CLARK GEX40 GEX45 GEX50 FORKLIFT TRUCK WORKSHOP SERVICE REPAIR, OPERATOR MANUAL

CLARK GEX40 GEX45 GEX50 FORKLIFT TRUCK WORKSHOP SERVICE REPAIR, OPERATOR MANUAL
LANGUAGE: ENGLISH
FORMAT: PDF
PAGES: 977
FILE SIZE: 118MB

MODEL COVERED:

GEX 40 4000 KG 8000 LBS

GEX 45 4500 KG 9000 LBS

GEX 50 4990 KG 10000 LBS

RATED CAPACITY : 4000~4990KG

PART NO. 8106230

BOOK NO: SM 889, SM 889 (REV 1.6)

ISSUED:

AUGUST, 2012

DECEMBER, 2021
                                                                                               

CONTENTS:

SA SAFE MAINTENANCE

Safety

Lifting, Jacking, and Blocking

Towing

PS PERIODIC SERVICE

Maintenance Schedule

Planned Maintenance

The PM Inspection Form

12 BATTERY

Battery Service

13 WIRING, SWITCHES, AND INSTRUMENTS

Schematic Electric Circuit Diagrams

General Electrical Service Tips

Wiring and Cables

Switches and Sensors

Instrument Panel

16 ELECTRIC MOTORS

Motor Specifications And Descriptions

Drive Motors Overhaul

Pump Motor Overhaul

17 ELECTRICAL CONTACTORS

Contactors Specifications and Overhaul

19 MOTOR CONTROLS

Description

Control Programming

Control troubleshooting

GEX Factory Control Settings

20 DRIVE AXLE

Specification and description of drive axle

Troubleshooting of wheel drive axle

General operation of drive axle

Disassembly and Reassembly of drive axle

Disassembly and Reassembly of axle end

Adjustment

22 WHEELS AND TIRES

Wheels & Tires Specifications and Description

Wheels and Tires

23 BRAKE SYSTEM

Brake System Specifications and Descriptions

Service Brake Troubleshooting

Brake Pedal Linkage & Adjustments

Brake Bleeding

Pedal and Master Cylinder Service

Parking Brake Service

25 STEERING COLUMN AND GEAR

Steering System Specifications and Description

Steering System Troubleshooting

Steering Column Removal and Installation

Steering System Relief Pressure Check and Adjustment

Steering Gear Overhaul

26 STEERING AXLE

Steering Axle Specifications and Description

Steering Wheel Bearing Maintenance and Adjustment

Steering Axle Removal and Installation

Steering Axle Overhaul

Steering Cylinder Removal and Installation

Steering Cylinder Overhaul

29 HYDRAULIC SUMP, FILTERS, AND PUMP

Main Hydraulic Sump, Filters, and Pump Specifications and Description

Main Hydraulic Pump Troubleshooting

Main Hydraulic Removal and Installation

30 HYDRAULIC CONTROL VALVE/LIFT CIRCUIT

Hydraulic Control Valve/Lift Circuit Specifications and Description

Hydraulic Schematic

Hydraulic System Troubleshooting

Hydraulic System Pressure Checks and Adjustments

Hydraulic Control Valve Removal and Replacement

32 TILT CYLINDERS

Tilt Cylinder Specifications and Description

Tilt Cylinder Checks and Adjustments

Tilt Cylinder Removal and Replacement

Tilt Cylinder Overhaul

34 UPRIGHTS

Upright Specifications and Description

Troubleshooting

Upright Inspection

Carriage and Upright Roller Clearance Checks and Shim Adjustments

Cylinder Removal, Shimming, Overhaul, and Replacement

Upright Chain Inspection, Adjustment, and Replacement

Fork and Carriage Removal and Replacement

Upright Removal and Replacement

38 COUNTERWEIGHT AND CHASSIS

Counterweight Specifications and Description

Counterweight Removal and Installation

Overhead Guard Removal and Installation

Floor Plate, Seat, and Seat Deck Removal and Installation

40 SPECIFICATIONS

Nameplate and Decals

General Specifications

Hydraulic Fitting Tightening Procedure