Operator's Manual Do not remove this manual from the tuck GTIDT 25/30/32/50 CLARK Book No. 2773106 OM 553Record the following information pertaining to your truck. Mode! No. _ Serial No. —% ‘Customer Truck Identification No. ‘Truck Weight, Empty. = ‘Truck Rated Capacity = i 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. ‘The following warnings are provided pursuant to California Health & Safety Code Sections 252495 et. seq: WARNING California Proposition 65 This product cont ‘and other reproductive harm. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some ‘of Its constituents are known {othe State of California to cause ‘cancer, birth defects or other reproductive harm. 4A WARNING ‘The engine exhaust from this product contains chemicals known to the to cause cancer, bith ther reproductive harm. 1995 Clark Material Handling Company) 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, you do not Next: Read your Operator's Manual, understand it ask your supervisor for help. F2 SY Learn about the unit you operate 7 \ ) TY KNOW your TRUCK ‘Then: Practice operating your truck safely ‘And: Keep your truck in safe ‘operating condition with correct and timely maintenance Breaking these rules will cause serious or fatal injury to yourself and othersA Message To CLARK Tow Tractor Operators ( Tow tractors are specialized machines with unique operating characteristics designed to perform spectic jobs. Their function and operation is not lke a ‘car or ordinary truck. They require specific instructions and rules for safe ‘operation and maintenance. Safe operation of tow tractors is of primary importaneo to CLARK. Our experi- fence with tow tractor accidents has shown that wher accidents happen and people are killed o injured, the causes are: + OPERATOR NOT PROPERLY TRAINED + OPERATOR NOT EXPERIENCED WITH TOW TRACTOR OPERATION + BASIC SAFETY RULES NOT FOLLOWED + TOW TRACTOR NOT MAINTAINED IN SAFE OPERATING CONDITION For these reasons, CLARK wants you to know about the safe operation and ‘correct maintenance of your tow tractor. ‘This manual is designed to help you operate your tow tractor safely. This manual shows and tells you about safety inspoctions and the important {general safaty rules and hazards of tow tractor operation. it describes the ‘special components and features of the truck and their function, The correct ‘operating procedures are shown and explained. Illustrations and important ssalety messages are Included for clear understanding. And, a section on ‘maintenance and lubrication is included for the tow tractor mechanic. ‘The operator's manual isnot a training manual. tt isa guide to help trained ‘and authorized operators safely operate their tow tractor by emphasizing and illustrating the correct procedures. But, it cannot cover every possible situation which may result in an accident. You must watch for hazards in your work ar- ‘eas and avoid of correct them. iis important that yo know and understand the information in this manual as well as to know and follow your company safety rules! Be sure that your equipment is maintained in a safe condition. Do not operate a damaged truck. And practice safe operation every time you use your tow tractor. Let's join together to set new standards in safety. Remember, belore you start operating this tow tract, be sure that you under- stand all étiving procedures. It is your responsibilty, and it is important to you ‘and your family, to operate your tow tractor safely ard efficiently. And bo ‘aware that the Federal Occupational Safety and Health Act (OSHA) and state Jaws require that operators be completely trained in the safe operation of tow tractors, if you think you need training, ask your supervisor CLARK tow tractors are built to take hard work, but rot 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. Do not make any repairs 10 this truck unless you have been trained in safe tow tractor repair procedures ‘and are authorized by your employer. 