Clark ESX Series User manual

65702
8
Book No. 2827061
OM-718 Do not remove this manual
from the truck.
Operator's Manual
ESX Stand-Up Counterbalanced Trucks

©2007 Clark Material Handling Company
Record the following information pertaining to your truck.
Model No. __________________________________________
Serial No.___________________________________________
Customer Truck Identification 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.

i
YOU can prevent accidents
Then: Practice operating your
truck safely.
And: Keep your truck in safe
operating condition with
correct and timely
maintenance.
KNOW YOUR TRUCK
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.
Breaking these rules will cause serious or fatal injury to
yourself and others
Operator's Manual
You must be trained and authorized to operate a lift truck.
65702
8

ii
A Message to CLARK Lift Truck Operators
Lift trucks are specialized machines with unique operating character-
istics, 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
Forthesereasons,CLARK wantsyou toknow aboutthe safeoperation
and correct maintenance of your lift truck.
This manual is designed to help you operate your lift truck safely. This
manualshowsand tellsyouabout safety inspectionsandthe 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 un-
derstanding. A section on maintenance and lubrication is included for
the lift truck mechanic.
A Message to CLARK Lift Truck Operators

iii
A Message To CLARK Lift Truck Operators
Theoperator’smanualisnotatrainingmanual.Itisaguidetohelptrained
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
hazardsinyourworkareasandavoidorcorrectthem.Itisimportantthat
you know and understand the information in this manual and that you
know and follow your company safety rules! Be sure that your equip-
ment 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 thislifttruck,besureyouunder-
stand all driving procedures. It is your responsibility, and it is important
to you and your family, to operate your lift truck safely and efficiently.
Beawarethatthe Federal Occupational Safety and HealthAct(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
inspectionbeperformedbeforeeveryshift.Ifyouthinkyouneedtraining
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

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 Maintenance and Care ............4-1
Section 5. Operating Procedures.............................5-1
Section 6. Planned Maintenance..............................6-1
Section 7. Specifications .........................................7-1
Index ................................................................... Index-1
Contents of this Manual

vi
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
maintenanceinformation aboutyournewlifttruck. Ithas beenspecially
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
efficientastoday’stechnologycanmakeit.Asmanufactured,itmeetsall
theapplicablemandatoryrequirementsofANSI B56.1SafetyStandard
for Powered Industrial Trucks. Each truck is also furnished with equip-
ment to help you operate safely; for example, load back rest, parking
brake and horn are standard equipment.
Safe,productiveoperationofalifttruckrequiresbothskillandknowledge
on the part of the operator. The operator must know, understand, and
practice the safety rules and safe driving and load handling techniques
describedinthismanual.Todeveloptheskillrequired,theoperatormust
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
otherpersonnelworkingnearit.Aswithallqualityequipment,keepyour
lift truck in good operating condition by following the recommended
schedule of maintenance.
Introduction
Introduction

vii
Introduction
Operator Daily Inspection — Safety and Operating Checks
A lift truck should always be examined by the operator, before driv-
ing, 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
Inaddition tothe dailyoperator inspection, CLARKrecommends thata
plannedmaintenanceandsafetyinspectionprogram(PM)beperformed
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
operatingconditionofyourlifttruck.Necessaryadjustmentsandrepairs
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.

viii
This manual is a digest of essential information about the safe opera-
tion, 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.
Section4,OperatorMaintenanceandCare,presentsdetailsonhowto
perform the operator's daily safety inspection and refuel the lift truck.
Section5,OperatingProcedures,discussesmorespecificinstruction
on the safe, efficient operation of your lift truck.
Section 6, Planned Maintenance, describes the PM program.
Section 7, 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
wereineffectatthetimeofprinting.CLARKMaterialHandlingCompany
reserves the right to make improvements and changes in specifica-
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 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
finddescriptionsofthecomponentsof 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
How to Use this Manual
How to Use this Manual

ix
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 specifications.
Take time to carefully read the “Know Your Truck” section. By acquiring
agoodbasicunderstandingofyourtruck'sfeatures,andhowtheyfunc-
tion, you are better prepared to operate it both efficiently and safely.
In “Planned Maintenance,” you will find 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 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 pro-
cedures 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.
Operateyourlift truck safely; carefuldrivingis your responsibility.Drive
defensivelyandthinkaboutthesafetyofpeoplewhoareworkingnearby.
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
driveorserviceit.Ifthetruckyouoperateisnotequippedwithamanual,
ask your supervisor to obtain one and have it attached to the truck.
And,remember,yourCLARKdealerispleasedtoansweranyquestions
about the operation and maintenance of your lift truck and will provide
you with additional information should you require it.

x
Safety Signs and Safety Messages
Improperoperationcancauseaccidents.Don’ttakechanceswithincor-
rector damaged equipment.Read andunderstand the proceduresfor
safe driving and maintenance outlined in this manual. Don't hesitate to
askforhelp.Stayalert!Followsafetyrules,regulations,andprocedures.
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.
Safetysignsandmessagesareplacedinthismanualandonthetruck
toprovideinstructionsandidentifyspecificareaswherepotentialhazards
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
thesemessagesarenot 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
Safety Signs and Safety Messages

Section 1. General Safety Rules
1.1
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
General Safety Rules
Contents

1.2
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.
Daily Inspection
Daily Inspection
CAUTION
DONOTMAKE REPAIRSYOURSELF. Lifttruckmechanics
are trained professionals. They know how to make repairs
safely. (See Section 4)

Section 1. General Safety Rules
1.3
XXX
OM0001
OM0002
OM0003
OM0004
OM0005
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.
Do's and Don'ts

1.4
No Riders
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.
No Riders

Section 1. General Safety Rules
1.5
Pedestrians
718002
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

1.6
718003
Operator Protection
IMPORTANT
• Keep under the overhead guard.
• Always keep your body within the confines of the
truck.
• Be especially careful when traveling in reverse and ma-
neuvering in tight areas.
Operator Protection
Keeparmsandlegsinthe
operator compartment

Section 1. General Safety Rules
1.7
657006
657005
There is special equip-
ment to raise people for
overhead work. DO NOT
USE LIFT TRUCKS.
Never allow anyone
to walk under raised
forks.
DANGER
Fork Safety
Fork Safety
2372604

1.8
718007
Pinch Points
2791862
WARNING
Keep hands, feet and legs out of the upright.
Pinch Points
WARNING
Don't use the upright as a ladder.
CAUTION
Never try to repair the upright, carriage, chain, or attach-
ment yourself! Always get a trained mechanic.