Clark WPL 25 Assembly Instructions Manual
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Clark WPL 25 Assembly Instructions Manual

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Operator's Manual
WPL 25
OM-745
IMPORTANT! Do not remove this manual from the lift truck.
JUN 2022 | REV 1.2

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  • Page 1 Operator's Manual WPL 25 OM-745 IMPORTANT! Do not remove this manual from the lift truck. JUN 2022 | REV 1.2...
  • Page 2 Customer Truck Identification No. ________________________ Truck Weight, Empty __________________________________ Truck Rated Capacity _________________________________ Truck Gross Weight ___________________________________ Special Equipment or Attachments _______________________ IMPORTANT Do not expose this manual to hot water or steam. Copyright © 2022 CLARK Material Handling Company...
  • Page 3 Operator's Manual You must be trained and authorized to operate a lift truck. YOU can prevent accidents First: Learn safe operating rules and your company rules. Next: Read your Operator's Manual. If you do not understand it, ask your supervisor for help. Learn about the unit you operate.

  • Page 4: A Message To Clark Lift Truck Operators

    They require specific instructions and rules for safe operation and maintenance. Safe operation of lift trucks is of primary importance to CLARK. Our experience with lift truck accidents has shown that when accidents happen and people are killed or injured, the causes are: •...
  • Page 5 (or need refresher training) operating or inspecting your lift truck, ask your supervisor. CLARK lift trucks are built to take hard work, but not abuse. They are built to be dependable, but they are only as safe and efficient as the operator and the persons responsible for maintaining them.

  • Page 7: Table Of Contents

    Contents of this Manual A Message to CLARK Lift Truck Operators ....ii Introduction ..............vi How to Use this Manual ........viii Safety Signs and Safety Messages ......x Section 1. General Safety Rules .......1-1 Section 2. Operating Hazards ........2-1 Section 3.

  • Page 8: Introduction

    This manual familiarizes you with safety, operating, and maintenance information about your new lift truck. It has been specially prepared to help you use and maintain your CLARK lift truck in a safe and correct manner. Your CLARK lift truck has been designed and built to be as safe and efficient as today’s technology can make it.
  • Page 9 “Drivers Daily Checklist.” Planned Maintenance In addition to the daily operator inspection, CLARK recommends that a planned maintenance and safety inspection program (PM) be performed by a trained and authorized mechanic on a regular basis. The PM will provide an opportunity to make a thorough inspection of the safety and operating condition of your lift truck.

  • Page 10: How To Use This Manual

    NOTICE: The descriptions and specifications included in this manual were in effect at the time of printing. CLARK Material Handling Company reserves the right to make improvements and changes in specifications or design, without notice and without incurring obligation. Please check with your authorized CLARK dealer for information on possible updates or revisions.
  • Page 11 If the truck you operate is not equipped with a manual, ask your supervisor to obtain one and have it attached to the truck. And, remember, your CLARK dealer is pleased to answer any questions about the operation and maintenance of your lift truck and will provide...

  • Page 12: Safety Signs And Safety Messages

    If warning decals are damaged, they must be replaced. Contact your CLARK dealer for replacements. NOTICE This message is used when special information, instruc-...
  • Page 13 General Safety Rules Contents Daily Inspection ............1.2 Do's and Don'ts ............1.3 No Riders ..............1.4 Pedestrians ..............1.4 Pinch Points ............... 1.5 Travel ................1.5 Surface and Capacity ..........1.6 Parking ................ 1.7...

  • Page 14: Daily Inspection

    General Safety Rules Daily Inspection Operator’s Daily Checklist Date: Check each Item Before Start of Each Shift Check one: Gas/LPG/Diesel Truck Electric Sit-down Electric Stand-up Electric Pallet Truck Serial Number: Operator: Supervisor's OK: Hour meter reading: Check each of the following items before the start of each shift. Let your supervisor and/or maintenance department know of any problem. DO NOT OPERATE A FAULTY TRUCK.

  • Page 15: Section 1. General Safety Rules

    General Safety Rules Do's and Don'ts Don't mix drugs or alcohol with your job. OM0001 Do watch for pedestrians. OM0002 Don't block safety or emergency equipment. OM0003 Do wear safety equipment when required. OM0004 Don't smoke in "NO SMOKING" areas or when refueling.

