Clark CTX 40 Operator's Manual
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Clark CTX 40 Operator's Manual

Electric towing truck
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Additional copies of this manual may be purchased from
YOUR AUTHORIZED CLARK DEALER
CLARK MATERIAL HANDLING COMPANY
700 Enterprise Drive
Lexington, Kentucky 40510 [ www.clarkmhc.com ]
●
Printed Date ; Feb. 2017
Electric Towing Truck
[Do not remove this manual from the truck]
CTX 40 / 70
Part No.
8087587 (Eng)
Book No. OM-847 (
Sep. 2016
Rev 2.2)

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  • Page 1 Electric Towing Truck Additional copies of this manual may be purchased from YOUR AUTHORIZED CLARK DEALER [Do not remove this manual from the truck] CTX 40 / 70 Part No. 8087587 (Eng) CLARK MATERIAL HANDLING COMPANY Book No. OM-847 ( Rev 2.2)
  • Page 2 Truck Weight, Empty __________________________________ Truck Rated Capacity _________________________________ Truck Gross Weight ___________________________________ Truck Gross Weight, Loaded w/ Rated Load________________ Special Equipment or Attachments _______________________ IMPORTANT Do not expose this manual to hot water or steam. 2012 Clark Material Handling Company...

  • Page 3: Table Of Contents

    Contents PAGE Foreword..............ii You must be authorized to operate a Tow Tractor . iii 1. Safety Regulations..........1.1 2. Know your Tow Tractor........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.

  • Page 4: Foreword

    Please note: Only original CLARK spare parts guarantee the trouble free functioning and optimum economy of your Tow Tractor. Original CLARK spare parts are the best for your Tow Tractor. With their dimensional stability as well as their high material quality due to continuous and strict quality control, they correspond to those parts used in the series production of our Tow Tractors.
  • Page 5 Operator’s Manual You must be trained and authorized to operate a Tow Tractor. 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 6 Operator’s Manual You must be trained and authorized to operate a Tow Tractor. 10. Make sure correct tire pressures are maintained. 11. Before driving over a dockboard or bridge plate, make sure it is correctly secured. Drive carefully and slowly across the dockboard or bridge plate, and never exceed its rated capacity.

  • Page 7: Safety Regulations

    Stability • CLARK Tow Tractors are stable in the working positions and when driving, if used with due care and attention and observing the maximum permissible loads. • The trailing capacity of your CLARK Tow Tractors should...
  • Page 8 Regular and statutory inspections • Tow Tractors must be regularly checked by trained and authorized service personnel. CLARK recommends an annual check-up based on an average operational perfor- mance. Modification of the truck prohibited •...
  • Page 9 Safety Regulations Operate truck from t 3. Operation The driver • Only trained and authorized personnel may be charged with driving a Tow Tractor. Please also observe all State and Federal laws and regula- tions. • Please read this Operator’s Manual and understand the contents carefully.
  • Page 10 he position of the t Safety Regulations The working area Operating aisles • Never drive in areas which are closed to Tow Tractors, but only use aisles cleared for Tow Tractors operation. Trav- eling aisles and loading areas must be clearly identified and free of obstacles.
  • Page 11 Safety Regulations 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 guide rail or steps to keep from losing your balance. •...
  • Page 12 Safety Regulations 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 Tow Tractor 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.
  • Page 13 Safety Regulations 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 of speed and that the drive wheels may spin or the truck may overturn in case of sudden braking.
  • Page 14 Safety Regulations Climatic condition for Operation • Maximum ambient temperature, short term(up to 1h) : +104 °F (+ 40 °C). • Average ambient temperature for continuous duty : + 77 °F (+ 25 °C). • Lowest ambient temperature : - 4 °F (- 25 °C) (in normal out- door condition), +41 °F (+ 5 °C) (in normal indoor condition).
  • Page 15 Safety Regulations 3) Rainy Weather  If forklift truck is to be operated outdoors during rainy con- ditions, make sure cab is in place to prevent damage to electrical components Behavior during operation Traffic rules • Observe all safety regulations and all warning signs.
  • Page 16 Safety Regulations When driving • Avoid any abrupt starting, excessive traveling speeds and sudden directional 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 Tow Tractor can cause the drive wheels to slip and the truck to tip over.
  • Page 17 Safety Regulations Tow Tractor tip over Tow Tractors 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.
  • Page 18 Safety Regulations The operator must wear personal safety devices and follow the instructions for safety to prevent serious personal injury if the equipment overturns. 1. In the event your Tow Trac- tor is equipped with a weather enclosure, wear safety belt. Never jump off the equipment.
  • Page 19 Alway Safety Regulations Troubleshooting Daily inspection before operation • Before starting to work check your Tow Tractor daily in accordance with the section "Daily Inspection". Always make sure that all safety sys- tems are operating correctly. Never operate a truck which is damaged or not safe to operate.
  • Page 20 Safety Regulations Leaving the tugger truck • When leaving the Tow Trac- tor, shall be turned key off. • Apply the parking brake, put the gear levers in the neutral position and secure your Tow Tractor against unauthorized use by third persons. •...
  • Page 21 Safety Regulations Additional regulations for special tasks Tow Tractors used for the transport of persons • The transport of persons by the Tow Tractor is only permissi- ble, if the truck is equipped with appropriate seats and if the latter are designed for the transport of persons. Otherwise the transport of persons is prohibited.
  • Page 22 Safety Regulations Trailer operation • Trailors without a power-brake system may only be moved if the braking force of the Tow Tractor is sufficient for a safe stop. For the permissible trailer load please look to the truck plate. • The tow tractor must be operated in such away that safe driving and braking of the towed vehicle is ensured for all driving movements.
  • Page 23 Safety Regulations • When driving through narrow road sections, the dimensions of the trailer and the load must be observed. In the case of Tow Tractors with trailers, an adequate minimum distance to fixed components shall be ensured when turning and in curves.
  • Page 24 CLARK spare parts guarantee the troublefree function- ing and optimum economy of your Tow Tractor. Original CLARK spare parts are the best for your Tow Tractor. With their dimensional stability as well as their high material qual- ity due to a continuous and strict quality control, they corre- spond to those parts used in the series production of our Tow Tractors.
  • Page 25 Safety Regulations 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.

