Clark WP45 Operator's Manual
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Clark WP45 Operator's Manual

Electric low lift pallet truck
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Operator's Manual
WP45
Electric Low Lift Pallet Truck
The operator must read and understand this manual before
operating this truck.
Warning
Warning
SM-698
Keep this OPERATOR'S MANUAL with unit
at all times in place provided when not in use.
DO NOT operate this equipment unless all
factory installed guards and shields are
properly secured in place.
Front Cover
Date: August 2002

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  • Page 1 Front Cover Operator’s Manual WP45 Electric Low Lift Pallet Truck The operator must read and understand this manual before operating this truck. Keep this OPERATOR’S MANUAL with unit Warning at all times in place provided when not in use. DO NOT operate this equipment unless all...
  • Page 2 Clark Material Handling Company 2317 Alumni Park Plaza, Lexington, KY 40517 © 2002 All Rights Reserved.
  • Page 3 CONTROLS BEFORE OPERATING. IT IS YOUR RESPONSIBILITY TO UNDERSTAND AND FOLLOW MANUFACTURER'S INSTRUCTIONS ON TRUCK OPERATION AND TO OBSERVE PERTINENT LAWS AND REGULATIONS. OPERATOR MANUALS, PARTS MANUALS, AND SERVICE MANUALS MAY BE OBTAINED FROM YOUR CLARK DEALER. Warning INJURY DEATH...
  • Page 4 Foreword It is important that you read and understand this Operator’s Manual for your own safety and the safety of those who work with you! Before you start to use this truck it is of extreme importance that you have read the contents of the entire Operator’s Manual to be able to use the truck in a safe and efficient manner.
  • Page 5 Foreword Standard Compliance This truck complies with the following standards and regulation in effect on the date the truck was manufactured: • American Society of Mechanical Engineers (ASME) B56.1 • Underwriters Laboratory (UL) # 583 • Occupational Safety and Health Administration (OSHA) 29 C.F.R.

  • Page 6: Table Of Contents

    Warning symbols ..............6 Ordinance symbols .............7 Ordinance symbols .............7 General safety regulations..........8 Warning and information signs...........18 Presentation of truck............23 Application area for CLARK trucks ........24 Prohibited applications for CLARK trucks......24 Truck data.................25 Truck battery dimensions..........25 WP45 truck dimensions ............26 Data plate .................27 U.L.
  • Page 7 Transporting loads .............. 48 General ................48 Collecting a load .............. 51 Leaving a load ..............52 Battery .................. 53 Type of battery..............53 Changing the battery ............53 Charging the battery ............55 Battery maintenance............58 Daily service/safety checks ..........60 Daily service/safety checks drawing ........

  • Page 8: Safety Regulations

    Safety regulations Safety Regulations Warning symbols Always follow the warnings given in this Operator’s Manual and on the truck to avoid accidents from occurring. Warning levels Warning texts are given in four levels and provide information on the risks, describe the consequences, and instruct how to avoid accidents.

  • Page 9: Ordinance Symbols

    Safety regulations Prohibitory symbols NO SMOKING If smoking occurs in situations where a restriction against smoking is stated, a serious accident can occur. OPEN FLAMES PROHIBITED If open flames are used in situations where open flames are prohibited, a serious accident can occur. GENERAL PROHIBITION If the prohibition is ignored, a serious accident can occur.

