Om 982

ENG ENGLISH
ENG Operator`s Manual

[Original instruction]
C40/45/50s/55s D
C40/45/50s/55s L
C60/70/75/80 D
C80D900
C60/70/75 L
Rated Capacity : 4000 ~ 8000 kg
Part No. 8116771

Book No. OM 982 (Rev 3.12)
Nov. 2022
CLARK MATERIAL HANDLING INTERNATIONAL

215, Ojeong-ro, Bucheon-Si, Gyeonggi-do, Korea
Tel: 82-32-680-6300 [ www.clarkmhc.co.kr ]
Contents
Foreword ........................................................................ II
1. Safety Regulations ................................................. 1.1
2. Know your Forklift Truck ....................................... 2.1
3. Daily Inspection ...................................................... 3.1
4. Maintenance and Care ........................................... 4.1
5. Lubrication and maintenance plan ....................... 5.1
6. Lubricant Recommendations ................................ 6.1
7. Technical Data ........................................................ 7.1
8. Specification ........................................................... 8.1
9. Attachments ............................................................ 9.1
10. DPF System ........................................................ 10.1
I
FOREWORD
All technical data and all illustrations in these Operating Instructions are without obligation.
We reserve the right to make alterations in the interests of technical progress.
The performance, economy and security of a forklift truck depend to a great extent on its proper handling as
well as on regular maintenance and care. The following Operator Instructions should help you to make the
best use of your CLARK forklift truck. Read through the instructions carefully and follow the given procedures
strictly. Acquaint yourself with the controls and in particular observe all the safety regulations. Carry out all
maintenance and care work at the recommended time intervals. CLARK forklift trucks are characterized by
their easy maintenance design. You will therefore be able to carry out this work in a short time and without too
much effort.
Regular maintenance and care of your forklift truck is recommended not just on economic ground because a
faulty forklift truck represents a source of potential danger.
In addition you should observe the national regulations which provide inspections at set intervals of time. The
contents and volume of the regulations could be different from country to country.
For any check-up, repair, maintenance and all other work concerning your forklift truck, please contact your
CLARK dealer. Here, specially trained service personnel will be glad to help you at any time. Should you desire
to carry out maintenance, repair and all other work on your forklift truck yourself, you can of course obtain all
required spare parts and all necessary materials from your CLARK dealer. Please note: Only original CLARK
spare parts guarantee the trouble free functioning and optimum economy of your forklift truck. Original
CLARK spare parts are the best for your forklift truck. With their dimensional stability as well as their high
material quality due to a continuous and strict quality control, they correspond to those parts used in the
series production of our forklift trucks.
Finally we would like to draw your attention to the fact that any secondary damages due to improper han-
dling, insufficient maintenance, wrong repairs or the use of other than original CLARK spare parts waive
any liability by CLARK.
Any independent constructional modification or extension of the fork lift truck can unduly affect the
safety resulting in the EU conformity being invalidated.
II
1. Safety Regulations
Guidelines for the due and correct use of CLARK forklift trucks
1. The forklift truck

Use in accordance with the regulations
Stability
Driver's protection
2. Inspection
Inspection prior to bringing into first use.
Regular and statutory inspections
3. Operation
The driver
The work area
Operating aisles
Hazard areas
Operation in closed rooms
Traveling on public roads
Handling of loads
Picking up and placing loads
When driving
Visibility
Stability
Gradients
Loading and unloading vehicles
With raised forks
Tilting the upright
Behavior during operations
Traffic rules
Traveling
Safety of people
Troubleshooting
Daily inspection before operation
Illumination
Leaving the forklift truck
Transport of forklift trucks in elevators
Attachments
Additional regulations for special tasks
Shunting of rail vehicles
Forklift trucks used as working platforms
Forklift trucks used for the transport of persons
Forklift trucks used for the transport of molten masses
Forklift trucks used for the transport of containers
Trailer operation
Parking the forklift truck
Refueling of forklift trucks with combustion engines
Repairs
1.1
1) The forkift truck

Use in accordance with the regulations
• Forklift trucks may only be used in accordance with the regulations, fol-
lowing these operating instructions.
• Forklift trucks with fork arms are designed to take up, transport and
stack individual loads and palleted goods.
• If a forklift truck is to be used for other purposes, permission must be
gained from CLARK and if necessary from the supervisory authorities
responsible, in order to prevent hazards arising.
• The use of attachments expands the possible uses of a forklift truck
many times over. Refer to the attachments operating manual for correct
use of the accessories in accordance with the regulations.
• No vehicles of whatever type may be pushed with the forklift truck. Nor
may it be used as a towing machine for rail vehicles. These prohibitions
do not apply if the forklift truck is especially equipped for these pur-
poses.
Stability
• CLARK forklift trucks are absolutely stable in the permitted working posi-
tions and when driving, if used with due care and attention and observ-
ing the maximum permissible loads. Proof of sufficient stability is given
by CLARK through tests on a tiltable platform corresponding to the
related regulations (EC guideline No. 2006/42/EC, American Safety
Standard ASME B56.1).
• Therefore, never overload your forklift truck. Take care as to the correct
weight and load center of your load. The mounting of extra counter
weights to increase the load capacity is not permitted. Memorize the
maximum permissible rated capacities of your forklift truck and, if you
use one or several attachments, also the remaining load capacities indicated separately for these attachments.
The load capacity of a forklift truck is influenced by the load center and also the lift height.
Driver's protection
• When stacking above the eye level of the seated driver an overhead
guard(1) must be used. If small parts are handled, a load backrest(2) (1)
(2)
must be present.
1.2
2) Inspection
Inspection prior to bringing into first use
• The forklift truck must be checked as to its functionability prior to taking it
into operation. The working area to be used must be tested as to its
ground conditions (carrying capacity, flatness, sufficient width).
Regular and statutory inspections

• Forklift trucks must be regularly checked by trained and authorized service personnel. The time intervals
between the regular checks are often prescribed by a national authority. CLARK recommends an annual
check-up based on an average operational performance.
• Statutory inspections are required, if for instance the operator adds an attachment to his forklift truck. Modifica-
tions to the forklift truck are prohibited.
Modification of the truck prohibited

Unauthorized modification of the truck is not permitted, and, in case that a problem has occurred due to a modifi-
cation without permission, the warranty service shall not be provided.
A) Except where provided in “B)”, no modifications or alterations to a powered forklift truck, which may affect, for
example, capacity, stability or safety requirements of the truck, shall be made without the prior written
approval of the original truck manufacturer, its authorized representative, or a successor thereof.
For instance, the modifications which may void the warranty include those that may negatively affect the per-
formance, 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. When the manufacturer or its successor approve a modification or alteration, they shall also make and
approve appropriate changes to capacity plate, decals, tags and operation and maintenance handbooks.
B) Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest
to the business, the user may arrange for a modification or alteration to a powered forklift truck, provided,
however, that the user shall:
• Arrange for the modification or alteration to be designed, tested and implemented by an engineer(s) expert
in forklift trucks and their safety
• Maintain a permanent record of the design, test(s) and implementation of the modification or alteration
• Approve and make appropriate changes to the capacity plate(s), decals, tags and instruction handbook
• Affix a permanent and readily visible label to the truck stating the manner in which the truck has been modi-
fied or altered together with the date of the modification or alteration, and the name and address of the orga-
nization that accomplished the tasks.
1.3
3) Operation
The driver
• Only trained and authorized personnel may be charged with driving a
forklift truck. Please also observe the legal regulations in your country
• The authorization of the supervisor shall be obtained for each, use about
which the operator is not sure if it conforms to the intended use. In par-
ticularly difficult cases such as a simultaneous use of two forklift trucks
for the transport of heavy or bulky loads, the supervisor himself shall be
present at the site and, assume the responsibility and management for
this transport.
• Please carefully read this Manual and understand the contents.
• We strongly recommend that you wear safety clothes suited for your
work. Any wide or loose clothing must be avoided. Always wear a hard
hat, safety shoes and, if required, safety glasses.
• Never drive your forklift with wet or oily hands or shoes. If you slip off the
brake pedal or the wheel, serious accidents and personal injury may
occur.
The working area

Operating aisles
• Never drive in areas which are closed to forklift trucks, but only use
aisles cleared for forklift truck operation. Traveling aisles and loading
areas must be clearly identified and free of obstacles. Forklift trucks
shall only be used on routes without sharp curves, excessive slopes and
gates which are too narrow or too low. Watch the road surface - it must
be sufficiently smooth and free of bumps, where possible. The floor
within the working area for the stacking of loads must be even, horizon-
tal and stable. The admissible area and point load of driving lanes or
routes may not be exceeded. Please further observe the legal regula-
tions in your country.
Hazard areas
• Forklift trucks which are to be used in flammable or explosive environments must be specially equipped for this
purpose. The hazard areas must be identified accordingly.
Operation in closed rooms

• Forklift trucks with combustion engines may only be operated in closed
rooms when any formation of harmful exhaust concentrations is pre-
vented (danger of intoxication). This can only be achieved through
exhaust gas cleaners (catalysts) or sufficient ventilation. GasG powered
forklift trucks may not be operated in the vicinity of excavations or in
rooms below ground level. All parking areas must be sufficiently venti-
lated.
1.4
Caution for Exhaust Gas

• Operation in wholly or partially enclosed areas is only permitted if no
inadmissible concentrations of hazardous exhaust gas components are
created in the breathing air. Particulate filters shall be used with diesel-
powered forklift trucks, if necessary.
• The special regulations for the use of trucks operated with LP gas shall
be observed.
• In a closed or poorly ventilated space, the carbon monoxide, which is a
colorless and odorless gas having strong toxicity, contained in the
engine exhaust gas can poison the people in the space without being
aware of the poisoning.
• Keep the work space well ventilated and discharge the exhaust gas to outside of the space.
• Keep the work space clean and the floor dry.
Getting ON/OFF the Equipment

• It is very dangerous to jump on or off the equipment.
• To get on or off the equipment, stop the equipment and use guiderail or
steps in order not to lose the balance of your body.
• The general rule is therefore that the operator shall always dismount
when facing the truck.
• When getting on or off the equipment, do no grab the gear lever or steer-
ing wheel.
• Keep the guiderail or steps clean and well-maintained.
Traveling on public roads

• When traveling on public roads with the forklift truck, it must be equipped in accordance with the respective
national regulations. The appropriate permission must be applied for from the competent authority.
Electrostatic charge
• If an electrostatic charge occurs as a result of the type of the tyres and floor, an appropriate reduction in ten-
sion must be ensured.
Handling of loads
Picking up and placing of loads
• Forklift trucks must never be loaded in excess of their rated capacity.
The values indicated on the name plate apply only when the upright is in
a vertical position.
• Spread the forks as far as possible. Always position the forks under the
load as far as is practicable. The load shall not protrude significantly
over the fork tips and the fork tips shall not extend substantially beyond
the load. Take care that the load is correctly balanced (centered) on both
forks. Check the stability and balance of the load. Never lift a load with
one fork only.
1.5
• When storing and stacking loads, correct placement is essential. Always

place the loads carefully. Make sure that you do not exceed the maxi-
mum permissible stacking load when stacking and storing loads onto
shelves.
• There shall be an adequate clearance between the highest parts of fork-
lift trucks or the load and the fixed parts of the surrounding areas.
• Never move loads stacked higher than the carriage backrest. The simul-
taneous pick-up of several unit loads is not advised. Defective unit loads
should not be moved or stacked.
• The following procedure shall always be observed:
If another person comes close to the mast, the lifting or lowering movement shall be stopped immediately.
Drive directly to the stack with a lowered, tilted or reached-back load
Keep the mast in a vertical position
Raise the load to the stacking height
Drive the truck carefully forward until the load has entered the stack and, if necessary, push the load forward
Lower the load
Look backwards
Reverse the truck so that the fork arms can be lowered without touching the stack
Lower the fork arm to just above the floor and tilt the mast backwards
Only proceed with a lowered load in a tilted position and, if necessary, reached back
(this does not apply for forklift trucks designed for driving with an,elevated load)
Only tilt forward in front of or over the stack with a raised load lifting device if the forklift truck is intended for
this purpose.
• If there is a risk of small loads falling through the struts of the overhead guard, an appropriate load protection
screen or a supplementary screen shall be used on the operator's overhead guard. If there is a risk of raised,
large compact load units falling on the operator's overhead guard, e.g. rolls of paper, it must be established
whether the existing overhead guard is appropriate for this use. Appropriate measures shall be taken if neces-
sary.
Transport of swinging loads

The transport of swinging loads is only permitted with the consent and approval of the forklift truck manufacturer.
The following points must be observed when transporting swinging loads:
The swinging of the load shall be prevented by the right selection of speed and the way of driving (careful
braking and steering). Jerky movements should always be avoided.
Driving on inclines or slopes with a hanging load is forbidden.
The fastening means of the suspended load shall not be unintentionally moved or loosened.
It shall be ensured that there are no persons in the driving lane and in the driving direction
It shall be ensured that no persons are in danger as a result of the swinging loads.
If necessary, appropriate aids shall be made available (e.g. holding ropes or bars) and that they are used by
the persons for guiding the load.
A load restriction may be necessary depending on the length of the swinging load. The forklift truck manu-
facturer shall be contacted for this purpose.
Transport of inflammable loads

The transport of molten loads is only permitted with the consent and approval of the forklift truck manufacturer.
The following instructions must be observed if molten loads are being transported:
A slopping over of the load must be prevented by a correct selection of speed and manner of driving (careful
braking and steering). Jerky movements should always be avoided,
Driving on inclines or slopes is forbidden with molten loads
The lowering speed shall be limited if necessary.
1.6
When driving
Driving conduct
The operator shall comply with internal instructions on in-house traffic regulations and the relevant road traffic
regulations on public roads. The speed of the forklift truck has to be adjusted to local conditions. For example, the
operator shall drive slowly in bends, at and in narrow passageways or gates, when driving through swinging
doors, at blind intersections or on uneven surfaces. He always shall keep a safe braking distance from vehicles
or persons in front of him and he must always have his truck under control. Sudden stops, quick turns, overtaking
at dangerous or blind intersections shall be avoided.
With the exception of forklift trucks specially fitted for this purpose, forklift trucks with a operator's seat or stand
shall not be put in motion when the operator is not assuming the operating position.
Whilst driving, it is forbidden, amongst other things:
• To put arms or legs outside the truck
• For the operator to lean over the edge of the forklift truck
• To move from one truck to another or to fixed parts of a building.
The operator shall bring his truck to a standstill as soon as possible if the power steering equipment is defective.
Visibility
• Do not drive forwards if the load is hindering your view. In this instance,
drive backwards.
• The operator shall always look in the driving direction even when revers-
ing over a short distance.
• If, however, the view is still impaired, a banksman should be used to
overcome the hindrance. The forklift truck may then only be driven at
walking speed and with particular caution. (See also page 1.10 ”Behav-
ior during Operation”)
• Ensure that the working area of your forklift truck is adequately illumi-
nated.
Stability
• Travel with the load tilted back and keep the load as low to the ground
as possible (say 10 cm). This makes a better stability of the forklift truck.
Keep in mind that an unladen forklift truck has a lower stability than a
laden truck. Always use the same care when traveling whether laden or
unladen.
Braking
• The driving speed must be selected so that there is always an adequate
braking distance in front of the truck. It should be noted in this respect
that the pure braking distance increases at a higher rate than the speed and that the drive wheels may spin or
the truck may overturn in case of sudden braking.
• A braking test shall be carried out after the forklift truck has been washed. If the brakes do not function properly
from the operator's seat of the forklift truck, the truck must be brought to a standstill by applying the parking
brake
1.7
Gradients
• Always keep the load on the upper-side on gradients. This prevents the
slipping of the load from the forks or the rolling over of the forklift truck.
In a laden condition, travel uphill in forward direction and downhill in
reverse direction. With restricted visibility always seek assistance when
travelling on gradients. Do not turn when going up or down a ramp.
Never drive diagonally across the gradient. The forklift truck can easily
roll over in this case. Always reduce your speed and drive with special
care.
• Gradients should always have a sufficiently rough surface. For smooth,
and even travel avoid any load contact with the ground.
• Gradients used by forklift trucks shall not exceed the limits specified by the manufacturer
Loading and unloading of vehicles

• Always approach the vehicle carefully. Make sure that load distribution is
well balanced when loading or unloading. If you have to travel onto a
vehicle for the loading or unloading process take particular care not to
exceed the maximum permissible load capacity of the vehicle floor and
the bridge plate. Both must be able to support the weight of the truck
and load. Bridge plates must be securely fixed and must not slip when
being entered. Secure the vehicle you enter with blocks against rolling.
When entering vehicles or travelling on bridge plates reduce speed and
be particularly careful. Also be very careful when travelling on bridge
plates, especially close to the ramp edges. Keep a safe distance from
the ramp edges particularly if the surface is wet or slippery.
Driving in containers
• The forklift truck shall be suitable for driving in containers. The operator shall ensure that the container to be
loaded or unloaded is sufficiently secured against rolling and that it can bear the load of the forklift truck.
• If lC-powered forklift trucks are used, section "Caution for exhaust gas" must be observed.
With raised forks

• Never move your forklift truck with the load raised and tilted forward.
Your forklift truck can lose stability in this condition. Only travel with the
upright extended in the immediate area for picking up and stacking the
loads. When raising the forks watch for obstacles above.
Tilting the upright

• The upright should only be tilted forward directly above the stacking area
when picking up or placing the load. Otherwise drive your forklift truck
with the upright tilted back.
1.8
Climatic condition for Operation

• Maximum ambient temperature continuous duty : + 40 °C
• Lowest ambient temperature : - 20 °C
• Service altitude : up to 2000m above sea level
• Relative humidity : in the range 30 % to 95 % (non-condensing)
Tips for Operation according to the Weather

1) Hot Weather
Observe following instructions for driving in hot weather.
Check the function of the radiator
If the heat radiation fins are dirty, the radiator and cooling system may overheat.
Clean the radiator fins by blowing with compressed air, on regular basis and as necessary.
Check if the cooling water is leaking.
Check, adjust as necessary, the tension of the fan belt.
If the engine is overheated and the cooling water is boiling, open up the engine hood, run the engine at low
idle speed to cool down the engine.
When the engine has cooled down, stop the engine.
Driving in hot weather impairs driving ability and work efficiency. Take a rest at regular intervals.
2) Cold Weather
! WARNING
Hydraulic systems respond to controls slowly in cold weather. It is strongly recommended to warm the
equipment up before starting operation.
Remove the ice, snow or frost on the cab window before start operation.
Take utmost care when driving on an icy surface.
Do not step on slippery surface when getting in or out of the equipment.
Use an ice removing device equipped with a handle and ladder to remove ice. Snow or frost.
Check the anti-freezing solution in the radiator. If the coolant in the radiator is frozen, the radiator may get
serious damage.
Replace worn tires immediately. Especially, worn tires can cause serious accident on icy ground.
Do not abruptly brake or start on icy ground.
! WARNING
Do not expose bare skin to the cold, metal surface of the equipment.
Otherwise, skin can be frozen and stick to the metal surface.
3) Rainy Weather
If forklift truck is to be operated outdoors during rainy conditions,
make sure cab is in place to prevent damage to electrical compo-
nents.
1.9
Operator Cabin
The operator cabin is optional equipment and could be provided with front
and rear windows, emergency rear window, and cooling and heating sys-
tem.
Observe following instructions when driving an equipment provided
(A)
with an operator cabin.
Take appropriate measures to secure field of view when driving in bad (B)
weather, such as rail, snow, frost, etc.

When operating with the cabin door (A) open, fix the door to the catch
(B) firmly.
Behavior during operation

Traffic rules
• Observe all safety regulations and all warning signs. Always behave as
if traveling on public roads. Reduce the speed of your forklift truck and 6t 3m
use the horn near corners, entrances, exits and near people.
Safety Belt
• Wear the safety belt below your waist and minimize the movement.
• Be sure to wear the safety belt before starting the equipment.
When driving
• Avoid any abrupt starting, excessive travelling speeds and sudden direc-
tional changes.
• Select the driving speed so that sufficient stopping distance is always
available. It must be remembered that the net stopping distance
increases by approximately the square of the speed and that sharp
braking of the forklift truck can cause the drive wheels to slip and the
truck to tip over.
• Braking on curves further increases the danger of the forklift truck tip-
ping due to the tilting moment which occurs.
• Reduce speed before curves and ramps, in narrow passageways, on
wet roads and restricted visibility.
• Always operate the truck carefully even without a load. An unladen fork-
lift truck can roll over more quickly on curves than a laden truck. Always
operate your truck safely and avoid accidents.
• Always look in the driving direction. No parts of the body should extend
outside the truck.
• Always keep a sufficient distance from other vehicles so as to be able to
stop in time in case of danger.
1.10
Safety of people
• Always make sure that there is nobody within the hazardous area of
your forklift truck. Ask these people to leave the area immediately.
• Never use your forklift truck with persons within this area. Never allow
anyone to stand under the lifted load or to pass under the load.
• Do not let other persons ride on the truck, on trailers or on the load.
Lift truck tip over

Lift trucks can be tipped over if not operated properly. Teach your operators
that there are a number of things they must watch for that can cause a
truck to tip over.
• Slow down before turning. Go into and out of turns slowly, using a slow
rotation of the steering wheel.
• Drive with the forks or attachments lowered and tilted back only enough
to stabilize the load.
• Raising a load high moves the center of gravity and lowers the capacity.
Keep your loads down, with the masts vertical or tilted back only enough
to stabilize the load. If you tilt a heavy load too far forward or back while
it is raised, you can tip your truck over.
• Check capacities; don’t overload the truck.
• Do not move unstable loads.
• Do not turn on down- and upslopes
• Do not drive with the load downhill on down- and upslopes
• Drive careful with swinging loads
• Drive careful and slowly at ramp edges or steps
• Move long, high, or wide loads slowly and carefully.
• Check your overhead clearance. Keep your truck at least 3m from any overhead electrical wires. Watch those
overhead obstructions, like pipes and low doors. If you hit them while you are moving, you can tip a lift truck
over.
• Don’t forget, your lift truck has rear steering. A turn into a soft shoulder or off a dock can tip a truck over. Watch
the steer end of your lift truck, and keep those steer tires on the road.
• Turn too sharply with forks raised and your truck can tip over, even at slow speeds and with no load. So take
your time: slow down.
• You may find that you have some long runs where you operate the truck empty, close to its top speed. Slow
way down before turning. Lift trucks are rear end heavy because of the counterweight used to offset loads. An
empty lift truck can turn over just like a loaded truck.
• Transporting spacious loads may in the result forklift truck tipping over in strong winds.
• When transporting liquids, a change in the centre of gravity within a picked-up container can result in the forklift
truck tipping over as a result of the effects of inertia e.g. when starting or braking or cornering.
1.11
The operator must wear personal safety devices and follow the instructions for safety to prevent serious personal
injury if the equipment overturns.
˄
1. Wear safety belt.
Never jump off the equipment.
2. Hold the steering wheel firmly.

