Clark ESX Series, ESX15, ESX12, ESX17, ESX20 Operator's Manual
...
65702
8
Operator's Manual
ESX Stand-Up Counterbalanced Trucks
Book No. 2827061
OM-718
Do not remove this manual
from the truck.
Record the following information pertaining to your truck.
Model No. __________________________________________
Serial No. ___________________________________________
Customer Truck Identifi cation No. ________________________
Truck Weight, Empty __________________________________
Truck Rated Capacity _________________________________
Truck Gross Weight ___________________________________
Truck Gross Weight, Loaded w/ Rated Load ________________
Special Equipment or Attachments _______________________
IMPORTANT
Do not expose this manual to hot water or steam.
©2007 Clark Material Handling Company
Operator's Manual
8
You must be trained and authorized to operate a lift truck.
YOU can prevent accidents
First: Learn safe operating rules and your company rules.
Next: Read your Operator's Manual. If you do not
understand it, ask your supervisor for help.
Learn about the unit you operate.
KNOW YOUR TRUCK
Then: Practice operating your
truck safely.
And: Keep your truck in safe
operating condition with
correct and timely
maintenance.
65702
Breaking these rules will cause serious or fatal injury to
yourself and others
i
A Message to CLARK Lift Truck Operators
Lift trucks are specialized machines with unique operating characteristics, designed to perform a specifi c job. Their function and operation
is not like a car or ordinary truck. They require specifi c instructions and
rules for safe operation and maintenance.
Safe operation of lift trucks is of primary importance to CLARK. Our
experience with lift truck accidents has shown that when accidents
happen and people are killed or injured, the causes are:
• Operator not properly trained
• Operator not experienced with lift truck operation
• Basic safety rules not followed
• Lift truck not maintained in safe operating condition
For these reasons, CLARK wants you to know about the safe operation
and correct maintenance of your lift truck.
This manual is designed to help you operate your lift truck safely . This
manual shows and tells you about safety inspections and the important
general safety rules and hazards of lift truck operation. It describes
the special components and features of the truck and explains their
functions. The correct operating procedures are shown and explained.
Illustrations and important safety messages are included for clear understanding. A section on maintenance and lubrication is included for
the lift truck mechanic.
ii
A Message to CLARK Lift Truck Operators
The operator’s manual is not a training manual. It is a guide to help trained
and authorized operators safely operate their lift truck by emphasizing
and illustrating the correct procedures. However, it cannot cover every
possible situation that may result in an accident. You must watch for
hazards in your work areas and avoid or correct them. It is important that
you know and understand the information in this manual and that you
know and follow your company safety rules! Be sure that your equipment is maintained in a safe condition. Do not operate a damaged or
malfunctioning truck. Practice safe operation every time you use your
lift truck. Let's join together to set high standards in safety.
Remember, before you start operating this lift truck, be sure you understand all driving procedures. It is your responsibility , and it is important
to you and your family, to operate your lift truck safely and effi ciently .
Be aware that the Federal Occupational Safety and Health Act (OSHA)
and state laws require that operators be completely trained in the safe
operation of lift trucks; it is also an OSHA requirement that a machine
inspection be performed before every shift. If you think you need training
in operating or inspecting your lift truck, ask your supervisor.
CLARK lift trucks are built to take hard work, but not abuse. They are
built to be dependable, but they are only as safe and effi cient as the
operator and the persons responsible for maintaining them. Do not
make any repairs to this truck unless you have been trained in safe lift
truck repair procedures and are authorized by your employer.
A Message To CLARK Lift Truck Operators
iii
iv
Contents of this Manual
A Message to CLARK Lift Truck Operators ................ii
Introduction ..................................................................vi
How to Use this Manual ........................................viii
Safety Signs and Safety Messages .........................x
Section 1. General Safety Rules ...............................1-1
Section 2. Operating Hazards ...................................2-1
Section 3. Common Truck .........................................3-1
Section 4. Operator Maintenance and Care ............4-1
Section 5. Operating Procedures .............................5-1
Section 6. Planned Maintenance ..............................6-1
Section 7. Specifi cations ......................................... 7-1
Index ................................................................... Index-1
Contents of this Manual
v
Introduction
CLARK welcomes you to the growing group of professionals who
own, operate, and maintain CLARK lift trucks. We take pride in the
long tradition of quality products and superior value the CLARK name
represents. This manual familiarizes you with safety, operating, and
maintenance information about your new lift truck. It has been specially
prepared to help you use and maintain your CLARK lift truck in a safe
and correct manner.
Your CLARK lift truck has been designed and built to be as safe and
effi cient as today’s technology can make it. As manufactured, it meets all
the applicable mandatory requirements of ANSI B56.1 Safety Standard
for Powered Industrial Trucks. Each truck is also furnished with equipment to help you operate safely; for example, load back rest, parking
brake and horn are standard equipment.
