CLARK PPX20 ELECTRIC PALLET TRUCK SERVICE REPAIR MANUAL PDF DOWNLOAD

Total Pages: 67
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Language Type: English
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Discover the comprehensive Clark PPX20 Electric Pallet Truck Service Repair Manual. Increase efficiency and lifespan while reducing maintenance costs through expert guidance and detailed instructions. Ensure top performance for your pallet truck with this essential resource.

Models Covered:
Clark PPX20 Electric Pallet Truck 8258

Manuals Content:
1 DESCRIPTION ……………………………………………..1
1-1. INTRODUCTION ……………………………………..1
1-2. GENERAL DESCRIPTION ………………………..1
1-3. SAFETY FEATURES ……………………………….1
2 OPERATION …………………………………………………3
2-1. GENERAL ………………………………………………3
2-2. OPERATING PRECAUTIONS …………………..3
2-3. BEFORE OPERATION ……………………………..3
2-4. GENERAL CONTROL OPERATION …………..6
2-5. DRIVING AND STOPPING
PROCEDURES ……………………………………….6
2-5.1. Stopping ……………………………………………6
2-6.BELLY-BUTTON SWITCH ………………………….7
2-7.STEERING ARM GAS SPRING ………………….7
2-8. LIFT AND LOWER CONTROLS ………………..7
2-9. LOADING AND UNLOADING ……………………7
2-10.PARKING ………………………………………………7
3 PLANNED MAINTENANCE ……………………………9
3-1. GENERAL ………………………………………………9
3-2. MONTHLY AND QUARTERLY CHECKS …….9
3-3. BATTERY CARE ……………………………………..9
3-3.1. General……………………………………………..9
3-3.2. Safety Rules …………………………………….10
3-3.3. Battery Care and Charging…………………10
3-3.4. Battery Cleaning ……………………………….10
3-4. CHARGING BATTERIES ………………………..11
3-5. LUBRICATION ………………………………………11
4 TROUBLESHOOTING …………………………………13
4-1. GENERAL …………………………………………….13
4-2. CONTROLLER TROUBLESHOOTING ……..16
4-2.1. Zapi Handset ……………………………………16
4-2.2. Fault Detection …………………………………16
4-2.2.1. General……………………………………….16
4-2.2.2. Logbook Access …………………………..16
4-2.3. Testing Truck Operation …………………….16
4-2.4. Settings and Adjustments …………………..17
4-2.4.1. Set Options………………………………….17
4-2.4.2. Adjustments …………………………………21
4-2.4.3. Parameter Change ……………………….23
4-2.5. Troubleshooting………………………………..27
5 OPERATING CONTROL SYSTEM ………………..35
5-1. CONTROL HEAD …………………………………..35
5-1.1. Cap Assembly Removal …………………….35
5-1.2. Cap Assembly Installation ………………….36
5-1.3. Control Head Removal ………………………37
5-1.4. Control Head Installation ……………………37
5-1.5. Potentiometer Replacement ……………….37
5-1.6. Belly-Button Switch Replacement ……….37
5-2. COMPARTMENT COVERS …………………….40
5-2.1. Removal ………………………………………….40
5-3. STEERING ARM ……………………………………40
5-3.1. Return Spring Replacement ……………….40
5-3.2. Steering Arm Removal ………………………40
5-3.3. Steering Arm Installation ……………………40
6 BRAKE SERVICING …………………………………….43
6-1. BRAKES ……………………………………………….43
6-1.1. Brake Assembly Replacement ……………43
7 DRIVING SYSTEM ………………………………………45
7-1. Drive Wheel …………………………………………..45
7-2. Transmission …………………………………………45
7-3. Load Wheel …………………………………………..47
7-3.1. Removal ………………………………………….47
7-3.2. Repair ……………………………………………..47
7-3.3. Load Wheel Installation ……………………..47
8 ELEVATION SYSTEM SERVICING ……………….49
8-1. LIFT LINKAGE ………………………………………49
8-1.1. Removal ………………………………………….49
8-1.2. Installation ……………………………………….49
8-2. POWER SECTION AND FORK SECTION ..49
8-2.1. Separating Power Section and Fork
Section……………………………………………49
8-2.2. Fork Frame Repair ……………………………49
8-2.3. Carrier Frame Repair ………………………..49
8-2.4. Mating Power Section and Fork
Section…………………………………………….49
9 HYDRAULIC SYSTEM …………………………………51
9-1. LINES AND FITTINGS ……………………………51
9-2. HYDRAULIC PUMP, MOTOR, AND
RESERVOIR ASSY ………………………………..51
9-2.1. Removal ………………………………………….51
9-2.2. Disassembly and Reassembly ……………51
9-2.3. Installation ……………………………………….51
9-2.4. Lift Cylinder ……………………………………..55
9-2.4.1. Removal ……………………………………..55
9-2.4.2. Repair …………………………………………55
9-2.4.3. Installation …………………………………..55
9-2.5. Pressurized Cylinder …………………………56
9-2.5.1. Removal ……………………………………..56
9-2.5.2. Repair …………………………………………56
9-2.5.3. Installation …………………………………..56
10 ELECTRICAL COMPONENTS …………………….57
10-1. ELECTRICAL CONTROL PANEL …………..57
10-1.1. Maintenance …………………………………..57
10-1.2. Cleaning ………………………………………..57
10-1.3. Panel Removal ……………………………….57
10-1.4. Panel Disassembly ………………………….57
10-1.5. Panel Installation …………………………….57
10-2. HORN REPLACEMENT ………………………..57
10-3. LIFT LIMIT SWITCH ……………………………..62
10-3.1. Replacement ………………………………….62
10-3.2. Adjustment……………………………………..62
10-4. PUMP MOTOR …………………………………….62
10-5. DRIVE MOTOR ……………………………………62
10-6. DEADMAN SWITCH …………………………….62
11 OPTIONAL EQUIPMENT ……………………………63
12 ILLUSTRATED PARTS BREAKDOWN …………65