Overview
The Clark GEX20, GEX25, GEX30S, GEX30, GEX32 forklift service repair manual provides a technical reference for maintenance, troubleshooting, inspection and component servicing of the covered equipment. The documented contents address safety and planned maintenance, inspection and technical specifications, batteries and charging, electrical wiring and instrumentation, and electric motors and drive controls, with the individual sections and repair subjects organised in the table below.
The source outline also identifies transmission and drive axle, brake and inching systems, lifting mechanisms and cylinders, and steering and axle components. Specific indexed topics include Battery, Battery Service, and Wiring, Switches, and Instruments. Use the applicable equipment identification and original chapter references when selecting inspection or repair procedures.
Table of Contents
Clark GEX20, GEX25, GEX30S, GEX30, GEX32 Manual
- 01. Safe Maintenance (Group SA)
- Safety
- Lifting, Jacking, and Blocking
- Towing
- 02. Periodic Service (Group PS)
- Maintenance Schedule
- Planned Maintenance
- The PM Inspection Form
- 03. Battery (Group 12)
- 04. Wiring, Switches, and Instruments (Group 13)
- Schematic Electric Circuit Diagrams
- General Electrical Service Tips
- Wiring and Cables
- Switches and Sensors
- Instrument Panel
- 05. Electric Motors (Group 16)
- Motor Specifications And Descriptions
- Drive Motors Overhaul
- Pump Motor Overhaul
- 06. Electrical Contactors (Group 17)
- Contactors Specifications and Overhaul
- 07. Motor Controls (Group 19)
- Description
- Control Programming
- Control troubleshooting
- GEX Factory Control Settings
- 08. Drive Axle (Group 20)
- 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
- 09. Wheels and Tires (Group 22)
- Wheels & Tires Specifications and Description
- Pneumatic Wheels and Tires
- 10. Brake System (Group 23)
- Brake System Specifications and Descriptions
- Service Brake Troubleshooting
- Brake Pedal Linkage & Adjustments
- Brake Bleeding
- Pedal and Master Cylinder Service
- Parking Brake Service
- 11. Steering Column and Gear (Group 25)
- Steering System Specifications and Description
- Steering System Troubleshooting
- Steering Column Removal and Installation
- Steering System Relief Pressure Check and Adjustment
- Steering Gear Overhaul
- 12. Steering Axle (Group 26)
- 1.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
- Pivot-Turn Steering Axle Maintenance
- 13. Hydraulic Sump, Filters, and Pump (Group 29)
- Main Hydraulic Sump, Filters, and Pump Specifications and Description
- Main Hydraulic Pump Troubleshooting
- Main Hydraulic Removal and Installation
- 14. Hydraulic Control Valve/Lift Circuit (Group 30)
- 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
- 15. Tilt Cylinders (Group 32)
- Tilt Cylinder Specifications and Description
- Tilt Cylinder Checks and Adjustments
- Tilt Cylinder Removal and Replacement
- Tilt Cylinder Overhaul
- 16. Uprights (Group 34)
- 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
- 17. Counterweight and Chassis (Group 38)
- Counterweight Specifications and Description
- Counterweight Removal and Installation
- Overhead Guard Removal and Installation
- Floor Plate, Seat, and Seat Deck Removal and Installation
- 18. Specifications (Group 40)
- Nameplate and Decals
- General Specifications
- Hydraulic Fitting Tightening Procedure
Tilt Cylinder and Valve — Controller Programming
Tilt-cylinder or tilt-valve service appears in the contents. The index contains controller programming or factory-setting information.
Match the control-related checks to the installed lifting equipment rather than assuming a mechanical lifting fault.
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