Stiffen your legs to support yourself.
3. Lean against the opposite side wall, as shown in the figure.
Troubleshooting
Daily inspection before operation
• Before starting to work check your forklift truck daily in accordance with
the section "Daily Inspection". Always make sure that all safety systems
are operating correctly. Never operate a truck which is damaged or not
safe to operate. Check all warning and information decals. Any missing
or damaged decals must be replaced immediately.
• Safety devices and switches may not be removed or rendered unusable.
Predetermined set values may only be changed in agreement with the
manufacturer. Damage and other faults must be reported immediately
to the person in charge.
Illumination
• Forklift trucks used in poorly illuminated areas must be equipped with
work lights.G
Forklift trucks used on public roads must be equipped with a lightning
system in ac-cordance with national regulations.
1.12
Leaving the forklift truck

• When leaving the forklift truck, the engine shall be turned off.
• Never leave the forklift truck with the upright raised. P
• Lower the forks fully to the ground, tilt the upright forward, apply the
parking brake, put the gear levers in the neutral position and secure your
forklift truck against unauthorized use by third persons.
• Never park your forklift truck on gradients. But if this is necessary always
secure the truck with wedges.
Transport of forklift trucks in elevators

• The transport of forklift trucks in elevators is only permitted if the eleva- ELEVATOR
tor has a sufficient load capacity and is designed for this purpose. The
forklift truck must be secured in a way that it cannot touch the elevator
walls and may not move inadvertently. All persons travelling with the
forklift truck must enter the elevator after the forklift truck and must leave
before the forklift truck.
Attachments
• Trucks can be fitted with one or more auxiliary hydraulic functions to
operate attachments. The auxiliary hydraulics are indicated on the
levers with Symbols or AUX 1,2.
• Attachments must fit the carriage without overlapping the carriage. The
assembly of the attachment may only be carried out by trained and
authorized personnel. If your fork-lift truck is equipped with one or sev-
eral attachments, please read the respective operating instructions care-
fully.
• Use only exchangeable equipment where a risk analysis is carried out
by the owner. Only use attachments that have been fitted for the pur-
pose by the owner and do not restrict visibility in the travel direction. If visibility in the travel direction is limited,
the operating company must determine and apply suitable measures to ensure the safe operation of the truck.
Adapt the travel speeds to the visibility and load. Make sure you have sufficient visibility when reversing.
• Always observe the maximum permissible load capacity of your truck when fitted with an attachment.
• The attachment capacity plate is positioned directly beside the name plate of the forklift truck and indicates the
load capacity with a central load pick-up. Only use the attachment for the function specified. Always pick up the
load centrally and additionally secure it, if required, against falling, slipping, rolling, swinging or tilting. You must
have been trained in using the attachment.
• If attachments are fitted, the residual load capacities must be obtained from the manufacturer and indicated on
an additional capacity plate. Note that the load capacity decreases steadily with increasing height and off cen-
tre loading.
• Read the operating and maintenance instructions for the add-on unit carefully and make sure you are com-
pletely familiar with all hydraulic functions before transporting a load. Learn to use the hydraulics in a gentle
and jolt-free manner.
1.13
Additional regulations for special tasks

Shunting of rail vehicles
• Rail vehicles may only be moved by a forklift truck, if the latter is
equipped for this purpose. Trucks may never be used to tow a vehicle
from the front, they must always be at the side of the vehicle. The travel-
ing road must be sufficiently firm.
• For moving rail vehicles no rigid linkage but only ropes may be used.
The rope is to be attached at the rear eyelet on the last rail vehicle. The
forklift truck must be equipped with a slip coupling. The slip coupling
must open automatically at a traction angle of 45 degrees. Additionally,
the driver must be able to manually open the slip coupling from the
driver's seat in case of danger.
• When pushing rail vehicles, the forklift truck and rail vehicle may not be connected to each other. The forklift
truck must be equipped with a bumper extending laterally. Only the last rail vehicle may be pushed.
Forklift trucks used as working platforms

• Platforms on forklift trucks may only be used for occasional work which
is fully supervised. This platform must be firmly connected to the forklift
truck and with no extending parts. It must offer sufficient protection
against the lifting mechanism and any persons on the platform must be
secured against falling off. A working platform with persons on it may not
be moved and the driver may not leave the forklift truck.G
• In addition, observe the statutory regulations of your country.
Forklift trucks used for the transport of persons

• The transport of persons by the forklift truck is only permissible, if the
truck is equipped with appropriate seats or standing places and if the lat-
ter are designed for the transport of persons. Otherwise the transport of
persons is prohibited.
Forklift trucks used for the transport of molten masses

• Any containers for the transport of molten masses must be fixed to the
forklift truck and with no extending parts. The inadvertent operation of
rotating or tilting devices must be prevented. The stability of the forklift
truck must be guaranteed and the energy supply lines must be protected
against high temperatures. The driver of the truck must handle the load
with special care.
1.14
Forklift trucks used for the transport of containers

• Containers may be transported with forklift trucks only if the forklift trucks
are specially designed for this purpose and are equipped with a
spreader as a load pick-up device.
Trailer operation
• Trailors without a power-brake system may only be moved if the braking
force of the towing forklift truck is sufficient for a safe stop. For the per-
missible trailer load please contact your CLARK dealer.
• The tow tractor must be operated in such away that safe driving and
braking of the towed vehicle is ensured for all driving movements.
• Forklift trucks may only tow trailered loads, if they are specially equipped
for this purpose. The regular towing of trailers may only be carried out
with a special trailer coupling (not by means of a tow pin). Please
observe the information on the name plate of the trailer coupling. Trailer
loads effect the braking force of your forklift truck ; this particularly
applies to travelling on gradients. During the coupling process no persons are allowed between the trailer and
the moving forklift truck.
• After each connection of trailers, the operator shall check before driving off, if
1. the trailer coupling is secured against becoming loose,
2. the existing connections for brakes and lighting are closed
3. the existing brake power regulator has been adjusted to the actual hailing load
• Disconnected trailers shall be secured against unintentional movement (e.g. with blocks).
• If the forklift truck to be connected is operated from the outside, it shall be equipped for this purpose and the
operator shall not step between the forklift truck and the trailer. If an assistant is used to connect trailers, the
operator shall ensure that the person is not endangered during the coupling process.
• When driving through narrow road sections, the dimensions of the trailer and the load must be observed. In the
case of forklift trucks with trailers, an adequate minimum distance to fixed components shall be ensured when
turning and in curves.
• The admissible length of an forklift truck with trailers depends on the trailer or the truck and on the distance to
be driven and shall be determined by means of a trial run, if necessary.
• The operators shall be informed of the admissible number of trailers and if necessary any speed reductions for
individual stretches in the form of driving instructions. Adequate trial runs shall be made before commencing
towing operations;
• Please observe the valid regulations of your country.
1.15
Parking the forklift truck

• Park your forklift truck in authorized areas only. For this purpose:
Fully lower the forks to the ground P
Tilt the upright to the front
Apply the parking brake
Put the directional control lever in neutral position
Turn the key to "Off" position
Remove the key.
• Gas powered forklift trucks should not be parked in the direct vicinity of
heaters, excavations, tunnels and cellar windows. The check valve at
the liquefied petroleum gas tank must always be closed.
Refueling of forklift trucks with combustion engines

• Forklift trucks may only be refueled at the places provided for this pur-
pose. Switch off the engine when refueling.
• Only those fuels listed in the operating instructions may be used.
• Smoking as well as the handling of open fires is strictly prohibited during
the refueling process. This prohibition also applies when changing the
liquid gas tank. Wipe off any spilt fuel and never forget to close the fuel
tank again before restarting the engine.
• When filling liquid fuels, care shall be taken to ensure that no fuel is
spilled and, in particular, that no fuel comes into contact with hot compo-
nents.
• Please also observe the legal regulations of your country.
! CAUTION
You are responsible for every quality issue caused by use of a similar fuel or a fuel containing lots
of moisture and you will be charged even during the warranty period.
Repairs
• Never carry out any maintenance or repair work under lifted loads. If the
carriage must be lifted for maintenance and repair work, the carriage
and inner rails must always be secured against inadvertent lowering.
This can be obtained by means of a crane or with suitably dimensioned
wooden beams. The beams must be inserted under the inner rails in a
way that they cannot tip over. Any maintenance and repair work may
only be carried out by trained and authorized personnel
• Safety equipment and switches may not be removed or made inefficient.

Factory set adjustment values may not be changed.
• For any check-up, repair, maintenance and all other work concerning
your forklift truck, please contact your CLARK dealer. Here, specially
trained service personnel will be glad to help you at any time. Should
you desire to carry out maintenance, repair and all other work on your
forklift truck yourself, you can of course obtain all required spare parts
and all necessary materials from your CLARK dealer.
1.16
• Please note: Only original CLARK spare parts guarantee the trouble free functioning and optimum economy of
your forklift truck. Original CLARK spare parts are the best for your forklift truck. With their dimensional stability
as well as their high material quality due to a continuous and strict quality control, they correspond to those
parts used in the series production of our forklift trucks.
• Finally we would like to draw your attention to the fact that any second-
ary damages due to improper handling, insufficient maintenance, wrong
repairs or the use of other than original CLARK spare parts waive any
liability by CLARK.
Fire Extinguisher
• Prepare a fire extinguisher at the designated place and learn how to use
it to prepare for a fire accident.
• You must be well aware of the actions to take in a fire or other accident.
• Define the emergency contact and prepare communication means and
contact information.
Waste Disposal
• Do not dump waste oil in sewer or river.
• Collect drain oil in an oil pan.
• Never spill waste oil on the ground.
• The waste materials from oil, fuel, coolant, filter, or battery must be clas-
sified and kept at designated places and disposed of by an authorized
disposal service provider or nearest A/S center.
1.17
2. Know Your Forklift Truck
Appearance

1. Upright
2. Upright deckGnumber
(necessary for ordering spare parts for the upright)
3. Fork carriage
4. Drive axle wheel
5. Truck serialGnumber (necessary for ordering spare parts)
6. Steering axle wheel
7. Counterweight
8. Driver's seat
9. Driver's overhead guard
2.1
Operator’s compartmant and Controls

1. Steering handwheel
2. Forward / Reverse Lever
3. Inching pedal
4. Brake pedal
5. Seat adjustment lever
6. Horn button
7. Instrument pod
8. Turn signal lever
9. Accelerator pedal
10. Key switch
11. Lift control lever
12. Tilt control lever
13. Auxiliary control lever
14. Parking brake lever
IMPORTANT
Familiarize yourself with the controls and follow safe operating procedures.
2.2
1 3 4 2 6 7 8
9
10
29MAR06[WED] H
11
12
13
C 14
SYSTEM CHECK
5
OP A2
15 16 17 18 19 20
1. Fuel level Indication

2. Engine coolant temperature indicator
3. Date & Time display
4. Hourmeter & Speed
5. Message display & Travel direction icon
6. Parking brake LED
7. Seat belt LED
8. Error LED
9. Down arrow button (Mode button)
10. Up arrow button (Enter button)
11. Left arrow button (Slow speed button)
12. Right arrow button (Power button)
13. Plus button
14. Minus button
15. Glow plug preheat
16. Engine oil pressure
17. Transmission oil temperature
18. Alternator charging status
19. Engine check
20. Service lamp
• Keep your eyes on the warning instrument panel while you work with your forklift truck.
• If instrument panel does an unusual operation, you must inspect the forklift truck immediately.
2.3
Functions
General function
• The instrument pod consists of indicator lights, an hour meter, a circuit
board and attached gauges.
29MAR06[WED] H
• Provides the operator with important information about truck condition

and shut down the truck in the event that certain critical conditions are
present.
C
SYSTEM CHECK
OP A2
Engine shutdown function

• The instrument pod circuit board receives signals from sensors in vari-
ous locations and shut down the truck when coolant temperature, trans-
axle fluid temperature are excessive or engine oil pressure is low. Before shutting down the truck, the
instrument pod sounds alarm for 30G seconds and flashes indicator lights. After shutdown, the truck may be
restarted, but if the fault condition persists, the truck is shut down again in 30 seconds.
Seat switch application

• The instrument pod shuts down the running truck without warning when
the operator leaves the seat over 3 seconds with the FWD/REV switch is 시작
정지
engaged. Directional switch must open and key switch must always be
예열 시동
turned OFF, to restart engine.
• When directional switch is open and parking brake is not engaged, if the
operator leaves a seat, after 3 seconds, the instrument pod will sound
buzzer, and then honk horn.
• Setting the parking brake shall reset the alarm.G(The engine is not shut
down.)
Neutral start function and Anti-restart function

Neutral start function
• The instrument pod will not allow the starter to be engaged if directional switches are closed or key has been in
start position once. Key switch must always be turned OFF to restart engine.
Anti-restart function
• When engine is already running, the start motor does not rotate although the key switch is turned start position.
Anti drive and parking brake reminder function

• When parking brake is engaged, the truck cannot be driven although the directional switch closed.
• A parking brake alarm shall be activated if key switch is turned to the OFF position and the parking brake is
not applied. Applying the parking brake will reset the alarm.
2.4
Gauges and indicators

Coolant temperature gauge
It is divided into 2 colour zones according to temperature.
H
Blue ~ 64ϸ When starting to operate
Blue 64 ~ 110ϸ While normal operating
Red 110ϸ When overloaded, enter Red zone
113ϸ When overheated, buzzer sound for 1sec
116 ϸ~ FlashingG and Buzzer sound for 2sec ; C
Engine will be shut down after 30sec.
If the wire of cooling water temp gauge is broken or the gauge scale
doesn't move after 10min of engine starting, engine will be shut down
because the gauge is recognized as defective.
Fuel gauge
It displays the remaining fuel level in fuel tank.
If the level is low, the Flashing and buzzer will sound 1 Second and "LOW
FUEL" message will be displayed in the LCD window.
Transmission oil temperature

Indicates that the transmission oil 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 sec-
onds.(the buzzer sounds)
Engine oil pressure

Indicates engine oil pressure is too low. 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 sec-
onds.(the buzzer sounds)
Engine check
When the engine has problem, this LED will be on.
2.5
Alternator charging status

Indicates that the alternator is not properly charging the battery. Service is
required to correct the problem.
Service lamp
LED will illuminate when preset service time is reached. When LED is on,
the preset service time has been reached indicating that a PM(Planned
Maintenance) is required. For service contact your responsible CLARK
dealer.
Turn signal
Indicates that the turn signal switch is actuated.
Hour meter
Indicates total engine operating time. Operating time is recorded only when the engine is running.
It is possible to make sure operating status through the hour meter indicator.
Short Circuit Protection

In the event that any output circuit becomes connected directly to ground continuously, the shorted circuit must
be turned off to prevent continuously cycling the affected switch. The circuit that is shorted will have the pin num-
ber from the Main Connector displayed on the LCD. The specific circuit should continue to be shut off until the
keyswitch is moved to the off position, then returned to the on position. If the short circuit is not removed, the
shutdown sequence must be repeated until the short is removed. If the pin number is displayed on the LCD con-
tinuously though the key switch was recycled, call the maintenance staff.
Glow plug preheat

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.
Seat belt
At start-up, this light and a buzzer come on for three seconds to remind
the operator to fasten the seat belt. There is no start interlock.
IMPORTANT
You should always have your seat belt securely fastened when
operating your lift truck.
2.6
Parking brake
Indicates that the parking brake is engaged.
Anytime the parking brake is on, the truck can't be driven because the
transmission solenoid valves switch is off.
When the parking brake is not set and the key switch is turned to the OFF
position, the instrument pod will sound. If the parking brake is set, buzzer
P
and horn will not sound.
Date & Time

• It displays current date and time. 29MAR06[WED]
Hourmeter & Speed

Hour Meter
• It displays the accumulated operating hour and traveling speed of truck.
• When the traveling speed is less than 0.5km/h, it displays the accumu-
lated operating hour.
Speed Meter
• When the traveling speed is more than 0.5km/h, it displays the traveling
speed.
Message display
The model name, POWER selection, travel direction, warning and error
message are displayed.
• In normal operating condition: Model name/POWER/Travel direction Normal
• When several messages are simultaneously displayed, it will be dis- Error

played in the order of Error, Warning and Normal condition.
• If many error conditions are simultaneously occurred, the priority 2 Warning
Errors will be displayed. (The priority means Error number)
Travel direction icon

• Function: To display the traveling direction or gear selected condition of
truck OP A1 OP A2 OP A3
• Receive the traveling direction data from the T/M controller.
• Receive the gear selected data from the T/M controller.
N
OP A1
• When it is in neutral, the arrow and gear icon will not be displayed.
OP A1 OP A2 OP ML
2.7
Auto / Manual mode

• Each time push the button (‘-’) on the display, auto and manual mode
are changed.
• Auto Mode
C
1) Case : 1’st lever position
A. Gear is only changed according forward and reverse direction. CHECK
B. During drive on 1’st gear, change of direction. OP AT
Truck will be neutral status until the driving speed drops to under
3km/h. Then truck will drive to the 1’st gear.
2) Case : 2’nd lever position

A. When truck starts on first gear and aboves 5km/h, at that time truck
will start driving to the 2’nd gear automatically.
B. During drive on 2’nd gear, change of direction.
; During drive on 1’st gear, change of direction :
Truck will be neutral status until the driving speed drops to under 3km/h, Then truck will drive to the 1’st
gear.
; During drive on 2’nd gear, change of direction :
Truck will be neutral status until the driving speed drops to under 3km/h, Then truck will drive to the 1’st
gear and 2’nd gear automatically.
Error LED
• When an error occurs this icon is displayed to distinguish the condition
easily. When the error message is displayed, this icon is simultaneously
displayed.
2.8
DPF System (for Stage-5 KUBOTA Engine) ; See Chapter 10 for details
The DPF (Diesel Particulate Filter) system is an exhaust gas post-treatment system that raises the temperature
of exhaust gas by physically collecting and burning soot collected from the exhaust gas of a diesel engine after
driving a certain distance.
1) DPF soot level indicator
DPF
Soot level
indicator
2) DPF display
On the DPF display, the appropriate levels will light depending on regeneration stage on which the forklift truck
is operated:
Step(ON) Level Color Soot% Status
01 White 030 Almostfreefromsoot.
02 Green 3161

Sootaccumulatestosomeextent.
03 Green 61
11 Green 130

Sootaccumulatestoaconsiderable
extent;automaticregenerationis
12 Green 131 possible.
Severeaccumulationofsoot;automatic
2 Black regenerationorparkedregenerationis
possible.
Severeaccumulationofsoot;parked
3 Red regenerationispossible,butautomatic
regenerationisnotpossible.
Red
41 Sootaccumulatestosuchanextentthat
(Blink,1Hz)
itreducesenginepower.
Red (Contactserviceengineerforrepairs)
42
(Blink,2Hz)
2.9
3) DPF lamp
• Automatic regeneration (or Parked regeneration) lamp
- This lamp is displayed during activated automatic regeneration.
- Heavy duty working condition of engne is helpful to improve effeicency of auto-
matic regeneration.
- Exhaust gas smell can be occured during regeneration process.
- The indicator also lights up during parked regeneration.
• Parked regeneration request lamp

- This lamp is displayed during conducted parked regeneration by driver.
- Parked regeneration is available from soot level 2.
- Process for parked regeneation is as below.
1. Truck parked safely and pull the parking lever.
2. Shift directional lever into neutral.
3. Push the parked regeneration button.
- C40~55s button: instrument panel left side
- C60~80 button: instrument panel right side
Parked
4. If you input accelerator during parked regeneration, proccess will be regeneration
stopped immediately. button
- Exhaust gas smell can be occured during regeneration process.
! CAUTION
When conducting a parked regeneration, it is recommended that the ventilation
is sufficiently conducted.
• The indicator lights up when DPF regeneration is not possible due to a prob-
lem with the truck or other such causes.
1. In such cases, regeneration is allowed for 20 minutes, and the indicator turns
off automatically after 20 minutes.
2. Turn the key to the OFF position to turn the indicator off.
• The lamp lights up when an error in the engine system occurs.

- This condition indicates failure of the engine system (including the DPF filter).
Contact the service engineer for repairs.
2.10
Operator controls
Control Function
1) Mode selection button

• 6 mode selection buttons are located on right side of LCD.
• Each button has a specific function, and some have multiple functions.
2) Down arrow button (Mode button)

1. Pressing this button in normal operating condition, it will move to Menu
mode.
2. Pressing it in Menu mode, it will move to lower menu.
3. Pressing it in the lowest mode, there will be no change.
3) Up arrow button (Enter button)

1. Pressing this button, it will move to the upper menu.
2. It will also take the role of an "Enter" button when confirming a
changed password or main parameters.
4) Left arrow button

1. Pressing this button, it will move to left menu.
5) Right arrow button

1. Pressing this button, it will move to right menu.
6) Plus(+) button
1. Increase the data as set value in the current Menu mode.
2. It performs DR/OP selection function at normal mode.
It selects DR˧OP in turns, whenever pressing the button.
The data for the selected mode will be transferred to T/M controller.
Under S/L mode, DR/OP does not change.
7) Minus(-) button
1. Decrease the data as set value in the current Menu mode.
2. It performs ML/A1/A2 selection function at normal mode.
It selects ML ˧ A1 ˧ A2 in turns, whenever pressing the button.
The data for the selected mode will be transferred to T/M controller.
Under S/L mode, ML/A1/A2 does not change.
2.11
Operating Instruction of LPG (C60~75L)

Operating procedure
1) Key on/off
2) Select to drive mode of manual or automatic with the button on controller(Ref. Fig.1)
3) Gear position variation according to the lever(selector) position (Ref. Table.1)
(1) Automatic mode
Gear position changed according to the lever position
Especially, at lever position 3rd, it will automatically changed gear position from 2nd to3rd as speed up.
Return to 2nd position as stop and when restart with 2nd gear position.
(2) Manual mode
Gear position is same as lever position regardless driving condition.
Fig. 1 Selection method of manual or automatic mode

Controller Manual/Automatic Automatic Manual
Select button mode mode
Lever
(Selector)
Table.1 Gear position variation accoding to the lever position

Gear Position
Controller Lever(Selector) Forward Reverse
Mode Position
Speed up Speed up
Start (Max speed) Stop Start (Max speed) Stop
1st 1st 1st 1st 1st 1st 1st
Automatic
Mode
2nd 2nd 2nd 2nd 2nd 2nd 2nd
3rd 2nd 3rd 2nd 2nd 3rd 2nd
1st 1st 1st 1st 1st 1st 1st
Manual
Mode
2nd 2nd 2nd 2nd 2nd 2nd 2nd
3rd 3rd 3rd 3rd 3rd 3rd 3rd
2.12
Seat adjustment
2
• The seat adjustment lever (1) is located under the seat. By pushing the
lever to the side, the seat can be adjusted so that all controls may be
comfortably reached. Once you have adjusted the seat to the desired 3
position, release the lever.