  • Page 27: Know Your Tow Tractor

    Know your Tow Tractor Operator's Compartment and Controls 1. Horn button 2. Steering handwheel 3. Key switch 4. Smart display 5. Combination lever 6. Direction control lever 7. Parking brake lever 8. Brake pedal (pressing the pedal activates the brake) 9.
  • Page 28 Know your Tow Tractor Dash display LED function The MDI-CAN has only a LED. This LED is red and lights and blinks when an alarm is present. Display function Hour meter An alpha-numeric liquid crystal display is fitted in the centre of the unit that shows the Hours Worked.
  • Page 29 Know your Tow Tractor Battery State of Charge The Battery's State of Charge indication is integrated in the LCD display; it is shown by ten notches. Each notch represents the 10% of the battery charge. As the battery becomes discharged, the notches turn off progressively, one after the other, in proportion to the value of the residual battery charge.
  • Page 30 Know your Tow Tractor Service Symbol: It is normally off; when it appears (fixed) it shows the request of programmed maintenance or the Alarm state. In this case the relative code will be displayed. The information supplied by the MDI-CAN can be extremely useful.
  • Page 31 Know your Tow Tractor Installation Connection scheme PLASTIC CASE DESCRIPTION 6 PIN CONNECTOR MDI CAN (MALE CRIMP TERMALS) FIXING BRACKET POS.1 +12V POS.2 GND GASKET CONNECTOR POS.3 CANL / NCLTXD POS.4 CANH / PCLTXD MOLEX MINI CONNECT. 6 PIN POS.5 CANT / PCLRXD RECEPT.
  • Page 32 Know your Tow Tractor Connector description CNA connector: Molex Minifit - CANBUS communication version +12V MDI CAN positive power supply MDI CAN negative power supply CANL CAN Low signal. CANH CAN High signal. CANBUS termination resistance is connected between this pin CANT and CANL.
  • Page 33 Know your Tow Tractor Hour-meter Memory Service The MDI-CAN indicator retains the Hour Meter value in its own memory (EEPROM). In this way it is possible to transfer the machine hour meter value into other controllers, if a replace- ment is required, without loss of the hour meter record for a particular machine.
  • Page 34 Know your Tow Tractor Alarms The ZAPI MDI-CAN gives indication of the Alarms of the controllers to which it is connected CAN-BUS, with a corresponding code. When an Alarm is generated, the Red LED blinks to attract the attention of the operator. symbol Monkey Wrench also appears.
  • Page 35 Know your Tow Tractor NONE CHOPPER RUNNING NO COMMUNICATION UNKNOWN CHOPPER CONSOLE EEPROM SERIAL ERROR 2 SERIAL ERROR 1 CHOPPER NOT CONFIG WATCHDOG FIELD FF FAILURE EEPROM DATA KO EEPROM PAR KO EEPROM CONF KO EEPROM KO EEPROM OFFLINE LOGIC FAILURE 5 LOGIC FAILURE 4 LOGIC FAILURE 3 LOGIC FAILURE 2...
  • Page 36 Know your Tow Tractor VMN NOT OK NO FULL COND RGT NO FULL COND LFT NO FULL COND PU NO FULL COND CONTACTOR CLOSED CONTACTOR OPEN BRAKE DON' T CLOSED BRAKE CONT OPEN DIR CONT CLOSED DIR CONT OPEN RIGHT CONT CLOSED RIGHT CONT OPEN LEFT CONT CLOSED LEFT CONT OPEN...
  • Page 37 Know your Tow Tractor THERMIC LEVEL 2 PUMP TEMPERATURE MOTOR TEMPERATURE BATTERY LOW BATTERY LEVEL 2 BATTERY LEVEL 1 CURRENT SENS KO POWER FAILURE 4 POWER FAILURE 3 POWER FAILURE 2 POWER FAILURE 1 DRIVER SHORTED CONTACTOR DRIVER COIL SHORTED COIL INTERRUPTED VACC NOT OK INCORRECT START...
  • Page 38 Know your Tow Tractor INPUT ERROR 6 INPUT ERROR 5 INVERSION POSITION HANDLE INPUT ERROR 2 INPUT ERROR 1 NOTICE 16A06 string corresponds COMMUNICATION alarm. It is the only MDI-CAN alarm and it indicates a problem in the communication with the traction controller.
  • Page 39 Know your Tow Tractor Key Switch • Connects battery with all truck operating systems (drive and steer electrical circuits) except the horn. • Connects battery to the diagnostic display hour- meter battery charge status. The key switch must always be turned to the ON position to operate the truck. When the key is in the vertical OFF position, instruments, drive motor electrical circuits are disconnected (shut-off), and the key can be removed.
  • Page 40 Know your Tow Tractor How to operate inching switch (Optional) An option offered on the Tow Tractors is an Inching Switch. When activated the switches located at the left rear of the tractor can be used to jog the tractor forward or backward at a very low speed for enabling the coupling of the tractor to the trailer.