  • Page 10: General Safety Regulations

    The truck must not be used if it is damaged or has faults that affect safety or its safe use. The truck may not be used if it has been repaired, modified, or adjusted unless it has been checked and approved by personnel authorized by Clark Material Handling Co.
  • Page 11 Safety regulations General safety regulations Operating the truck • The truck is designed and produced to be your tool when transporting goods to locations. • If the truck is to be used in cold storage environments the truck must be especially built for this type of use. •...
  • Page 12 Safety regulations General safety regulations Operator’s responsibility • The truck shall only be driven by personnel that have been specially trained and that have permission to drive the truck. • The truck shall only be driven with care, good judgement, and in a responsible manner.
  • Page 13 Safety regulations General safety regulations Working area • If there are marked truck routes these shall be used. • The truck should only be driven on a dry, clean surface. Do not operate on wet, oily surfaces. • The truck should only be driven on hard and even surfaces, for example concrete or asphalt.
  • Page 14 Safety regulations General safety regulations Driving and conduct while driving • Always drive the truck from the normal operator position. • Always drive the truck in a responsible manner and with full control. Sudden starts and braking, as well as cornering at high speed, should be avoided.
  • Page 15 Safety regulations • Never allow passengers to ride on the truck. • Never drive with any part of your body outside of the operator position. • Before the truck is driven over a loading ramp ensure that the ramp is correctly secured and has the necessary load bearing capacity.
  • Page 16 Safety regulations General safety regulations Handling loads • Drive with care when collecting or leaving a load. • Keep a safe distance from persons in the immediate area. • Only handle loads that are within the truck’s permitted lifting capacity. •...
  • Page 17 Safety regulations General safety regulations Parking the truck • Always park in designated areas if available. • Never leave the truck parked with the key still in the key switch. • Never park the truck on an incline. • Never park the truck so that it obstructs emergency exits. •...
  • Page 18 Safety regulations General safety regulations Handling the battery • Always handle the battery and its connections with care. Read and follow the instructions for changing or recharging the battery carefully. See chapter Battery. • Always wear protective glasses when working with the battery.
  • Page 19 See the chapter covering Maintenance. Only qualified and trained personnel are permitted to maintain, adjust, or repair the truck. All replacement parts shall be CLARK approved spare parts. Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturer’s prior written approval.

  • Page 20: Warning And Information Signs

    Warning and information decals Warn ing and information signs Warning and information decals The figure shows the position and significance of the location of signs on the truck. 1. Warning decal: Do Not Steam Clean 2. Horn: Control handle Horn sign 3.
  • Page 21 You must replace a decal if the decal is damaged, missing, or cannot be read. If a decal is on a part that is replaced, make sure you install a new decal on the new part. New warning decals can be obtained from your CLARK Dealer.
  • Page 22 Warning and information signs Warning and information signs Battery Pack Warnings The Battery Pack Warnings decal is located directly under the battery charger access door. This decal describes basic warnings for safe operation of charger and batteries. Carefully read the decal and make sure you understand the warning instructions.
  • Page 23 Warning and information signs Battery Pack Warnings This decal is located on the battery swing out tray to warn the service department that the battery pack must be mounted to the truck frame to avoid batteries from falling out or spilling battery acid.
  • Page 24 For further information and specifications on the battery review the section on battery at the end of this manual. If you are in need of further information about battery pack/ charger or any other part of this unit, contact your CLARK Dealer.

  • Page 25: Presentation Of Truck

    This CLARK truck has available different fork lengths and lifting capacities. Refer to the truck’s data plate for this information. The maximum lifting capacity on WP45 is 4500 lb [2043 kg]. Refer to the truck’s data plate for this information on lifting capacities.

  • Page 26: Application Area For Clark Trucks

    Presentation of truck Application area for CLARK trucks CLARK trucks are solely designed and manufactured to handle goods. The truck should be fitted with the appropriate accessories relevant to the application. Prohibited applications for CLARK trucks. The trucks are designed for handling goods indoors. It is not...

  • Page 27: Truck Data

    Presentation of truck Truck data The table provides information regarding some technical data which is of value with daily use of the truck. Truck type WP45 Voltage Operating speed without load 3.7 mph [5.9 km/h] Operating speed with classified load 3.3 mph...

  • Page 28: Wp45 Truck Dimensions

    Presentation of truck WP45 truck dimensions The following diagrams show external dimensions for the WP45 trucks in its standard design. All Dimensions shown for 48 in. [1219.2 mm] long pallet 30 in. [762 mm] 4 in. [101.6 mm] 7.3 in. [185.4 mm] 55.1 in.

  • Page 29: Data Plate

    This data plate is located on the left side of dash panel. Knowing the model and serial numbers for this unit are very helpful when ordering repair parts. For further information and specifications on this unit or any other, contact your local Clark dealer.