• The back reclining adjustment lever(3) is located on the left side of seat 1
cushion. Pull the lever up and adjust the back, release the lever.
Attention
Be sure that the seat locking mechanism has engaged.
Seat belt
• When working with the forklift truck, the seat belt(2) must always be fitted correctly.
Adjusting the steering column

• The forkliftGtruck is provided with an adjustable steering column.
• Release the locking lever by pushing it up. After adjusting the steering
column, it must be relocked in place securely.
Steering System and horn button

• When the engine is running, the steering is assisted by a hydrostatic
steering system. This makes for very light steering over the entire turn-
ing range.
• The horn button is located in the center hub of the steering handwheel.
(or right side of steering column)
• Press it softly to sound the horn.
Attention
The power steering system will not work properly when engine is switched
off, considerably more force must be applied to the steering handwheel for
steering.
Never drive a forklift truck which has a defect in the steering system.
Observe the safety regulations outlined in "Section 1" of the operating
instructions, especially "3. Operation".
2.13
Direction Control Lever

• This lever is on the left next to the steering column. When changing the
direction of travel, make sure that your lift truck has come to a complete
stop before moving the lever to the other position.
IMPORTANT
For safety reasons, your CLARK forklift truck is fitted with a neu-
tral start switch. The purpose of this is to prevent the engine from
being started while the transmission is in gear. Thus the engine
may only start when the direction control lever is in the neutral
position.
Brake Pedals
1. Inching Pedal (2)
• The left hand brake pedal (inching pedal) has two functions in order to
improve handling and efficiency. While pressing the inching pedal the
first part of its movement interrupts the power from the engine to the
transmission. The level of disengagement is dependent on the move-
ment of the pedal. The last part of the travel applies the brake system.
• In this way you are able to lift a load rapidly with full engine RPM while
controlling the driving speed with the inching pedal like a clutch. This is
very useful in confined working spaces. 2 1
• On ramps or inclines the right hand brake pedal only should be used.
When using the inching pedal on slopes the lift truck could move invol-
untary backwards or forwards.
2. Brake Pedal (1)

• Activates brake operation.
Check the parking brake

• It is released by pushing the button on top of the lever and then by mov-
ing down the lever.
Opening the hood

• The hood release lever is located on the left side of hood. (C40-55s)
• Pull the lever to release the catch.(C60-80)
(C40-55s)
2.14
Starting the engine

• The starter key lock has 3 positions
1
1. Off (Park) 2
2. On
3. Start
Set the direction control lever in position neutral. Turn the starter key to 3
"On" position. The warning lights light up. Turn the key to the "start" posi-
tion. Release the key immediately when the engine has started, the key
switch will return to the "On" position automatically. A restart is only possi-
ble, if the key switch is turned to the "off" position, otherwise the start pro-
cess is locked at a before trying to start again "anti-restart" feature.
! CAUTION
Turn the key to START position one or two seconds after being turned to the ON position to start
the C40 ~ C80 trucks mounted with DEUTZ engine.
Cold start preheating ODiesel onlyP

Turn the starter key to "On"Gposition.G
The indicator light will illuminate indicating that an electrical operated glow
wire is heating the air in the induction manifold. After the light goes out, you
may start the engine.
If the engine fails to start, turn the key switch to "On" and wait for 30 sec-
onds before turning it to start.
Cold start (with LPG engines)

The driver must be clearly informed of the following safety instruction:
"After every cold start, let the engine run at least 1 - 2 minutes before
switching it off".
This warms up the evaporator pressure regulator installed in the LPG sys-
tem sufficiently, preventing liquefiedG petroleum gas from remaining in the
evaporator pressure regulator. A heightened pressure build-up is avoided,
which can lead to damage in the LPG system.
IMPORTANT
Also make sure to take the additional instructions concerning the
"LPG system" in sections 3 and 4 into consideration.
2.15
Inspection after Engine Startup

Inspect the following after starting the engine.
• Keep the engine in idle run for about 5 minutes without applying load.
• When the engine reaches the normal operation speed, Inspect that the engine coolant temperature indicator is
in the green zone.
• When the engine has reached the normal operation temperature, Inspect that various gauge indicator lamps
and warning lamps function properly.
• Inspect that the color of the exhaust gas is normal. Inspection if there is abnormal noise or vibration
Traveling
• During traveling, tilt the mast backward and lift the forks up from the ground by about 30cm.
• Take off your foot from the brake pedal and push down the accelerator pedal slowly to start.
• Acceleration and deceleration can be controlled by the degree of pushing down the pedal.
• Take care to decelerate in following cases : sharp turn, narrow passage, uneven ground.
• Observe speed limits, when operating indoors.
• To make a turn, slow down, bring the forklift truck to the turning position, slightly turn the steering wheel, and
then turn the forklift truck while paying attention not to hit anything with the rear side.
• For your safety, when climbing up a slope, travel with the load in the front, and when coming down a slope,
travel in reverse with the load to the rear.
• When starting on a slope, the parking brake can be used in place of the service brake pedal.
Engine stop
• Run the engine at idle speed briefly before turning the key switch to "Off"
1
(1).
• Turn the starter key to the "Off" position to stop the engine. The engine
will be stopped electrically.
Halting
• To stop the equipment, remove your foot from the accelerator pedal and slowly push down on the service
brake pedal slowly.
! CAUTION
Do not step on the service brake pedal suddenly.
Otherwise, the equipment can tilt forward, or the load, if loaded, can fall down.
2.16
Hydraulic control levers

• The levers of the control valve activate the lift and tilt cylinders as well as
any other hydraulic devices which are fitted.
• The knobs on the levers have symbols on them which makes their par-
ticular function clear.
Tilt control lever

• You control the direction in which the upright is tilted with the tilt control
lever.
• Pulling the lever backwards, causes the upright to tilt back.
• Pushing the lever forwards, tilts the upright forward.
• You control the tilting speed with the accelerator pedal.
• The travel direction lever is to be brought into the neutral position or the
inching pedal is to be depressed.
Lift control lever

• Pulling back on the lever causes the fork carrier to be lifted.
• The lifting speed increases variably, depending on the lever position.
• The travel direction lever is to be brought into the neutral position or the
inching pedal is to be depressed.
Controlling the speed of lowering

• The fork carriage moves down when you push the lift control lever for-
ward.
• You regulate the speed of lowering by the amount you push the lever
forward.
• The maximum speed of lowering is determined by a lowering regulator
valve.
2.17
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.
• Stop the vehicle before shifting between forward and backward travel-
ing.
• After the system has been activated, return the accelerator pedal to their
neutral positions and return to the seat before recommencing opera-
tions.
• Always operate the control switch from a properly seated position.
2) Lift lever
Raise and lower the forks for loading.
Raise..........................................Pull backward
Lower..........................................Push forward
Raising speed can be adjusted by the extent of pulling the lift lever.
Lowering speed can be adjusted by the extent of pushing the lift lever.
• After the system has been activated, return all of the levers to their neu-
tral positions and return to the seat before recommencing operations.
• If you return to the seat while lowering the lift lever, the forks will not
descend due to the return to neutral function.
3) Tilt lever
Tilt the mast forward and backward.
Forward .................................. Push forward
Backward................................. Pull backward
Forward or backward tilting speed can be adjusted by the extent of operat-
ing the lever.
NOTE
After the system has been activated, return the accelerator pedal
and all of the levers to their neutral positions and return to the seat
before recommencing operations.
4) Attachment lever
Operates the attachment.
Attachment speed can be adjusted by the extent of operating the lever.
NOTE
After the system has been activated, return the accelerator pedal
and all of the levers to their neutral positions and return to the seat
position before recommencing operations.
2.18
5) Clamp lever lock switch

This switch allows attachment lever operations to be switched between the
3rd and 4th ways.
It is for 3rd or 4th clamp lever lock option when clamp release is not
allowed, then pushing it with 3rd or 4th lever
! CAUTION
Operate the attachment lever switch when attachment operations
are stopped.
Attachments
• Forklift-trucks with hydraulic attachments are provided with one or two
further control levers. These are fitted on the right hand side of the lift
and tilt control levers. The function of these levers depends on the
attachment, and the driver should be trained in the operation of these
levers and the relevant attachment by the customer service.
• Please check the additional plate indicating the load carrying capacity.
• Here, you will find the maximum load capacity of your forklift-truck when
fitted with the respective attachment.
• Read the operating instructions for the attachment carefully, and make
yourself completely familiar with all hydraulic functions before carrying a
load. Learn how to operate the hydraulics smoothly and without jerks.
Action to be taken in emergency

• Move the vehicle to a safe location and ask a CLARK dealer for a repair.
If any phenomenon different from normal operations (failure to run or the like) among others, should take place,
ask a CLARK dealer for an inspection
Attachment - Control lever

• Actuating the corresponding lever causes the working speed to be increased automatically through the accel-
erator pedal position.
• The direction lever is to be brought into the neutral position or the inching pedal is to be depressed.
Safety instructions for sideshifter and fork positioner attachments

• With a side shifter, with two fork arms fitted, you can pick up a load (see carrying force diagram), carry it and
shift it horizontally to the left and to the right.
• This makes it possible to pick up and set down the load precisely. Repeated shunting can thus be avoided.
• For attachments with the ability to move loads more than 100 mm either side of centre, the residual load
capacities must be obtained from the manufacturer and indicated on an additional capacity plate.
2.19
Safety instructions for clamping attachments (e.g. clamps, etc.)

• Falling loads can cause accidents. This can result in malfunctions and the load can fall accidentally.
Clamping attachments only be allowed on trucks which have a secondary function to prevent unintentional
release of the load.
Safety instructions for rotary attachments

• A non-centred load centre of gravity can result in accidents. When using rotary devices and non-centred loads,
the centre of gravity can be displaced from the centre with a high risk of accidents. Adapt the travel speed to
the load. Lift the load from the centre.
Safety instructions for telescopic attachments

• Accident risk from increased tipover hazard and reduced residual capacity. There is a greater risk of tipover
with extended telescopic attachments. Do not exceed the maximum loads specified on the capacity plate. Only
use the telescopic function for stacking and retrieving. Retract the telescopic attachment fully during transport.
Adapt the travel speed to changed load centre of gravity.
Safety instructions for attachments when transporting suspended loads

• Swinging loads and a reduced residual capacity can result in accidents. Transporting hanging loads can
reduce the stability of the truck. Adapt the travel speed to the load, less than walking pace. Secure swinging
loads for example with lifting slings. Reduce the residual capacity and have it certified by a expert. If the truck
is to be operated with hanging loads, proof of sufficient safety distance under local operating conditions must
be obtained from a specialist assessor.
Fork extension safety instructions

• Unsecured and oversized fork extensions can cause accidents. For fork extensions with an open cross sec-
tional area, carry only loads that are resting along the entire length of the fork extension.
• The basic fork length must be at least 60% of the length of the fork extension. Use only fork extensions with
the same fork cross section and minimum fork length of the truck and which comply with the details on the fork
extension data plate. Lock the fork extensions onto the basic forks.
• Mark any fork extensions with an incomplete or faulty lock and take them out of service.
2.20
Symbols indicating the movement of attachments

NOTE
The upper symbol indicates the movement of the attachment if the control lever is pushed forwards. The lower
symbol indicates the movement of the attachment if the control lever is pulled back.
1. Lifting / lowering / forks or mast
2. Tilting mast or forks forwards / back
3. Advancing / retracting reach frame or forks
4. Side shifting to the left / right
5. Increasing / reducing fork spread
6. Rotating mast or forks to the left / right
2.21
7. Actuating / releasing load holder
8. Pushing load off forks / pulling load on to forks
9. Opening / closing clamp
10. Rotating
11. Dumping / scooping with bucket
2.22
Fuses
• The fuses are located at the inside of cowl cover,
on the right when looking forwards.
• The fuse ratings are clearly visible on the fuses
KUBOTA GM,
C40-55s (Diesel / LPG) DEUTZ
Tier3 Stage 5 PSI 4X
F1 Turn Signal 10 Amp ̻ ̻ ̻ ̻
F2 Head Lamp 15 Amp ̻ ̻ ̻ ̻
F3 Rear Lamp 10 Amp ̻ ̻ ̻ ̻
F4 Tail Lamp 10 Amp ̻ ̻ ̻ ̻
F5 Horn 5 Amp ̻ ̻ ̻ ̻
F6 Sub Controller (B+) 5 Amp ̻ ̻ ̻ ̻
Sub Controller (IG) 5 Amp ̻ ̻ ̻
F7
Brake 5 Amp ̻
Engine Shutdown Relay 10 Amp ̻ ̻
F8 Engine Shutdown Relay 5 Amp ̻
Engine Shutdown Relay 15 Amp ̻ ( ( (
F9 Spare 15 Amp ̻ ̻ ̻ ̻
F10 Spare 5 Amp ̻ ̻ ̻ ̻
( ( (
F11 Audio 10 Amp ̻ ̻ ̻ ̻ ( ( (
F12 Back Up alram 10 Amp ̻ ̻ ̻ ̻
( ( (
F13 Hydraulic Relay 10 Amp ̻ ̻ ̻ ̻
F14 Fuel Relay 20 Amp ̻
ECU (B+) 7.5 Amp ̻
F15
Fuel Lamp 10 Amp ̻
ECU (B+) 7.5 Amp
( ( (
̻
F16
Delay Relay 5 Amp ̻ ( ( (
F17 S.L.C (B+) 5 Amp ̻
( ( (
F18 - -
F19 Spare 10 Amp ̻ ̻ ̻ ̻ ( ( (
Spare 5 Amp ̻ ̻ ( ( (
F20
Spare 7.5 Amp ̻ ̻
( ( (
F21 Display 5 Amp ̻ ̻ ̻ ̻
F22 Column Switch 5 Amp ̻ ̻ ̻ ̻
(C40~55sD/L, C60~80D)
Alternator 10 Amp ̻ ̻
F23
Aircon - Option 7.5 Amp ̻ ̻
F24 Lamp Relay 5 Amp ̻ ̻ ̻ ̻
F25 Weight 5 Amp ̻
F26 Heater 15 Amp ̻ ̻ ̻ ̻
F27 Wiper 15 Amp ̻ ̻ ̻ ̻
Brake 5 Amp ̻ ̻ ̻
F28
Strobe light 5 Amp ̻
Strobe light 5 Amp ̻ ̻ ̻ ̻
F29
Sub Controller (IG) 5 Amp ̻
KUBOTA
C60-80 (Diesel) IVECO DEUTZ
Stage 5
TCU Battery+ 10 Amp ̻ ̻
F1
Parking Brake 10 Amp ̻
Brake 10 Amp ̻
F2 Brake / Strobe light 10 Amp ̻
TCU Battery+ 10 Amp ̻
Horn 10 Amp ̻ ̻
F3
HVAC 20 Amp ̻
Flasher 10 Amp ̻
F4 Turn Signal 10 Amp ̻
Condenser 15 Amp ̻
2.23
KUBOTA
C60-80 (Diesel) IVECO DEUTZ
Stage 5
Head Lamp 15 Amp ̻ ̻
F5
Compressor 5 Amp ̻
Parking Brake 10 Amp ̻ ̻
F6
Head Lamp Switch 15 Amp ̻
F7 Cassette 10 Amp ̻ ̻ ̻
Column Switch 10 Amp ̻ ̻
F8
Heating Line 30 Amp ̻
Back Up alram 10 Amp ̻ ̻
F9
Turn Signal 10 Amp ̻
Spare 30 Amp ̻
F10 Engine Shutdown 10 Amp ̻
Horn 10 Amp ̻
Seat Switch 10 Amp ̻ ̻
F11
Display 10 Amp ̻
Display 10 Amp ̻ ̻
F12
Column Switch 10 Amp ̻
Head Lamp Switch 10 Amp ̻ ̻
F13
Hydraulic Relay 10 Amp ̻
Hydraulic Relay 10 Amp ̻ ̻
F14
Seat Switch 10 Amp ̻
Wiper 15 Amp ̻ ̻
F15
Back Up alram 10 Amp ̻
F16 Power jack 15 Amp ̻ ̻ ̻
Strobe light 5 Amp ̻
F17 Fuel Pump 20 Amp ̻
Wiper 15 Amp ̻
ECU Power 10 Amp ̻ ̻
F18
Head Lamp Switch 10 Amp ̻
Spare 10 Amp ̻ ̻
F19
Brake / Strobe light 10 Amp ̻
F20 Spare 10 Amp ̻ ̻ ̻
Heat wire - rear glass 20 Amp ̻ ̻
F21
ECU Power 20 Amp ̻
HVAC 20 Amp ̻ ̻
F22
E/S Relay 15 Amp ̻
Condenser 15 Amp ̻ ̻
F23
Spare 5 Amp ̻
Compressor 5 Amp ̻ ̻
F24
Spare 10 Amp ̻
Controller 5 Amp ̻
F25 ECU Power 10 Amp ̻
Spare 10 Amp ̻
F26 Spare 15 Amp ̻
F27 Spare 15 Amp ̻
Spare 5 Amp ̻ ̻
F28
Spare 20 Amp ̻
Spare 15 Amp ̻ ̻
F29
Spare 20 Amp ̻
Spare 20 Amp ̻ ̻
F30
Spare 30 Amp ̻
2.24
C60-75 (LPG) GM, PSI 4X

F1 Cont / Parking 10 Amp
F2 Brake 10 Amp
F3 Horn 10 Amp
F4 Turn Signal light 10 Amp
HEATER
F5 Head Lamp 20 Amp RELAY
F6 Audio 10 Amp
F7 Seat / Power 15 Amp
F8 SECM Dist 10 Amp
F9 Directional switch 10 Amp FLASHER
UNIT
F10 Back Up / Strobe light 15 Amp

F11 TM Cont+ 10 Amp
F12 Display / Alternator 10 Amp
F13 Head Lamp switch 10 Amp START
F14 Wiper 15 Amp INTERLOCK

RELAY
F15 Heater 20 Amp

F16 Heat wire - rear glass 20 Amp SPARE1 SPARE3 BACKUP
ALARM
Spare 1 10 Amp SPARE2 SPARE4 RELAY
Spare 2 10 Amp
Spare 3 15 Amp (C60~75L)
Spare 4 20 Amp
Attention
Never replace a faulty fuse with one of a higher rating. If a fuse persistently fails, there is a fault in the electrical
system. You can contact your CLARK dealer with confidence to have faults rectified.
Forklift with two-way radio or mobile phone

• For mobile phones and two-way radios the usual regulations, as in the
automotive sector, apply.
• High-frequency transmission energy emitted by these and similar
devices may cause malfunctions of the vehicle electronics.When install-
ing such equipment, please contact your CLARK dealer for advice and
assistance.
CE Marking, EMC Regulation

1) CE Marking (Declaration of Conformity)
The description below applies to the equipments sold in the EU/EEA
market.
This equipment is indicated with the CE Marking which means that, at
the time of the delivery, the equipment meets the essential health and
safety requirements of the EU Machinery Directive 2006/42/EC. The
responsibilities related with any remodeling of the equipment shall be
born exclusively by the person or organization that performed the remod-
eling.
As an evidence of the conformity, the EU Declaration of Conformity Cer-
tificate is issued with the equipment. This Certificate must be transferred together with the equipment when the
2.25
equipment is sold. If the equipment is used for a different use or attachments described in this User Manual, the
user must take special care for safety.
If the equipment is used for a different use or attachments described in this User Manual, the user shall take the
responsibility on such operation. A new CE Marking or new EU Declaration of Conformity may be necessary.
2) EU EMC Regulation
The electronic circuit and/or devices of the equipment may cause a dangerous condition due to electromag-
netic interference with other electronic device(s).
If, electromagnetic fields (>10 V/m) occur in the area the forklift truck is used, the operator shall check whether
the forklift truck is suitable for the intended work.
If very EMC sensitive equipment is present in the operating area of the truck it must be checked whether prob-
lems can occur with this equipment as a result of the operation of the forklift truck.
The EU EMC (Electro-Magnetic Compatibility) Directive 2014/30/EC describes the general matters on the
safety requirements and the allowable range determined in compliance with related international standards.
The applicable equipment or device must obtain CE Marking Certificate by satisfying the requirements.
The equipments of CLARK have been tested for EMC and the CE Marking and Declaration of Conformity satis-
fies the EMC Regulation. If an additional electronic device is installed in the equipment, the device must obtain
the CE Marking Certificate and pass the EMC test.
UL Classification Symbol
• Your forklift truck meets the a UL standard if the UL classification sym-
bol is affixed (see fig.).
• If this symbol is absent, you may want to not place the forklift truck in
service in your operation.
Warning plates
• Your forklift truck is fitted with warning plates. Make sure that these
plates are always clearly visible.
• Defective, missing or illegible plates must be replaced immediately.
Remaining in area where a load is lifted is prohibited

• This warning plate must be fitted on the both sides on the upright and
has 2 meanings:
1. Persons must not stand or walk beneath raised forks (including you as
the driver).
2. Persons may not be lifted or transported with the forklift truck.
2.26
Crushing and shearing points

This plate is fitted on the upright. It warns of the risk of injury which exists
between crossbeams, chains, rope pulleys, fork carriage and other parts of
the upright. Do not climb on the upright and do not reach inside. Be aware
that you will be injured if any part of your body gets caught between moving
parts of the upright.
Cooling-air blower
• This warning plate is fitted on the air fan shroud of the radiator.
• Make sure that you never get too near a rotating fan with your hands,
fingers, arms or clothing. Do not stand in the blowing direction of a rotat-
ing fan. At excessive speeds, the vanes of a fan can break off and be
thrown out of the engine compartment.
Warning plate-safety belt

1. If the forklift should tip over, do not jump down from the forklift truck, it
could kill you. You are safest if you stay in your driving position and tip
over with the truck.
2. When working with the fork lift truck, the seat belt must always be fit-
ted correctly.
3. Read the operating instructions if you are not familiar with operation of
the forklift truck.
Hot surface
• These warning plates are attached to the engine, the tail pipe when ver-
ticalGexhaust system is installed and the heater when cab is installed.
• The surface of decal is very hot by the heat generated when running.
• If this surface is touched, serious burns may result.
8009466
2.27
LPG Fuel System
LPG System
1. Shut-Off Valve
2. Gauge
3. O-Ring
4. Locator Pin 3 4
If your lift truck uses liquefied petroleum gas (LPG), the fuel is stored in a tank mounted on the truck. A shut-off
valve, a safety check valve, a relief valve, and a pressure gauge are attached to the tank.
You manually operate the shut-off valve to control the flow of fuel from the tank. You must close this valve when
the engine is not running. Close this valve by hand, only to a firm tightness. Do not over-tighten.
When you open the shut-off valve before starting the engine, turn the handle slowly; otherwise, the check valve
will block fuel-flow for a two to three minute period.
The O-Ring on the coupling must be kept in good condition. The tank must lock onto the locator pin before the
fastener is secured.
There are also tanks without gauge.
Changing the gas bottles

Gas bottles shall only be changed by trained persons. The location of the bottle change shall be at least 3 meters
away from cellar openings, pits, shafts and sources of ignition; Changing gas bottles in enclosed areas is forbid-
den. When replacing gas bottles, no hot objects shall be used, smoking is forbidden and no open lights shall be
used.
LP gas tank
The LP gas tank shall only be filled,at fuel stations intended for this purpose. When filling the LP gas tank, the
tank and its fittings shall be checked for defects. The inspection-interval specified in the Directive for Pressurised
Equipment (97/23/EG) or in national regulations shall not be exceeded. If any irregularities occur during the filling
process, the res'p6nsible supervisor shall be notified immediately; Smoking is forbidden and no open flames
may be used.
2.28
Transportation
• When transporting the equipment on a vehicle (e.g., low loader), care should be taken to secure sufficient dis-
tance from edges, bridge plate, etc. When transporting the equipment on a flat bed loader, the ramp must have
sufficient load bearing capacity.
• The fork lift truck can be loaded on a transportation trailer or a freight car. In such cases, observe the applica-
ble laws and regulations.
• The dimensions (length, width, height) and load capacities of the fork lift truck are marked on the name plate.
! CAUTION
The lifting chains and /or straps must satisfy the load lifting capacities in accordance with the
applicable standards and technical requirements.
Htxlsphqw#Ordglqj
(1) Equipment having lifting eyes on the front
2 1 2 1
2 1 2 1 3
3
3
2 1 2 1 3
The procedures for loading the fork lift truck are as follows;
Apply the parking brake.
Put wheel chocks (1) at the front and rear sides of the front wheels to fix the equipment against lengthwise
movement.
Put wheel chocks (2) on the sides of all four wheels to fix the equipment against lateral movement.
Install tension straps (3) at the front and rear sides of the equipment.
Check that the tension straps are tied firmly.
Connect the tension straps to the lifting eyes at the front side and at the tow coupling on the rear side of the
equipment. Tie the tension straps downward at the front and diagonally at the rear side of the equipment. Take
care not to damage the tension straps
2.29
(2) Equipment without lifting eyes
2 1 2 1
3
2 1 2 1
3
3
2 1 2 1
3
The procedures for loading the fork lift truck are as follows;
Apply the parking brake.
Put wheel chocks (1) at the front and rear sides of the front wheels to fix the equipment against lengthwise
movement.
Put wheel chocks (2) on the sides of all four wheels to fix the equipment against lateral movement.
Install tension straps (3) at the front and rear sides of the equipment.
Check that the tension straps are tied firmly.
Connect the tension straps across the floor plate at the front side and at the tow coupling at the rear side of the
equipment. Tie the tension straps downward at the front and diagonally at the rear side of the equipment. Take
care not to damage the tension straps
! CAUTION
Use only tension straps which have sufficient load-bearing capacity in accordance with the techni-
cal requirements of the corresponding valid standards.
2.30
Attachment Disassembly
When a truck can’t be loaded in a container because of a highGupright, the
upright should be removed.
Disassembling method is described below
FX1165
1) Tilt cylinder pin

1 2 3
NO Part name Qty Remarks
1 Lock pin 2
2 Washer Tspring 2
3 Bolt 2 4
FX1201
4 Bolt 2 170~190N·m
2) Upright trunnion bracket
NO Part name Model Qty Remarks

1 Bolt C40-80 4 170~190N·m
2 Pin C40-80 2 1
4
3 Bushing C40-80 2 3
2
4 Spacer C60-80 2
3) Main hose & low pressure hose
NO Part name Qty Remarks

1
1 Hose assy 1 69N·m
QGAssembling isGin reverse order to disassembling. FX1200
2.31
Name plate
What you should know about your forklift truck :
1. The location of the model name.

