Clark WPL 25 User manual

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

Copyright © 2022 CLARK Material Handling Company
Record the following information pertaining to your truck.
Model No. __________________________________________
Serial No.___________________________________________
Customer Truck Identication 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.

i
YOU can prevent accidents
KNOW YOUR TRUCK
First: Learn safe operating rules and your company rules.
Next: Read your Operator's Manual. If you do not
understand it, ask your supervisor for help.
Learn about the unit you operate.
Breaking these rules will cause serious or fatal injury
to yourself and others
Operator's Manual
You must be trained and authorized to operate a lift truck.
Then: Practice operating your
truck safely.
And: Keep your truck in safe
operating condition with
correct and timely
maintenance.

ii
Lift trucks are specialized machines with unique operating character-
istics, designed to perform a specic job. Their function and operation
is not like a car or ordinary truck. They require specic instructions and
rules for safe operation and maintenance.
Safe operation of lift trucks is of primary importance to CLARK. Our
experience with lift truck accidents has shown that when accidents
happen and people are killed or injured, the causes are:
• Operator not properly trained
• Operator not experienced with lift truck operation
• Basic safety rules not followed
• Lift truck not maintained in safe operating condition
For these reasons, CLARK wants you to know about the safe operation
and correct maintenance of your lift truck.
This manual is designed to help you operate your lift truck safely. This
manual shows and tells you about safety inspections and the important
general safety rules and hazards of lift truck operation. It describes
the special components and features of the truck and explains their
functions. The correct operating procedures are shown and explained.
Illustrations and important safety messages are included for clear un-
derstanding. A section on maintenance and lubrication is included for
the lift truck mechanic.
A Message to CLARK Lift Truck Operators

iii
The operator’s manual is not a training manual. It is a guide to help trained
and authorized operators safely operate their lift truck by emphasizing
and illustrating the correct procedures. However, it cannot cover every
possible situation that may result in an accident. You must watch for
hazards in your work areas and avoid or correct them. It is important that
you know and understand the information in this manual and that you
know and follow your company safety rules! Be sure that your equip-
ment is maintained in a safe condition. Do not operate a damaged or
malfunctioning truck. Practice safe operation every time you use your
lift truck. Let's join together to set high standards in safety.
Remember, before you start operating this lift truck, be sure you under-
stand all driving procedures. It is your responsibility, and it is important
to you and your family, to operate your lift truck safely and e󰀩ciently. Be
aware that the Federal Occupational Safety and Health Administration
(OSHA) and state laws require that operators be completely trained
in the safe operation of lift trucks; it is also an OSHA requirement that
a machine inspection be performed before every shift. If you have not
been trained (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 e󰀩cient as the
operator and the persons responsible for maintaining them. Do not
make any repairs to this truck unless you have been trained in safe lift
truck repair procedures and are authorized by your employer.

iv

v
Contents of this Manual
A Message to CLARK Lift Truck Operators................ii
Introduction..................................................................vi
How to Use this Manual ........................................viii
Safety Signs and Safety Messages .........................x
Section 1. General Safety Rules...............................1-1
Section 2. Operating Hazards...................................2-1
Section 3. Common Truck.........................................3-1
Section 4. Operator Maintenance and Care ............4-1
Section 5. Operating Procedures .............................5-1
Section 6. Planned Maintenance ..............................6-1
Section 7. Towing ......................................................7-1
Section 8. Specications .........................................8-1

vi
CLARK welcomes you to the growing group of professionals who
own, operate, and maintain CLARK lift trucks. We take pride in the
long tradition of quality products and superior value the CLARK name
represents. This manual familiarizes you with safety, operating, and
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
e󰀩cient as today’s technology can make it. As manufactured, it meets
all the applicable requirements of ANSI/ITSDF B56.1 Safety Standard
for Powered Industrial Trucks. Each truck is also furnished with equip-
ment to help you operate safely; for example parking brake and horn
are standard equipment.
Safe, productive operation of a lift truck requires both skill and knowledge
on the part of the operator. The operator must know, understand, and
practice the safety rules and safe driving and load handling techniques
described in this manual. To develop the skill required, the operator must
become familiar with the construction and features of the lift truck and
how they function. The operator must understand its capabilities and
limitations, and see that it is kept in a safe condition.
Routine Servicing and Maintenance
Regular maintenance and care of your lift truck is not only important
for economy and utilization reasons; it is essential for your safety. A
faulty lift truck is a potential source of danger to the operator, and to
other personnel working near it.As with all quality equipment, keep your
lift truck in good operating condition by following the recommended
schedule of maintenance.
Introduction