0CONTENTS This manual covers the folowing mocels GT 25;40;2/80 & DT 250332150 ‘A MESSAGE TO CLARK TOW TRACTOR OPERATORS. INTRODUCTION. ‘About This Manual - How To Use This Manual. Safety Signs and Messages. GENERAL SAFETY RULES AND PRACTICES. KNOW YOUR TRUCK... OPERATOR CARE AND MAINTENANCE. . . STARTING AND OPERATING PROCEDURES. EMERGENCY STARTING AND MOVING. ‘SPECIFICATIONS. INDEX. eNoasans PLANNED MAINTENANCE AND LUBRICATION. ... vil vill 14 24 34 4d 5A 61 7d. 81Introduction Clark weleomes you to the growing group of professional people who ow. ‘operate and maintain Clark tow tractors. We take pride in the long tradition of quality products and superior value that the Clark name represents, This manual wil familiarize you with safety, operating, and ‘maintenance information about your new tow tractor. I has been espe- cially prepared to help you use and maintain your Clark tow tractor in a sate and correct manner. ‘Your Ciark tow tractor has been designed and built o be as safe and efficient as today's technology can make it. As manutactured, it meets all the applicable mandatory requirements of ANSI B5E.9 1987 Safety ‘Standard for Powered Industrial Trucks. In addition, all trucks that conform to Underwriters Laboratories requirements have the Type Desig- nation shown on the truck capacity plate. Each truck is also furnished with ‘equipment to help you operate safely e.g. parking brake, horn, lights, as standard equipment ‘Safe, productive operation of a tow tractor requires both skill and know- ‘edge on tho part of the operator. The operator must know, understand ‘and practice the safaty rules and safe driving and load handling tech riques described in this manual. To develop the skil required, the ‘operator must become familiar with the construction and features of the tow tractor and how they function. The operator must understand its capa- bilities and limitations, and see that itis kept in a safe condition. Routine Servicing and Maintenance Regular maintenance and care of your tow tractor isnot only important for ‘economy and utilization reasons; itis essential for your safety. A faulty tow tractor is a potential source of danger to the operator, and to other per- sonnel working near it. As with all quality equipment, keop your tow tractor in good operating condition by following the recommended schedule of ‘maintenancs User Dally Inspection — Safaty and Operating Checks A tow tractor should always be examined by the user before driving to be ‘sure its safe to operate. The importance of this procedure is emphasized in this manual with a brie ilustrated review and late’ with more detailed in- structions. Clark dealers can supply copies of a helpful “Drivers Daily Checklist”Introduction Planned Maintenance In addition to the daily user 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 ofthe safety and operating condition of your tow tractor. Necessary adjustments and repairs can be done during the PM, which will increase the ite of components and reduce. Unscheduled downtime, The PM can be scheduled to meet your particular ‘application and tow tractor usage ‘The procedures for a periodic planned maintenance program which 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 with trained service personnel who know your tow tractor and can keep t operating salely and ‘tficiently. For additional information, see Service Naval SM-553,About This Manual ‘The purpose of this manual isto provide a digest of essential information about the safe operation of your tow tractor and to acquaint you with its features and how they function and are maintained. This manual is organized into 7 major parts for easy reference: Part 1 General Safety Rules... reviews and ilustrates accepted prac tices for sate operation of a tow tractor. Part 2 Know Your Truck... describes the major operating components, systems, controls and other features of your ruck and how they func tion Part 3 Operator Care and Maintenance... presents added details on how to perform the operator's dally safety inspection. Part 4 Operating Procedures... discusses more specific instructions on starting and the safe, efficient operation of your tow tractor. Part § Emergency Starting and Emergency Moving... gives instructions {or the use of battery jumper cables and for moving your truck when necessary. Part 6 Planned Maintenance and Lubrication... describes a PM pro- {gram for your truck Part 7 Specifications... provides reference information and data on features components, and maintenance items for your tow tractor. Index... provides help for locating information about various topics. Safety Signs and Messages Throughout this manval, you wil ind safety signs