2. The location of the serial number.
3. The description of the additional attachments (if any) . Take note of the additional capacity load plate.
4. Which tire type (dimension, ply-rating) to be used.
The type of tire (pneumatic/elastic) influences the static stability of the forklift truck.
For this reasonS only the tire types approved by the manufacturer may be used. Column 4 shows the tire
types which are approved by the manufacturer. Tire code.
E = cushionL = pneumaticS = super elastic
Z = twin tiresR = radial
5. The year of build.
6. The capacity of the forklift-truck with forks.
In this space the capacity, the load center and the lift height are stated. The specified maximum values must
not be exceeded.
Attention
For additional attachments there must be mounted an additional load capacity plate beside the name plate, which
gives the permissible load capacity of your forklift truck for a CENTERED LOAD in conjunction with additional
attachments. These load capacities must not be exceeded.
The subsequent mounting (not supplied by the manufacturer) of one or more additional attachments requires
immediate mounting of a new capacity plate for the combination forkliftG truck / additional attachments. The cus-
tomer must obtain this from the manufacturer or local dealer.
7. The forklift-truck weight less load.

8. Where the nominal drive output is specified in "kW".
A damaged name plate or capacity plate must be replaced.
2.32
Attached position of Safety decals
DETAIL F
VIEW A DETAIL F
DETAIL B
DETAIL E
8009466
DETAIL C
DETAIL E
DETAIL B,C
DETAIL D
RECOMMENDED SAFETY MAINTENANCE PROCEDURE Y\W

FOR LP GAS FUELED FORKLIFT TRUCKS
8"3/*/(
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--.-----------------.--------------.----------
------------------------------.
-----------------------------------.-------
-------. ------------.---------------.
NOTE --------------------,------------------
------------------.--------------------------
-----.----------------------------------.
NOTE --------------------------------------
-------------------------------------------------
----------------------------------------------
-----------.-----------------------------------.
SERVICE WORK SHOULD BE PERFORMED BY
QUALIFIED PERSONNEL ONLY.
P/No. 928847
LPG FUEL CYLINDER REPLACEMENT PROCEDURE

-----------------------------------------------------------------------
1 .---------------------------------------------------
------------------------------------.
2 .----------------------------------------------------
----------------------------------------------------.
3 .---------------------------------------------------
--------------------------------------------------.
-----------------------------------------------
------------------------------------.
4 .----------------------------- -----------------------
---------------------------------------------------.
-----------------------------------------------------
-----------------------.
5 .--------------------------------------------------
-----------------------------------.
NOTE --------------------,-------------.
------------------.-----------------------------
-----.--------------------------------------------
--------------------------------------------------
------.
DIESEL
P/NO.8009528
GASOLINE
‫چ‬١‫ڌٵ‬ٟ٪٠‫ڋ‬٧‫ڃ‬ٟ‫ٵ‬١‫ڊ‬ٟ٪٢‫ٻ‬ٟ١ٰ‫ڌڄڃ‬٠٠ٟ‫ٻ‬
<; #
1 2
3
VIEW A
DETAIL D
! CAUTION
Do not operate a forklift truck with damaged or missing decals or data plates.
Replace them immediately. Contact your local CLARK dealer to acquire new decals or data plates.
2.33
3. Daily inspection
• Before starting work, you should convince yourself that the forklift truck is in an operationally safe state. Carry
out this inspection by the following list.
page
Checking the forklift truck for any signs of damage and dirt ........................................................... 3.2
Check the LPG system for leaks and damage................................................................................ 3.2
Check tires and tire pressures ....................................................................................................... 3.2
Check wheel nuts for tightness ...................................................................................................... 3.2
Check the warning lights are working properly .............................................................................. 3.2
Check coolant level and top up if necessary.................................................................................. 3.3
Check engine oil level and top up if necessary
Check horn is working properly
Check service brake is working properly (pads are in good condition?)........................................ 3.4
Check parking brake is properly .................................................................................................... 3.4
Check upright and hydraulic system are working properly ............................................................ 3.5
Check tension of lift chains is equal
Check forks and fork locking device .............................................................................................. 3.5
Check that driver’s overhead guard and load back rest are secured properly
Check trailer coupling and safety device (if fitted)
Check battery acid level and battery charge.................................................................................. 3.5
Check battery connectors are tight fit
Check battery and wiring connectors are tight fit
Check lighting (if any)
Always check that your forklift-truck is operationally safe.GNever drive a forklift-truck you have not
checked.
3.1
3. Daily inspection
1) Visual Inspection
Walk around your forklift truck and look for any obvious signs of damage, leaks and
dirt.
• The degree to which cleaning is required depends on the operating
environment of the forklift truck. For operation in areas with large
amounts of dust or paper, thorough cleaning is required after each
operating shift, or several times a day. The same applies to operation
with cement and chemicals. See also section 4 for “maintenance and
care”.
Checking the LPG system for leaks and damage

• Check the system for leaks (smell of gas).
Always carry out a leak test after changing LPG tank, see also page 4.3-
4.4.
Check the gas hoses for damage.
Wheels and tires

• Check the
state of the drive wheels, the steer wheels and all tires.
tight of wheel nuts.
pressure of pneumatic tires from a position facing the tread of the
tire, not from the side.
Use a long handled gauge to keep your body to the side.
• See section 7 "Technical Data" for tightening torques and tire pressure.
Attention!
A wrong tire pressure influences the stability of the forklift-truck.
If you change a tire, always change both tires on the axle.
Indicator lights
• Check that all lights are functioning and indicate normal truck operation
as described in Section 2, "Know your Forklift Truck" in this manual.
29MAR06[WED] H
SYSTEM CHECK
OP A2
3.2
3. Daily inspection
2) Test in the engine compartment

Engine cooling system
! WARNING
Check the coolant level directly in the radiator (A) and at the overflow canister (B).
• To check the engine coolant level, the hood to the engine chamber and
the radiator cover must be opened.
2
• Open the engine hood as follows :
A 3
1. Release the steering column lock and move the steering column for-
wards. 1
2. Push the driver's seat forwards. 4
3. Fold the seat back and lock.

4. Release hood latch and slowly open the hood.
A) Checking the radiator
! CAUTION
Do not open the cap of the radiator when the engine is hot. Danger of scalding. The cooling system
is pressurised, see also page 4.10
• Remove the radiator cap. The coolant should come up to the lower A
edge of the filler neck. If the fluid level is lower than this, add coolant,
see page 6.2. Check the cooling system for leaks.
• Check the cooling system for leaks
B) Checking the overflow canister

When the engine is cold, the engine coolant must come up to the "COLD"
marking. If required, add coolant - see page 6.2 and check the cooling B
system for leaks. Carry out additional checks on the engine interior in
accordance with page 3.1.
After the checks, close the hood and radiator cover.
C) Radiator fin cleaning
! CAUTION
Beware of dirt from air blowing. Wear protective equipment such
as goggles to protect your eyes when blowing compressed air.
Dust or flying debris can hurt eyes.
Dirt and dust adhering on the radiator fins reduce the cooling perfor-
mance, causing overheating. Make it a rule to check the radiator fins daily
and clean as needed
3.3
3. Daily inspection
Check the service brake (1)

1. Check the pedal play
Depress the pedal by hand until resistance from the brake master cyl-
inder can be felt. The distance travelled should be 3-6 mm .
2. Checking the operation of the brakes.
Depress the brake pedal by foot to check whether firm resistance can
be felt. The pedal must not feel spongy or give. If it does, the forklift
truck must not be used under any circumstances. Instead, you should
arrange for the brake system to be serviced immediately. The pedal 2 1
pad should also be replaced if it no longer provides a good grip.
Check the inching functionG(2)

1. Check the pedal play
Depress the pedal by hand until resistance can be felt. The distance
traveled should be 3-6 mm(A).
A
2. Check operation
Fully depress the inching pedal (the brake will be actuated as well). B
With the pedal in this position, engage forward or reverse gear. The
forklift-truck must not move even at maximum engine revolutions, but
the upright must remain fully operational.
Check the parking brake

• Check the function of the parking brake. Pushing down, then pulling the
lever upwards.
• To check parking brake holding capability, park the lift truck on a grade
and apply the parking barke.
Fuel level check and supply

1) Observe the fuel meter to see if the fuel is sufficient.
After the end of daily operation, fill the tank with fuel to prevent mois-
ture in the air in the tank from mixing into the fuel.
2) When supplying fuel, stop the engine, remove the fuel tank cap by
turning it counterclockwise, and pour fuel through the fuel filler neck.
3) After fueling, be sure to tighten the fuel tank cap.
Fuel tank cap
! CAUTION
• Always stop the engine and keep any fire source away before and dur-
ing the fueling operation.
• Carefully prevent entrance of water and dirt into the tank during fueling.
3.4
3. Daily inspection
Checking the uprights/hydraulic system function

• Check for obvious signs of damage, leaks and dirt. If necessary, carry
out maintenance and service work in accordance with section 4.
• The uprights should be raised to maximum height at least once a week,
in order to check that the hoist function is fully operational. In addition,
this allows full lubrication of the lift piston rod and the lift cylinder wall.
• Observe the safety regulations outlined in section 1.
Checking the forks of the fork carriage

• The forks should be checked using the following list.
• They must be replaced immediately if the given specifications are not
met 2
1. Measure the distance from the fork tips to the ground. The height dif-
ference between the forks tips should be no more than 1.5% of the
blade length. 1
2. The blades of the forks must not be worn down by more than 10% at
the heel and the forks must not be bent.
Checking the forks are locked

• Check whether the device, which locks the forks into position, has
engaged properly, so that the forks cannot slide.
• Check whether the forks are correctly positioned in the fork carriage and
cannot unhinge themselves. Check whether the lateral fork limit stop is
tightened securely.
Operational safety of the forklift-truck

• Do not start using any forklift-truck, which is not in a safe operational
state.
• Forklift-trucks should only be repaired by competent and authorized per-
sons.
Battery
• Check the battery and corrossion of the electrodes. Clean up the elec-
trodes and apply small amount of grease. Cap them with protective
cover.
• Check the battery acid level and battery charge. If required, let the bat-
tery refill with distilled water or charge it up from a authorized persons.
Option :
• Check indicator color on top of the battery.
,QGLFDWRUUHDGLQJ൯*UHHQ1RUPDO
GGGGGGGGGGGGGGGGGGGGGGGGGGG %ODFN5HFKDUJLQJUHTXLUHG
GGGGGGGGGGGGGGGGGGGGGGGGGGG :KLWH,QVXIILFLHQWHOHFWURO\WH
• The indicator color may read "Insufficient electrolyte", even when the battery is normal. In this case, if you
shake the battery, the color will be change to "Normal ".
3.5
3. Daily inspection
Checklist after Equipment Deployment

Check followings after deploying the equipment;
- Check engine coolant condition and leakage
- Check LPG leakage
- Check T.M clutch function and noise
- Check braking distance and abnormal noise
- Check brake pedal force and clearance
- Check parking brake
- Check tire air pressure and biased wear
- Check start motor operation
- Check alternator's battery charging performance
- Check battery fluid and terminals
- Check instrument gauges and warning lamps
- Check the function of head lights and lamps
- Check the function of various levers
- Check hydraulic oil condition and leakage
- Check front/rear tilting angles of the mast
- Check tension and grease of the lift chain
- Check function and grease of the carriage and master rail.
3.6
4. Maintenance and Care
1) General
Persons to be appointed for maintenance and recurring inspections
Only qualified and authorized persons are allowed to carry out maintenance work. Periodic inspections shall be
carried out by a technical expert. The aforesaid technical expert shall submit his expert opinion and evaluation
only from the point of view of safety without being influenced by company and economic circumstances. He shall
have sufficient knowledge and experience in order to be able to assess the status and condition of the forklift
truck and the effectiveness of the protective equipment in accordance with the latest state of the art and the basic
principles for the inspection of forklift trucks. The forklift truck manufacturer has trained staff available for mainte-
nance and periodic inspections.
Intervals for maintenance work

The maintenance work shall be carried out in intervals specified in Chapter 5.
Important is to carry out the safety check in accordance with national regulations. Clark recommends checks in
accordance with the FEM 4.004. The truck must be inspected at least annually (consider national regulations) or
after any unusual event by a qualified inspector. The owner is responsible for ensuring that faults are immediately
rectified. The service intervals stated are based on single shift operation under normal operating conditions. They
must be reduced accordingly if the truck is to be used in conditions of extreme dust, temperature fluctuations or
multiple shifts.
Periodic inspections
A periodic inspection shall be carried out in the EU member states in accordance with directive 95/63/EC (Direc-
tive on Minimum Regulations for Safety and Health Protection) then equipment is used by employees at work.
The relevant national regulations shall be observed with regard to non-EU states. A periodic inspection by a tech-
nical expert shall include an examination of the current state of the components, equipment and installations,
together with the completeness and effectiveness of the safety devices. The forklift truck also shall be thoroughly
examined for any damages or impediments caused by possible improper use. A test record must be issued. The
results of the tests must be kept until the next examination at the latest. The operator shall ensure that defects
are rectified as soon as possible.
Quality and quantity of the required oils and lubricants

Only the oils and lubricants stated in the operating instructions shall be used.
Spare parts
Only those spare parts shall be used which are specified by the manufacturer. If spare parts are used which have
not been approved by the forklift truck manufacturer, the risk of accidents can increase due to inadequate quality
or an incorrect connection. If inadmissible spare parts are used, the user shall assume full and unlimited respon-
sibility for any damage sustained. The CE Declaration of Conformity of the manufacturer ceases to be valid if
spare parts not approved by the manufacturer are used.
Servicing for which no special qualification is required

Simple servicing such as checking the oil level or checking the level of liquid in the battery lay also be carried out
by the operator. Additional details can be found in the operating instructions.
Safety installations
All safety devices shall be re-installed after servicing and repairs and shall be checked for proper functioning.
Settings
If hydraulic and electric components are repaired or replaced, the equipment related settings shall be observed.
4.1
2) Safety tips
Safety tips
• Make sure that any unintentional movement or unintentional starting up
of the forklift truck is prevented.
• The forklift truck should be secured by activating the parking brake and
by inserting chocks under the wheels in order to avoid unintentional
movements.
• When working under a raised fork carriage, never forget to secure the
fork carriage and the inner rail (both inner rails on Triple stage upright)
with suitably dimensioned wooden beams and chains.
• The forklift truck can be secured against inadvertently moving by apply-
ing the parking brake and by chocking the wheels.
Counterweight
• If the counterweight has to be removed for repair work, you must take its
weight with a crane before undoing the mounting bolts. The counter-
weight is only held on by the mounting bolts and would otherwise fall off
when these were undone. This could lead to severe injuries at least.
Hoses, cables and rubber parts

• Hydraulic lines must be depressurized.
• Hoses, cables and rubber parts succumb to a natural process of ageing,
which is dependent on outside influences (e.g., temperature, environ-
mental factors, etc.).
• At every maintenance, check all hoses, cables and rubber parts for dam-
age and ageing.
• Replace all defective parts.
Disposing of lubricants, filters and batteries

• Used parts and lubricants which arise during repair work must be stored
safely until they can be disposed of in accordance with the regulations.
In this respect, follow the regulations applicable in your country.
4.2
3) Maintenance
Changing the fuel filter (diesel engine)
• Replace the fuel filter using the following procedure:
Clean the filter housing.
Unscrew the filter cartridge and absorb the flow out diesel fuel.
Remove the filter element.
Lightly oil the seal of the new filter cartridge.
Screw on the filter cartridge by hand.
Bleed the fuel system.
• Check the fuel system for leaks during a test run of the engine.
! CAUTION
The fuel in the injection pipes is at high pressure.
Fuel spraying out can penetrate and damage the skin.
Do not use your fingers to check whether fuel is emerging at the injection pipes.
Bleeding the fuel system

• Loosen the bleed screw on the fuel filter and pump fuel (using the hand
pump) until fuel emerges without bubbles.
• Close the bleed screw.
Warning for LPG Operation
! CAUTION
Forklift trucks with LPG drive may only be serviced and operated in locations which are sufficiently
ventilated.
• Liquefied petroleum gas (LPG) consists essentially of butane and pro-

pane. The ratio in which these two gases are present differs from coun-
try to country. Propane and butane belong to the group of easily
inflammable gases. Liquefied petroleum gas is highly explosive in mix-
tures with air or oxygen. For this reason do not smoke and do not use an
open flame when filling LPG tanks, changing LPG tank or working on the
fuel gas system. Liquefied petroleum gas differs from petrol as it
becomes gaseous immediately it draws heat from it´s surroundings and
can immediately fill small spaces with gas.
• Hence you must be very careful. Liquefied petroleum gas produces
frostbite on the naked skin. There is an increased risk of explosion in
rooms filled with the gas. For these reasons you should therefore never
change the LPG tank in closed rooms and garages. Since the gas is
heavier than air, make sure that there are no pits or drains in the vicinity.
When changing LPG tanks, wear gloves and work in accordance with
the following instructions.
4.3
Changing the LPG-tank

1. Close the shut-off valve of the LPG tank to be changed by turning the
valve as far as possible clockwise. Let the engine run until it stops of
its own accord. By doing this you will avoid the risk of liquefied gas
spraying out from the hose (danger of frostbite) when you loosen the
union.
2. Turn the ignition off.
3. Separate the hose from the LPG tank (left hand thread). Close the
connection on the LPG-tank with the cap nut.
4. Slacken the strap holding the LPG tank and take away the empty LPG
tank.
5. Replace the empty LPG tank with a full one. Check that the unions at
the end of the hose and on the LPG tank are of the same type. Take
care that you place the LPG tank in the correct position. The union for
the hose must face downwards.
6. Secure the LPG tank strap and connect the hose.
7. Open the shut-off valve of the LPG tank slowly by turning it anticlock-
wise as far as it will go. Check the LPG system for tightness (see 4.6
page).
Engine inspection
Start the engine and warm it up sufficiently.
1. Check each meter and warning lamp to see there is no abnormality.
2. Check if the engine is generating abnormal sound or vibration.
3. Check the exhaust gas color to see it is normal. Colorless or light blue
exhaust indicates complete combustion ; black exhaust, incomplete
combustion; and white exhaust, burning oil as a result of oil getting
into the cylinders.
! WARNING
• The exhaust gas can cause serious injury if inhaled.
If you must start the engine inside building or enclosure,
insure sufficient ventilation.
• The gasoline engine carburetor is equipped with the automatic choke that
keeps the engine running at a relatively high speed a while.
Do not be bothered, however, becomes the engine resumes a normal speed upon warming enough.
Leakage inspection
Check the engine compartment for any oil or fuel leakage.
Clean the radiator if it is clogged and check if there are any foreign objects, such as paper or other, onto the radi-
ator grill.
Operator restraint system

Visually inspect and check safety function of restraint system.
e.g.) lap belt, when duo-sensitive belt is fitted, check whether it is arrested with seat when seat is at a specified
angle.
4.4
Battery restraint
Visually inspect the battery restraint according to specifications of industrial truck manufacturer.
Battery data
Check battery voltage and weight (on the battery data plate) against truck manufacturer’s data plate on the truck.
Emergency shut-off
Check control function of the emergency shut-off (separate switch or battery connector).
Electrical fuses
Visually check electrical fuse for damage
• Park the truck securely.
• Remove the key from the key switch and open the fuse cover of the truck
• Check condition and rating of the fuses in accordance with the table.
• Replace any damaged fuses in accordance with the table.
Safety switches on tiller

When the tiller is released on pedestrian controlled trucks, the power to the drive unit must be switched off.
Check emergency reverse switch for correct function.
Steering System
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,
excessive freeplay (looseness), or unusual sound when turning or maneuvering indicates a need for inspection
or servicing. Never operate a truck that has a steering system fault.
Steering wheel inspection

Perform the inspection after starting the Forklift.
1. Check the steering wheel play with the rear wheel set in the straight
traveling direction
2. Turn the steering wheel in the circumferential direction and also move
it up and down to check there is no looseness.
3. Push the horn button to check if the horn sounds normally.
4. If any abnormality is found, ask a CLARK dealer for inspection.
Instrument inspection
Start the Forklift and see that instrument operate properly.
4.5
Mounting points
Visually check the mounting points for the mast, counterweight, steering axle, overhead guard, tilt cylinder etc.
Overhead Guard
Be sure that the overhead guard and any other safety devices are in
Overhead guard
place, undamaged, and attached securely.
Upright
Inspect welds and structural members for cracks or other damage. Also
check for loose or missing fasteners. Load Backrest
Carriage
Fork
Carriage, Load Backrest, and Upright
Inspect the welds on the carriage, load backrest, and upright for cracks.
Be sure that the mounting fasteners are in place and tight.
Check attachments
Check attachments for damage, excessive wear, leaks, security of mounting and safe function according to spec-
ifications.
Check Optional equipment

Check optional equipment such as lighting, mirrors, windshield wipers etc. for correct function.
Maintenance of the LPG system

• In order to be able to evaluate whether a liquefied petroleum gas system
is in an operationally safe state, it is necessary to have had a proper
course of training in these systems.
• In addition it is necessary to have a good knowledge of the relevant offi-
cial Work Protection Regulation and Accident Prevention Regulations.
For this reason, LPG units may only be repaired and maintained by
trained personnel. Contact your CLARK dealer when maintenance or
repairs need to be carry out.
• The complete liquified petroleum gas system must be checked regu-
larly (weekly) to see that it is in an operationally safe state.
• Special attention must be paid to checking that the system is not leak-
ing. Check hoses, connections and assembly groups with soapy water,
nekal solution or a suitable leak indicator spray.
• Use of open flames, smoking and use of hot objects is strictly prohib-
ited.
Extraordinary inspection of the LPG system

• Observe the statutory regulations of your country.
• The entire liquid petroleum gas system must be checked regularly to ensure that is in full and safe working
order in accordance with the national work protection and accident prevention regulations.
4.6
• This inspection must be carried out by a qualified specialist.

