CLARK GEX 20 25 30 FORKLIFT TRUCK WORKSHOP SERVICE REPAIR MANUAL

CLARK GEX 20 25 30 FORKLIFT TRUCK WORKSHOP SERVICE REPAIR MANUAL
LANGUAGE: ENGLISH
FORMAT: PDF
PAGES: 476
FILE SIZE: 51.2MB

MODEL COVERED:

GEX 20 2000 KG 4000 LBS

GEX 25 2500 KG 5000 LBS

GEX 30 3000 KG 6000 LBS

RATED CAPACITY: 2000 - 3000KG

PART NO. SM-765

ISSUED:

OCTOBER, 2007
                                                                                               

CONTENTS:

SA SAFE MAINTENANCE

1. Safety

2. Lifting, Jacking, and Blocking

3. Towing

PS PERIODIC SERVICE

1. Maintenance Schedule

2. Planned Maintenance

3. The PM Inspection Form

12 BATTERY

1. Battery Service

13 WIRING, SWITCHES, AND INSTRUMENTS

1. Schematic Electric Circuit Diagrams

2. General Electrical Service Tips

3. Wiring and Cables

4. Switches and Sensors

5. Instrument Panel

16 ELECTRIC MOTORS

1. Motor Specifications And Descriptions

2. Drive Motors Overhaul

3. Pump Motor Overhaul

17 ELECTRICAL CONTACTORS

1. Contactors Specifications and Overhaul

19 MOTOR CONTROLS

1. Description

2. Control Programming

3. Control troubleshooting

4. GEX Factory Control Settings

20 DRIVE AXLE

1. Specification and description of drive axle

2. Troubleshooting of wheel drive axle

3. General operation of drive axle

4. Disassembly and Reassembly of drive axle

5. Disassembly and Reassembly of axle end

6. Adjustment

22 WHEELS AND TIRES

1. Wheels & Tires Specifications and Description

2. Pneumatic Wheels and Tires

23 BRAKE SYSTEM

1. Brake System Specifications and Descriptions

2. Service Brake Troubleshooting

3. Brake Pedal Linkage & Adjustments

4. Brake Bleeding

5. Pedal and Master Cylinder Service

6. Parking Brake Service

25 STEERING COLUMN AND GEAR

1. Steering System Specifications and Description

2. Steering System Troubleshooting

3. Steering Column Removal and Installation

4. Steering System Relief Pressure Check and

Adjustment

5. Steering Gear Overhaul

26 STEERING AXLE

1.Steering Axle Specifications and Description

2. Steering Wheel Bearing Maintenance and Adjustment

3. Steering Axle Removal and Installation

4. Steering Axle Overhaul

5. Steering Cylinder Removal and Installation

6. Steering Cylinder Overhaul

7. Pivot-Turn Steering Axle Maintenance

29 HYDRAULIC SUMP, FILTERS, AND PUMP

1. Main Hydraulic Sump, Filters, and Pump Specifications

and Description

2. Main Hydraulic Pump Troubleshooting

3. Main Hydraulic Removal and Installation

30 HYDRAULIC CONTROL VALVE/LIFT CIRCUIT

1. Hydraulic Control Valve/Lift Circuit Specifications

and Description

2. Hydraulic Schematic

3. Hydraulic System Troubleshooting

4. Hydraulic System Pressure Checks and Adjustments

5. Hydraulic Control Valve Removal and Replacement

32 TILT CYLINDERS

1. Tilt Cylinder Specifications and Description

2. Tilt Cylinder Checks and Adjustments

3. Tilt Cylinder Removal and Replacement

4. Tilt Cylinder Overhaul

34 UPRIGHTS

1. Upright Specifications and Description

2. Troubleshooting

3. Upright Inspection

4. Carriage and Upright Roller Clearance Checks

and Shim Adjustments

5. Cylinder Removal, Shimming, Overhaul and

Replacement

6. Upright Chain Inspection, Adjustment, and

Replacement

7. Fork and Carriage Removal and Replacement

8. Upright Removal and Replacement

38 COUNTERWEIGHT AND CHASSIS

1. Counterweight Specifications and Description

2. Counterweight Removal and Installation

3. Overhead Guard Removal and Installation

4. Floor Plate, Seat, and Seat Deck Removal and

Installation

40 SPECIFICATIONS

1. Nameplate and Decals

2. General Specifications

3. Hydraulic Fitting Tightening Procedure