Clark GCS 17 User manual

•c*
Additional copies of this manual maybe purchased from
YOUR AUTHORIZEDCLARKDEALER.
Operator's Manual
Do not removethismanual
from the truck.
GCS/GPS17thru30
GCX/GPX20thru30
CLIHK
Material Handling
Company Lexington, KY 40507
Printed inUSA
ClflRh
Book No. 2779027
OM-520 3rd Rev.

Record the followinginformationpertaining to yourtruck.
Model No.
Serial No
CustomerTruck Identification No.
TruckWeight, Empty
TruckRatedCapacity
TruckGross Weight, Loaded w/ RatedLoad
Special Equipment
IMPORTANT
Do not exposethismanual tohot water or steam.
©1990 ClarkEquipmentCompany

NOTESOperator's
Manual
You must be trained and authorized to operate a lifttruck.
Followtheserules:
Read and understandyour
Operator's Manual.
OVERHEAD
GUARD
PARKING
BRAKE
LOAD BACKREST
EXTENSION
Knowyourtruck.
FORK CARRIAGE
LOAD FORKS
STEER AXLE
AND WHEELS
MACHINE SERIAL DRIVE AXLE
NUMBER AND WHEELS
Learnsafeoperatingrules
and practiceoperating
yourtruck.
Breaking theseruleswillcauseserious or fatalinjury to
yourself and others.

NOTES
CONTENTS
This manualcoverstruckswithcapacitiesfrom3,000poundsthrough6,000pounds.
A MESSAGE TO CLARKLIFTTRUCK OPERATORS iii
TRUCK APPLICATION iv
OPERATOR MAINTENANCE 1
GENERAL SAFETYRULES 2
OPERATING HAZARDS 3
KNOWYOURTRUCK 4
OPERATING PROCEDURES 5
EMERGENCY STARTING 6
EMERGENCY TOWING 7
PLANNEDMAINTENANCE AND LUBRICATION 8
SPECIFICATIONS 9

A Message To CLARK Lift TruckOperators ; ) NOTES
Lift trucks are specializedmachineswithuniqueoperatingcharacteristics
designed to performspecificjobs.Theirfunction and operation isnot like a
car or ordinarytruck.Theyrequirespecificinstructions and rules for safe
operation and maintenance.
Safe operation of lift trucks isof primaryimportance to CLARK. Ourex-
perience with lift truckaccidents has shownthatwhenaccidentshappen
and people are killed or injured the causesare:
1. OPERATOR NOT PROPERLY TRAINED
2. OPERATOR NOT EXPERIENCED WITHLIFTTRUCKOPERATION
3. BASIC SAFETY RULES NOT FOLLOWED
4. LIFT TRUCK WASNOT MAINTAINED INA
SAFE OPERATING CONDITION
For thesereasons,CLARKwants youto knowabout the safe operation and
correctmaintenance of your lift truck.
This manual is designed to help you learn howto operateyour lift truck safe-
ly. This manualshows and tells you aboutoperatormaintenance andtheim-
portantgeneralsafetyrules and hazards of lift truckoperation. It describes
the specialcomponents and features ofthe truck and theirfunction. The
correctoperatingprocedures are shown and explained.Illustrations andim-
portantsafetymessages are included for clearunderstanding.And,finally,
a section on maintenance and lubrication is included forthe lifttruck
mechanic.
The operator'smanual isnot a trainingmanual. Itisa guide to helpautho-
rizedoperatorssafelyoperatetheir lift truck by illustrating the correctpro-
cedures. It cannotcover every possiblesituationwhich may result inanac-
cident. You must watch for hazards in yourworkareas and correct them. Itis
importantthat you learn the information in this manual and knowyourcom-
panysafetyrules! Be surethatyourequipment is maintained ina safecon-
dition anddonot operate a damagedtruck.Practicesafeoperationevery
time youuse yourlifttruck.Let'sjointogether tosetnew standards in
safety.
Remember,before you start operating this lift truck, be sure that you
understand all drivingprocedures. Itis yourresponsibility, anditis impor-
tant toyouand yourfamily, to operateyour lift trucksafely and efficiently.
Andbe awarethat the FederalOccupationalSafety and Health Actand state
laws require that operators be completely trained inthe safe operation of lift
trucks.
And letus makethispoint,Clark lift trucks are built to takehardwork, but
not abuse.They are built tobe dependable, but they are only as safe andef-
ficient asthe operator andthe personsresponsible for maintainingthem.
Do not make any repairs to this truckunless you have beentrained in lift
truckrepairprocedures and authorized by youremployer.
iii

