these safety rules: • Park in a safe area away from normal traffic. • Never park on a grade. •…
Page 75
Section 5. Operator Maintenance and Care Operator Maintenance and Care Contents Daily Safety Inspection ………. 5-2 Fuel Safety Practices ……….5-5 Refueling LPG Tanks ……….5-6 NOTICE The Occupational Safety and Health Act (OSHA) requires that truck users examine their trucks before each shift to be sure they are in safe working order.
Page 76
In general, the daily inspection should include the visual and functional checks described on the following pages. As an aid in carrying out this inspection, CLARK has prepared a form called the «Driver’s Daily Checklist.» We recommend that you use this form to make a daily record of your inspections and truck condition.
Page 77
Section 5. Operator Maintenance and Care Visual Checks First, perform a visual inspection of the truck and its major components: 1. Walk around your lift truck and take note of obvious damage that may have been caused by operation during the last shift. 2.
Page 78
Functional Checks Check the operation of the truck as follows. NOTICE Before performing these checks, familiarize yourself with the starting, operating, and shutdown procedures in Sec- tion 4 of this manual. Also, know the safety rules given in Section 1 of this manual. 1.
Page 79
Section 5. Operator Maintenance and Care Fuel Safety Practices Refueling Gasoline and Diesel Trucks Use clean, properly marked fuel cans. Clean up spills. Fuel Safety Practices…
Page 80
Refueling LPG Tanks When changing liquefied petroleum gas (LPG), tanks follow these basic rules: • Change only in well ventilated areas. • Never allow open flames. • Turn the ignition switch to the OFF position. • Check for leaks. • Check condition of the O-ring. •…
Page 81
Section 5. Operator Maintenance and Care RECOMMENDED SAFETY MAINTENANCE PROCEDURES FOR LPG FUELED LIFT TRUCKS WARNING LPG is a combustible fuel that is heavier than air. Escaping gas may accumulate in low areas. The fuel cylinder should be mounted so that it does not extend outside the truck and should also be properly positioned by using the locating pin or key way.
Page 83
Section 6. Emergency Starting and Towing Emergency Starting and Towing Contents How to Tow a Disabled Truck ……. 6-2 How to Use Battery Jumper Cables ….. 6-4 Contents…
Page 84
(This bolt is made of a special high-tensile steel and is not commercially available. Replace it, when necessary, only with a genuine CLARK replacement part). 5. Use an approved, solid metal tow bar with towing couplers that connect to the towing pins in the counterweights.
Page 85
Section 6. Emergency Starting and Towing CAUTION The power steering and brakes will not operate on the disabled truck when the engine is not running. Manual operation of the handwheel and brakes will be difficult to operate. More manual effort will be required to perform these functions.
Page 86
How to Use Battery Jumper Cables CAUTION If the fork lift truck is laid off for more than 1 month, the (-) cable of battery should be disconnected. Otherwise, the starting of engine will be impossible due to discharge of battery.
Page 87
Section 6. Emergency Starting and Towing WARNING BATTERIES EMIT EXPLOSIVE GAS. Do not smoke or have open flames or sparks in battery charging areas or near batteries. An explosion can result and cause injury or death. Hydrogen gas is produced during normal battery operation.
Page 88
4. Connect the jumper cables in the following sequence: a. Connect a jumper cable from the positive (+; red) terminal on one battery to the positive (+; red) terminal on the other bat- tery. Never connect positive (+; red) to negative (-; black), or negative to positive.
Page 89
Section 7. Planned Maintenance and Lubrication Planned Maintenance and Lubrication Contents Introduction …………7-2 Safe Maintenance Practices ……..7-3 Major Component Locations …….. 7-8 Planned Maintenance Intervals ……7-9 PM Report Form ……….. 7-12 How to Perform Planned Maintenance ….7-14 NOTICE THIS SECTION IS FOR TRAINED SERVICE PERSONNEL to use as a reference for Planned Maintenance proce-…
Page 90: Introduction

In addition to the operator’s daily inspection, CLARK recommends that the owner set up and follow a periodic planned maintenance (PM) and inspection program. Performed on a regular basis by trained personnel, the program provides thorough inspections and checks of the safe operating condition of the lift truck.
Page 91: Safe Maintenance Practices

Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please contact your local CLARK dealer. 1. Powered industrial trucks can become hazardous if mainte- nance is neglected. Therefore, suitable maintenance facilities and trained personnel and procedures shall be provided.
Page 92
CAUTION CAUTION Refer to the “Jacking and Blocking” section in the Service Manual for proper procedures. 9. Operation of the truck to check performance must be conducted in an authorized, safe, clear area. 10. Before starting to operate the truck: a.
Page 93
Section 7. Planned Maintenance and Lubrication 14. Fuel systems must be checked for leaks and condition of parts. Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected.
Page 94
Be sure that lifting and handling equipment is of the correct capacity and in good condition. IMPORTANT Your new CLARK lift truck has been built to meet all appli- cable mandatory requirements of ANSI / ITSDF B56.1 Safety Standard for Powered Industrial Trucks. Each truck also includes certain safety devices—such as horn, over-…
Page 95
Section 7. Planned Maintenance and Lubrication NOTICE You should be familiar with additional operating and maintenance safety instructions contained in the follow- ing publications: ANSI / ITSDF B56.1: Safety Standard for Low Lift and High Lift Trucks (Safety Code For Powered Industrial Trucks). NFPA 505:Fire Safety Standard for Powered Industrial Trucks: Type Designations, Areas of Use, Maintenance and Operation.
Page 96: Major Component Locations

5. Engine 12. Sheet Metal 6. Transmission 13. Upright and Carriage 7. Wheels and Tires 14. Drive axle The truck shown above is a typical representation of a CLARK internal combustion lift truck. Your model may vary slightly. Major Component Locations…
Page 97: Planned Maintenance Intervals

Section 7. Planned Maintenance and Lubrication Planned Maintenance Intervals Time intervals between maintenances are largely determined by operating conditions. For example, operation in sandy, dusty locations requires shorter maintenance intervals than operation in clean warehouses. The indicated intervals are intended for normal operation.
Page 98
The maintenance time intervals referred to in this manual relate to truck operating hours as recorded on the hourmeter, and are based on experience CLARK has found to be convenient and suitable under typical (normal or average) operating conditions. The periods…
Page 99
Section 7. Planned Maintenance and Lubrication NOTES: * Air filter change interval may be determined by using an air restriction indicator. ** Hydraulic filter change interval may be determined by hydraulic filter restriction indicator. B C D E Check truck for obvious damage and leaks. •…
Page 100: Pm Report Form

CLARK has prepared a Gas, LPG, or Diesel Planned Maintenance Report Form. Copies of this form may be obtained from your authorized CLARK dealer. We recommend that you use this form as a checklist and record of your inspection and truck condition.
Page 101
Section 7. Planned Maintenance and Lubrication PM Report Form 7-13…
Page 102: How To Perform Planned Maintenance

