Clark G127, GP127, G127E, GP127E Service Manual SM-619

Description

• Model List:
  • G127
  • GP127
  • G127E
  • GP127E

• 1. Arrangement and Use of This Manual
• 2. Foreword
• 3. CONTENTS
• 4. SA SAFE MAINTENANCE
• 4.1. Section 1 Safety
• 4.1.1. Safety Signs and Messages
• 4.1.2. Safe Maintenance Practices
• 4.2. Section 2 Lifting, Jacking, and Blocking
• 4.2.1. Raising Drive Wheels
• 4.2.2. Chaining the Upright in Raised Position
• 4.2.3. Raising Rear of Truck
• 4.2.4. Raising Entire Truck
• 4.2.5. Shipping TieDown Instructions
• 4.3. Section 3 Towing
• 5. PS PERIODIC SERVICE
• 5.1. Section 1 Maintenance Schedules
• 5.1.1. Maintenance Schedules
• 5.1.2. Lubrication Chart Key
• 5.1.3. Miscellaneous Lubricants
• 5.2. Section 2 Planned Maintenance
• 5.2.1. PM Report Form
• 5.2.2. Visual Inspection
• 5.2.3. Wheels and Tires
• 5.2.4. Pneumatic tires
• 5.2.5. Functional Tests
• 5.2.6. Steering system
• 5.2.7. Lift mechanism and controls
• 5.2.8. Auxiliary function control
• 5.2.9. Test Drive The Truck
• 5.2.10. Inspect Engine Accessories
• 5.2.11. Air Cleaning
• 5.2.12. Critical Fastener Torque Checks
• 5.2.13. LUBRICATION, FLUIDS AND FILTERS
• 5.2.14. PLANNED MAINTENANCE INTERVALS
• 5.3. Section 3. The PM Inspection Form
• 5.3.1. GAS LPG or DIESEL PLANNED MAINTENANCE REPORT
• 6. ENGINES
• 6.1. ENGINE 0011
• 6.1.1. GENERAL DESCRIPTION
• 6.1.2. ENGINE TUNEUP
• 6.2. ENGINE 0021
• 6.2.1. CONTENTS
• 6.2.2. GENERAL DESCRIPTION
• 6.2.3. ENGINE TUNEUP
• 6.3. ENGINE 0031
• 6.3.1. Engine Specifications (4G63 Gas LPG Engine)
• 6.3.2. Engine Troubleshooting (4G63 Gas LPG Engine)
• 6.3.3. Engine Oil (4G63 Gas LPG Engine)
• 6.3.4. Engine TuneUp (4G63 Gas LPG Engine)
• 6.3.5. RPM, Vacuum, and Stall Tests (4G63 Gas LPG Engine)
• 6.3.6. Compression Checks (4G63 Gas LPG Engine)
• 6.3.7. ENGINE REMOVAL
• 6.3.8. Engine Overhaul (4G63 Gas LPG)
• 7. COOLING SYSTEM
• 7.1. SECTION 1 COOLING SYSTEM TROUBLESHOOTING
• 7.2. SECTION 2 COOLING SYSTEM
• 8. FUEL SYSTEMS
• 8.1. SECTION 01 FUEL SYSTEMGASOLINE
• 8.1.1. CARBURETOR
• 8.1.2. ENGINE IDLE SPEED ADJUSTMENT
• 8.1.3. GOVERNOR
• 8.1.4. GOVERNOR ADJUSTMENT PROCEDURE
• 8.1.5. CARBURETOR OVERHAUL
• 8.2. SECTION 02 FUEL SYSTEMLPG
• 8.2.1. GENERAL DESCRIPTION LPG FUEL SYSTEM
• 8.2.2. MAINTENANCE
• 8.2.3. CARBURETOR OVERHAUL
• 8.2.4. VAPOR REGULATOR OVERHAUL
• 8.2.5. LPG Air Intake System
• 9. TRANSAXLE
• 9.1. GENERAL DESCRIPTION
• 9.2. TRANSMISSION TROUBLESHOOTING
• 9.3. TRANSMISSION PRESSURE CHECKS
• 9.4. TRANSAXLE REMOVAL
• 9.5. TRANSAXLE OVERHAUL