For HandyReference
Record the followinginformation
pertaining to your truck:
Truck Application
Eachtruck is designed fora specificapplication.Makesure
you are using the correcttruck forthe job.
Mode! No
Serial No
Attachments
Truck Weight — Empty
Truck RatedCapacity
GrossTruckWeight (W/Rated Load) .
Customer TruckIdentification No
Cushion (solid tires)
Cushion(solid)tire
trucks are designed for
use inside on smooth
dry surfaces.
Pneumatic (air-filled tires)
DD
Use pneumatic (air)'
tiretrucks on
improvedsurface-
inside or outside.
9.6
iv

Specifications
Truck Specifications
Engine crankcase oil
Gasoline/LPG Engines
Transmissionfluid
Powershift Transmission.
Torque Converter and
Drive Axle
Hydraulicfluid
HydraulicSump
Normal Application
Multi-purposegrease
Axle Ends,WheelBearings,
SteerAxle Linkage/Tie Rod
Ends,SteerAxleKnuckle
Bearings
UprightMastRollers,
TrunnionBushings,
Tilt Cylinder Rod Ends
Chainlube
Upright LiftChains
Dry-Filmlubricant
Side Shifter,Attachments
ClampSlidesBondedLubricant,
Battery
(Unsealed-type)
FiltersEngineFuel
Engine Oil
Engine Air
Transmission Oil
HydraulicSystem Oil
HydraulicSumpBreather
Brake Fluid
HR500/TA18
HR600
APICC/SEMH-Z104B,
MIL-45199B
(HR600) - TEXACO8570 ATF
or Clark#962669
(HR500) - AMOCO 300 Motor Oil
SAE 20W
(TA18) AMOCO1000
or TEXACO 1893 TDH
Clark Specification
MS-68
NLGI Grade No. 1
Lithium soap basegrease,
Clark SpecificationMS-9B and
MS-107B, or equivalent.
MLGI GradeNo.2
Lithiumsoapbasegrease,
Clark Specification
MS-107C, or equivalent.
Clark #886399 Chain and
CableLube, or equivalent.
Dow Corning Milykote 321
Graph-O-Kote
#220, Molub-Alloy #369 Dry
Lube, or equivalent.
Distilled Water.
Use GenuineClarkparts.
See yourClarkdealer.
D.O.T 3 Brake Fluid
TrucksHydraulicSystem Fluid.
9.4
( 1 OperatorMaintenance
Daily Inspection
At the beginning of each
shift, fill outa daily
inspection sheet.
Do not make repairs your-
self. Lifttruckmechanics
are trainedprofessionals.
They know howto make
repairs safely.
1.1