  • Page 16: No Riders

    General Safety Rules No Riders WARNING Always walk the truck. Never attempt to ride or allow passengers. Pedestrians IMPORTANT • Watch where you are going. • Look in the direction of travel. • Pedestrians may use the same roadway you do. •...

  • Page 17: Pinch Points

    2791862 WARNING Keep hands, feet and legs out of the lifting mechanism Travel CAUTION The WPL 25 Powered Pallet Truck is designed for smooth level surfaces. • Never lift or lower the load when the truck is in motion. •...

  • Page 18: Surface And Capacity

    General Safety Rules Surface and Capacity WSTX004 Avoid these conditions. They can cause a truck to tip over or lose trac- tion when braking or driving. WARNING Know the weight of your truck and load. Especially when using elevators. Know the capacity of the elevator you intend to use.

  • Page 19: Parking

    General Safety Rules Parking • Park only in authorized locations. • Never park on a grade. • Always come to a complete stop. • Be sure travel control is in NEUTRAL. • Lower forks fully to floor. • Place control handle in full turn and raise handle to "UP"...
  • Page 20 Operating Hazards Contents Loose Loads ............... 2.2 Long and Wide Loads ..........2.3 Rear Swing ..............2.3 Low Overhead Clearance .......... 2.4 Fast Turns and High Loads ........2.4 Pallets and Skids ............2.5 This Section shows some of the hazards that may cause you, or some- one around you, to be killed or badly hurt.
  • Page 21 Loose Loads WARNING Loose or unbalanced loads are dangerous. Observe these precautions. Never carry loose or uneven material. OM0006 Center wide loads. OM0007 Stack and band loose material. OM0008...
  • Page 22 Long and Wide Loads / Rear Swing WARNING With long or wide loads, you need more room. So slow down and watch your clearance. A long load reduces the capacity of the truck. Know and understand your truck load rating. When extra-long material makes it necessary to travel with the load elevated, do so with extreme care and be alert to load end-swing when turning.
  • Page 23 Low Overhead Clearance/Fast Turns and High Loads WARNING • Know the height of your truck, with and without a load. • Check your clearances. • Keep the load as low as possible. • Watch overhead clearance. • Moving into overhead structures can tip a truck over, or spill a load.
  • Page 24 Pallets and Skids OM0011 WARNING Do not move or store materials on damaged pallets or skids. Items can fall through them causing severe injury or death! Be sure the pallet or skid you are using is in good condi- tion and does not have defective or missing components and fasteners.
  • Page 26 Common Truck Contents Truck Description............3.2 Operator Controls ............3.3 Electronic Display ............3.4 Nameplate ..............3.5 Warning Decals .............3.6...

  • Page 27: Truck Description

    Common Truck Truck Model Description 1. Control Handle 2. Emergency Shut Off Switch 3. Frame 4. Load Wheel 5. Fork 6. Cover 7. Drive Wheel 8. Lift Cylinder...

  • Page 28: Section 3. Common Truck

    Common Truck Operator Controls Key Switch • Connects the battery with all truck operating systems (drive, lift, and steer electrical circuits) including the horn. • Connects battery to the diagnostic display. The key must always be inserted (in the ON position) to operate the truck.

  • Page 29: Electronic Display

    Common Truck Electronic Display WPL25 1. Horn Status 2. Function Indicator 3. Hour Display Hour 4. Interlock Switch Status Meter 5. Battery Indicator When the truck is functioning proper- ly the display will alternate between the hour meter and the battery state of charge.

  • Page 30: Nameplate

    CAUTION When attachments are added or if the truck is modified, the capacity of the truck may be affected. Contact your authorized Clark dealer for a new nameplate showing the revised capacity. IMPORTANT OSHA requires prior written approval from the manufacturer before any modifications affecting capacity or safety may be made.

  • Page 31: Warning Decals

    Common Truck Warning Decals IMPORTANT Safety and warning decals are placed in conspicuous locations on the truck to remind you of essential procedures or to prevent you from making an error that could damage the truck or possibly cause personal injury. You should know, understand, and follow these instructions.
  • Page 32 This safety decal is placed on the top cover to warn of the danger of injury by riding on the truck. Always walk with WPL 25 model truck. PART NO. 2777635 No Passenger Decal This safety decal is placed on the...
  • Page 33 Common Truck...
  • Page 34 Operator Maintenance and Care Contents Daily Safety Inspection ..........4.2 Visual Checks ............4.3 Functional Checks ............. 4.4 Concluding Inspection ..........4.5 CAUTION The Occupational Safety and Health Administration (OSHA) requires that truck users examine their trucks before each shift to be sure they are in safe working order.