anc safety messages, 1s well as other notes and informational instructions. These messages are ‘given to remind you of either essential procedures orto prevent you from making an error which could damage the truck and possibly cause per- sonal injury. Please refer to page vill for further defirtion and explanation of these messages. NOTICE — The descriptions and specifications inctided in this manual ‘were in effect at the time of printing. Clark Equipment Company reserves the right to make improvements and changes in spectications or design, without notice and without incurring obligation. Please check with your authorized CLARK dealer for information on possible updates or revi- viry How To Use This Manual ‘The examples, illustrations and explanations in this manval will help you improve your skill and knowledge as a professional tow tractor operator while taking full advantage of the capabiltios and safety features of your new tow tractor. The first 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 tow tractor. Next, youwill find descriptions of the components of your specific tow tractor model and how the instruments, {gauges and controls operate. Then, you will find a discassion of typical starting and operating procedures with more specific instructions for safe and Planned Maintenance and Lubrication Pictorial Index 00 - Engine 01 - Cooling System 02 - Fuel Systerr-induction System-Accelerator 03 - Exhaust System 06 - Transmission & Controls, 11 - Electrical Components 14 - Electrical Wiring 20 - Drive Axle-Ditferential 21- Prop Shaft, U-Joint 22- Wheels & Tires 23 - Brake System-Linkage & Parking Brake 24- Brake System-Master Cyl, Lines & Brk Assist 25 - Steering Gear-Handwheel-Linkage 26 - Steer Axle-Power Steering System 37 - Counterweights 38- Frame 39 - Sheet Metal-Foam-Trim-Cab-Seat 40 - Nameplates & Decals 64y Planned Maintenance and Lubrication Safety And Operational Checks M Interval: 8 = 10hours, or daily 50 - 250 hours, or every month 450 - 500 hours, or every 3 months {900 - 1000 hours, or every 6 months 2000 hours, or every year Pr A 8 c D E DAILY MAINTENANCE CHECKS week Tuck Tor obvious damage and Teaks, heck fuel system for leaks, ot. jack condition of tres and wheels. Remove ‘embedded objects. Check air prossure, eck wheel lug nuts Cheek vel love ck gauges and Instruments, heck hom oparalion an [Check service brake operation. ing brake operation jack directional a Hole ‘accelerator and engine speet 6.5Planned Maintenance and Lubrication Recommended Planned Maintenance And Lubrication Schedule For: GT/DT 25-50 PM interval Notes: A= - 10hours, or dal + Ollchango intervals may be 880. Zo0hour, oravery month detained by laboratory G2850: 2000 RouCorsvey Cmonihs ——“"Artfr change intra may 5 2800-1009 hour, or avery 8 mont iter charge tonal nay, F = 2000 hours, hours, or every year restiction indicator, Nominal Maintenance Interval PERIODIC CHECKS AND PLANNED MAINTENANCE (PM ) col fa bel ce weak ruck vi “Test drive truck = functional ‘Ar clean truck and radiat rack torque on erfical fash rica je8 component (Drain and replace engine oll” rier =) A ‘Drainflush radiator coolant ie fgniion and tia anemission ol iter lean drive axle at ve rack brake condition and waar. ‘Check drive axle mounting and fastener Ubricate steer axle linkage ‘eck/lubricate steer axle wheel bearingsPlanned Maintenance and Lubrication Maintenance Procedures USER SAFE MAINTENANCE PRACTICES ‘The following instructions have been prepared from curreat industry and goverr mont salty Standards applicable to industria truck operations and maintenance, ‘These recommended procedures spectty conditions, methods, and accepted ractices that aid in the safe maintenance of industrial trucks. ‘They are listed ara for the reference and safety of all workers during mantenance operations. Carefuly read and understand these instructions and the spactic maintenance procedures before attempting to do any repair work, When in doubt of any fraintenanca procedure, please contact your local CLARK dealer. 