• 9.5.1. TRANSAXLE DISASSEMBLY
• 9.5.2. CLUTCH DISASSEMBLY
• 9.5.3. CLUTCH ASSEMBLY
• 9.5.4. DIFFERENTIAL DISASSEMBLY
• 9.5.5. DIFFERENTIAL ASSEMBLY
• 9.5.6. TRANSAXLE ASSEMBLY
• 9.5.7. BRAKE ADJUSTMENT PROCEDURE
• 9.6. TRANSAXLE INSTALLATION
• 10. ELECTRICAL
• 10.1. SECTION 1 DISTRIBUTOR 1.6L ENGINE
• 10.1.1. DISTRIBUTOR OVERVIEW
• 10.1.2. DISTRIBUTOR CHECKING
• 10.1.3. DISTRIBUTOR REMOVAL
• 10.1.4. DISTRIBUTOR INSPECTION
• 10.1.5. DISTRIBUTOR ASSEMBLY
• 10.2. SECTION 2 DISTRIBUTOR 2.0 ENGINE
• 10.2.1. DISTRIBUTOR OVERVIEW
• 10.2.2. DISTRIBUTOR TESTS
• 10.2.3. DISTRIBUTOR REMOVAL
• 10.2.4. DISTRIBUTOR INSPECTION
• 10.2.5. DISTRIBUTOR MAINTENANCE
• 10.2.6. DISTRIBUTOR INSTALLATION
• 11. ELECTRICAL
• 11.1. SECTION 1 ALTERNATOR
• 11.1.1. ALTERNATOR DESCRIPTION
• 11.1.2. ALTERNATOR INSPECTION
• 11.1.3. ALTERNATOR REMOVAL
• 11.1.4. ALTERNATOR OVERHAUL
• 11.1.5. ALTERNATOR INSTALLATION
• 11.2. SECTION 2 STARTER
• 11.2.1. STARTER OVERVIEW
• 11.2.2. STARTER INSPECTION (BEFORE REMOVAL)
• 11.2.3. STARTER REMOVAL
• 11.2.4. STARTER DISASSEMBLY
• 11.2.5. STARTER INSPECTION (AFTER REMOVAL)
• 11.2.6. STARTER ASSEMBLY
• 11.2.7. STARTER INSTALLATION
• 12. WHEELS AND TIRES
• 12.1. SECTION 1 CUSHION WHEELS AND TIRES
• 12.1.1. DRIVE TIRE SPECIFICATIONS
• 12.1.2. DRIVE TIRE REMOVAL
• 12.1.3. STEER TIRE SPECIFICATIONS
• 12.1.4. STEER TIRE REPLACEMENT
• 12.2. SECTION 2 PNEUMATIC TIRE AND WHEEL MAINTENANCE
• 12.2.1. PNEUMATIC TIRE MAINTENANCE
• 12.2.2. TIRE REMOVAL AND DISASSEMBLY
• 12.2.3. TIRE ASSEMBLY
• 12.2.4. FILLING TIRES WITH AIR
• 12.2.5. FILLING TIRES WITH NITROGEN
• 12.2.6. SPLIT WHEEL ASSEMBLIES
• 12.2.7. DIRECTIONALTREAD TIRES
• 12.2.8. SAFETY PROCEDURES
• 13. HYDRAULIC SERVICE BRAKE INCHING SYSTEM
• 13.1. GENERAL DESCRIPTION
• 13.2. BRAKE BLEEDING PROCEDURE
• 13.3. INCHING BRAKE
• 13.4. INCHING CYLINDER ADJUSTMENT
• 13.5. BRAKE MASTER CYLINDER PEDAL REMOVAL/DISASSEMBLY
• 13.6. BRAKE REASSEMBLY
• 13.7. HYDRAULIC BRAKE FLUID AND BLEEDING GENERAL INFORMATION
• 14. STEERING GEAR
• 14.1. STEERING GEAR SYSTEM
• 14.2. STEERING SYSTEM RELIEF PRESSURE CHECK
• 14.3. STEERING GEAR TROUBLESHOOTING
• 14.4. STEERING GEAR REMOVAL
• 14.5. STEERING GEAR OVERHAUL
• 14.5.1. STEERING GEAR DISSASSEMBLY
• 14.5.2. STEERING GEAR INSPECTION
• 14.5.3. STEERING GEAR ASSEMBLY
• 14.5.4. STEERING GEAR INSTALLATION
• 15. POWER STEERING SYSTEM, STEER AXLE
• 15.1. POWER STEERING SYSTEM
• 15.2. STEERING SYSTEM RELIEF PRESSURE CHECK
• 15.3. STEER AXLE DESCRIPTION
• 15.4. STEER AXLE REMOVAL