• The qualified specialist must be in a position to give his report and appraisal objectively, from a point of view of
safety, and uninfluenced by operating and economic arguments.
• This specialist should write out a test certificate as proof.
This test certificate should be included in the inspection log book.
Maintaining LPG filter

• Based on chapter 5 Lubrication and maintenance plan, the filter ele-
ments in the liquid gas preliminary filter and in the shut-off valve must
be renewed, as well as diaphragm, seals and valves.
• After each maintenance, the cap screws of the evaporator based on
national regulations or the service interval of heavy duty application
must be reduced.
• Hose lines must be exchanged at least every two years.
• Check the LPG system after every repair or service to make sure that it
is free of leaks.
Engine air cleaner

• Check the engine air cleaner for damage and contamination (excessive
dirt buildup and clogging). Be sure that the air cleaner hose is securely
connected (not loose or leaking). Fan or cone shaped dust deposits on
tube or hose surfaces indicate a leak.
• Change or service the air cleaner based on the information in Chapter
5. Shorter intervals in case of heavy duty or dusty application could be
necessary.
• Service intervals may also be determined by the air restriction indicator.
(Air filter indicators is optional equipment)
• Clean the air filter housing thoroughly before fitting the filter.
• Do not open the air filter housing to check the filter element.
! CAUTION
Only open it when it is the specified service interval or the air restriction indicator indicates it
should be changed. Never reuse the element.
Engine oil and filter

• Locate the engine oil dipstick. Pull the dipstick out, wipe it with a clean
wiper, and reinsert it fully into the dipstick tube. Remove the dipstick FUL
and check oil level. L
• It is normal to add some oil between oil changes. Keep the oil level ADD
above the "L" mark on the dipstick by adding oil as required. Do not
overfill. Use the correct oil as specified under Lubricant Specifications.
4.7
Changing the engine oil and oil filter

• Remove the filter cartridge.
• Lightly grease the sealing ring on the new filter cartridge and screw in
the cartridge until it is hand tight.
• Remove the oil pan drain plug to drain old oil after the truck has been in
operation and the engine (oil) is at operating temperature.
• Carefully check for leaks after changing oil and installing new filter.
Check and Adjust Cooling Fan V-belt

The V-belt will slip if it does not have the proper tension.
This will prevent the alternator from generating sufficient power. Also, the engine will overheat due to the engine
coolant pump pulley slipping.
In particular, it is necessary to check and adjust the V-belt tension (deflection) as follows cases.
1. Vibration of the V-belt

- Insufficient tension may cause thermal degradation of the rubber part on the side of the V-belt, thereby
reducing the life cycle of the V-belt.Excessive vibration may cause the V-belt to slip off.
2. Abnormal noise during rotation of the V-belt
- Insufficient or excessive tension may cause the V-belt to slip off, as well as causing an abnormal noise, and
may result in the V-belt overheatingor wearing out completely.
Check the V-belt tension

1. Press the V-belt down with your thumb with a force of approximately (A)
22 ft•lbs (98 N•m, 10 kgf•m) to check thedeflection.
2. There are three positions to check for V-belt tension (Figure (A), (B)
and (C)). You can check the tension at whichever position is the most (C)
accessible. The proper deflection of the V-belt at each position is:
A ; 3/8 ~1/2 in B ; 1/4 ~3/8 in C ; 5/16 ~1/2 in (B)
(10~14 mm) (7~10 mm) (9~13 mm)
&'67<'PIKPG
(A)
(B)
(C)
'ZEGRV&'76<'PIKPG
4.8
Adjust the V-belt tension

1. DEUTZ Engine
• If the tension is incorrect, loosen the lock nut (D) and adjust the bolt '
(E) to set the correct tension.
• Once the adjustment is complete, fasten the lock nut (D). (Fastening
torque: 70-80 N.m)
2. Except DEUTZ Engine

• If the tension is incorrect, loosen the set bolt and move the alternator
with a pry bar to adjust the V-belt tension.
Timing replacing the V-belt

• See Chapter 5 Maintenance Plan for timing of replacement of the V-belt.
• Please, however, note that the V-belt should immediately be replaced with a new V-belt if you detect damage
on the side of the V-belt, or cord is exposed.
Inspection of the Fuel Injectors

• Visually inspect the fuel injectors and nozzle protectors for deposits or damage. Clean, repair or replace as
necessary.
Transmission fluid check

NOTE
Check the planned maintenance interval (operating hours) or the condition of the oil to determine if
the transmission fluid needs to be changed.
• Before checking, run the engine until the unit is at operating tempera-
ture. This is important since transmission oil temperature should be min-
imum of 65°C to 121°C maximum, the engine should also be at
operating temperature. Apply the parking brake.
• 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. ADD
• Fill to the ADD mark with the system at ambient temperature. If filled to
the full mark while not at the operating temperature, it may be overfilled. FULL
4.9
Hydraulic system
Sump tank breather maintenance and inspection

• Remove the sump tank fill cap/breather and inspect for excessive (obvi-
ous) contamination and damage.
• Replace the fill cap/breather, per recommended PM schedule or as
required by operating conditions.
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.
• Hydraulic fluid expands as its temperature rises. Therefore, it is prefera-
ble to check the fluid level at operating temperature (after approximately
30 minutes of truck operation).
• To check the fluid level, first park the truck on a level surface and apply
the parking brake. Put the upright in a vertical position and lower the fork
carriage fully down. Pull the dipstick out, (attached to the sump breather)
wipe it with a clean wiper, and reinsert it.
• Remove dipstick and check oil level. Keep the oil level above the LOW mark on the dipstick by adding recom-
mended hydraulic fluid only, as required.
Do not overfill.
• Check the condition of the hydraulic fluid (age, color or clarity, contami-
nation). Change (replace) the oil as necessary.
Hydraulic Fluid and Filter Change

• Drain and replace hydraulic oil based on chapter 5. Lubrication and
Maintenance Plan.
• Replace the hydraulic oil filters elements at every oil change. Remove,
clean, and reinstall the hydraulic and steer system suction line screens
changes should be based on Chapter 5.
• Check for leaks after installation of the filters. Also, check that the
hydraulic line connections at the filter adapter are tightened correctly.
• The procedure for draining hydraulic sump tank is in your Service Man-
ual.
Checking the cooling system

• Check the coolant level (A & B), see page 3.3
A
! WARNING
Only remove the radiator cap when the engine is cold (danger of
scalding). Never add cold coolant to the radiator of an overheated
engine. This carries the risk of the cylinder head or block cracking.
4.10
• Check the radiator and cooling water hoses for any signs of damage.
• Check the radiator fins for dirt. If the radiator fins are dirty, clean the radi- B
ator from the counterweight side with compressed air or, if necessary,
with a steam cleaner.
Grease
• Grease your forklift-truck carefully in accordance with the greasing and
lubrication plan. Clean the grease nipples before greasing and after
lubricating remove any excess grease which has come out at the greas-
ing points.
Brake system
• In more demanding operating conditions, the brake linings may become
worn more quickly. It may therefore be necessary to check the brake
system between the intervals prescribed in the service schedule.
• New brake linings must get worn in and therefore do not have the opti-
mum frictional force initially. The slightly diminished braking effect which
results when the brakes are first applied can be overcome by applying
the brake pedal harder.
Checking the brake fluid level

• If the brake fluid level is too low, the brake system must be examined by an expert.
• Check the level of brake fluid in the reservoir positioned at upper side of the cowl. The level should be between
"MIN" and "MAX".
! WARNING
Only recommended oil (Page 6.1) should be used. Unauthorised brake fluid may cause serious dam-
age to the brake system.
Brake fluid absorbs moisture from the air (hygroscopic) and must therefore be changed every year.
Clean the lift chains

• Never clean the lifting chains with a steam cleaner. Clean the chains
with a self-lubricating cleaner (e.g. Diesel).
Lubricate the lift chains

The lift chains are subjected to heavy loading and therefore can only attain
their maximum life if they are oiled regularly and adequately. Oiling the lift
chains is therefore an important part of the maintenance work. You can
carry out this work quickly and correctly with chain lube, see lubricant recommendations.
4.11
Upright inside rails, rollers and sideshifter.

• Clean and lubricate the upright inside rails, rollers and side shifter (if fitted). Use only suitable lubricants in
accordance with the recommended lubricants list. For add-on equipment, the service instructions of the manu-
facturer, see separate operating manual, must be observed.
Check the lift chain adjustment

• Lift the rated load of the forklift on the forks. Bring the upright to the ver-
tical and lower the fork carriage completely. The underside of the forks
at the heel must be 10 mm above the floor.
NOTE
It is important to use a load equal to the rated capacity of the fork-
lift when checking the lift chains, since any expansion of the
chains is then allowed for.
Adjust the lift chains

• The lift chains are adjusted at the chain anchors. For this, the locknuts
must be undone and, depending on the required setting, the top nut
screwed up or down. After the adjustment has been made, the locknuts
must be tightened up again.
! CAUTION
If the lift chains stretch by more than 3% of their original length,
they must be replaced for safety reasons. Observe the statutory
regulations of your country.
You can contact your CLARK dealer with confidence for this.
Chain pin rotating or protruding

• If high-load tension is applied to the chain in an inappropriate state of
lubrication, this may cause abnormal frictional force between the link plate Normal Rotated pin
and the pin, and the pin may rotate if the fixing force is exceeded. (Replace the
chain assembly
• If a rotated pin is detected during the regular inspection, immediately immediately)
replace the chain assembly.
4.12
Lift Chain Wear and Replacement Criteria

1. (NEW CHAIN LENGTH) The distance from the first pin counted to the
last pin counted in a span while the chains are lifting a small load.
2. (WORN CHAIN LENGTH) The distance from the first pin counted to the
last pin counted in a span while the chains are lifting a small load
3. (SPAN) The number of pins in the length (segment) of chain to be mea-
sured. 2 3
1
4. (PITCH) The distance from the center of one pin to the center of the
next pin.
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 4
chains. Replace anchor pins and worn or broken anchors when installing
new chains. Adjust tension on new chains. Lubricate chains when they are
installed on the upright
Fork Alignment
1. Park the truck on a flat, even surface, tilt upright to vertical position, and
set forks 25-50 mm (1-2 in) above the ground.
2. Compare fork arms to be sure they are straight, on the same plane
(level), and the same length.
3. Measure the distance from the fork tips to the ground. The height dif-
ference between the forks tips should be no more than 1.5% of the
blade length. 1.5% is max.
height difference
4. If the fork tips are not aligned within the specified 1.5% difference, the
cause of the problem must be determined and corrected before return-
ing the truck to service. If replacement is necessary, always replace
the forks in a set.
Fork Bending
Overloading, glancing blows against solid objects, or picking up loads
unevenly can bend or twist a fork. Use the following procedure to check for 1" max
fork bending.
1. Place a 50 x 100 x 610 mm (2 x 4 x 24 in) wood block flat on the fork.
Make sure the block is not resting on the heel radius. 20"
2. Set a carpenter’s square on the block against the fork shank

3. Check the fork 508 mm (20 in) above the blade to make sure it is not
bent more than 25.4 mm (1 in) at the maximum.
4. If blades are bent over the 25.4 mm (1 in) allowance they should be
replaced as a set.
4.13
Fork Fatigue
Fatigue cracks normally start in the heel area or on the underside of the top hanger. If cracks are found, the fork
should be replaced. Dye penetrants or magnaflux can be used for a more accurate inspection.
Rollers Inspection
Inspect the upright and carriage rollers for :
• Broken or loose rollers.
• Loose, broken, or misadjusted thrust roller on the carriage.
• Obvious signs of failed bearing seals.
• Excessive looseness in carriage or upright roller shimming.
Cylinder Leakage
To check for leakage on the cylinder: Σ
1. Clean the top of the gland and rod to remove any buildup of debris.
2. Check rod surface for defects or unusual wear.
3. Check for external leakage from the cylinder barrel, gland O-rings and
backup ring, and the rod seal.
4. After cleaning the top of the gland and the barrel, cycle the upright 5-
10 times. If a ring of oil forms to run 3 mm (0.125 in) down the rod, the
cylinder must be overhauled or replaced.
Steer Wheel Bearing Check and Lubrication

• To check the steer wheel bearings for excessive free play or looseness :
Grasp the wheel with both hands and try to move it by a rocking motion top-to-bottom.
Try to pull it in and out along the wheel spindle.
• Watch for excessive free movement in wheel bearings or steering knuckle bearings. There should be a small
amount of free movement. If the wheel has excessive free movement, the bearings require adjustment and
lubrication
Changing the drive wheels

• The quality of tyres influences the stability and driving behaviour of fork-
lift trucks. Changes shall only be made after prior consultation with the
forklift truck manufacturer. When changing wheels or tyres, care shall be
taken to ensure that the forklift truck is not in a sloping position (wheel
changes always on the left and right simultaneously, for example). When
using wheels with divided wheel disks, special measure shall be
observed when changing the tyres. The air pressure stated in the oper-
ating instructions shall be observed.
• Before lifting, the forklift must be secured against rolling by means of
chocks at the front and rear of the steer wheels.
• To change the drive wheels, the forklifttruck must be lifted using the upright. For this purpose, tilt the upright
backwards up to the stop. Lay wooden beams and steel sheets under the upright. Then tilt the upright forwards
to a vertical position. The drive wheels are now free and can be dismounted.
4.14
Changing the steer wheels

• Never lift the forklift truck below the counterweight.
• The quality of tyres influences the stability and driving behaviour of fork-
lift trucks. Changes shall only be made after prior consultation with the
forklift truck manufacturer. When changing wheels or tyres, care shall be
taken to ensure that the forklift truck is not in a sloping position (wheel
changes always on the left and right simultaneously, for example). When
using wheels with split rims, special measure shall be observed when
changing the tyres. The air pressure stated in the operating instructions
shall be observed.
• Before lifting the truck, slightly loosen the wheel bolts, apply the parking
brake and secure the forklift truck against any accidental forward motion by putting wooden wedges in front of
the driving wheels. Moreover, lift the fork carriage off the ground by approx. 10 cm.
• Now, lift the forklift truck, until wooden beams with a sufficient load capacity can be pushed under both sides of
the frame but not under the counterweight. With the forklift truck secured in this way, you can now remove the
devices and the hoist tool to dismount a steer wheel safely.
! WARNING
When refitting the wheels, ensure correct seating of the valve. It
must lock into the grooves of the wheel hub.
Tighten the wheel nuts evenly at the specified tightening torque.
Check the tyre pressure.
• Wheel bolts and nuts need time to settle into their correct location while 4339705
driving under load. It is therefore essential to retighten the wheel bolts/

nuts with the prescribed torque values after 50 operation hours on new
machines and every wheel change.
Disassembling the split-rim wheel.

• When you disassemble the split-rim wheel, NEVER remove the tire
before you deflate the tire pressure.
• First, remove the tire pressure and then loosen the wheel bolts and nuts.
• Failure to do so could result in serious personal injury.
• This operation shall be performed by the certified mechanic only.
4.15
4) Towing the fork lift truck

• Towing on ramps and steep inclines, whether in the upward or down-
ward direction, is PROHIBITED.
• While you are working around the inoperative forklift truck, the parking
brake must always be applied or the drive wheels blocked.
! CAUTION
When the engine is not running, the powerassisted steering
and brake of the forklift truck being towed will not function
either. Turning of the steering wheel and braking will then be
more difficult.
The towing speed must not be more than walking speed 3~4
km/h. The towing distance should be as short as possible
(approx. 500 m).
• If your forklift truck must be towed (engine defect etc.), the following
measures should be taken:
1. The lifting framework (the forks) of the forklift truck should, if possible,
be raised around 300 mm above floor level. Secure the lifting frame-
work with a chain.
If this is not possible, remove the fork arms from the fork carriage.
2. The towing vehicle must have sufficient towing and braking force.
3. Attach the towing vehicle to the trailer pin of the forklift truck with an
approved towbar.
4. Tow the inoperative forklift truck backwards. There must always be a driver in the forklift truck being towed.
5. Park the inoperative forklift truck only in areas provided for this purpose (see also safety section, “parking the
forklift truck”, see page 1.15).
4.16
5) Cleaning and Storage
Cleaning the forklift truck
• Cleaning work may only be carried out in locations provided for this
purpose. Ensure that pollution is avoided as far as possible.
• All areas which must be kept free of water, steam jet or cleaning
agent, for functional or safety reasons, must be protected by covers
or by taping them up. This applies, for example, for the electronic
system.
• Do not expose insulating material to the direct jet spray. When spray-
ing, do not spray into the air filter or exhaust systems.
• Only brand name, stipulated cleaning agents may be used. Do not
use petrol or diesel under any circumstances.
• Once the forklift truck has been cleaned, remove all covers and tape.
• Lubricate the forklift truck in accordance with the lubrication plan.
• A braking test shall be carried out after the forklift truck has been washed. If the brakes do not function
properly from the operator's seat of the forklift truck, the truck must be brought to a standstill by applying the
parking brake.
Measures for longer lay-off periods, storage

(> 1 months)
• The following measures must be carried out :
Remove the battery : Disconnect the ( - )cable
! CAUTION
If the forklift truck is stored without disconnecting (-)cable of
battery for a long time, it will not be started due to the dis-
charged battery.
(> 6 months)
• The following measures must be carried out :
Clean the forklift truck and grease the piston rods.
Remove the battery. : Disconnect the ( - )cable.
Fill up the fuel tank. Before recommissioning, the fuel and the fuel filter must be replaced. Bleed the fuel
system.
Remove the engine oil and replace with suitable conservation oil. Replace the oil filter.
Before recommissioning, the conservation oil must be drained off again. The engine must be filled with
normal service oil again.
Check the antifreeze level in the cooling system.
Jack up the forklift truck to prevent the tyres going flat.
All lubricants must be replaced before recommissioning.
4.17
5. Lubrication and maintenance plan
1
4 2
1 4 2
1
2
2
2
9
7
9
2 4
4 7
3
3
7 5
6
6
5 5
7
5
7 7 7
7
7
7 7
7
7
9 9
9 9
9 9 9 9
8 8
C40-55s C60-80
Legend
1. Liftting device
2. Drive unit and brakes
3. Driver's seat and controls
4. Electrical equipment
5. Hydraulic system
6. Truck frame and safety equipment
7. Engine and cooling
8. Exhaust system and catalytic converter (option)
9. Steering system
10. Miscellaneous and special equipment
11. Cabin (option)
12. Speed limit system (option)
13. Other inspections
NOTE
All further sub-items where service work needs be carried out, including filling and lubrication
points listed in the overview of the maintenance areas, can be found in more detail in the follow-
ing list.
5.1
Service to be carried in accordance with specified below

A - Weekly by operator
B - 450~500 hours or annually
C - 900~1000 hours or annually
D - 2000 hours or annually
In heavy duty conditions, service intervals may be reduced A B C D
1 Load Handling
Check fork thickness at heel X
Check permanent deformation of forks, left and right forks uniformity X
Check fork cracking at heel and mountings X
Check fork carriage and load backrest X
Clean and lubricate lift chains X
Check and adjust lift chains X
Check the condition of the chain anchor bolts X
Check lift chain wear X
Clean, check and lubricate upright X
Check rollers bearings and stubs for wear and rotation X
Check deformation, damage and cracks to welded areas of upright and upright
X
mountings
Check upright mounting is secure X
Check wear and damage to upright rails X
Check upright cylinder leakage, deformation, mounting, uneven movement X
Check and lubricate tilt cylinder bearings and mountings X
Lubricate attachment X
Check accessories (option) and mounting condition X
2 Drive unit and brakes
Check tire condition (tire wear line, tearing, debris, bonding and size) X
Check the rim condition (damage, fixing bolts and nuts) X
Service brake, check performance X
Parking brake, check function X
Check brake hydraulic system for leaks X
Check the brake system for damage, tightness of hoses, pipes,
X
linkages and cables
Check transmission oil level (first time after 50 hours) X
Replace transmission oil X
Replace transmission oil filter X
Check oil level of drive axle (first time after 50 hours) X
Replace drive axle oil X
Check installation and mounting of drive axle X
Check transmission and front axle housing for cracks and damage X
Check and lubricate the prop shaft X
3 Operator compartment and controls
Check operator restraint system X
Check seat mounting and adjustment function X
Check control lever linkage for tightness and function X
Check rear view mirror X
5.2

4 Electrical equipment
Check battery condition (damage, fixing, battery terminals) X
Check emergency shut-down X
Check electric wiring and fuses X
Check spark plugs and HT leads X
Check function and mounting of the lighting system X
Operation of audible device function X
Instrument function X
5 Hydraulic system
Lift function drift test X
Tilt function drift test X
Check for oil leaks, damage and noise X
Check hydraulic oil level X
Replace hydraulic oil filter and hydraulic tank breather X
Replace hydraulic oil and check hydraulic oil sump filter X
Check setting and function of pressure relief valve X
Check the tilt lock valve X
Check oil pressure lines for deformation, damage and tightness X
6 Truck chassis and safety equipment
Check mounting points X
Check chassis, overhead guard and safety equipment for deformation,
X
damage and cracks
Check towing device X
Engine cover latch(s) check for function and safety X
7 Engine and cooling
Check air intake system for leaks X
Clean engine air filter (O) or replace (X) (LPG) O X
Clean engine air filter (O) or replace (X) (Diesel) O X
Check fuel, coolant and oil system for leaks X
Check coolant hose condition X
Check radiator mountings X
Check coolant level X
Drain coolant / flushradiator X
Check engine oil level X
C40-80D (Kubota Stage V) 500 Hours/ Annually
C60-80D (Iveco) 600
Replace engine oil and oil filter
C40-80D (Kubota, Deutz) 500
C40-80L (GM, PSI 4X) 500
Check crankcase breather function X
Check crankcase breather function (Kubota Stage V) 1500 Hours
5.3

Replace engine crankcase breather oil separator filter (Kubota stage V) 1500 Hours
Replace fuel filter element (LPG) X
C40-80D (Kubota, Iveco) X
Replace fuel filter element (Diesel) C40-80D (Kubota, Deutz) X
C40-80D (Kubota Stage V) X
Replace water separator filter element (Deutz) 1000 Hours/ Annually
Replace water separator filter element (Kubota Stage V) 500 Hours/ Annually
Check and adjust valve clearances (Diesel engine) X
Check injectors and injection timing (Kubota Stage V with Diagnostic master) 1500
Clean the injectors and check for damage X
LPG system function and leakage test X
Replace spark plugs (LPG engine) X
Check drive-belt (s) for wear, adjust or replace if necessary X
8 Exhaust system and catalytic converter (option)
Exhaust emission test with diesel engine X
Check exhaust system connections for leaks X
EGR Cooler check for leaks (Kubota stage V) 1500 Hours
EGR Cooler function check with Diagnostic master (Kubota stage V) 1500 Hours
DPF Service (contact CLARK service) 3000-6000 Hours
9 Steering
Check steering wheel and column for tightness, freedom of movement and function X
Check steering system for leaks (steering valve and cylinders) X
Check steering hoses, lines for damage and leaks X
Check steering axle for cracks, damage and deformation X
Check steering axle for tightness in both travel directions X
Check and lubricate steering axle stub axles and king pins X
Check steering axle wheel bearing play X
Lubricate steering link pins, bushes X
Check / re-pack steer axle wheel bearings X
10 Miscellaneous and special equipment
Check visible safety warnings and symbols X
Operating manual available X
Check mounting parts X
Check additional equipment X
11 Cabin (option)
Check for deformation, cracks and damage X
Check wear on PVC doors, and seals X
12 Speed limit system (option)
Speed limit system function check X
13 Other checks
Check critical fastener torques X
5.4
6. Lubricant Recommendations
E Engine oil
LPG truck
: GM, PSI 4X - in accordance with API classification SM grade and SAE 5W-30 full synthetic
Diesel truck
: KUBOTA - in accordance with API classification CJ-4 with high sulfur fuel / SAE 15W-40
: IVECO - in accordance with API classification CI-4 and ACEA E9,E7,E6 / SAE 10W-40
: DEUTZ - in accordance with API classification CI-4 and ACEA E3 / SAE 15W-40
-40 -30 -20 -10 0 +10 +20 +30 +40 +50
SAE 0W-30
SAE 5W-30
SAE 5W-40
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-50
SAE 10W
SAE 20W
SAE 30
SAE 40
H Hydraulic fluid
RANDO HD 32, or in accordance with CLARK specification MS-68 (CLARK #2776239)
T Transmission oil
CLARK MS-276A (CLARK #2776236)
G Multipurpose grease
In accordance with CLARK specification MS-9 or MS-107C
e.g.) BP : Multipurpose grease L2 FINA : Marson EPL2