Safe, productive operation of a lift truck requires both skill and knowledge
on the part of the operator. The operator must know, understand, and
practice the safety rules and safe driving and load handling techniques
described in this manual. T o develop the skill required, the operator must
become familiar with the construction and features of the lift truck and
how they function. The operator must understand its capabilities and
limitations, and see that it is kept in a safe condition.
Routine Servicing and Maintenance
Regular maintenance and care of your lift truck is not only important
for economy and utilization reasons; it is essential for your safety. A
faulty lift truck is a potential source of danger to the operator, and to
other personnel working near it. As with all quality equipment, keep your
lift truck in good operating condition by following the recommended
schedule of maintenance.
vi
Introduction
Operator Daily Inspection — Safety and Operating Checks
A lift truck should always be examined by the operator, before driving, to be sure it is safe to operate. The importance of this procedure
is emphasized in this manual with a brief illustrated review and later
with more detailed instructions. CLARK dealers can supply copies of
a helpful “Drivers Daily Checklist.”
Planned Maintenance
In addition to the daily operator inspection, CLARK recommends that a
planned maintenance and safety inspection program (PM) be performed
by a trained and authorized mechanic on a regular basis. The PM will
provide an opportunity to make a thorough inspection of the safety and
operating condition of your lift truck. Necessary adjustments and repairs
can be done during the PM, which will increase the life of components
and reduce unscheduled downtime and increase safety. The PM can
be scheduled to meet your particular application and lift truck usage.
The procedures for a periodic planned maintenance program that
covers inspections, operational checks, cleaning, lubrication, and
minor adjustments are outlined in this manual. Your CLARK dealer is
prepared to help you with a Planned Maintenance Program by trained
service personnel who know your lift truck and can keep it operating
safely and effi ciently.
Introduction
vii
How to Use this Manual
This manual is a digest of essential information about the safe operation, the features and functions and explains how to maintain your lift
truck. This manual is organized into eight major parts:
Section 1, General Safety Rules, reviews and illustrates accepted
practices for safe operation of a lift truck.
Section 2, Operating Hazards, warns of conditions that could cause
damage to the truck or injury to the operator or other personnel.
Section 3, Common Truck, describes the most common operating
components, systems, controls, and other features of your truck and
tells how they function.
Section 4, Operator Maintenance and Care, presents details on how to
perform the operator's daily safety inspection and refuel the lift truck.
Section 5, Operating Procedures, discusses more specifi c instruction
on the safe, effi cient operation of your lift truck.
Section 6, Planned Maintenance, describes the PM program.
Section 7, Specifi cations, provides reference information and data
on features, components, and maintenance items.
Also, the Index helps you locate information about various topics.
NOTICE: The descriptions and specifi cations 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 specifi ca-
tions or design, without notice and without incurring obligation. Please
check with your authorized CLARK dealer for information on possible
updates or revisions.
The examples, illustrations, and explanations in this manual should
help you improve your skill and knowledge as a professional lift truck
operator and take full advantage of the capabilities and safety features
of your new lift truck.
The fi rst Section of the manual is devoted to a review, with illustrations
and brief messages, of general safety rules and the major operating
hazards you can encounter while operating a lift truck. Next, you will
fi nd descriptions of the components of your specifi c lift truck model and
how the instruments, gauges, and controls operate. Then, you will fi nd
a discussion of safe and effi cient operating procedures, followed by
viii
How to Use this Manual
instructions on how to tow a disabled lift truck. The later sections of the
manual are devoted to maintenance and truck specifi cations.
T ake time to carefully read the “Know Your Truck” section. By acquiring
a good basic understanding of your truck's features, and how they function, you are better prepared to operate it both effi ciently and safely.
In “Planned Maintenance,” you will fi nd essential information for cor-
rect servicing and periodic maintenance of your truck, including charts
with recommended maintenance intervals and component capacities.
Carefully follow these instructions and procedures.
Each major Section has its own table of contents, so that you can fi nd
the various topics more easily . If you cannot fi nd a topic in the table of
contents, check the index at the back of the manual.
We urge you to fi rst carefully read the manual from cover to cover.
Take time to read and understand the information on general safety
rules and operating hazards. Acquaint yourself with the various procedures in this manual. Understand how all gauges, indicator lights,
and controls function. Please contact your authorized CLARK dealer
for the answers to any questions you may have about your lift truck’s
features, operation, or manuals.
Operate your lift truck safely; careful driving is your responsibility . Drive
defensively and think about the safety of people who are working nearby .
Know your truck’s capabilities and limitations. Follow all instructions
in this manual, including all IMPORTANT, CAUTION, WARNING, and
DANGER messages to avoid damage to your lift truck or the possibility
of any harm to yourself or others.