Operator Maintenance
Safety inspection
Check safety
equipment —
the overhead
guard, load
backrest
extension, horn,
andif present,
backup alarms,
and rotary
lights.
Look atthe upright, BUT KEEP
YOUR HANDSOUT.
BackupAlarm
Warning Light
Othersafety
devices are
availablefrom
your Clark
dealer.
Make minoradjustments.Major
adjustments are made by trained
and authorizedmechanics.
Check forkretainerpins
and locks.
1.2
Specifications
TruckSpecifications
Fill capacities/fluid volumes:
Fuel Tank -- Gasoline/Diesel [30,0 L]8 gal
LPG [ICCHorizTank] [15kg] 33.5 Ib
Cooling System:
Mitsubishi2.6LGasoline/LPG[8,5 L]9qt
Waukesha 2.9L Gasoline/LPG [10,4 L]11qt
Continental2.7LGasoline/Diesel[8,5 L]9qt
EngineOil, w/Filter
Mitsubishi2.6LGasoline/LPG[4,5 L]4.8qt
Waukesha2.9L Gasoline/LPG [4,7 L]5.0qt
Continental2.7LGasoline/LPG[6.65 L]7.0qt
Continental2.7LDiesel[6.65 L]7.0qt
Transaxle[Transmission & DriveAxle]
HR500[15,1 L]32 pints
HR600[12, 8 L]27 pints
TA18 [15,1 L]32 pints
HydraulicSumpTank[Useable Volume] [20, 8 L]5.5gal
Hydraulicsystemreliefpressuresetting:
Lift and TiltModel 17,20 [16200 kPa]2350 psi
[Adjustable]22,35 [18270 kPa]2650 psi
27,30 [20685kPa]3000 psi
Steeringsystemreliefpressuresetting:[8615 kPa]1250 psi
Enginespeedsettings: [+1 H 50 rPm
Engine 2.6L
Transaxle HR500HR600
*ldleSpeed, 600600
rpm Max.
No-Load
Governed
Speed,
rpm 2300-26002350-2650
2.7 L
HR600
600
2.9 L
HR600
550
2.6 L
TA18
600
2350-265023502300-2600
Electrical system: 12 volt DC, NegativeGround
Alternator: 37 amp
Battery Rating [Cold-Crank]:
Gasoline/LPG -- Water-FillType 12vDC -295amps @ 0°F
Gasoline/LPG --Maintenance-Free 12v DC--320 amps @ 0°F
Diesel -- Maintenance-Free 12v DC --625 amps @ 0°F
Idlespeedmust be adjusted so truck has adequate oil supply to steercorrectly.
'Idle speedmust be adjusted so truck(whenempty)does not haveexcessive
creepspeed.Creepspeedshould be limited to2ft.per second.
9.3

Specifications
Truck Specifications
Fuel recommendations:
Gasoline
LPGas
DieselFuel Oil
Engine oil recommendations:
RegularGrade, 85 OctaneMinimum(Motor
Method)
HD-5 Propane
ASTMGrade No. 1D and2D,45 Cetane
Minimum,50 Cetane Preferred
(Gas — LPG) API ServiceClassification CC,SC,SE,SF, MIL-B Motor Oil
MIL-L-46152
(Diesel) — API ServiceClassificationCD/SEMIL-45199B
AmbientTemperature(Average)
32°Fto 1100F[00Clo430C]
70°Fto 0°F[21°Cto -17°C]
0°F to -30°F [- 17°C to -34°C]
Engine coolantrecommendation:
Viscosity
SAE 30
SAE 20W
SAE 10W
50% water and50% ethylene glycolpermanent-typeantifreeze containing
rust and corrosion inhibitors. (Antifreezeprotectionlevel [-37°C] -34°F)
Tire inflationpressure:
Drive Tires (7.00 x 12— 14 Ply, 28x 9 x 15-14Ply)
Steer Tires (6.50 x 10— 10 Ply)
[965 kPa] 140psi
[792 kPa] 115 psi
9.2
Operator Maintenance
Tire inspection
Check tire pressure from a position
facing the tread ofthe tire, notthe
side. Use a long-handled gauge to
keep your body away from the side.
Low tires can effect the truck'sstability
. . .but don'tjust add air! A damaged or
improperlyinstalled split rimcan come
apart underhighpressure, resulting in
severe injury or death.Checkwith a
mechanic; the tire may requireremoval or
repair.
1.3

Operator Maintenance
Maintenanceproblem
DONOT OPERATE A LIFT
TRUCK THAT HASA
MAINTENANCEPROBLEM.
Remove thekeyandput
an "Out of Service" tag
onthe truck.
9 Specifications
NOTICE
Clark products and specifications are
subject to improvements and changes
without notice or obligation.
1.4

Operator Maintenance
Refuel gasor diesel
Refuel in designated
areas only.
Do notmix
gasoline and
dieselfuel.
Use only clean,
water-free diesel
fuel.Check and
drainfuelbowl
daily if water
is present.
1.5

OperatorMaintenance
Refuel LPG tanks
Whenchanging LPG tanks:
Follow these basic rules:
• Change only in well-ventilatedareas.
• Turn the ignition off.
• Check for leaks.
• Never allow open flames.
• Store tanks following local fire codes.
If you refill LPG tanks:
Makesuresomeoneexplains all
procedures to you, and followthem.
DANGER PROPANE
FLAfUIABLE
LPG ... is heavierthan air — it will settle
on your clothes andthe ground where
you'reworking.Openflame can cause
flashfires.
Check all connections
for damage or leaks. Ifthe truck
will not startafter you change a
tank, geta mechanic to check it.
PlannedMaintenance and Lubrication
Wheel and Tire Inspection
Remove air from the tirebeforeremov-
ing wheelclampingnuts(twopiece
wheels) orrim lockingrings on multi-
piecerims.
Always usea safetycage to inflate
tires afterservicing.
18631
24306
Trained and qualifiedmechanics
shouldrefer to information inthe
Planned MaintenanceManualbefore
working on pneumatictires and rims.
GROUP
22
SECTION
1
PNEUMATIC
TIRE
WHEEL
1.6