MOBIL : Mobilgrease MP SHELL : Alkvania grease EP2
DEFROL : M2F 2 EP 2 GULF : Crow Grease EP 2
CHEVRON : Dura-Lit EP 2
6.1
6. Lubricant Recommendations
G1 Inside rail lubricants

In accordance with CLARK # 886396 specifications
C Chain lube
In accordance with CLARK # 886399 specifications
B Brake fluid
RANDO HD 32, or in accordance with CLARK specification MS-68 (CLARK #2776239)
D Diesel fuel
D-2 with cetane rating of 45 or higher.
D-1 and Jet A-1 also acceptable
L Liquefied petroleum gas (LPG)

HD-5 Propane
G2 Gasoline
87 Octane minimum
W Engine cooling system

Use a mixture of 50% ethylene glycol permanent-type antifreeze containing rust and corrosion inhibitors
only.
A Drive axle oil

MOBIL Fluid #424 (CLARK #8065510)
6.2
7. Technical data
Filling quantities (liter)

C40D C45D C50sD C55sD C40L C45L C50sL C55sL
KUBOTA 13.2 l 13.2 l 13.2 l 13.2 l
Engine oil DEUTZ 8.0 l 8.0 l 8.0 l 8.0 l
GM,PSI 4X 4.7 l 4.7 l 4.7 l 4.7 l
Cooling System 18 l 18 l 18 l 18 l 18 l 18 l 18 l 18 l
Transmission fluid 13 l 13 l 13 l 13 l 13 l 13 l 13 l 13 l
Hydraulic sump 88 l 88 l 100 l 100 l 88 l 88 l 100 l 100 l
Fuel tank 94 l 94 l 106 l 106 l 20kg 20kg 20kg 20kg
Battery
C40-55sD (KOBOTA) ............................................................................................................... 12V, 150Ah
C40-55sD (DEUTZ) ................................................................................................................. 12V, 120Ah
C40-55sL ...... .............................................................................................................................. 12V, 60Ah
Fuses ............................................................................................................................. 5, 7.5, 10, 15, 20Amp
Wheels and Tire

Steering axle tires
C40-55s ............................ 7.00 x 12-14PR ...................................................... 1000 kPa (145 psi) (10bar)
Drive axle tires
Single drive
C40 ................................... 8.25 x 15-14PR ...................................................... 820 kPa (119 psi) (8.2 bar)
C45 .................................... 8.25 x 15-16PR ..................................................... 951 kPa (138 psi) (9.5 bar)
C50s ................................... 300 x 15-18PR ....................................................... 820 kPa (119 psi) (8.2 bar)
C55s ................................... 300 x 15-20PR ...................................................... 951 kPa (138 psi) (9.5 bar)
Dual drive
C40-55s ............................. 7.50 x 15-12PR ....................................................... 820 kPa (119 psi) (8.2 bar)
Torques
Steering axle wheel nut .............................................................. 343-392 N.m (35-40 kg·m) (253-289 ft·lb)
Drive axle wheel nut ................................................................... 340-380 N.m (35-39 kg·m) (251-280 ft·lb)
Driver´s overhead guard (front) ............................................................... 70-80 N.m (7-8 kg·m) (51-59 ft·lb)
(rear) ...................................................170-190 N.m (17-19 kg·m) (125-140 ft·lb)
Counterweight ............................................................................ 441-490 N.m (45-50 kg·m) (325-362 ft·lb)
Drive axle to frame ..................................................................... 800-900 N.m (82-92 kg·m) (590-664 ft·lb)
Tilting cylinder clamping bolt on piston rod head ........................ 170-190 N.m (17-19 kg·m) (125-140 ft·lb)
Tilt cylinder pin retainer bolts ............................................................ 40-45 N.m (4.0-4.6kg·m) (30-33 ft·lb)
Upright mounting screws ........................................................... 170-190 N.m (17-19 kg·m) (123-137 ft·lb)
Steering axle mounting .............................................................. 167-196 N.m (17-20 kg·m) (123-145 ft·lb)
7.1
7. Technical data
Filling quantities (liter)

C60-70D C80D C60-75L
IVECO 12.8 l 12.8 l
DEUTZ 8.0 l 8.0 l
Engine oil
KUBOTA 13.2 l 13.2 l
GM, PSI 4X 4.7 l
Cooling System 24 l 24 l 24 l
Transmission fluid 23 l 23 l 13.9 l
Hydraulic sump 120 l 147 l 120 l
Fuel tank 160 l 200 l 20kg
Drive Axle Oil 12.5 l 12.5 l 12.5 l
Battery
C60-80D ..................................................................................................................... 24V (12V x 2), 80 Ah
C60-75L ..................................................................................................................................... 12V, 80 Ah
Fuses .............................................................................................................................. 5, 10, 15, 20, 30 Amp
Wheels and Tire

Steering axle tires
C60-75 ................................8.25 × 15-14PR ......................................................... 820kPa (119psi) (8.2bar)
C80 .....................................8.25 × 15-18PR ........................................................ 1000kPa (145psi) (10bar)
Drive axle tires
Dual drive
C60-75 ................................8.25 × 15-14PR ......................................................... 820kPa (119psi) (8.2bar)
C80 .....................................8.25 × 15-18PR ........................................................ 1000kPa (145psi) (10bar)
Torques
Steering axle wheel nut................................................... 392 - 490 Nm (40~50kg·m) (289~361ft·lb)
Drive axle wheel nut ....................................................... 539 - 588 Nm (55~60kg·m) (397~433ft·lb)
Driver´s overhead guard ...................................................... 70 - 80 Nm (7~8kg·m) (51~59ft·lb)
Counterweight ................................................................ 441 - 490 Nm (45~50kg·m) (325~361ft·lb)
Drive axle to frame.......................................................... 800 - 900 Nm (82~92kg·m) (590~663ft·lb)
Tilting cylinder clamping bolt on piston rod head ............ 170 - 190 Nm (17~19kg·m) (125~140ft·lb)
Tilt cylinder pin retainer bolts ............................................. 40 - 45 Nm (4.0~4.6kg·m) (30~33ft·lb)
Upright mounting screws .................................................... 57 - 71 Nm (5.8~7.2kg·m) (42~52ft·lb)
Steering axle mounting .................................................... 167 - 196 Nm (17~20kg·m) (123~145ft·lb)
7.2
8. Specification
Dimensions (C40-55s D, DEUTZ) Product Specifications

1.1 Manufacturer (Abbreviation)
1.2 Manufacturer’s designation
Specifications
1.3 Drive unit Diesel, L.P. Gas
1.4 Operator type stand on / driver seated
1.5 Load capacity / rated load Q (t)
4.5 h
1.6 Load centre distance c (mm)
4.7 h6
1.8 Load centre distance, centre of drive axle to fork face x (mm)
4.4 h3
1.9 Wheelbase y (mm)
4.2 h1 2.1 Service weight kg
WT
2.2 Axle loading, laden front / rear kg
4.8 h7
4.3 h2
2.3 Axle loading, unladen front / rear kg
3.1 Tyre type, P = pneumatic, SE = superelastic, C = cushion 1)
Tyres, Chassis
4.12 h10
3.2 Tyre size, front
4.31
1.8 1.6 4.22 3.3 Tyre size, rear
1.9
4.20 4.22 3.5 Wheels, number front/rear (x = drive wheels)
4.19 3.6 Tread, front b10 (mm)
3.7 Tread, rear b11 (mm)
4.34
4.1 Tilt of upright/fork carriage, Ȼ / ȼ degree
4.2 Height, upright lowered h1 (mm)
4.3 Freelift h2 (mm)
4.4 Lift height 2) h3 (mm)
4.21
4.5 Height, upright extended h4 (mm)
4.34 4.7 Height overheadguard (cab); Std / Container h6 (mm)
4.8 Seat height h7 (mm)
4.12 Coupling height h10 (mm)
4.19 Overall length l1 (mm)
Dimensions
4.20 Length to face of forks l2 (mm)

4.21 Width b1, b2 (mm)
For data see corresponding number in chart "Product Speci- 4.22 Fork dimensions s • e • l (mm)
fications" 4.23 Fork carriage DIN 15173, A, B
4.24 Fork carriage width b3 (mm)
4.31 Ground clearance minimum, laden m1 (mm)
Truck Capacities 4.32 Ground clearance centre of wheelbase m2 (mm)
4.34 Stacking aisle for pallets 1000 x 1200 Ast (mm)
Capacity at different load centres
6000
5500
4.35 Turning radius Wa (mm)
5000 4.36 Internal turning radius b13 (mm)
j GOP
5.1 Travel speed, laden/unladen km/h

4500
5.2 Lift speed, laden/unladen m/s
Performances
4000 5.3 Lowering speed, laden / unladen m/s

5.5 Drawbar pull, laden / unladen 3) 4) kg
3500 C55s
C50s
5.6 Max. drawbar pull, laden / unladen 4) kg
3000 C45 5.7 Gradeability, laden / unladen 3) 4) %
2500
C40 5.8 Max. gradeability, laden / unladen 4) %
5.9 Acceleration time, laden / unladen (0 - 15 m) s
500 600 700 800 900 1000 1100 1200
5.10 Service brake
sGGOP
7.1 Manufacturer / Type
I.C.-Engine
NOTE 7.2 Rated output acc. DIN 70020 kW

7.3 Rated speed acc. DIN 70020 r.p.m
The listed capacities are valid only for the standard
7.4 No. of cylinders / displacement cc
upright in vertical position with standard fork car-
7.5 Fuel consumption acc. VDI-Cycles Diesel= l/h, L.P.-Gas= kg/h
riage and standard forks, up to max. lifting height of
8.1 Type of control
Miscellaneous
C40-50s : 3000mm, C55s : 2800mm.

8.2 Operating pressure for attachments bar
The centre of gravity of the load may be displaced
8.3 Oil volume for attachments l/min
by max. 100mm against the longitudinal centre line
8.4 Sound level, driver's ear 5) dB (A)
of the truck. Load centre is determined from top and
8.5 Vibration in accordance with EN 13059 GGm/s¸
front face of forks. The values are based on a
1000mm, cube load configuration with the centre of
1) Optional with super-elastic tyres
gravity at the true centre of the cube. With upright 2) Further lift heights see upright table
tilted forward lower capacity values are valid. 3) Laden with 1,6 km/h
Attachments, longer forks, exceptional load dimen- 4) Without load at friction coefficient = 0,6
sions and higher lifting heights may reduce the 5) Equivalent permanent sound-pressure level L pAeq,T
capacity. in accordance with EN 12053
8.1
8. Specification
CLARK 1.1
C40D C45D C50sD C55sD 1.2
Diesel Diesel Diesel Diesel 1.3
Rider counterbalanced Rider counterbalanced Rider counterbalanced Rider counterbalanced 1.4
4000 4500 5000 5500 1.5
500 500 500 500 1.6
573 573 573 598 1.8
1950 1950 2100 2100 1.9
6062 6608 7205 7645 2.1
8892 / 1170 9844 / 1264 10848 / 1357 11657 / 1488 2.2
2675 / 3386 2840 / 3767 3217 / 3988 3143 / 4502 2.3
P P P P 3.1
8.25x15-14PR 7.50x15-12PR 7.50x15-12PR 7.50x15-12PR 3.2
7.00x12-14PR 7.00x12-14PR 7.00x12-14PR 7.00x12-14PR 3.3
2x /2 4x /2 4x /2 4x /2 3.5
1165 1288 1288 1288 3.6
1134 1134 1134 1134 3.7
10 / 8 10 / 8 10 / 8 10 / 8 4.1
2234 2207 2207 2207 4.2
156 156 156 166 4.3
3000 3000 3000 2800 4.4
3769 3769 3769 3762 4.5
2324 / 2336 2310 / 2322 2310 / 2322 2310 / 2322 4.7
1265 1265 1265 1265 4.8
460 460 460 460 4.12
4113 4163 4453 4533 4.19
3043 3093 3233 3313 4.20
1400 1742 1742 1742 4.21
50x122x1070 50x122x1070 50x150x1220 60x150x1220 4.22
CL III A CL III A CL III A CL IV A 4.23
1348 1678 1678 1678 4.24
169 142 142 142 4.31
212 186 185 185 4.32
4616 4651 4805 4869 4.34
4816 4851 5005 5069 4.34
4.34
2843 2878 3032 3071 4.35
4.36
22.0 / 23.2 20.5 / 21.7 20.3 / 21.6 20.2 / 21.6 5.1
0.55 / 0.57 0.53 / 0.57 0.50 / 0.57 0.48 / 0.57 5.2
0.50 / 0.47 0.50 / 0.47 0.50 / 0.47 0.50 / 0.47 5.3
5.5
3847 / 1298 4122 / 1376 4128 / 1579 4127 / 1532 5.6
5.7
37.4 / 21.4 35.9 / 20.9 32.1 / 21.8 39.4 / 20.1 5.8
5.9
Wet disc brake Wet disc brake Wet disc brake Wet disc brake 5.10
DEUTZ TD 3.6 DEUTZ TD 3.6 DEUTZ TD 3.6 DEUTZ TD 3.6 7.1
55.4 55.4 55.4 55.4 7.2
2200 2200 2200 2200 7.3
4 / 3621 4 / 3621 4 / 3621 4 / 3621 7.4
7.5
8.1
140 140 140 140 8.2
8.3
80.6 80.6 80.6 80.6 8.4
1.22 1.22 1.22 1.22 8.5
Note:
All values shown are for standard lift truck with standard equipment.
If the truck is supplied with options, values may change.
All values given may vary +5% and -10% due the motor and system tolerances and represent nominal values obtained under typical
operating conditions.
8.2
8. Specification
Dimensions (C40-55s D, KUBOTA) Product Specifications

Specifications
4.5 h 1.6 Load centre distance c (mm)
4.7 h6
4.4 h3
4.2 h1
2.1 Service weight kg
WT
4.8 h7
4.3 h2
Tyres, Chassis
4.12 h10
1.8
4.31
4.22
3.3 Tyre size, rear
1.6
1.9
4.20 4.22
3.5 Wheels, number front/rear (x = drive wheels)
4.34 4.1 Tilt of upright/fork carriage, Ȼ / ȼ degree
4.21
Dimensions

Truck Capacities 4.31 Ground clearance minimum, laden m1 (mm)
4.32 Ground clearance centre of wheelbase m2 (mm)
Capacity at different load centres 4.34 Stacking aisle for pallets 1000 x 1200 Ast (mm)
6000
5500 4.34 Stacking aisle for pallets 1200 x 800 Ast (mm)
5000
j GOP
4.36 Internal turning radius b13 (mm)

4500 5.1 Travel speed, laden/unladen km/h
4000
Performances
5.3 Lowering speed, laden / unladen m/s

3500 C55s 5.5 Drawbar pull, laden / unladen 3) 4) kg
C50s
3000 C45
C40 5.7 Gradeability, laden / unladen 3) 4) %
2500
5.8 Max. gradeability, laden / unladen 4) %
500 600 700 800 900 1000 1100 1200 5.9 Acceleration time, laden / unladen (0 - 15 m) s
sGGOP 5.10 Service brake
NOTE
I.C.-Engine
7.2 Rated output acc. DIN 70020 kW

The listed capacities are valid only for the standard 7.3 Rated speed acc. DIN 70020 r.p.m
upright in vertical position with standard fork car- 7.4 No. of cylinders / displacement cc
riage and standard forks, up to max. lifting height of 7.5 Fuel consumption acc. VDI-Cycles Diesel= l/h, L.P.-Gas= kg/h
C40-50s : 3000mm, C55s : 2800mm. 8.1 Type of control
Miscellaneous
The centre of gravity of the load may be displaced 8.2 Operating pressure for attachments bar
by max. 100mm against the longitudinal centre line 8.3 Oil volume for attachments l/min
of the truck. Load centre is determined from top and 8.4 Sound level, driver's ear 5) dB (A)
front face of forks. The values are based on a 8.5 Vibration in accordance with EN 13059 GGm/s¸
gravity at the true centre of the cube. With upright
2) Further lift heights see upright table
tilted forward lower capacity values are valid.
3) Laden with 1,6 km/h
8.3
8. Specification
G
CLARK 1.1
C40D C45D C50sD C55sD 1.2
4000 4500 5000 5500 1.5
500 500 500 500 1.6
573 573 573 598 1.8
1950 1950 2100 2100 1.9
5986 [6062] 6532 [6608] 7129 [7205] 7569 [7645] 2.1
8842 / 1143 [8892 / 1170] 9784 / 1248 [9844 / 1264] 10798 / 1332 [10848 / 1357] 11487 / 1582 [11657 / 1488] 2.2
2641 / 3344 [2675 / 3386] 2807 / 3724 [2840 / 3767] 3183 / 3946 [ 3217 / 3988] 3112 / 4457 [3143 / 4502] 2.3
P P P P 3.1
8.25x15-14PR 7.50x15-12PR 7.50x15-12PR 7.50x15-12PR 3.2
7.00x12-14PR 7.00x12-14PR 7.00x12-14PR 7.00x12-14PR 3.3
2x /2 4x /2 4x /2 4x /2 3.5
1165 1288 1288 1288 3.6
1134 1134 1134 1134 3.7
10 / 8 10 / 8 10 / 8 10 / 8 4.1
2234 2207 2207 2206 4.2
156 156 156 166 4.3
3000 3000 3000 2800 4.4
3769 3769 3769 3752 [3762] 4.5
2324 / 2253 [2324 / 2336] 2310 / 2227 [2310 / 2322] 2310 / 2226 [2310 / 2322] 2310 / 2226 [ 2310 / 2322] 4.7
1265 1265 1265 1265 4.8
460 460 460 460 4.12
4113 4163 4453 4533 4.19
3043 3093 3233 3313 4.20
1400 1742 1742 1742 4.21
50x122x1070 50x122x1070 50x150x1220 60x150x1220 4.22
1348 1678 1678 1678 4.24
169 142 142 142 4.31
212 186 185 185 4.32
4616 4651 4805 4869 4.34
4816 4851 5005 5069 4.34
4.34
2843 2878 3032 3071 4.35
4.36
21.8 / 23.2 [22.0 / 23.2] 20.5 / 21.7 [20.5 / 21.7] 20.4 / 21.6 [20.3 / 21.6] 20.3 / 21.6 [20.2 / 21.6] 5.1
0.52 / 0.56 [0.55 / 0.57] 0.51 / 0.56 [0.53 / 0.57] 0.50 / 0.56 [0.50 / 0.57] 0.49 / 0.56 [0.48 / 0.57] 5.2
0.50 / 0.47 0.50 / 0.47 0.50 / 0.47 0.50 / 0.47 5.3
5.5
4220 / 1298 [3847 / 1298] 4550 / 1376 [3959 / 1362] 4558 / 1579 [3964 / 1566] 4559 / 1533 [3963 / 1519] 5.6
5.7
52.2 / 21.4 [37.2 / 21.4] 47.5 / 20.9 [34.3 / 20.9] 42.3 / 21.8 [30.7 / 21.8] 38.7 / 20.1 [28.1 / 20.1] 5.8
5.9
KUBOTA V3800 KUBOTA V3800 KUBOTA V3800 KUBOTA V3800
[KUBOTA V3800-CR-TE5] [KUBOTA V3800-CR-TE5] [KUBOTA V3800-CR-TE5] [KUBOTA V3800-CR-TE5] 7.1
68.6 [54.6] 68.6 [54.6] 68.6 [54.6] 68.6 [54.6] 7.2
2400 [2000] 2400 [2000] 2400 [2000] 2400 [2000] 7.3
4 / 3769 4 / 3769 4 / 3769 4 / 3769 7.4
7.5
8.1
140 140 140 140 8.2
8.3
83 [80] 83 [80] 83 [80] 83 [80] 8.4
1.22 1.22 1.22 1.22 8.5
Note:
GG
[ GG ] : Specification for KUBOTA Stage 5 Engine.
8.4
8. Specification
Dimensions (C40-55s L, GM) Product Specifications

Specifications
4.5 h4 1.6 Load centre distance c (mm)
4.7 h6
4.4 h3
4.2 h1
WT
4.8 h7
4.3 h2
Tyres, Chassis
4.12 h10
4.31 3.3 Tyre size, rear
1.8 1.6 4.22
1.9
4.20 4.22
4.34 4.1 Tilt of upright/fork carriage, Ȼ / ȼ degree
4.21
Dimensions

4.32 Ground clearance centre of wheelbase m2 (mm)
6000
5000
j GOP

4000
Performances

3500 C55s 5.5 Drawbar pull, laden / unladen 3) 4) kg
C50s
3000
C45
2500
500 600 700 800 900 1000 1100 1200 5.9 Acceleration time, laden / unladen (0 - 15 m) s
sGGOP 5.10 Service brake
NOTE
I.C.-Engine