This manual is intended to be a permanently attached part of your lift
truck. Keep it on the truck as a ready reference for anyone who may
drive or service it. If the truck you operate is not equipped with a manual,
ask your supervisor to obtain one and have it attached to the truck.
And, remember, your CLARK dealer is pleased to answer any questions
about the operation and maintenance of your lift truck and will provide
you with additional information should you require it.
How to Use this Manual
ix
Safety Signs and Safety Messages
Improper operation can cause accidents. Don’t take chances with incorrect or damaged equipment. Read and understand the procedures for
safe driving and maintenance outlined in this manual. Don't hesitate to
ask for help. Stay alert! Follow safety rules, regulations, and procedures.
Avoid accidents by recognizing dangerous procedures or situations
before they occur. Drive and work safely and follow the safety signs
and their messages on the truck and in this manual.
Safety signs and messages are placed in this manual and on the truck
to provide instructions and identify specifi c areas where potential hazards
exist and special precautions should be taken. Know and understand
the meaning of these instructions, signs, and messages. Damage to
the truck, death, or serious injury to you or other persons may result if
these messages are not followed. If warning decals are damaged, they
must be replaced. Contact your CLARK dealer for replacements.
NOTICE
This message is used when special information, instructions or identifi cation are required relating to procedures,
equipment, tools, pressures, capacities and other special
data.
IMPORTANT
This message is used when special precautions should
be taken to ensure a correct action or to avoid damage to
or malfunction of the truck or a component.
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates an imminently hazardous situation which, if not
avoided, will result in death or injury
x
Safety Signs and Safety Messages
CAUTION
WARNING
DANGER
Section 1. General Safety Rules
General Safety Rules
Contents
Daily Inspection .........................................................1.2
Do's and Don'ts ..........................................................1.3
No Riders ....................................................................1.4
Pedestrians ................................................................1.5
Operator Protection ...................................................1.6
Fork Safety .................................................................1.7
Pinch Points ...............................................................1.8
Travel ..........................................................................1.9
Surface and Capacity ..............................................1.10
Grades, Ramps, Slopes, and Inclines ....................1.11
Tip Over ....................................................................1.12
What to do in Case of a Tip-Over ..........................1.13
Parking ......................................................................1.14
Contents
1.1
Daily Inspection
At the beginning of each shift, inspect your truck and fi ll out a daily
inspection sheet.
Check for damage and maintenance problems.
Have repairs made before you operate the truck.
CAUTION
DO NOT MAKE REP AIRS YOURSELF . Lift truck mechanics
are trained professionals. They know how to make repairs
safely. (See Section 4)
1.2
Daily Inspection
XXX
Section 1. General Safety Rules
Do's and Don'ts
Don't mix drugs or alcohol with your job.
OM0001
Do watch for pedestrians.
OM0002
Don't block safety or emergency
equipment.
OM0003
Do wear safety equipment when
required.
Don't smoke in "NO SMOKING" areas
or when refueling.
OM0005
Do's and Don'ts
OM0004
1.3
No R iders
718001
657028
The operator is the only one who should be on a truck.
WARNING
Never transport personnel on the forks of a lift truck.
1.4
No Riders
Pedestrians
718002
Section 1. General Safety Rules
IMPORTANT
• 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. People may not watch for
you.
• Make people stand back, even when you are parked.
Pedestrians
1.5
718003
Operator Protection
IMPORTANT
• Keep under the overhead guard.
• Always keep your body within the confi nes of the
truck.
• Be especially careful when traveling in reverse and maneuvering in tight areas.
Keep arms and legs in the
operator compartment
1.6
Operator Protection
Fork Safety
Section 1. General Safety Rules
Never allow anyone
to walk under raised
forks.
657005
DANGER
There is special equip-
2372604
ment to raise people for
overhead work. DO NOT
USE LIFT TRUCKS.
657006
Fork Safety
1.7
718007
Pinch Points
2791862
WARNING
Keep hands, feet and legs out of the upright.
WARNING
Don't use the upright as a ladder.
CAUTION
Never try to repair the upright, carriage, chain, or attachment yourself! Always get a trained mechanic.
1.8
Pinch Points
Travel with the load near
the fl oor/ground with forks
tilted back to cradle the load
whenever possible.
Never lift or lower the
load when the truck is in
motion.
When handling bulky
loads that restrict your
vision operate your truck
in reverse to improve visibility.
Be sure to pivot in the
operator compartment to
give maximum visibility.
Section 1. General Safety Rules
Travel
718008
718009
Unstable loads are a
hazard to you and to your
fellow workers.
Always make certain that
the load is well stacked
and evenly positioned
across both forks.
Never attempt to lift a
load with only one fork.
718008
718010
Travel
Right
Wrong
1.9
Surface and Capacity
657011
Avoid these conditions. They can cause a truck to tip over or lose traction for braking or driving.
