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

Clark G127, GP127, G127E, GP127E Service Manual SM-619 - Image 2

Clark G127, GP127, G127E, GP127E Service Manual SM-619 - Image 3

Clark G127, GP127, G127E, GP127E Service Manual SM-619 - Image 4

Clark G127, GP127, G127E, GP127E Service Manual SM-619 - Image 5

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

$30.00

Type Of Manual: Service Manual
Manual ID: SM-619
Format: PDF
Size: 21.9MB
Number of Pages: 389

Category: Clark Service Manual PDF

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

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