• 15.5. STEER AXLE OVERHAUL
• 15.6. STEER AXLE INSTALLATION
• 16. HYDRAULIC SYSTEM
• 16.1. MAIN HYDRAULIC SYSTEM
• 16.2. HYDRAULIC FLUID AND FILTER CHANGE
• 16.2.1. ALTERNATE DRAINAGE METHOD
• 16.2.2. REVISED FILTER SYSTEM
• 16.2.3. HYDRAULIC SUMP FILTER
• 16.3. MAIN HYDRAULIC PUMP
• 16.4. PUMP TROUBLESHOOTING
• 16.5. PUMP REMOVAL
• 16.6. PUMP OVERHAUL
• 16.6.1. PUMP DISASSEMBLY
• 16.6.2. INSPECTION OF PUMP PARTS
• 16.6.3. PUMP REASSEMBLY
• 16.6.4. PUMP TEST PROCEDURE
• 16.6.5. PUMP INSTALLATION
• 17. MAIN HYDRAULIC VALVE
• 17.1. GENERAL DESCRIPTION
• 17.2. MAIN VALVE RELIEF PRESSURE CHECK ADJUSTMENT
• 17.3. MAIN VALVE REMOVAL
• 17.4. MAIN VALVE OVERHAUL
• 17.4.1. VALVE DISASSEMBLY
• 17.4.2. INSPECTION OF COMPONENTS
• 17.4.3. VALVE REASSEMBLY
• 17.5. MAIN VALVE INSTALLATION
• 18. TILT CYLINDER
• 18.1. TILT CYLINDER ADJUSTMENT
• 18.2. TILT CYLINDER REMOVAL
• 18.3. TILT CYLINDER OVERHAUL
• 18.3.1. TILT CYLINDER DISASSEMBLY
• 18.3.2. TILT CYLINDER INSPECTION
• 18.3.3. TILT CYLINDER ASSEMBLY
• 18.3.4. TILT CYLINDER INSTALLATION
• 19. UPRIGHT
• 19.1. UPRIGHT MAINTENANCE
• 19.2. UPRIGHT SHIM INSPECTION, TRIPLE STAGE
• 19.3. CARRIAGE SHIM INSPECTION TRIPLE STAGE
• 19.4. CARRIAGE SHIM INSTALLATION TRIPLE STAGE
• 19.5. UPRIGHT AND CARRIAGE SHIM INSPECTION TRIPLE STAGE
• 19.6. TRIPLE STAGE SHIM DISASSEMBLY
• 19.7. UPRIGHT TRIPLE STAGE REASSEMBLY
• 19.8. TRIPLE STAGE CYLINDER TROUBLESHOOTING
• 19.9. HYDRAULIC CYLINDER REPAIR TRIPLE STAGE
• 19.10. SEAL INSTALLATION TOOL LIFT CYLINDER
• 19.11. T INSTALLATION TOOL UCUP TO PISTONLIFT CYLINDER
• 19.12. T INSTALLATION TOOL UCUP TO PISTONLIFT CYLINDER
• 19.13. UPRIGHT LIFT CHAIN MAINTENANCE
• 19.13.1. Periodic Inspections
• 19.13.2. Chain Length Adjustments
• 20. COUNTERWEIGHT JACKING BLOCKING
• 20.1. SECTION 1 COUNTERWEIGHT
• 20.1.1. COUNTERWEIGHT MAINTENANCE
• 20.1.2. COUNTERWEIGHT REMOVAL
• 20.1.3. COUNTERWEIGHT INSTALLATION
• 20.2. SECTION 2 MACHINE JACKING AND BLOCKING
• 20.2.1. RAISING DRIVE WHEELS
• 20.2.2. BLOCKING THE UPRIGHT IN RAISED POSITION
• 20.2.3. RAISING REAR OF TRUCK
• 20.2.4. RAISING ENTIRE TRUCK
• 20.2.5. RAISING TRUCK WITH A HOIST
• 21. SPECIFICATIONS
• 21.1. SECTION 1 TRUCK DATE PLATES DECALS
• 21.2. SECTION 2 SPECIFICATIONS
• 21.2.1. FILL CAPACITIES
• 21.2.2. FLUID RECOMMENDATIONS
• 21.2.3. TRUCK WEIGHTS
• 21.2.4. COUNTERWEIGHT
• 21.2.5. HYDRAULIC SYSTEM
• 21.2.6. LUBRICANT SPECIFICATIONS
• 21.2.7. CRITICAL FASTENER TORQUE SPECIFICATIONS
• 21.3. SECTION 3 HYDRAULIC AND ELECTRICAL DIAGRAMS
• 22. SM619 INDEX