vii
Operator Daily Inspection — Safety and Operating Checks
A lift truck should always be examined by the operator, before driv-
ing, to be sure it is safe to operate. The importance of this procedure
is emphasized in this manual with a brief illustrated review and later
with more detailed instructions. CLARK dealers can supply copies of
a helpful “Drivers Daily Checklist.”
Planned Maintenance
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. Necessary adjustments and repairs
can be done during the PM, which will increase the life of components
and reduce unscheduled downtime and increase safety. The PM can
be scheduled to meet your particular application and lift truck usage.
The procedures for a periodic planned maintenance program that
covers inspections, operational checks, cleaning, lubrication, and
minor adjustments are outlined in this manual. Your CLARK dealer is
prepared to help you with a Planned Maintenance Program by trained
service personnel who know your lift truck and can keep it operating
safely and e󰀩ciently.

viii
This manual is a digest of essential information about the safe operation,
the features and functions, and explains how to maintain your lift truck.
This manual is organized into eight major parts:
Section 1, General Safety Rules, reviews and illustrates accepted
practices for safe operation of a lift truck.
Section 2,Operating Hazards, warns of conditions that could cause
damage to the truck or injury to the operator or other personnel.
Section 3, Common Truck, describes the most common operating
components, systems, controls, and other features of your truck and
tells how they function.
Section 4, Operator Maintenance and Care, presents details on how to
perform the operator's daily safety inspection and refuel the lift truck.
Section 5, Operating Procedures, discusses more specic instruction
on the safe, e󰀩cient operation of your lift truck.
Section 6, Planned Maintenance, describes the PM program.
Section 7, Towing, Provides information regarding towing a disabled
truck.
Section 8, Specications, provides reference information and data
on features, components, and maintenance items.
NOTICE: The descriptions and specications included in this manual
were in e󰀨ect at the time of printing. CLARK Material Handling Company
reserves the right to make improvements and changes in specications
or design, without notice and without incurring obligation. Please check
with your authorized CLARK dealer for information on possible updates
or revisions.
The examples, illustrations, and explanations in this manual should
help you improve your skill and knowledge as a professional lift truck
operator and take full advantage of the capabilities and safety features
of your new lift truck.
The rst Section of the manual is devoted to a review, with illustrations
and brief messages, of general safety rules and the major operating
hazards you can encounter while operating a lift truck.
How to Use this Manual

ix
Next, you will nd descriptions of the components of your specic lift
truck model and how the instruments, gauge, and controls operate.
Then, you will nd a discussion of safe and e󰀩cient operating proce-
dures, followed by instructions on how to tow a disabled lift truck. The
later sections of the manual are devoted to maintenance and truck
specications.
Take time to carefully read the “Know Your Truck” section. By acquiring
a good basic understanding of your truck's features, and how they func-
tion, you are better prepared to operate it both e󰀩ciently and safely.
In “Planned Maintenance,” you will nd essential information for cor-
rect servicing and periodic maintenance of your truck, including charts
with recommended maintenance intervals and component capacities.
Carefully follow these instructions and procedures.
Each major Section has its own table of contents, so that you can nd
the various topics more easily. If you cannot nd a topic in the table of
contents, check the index at the back of the manual.
We urge you to rst carefully read the manual from cover to cover. Take
time to read and understand the information on general safety rules
and operating hazards. Acquaint yourself with the various procedures
in this manual. Understand how the electronic display, indicator lights,
and control functions. Please contact your authorized CLARK dealer
for the answers to any questions you may have about your lift truck’s
features, operation, or manuals.
Operate your lift truck safely; careful driving is your responsibility. Drive
defensively and think about the safety of people who are working nearby.
Know your truck’s capabilities and limitations. Follow all instructions
in this manual, including all IMPORTANT, CAUTION, WARNING, and
DANGER messages to avoid damage to your lift truck or the possibility
of any harm to yourself or others.
This manual is intended to be a permanently attached part of your lift
truck. Keep it on the truck as a ready reference for anyone who may
drive or service it. 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
you with additional information should you require it.

x
Improper operation can cause accidents. Don’t take chances with incor-
rect or damaged equipment. Read and understand the procedures for
safe driving and maintenance outlined in this manual. Don't hesitate to
ask for help. Stay alert! Follow safety rules, regulations, and procedures.
Avoid accidents by recognizing dangerous procedures or situations
before they occur. Drive and work safely and follow the safety signs
and their messages on the truck and in this manual.
Safety signs and messages are placed in this manual and on the truck
to provide instructions and identify specic areas where potential hazards
exist and special precautions should be taken. Know and understand
the meaning of these instructions, signs, and messages. Damage to
the truck, death, or serious injury to you or other persons may result
if these messages are not followed. If warning decals are damaged,
they must be replaced. Contact your CLARK dealer for replacements.
NOTICE
This message is used when special information, instruc-
tions or identication are required relating to procedures,
equipment, tools, pressures, capacities and other special
data.
IMPORTANT
This message is used when special precautions should
be taken to ensure a correct action or to avoid damage to
or malfunction of the truck or a component.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
DANGER
Indicates an imminently hazardous situation which, if not
avoided, will result in death or injury.
Safety Signs and Safety Messages