WARNING
Know the weight of your truck and load. Especially when
using elevators. Know the capacity of the elevator you
intend to use. Do not overload.
1.10
Surface and Capacity
Grade, Ramps, Slopes and Inclines
There are fi ve basic points you
should practice when operating on
grades:
1. Travel up and down grades
slowly.
2. Travel straight up and straight
down.
3. Without a load, travel up or
down with the forks pointing
downgrade. (see illustration)
Section 1. General Safety Rules
657012
657013
Without Load
WARNING
Never turn on grades, ramps,
slopes or inclines; wait until
you are back on level surface.
4. With a load travel up or
down with the load pointing
upgrade. (see illustration)
5. The load should be tilted back
and raised only high as necessary to clear the surface.
Grade, Ramps, Slopes and Inclines
657014
657015
With Load
1.11
657017
Tip-over
Lateral Tip-over
• Lateral tip-over can occur with a combination of travel speed and sharpness
of turn. This combination may exceed
the stability of the truck. This condition
is even more likely with an unloaded
truck.
• While traveling with the load or upright
raised, lateral tip-over can occur while
turning and/or braking when in reverse
or accelerating and turning while traveling forward.
• Lateral tip-over can occur loaded or
unloaded by turning on an incline or
ramp.
Longitudinal Tip-over
• Longitudinal tip-over can occur with a
combination of overloading and load
elevated also with capacity load and
elevated. Traveling with this combination may exceed the stability of the truck.
This condition is even more likely with
excessive forward tilt, braking in forward
travel or accelerating rearward.
• Longitudinal tip-over can occur by driving with the load down slope on a steep
grade.
Lateral and longitudinal tip-over can occur if the truck is driven over objects
on the fl oor or ground, off the edge of improved surfaces, or into potholes
in the road surface, or by running into overhead objects or collisions.
657016
An off dock type of tip-over can occur if the truck is steered too close to the
dock edge, driven off the edge of the dock or ramp, or if the highway truck
or trailer rolls away from the dock or is driven away during loading.
WARNING
The conditions listed above can be further aggravated by
overloading, excessive tilt, or off center loads.
DANGER
Lift truck tip-over can cause serious injury or death if the
operator is trapped between the truck and the ground.
1.12
Tip Over
Section 1. General Safety Rules
What to do in Case of a Tip-over
If your truck starts to tip over,
DANGER
If your electric stand-up lift truck starts to tip over in
any direction, CLARK recommends stepping off and
away from the rear of the truck.
657018
IMPORTANT
If you tip an electric stand-up lift truck over, you can
be seriously injured, or killed, no matter what you do!
Y our best chance of surviving a tip over is to get away
from the falling truck and load. You must step out and
away from the driver's compartment.
NOTE: This only applies to a stand-up rider type truck
with a large rear opening in the drivers compartment.
Tip-over
1.13
Parking
• Always come to a complete
stop.
Tilt
718019
• Park only in authorized locations.
• Never park on a grade.
• Be sure travel control is in NEUTRAL.
• Lower forks fully to fl oor and tilt
forward.
• Turn key to OFF position.
• When you step from the truck or
turn the key switch to OFF, the
brake will set itself.
• Never step from the truck while
it is motion. Always come to a
complete stop before leaving
the truck. Doing so is not only
dangerous, but will cause accelerated wear of the brake
components.
1.14
Parking
RUN
OFF
657020
Section 2. Operating Hazards
Operating Hazards
Contents
Loose Loads ...............................................................2.2
Long and Wide Loads ...............................................2.3
Rear Swing .................................................................2.3
Low Overhead Clearance ..........................................2.4
Fast Turns and High Loads .......................................2.4
Docks / Drop-offs .......................................................2.5
Right-Angle Stacking ................................................2.6
Chain Slack ................................................................2.7
Pallets and Skids .......................................................2.8
This Section shows some of the hazards that may cause you, or someone around you, to be killed or badly hurt. As the operator, you must
look for other hazards. Get your supervisor to help you identify and
avoid those hazards.
Contents
2.1
Loose Loads
WARNING
Loose or unbalanced loads
are dangerous. Observe
these precautions.
Never carry loose or uneven material.
Center wide loads.
OM0006
Stack and band loose material.
2.2
Loose Loads
OM0007
OM0008
Section 2. Operating Hazards
718066
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.
718022
WARNING
When turning, be
sure the rear end
of the truck does
not swing into
racks, posts, etc.
Watch for pedestrians beside the
truck.
Long and Wide Loads • Rear Swing
2.3
Low Overhead Clearance
718064
718065
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.
WARNING
Slow down before turning. The truck
can tip over.
Turn too sharp with a raised load
and your truck can tip even at slow
speeds.
Travel with a load raised only when
removing or depositing a load.
2.4
Low Overhead Clearance • Fast Turns
657017
657016
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