Clark GEX 40 User manual

ELECTRIC RIDER LIFT TRUCKS
Part No. 8106240
OM 899 (Rev 1.3)
Jun. 2019
GEX 40/45/50
[Do not remove this manual from the truck]

i
Operator’s Manual
You must be trained and authorized to operate a lift truck.
Breaking these rules will cause serious or fatal injury to
yourself and others.
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.

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

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

iv

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

vi Introduction
Introduction
CLARK welcomes you to the growing group of professionals who
own, operate, and maintain CLARK lift trucks. We take pride in the
long tradition of quality products and superior value the CLARK
name represents. This manual familiarizes you with safety,
operating, and maintenance information about your new lift truck. It
has been specially prepared to help you use and maintain your
CLARK lift truck in a safe and correct manner.
Your CLARK lift truck has been designed and built to be as safe and
efficient as today’s technology can make it. As manufactured, it
meets all the applicable mandatory requirements of ANSI / ITSDF
B56.1 Safety Standard for Powered Industrial Trucks. Each truck is
also furnished with equipment to help you operate safely; for
example, load back rest, parking brake, safety restraint system, seat
belts and horn are standard equipment.
Safe, productive operation of a lift truck requires both skill and
knowledge on the part of the operator. The operator must know,
understand, and practice the safety rules and safe driving and load
handling techniques described in this manual. To develop the skill
required, the operator must become familiar with the construction
and features of the lift truck and how they function. The operator
must understand its capabilities and limitations, and see that it is kept
in a safe condition.
Routine Servicing and Maintenance
Regular maintenance and care of your lift truck are not only
important for economy and utilization reasons; it is essential for your
safety. A faulty lift truck is a potential source of danger to the
operator, and to other personnel working near it. As with all quality
equipment, keep your lift truck in good operating condition by
following the recommended schedule of maintenance.

Introduction vii
Operator Daily Inspection — Safety and Operating Checks
A lift truck should always be examined by the operator, before
driving, to be sure it is safe to operate. The importance of this
procedure is emphasized in this manual with a brief illustrated review
and later with more detailed instructions. CLARK dealers can supply
copies of a helpful “Drivers Daily Checklist.”
Planned Maintenance
In addition to the daily operator inspection, CLARK recommends
that a planned maintenance and safety inspection program (PM) be
performed by a trained and authorized mechanic on a regular basis.
The PM will provide an opportunity to make a thorough inspection of
the safety and operating condition of your lift truck. Necessary
adjustments and repairs can be done during the PM, which will
increase the life of components and reduce unscheduled downtime
and increase safety. The PM can be scheduled to meet your
particular application and lift truck usage.
The procedures for a periodic planned maintenance program that
covers inspections, operational checks, cleaning, lubrication, and
minor adjustments are outlined in this manual. Your CLARK dealer is
prepared to help you with a Planned Maintenance Program by
trained service personnel who know your lift truck and can keep it
operating safely and efficiently.
Modification of the truck prohibited
Unauthorized modification of the truck is not permitted, and, in case
that a problem has occurred due to a modification without permis-
sion, the warranty service shall not be provided.
For instance, the modifications which may void the warranty include
those that may negatively affect the performance, durability and
safety of the truck due to addition of unauthorized electrical devices
(lamp, black box, electrical instrument, communication equipment,
etc.), braking system, steering system, vision improvement system
and detachable attachment device that were not mounted when the
equipment was shipped out of the factory.

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

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

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

Section 1. General Safety Rules
Contents 1-1
General Safety Rules
Contents
Daily Inspection ..................................................... 1-2
Do’s and Don’ts ...................................................... 1-3
Seat Belts ................................................................ 1-4
No Riders ................................................................ 1-5
Pedestrians ............................................................. 1-6
Operator Protection ............................................... 1-7
Fork Safety ............................................................. 1-8
Pinch Points ........................................................... 1-9
Travel .................................................................... 1-10
Grades, Ramps, Slopes, and lnclines ................ 1-11
Surface and Capacity ......................................... 1-12
Tip-Over ................................................................ 1-13
What to do in Case of a Tip-over ........................ 1-14
Parking .................................................................. 1-15
General Tire Maintenance, Inspection,
and Repair ............................................................ 1-16

1-2 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. They know how to make repairs
safely. (See Section 4)
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Section 1. General Safety Rules
Do’s and Don’ts 1-3
Do’s and Don’ts
Don't mixdrugsor alcohol with yourjob.
Do watch for pedestrians.
Don't block safety or emergency
equipment.
Do wear safetyequipment
when required.
Don't smoke in "NO SMOKING"areas
or when refueling.
XXX
If forklift truck isto be operated outdoors
during rainyconditions, make sure cab is
in place to prevent damage to electrical
components.

1-4 Seat Belts
Seat Belts
ALWAYS BUCKLE UP
Seat beltscan reduce injuries.

Section 1. General Safety Rules
No Riders 1-5
No Riders

1-6 Pedestrians
Pedestrians
Estar atento cuando se maneja. Mirar en el sentido de
marcha. Los peatones pueden estar usando la misma vía
que usted. Sonar la bocina en todas las intersecciones o
puntos con visibilidad limitada. Estar atento a la
presencia de las personas en la zona de trabajo, aun si el
montacargas tiene luces de advertencia o alarmas. Las
demás personas pueden no estar atentas a lo que hace
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.

Section 1. General Safety Rules
Operator Protection 1-7
Operator Protection
Keep under the overhead guard.
Always keep your body within the confines of the truck.

1-8 Fork Safety
Fork Safety
Never allow anyone to
walk under raised forks.
There is special
equipment to raise
people for overhead
work. DO NOT USE
LIFTTRUCKS.
2372604
DANGER