  • Page 41 Know your Tow Tractor Seat switch • The seat switch interrupts the driving current as soon as the driver's seat remains unloaded for about 2seconds. • The driving current circuit is reconnected automatically when a load is applied to the driver's seat and the direction lever is set to the neutral position once and then back to for- ward / reverse position.
  • Page 42 Know your Tow Tractor Seat adjustment • 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 com- fortably reached. Once you have adjusted the seat to the desired position, release the lever.
  • Page 43 Know your Tow Tractor Adjusting the steering column • The Tow Tractor is equipped with an adjustable steering col- umn. • Release the locking lever by rotating it C.C.W. After adjust- ing the steering column, it must be relocked in place securely.
  • Page 44 Know your Tow Tractor Parking brake • The parking brake is released by pushing the button on top of the lever and then by mov- ing the lever forwards. Battery Specifications The information on the battery specifications is printed on the label affixed to the battery.
  • Page 45 Know your Tow Tractor Battery Recharging To charge the batteries, park the Tow Tractor safely in the designated place, and ensure that it is sufficiently ventilated in order to remove the hazardous gas generated during battery charging. During battery charging, make sure to open the top cover of the battery to provide sufficient ventilation of the gas generated during charging.
  • Page 46 Know your Tow Tractor Battery Compartment Access • The combination seat deck / battery compartment cover pivots upward to provide access to the battery com- partment. The cover latch is located just above the floor board in the center of the cover. Release compartment latch and lift the battery cover...
  • Page 47 In order to avoid dangers from unforeseen movements, batteries in the Tow Tractor shall be secured as specified by CLARK. • When removing and installing batteries, ensure that the bat- tery cables are not damaged.
  • Page 48 Know your Tow Tractor (Exchange with crane) 5. If the truck is fitted with a weather enclosure, remove the cover at the opening. 6. Remove the battery retainer. 7. In the event of a battery change with a hoisting gear, the lift should be vertical to ensure that the battery tray is not squeezed.
  • Page 49 10 AMP IMPORTANT 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 the faults rectified. 2-23...
  • Page 50 • When installing such equipment, please contact your CLARK dealer for advice and assistance. UL Classification Symbol • Your truck meets the UL stan- dard if the UL classification symbol is affixed (see fig.).
  • Page 51 Know your Tow Tractor Truck Lifting by crane Improper lifting by crane can result in accidents. The use of unsuitable lifting gear can cause the truck to crash when being lifted by crane.  Prevent the truck from striking other objects when they are being raised, and avoid uncontrolled...
  • Page 52 Know your Tow Tractor Lifting gear attachment points are provided on the chassis (1) and the trailer hitch (2) in case the truck is to be lifted or transported by crane.  Park the truck securely.  Secure the lifting gear to the attachment points (1) and (2).
  • Page 53 Know your Tow Tractor Transporting Load the truck as follows if being transported in an enclosed trailer.  Apply the parking brake.  To fix lengthwise, install wooden props (1) at the front and rear on both sides of the front wheel. ...
  • Page 54 Know your Tow Tractor If transporting on an open trailer: The truck must be securely fastened when transported on a trailer. The trailer must have fastening rings.  To fasten the truck pull the tensioning belt (3) over truck attach it to the fastening rings.
  • Page 55 Plate-UL Decal-Brake oil VIEW ‘A’ Attached Position of Safety Decals CAUTION Do not operate a truck with damaged or missing decals or data plates. Replace them immediately. Contact your local CLARK dealer to acquire new decals or data plates. 2-29...
  • Page 56 Know your Tow Tractor Name plate What you should know about your truck : 1. The location of the model name. 2. The location of the serial number. 3. The location of the drawbar pull. 4. Maximum Ampere Hours 5. Standard Coupler Height 6.

