Clark PPX20 Electric Pallet Truck Service Repair Manual

Download Service Repair Manual For Clark PPX20 Electric Pallet Truck.

This Service Repair Manual offers all the service and repair information for Clark PPX20 Electric Pallet Truck. With this in-depth & highly detailed manual you will be able to work on your vehicle with the absolute best resources available, which will not only save you money in repair bills but will also help you to look after your bussiness. The information on this manual covered everything you need to know when you want to repair or service Clark PPX20 Electric Pallet Truck.

Manual No. SM-EU 103 / 02.2017

Models Covered:

Clark PPX20 Electric Pallet Truck 8258

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Manual Contents:

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

Total pages: 67

This manual can be used by anyone from a first time owner/amateur to a professional technician. Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawings. Keep this manual handy and use it often. Performing routine, preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.

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File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English