  • Page 35: Daily Safety Inspection

    In general, the daily inspection should include the visual and functional checks described on the following pages. As an aid in carrying out this inspection, CLARK has prepared a form called the "Driver's Daily Checklist." We recommend that you use this form to make a daily record of your inspections and truck condition.

  • Page 36: Section 4. Operator Maintenance And Care

    Operator Maintenance and Care Visual Checks First, perform a visual inspection of the truck and its major components: 1. Walk around your lift truck and take note of obvious damage that may have been caused by operation during the last shift. 2.

  • Page 37: Functional Checks

    Operator Maintenance and Care Functional Checks Check the operation of the truck as follows: NOTICE Before performing these checks, familiarize yourself with the operating procedures in Section 5. 1. Test warning devices, horn, and other safety equipment and accessories. 2. With the key switch ON, check the electronic display. The elec- tronic display should show the charge remaining on the battery, the hour meter or a fault code.

  • Page 38: Concluding Inspection

    Operator Maintenance and Care Concluding the Inspection Make a record on the "Driver's Daily Checklist' of all the operating and truck problems that you find. Review the checklist to be sure it has been completed and turn it in to the person responsible for lift truck maintenance.
  • Page 39 Operator Maintenance and Care...
  • Page 40 Operating Procedures Contents Before Operating the Truck ........5.2 Starting from a Safe Condition ......... 5.2 Controls ..............5.3 Braking ............... 5.5 Load Handling ............5.6 After Operating the Truck ........5.10...

  • Page 41: Before Operating The Truck

    Operating Procedures Before Operating the Truck Be sure that you have read and understand the information in this Operator's Manual before operating the lift truck. WARNING • This equipment can be dangerous if not used properly. Safe operation is the responsibility of the operator. •...

  • Page 42: Section 5. Operating Procedures

    Operating Procedures Controls 1. Emergency Reverse Button 2. Horn 3. Lift Switch 4. Electronic Display 5. Lower Lever 6. Direction/Speed Control 7. Handle 1. Emergency Reverse Button (Belly Button) When the emergency reverse button strikes an object or a person, or is held in by the operator, the truck automatically propels itself in the "reverse"...
  • Page 43 Operating Procedures 3. Lift Switch The switch is used for lifting the forks. The movement speed is not adjustable. The switch is automatically turned off when the forks reach a certain height as detected by a sensor. 4. Electronic Display Displays Hour Meter, Battery Charge and Status of truck's operation.

  • Page 44: Braking

    Operating Procedures Braking The stopping distance of the truck depends on the ground conditions. The driver must take this into account when operating the truck. The driver must be looking ahead when traveling. If there is no hazard, brake moderately to avoid moving the load. The brake is fully applied by lowering or raising the steering arm.

  • Page 45: Load Handling

    Operating Procedures Load Handling • Lower forks completely before entering load. • Center forks with load as you approach. • Enter load as far as possible. • Make sure the lifting area is clear before lifting load. • Raise forks enough to elevate the load before moving truck.
  • Page 46 Operating Procedures Always be in full control of your powered pallet truck... Never operate a truck or its attachments if you are not in the designated operator's position. Never operate a lift truck when your hands are wet or greasy. Always pick the smoothest travel route for your truck.
  • Page 47 Operating Procedures CAUTION Be sure that your truck is the correct fire safety type for the area in which you are working. The proper type designation for this truck is listed on the nameplate. In areas classified as hazardous, use only trucks approved for use in those areas.
  • Page 48 Operating Procedures Load Handling (continued) Handle only loads that are within the truck rated capacity as shown on the nameplate. This rating specifies the maximum load that should be lifted. However, other factors such as special load handling attachments, loads having a high center of gravity, or uneven terrain may dictate that the safe working load be less than the rated capacity.