  • Page 30: U.l. Construction Type

    Presentation of truck U.L. construction type Know the U.L. construction type of this truck and make certain that trucks of this type may be operated in restricted areas before you enter. Never take an unauthorized truck in restricted or hazardous areas.

  • Page 31: Presentation Of Main Components

    Presentation of main components Presentation of m ain components Presentation of main components 1. Reverser switch The end of the control handle is equipped with a red automatic reversing switch which causes the truck to travel in the rearward direction when activated 2.
  • Page 32 Presentation of main components 12. Steering pivot point Lubricate pivot point to prevent stiff steering. 13. Hydraulic unit Pump motor, pump, electric valves and oil tank integrated in a compact unit. 14. Hydraulic electric solenoid valve For controlling lifting and lowering function with electric solenoid valve.
  • Page 33 Presentation of main components...

  • Page 34: Controls And Instruments

    Controls and instruments Controls and instruments Controls and instruments Guards and shields have been provided on the truck for your protection. DO NOT operate this truck unless all factory Warning installed guards and shields are properly secured in place. Decals are also provided to warn of potential danger as well as to display special operating procedures.

  • Page 35: Control For Raising The Forks

    Controls and instruments Control for raising the forks The control button activates a micro switch to start the pump motor with lifting. The diagram illustrates the controls as seen from the operator’s position. Lift the forks by pressing ‘A’. NOTE! The forks cannot be raised with the key switch in Off position.

  • Page 36: Travel Direction Selector And Speed Control

    Controls and instruments Travel direction selector and speed control Select the travel direction by rotating ‘R’ in the required direction. The speed is controlled variably based on the position of the lever. This truck is equipped with a thumb control and optional picking knob for speed and direction control.

  • Page 37: Reverser Switch

    Controls and instruments Reverser switch Reverser Switch The end of the control handle is equipped with a red automatic reversing switch which causes the truck to travel in the rearward direction when activated. Its function is to prevent the operator from being pinched between the handle and obstruction when traveling in the forward direction.

  • Page 38: Steering Control Handle/Brake Control

    Controls and instruments Steering control handle/brake control Operate the truck with the steering control handle in the center range, F. The brake is activated mechanically by the steering control handle/brake control. The brake is applied in two ranges, B1 and B2. Parking brake (B1): The arm automatically returns to position B1 when released.

  • Page 39: Braking Using Plugging Function

    Controls and instruments Braking using plugging function The truck is equipped with plug braking. This method involves reversing the travel control to the opposite direction without applying the brake causing the truck to decelerate smoothly. The operator choose continue holding the controls in the opposite direction. This will start the truck moving in that direction or the operator may release the handle and allow the truck to come to a complete halt.

  • Page 40: Key Switch (Toggle Switch)

    Controls and instruments Battery Discharge Indicator/Hourmeter Dash Display Master Control On/Off Switch Key Switch Dash Panel Layout Key switch A key switch is provided to prevent unauthorized use of this unit. The key switch is located on the control panel cover. The key switch has two (2) positions: OFF and ON.
  • Page 41 Controls and instruments Emergency battery disconnect In an emergency, first push the master control on/off switch to OFF this will disable all controls under normal circumstances. Then disconnect the battery connector, this will cut all electrical power to the truck. Preform all repairs before using and reconnecting battery after emergency.

  • Page 42: Bdi/Hourmeter With Lift Interrupt

    Controls and instruments BDI/hourmeter with lift interrupt Fully-charged battery Half-charged battery Discharged battery The battery indicator shows the actual charge level of the truck’s battery. The battery indicator has an integrated lift interrupt that disables the truck’s lift function when a preset discharge level is reached.

  • Page 43: Hourmeter

    Controls and instruments Hourmeter The hourmeter displays the time the drive motor and/or the pump motor are operating. Load backrest (optional) This device is intended to be used whenever handling high loads.

