Clark GEX40, GEX45, GEX50 Forklift Service Repair Manual

Manual Type: Service Repair Manual, Operators Manual
Clark GEX40, GEX45, GEX50 Forklift Service Repair Manual – 408 Pages
Clark GEX40, GEX45, GEX50 Forklift Operators Manual – 116 Pages

Table of content of the Service Repair Manual

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

This service publication provides information covering normal service, maintenance and repair of the Clark industrial ltrucks noted on the cover. It has been specifically prepared to help owners and service personnel maintain these trucks in efficient and safe operating condition. Regular, correct maintenance and care of industrial trucks is not only important for long and efficient truck life; it is essential for safe operation. The importance of proper maintenance through planned service, inspection and qualified repairs cannot be emphasized too strongly.