1, Powered industrial trucks can be- 8. Botore working on engine fuel come hazardous if maintenance is. /stam of LP.gas powered trucks, close neglected. Therefore, sutablemain- __P-gas eylincer valve and run engine ‘tenance facilties, trained personnel, untilthera is no more fuel in the system. ‘and procedures shall be provided, ‘and engine stops running. engine will ‘ot run, close LP-tank valve and vent. 2. Maintenance and inspection of al fuel slowiy na safe area. Powered industrial trucks shall be done Inconformance with the manufacturer's 9, Operation of the truck to check per- recommendations. formance must be conducted in an authorized, safe, clear area, 43. A scheduled planned maintenance, iUbrication, and Inspection system shall 10, Before S.arting To Drive Truck: be followed, a) Be in operating positon. ‘4, Only trained and authorized porson- _b).Disengage clutch on manual trans- Nel shall be permitted to maintain, re- missions, or apply brake on trucks with pair, adjust, and inspect industrial owershit transmission and electric {rucks, and in accordance with the man- _frucks. Ulacturer's specications. °¢) Put direcional contol in neutral Start engine or turn on power. 5. Propery ventilate work area, vent 2) Check functioning of directional and ‘exhaust fumes, and keop shop clean ‘Speed controls, steering, brakes, {and floor dry faring doves and ary lad handing atiachmorts, 6. Avoid fire hazards and have fre pro- tection equipment present in the work 11, Before Leaving The Truck: area, Do not use an open flame to heck foriovel clestage ofl slsc- 3) Sop nek Woes eeoan,Constiseapon 8) Putretoal conan eval pore slla orfarmnabeceanhg feoirepunig se" Aig for desnng pats 8) Sine angio or un 8) Tun of eeantel or gmten ere 7. Bator Starting Work On Truk 3} Pubs a he whoo fuck ‘must be fon an incin a) Raise drive wheels fr00of floor or disconnect power source and use 12. Handle L?-gas cylinders with caro blocks or other postive truck-posttioning Damage such as dents, scrapes, or devices. ‘gouges may dangerously weaken the 'b) Disconnect battery betore working tank and make t Unsafe for use. ‘on the electrical system. 6.7Planned Maintenance and Lubrication User Safe Maintenance Practices 19. Brakes, steering mechanisms, control mechanisms, warming davices, lights, governors, guards and safet devices, articulating axle stops an: frame members must be caretuly and regulary inspected and maintained in ‘2 Bafe operating condition. 14, Special trucks or devices de- signed and approved for hazardous area operation must receive special at- tention to ensure that maintenance pre: serves the original, approved safe ‘operating features, 15. Fuel systems must be checked for leaks and condtion of pars, Extra special consideration must be given in the case of a leak in the fuel system. ‘Action must be taken to prevent the uso ‘of the truck until the loak has been ‘corrected. 15, Al dauesytoms must be regulary inspected and mairained in ‘onformance with good practic. 17. The truck manufacturer's capaci operation, and mainionance instruct plates, tags, or decals must be main- tained in legible condition. 18. Batteries, motors, controler, mit witches, proiacive devices, electrical onductets, and connections must be inspected and maintained n con- formance with good practice. Special attention must be paid tothe conditon of electrical insulation 419. To avoid injury to personnel or damage to the equipment, consult the manufacturer's procedures in replacing contacts on any battery connection, 20. Industrial trucks must be kept in a ‘clean condition to minimize fie hazards ‘and halp in the detection of loose or de- fective parts. 2.1, Moateations and adios that a capacity and safe truck operation ‘must not be done without the manu- facture’ por wien approval apacity, operation and maintenance instruction plates, tags, or decals must bbe changed accordingly. 22. Care mist be taken to assure that all replacement pars, including tres, aro isarchangoabi wih he orginal pats and of a quaity atleast equal to that pro- ‘vided in the onginal equipment. Parts, including res, are to be installed par the mandlacuras procadures, Avays use ‘genuine CLARK or CLARK-approved Pars. 23, When removing tres, follow industry Saisty practices. Most important, deflate Pneumatic tres completely prior to froval. Flowing assemby of tires on ‘mult-piece rims, use a safety cage or re- Staining device while inflating. 24. Use spacial care when removing heavy components fromthe truck, such as counterweight, etc. Be sure that fiting and handing equipment is ofthe correct capasty and in good condition.