1.1
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
General Safety Rules
Contents

1.2
At the beginning of each shift, inspect your truck and ll out a daily
inspection sheet.
Check for damage and maintenance problems.
Have repairs made before you operate the truck.
Daily Inspection
General Safety Rules
CAUTION
DO NOT MAKE REPAIRS YOURSELF. Lift truck mechanics
are trained professionals. They know how to make repairs
safely. (See Section 4)
59-770-2937 August 2007
Operator’s Daily Checklist
Check each Item Before Start of Each Shift Date:
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. Your safety is at risk.
After checking, mark each item accordingly. Explain below as necessary.
Check boxes as follows: √OK X NG; needs attention or repair. Circle problem and explain below.
OK NG Visual Checks OK NG Visual Checks
Tires/Wheels: wear, damage, nuts tight Engine: runs rough, noisy, leaks
Head/Tail/Work Lights: damage, mounting, operation Steering: loose/binding, leaks, operation
Gauges/Instruments: damage, operation Service Brake: linkage loose/binding, stops OK, grab
Operator Restraint: damage, mounting, operation, oily, dirty Parking Brake: loose/binding, operational, adjustment
Warning Decals/Operator’s Manual: missing, not readable Seat Brake (if equipped): loose/binding, operational,
adjustment
Data Plate: not readable, missing Horn: Operation
Overhead Guard: bent, cracked, loose, missing Backup Alarm (if equipped): mounting, operation
Load Back Rest: bent, cracked, loose, missing Warning Lights (if equipped): mounting, operation
Forks: bent, worn, stops OK Lift/Lower: loose/binding, excessive drift, leaks
Engine Oil: level, dirty, leaks Tilt: loose/binding, excessive drift, "chatters," leaks
Hydraulic Oil: level, dirty, leaks Attachments: mounting, damaged, operation, leaks
Radiator: level, dirty, leaks Battery Test (electric trucks only): indicator in green
while holding full forward tilt
Fuel: level, leaks Control Levers: loose/binding, freely return to neutral
Battery: connections loose, charge, electrolyte low Directional Control: loose/binding, find neutral OK
Covers/Sheet metal: damaged, missing
Brakes: linkage, reservoir fluid level, leaks debris on floor
Explanation of problems marked above:

1.3
XXX
OM0001
OM0002
OM0003
OM0004
OM0005
Don't mix drugs or alcohol with your job.
Do watch for pedestrians.
Don't block safety or emergency
equipment.
Do wear safety equipment when
required.
Don't smoke in "NO SMOKING" areas
or when refueling.
Do's and Don'ts
General Safety Rules

1.4
Pedestrians
IMPORTANT
• Watch where you are going.
• Look in the direction of travel.
• Pedestrians may use the same roadway you do.
• Sound your horn at all intersections or blind spots.
• Watch for people in your work area even if your truck has
warning lights or alarms. People may not watch for you.
• Make people stand back, even when you are parked.
No Riders
WARNING
Always walk the truck. Never attempt to ride or allow passengers.
General Safety Rules

1.5
2791862
WARNING
Keep hands, feet and legs out of the lifting mechanism
Pinch Points
General Safety Rules
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.
• Travel with the load near the oor/ground whenever possible.
• Ramps should be traveled with operator uphill of truck when empty,
or operator downhill of truck with load on forks standing o󰀨 to side
of truck.
• Unstable loads are a hazard to you and to your fellow workers.
• Always make certain that the load is well stacked and evenly po-
sitioned across both forks.
• Never attempt to lift a load with only one fork.

1.6
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. DO NOT OVERLOAD.
General Safety Rules

1.7
• 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 oor.
• Place control handle in full turn
and raise handle to "UP" position
to apply brake.
• Remove the key from the key hole
to power truck o󰀨.
• Block drive wheel to prevent ac-
cidental roll.
• Turn key in to proper authority.
Parking
OFF
General Safety Rules

2.1
This Section shows some of the hazards that may cause you, or some-
one around you, to be killed or badly hurt. As the operator, you must
look for other hazards. Get your supervisor to help you identify and
avoid those hazards.
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
Operating Hazards
Contents