How to Perform Planned Maintenance Visual Inspection First, perform a visual inspection of the lift truck and its components. Walk around the truck and take note of any obvious damage or maintenance problems. Check to be sure all capacity, safety, and warning plates are attached and legible.
Page 103
Section 7. Planned Maintenance and Lubrication wear, rust, corrosion, cracked or broken links, stretching, etc. Check that the lift and carriage chains are correctly adjusted to have equal tension. Check that the lift chain anchor fasteners and locking means are in place and tight. Inspect all lift line hydraulic connections for leaks.
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If the fork blades are obviously bent or damaged, have them inspected by a trained maintenance person before operating the truck. Inspect the fork locking pins for cracks or damage. Reinsert them and note whether they fit properly. Wheels and Tires Check the condition of the drive and steer wheels and tires.
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Section 7. Planned Maintenance and Lubrication Disassembling the split rim wheel When you disassemble the split-rim wheel, NEVER remove the tire before you deflate the tire pressure. First, deflate the tire pressure and then loosen the wheel bolts and nuts. Failure to do so could result in serious personal injury.
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Indicator Lights Check that all lights are functioning and indicate normal truck operation as described in Section 3, “Operator Compartment and Controls,” in this manual. Service Brakes and Inching Pedal With the direction control in NEUTRAL and the engine running, push the service brake pedal fully down and hold.
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Section 7. Planned Maintenance and Lubrication If the maximum fork height is not reached, this indicates there is an inadequate (low) oil level in the hydraulic sump tank or severe binding within the upright. Push forward on the lift control lever. Watch the upright as it lowers. When the forks reach the floor, release the lever.
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2. Remove your right foot from the service 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 service brake pedal to stop the truck. The brakes should apply smoothly and equally.
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Battery Inspect the battery for damage, cracks, leaking condition, etc. If the terminals are corroded, clean and protect them with CLARK Battery Saver (available from your CLARK dealer). If your battery has removable cell caps, check to be sure the cells are all filled. Refill them with distilled water.
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The recovery bottle shown is a typical illustration of overflow system. Your actual system may vary slightly. A level anywhere between the HOT and COLD marks is nor- mal. Inspect the coolant level in the overflow bottle only. WARNING Do not remove the radiator cap when the radiator is hot. STEAM from the radiator will cause severe burns.
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Section 7. Planned Maintenance and Lubrication NOTICE Your lift truck cooling system is filled with a factory- installed solution of 50% water and 50% permanent-type antifreeze containing rust and corrosion inhibitors. You should leave the solution in year around. Plain water may be used in an emergency, but replace it with the specified coolant as soon as possible to avoid damage to the sys- tem.
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ENGINE OIL PERFORMANCE DESIGNATION : Refer to the “Engine Oil” in Section 8. Hydraulic Sump Tank Check the hydraulic sump tank fluid level. Correct fluid level is important for proper system operation. Low fluid level can cause pump damage. Overfilling can cause loss of fluid or lift system malfunction.
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With the engine operating at idle and the transmission in NEUTRAL, and the parking brake set, check the fluid on the dipstick. Fill, if necessary, to the FULL mark on the dipstick, using CLARK transmission fluid. If unable to determine actual oil temperature, use…
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(forward end) and both the base rod-end bushings (rear end). Clean and lubricate the upright trunnion bushings Lift Chains Lubricate the entire length of the upright rail lift and carriage chains with CLARK Chain and Cable Lube. IMPORTANT Do not lubricate the carriage roller rails. Air Cleaning Always maintain a lift truck in a clean condition.
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Section 7. Planned Maintenance and Lubrication CAUTION CAUTION Wear suitable eye protection and protective clothing when air cleaning. Never point the air nozzle at anyone. Air clean the upright assembly, drive axle, radiator—from both counterweight and engine side, engine and accessories, driveline and related components, and steer axle and cylinder.
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The lift chains operate under heavy loadings and function more safely and have longer life if they are regularly and correctly lubricated. CLARK chain lubricant is recommended; it is easily sprayed on and provides superior lubrication. Heavy motor oil may also be used as a lubricant and corrosion inhibitor.
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All chains must be replaced if any link has wear of 3% or more, or if any of the damaged conditions noted above are found during inspection. Order replacement chains from your CLARK dealer. Replace all chains as a set. Do not remove factory lubrication or paint new chains.
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Section 8. Specifications Specifications Contents GTS20-33 …………..8-2 Engine Oil …………… 8-5 Contents…
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GTS20-33 CLARK products and specifications are subject to improvements and changes without notice or obligation. Model Designation — Rated Load Capacity GTS20 2000 kg @500mm load center [4409 lbs @20in] GTS25 2500 kg @500mm load center [5511 lbs @20in] GTS30…
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Engine Coolant Recommendation Use a mixture of 50% ethylene glycol permanent-type anti-freeze containing rust and corrosion inhibitor only. Note: This mixture provides anti-freeze protection level of -37°C (-34°F), approximately. Transmission Fluid Recommendation Use CLARK Specification MS-276A CLARK Part number 2776236. GTS20-33…
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Hydraulic Fluid Recommendation Use CLARK Specification MS-68 CLARK Part number 2776239 Hydraulic Oil, with anti-wear additives, or equivalent only. Truck Weights — with standard upright. [GTS20-30 : 3195mm, GTS33 : 3165mm MFH] Gross Vehicle Empty Vehicle Loaded Drive Empty Drive…
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Section 8. Specifications Engine Oil Engine Oil Recommendation LPG truck PSI 4G64 — in accordance with API classification more than a class SM grade / SAE 10W-30 HMC — in accordance with API classification more than a class SM / SAE 10W-30 (in accordance with ILSAC classification more than a class GF-4 / SAE 10W-30) Diesel truck Yanmar — in accordance with API classification CD or higher / SAE…
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IMPORTANT Do not extend oil change intervals from those specified when using synthetic lubricants. Fill crankcase with correct amount of oil. When adding oil between oil changes, it is preferable to use the same brand as various oils may be incompatible. Refer to the Maintenance and Lubrication Section for recommended oil change intervals.
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Index Disassembling the split rim wheel ……..7-17 A Message to CLARK Do’s and Don’ts ……1-3 Lift Truck Operators ….. ii Drop-Offs ……..2-5 Adjusting the Load Forks ..4-10 Adjusting the Seat ….4-4 After Operating the Truck ..4-16 Engine ……..8-2 Air Cleaning ……
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Horn Button ……3-11 Longitudinal Tip-over ….1-13 Hot Surface Warning Decal … 3-16 Loose Loads ……2-2 Hour Meter ……3-10 Low Overhead Clearance Fast Turns and High Loads ..2-4 Hour Meter ……7-17 Lubrication ……7-25 How to Perform Planned Maintenance ……7-14 Lift Chain wear and Replacement Criteriai …..7-28 How to Tow a Disabled Truck ..
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PM Report Form ….7-12 Traveling with a Load …..4-12 Pod Symbols and Functions ..3-5 Truck Chassis Inspection and Lubrication …….7-25 Positioning Forks and Upright . 4-5 Truck Data and Capacity Powershift Transmission ..8-2 Plate ……..3-14 Truck Description …..3-2 Refueling Gasoline and Truck Weights ……8-4 Diesel Trucks ……
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Additional copies of this manual may be purchased from YOUR AUTHORIZED CLARK DEALER CLARK MATERIAL HANDLING COMPANY 700 Enterprise Drive Lexington, Kentucky 40510 [ www.clarkmhc.com ] ● Printed Date ; Feb. 2019…