  • Page 57: Daily Inspection

    Daily Inspection • Always check that your Tow Tractor is operationally safe. Never drive a Tow Tractor you have not checked. Before starting work, you should convince yourself that the Tow Tractor is in an operationally safe state. Carry out this inspection by following the following list.
  • Page 58 Daily Inspection Visual inspection Walk around your Tow Tractor and look for any obvious signs of damage, leaks and dirt. • The degree to which clean- ing is required depends on the operating environment of the Tow Tractor. For opera- tion in areas with large amounts of dust or paper, thorough cleaning is required...
  • Page 59 Daily Inspection Lifting up the battery compartment • Release the compartment lock and lift the battery cover up and backwards. • Carry out the checks on the battery. Checking the battery and cables • Check for visible damage such as: ...
  • Page 60 Daily Inspection • If a Tow Tractor is operated with the old cables, the insula- tion of the cable may be hardened or cracked. In that case, the cables should be replaced with new cables having over 194°F (90°C) temperature rating. Checking the service brake •...
  • Page 61 Daily Inspection Starting the Truck • Before you start the Tow Tractor, make sure that you have taken all the above- mentioned precautions and that the directional control (1) is in NEUTRAL. To start the Tow Tractor, turn the key switch (2) clockwise to the ON position.
  • Page 62 Daily Inspection Operational safety of the Tow Tractor • Do not start using any Tow Tractor, which is not in a safe operational state. • Tow Tractors should only be repaired by competent and authorized persons. Checklist after Equipment Deployment Check followings after deploying the equipment;...