  • Page 49: After Operating The Truck

    Operating Procedures After Operating the Truck Always leave your lift truck in a safe condition. When you leave your truck, or park it, follow these safety rules: • Park truck in designated parking area. • Never park in areas that block emergency routes or equipment, access to fire aisles, or stairways and fire equipment.
  • Page 50 Planned Maintenance and Lubrication Contents Daily Inspection Points ..........6.2 Typical Operating Conditions ........6.2 Maintenance and Lubrication Schedule ....6.3 Safe Maintenance Practices ........6.4 Safety Standards ............6.7 Battery Removal from Truck ........6.8 Battery Charging ............6.9 NOTICE THIS SECTION IS FOR TRAINED SERVICE PERSON- NEL to use as a reference for Planned Maintenance...

  • Page 51: Daily Inspection Points

    Time intervals between maintenance are largely determined by op- erating conditions. The intervals specified in the following table are for normal operation. For more severe operation, the maintenance intervals should be shortened accordingly. Contact you CLARK dealer for recommendations. Normal Operation: Basically, eight hour material handling in clean buildings with smooth clean and level floors.

  • Page 52: Maintenance And Lubrication Schedule

    Planned Maintenance and Lubrication Maintenance and Lubrication Schedule Recommended Planned Maintenance Intervals: A = 8-10 hours daily B = 50-250 hours or every month C = 450 - 500 hours or every 3 months D = 900 - 1000 hours or every 6 months E = 2000 hours or every year Check truck visually and inspect components.

  • Page 53: Safe Maintenance Practices

    They are listed here for the reference and safety of all workers during inspection / maintenance operations. When in doubt of any inspection / maintenance procedures, please contact your local CLARK dealer. 1. Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities, trained person- nel and procedures shall be provided.
  • Page 54 Planned Maintenance and Lubrication 9. Before Starting to Drive the Truck: a) Remove drive wheel chocks if needed. b) Insert battery. c) Insert key (ON position). d) Lower control handle to operating position. e) Make sure path of travel is clear. f) Check function of controls and emergency reversal switch.
  • Page 55 Be sure that lifting and handling equipment is of the correct capacity and in good condition. IMPORTANT Your new CLARK lift truck has been built to meet all ap- plicable mandatory requirements of ANSI/ITSDF B56.1 Safety Standard for Powered Industrial Trucks. Each truck also includes certain safety devices-such as a horn as standard equipment.

  • Page 56: Safety Standards

    General Industry Standards, OSHA 2206: OSHA Safety and Health Standards (29 CFR 1910), Subpart N - Materials Handling and Storage, Section 1910.178 Powered Industrial Trucks. For sale by: Superin- tendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 or contact your CLARK dealer.

  • Page 57: Battery Removal From Truck

    Planned Maintenance and Lubrication Battery Removal from Truck The WPL25 is equipped with a Lithium Ion battery that must be removed from the truck to be charged. • Park truck on flat solid flooring, only in authorized locations. • Be sure travel control is in NEUTRAL. •...

  • Page 58: Battery Charging

    Planned Maintenance and Lubrication Battery Charging 1. Please prevent the battery from water or infiltration on any liquid. 2. Do not let the battery close to any open flame, heat, flammable and explosive objects. 3. Do not place the battery vertically on a conductive object to prevent the electrodes from being touched by protruding objects.
  • Page 59 Planned Maintenance and Lubrication 6.10...

  • Page 60: Section 7. Towing

    Towing IMPORTANT The WPL25 Powered Pallet Truck truck has an electronic emergency brake that must be disabled prior to towing. (See service manual) Once the electronic emergency brake system is disabled the truck can be pulled by hand to a service area. If your truck becomes disabled contact a trained and authorized me- chanic.

  • Page 62: Section 8. Specifications

    2% loaded 6% unloaded Tires and Wheels Drive Wheel Load Wheel 80x60 polyurethane 74x88 or 85x60 polyurethane Fluid Recommendations Hydraulic Unit AW ISO32 (CLARK MS-68) Drive Unit Grease Fluid Capacities Hydraulic Unit 1.0 qts (nominal) Drive Unit 100 grams MoS Grease...
  • Page 64 Scan Link Below Safety Starts with You! OM-745 700 Enterprise Drive Lexington KY 40510 Additional copies of this manual are available from your CLARK dealer.

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