The listed capacities are valid only for the standard 7.3 Rated speed acc. DIN 70020 r.p.m
upright in vertical position with standard fork car- 7.4 No. of cylinders / displacement cc
riage and standard forks, up to max. lifting height of 7.5 Fuel consumption acc. VDI-Cycles Diesel= l/h, L.P.-Gas= kg/h
C40-50s : 3000mm, C55s : 2800mm. 8.1 Type of control
Miscellaneous
The centre of gravity of the load may be displaced 8.2 Operating pressure for attachments bar
by max. 100mm against the longitudinal centre line 8.3 Oil volume for attachments l/min
of the truck. Load centre is determined from top and 8.4 Sound level, driver's ear 5) dB (A)
front face of forks. The values are based on a 8.5 Vibration in accordance with EN 13059 GGm/s¸
gravity at the true centre of the cube. With upright
2) Further lift heights see upright table
tilted forward lower capacity values are valid.
3) Laden with 1,6 km/h
8.5
8. Specification
CLARK 1.1
C40L C45L C50sL C55sL 1.2
LPG LPG LPG LPG 1.3
4000 4500 5000 5500 1.5
500 500 500 500 1.6
573 573 573 598 1.8
1950 1950 2100 2100 1.9
5833 6379 6977 7417 2.1
8749 / 1084 9690 / 1189 10701 / 1276 11487/ 1582 2.2
2548 / 3285 2714/ 3665 3087 / 3890 3112 / 4458 2.3
P P P P 3.1
8.25x15-14PR 7.50x15-12PR 7.50x15-12PR 7.50x15-12PR 3.2
7.00x12-14PR 7.00x12-14PR 7.00x12-14PR 7.00x12-14PR 3.3
2x /2 4x /2 4x /2 4x /2 3.5
1165 1288 1288 1288 3.6
1134 1134 1134 1134 3.7
10 / 8 10 / 8 10 / 8 10 / 8 4.1
2234 2207 2207 2206 4.2
156 156 156 166 4.3
3000 3000 3000 2800 4.4
3769 3769 3769 3752 4.5
2253 2227 2226 2226 4.7
1265 1265 1265 1265 4.8
460 460 460 460 4.12
4113 4163 4453 4533 4.19
3043 3093 3233 3313 4.20
1400 1742 1742 1742 4.21
50x122x1070 50x122x1070 50x150x1220 60x150x1220 4.22
1348 1678 1678 1678 4.24
169 142 142 142 4.31
212 186 185 185 4.32
4616 4651 4805 4869 4.34
4816 4851 5005 5069 4.34
4.34
2843 2878 3032 3071 4.35
4.36
20.2 / 21.5 (20.2 / 21.5) 19.0 / 20.1 (19.0 / 20.1) 18.8 / 20.0 (18.8 / 20.0) 18.7 / 20.0 (18.7 / 20.0) 5.1
0.49 / 0.51 (0.49 / 0.51) 0.48 / 0.51 (0.48 / 0.51) 0.48 / 0.51 (0.48 / 0.51) 0.47 / 0.50 (0.47 / 0.50) 5.2
0.50 / 0.47 0.50 / 0.47 0.50 / 0.47 0.50 / 0.47 5.3
5.5
3733 / 1251 3949 / 1329 3953 / 1530 3952 / 1483 5.6
5.7
43.3 / 21.1 40.8 / 20.7 36.5 / 21.8 33.4 / 20.0 5.8
5.9
5.10
GM V6 4.3 GM V6 4.3 GM V6 4.3 GM V6 4.3 7.1
82 (63.6) 82 (63.6) 82 (63.6) 82 (63.6) 7.2
2400 (2200) 2400 (2200) 2400 (2200) 2400 (2200) 7.3
6 / 4299 6 / 4299 6 / 4299 6 / 4299 7.4
7.5
8.1
140 140 140 140 8.2
8.3
83 83 83 83 8.4
1.25 1.25 1.25 1.25 8.5
Note:
( ) : Specification for non emission complied truck.
8.6
8. Specification
Dimensions (C40-55s L, PSI 4X) Product Specifications

Specifications
4.5 h4 1.6 Load centre distance c (mm)
4.7 h6
4.4 h3
4.2 h1
WT
4.8 h7
4.3 h2
Tyres, Chassis
4.12 h10
4.31
1.8 1.6 4.22 3.3 Tyre size, rear
1.9
4.20 4.22 3.5 Wheels, number front/rear (x = drive wheels)
4.19
3.6 Tread, front b10 (mm)
4.34
4.21 4.5 Height, upright extended h4 (mm)
4.34
4.7 Height overheadguard (cab); Std / Container h6 (mm)
Dimensions

Capacity at different load centres 4.32 Ground clearance centre of wheelbase m2 (mm)
6000
5500
5000 4.35 Turning radius Wa (mm)
j GOP

4500
4000 5.2 Lift speed, laden/unladen m/s
Performances

3500 C55s
C50s 5.5 Drawbar pull, laden / unladen 3) 4) kg
3000 C45 5.6 Max. drawbar pull, laden / unladen 4) kg
2500
500 600 700 800 900 1000 1100 1200
sGGOP
5.10 Service brake
NOTE 7.1 Manufacturer / Type
I.C.-Engine
The listed capacities are valid only for the standard 7.2 Rated output acc. DIN 70020 kW
upright in vertical position with standard fork car- 7.3 Rated speed acc. DIN 70020 r.p.m
riage and standard forks, up to max. lifting height of 7.4 No. of cylinders / displacement cc
C40-50s : 3000mm, C55s : 2800mm. 7.5 Fuel consumption acc. VDI-Cycles Diesel= l/h, L.P.-Gas= kg/h
8.1 Type of control
Miscellaneous
The centre of gravity of the load may be displaced

by max. 100mm against the longitudinal centre line 8.2 Operating pressure for attachments bar
of the truck. Load centre is determined from top and 8.3 Oil volume for attachments l/min
front face of forks. The values are based on a 8.4 Sound level, driver's ear 5) dB (A)
1000mm, cube load configuration with the centre of 8.5 Vibration in accordance with EN 13059 GGm/s¸
gravity at the true centre of the cube. With upright 1) Optional with super-elastic tyres
tilted forward lower capacity values are valid. 2) Further lift heights see upright table
Attachments, longer forks, exceptional load dimen- 3) Laden with 1,6 km/h
sions and higher lifting heights may reduce the 4) Without load at friction coefficient = 0,6
capacity. 5) Equivalent permanent sound-pressure level L pAeq,T
in accordance with EN 12053
8.7
8. Specification
CLARK 1.1
C40L C45L C50sL C55sL 1.2
LPG LPG LPG LPG 1.3
Driver seated Driver seated Driver seated Driver seated 1.4
4000 4500 5000 5500 1.5
500 500 500 500 1.6
573 573 573 598 1.8
1950 1950 2100 2100 1.9
5833 6379 6977 7417 2.1
8749 / 1084 9690 / 1189 10701 / 1276 11487/ 1582 2.2
2548 / 3285 2714/ 3665 3087 / 3890 3112 / 4458 2.3
P P P P 3.1
8.25x15-14PR 7.50x15-12PR 7.50x15-12PR 7.50x15-12PR 3.2
7.00x12-14PR 7.00x12-14PR 7.00x12-14PR 7.00x12-14PR 3.3
2x /2 4x /2 4x /2 4x /2 3.5
1165 1288 1288 1288 3.6
1134 1134 1134 1134 3.7
10 / 8 10 / 8 10 / 8 10 / 8 4.1
2234 2207 2207 2206 4.2
156 156 156 166 4.3
3000 3000 3000 2800 4.4
3769 3769 3769 3752 4.5
2324 2310 2310 2310 4.7
1265 1265 1265 1265 4.8
460 460 460 460 4.12
4113 4163 4453 4533 4.19
3043 3093 3233 3313 4.20
1400 1742 1742 1742 4.21
50x122x1070 50x122x1070 50x150x1220 60x150x1220 4.22
1348 1678 1678 1678 4.24
169 142 142 142 4.31
212 186 185 185 4.32
4616 4651 4805 4869 4.34
4816 4851 5005 5069 4.34
4816 4851 5005 5069 4.34
2843 2878 3032 3071 4.35
4.36
20.4 / 21.7 19.3 / 20.3 19.1 / 20.2 19.0 / 20.2 5.1
0.49 / 0.51 0.48 / 0.51 0.48 / 0.51 0.47 / 0.50 5.2
0.50 / 0.47 0.50 / 0.47 0.50 / 0.47 0.50 / 0.47 5.3
5.5
3948/1251 4177/1329 4183/1530 4182/1483 5.6
5.7
46.3 / 21.1 43.6 / 20.6 38.9 / 21.6 35.6 / 19.8 5.8
5.9
Wet disk brake Wet disk brake Wet disk brake Wet disk brake 5.10
PSI 4X PSI 4X PSI 4X PSI 4X 7.1
82 82 82 82 7.2
2400 2400 2400 2400 7.3
6 / 4300 6 / 4300 6 / 4300 6 / 4300 7.4
7.5
8.1
140 140 140 140 8.2
8.3
83 83 83 83 8.4
1.25 1.25 1.25 1.25 8.5
Note:
8.8
8. Specification
Dimensions (C60-80 D, IVECO) Product Specifications

Specifications
WT
Tyres, Chassis
3.3 Tyre size, rear
Dimensions

For data see corresponding number in chart "Product Specifi- 4.22 Fork dimensions s • e • l (mm)
cations" 4.23 Fork carriage DIN 15173, A, B
7000
6000
C80
Capacity (kg)
Performances
C70 5.3 Lowering speed, laden / unladen m/s

4000
C60 5.5 Drawbar pull, laden / unladen 3) 4) kg
3000 5.6 Max. drawbar pull, laden / unladen 4) kg
2000 5.7 Gradeability, laden / unladen 3) 4) %
1000
0
0 600 700 800 900 1000 1100 1200 5.10 Service brake
Load Center (mm) 7.1 Manufacturer / Type
I.C.-Engine

NOTE 7.3 Rated speed acc. DIN 70020 r.p.m
The listed capacities are valid only for the standard 7.4 No. of cylinders / displacement cc
upright in vertical position with standard fork car- 7.5 Fuel consumption acc. VDI-Cycles Diesel= l/h, L.P.-Gas= kg/h
riage and standard forks, up to max. lifting height of 8.1 Type of control
Miscellaneous
C60-70 : 3000mm, C80 : 2800mm. 8.2 Operating pressure for attachments bar
The centre of gravity of the load may be displaced 8.3 Oil volume for attachments l/min
by max. 100mm against the longitudinal centre line 8.4 Sound level, driver's ear 5) dB (A)
of the truck. Load centre is determined from top and 8.5 Vibration in accordance with EN 13059 GGm/s¸
1200mm, cube load configuration with the centre of 1) Optional with super-elastic tyres
4) Without load at friction coefficient = 0,6
Attachments, longer forks, exceptional load dimen-
5) Equivalent permanent sound-pressure level L pAeq,T
sions and higher lifting heights may reduce the in accordance with EN 12053
capacity.
8.9
8. Specification
CLARK 1.1
C60D C70D C80D 1.2
Diesel Diesel Diesel 1.3
driver seated driver seated driver seated 1.4
6000 7000 8000 1.5
600 600 600 1.6
617 617 641 1.8
2250 2250 2500 1.9
9260 9630 10360 2.1
13296 / 1964 14717 / 1913 16186 / 2154 2.2
4050 / 5210 3931 / 5699 4231 / 6110 2.3
P/P P/P P/P 3.1
8.25x15-14PR 8.25x15-14PR 8.25x15-18PR 3.2
8.25x15-14PR 8.25x15-14PR 8.25x15-18PR 3.3
4x / 2 4x / 2 4x / 2 3.5
1575 1575 1575 3.6
1610 1610 1610 3.7
10 / 15 10 / 15 10 / 15 4.1
2480 2480 2480 4.2
222 222 232 4.3
3000 3000 2800 4.4
4232 4232 4025 4.5
2370 2370 2370 4.7
1320 1320 1320 4.8
- - - 4.12
4710 4770 5095 4.19
3510 3570 3895 4.20
2125 2125 2125 4.21
60x150x1200 60x150x1200 70x180x1200 4.22
Shaft type CL •ŠA Shaft type CL •ŠA Shaft type CL •ŠA 4.23
2118 2118 2118 4.24
200 200 200 4.31
230 230 230 4.32
5237 5267 5616 4.34
5437 5467 5816 4.34
- - - 4.34
3420 3450 3775 4.35
- - - 4.36
31.8 / 34.6 {32.9 / 35.1} 29.0 / 33.5 {32.1 / 35.1} 29.0 / 33.6 {31.8 / 34.9} 5.1
0.43 / 0.45 0.42 / 0.45 0.39 / 0.45 5.2
0.45 / 0.43 0.45 / 0.43 0.45 / 0.43 5.3
- - - 5.5
5811 / 1987 {6609 / 1987} 5847 / 1918 {6632 / 1917} 5780 / 1985 {6643 / 1985} 5.6
- - - 5.7
41.2 / 21.2 {51.3 / 21.2} 37.4 / 19.8 {46.3 / 19.8} 33.0 / 19.3 {41.2 / 19.2} 5.8
- - - 5.9
Wet disc brake Wet disc brake Wet disc brake 5.10
IVECO F4GE9454C {F4GE0454A} IVECO F4GE9454C {F4GE0454A} IVECO F4GE9454C {F4GE0454A} 7.1
67 {74} 67 {74} 67 {74} 7.2
2300 2300 2300 7.3
4 / 4500 4 / 4500 4 / 4500 7.4
- - - 7.5
Hydrodynamic Hydrodynamic Hydrodynamic 8.1
140 140 140 8.2
- - - 8.3
83 83 83 8.4
1.14 1.14 1.14 8.5
Note:
All values given may vary +5% and -10% due the motor and system tolerances and represent nominal values obtained under typical operat-
ing conditions.
{ } :GSpecification for EPA Tier2 emission complied truck.
8.10
8. Specification
Dimensions (C60-80 D / C80D900, DEUTZ) Product Specifications

Specifications
WT
Tyres, Chassis
3.3 Tyre size, rear
Dimensions

8000
7000
C80D900 4.36 Internal turning radius b13 (mm)
C80 5.2 Lift speed, laden/unladen m/s
5000
Performances
5.3
Capacity (kg)
Lowering speed, laden / unladen m/s

C70
4000 5.5 Drawbar pull, laden / unladen 3) 4) kg
C60
3000
5.7 Gradeability, laden / unladen 3) 4) %
2000
1000 5.9 Acceleration time, laden / unladen (0 - 15 m) s
0
5.10 Service brake
0 600 700 800 900 1000 1100 1200 7.1 Manufacturer / Type
I.C.-Engine
Load Center (mm)

NOTE 7.4 No. of cylinders / displacement cc
The listed capacities are valid only for the standard 7.5 Fuel consumption acc. VDI-Cycles Diesel= l/h, L.P.-Gas= kg/h
upright in vertical position with standard fork carriage 8.1 Type of control
Miscellaneous
and standard forks, up to max. lifting height of C60-70: 8.2 Operating pressure for attachments bar
3000mm, C80: 2800mm, C80D900: 3100mm. The cen- 8.3 Oil volume for attachments l/min
tre of gravity of the load may be displaced by max. 8.4 Sound level, driver's ear 5) dB (A)
100mm against the longitudinal centre line of the truck. 8.5 Vibration in accordance with EN 13059 GGm/s¸
Load centre is determined from top and front face of
forks. The values are based on a 1200mm, cube load 1) Optional with super-elastic tyres
configuration with the centre of gravity at the true cen- 2) Further lift heights see upright table
tre of the cube. With upright tilted forward lower capac- 3) Laden with 1,6 km/h
ity values are valid. Attachments, longer forks, 4) Without load at friction coefficient = 0,6
exceptional load dimensions and higher lifting heights 5) Equivalent permanent sound-pressure level L pAeq,T
may reduce the capacity. in accordance with EN 12053
8.11
8. Specification
CLARK 1.1
C60D C70D C80D C80D900 1.2
driver seated driver seated driver seated driver seated 1.4
6000 7000 8000 8000 1.5
600 600 600 900 1.6
630 630 660 660 1.8
2250 2250 2500 2500 1.9
10210 10570 11490 12950 2.1
14130 / 2080 15880 / 1710 17280 / 2190 19040 / 1910 2.2
4460 / 5750 4750 / 5820 5040 / 6450 5680 / 7270 2.3
P/P P/P P/P P/P 3.1
8.25x15-14PR 8.25x15-14PR 8.25x15-18PR 8.25x15-18PR 3.2
8.25x15-14PR 8.25x15-14PR 8.25x15-18PR 8.25x15-18PR 3.3
4x / 2 4x / 2 4x / 2 4x / 2 3.5
1575 1575 1575 1685 3.6
1740 1740 1740 1740 3.7
10 / 15 10 / 15 10 / 15 10 / 15 4.1
2500 2500 2476 2796 4.2
112 112 233 233 4.3
3000 3000 2800 3100 4.4
4164 4164 3944 4214 4.5
2370 (2428) 2370 (2428) 2370 (2428) 2370 (2428) 4.7
1320 1320 1320 1320 4.8
460 460 460 460 4.12
4723 4783 5095 5746 4.19
3523 3583 3895 3946 4.20
2125 2125 2125 2235 4.21
60x150x1200 60x150x1200 70x180x1200 70x180x1800 4.22
Shaft type CL •ŠA Shaft type CL •ŠA Shaft type CL •ŠA Shaft type CL •ŠA 4.23
2040 2040 2040 2040 4.24
216 216 216 216 4.31
230 230 230 230 4.32
5250 5280 5616 6138 4.34
5450 5480 5816 6338 4.34
- - - - 4.34
3420 3450 3775 3838 4.35
- - - - 4.36
30.4 / 32.9 30.1 / 32.9 29.7 / 32.7 26.2 / 29.4 5.1
0.39 / 0.44 0.36 / 0.44 0.34 / 0.43 0.34 / 0.43 5.2
0.45 / 0.43 0.45 / 0.43 0.45 / 0.43 0.45 / 0.43 5.3
- - - - 5.5
6329 / 2087 6341 / 2323 6349 / 2499 7526 / 3370 5.6
- - - - 5.7
44.1 / 21.4 38.6 / 21.6 34.5 / 21.6 37.1 / 24.1 5.8
- - - - 5.9
DEUTZ TD3.6 Tier4 DEUTZ TD3.6 Tier4 DEUTZ TD3.6 Tier4 DEUTZ TD3.6 Tier4 7.1
55.4 55.4 55.4 55.4 7.2
2300 2300 2300 2300 7.3
4 / 3620 4 / 3620 4 / 3620 4 / 3620 7.4
8.80 9.78 10.85 9.95 7.5
Hydrodynamic Hydrodynamic Hydrodynamic Hydrodynamic 8.1
140 140 140 140 8.2
- - - - 8.3
80 80 80 80 8.4
0.85 0.85 0.85 0.85 8.5
Note:
All values given may vary +5% and -10% due the motor and system tolerances and represent nominal values obtained under typical operat-
ing conditions.
8.12
8. Specification
Dimensions (C60-80 D / C80D900, KUBOTA) Product Specifications

Specifications
WT
Tyres, Chassis
3.3 Tyre size, rear
Dimensions

7000 4.36 Internal turning radius b13 (mm)
C80D900
6000
C80
Performances
Capacity (kg)

C75
5.5 Drawbar pull, laden / unladen 3) 4) kg
C70
4000 5.6 Max. drawbar pull, laden / unladen 4) kg
C60
3000
0 600 700 800 900 1000 1100 1200
5.10 Service brake
Load Center (mm)
I.C.-Engine

NOTE
Miscellaneous
C60-75: 3000mm, C80: 2800mm, C80D900: 3100mm. 8.2 Operating pressure for attachments bar
8.13
8. Specification
CLARK 1.1
C60D C70D C75D C80D C80D900 1.2
Diesel Diesel Diesel Diesel Diesel 1.3
driver seated driver seated driver seated driver seated driver seated 1.4
6000 7000 7500 8000 8000 1.5
600 600 600 600 900 1.6
630 630 630 660 660 1.8
2250 2250 2250 2500 2250 1.9
10214 10577 10661 11484 12957 2.1
14161 / 2053 15902 / 1675 16460 / 1701 17323 / 2161 19048 / 1909 2.2
4491 / 5723 4782 / 5795 4505 / 6156 5073 / 6411 5688/ 7269 2.3
P P P P P 3.1
8.25x15-14PR 8.25x15-14PR 8.25x15-14PR 8.25x15-18PR 8.25x15-18PR 3.2
8.25x15-14PR 8.25x15-14PR 8.25x15-14PR 8.25x15-18PR 8.25x15-18PR 3.3
4x / 2 4x / 2 4x / 2 4x / 2 4x / 2 3.5
1575 1575 1575 1575 1685 3.6
1610 1610 1610 1610 1610 3.7
10 / 15 10 / 15 10 / 15 10 / 15 10 / 15 4.1
2500 2500 2500 2476 2796 4.2
112 112 112 233 233 4.3
3000 3000 3000 2800 3100 4.4
4164 4164 4164 3944 4214 4.5
2370 2370 2370 2370 2370 4.7
1320 1320 1320 1320 1320 4.8
460 460 460 460 460 4.12
4723 4783 4783 5095 5746 4.19
3523 3583 3583 3895 3946 4.20
2125 2125 2125 2125 2235 4.21
60x150x1220 60x150x1220 60x150x1220 70x180x1200 70x180x1800 4.22
Shaft type CL •ŠA Shaft type CL •ŠA Shaft type CL •ŠA Shaft type CL •ŠA Shaft type CL •ŠA 4.23
2040 2040 2040 2040 2040 4.24
216 216 216 216 216 4.31
230 230 230 230 230 4.32
5250 5280 5280 5616 6138 4.34
5450 5480 5480 5816 6338 4.34
- - - - - 4.34
3420 3450 3450 3775 3838 4.35
- - - - - 4.36
30.4 / 32.9 30.1 / 32.9 27.9 / 30.8 29.7 / 32.7 24.1 / 26.6 5.1
0.40 / 0.42 0.39 / 0.42 0.38 / 0.42 0.37 / 0.42 0.37 / 0.42 5.2
0.45 / 0.43 0.45 / 0.43 0.45 / 0.43 0.45 / 0.43 0.45 / 0.43 5.3
- - - - - 5.5
6300 / 1968 6233 / 1898 6078 / 2340 6324 / 1966 7149 / 2798 5.6
- - - - - 5.7
44.5 / 20.7 40.4 / 19.8 36.6 / 21.7 36.0 / 18.8 34.9 / 24.1 5.8
- - - - - 5.9
Wet disc brake Wet disc brake Wet disc brake Wet disc brake Wet disc brake 5.10
KUBOTA V3800-CR-TE5 7.1
55.4 55.4 55.4 55.4 55.4 7.2
2200 2200 2200 2200 2200 7.3
4 / 3769 4 / 3769 4 / 3769 4 / 3769 4 / 3769 7.4
8.7 9.0 9.0 9.4 9.8 7.5
Hydrodynamic Hydrodynamic Hydrodynamic Hydrodynamic Hydrodynamic 8.1
140 140 140 140 140 8.2
- - - - - 8.3
80 80 80 80 80 8.4
1.16 1.16 1.16 1.16 1.16 8.5
Note:
All values given may vary +5% and -10% due the motor and system tolerances and represent nominal values obtained under typical operating
conditions.
8.14
8. Specification
Dimensions (C60-75 L, GM) Product Specifications

Specifications
WT
Tyres, Chassis
3.3 Tyre size, rear
Dimensions

7000 4.35 Turning radius Wa (mm)
6000
5000
Capacity (kg)
C75
C70
Performances

3000
2000
1000 5.8 Max. gradeability, laden / unladen 4) %
0 600 700 800 900 1000 1100 1200
5.10 Service brake
Load Center (mm)
I.C.-Engine