PlannedMaintenance and Lubrication
Wheel and Tire Inspection
Federal andStatelawsrequirepersons
tobe fullytrained and qualifiedbefore
doingmaintenance on wheels and
tires. Injury or death can resultfrom the
explosive separation ofrim com-
ponents if serviceprocedures arenot
donecorrectly.
Check tirepressurefrom a position
facing the tread ofthe tire, notthe side.
Use a longhandledgauge to keep your
bodyawayfrom the trajectorypath of
multi-piecerims and wheels.
DANGER
RIM SEPARATION
REMOVE THEAIR FROM TIRES
BEFORE DOING ANY WORK ON
TIRES OR RIMS.MULTI-PIECE
RIMS CAN SEPARATE WITH
ENOUGH FORCE TO CAUSE
INJURY OR DEATH.
24964
If tires are low, donotadd air.Check
with a mechanic. The tire may need to
be removed and repaired.
8.20
2 GeneralSafetyRules
Follow the rules
Never mix drugs and
alcohol withyourjob.
Watch for
pedestrians.
Don't block safety or
emergency equipment.
Wear safety equipment
when required.
Watch those "No
Smoking"areas.
2.1

GeneralSafetyRules
Surface and capacity
Avoid or slow
down on these
conditions ...
o°o
o?;^
°4; GRAVEL
&&•*•
O-O
they can
cause a truck
totip over.
Know the weight of your truck and load.
Check capacities:
LJ Elevators
LJ Floors
PlannedMaintenance and Lubrication
Truck Lubrication
Raise the rear ofthe truck and place
blockingunder the frame for safety.
Lubricate the steeraxle linkage — tie
rod ends and kingpinbearings. Be sure
to clean the greasefittingsbefore
lubricating and remove the excess
grease from all pointsafterlubrication.
Inspect the steeringcylinderpiston
rod,seals and fasteners for damage,
leaks and looseness.
Remove the blocking and lower the rear
of the truck.
Lubricate the tilt cylinder rod ends (at
the forwardend) andthe uprighttrun-
nion bushings.
83M480
84M274
Your CLARK Dealer
keeps all lubricant
available foryou
2.2

Planned Maintenance and Lubrication
Lift Chain Lubrication
Lift chainlubrication isan important
part of yourmaintenanceprogram. The
lift chainsoperateunderheavy
loadings and willfunctionmoresafely
and have longer life if they are regularly
correctly lubricated. Clark chain lubri-
cant is recommended. Itis easily
sprayed onand providessuperior
lubrication.
Lift ChainAdjustmentCheck
The lift chains are correctlyadjusted if
the lowerforkcarriagerollersreach
their end (lowest)positionapprox-
imately [13mm] 0.50 inch from the
lower edge ofthe innerrail.Thisalso
positions the bottom ofthe forks the
same(equal)distanceabove the floor.
To checkthis dimension, raise the car-
riage toa heightthatexposesseveral
inches ofthe innerrail atthe roller
path.Apply a layer of grease tothe
rollerpath onthe innerrail.Lower the
carriage and pick upa ratedcapacity
load, (tilt the uprightbackslightly) and
raise the loaduntil the carriagerollers
have passedover the greasedarea.
Lower the load completely and remove
the load from the forks.Raise the car-
riageagain to expose the innerrail. You
can now check the rollerpath pattern
in the grease and determine the correct
adjustmentofthechains.
The liftchains canbe adjusted by
loosening or tightening ofthe chain an-
chor nuts.
GeneralSafetyRules
Seat belts
17643
NOTICE: Itis important to make
the lift chain adjustment check
with a ratedload to makesure
that the chains are stretched to
theirmaximumlength.
If the chains show slack duetoan
increase in lengththeyshould be
measured for wear.Whenchains
have stretched by wearmorethan
3% of their original length they
are not safe and must bere-
placed.
ALWAYS BUCKLE UP
Seat belts and wingseats can
reduce injuries.
8.18
2.3

