🏷️ Basic Information

Make:

Clark

Model:

GEX Series Forklift Trucks

Model Codes:

GEX20, GEX25, GEX30S, GEX30, GEX32

👋 Introduction

Target Audience:

Forklift owners, technicians, maintenance personnel

Value Proposition:

Provides comprehensive repair and maintenance resources to save on service costs and maintain optimal vehicle condition.

Visual Aids:

Includes highly detailed exploded pictures for step-by-step guidance.

Accessibility:

Instant PDF download for immediate access on various devices (PC, Mac, tablet, smartphone).

Cost Savings:

Aimed at saving money on repair bills and maintaining the investment.

📋 Manual Details

Manual Type:

Workshop Service & Repair Manual

Language:

English

Format:

Downloadable PDF

Estimated Pages:

Large and comprehensive, likely several hundred pages given the breadth of topics covered.

📖 Manual Coverage

Safety:

Safe Maintenance procedures, Lifting, Jacking, Blocking, Towing

Electrical System:

Battery Service, Wiring, Switches, Instruments, Electric Motors (Drive & Pump), Electrical Contactors, Motor Controls (Programming, Troubleshooting, Factory Settings)

Drivetrain:

Drive Axle (Specifications, Troubleshooting, Disassembly/Reassembly), Wheels & Tires

Braking System:

Brake System (Specifications, Troubleshooting, Pedal Linkage, Bleeding, Master Cylinder, Parking Brake)

Steering System:

Steering Column and Gear, Steering Axle (Specifications, Wheel Bearing, Removal/Installation, Overhaul, Cylinder Service), Pivot-Turn Steering Axle Maintenance

Hydraulic System:

Hydraulic Sump, Filters, Pump, Hydraulic Control Valve/Lift Circuit, Tilt Cylinders, Uprights (Carriage & Roller Clearance, Cylinder Service, Upright Chain Service), Hydraulic Schematics, Troubleshooting, Pressure Checks

Chassis And Frame:

Counterweight (Specifications, Removal/Installation), Overhead Guard, Floor Plate, Seat, Seat Deck

General Specifications:

Includes 'General Specifications' and 'Nameplate and Decals' for model identification and basic data.

Maintenance:

Maintenance Schedule, Planned Maintenance, PM Inspection Form

Diagnostics:

Troubleshooting for Drive Axle, Brake System, Steering System, Hydraulic Pump, Hydraulic System, Uprights

Repair:

Overhaul procedures for Drive Axle components, Electric Motors, Electrical Contactors, Steering Gear, Steering Cylinders, Tilt Cylinders, Uprights components (cylinders, chains, carriage)

Installation Removal:

Removal and installation procedures for Drive Axle, Steering Column, Steering Axle, Steering Cylinders, Hydraulic Pump, Hydraulic Control Valve, Tilt Cylinders, Uprights, Counterweight, Overhead Guard, Seat Deck components

Adjustments:

Brake Pedal Linkage, Steering System Relief Pressure, Steering Wheel Bearing, Upright Roller Clearance, Upright Chains

Wheel Tire Service:

Covers Wheels & Tires Specifications and Description, including Pneumatic Wheels and Tires service.

Depth:

Comprehensive Workshop Level (covers disassembly, overhaul, repair, troubleshooting, and adjustments for all major systems)

Diagrams Illustrations:

Includes exploded pictures and schematics (hydraulic and electrical).

Schematic Detail:

Detailed Hydraulic Schematics and Electric Circuit Diagrams.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable PDF (standard for professional manuals)

Delivery Method:

Instant Download

Compatibility:

Compatible with Windows PC, Mac, tablet, and smartphone.

Printability:

Printable (user can print entire manual or specific sections)

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Type:

Electric Forklift Truck (Engine specifications not applicable in the traditional sense for internal combustion)

Motor Types:

Separate specifications and overhaul procedures for Drive Motors and Pump Motors.

Power Source:

Battery Power

Drive Motor Overhaul:

Detailed overhaul procedures for Drive Motors.

Pump Motor Overhaul:

Detailed overhaul procedures for Pump Motors.

🔧 Transmission

Type:

Electric Drive System (details covered under Drive Axle and Motor Controls)

Features:

Control programming and factory settings for GEX series are detailed.

Gex Factory Settings:

Specific section on GEX Factory Control Settings.

📐 Dimensions

Model Variations:

Covers multiple truck capacities/sizes (GEX20, GEX25, GEX30S, GEX30, GEX32), implying dimensional differences.

Upright Specifications:

Detailed specifications and inspection procedures for Uprights.

Counterweight:

Detailed procedures for Counterweight Removal and Installation.

🛡️ Safety Features

Safety Standards:

Covers Safe Maintenance practices, Lifting, Jacking, and Blocking procedures.

Braking System:

Detailed service and troubleshooting for Service Brakes and Parking Brakes.

Towing Procedures:

Covers Towing procedures.

💡 Technology Features

Instrument Panel:

Covers Instrument Panel service and schematic diagrams.

Control Systems:

Detailed coverage of Motor Controls, including programming, troubleshooting, and factory settings.

Control Troubleshooting:

Dedicated section for Motor Control troubleshooting.

Electrical Schematics:

Provides Schematic Electric Circuit Diagrams for comprehensive understanding of the electrical system.

🔧 Maintenance

Schedule Coverage:

Includes a detailed Maintenance Schedule and Planned Maintenance procedures.

Hydraulic Fluid:

Covers Hydraulic Sump and Pump specifications. Specific fluid type would be detailed within the manual.

Brake Fluid:

Covers Brake System specifications, including bleeding procedures, implying fluid requirements are specified.

Hydraulic Fitting Tightening:

Includes a specific procedure for Hydraulic Fitting Tightening. Exact torque values would be within this section.

Troubleshooting Coverage:

Extensive troubleshooting sections for Drive Axle, Brake System, Steering System, Hydraulic Systems, and Motor Controls.

Electrical Troubleshooting Tips:

Provides General Electrical Service Tips.

📚 Vehicle History

Manufacturer:

Clark (a long-standing manufacturer in the material handling industry)

Series Designation:

GEX series represents Clark's electric forklift truck offerings.