  • Page 44: Driving

    Driving Driving There are certain hazards that cannot be avoided solely by mechanical means in the everyday use of material handling trucks. Only the intelligence, good sense and care of the operator, along with proper maintenance, will assure trucks are operated properly. It is important to have trained, reliable personnel operating trucks.

  • Page 45: Starting The Truck

    Driving Starting the Truck Ensure battery connector is connected to truck. Master control on/off switch is in the on position. Turn key switch to position I. The instrument lighting comes on. Make sure battery indicator indicates a sufficient charge level (1/2 - 1) to operate truck. NOTE! Low charge level.
  • Page 46 Driving - Horn functions correctly. - Steering functions correctly. - Brakes function correctly. Start gently by accelerating slowly until the desired speed is reached. Dangerous driving. Warning Accidents can occur. Always drive with care, good judgement and responsibility as set out in the general safety guidelines.

  • Page 47: Braking

    Driving Braking B2 2 Brake by moving the arm to the B2 position will apply the travel brake. Release of the tiller arm automatically returns it to the parking brake position (B1). The truck is equipped with plug braking. This method involves reversing the travel control to the opposite direction without applying the brake causing the truck to decelerate smoothly.
  • Page 48 Driving opposite direction. For the strongest plugging power, and shortest distance, the travel control should be operated to full speed in the opposite direction. Plug braking may be regulated with the control handle at any point between the creep position and full speed.

  • Page 49: Steering

    Driving Steering Steer by means of the control handle. If the truck gets caught against an obstacle do not use more force to steer than used when steering the truck under normal conditions. When this occurs try to free the truck by carefully driving forwards and backwards and at the same time carefully moving the control handle.

  • Page 50: Transporting Loads

    Transporting loads Transpor ting loads Transporting loads General The weight of the load should be within the truck’s permitted lifting capacity. See the truck’s data plate. Risk of overturning. Warning The lifting capacity is reduced if additional equipment is attached to the truck. Always check the truck’s overall lifting capacity.
  • Page 51 Transporting loads NOTE! Increased machine width. The load can collide with fixed objects. A truck with wide loads requires a greater operating area. Drive the truck with the load trailing when the load impairs the line of vision. If necessary, when the operator’s vision is impaired, ask someone to direct operations so that transportation can take place without the risk of causing personal injury or material damage.
  • Page 52 Transporting loads Risk of overloading the elevator. Warning An overloaded elevator can fall out of control down the elevator shaft. Always check the capacity of the elevator before driving in with the truck. • Before you drive the truck over a loading ramp ensure that the ramp is correctly secured and that it has the necessary load bearing capacity.

  • Page 53: Collecting A Load

    Transporting loads Collecting a load Slow down and position the truck carefully in front of the load. Lower the forks to the fully down position. Drive the truck rearward so that the forks are positioned in the center and as far as possible under the load. Lift the forks so that the load is lifted free of the floor.

  • Page 54: Leaving A Load

    Transporting loads Leaving a load • Slow down and position truck carefully where load is to be left. • Lower the forks to the fully down position so that they clear the load. • Drive carefully away from the load. Start slowly and then increase the speed.

  • Page 55: Battery

    Battery Battery Battery Type of battery • Check that the battery used in this truck is the correct voltage as shown on the truck’s data plate. Use a traction battery having a weight within the minimum/maximum values stated on the data plate. Changing the battery •...
  • Page 56 Battery • Slide out the discharged/old battery, then slide in the new battery. • Connect battery and truck connectors. • Connect the battery connector and truck connector. NOTE! Risk of short-circuiting. The cables can be damaged and cause a short-circuit. Ensure the battery cables are not crushed.

  • Page 57: Charging The Battery

    Battery Charging the battery General prohibition When recharging the battery it is absolutely forbidden to smoke or use an open flame. Use an automatic charger intended for recharging traction batteries. The charger must have an automatic maintenance charging feature for a certain period after the main charging period has been completed.
  • Page 58 Battery Pre-charging • Park the truck in the assigned charging area. • Ensure nothing prevents ventilation above the battery. • Turn key switch to the OFF position. • Remove the battery connector from the truck’s connector. • Make sure the battery charger is switched OFF. •...
  • Page 59 Battery After charging • Make sure that the ammeter indicates an insignificant or no reading and that maintenance charge lamp is ON, if equipped. • Switch OFF the charger. • Disconnect the battery connector from charger connector. NOTE! Risk of short circuiting. The terminals can otherwise be damaged inside and result in a subsequent short circuit.