GeneralSafetyRules
No riders
The operator isthe only one
who should beona truck.
Planned Maintenance and Lubrication
5. Brakediscgauge (6) dimensions are
shown by Figure20716.
T
[25,4]
1.0
1
£- [152] 6.0 — j
LWJ
0.25
1
1
1 [2,6] 0.104 -j
^ ' 1
Fig.20716
6. Insert the gauge into the axlethrough
the brakeinspectionplugopening(5).
Try toputthe brakediscclearance
gauge (6) between two steeldiscs
(8), Figure24982.Minimumdisc clear-
ance is [2,6 mm] 0.104inch.
Fig. 21977
7. The gauge (6) should go between the
outerdiscs(8). Ifit doesnot, the
brakeinner(friction)discs (7)are
worn and require replacement. Refer
to OverhaulManualOH-522, GROUP
20, for drive axleoverhaul.
Fig.24982
2.4
8.17

Planned Maintenance and Lubrication
HR600 TRANSAXLE - BRAKE DISC WEAR CLEARANCECHECK
The purpose of thischeck isto determine the "worn" thickness ofthe inner
(friction)brakediscs. The remainingthickness ofthe innerplates is readily
determined by measuring the space(clearance)between two steelouter
discs. The minimum allowab'e "worn" thickness ofthe innerfrictiondiscs
is [2,6 mm] 0.104 inch. Measurable wear ofthe steel outer discs is normally
not expected. The brakesmust be fullyappliedduringthischeck to make
sure that all of the operatingrunningclearance is removed.
General SafetyRules
Pedestrians
Watch where you
are going.
Pedestrians may
use the same
roadway youdo.
Sound your horn
at all inter-
sections.
Please refer tothe proceduredescribed
previously in "Access ToThe Drive
Axle".
A WARNING
PUT POSTSUNDER THE UPRIGHT AND
CARRIAGE AS SHOWN IN FIGURE 84M255
TO KEEP IT FROMFALLING AND
CAUSING PERSONALINJURY.
3. Remove the brakeinspectionplugs
(4) from topof driveaxlehousing.24984
Watch for people in your
work area even if your
truck has warning lights
or alarms. They maynot
watch for you.
4. Apply parking brake or pushdown on
the brakepedal and maintain[445N]
100 Ibf. force onthe pedalwhile
checking the brakediscs.
Make people
stand back, even
when youare
parked.
84M244
8.16
2.5

General SafetyRules
Stay inthe confines ofthe truck
Keep under the
overhead guard
Keep hands onthe
wheel.
Keep arms and legs
inside.
O K
Planned Maintenance and Lubrication
HR500 Transaxle
HR500transaxle hastwo openings in
driveaxlesection.
1. Fill/oil leveldipstick plug.
2. Drain plug, in lowerfront surface of
axlecenterhousing.
In addition, HR500transaxle hasa
transmission housingdrainplug(3), and
a transmission oil strainerscreen
access plug (4) locatedsimilarly to
HR600transaxle.
Transaxle Fluid
Replacement/Refill
HR500 transaxle
After driveaxle and transmission
housing has drainedcompletely,
1. Installdrainplug in driveaxle.
2. Install drain plug in transmission
housing.
3. Removeinspection/fillerplug in from
center surface of driveaxlehousing.
4. Fill transaxle to bottomedge of fill/oil
levelplugopeningwithrecommend-
ed fluid noted below. Please refer to
previousinstruction on "Transaxle
Fluid LevelCheck".
5. Install fill/level plug.
6. Removedrainpan.Remove
blocking fromunderupright (if
used).Lowercarriage and forks to
floor.
IMPORTANT
HR500 use only API Class CC.SC, SE,
SF Motor Oil
SAE30@32°F-110°F
SAE10@32°F-(-30°F)
DO NOT SUBSTITUTE.
IMPORTANT
TA18 use only AMOCO1000 or
TEXACO 1893 TDH CLARK # 2776236
DO NOT SUBSTITUTE.
Fig.24992
Fig. 24994
2.6