  • Page 63: Maintenance And Care

    Spare parts Only those spare parts shall be used which are specified by CLARK. If spare parts are used which have not been approved by CLARK, 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 responsibility for any damage sustained.
  • Page 64 Maintenance and Care 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 may also be carried out by the operator. Safety installations All safety devices shall be re-installed after servicing and repairs and shall be checked for proper functioning.
  • Page 65 Maintenance and Care 2) Safety tips Hoses, cables and rubber parts • Hydraulic lines must depressurised. • Hoses, cables and rubber parts succumb to a natural process of ageing, which is dependent on outside influ- ences (e.g., temperature, environmental factors, etc.). •...
  • Page 66 Maintenance and Care Electronic system WARNING Work on the electric equipment of truck shall only be carried out in a powerfree condition. Work on live components for functional testing, checks and adjustments shall only be carried out by instructed and authorized persons taking...
  • Page 67 Maintenance and Care Before calling customer service at your CLARK dealer because of a performance drop or total failure of your truck, please check the following points : 1. Is the battery sufficiently charged? 2. Is the battery connector connected correctly and securely? 3.
  • Page 68 Maintenance and Care Electric-motors General visual check • Check for damage to termi- nal boards. Check for dam- age to encoder connector and temperature sensor con- nector. Batteries - General information Always observe the instructions provided by the battery and charger manufacturers.
  • Page 69 8. The battery retainer shall be checked after each battery change and adjusted if needed. In order to avoid dangers from unforeseen movement, batteries in the truck shall be secured as specified by CLARK.
  • Page 70 Replacement with new parts is usually more cost effective and result in less machine downtime than risking replaced failure of a used part. When parts replacement is needed, only genuine CLARK ser- vice parts should be used to maintain optimum performance and service life.
  • Page 71 Maintenance and Care Greasing • Grease your truck carefully in accordance with the greasing and lubrication schedule. • Clean the grease nipples before greasing, and after lubri- cating. Remove any excess grease which has come out at the greasing points. Checking the brake fluid level •...
  • Page 72 1. Rear driving wheels WARNING To be able to disassemble the wheels previous experience is needed. If necessary, get in touch with a CLARK dealer. 1) Park the truck on a firm and level surface. 2) Turn the key switch to Off and disconnect the battery.
  • Page 73 Maintenance and Care WARNING Do not remove the nuts until the wheels are lifted off the ground. 5) Hold the truck by placing a wooden block under the rear part of the frame. 6) Remove the nuts completely and change the wheels. WARNING Be sure that the wooden blocks used to hold the truck are solid and in one only piece.
  • Page 74 2. Front wheel WARNING To be able to disassemble the wheels you need previ- ous experience. If needed, get in touch with a CLARK dealer. 1) Park the truck on a firm and levelled surface. 2) Turn the key switch to Off and disconnect the battery.
  • Page 75 Maintenance and Care 10) After several hours of operation, tighten the nuts again. CAUTION When reinstalling the wheels, ensure correct seating of the valve stem. It must lock into the grooves of the wheel hub. Tighten the wheel nuts evenly at the specified tightening torque.
  • Page 76 Maintenance and Care • Only brand name, stipulated cleaning agents may be used. Do not use gasoline or diesel under any circumstances. • Once the truck has been cleaned, remove all covers and tape. • Lubricate the truck in accordance with the lubrication plan. WARNING A braking test shall be carried out after the truck has been washed.

  • Page 77: Lubrication And Maintenance Plan

    Lubrication and Maintenance Plan Service to be done in accordance of list (1/2) Type of lubricant Brake fluid Multipurpose grease Drive axle oil Type of lubricant Item number in the drawing Check the tightening torque of critical fastening ele- ments Carry out one equalization charge Check drive axle oil level 1 T a...
  • Page 78 Lubrication and Maintenance Plan Service to be done in accordance of list (2/2) Type of lubricant Brake fluid Multipurpose grease Drive axle oil Type of lubricant Item number in the drawing Emergency shut off Electrical wiring and fuses Lightning system functionality and mounting Instrumentation functionality Check steer oil leackage Steering wheel looseness and play, funtionality...
  • Page 79 Lubrication and Maintenance Plan...

  • Page 80: Lubricant Recommendations

    T Drive axle oil CTX 40 / 70 : - In accordance with specification SAE 80W90 (CLARK #6094-10060) G Multipurpose grease In accordance with CLARK specification MS-9 or MS-107C e.g.) BP : Multipurpose grease L2 MOBIL : Mobilgrease MP DEFROL...

  • Page 81: Technical Data

    Drive axle ............1.8 Qts (2 liters) Brake system ............1 Qt (1 liter) Wheels and Tire Steering tire CTX 40/70..4.00 × 8 - 6PR ..800kPa (116psi) (8bar) Drive tires CTX 40/70..4.00 × 8 - 6PR ..800kPa (116psi) (8bar) Fuses Main fuses (Traction) - CTX 40 ........200 Amp...

  • Page 82: Specification

    Specification Dimensions (CTX40 / 70) 22.2 (l3) (l5) 41 (y) 18 (l1)
  • Page 83 Specification Manufacture CLARK CLARK Model Manufacture's Designation CTX40 CTX70 Rolling Load Capacity lbs(kg) 8800(4000) 15400(7000) Power Unit 48 Volt 48 Volt Operator Type Electric Rider Rider Tire Type Solid Pneumatic Solid Pneumatic Wheels (x=driven) Front/Rear 1 / 2X 1 / 2X...

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