  • Page 60: Battery Maintenance

    Battery Battery maintenance Carry out battery maintenance after recharging. Corrosive acid. Warning The battery fluid contains sulfuric acid. Fluid spilled on skin should be rinsed OFF immediately. Wash thoroughly with soap and water. If the fluid has come into contact with the eyes, wash the eyes immediately using an eye shower.
  • Page 61 Battery Each month: • Measure the temperature in one of the center cells immediately after charging. The temperature should not exceed 122°F [50°C.] • Measure the density of the battery fluid using an acid tester. Hold the acid tester absolutely vertical and extract sufficient fluid so that the hydrometer float moves freely.

  • Page 62: Daily Service/Safety Checks

    Daily service/safety checks Daily service/safety checks Daily service/safety checks • The operator is responsible for the daily service and care of the truck. • Carry out the daily service at the start of the day or shift, before the truck is used. The daily service is a simple safety and function control as shown in the chart.

  • Page 63: Daily Service/Safety Checks Drawing

    Daily service/safety checks Daily service/safety checks drawing DO NOT continue to operate the truck Warning when it is not functioning properly.
  • Page 64 Daily service/safety checks Item Check points Action Reverser switch Check its function Direction / speed Check its function control Hydraulic function Check its function Horn Check its function Battery Check acid level, charge, and condition. See “Battery Maintenance” section Battery cables and Check for breakage, cutting, or connections damage...

  • Page 65: Special Equipment

    Daily service/safety checks Special equipment Your truck may have been fitted with optional or special equipment that requires a routine check. To ensure safe operation consult with your supervisor and your CLARK dealer representative about routine checks.

  • Page 66: Maintenance

    Only use genuine CLARK approved spare parts when service and repair work are carried out. • CLARK recommends that you contact your local CLARK dealer representative to set up a service and maintenance agreement to ensure your truck’s operating economy and safety. Safety regulations with maintenance work •...
  • Page 67 Hot transmission and hydraulic oil. Let the truck cool before changing the oil. • Only fill the hydraulic system with new clean oil. Oil should meet CLARK's cleanliness specification 12-00-002. Contact your CLARK dealer representative for assistance or more information.
  • Page 68 Maintenance The hydraulic system can be damaged. Warning If oil is contaminated hydraulic components can be damaged. Always use new and clean oil in the hydraulic system. • Store and dispose of changed oil in accordance with local regulations. • Do not dump solvents, which are used for cleaning/ washing, into drains that are not intended for this purpose.
  • Page 69 Maintenance Maintenance that can be carried out by driver The Daily service/Safety checks as set out in the check list. Maintenance points with intervals 1 day and 1 week, as set out in the Maintenance chart may be carried out by the driver without more knowledge than that provided by the Operator’s Manual.

  • Page 70: Cleaning And Washing

    Maintenance Cleaning and washing General Cleaning and washing the truck is important to ensure the truck will operate safely and reliably. • Carry out general cleaning and washing weekly. NOTE! Risk of short circuiting. The electrical system can be damaged. Disconnect the battery before washing by pulling out the battery connector.
  • Page 71 Maintenance • Clean carefully using the minimum of water and detergent. Never pressure wash steam clean compartments. NOTE! Risk of short-circuiting. The electrical system can be damaged. Electrical components must not be cleaned with a high pressure washing unit. • Clean the motor compartment using a degreasing agent diluted to a suitable concentration.