NOTE
Miscellaneous
C60-75 : 3000mm. 8.2 Operating pressure for attachments bar

8.15
8. Specification
CLARK 1.1
C60L C70L C75L 1.2
LPG LPG LPG 1.3
driver seated driver seated driver seated 1.4
6000 7000 7500 1.5
600 600 600 1.6
617 617 641 1.8
2250 2250 2500 1.9
9029 9399 9542 2.1
13221 / 1808 14642 / 1757 15471 / 1571 2.2
3976 / 5053 3856 / 5543 3914 / 5628 2.3
L/L L/L L/L 3.1
8.25x15-14PR 8.25x15-14PR 8.25x15-14PR 3.2
8.25x15-14PR 8.25x15-14PR 8.25x15-14PR 3.3
4x / 2 4x / 2 4x / 2 3.5
1575 1575 1575 3.6
1610 1610 1610 3.7
10 / 15 10 / 15 10 / 15 4.1
2480 2480 2480 4.2
222 222 222 4.3
3000 3000 3000 4.4
4232 4232 4232 4.5
2370 2370 2370 4.7
1320 1320 1320 4.8
- - - 4.12
4710 4770 4770 4.19
3510 3570 3570 4.20
2125 2125 2125 4.21
60x150x1200 60x150x1200 60x180x1200 4.22
Shaft type CL •ŠA Shaft type CL •ŠA Shaft type CL •ŠA 4.23
- - - 4.24
200 200 200 4.31
230 230 230 4.32
5237 5267 5267 4.34
5437 5467 5467 4.34
- - - 4.34
3420 3450 3450 4.35
- - - 4.36
29.3 / 31.4 29.0 / 30.2 28.3 / 29.6 5.1
0.44 / 0.49 0.42 / 0.49 0.39 / 0.49 5.2
0.45 / 0.43 0.45 / 0.43 0.45 / 0.43 5.3
- - - 5.5
6100 / 2380 6400 / 2310 6060 / 2340 5.6
- - - 5.7
41.0 / 21.4 42.2 / 20.0 38.4 / 20.0 5.8
- - - 5.9
GM V6 GM V6 GM V6 7.1
69 69 69 7.2
2400 2400 2400 7.3
6 / 4300 6 / 4300 6 / 4300 7.4
- - - 7.5
140 140 140 8.2
- - - 8.3
82.7 82.7 82.7 8.4
1.16 1.16 1.16 8.5
Note:
conditions.
8.16
8. Specification
Dimensions (C60-75 L, PSI 4X) Product Specifications

Specifications
WT
Tyres, Chassis
3.3 Tyre size, rear
Dimensions

7000
6000
Capacity (kg)
C75
Performances
4000
C70 5.3 Lowering speed, laden / unladen m/s
3000
2000 5.7 Gradeability, laden / unladen 3) 4) %
1000 5.8 Max. gradeability, laden / unladen 4) %
0
0 600 700 800 900 1000 1100 1200
5.10 Service brake
Load Center (mm)
I.C.-Engine

NOTE
Miscellaneous
C60-75 : 3000mm. 8.2 Operating pressure for attachments bar

8.17
8. Specification
CLARK 1.1
C60L C70L C75L 1.2
LPG LPG LPG 1.3
Driver seated Driver seated Driver seated 1.4
6000 7000 7500 1.5
600 600 600 1.6
617 617 641 1.8
2250 2250 2500 1.9
9029 9399 9542 2.1
13221 / 1808 14642 / 1757 15471 / 1571 2.2
3976 / 5053 3856 / 5543 3914 / 5628 2.3
P P P 3.1
8.25x15-14PR 8.25x15-14PR 8.25x15-14PR 3.2
8.25x15-14PR 8.25x15-14PR 8.25x15-14PR 3.3
4x / 2 4x / 2 4x / 2 3.5
1575 1575 1575 3.6
1610 1610 1610 3.7
10 / 15 10 / 15 10 / 15 4.1
2500 2500 2500 4.2
110 110 110 4.3
3000 3000 3000 4.4
4164 4164 4164 4.5
2370 2370 2370 4.7
1320 1320 1320 4.8
460 460 460 4.12
4723 4783 4783 4.19
3523 3583 3583 4.20
2125 2125 2125 4.21
60x150x1200 60x150x1200 60x180x1200 4.22
Shaft type Shaft type Shaft type 4.23
2040 2040 2040 4.24
200 200 200 4.31
230 230 230 4.32
5250 5280 5280 4.34
5450 5480 5480 4.34
- - - 4.34
3420 3450 3450 4.35
- - - 4.36
29.3 / 31.4 29.0 / 30.2 28.3 / 29.6 5.1
0.44 / 0.49 0.42 / 0.49 0.39 / 0.49 5.2
0.45 / 0.43 0.45 / 0.43 0.45 / 0.43 5.3
- - - 5.5
6802/2382 7137/2312 6757/2342 5.6
- - - 5.7
43.0 / 21.4 44.0 / 20.0 40.4 / 20.0 5.8
- - - 5.9
PSI 4X PSI 4X PSI 4X 7.1
82 82 82 7.2
2400 2400 2400 7.3
6 / 4300 6 / 4300 6 / 4300 7.4
- - - 7.5
140 140 140 8.2
- - - 8.3
82.7 82.7 82.7 8.4
1.16 1.16 1.16 8.5
Note:
conditions.
8.18
9. Attachments [ENG]
Attachments
– Industrial trucks can be fitted with one or more auxiliary

hydraulic functions to operate attachments. The auxiliary
hydraulics are indicated on the levers with symbols or
AUX 1,2.
– Attachments must fit the receptacle without overlapping.
Attachments may only be assembled by trained and
authorised personnel. If your industrial truck is equipped
with one or more attachments, read the respective
operator’s manual carefully.
– Use only exchangeable equipment where a risk analysis is carried out by the operating
company. Only use attachments that have been approved for their purpose by the
manufacturer and do not restrict visibility in the travel direction. If visibility in the travel direction
is limited, the owner must determine and apply suitable measures to ensure the safe operation
of the industrial truck.
– Adapt the travel speeds to the visibility and load. Make sure you have sufficient visibility when
reversing.
– Always observe the maximum permissible load capacity of your industrial truck when fitted with
an attachment.
– The attachment capacity plate is positioned directly beside the rating plate of the industrial
truck and indicates the load capacity with a central load pick-up. Only use the attachment for
the function specified. Always pick up the load centrally and also prevent it, if necessary, from
falling, slipping, rolling, swinging or tilting. You must be trained to use the attachment.
– If attachments are fitted, the residual load capacities must be obtained from the manufacturer
and indicated on an additional capacity plate. Note that the load capacity decreases steadily
with increased height and off center loading.
– Read the operating and maintenance instructions for the attachment carefully and make sure
you are completely familiar with all hydraulic functions before transporting a load. Learn to
operate the hydraulics gently, without sudden movements.
Sideshifter disassembly/ assembly (option)
WARNING
Uncontrolled hydraulic function!
Make sure that the corresponding hydraulic functions are depressurised.
● Observe the safety instructions.
● Park the industrial truck and tilt the upright to a vertical position.
● Switch off the engine, stay in the driver's seat and turn the key switch back to “ON”.
● Do not start the engine.
● Move the hydraulic levers several times in both directions as far as the stop, so that the
pressure in the hydraulic system can completely dissipate.
9.1 ENG
9. Attachments
Environmental hazard!
Used parts or lubricants incurred during maintenance and repair work must be stored safely until
they are disposed of in accordance with regulations. Observe the national guidelines
respectively to legal regulations.
– Remove the forks (3), set them down and prevent them
from tipping over. 2 3
– Loosen the two hydraulic screw connections (arrows)
and seal them with appropriate dummy plugs to prevent
the hydraulic oil from escaping.
– Loosen the lower sideshifter lock brackets (5) and pay
attention to the slide pieces as described in position (1).
– Use suitable sling devices and lift the sideshifter off the
fork carriage by the eyelet (2).
– When lifting the sideshifter, be aware of the slide pieces
(1) located between the carriage and the sideshifter.
5 4 3
– The hydraulic cylinder (4) is connected to the fork carriage. Loosen the screw connection and
remove the cylinder.
Note
Assembly takes place in reverse order.
Note
Replace defective slide pieces and ensure adequate lubrication on the slide pieces and upper
sideshifter support during assembly. Before putting the unit into operation, check that all
fasteners and hydraulic couplings are correctly and firmly seated. Finally, test the operation of
the sideshifter.
Fork positioner disassembly/ assembly (option)
WARNING
Uncontrolled hydraulic function!
Make sure that the corresponding hydraulic functions are depressurised.
● Observe the safety instructions.
● Park the industrial truck and tilt the upright in a vertical position.
● Switch off the engine, stay in the driver's seat and turn the key switch back to “ON”.
● Do not start the engine.
● Move the hydraulic levers several times in both directions until the stop, so that the pressure
in the hydraulic system can completely dissipate.
9.2 ENG
9. Attachments
Environmental hazard!
Used parts or lubricants incurred during maintenance and repair work must be stored safely until
they are disposed of in accordance with regulations. Observe the national guidelines
respectively to legal regulations.
– Remove the forks (3), set them down and prevent them
from tipping over. 2 3
– Loosen the four hydraulic screw connections (arrows)
and seal them with appropriate dummy plugs to prevent
the hydraulic oil from escaping.
– Loosen the lower sideshifter lock brackets (5) and pay
attention to the slide pieces as described in position (1).
– Use suitable sling devices and lift the sideshifter off the
fork carriage by the eyelet (2).
– When lifting the sideshifter, be aware of the slide pieces
(1) located between the carriage and the sideshifter.
5 4 3
– The hydraulic cylinder (4) is connected to the fork carriage. Loose the screw connection and
remove the cylinder.
Note
Assembly takes place in reverse order.
Note
Replace defective slide pieces and ensure adequate lubrication on the slide pieces and upper
sideshifter support during assembly. Before putting the unit into operation, check that all
fasteners and hydraulic couplings are correctly and firmly seated. Finally, test the correct
operation of the fork positioner.
9.3 ENG
10. DPF system [ENG]
1 Introduction
The document shows the principle of a Kubota DPF system in a diesel engine, CLARK model
range C40-55 and C60-80.
1.1 Abbreviations and their description
Abbreviation Description
CaSO4 Calcium Phosphate
CRS Common Rail System
DOC Diesel Oxidation Catalyst
DPF Diesel Particulate Filter
EATS Exhaust After Treatment System
ECU Engine Control Unit
E4 Stage IV Engine Models
E5 Stage V Engine Models
MIL Malfunction Indicator Light
PM Particulate Matter
Regeneration Regeneration
Tab. 1: Abbreviations and their description
1.2 Explanation of signal words and icons
ATTENTION
This safety notice means that material damage CAN occur if you fail to observe the appropriate
precautionary measures.
Note
This note provides useful or additional information regarding the safe and easy handling of the
industrial truck and the operator’s manual.
10.1 ENG
10. DPF system
2 DPF system overview

For a better understanding below a typical DPF system overview with different components.
Fig. 1: DPF System overview
Legend
1 Display 4 DPF
2 Rocker Switch 5 Truck Controller
3 Engine 6 Engine ECU
10.2 ENG
10. DPF system
3 DPF functional description

3.1 KUBOTA
Below the process of the different levels due to the accumulated PM quantity.
3.1.1 Overview DPF operation modes
Fig. 2: Kubota regeneration process
Service Required:
All regeneration requests are ignored by operator; soot level exceed maximum value. External
service with special service tool is required.
Parked Active Regeneration:

Parked active regeneration is required when the soot level reaches a certain value. During
regeneration machine operation is restricted.
Automatic Active Regeneration:

Automatic controlled regeneration with the aid of post injection despite low exhaust temp. Machine
operation is not interrupted.
If truck is switched off, auto regeneration starts automatically if conditions are fulfilled again.
Inhibit Mode:
Operator is able to interrupt Automatic Active Regeneration by pressing the INHIBIT BUTTON.
Passive Regeneration:
Continuous regeneration thanks to high exhaust temperature above 300 °C.
10.3 ENG
10. DPF system
3.1.1.1 Passive Regeneration

Level 0
– Soot filter load < 100 %
– No need to activate regeneration
– Passive self regeneration will occur due to high exhaust temperature based on normal usage of
truck
– Automatic regeneration is not active, neither the operator has no possibility to start park
regeneration
– Parked active regeneration button is inactive
3.1.1.2 Automatic Active Regeneration

Level 1-2
– Soot filter load = 100 %
– Automatic controlled regeneration starts automatically during machine operation, system works
with the aid of post injection despite low exhaust temperature
– When the process is started, it takes ≈ 25 min. for a successful regeneration completion
– The operator has no possibility to start park regeneration
– Parked active regeneration button is still inactive
Note
Automatic regeneration will be effective if coolant temperature exceeds 65 °C and truck is in
active operation (not idle condition).
ATTENTION
Possible Danger for the machine!
Severe condition for DPF
● Go down to idle condition while automatic active regeneration has started to burn soot locally
causes extremely high thermal stress of the DPF.
● Avoid to stop working during on-going process.
3.1.1.3 Inhibit Mode

Level 1-2
– Active Inhibit Mode = INHIBIT BUTTON lights up red, automatic active regeneration is disabled
– Automatic active regeneration heats up DOC (Diesel Oxidation Catalyst) by injecting fuel,
which leads to high exhaust temperature
– To avoid danger situation (e.g. operation in-house or operation in paper factory) automatic
active regeneration can be interrupted
– By pressing the INHIBIT BUTTON automatic regeneration is disabled for 20 min. and starts
automatically thereafter
10.4 ENG
10. DPF system
Note
Inhibit button disactivates Automatic active regeneration only, parked regeneration will not be
interrupted.
3.1.1.4 Active Parked Regeneration

Level 2-3
– Active parked regeneration = DPF REGENERATION BUTTON lights up yellow
– If DPF doesn’t recover to the certain soot level after 1800 sec. in automatic active regeneration,
mode parked active regeneration is requested
– Operator is requested to start parked regeneration by pressing the button.
– Display shows message and warning signal appears
– Before starting parked regeneration by pressing the DPF Regeneration button you need to
satisfy the safety conditions:
1 Truck is parked at safe location
2 Engine is running
3 Parking switch is ON
4 FW/ REV lever at neutral position
5 Accelerator pedal position = 0 %
– When the process is started, it takes max. 30 min. for a successful regeneration completion
– If only one condition is not met, parked regeneration will be interrupted and has to be restarted
– Truck cannot be operated during active parked regeneration
ATTENTION
Possible Danger for the machine!
Protect DPF from overloading by soot
● Several warning step levels are implemented with different warnings to ensure that the DPF
will get active regenerated properly.
● The ceramic wall flow substrate of the DPF is fragile and cannot withstand high thermal
tensions. Therefore, it is important that the DPF is active regenerated at a soot load safely.
● In order to protect DPF, engine output power is reduced. This is the last chance for operator
to start park regeneration.
3.1.1.5 Service required

Service tool => Level 4
– DPF regeneration button is disabled; operator cannot start park regeneration
– Engine power output is de-rated by 50 %
– Active parked regeneration is only possible by using service tool
Stop level => Level 5

– Active regeneration is not possible even by service tool
– Engine power output is de-rated significantly
– Ash load reached 100 % so DPF has to be detached and cleaned
10.5 ENG
10. DPF system
4 CLARK DPF system functional description

4.1 DPF Display icon description
Fig. 3: Separate display icon description
Legend
1 DPF: Soot level indication 4 MIL icon
2 Warning/ Error messages 5 DPF: high exhaust temperature warning icon (indicates
active regeneration)
3 DPF: Inhibit icon (indicates disabled regeneration) 6 DPF: Regeneration icon (indicates regeneration request
and active regeneration)
DPF icon type of light Description

OFF Normal exhaust temperature
ON solid Automatic active regeneration is in process
Flashing Park regeneration is in process
OFF No regeneration request.
ON solid Automatic active regeneration is in process
Flashing Request for Park regeneration
OFF Normal operation
ON solid Automatic active regeneration is inhibited
Tab. 2: DPF icon description
Note
Inform about high temperature during regeneration. Operator interface for DPF system is
essentially important to inform the machine operator of the increased tailpipe temperatures. The
increased tailpipe exhaust temperature during active regeneration compared to normal
operation has to be highlighted to the machine operator.
10.6 ENG
10. DPF system
4.2 Separate switch description
We have a separate rocker switch for the following function:
– Regeneration inhibit
– Park-regeneration
Rocker switch will be in the following with 3 positions:
1. Middle position = default setting
2. Second position
Illuminated in YELLOW-flashing when Regeneration-Request
is active.
Illuminated in YELLOW-ON-SOLID when Regeneration is
active (automatic active regeneration or park regeneration).
Will be called YELLOW REGENERATION SWITCH.
Fig. 4: DPF switch design
3. Third position
Automatic Active Regeneration can be inhibited by the driver, when in use illuminated RED (on solid).
Will be called RED INHIBIT SWITCH.
The DPF switch is equipped with additionally delay, by pressing the RED INHIBIT SWITCH only
once, delay ensures the INHIBIT MODE for 20 min.
Note
Inhibit button deactivates automatic active regeneration only, parked regeneration will not be
interrupted.
10.7 ENG
10. DPF system
4.3 Level overview (KUBOTA S5)
DANGER
Toxic substances!
Regeneration process leads to increased tailpipe temperatures and causes more emissions
comparing to normal operation.
● The truck should be parked outside.
● Truck operation is restricted.
WARNING
Flammable materials!
● Keep the truck in sufficient distance to flammable materials.
● This prevision is valid for indoor and outdoor areas.
Level overview Shown level indicator and display icons Status of DPF-System Operators action needed?
Level 0 – NO
Level 1 – Automatic – NO
regeneration is
ACTIVE
Level 2 – Automatic – Driver could activate PARK
regeneration is still regeneration by pushing the
ACTIVE REGENERATION-BUTTON
– Park regeneration is
+ HORN or BUZZER sounds requested to avoid
further soot loading
Level 3 – FULL DPF – START PARK
– Engine torque is REGENERATION
reduced
+ HORN or BUZZER sounds

Level 4 ./. – CALL SERVICE
+ HORN sounds
Tab. 3: Level overview (KUBOTA S5)
10.8 ENG
10. DPF system
Note
When HORN or BUZZER sounds and warning message “ACTIVATE PARK REGEN” on display
occurs, driver should activate Park Regeneration.
1. Put direction lever in neutral position

2. Activate parking brake
3. Start engine
4. Press REGENERATION BUTTON
Wait until Park regeneration process is finished after ≈ 25 min.
10.9 ENG
10. DPF system
5 DPF Service related items

5.1.1 DPF maintenance
5.1.1.1 Oil specification
API CJ-4 or CK-4 grade, oil was developed for diesel engines with DPF (V3800-CR-TE5).
Interval: every 500 hrs or 1 year, whichever comes first.
Service interval 3000–6000 hr

Ash consists of inorganic oxides, mainly CaSO4. It comes from burned engine lubricants. API CJ-
4/ CK-4 oil s developed for diesel engines with DPF. Less ash is produced to prevent ash
accumulation in DPF.
ATTENTION
Possible danger for the machine!
Be careful with additives
● Do not use anti-corrosion or fuel additives, these might contain metals which lead to ash
accumulation.
Ash cannot be cleaned by normal regeneration process. To clean it up, DPF has to be removed and
serviced.
This cleaning process must be handled by specialists, since ash consists of toxic materials.
Ash cleaning period:

– 3000–6000 hours for E5 model engines with DPF cleaning alarm system
In case of an existing alarm maintenance should be done anytime the alarm occurs.
Warning message of Level 5 is shown if DPF cleaning or exchange request due to heavy soot/ ash
accumulation is active.
Impacts of ash accumulation:

– DPF is clogged and exhaust pressure increases
– PM trap capacity decreases
– Accuracy drop of sensing PM accumulated volume
– Shorter Regeneration interval
10.10 ENG
10. DPF system
5.1.2 DPF error codes
Level overview Output limitation (engine torque) Max. speed DM1 code
Level 3 ≈ 50 % of normal condition ≈ 10 km/h SPN FMI 3701 15 (= P3006)
Level 4 ≈ 50 % of normal condition ≈ 9 km/h SPN FMI 3701 16 (= P3007)
Level 5 ≈ 50 % of normal condition ./. SPN FMI 3701 00 (= P3008)
Tab. 4: DPF error codes
Note
All three codes (= P3006, P3007, P3008) are related to full DPF. Although an error code is active
the MIL icon on display is NOT shown!
If a second error will occur, MIL icon goes on and the message “ENGINE CHECK” is shown.
10.11 ENG
CLARK Europe GmbH
Dr.-Alfred-Herrhausen Allee 33
47228 Duisburg/ Germany
EC Declaration of Conformity
according to EC Machinery Directive 2006/42/EC Annex II Nr. 1 A
We herewith declare, that the following described machine in our delivered version complies with the appropriate basic safety and health
requirement of the EC Machinery Directive 2006/42/EC based on its design and type, as brought into circulation by us. In case of alteration of
the machine, not agreed upon by us, this declaration will lose its validity.
Model Serial Number
Definition of the machine by type, model and applied standards:
Selection Description of the machine Model series Harmonised standards

PPFXS/ PPX/ PPXS/ PX/
PALLET TRUCK
LWio/ WPio/ WP/ WPX
PSX/ SX/ WS/ WSX/
PALLET STACKING TRUCK
WSXD EN ISO 3691-1:2015
EN 16307-1:2013+A1:2015
REACH TRUCK SRX
EN 1175-1:1998+A1:2010
TOW TRACTOR CTX
FORKLIFT TRUCK
EPX/ GTX/ GEX
(electrical motor)
EN ISO 3691-1:2015
FORKLIFT TRUCK
C/ GTS/ S EN 16307-1:2013+A1:2015
(combustion engine)
EN 1175-2:1998+A1:2010
EN ISO 3691-3:2015
ORDER-PICKING TRUCK COP1 EN 16307-1:2013+A1:2015
EN 1175-1:1998+A1:2010
CLARK also declares that the EU directives and standards stated below have been satisfied:
2006/42/EC Machinery directive
2006/42/EC & 2014/30/EU Electromagnetic Compatibility
2000/14/EC & 2005/88/EC Polluting noise emissions from devices and machines intended for
use outdoors
Additional country-specific information:
Compilation of the technical documents:

Mr. Thomas Bach is appointed as the responsible person for collecting the technical information.
Address: CLARK Europe GmbH, Dr.-Alfred-Herrhausen-Allee 33, 47228 Duisburg, Germany
Name Klaus Krentscher Date 2023-03-22

Position Technical Director Signature
DOC-ENG-2023-01

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ENG ENGLISH

ENG Operator`s Manual

Rated Capacity : 4000 ~ 8000 kg

Part No. 8116771

CLARK MATERIAL HANDLING INTERNATIONAL

1. Safety Regulations ................................................. 1.1

2. Know your Forklift Truck ....................................... 2.1

3. Daily Inspection ...................................................... 3.1

4. Maintenance and Care ........................................... 4.1

5. Lubrication and maintenance plan ....................... 5.1

6. Lubricant Recommendations ................................ 6.1

7. Technical Data ........................................................ 7.1

8. Specification ........................................................... 8.1

9. Attachments ............................................................ 9.1

10. DPF System ........................................................ 10.1

1. The forklift truck

1) The forkift truck

Regular and statutory inspections

Modification of the truck prohibited

The working area

Operation in closed rooms

Caution for Exhaust Gas

Getting ON/OFF the Equipment

Traveling on public roads

• When storing and stacking loads, correct placement is essential. Always

Transport of swinging loads

Transport of inflammable loads

Loading and unloading of vehicles

With raised forks

Tilting the upright

Climatic condition for Operation

Tips for Operation according to the Weather

weather, such as rail, snow, frost, etc.

Behavior during operation

Lift truck tip over

2. Hold the steering wheel firmly.

3. Lean against the opposite side wall, as shown in the figure.

Leaving the forklift truck

Transport of forklift trucks in elevators

Additional regulations for special tasks

Forklift trucks used as working platforms

Forklift trucks used for the transport of persons

Forklift trucks used for the transport of molten masses

Forklift trucks used for the transport of containers

Parking the forklift truck

Refueling of forklift trucks with combustion engines

• Safety equipment and switches may not be removed or made inefficient.

Operator’s compartmant and Controls

1. Fuel level Indication

• Provides the operator with important information about truck condition

Engine shutdown function

Seat switch application

Neutral start function and Anti-restart function

Anti drive and parking brake reminder function

Gauges and indicators

Transmission oil temperature

Engine oil pressure

Alternator charging status

Short Circuit Protection

11 Green 130