  • Page 72: Maintenance Chart

    Maintenance Maintenance chart PM Interval: A=8 Hours or 1 Day E=720 Hours or 6 Months B=30 Hours or 1 Week F=1440 Hours or 12 Months C=120 Hours or 1 Month G=4320 Hours or 36 Months D=360 Hours or 3 Months Action Chassis Check that the truck’s data plate is...
  • Page 73 Maintenance Action Grease load wheel bearings Grease caster and caster wheels Dismantle and lubricate all wheel bearings. Brake Clean dust and debris Check shoes and discs for wear Check correct clearance brake Check brake operation Electrical panel Clean and check the mounting Tighten cable connections Check main contactor function Check all cable insulation for damage...
  • Page 74 Maintenance Action 10.0 Hydraulic system 10.1 Check hoses and connections for leakage 10.2 Check hoses for wear and damage 10.3 Check oil tank for cracks, leaks, and mounting 10.4 Check oil level 10.5 Change oil 11.0 Cylinder 11.1 Check for leakage 11.2 Check the mountings 12.0...
  • Page 75 Maintenance Action 17.0 Master control on/off switch 17.1 Check the function of switch Maintenance chart drawing...

  • Page 76: Lubrication Chart

    Maintenance Lubrication chart Interval/Running hours Service point Lubricant 500h 1000h 3000h Wheel bearings Hydraulic system Travel brake Drive gear Hinges Steering bearings L=Lubrication C=Check O=Oil change...

  • Page 77: Approved Oils And Grease

    Sunoco TH Sunoco TH Texaco 15 system Transmission SAE 80W/90 SAE 75W SAE 75W Gears Motor oil SAE 40 SAE5W-20 SAE5W-20 Pivot Oil should meet CLARK's cleanliness specification 12-00-002. Contact your CLARK dealer representative for assistance or for more information.

  • Page 78: Transporting And Storing The Truck

    Transpor ting and storin g the truck Transporting and storing the truck Truck’s standard dimensions and weight NOTE! The truck’s dimensions and weight can vary with different accessories. Truck’s dimensions and weight Truck data WP45 Height 50.4 in. [1280 mm] Width 30.0 in. [762 mm] Length (this length is with 48 in.

  • Page 79: Towing And Transporting A Disabled Truck

    Transporting and storing the truck Towing and transporting a disabled truck Warning DO NOT tow a disabled truck. It is not recommended to tow a disabled lift truck.

  • Page 80: Storing The Truck

    Transporting and storing the truck Storing the truck Take the following action if the truck is not used for one week or more: Battery • Recharge the battery fully and carry out usual battery maintenance. • Maintenance charge the battery every 3rd month and check the fluid level.

  • Page 81: Appendix A, Section Osha Regulations

    APPENDEX A - Selected OSHA Regulations Ap pendix A, Section OSHA Regulations APPENDIX A - Selected OSHA Regulations The use of forklift trucks in the workplace is governed by various regulations. In the United States, the Department of Labor Occupational Safety and Health Administration (OSHA) has issued regulations which cover the majority of workplaces.
  • Page 82 Appendix A, Section OSHA Regulations • Trainees may operate a powered industrial truck only under the direct supervision of persons who have the knowledge, training, and experience to train operators and evaluate their competence and where such operation does not endanger the trainee or other employees. (l) (2) (i) (A) •...
  • Page 83 APPENDEX A - Selected OSHA Regulations • Brakes shall be set and wheel blocks shall be in place to prevent movement of trucks, trailers or railroad cars while loading or unloading. Fixed jacks may be necessary to support a semitrailer when the trailer is not coupled to a tractor.
  • Page 84 Appendix A, Section OSHA Regulations • Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the truck. Such examination shall be made at least daily.

  • Page 85: Index

    After charging ....... . 57 Application area for CLARK trucks ....24 Approved Oils and Grease .
  • Page 86 Index During charging ....... 56 Each month ........59 Each week .
  • Page 87 Plug braking ........37 WP45 truck dimensions ......26 Pre-charging .
  • Page 88 Index Starting the Truck ......43 Steering control handle ......30 Steering control handle/brake control .
  • Page 90 CLARK Material Handling Company 2317 Alumni Park Plaza, Suite 500 Lexington, KY 40517...

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