Clark G127, GP127, G127E, GP127E Forklift Service Repair Workshop Manual

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM-619 G127,GP127 Gl27E, GPl27E Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Service Manual SM 619 Jan 1998 G127 GP127 Gl27E GP127E Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Arrangement and Use of This Manual Clark arranges parts and service procedures by standardized Groups. In this manual, Groups are similar to “chapters.” Groups are listed on the “Contents” page. Each Group begins with a table of contents that shows the Sections contained within the Group. Lengthy Sections also begin with a table of contents. Each Group and Section has an identifying name and number, or “ID.” Each page also has a unique ID. The page ID consists of three numbers separated by hy- phens. The three numbers represent the Group number, the Section number, and the page number. For Example, “00-1-2” on the lower corner of the page indicates Group 00, Section 1, Page 2. The Group number sometimes has a letter or letters added to it in parentheses if one or more variations of the Group exist. For example, if the truck has a standard transaxle, Group 06 is expressed as “06(S);” if the truck has a hy- drostatic transmission, Group 06 is expressed as “06(H).” You can quickly locate a specific point in the manual by using the headers and footers that appear on every Section page. The following illustration points out these areas.. IL -, Group ID Page IDA Section ID I V h Page ID Manual ID Section ID IMPORTANT This manual is intended for the use of trained service personnel. Please read Group SA, “Safe Maintenance” and the Operator’s Manual before working on or operating the truck. Copyright Clark Material Handling 1998 SM 619, Jan ‘98 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ClRRU Foreword Foreword This service publication provides information covering normal service, maintenance and repair of the Clark industrial lift trucks noted on the cover. It has been specifically prepared to help owners and service personnel maintain these trucks in efficient and safe operating condition. This manual is intended for use by persons who are trained and authorized to do lift truck maintenance. It is designed to provide essential information about the correct and safe service maintenance and repair of the truck by trained mechanics or sewice technicians. General and detailed service and repair procedures are outlined (as required) for each component or subsystem. Some procedures include explanations that are common to several components or sub- systems. Not every configuration can be pictured. Only “base” module and original designs are shown. Procedures have been made easier to use by provid- ing specific steps only when necessary and general instructions required to explain the activity, component, assembly, or process being worked on. The technician is expected to include obvious additional steps of standard procedure for removal, disassem- bly, cleaning, inspection, reassembly, installation, etc., as needed. To be better prepared to do the necessary service work, take time to completely read the entire procedure, including any special instructions, before starting any work. Before beginning to work, the technician is cau- tioned and expected to: l Do all necessary service work. l Take time to read entire procedures, including any special instructions. l Contact Clark dealer or, Clark with any questions or procedures not addressed in this manual. NOTICE The descriptions and specifications included in this manual were in effect at the time of printing. Clark reserves the right to discontinue models at any time, or make improvements and changes in specifications or design without notice and without incurring obligation. Specifications, torques, pressures, measurements, adjustments, illustrations and other items may change at any time. Contact your authorized CLARK dealer for information on possible updates or revisions. SM 619, Jan ‘98 Foreword l i Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute CUIRK CONTENTS SERVICE MANUAL SM619 GCSl2-15-17s GCXl2-15E GPSl2-15-17 GPXl5-17E CONTENTS GROUP PAGE FOREWORD HOW TO USE THIS MANUAL SAFETY SIGNS AND SAFETY MESSAGES USER SAFE MAINTENANCE PRACTICES PICTORIAL INDEX PLANNED MAINTENANCE INTERVALS SAFETY AND OPERATIONAL CHECKS RECOMMENDED PLANNED MAINTENANCE AND LUBRICATION SCHEDULE PM 00 00 00 01 01 02 02 06 11 12 12 22 22 23 25 26 29 30 32 34 38 38 40 40 40 Planned Maintenance Program 4G32 Engine - 1.6 Liter 4652 Engine - 2.0 Liter 4663 Engine - 2.0 Liter Cooling System - Troubleshooting Cooling System Fuel System - Gas Fuel System - LPG Transaxle (Transmission) Electrical - Distributor Electrical - Alternator Electrical - Starter Wheels and Tires - Cushion Wheels and Tires - Pneumatic Hydraulic Brakes & Inching Steering Gear Power Steering System - Steer Axle Hydraulic System, Main Pump Main Hydraulic Valve Tilt Cylinder Upright Counterweight Machine Jacking & Blocking Truck Data Plate and Decals Specifications Hydraulic and Electrical Diagrams ii ii III iv vi vi vii ... VIII PM-l 00-l -1 00-2-l 00-3-l 01-1-l 01-2-l 02-l -1 02-2-l 06-l -1 11-1-l 12-1-1 12-2-l 22-l -1 22-2-l 23-l -1 25-1-l 26-l -1 29-l -1 30-l -1 32-l -1 34-l -1 38-l -1 38-2-l 40-l -1 40-2-l 40-3-l Index - Provides help for locating information about various topics. SM 619, Jan ‘98 Contents-l Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ClflRK Group SA GROUP SA SAFE MAINTENANCE Safety .................................................................... Section 1 Lifting, Jacking, and Blocking ............................ Section 2 Towing ................................................................... Section 3 SM 619, Jan ‘98 Safe Maintenance Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Group SA, Safe Maintenance Section 1 Safety Safety Signs and Messages .......................................................................... 2 Safe Maintenance Practices .......................................................................... 2 General Shop Precautions ....................................................................... 4 NOTE This section includes information for both Internal Combustion and Electric Powered Forklift Trucks SM 619, Jan ‘98 Safety l SA-l-l Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Group SA, Safe Maintenance Safety Signs and Messages Safe Maintenance Practices Safety signs and messages in this manual and on the lift truck provide instructions and identify specific areas where potential hazards exist and special precautions should be taken. Be sure you know and understand the meaning of these instructions, signs, and messages. Damage to the truck and death or serious injury to you or other persons may result if these messages are not followed. NOTE The following instructions have been prepared from current industry and government safety standards ap- plicable to industry truck operation and maintenance. These recommended procedures specify conditions, methods, and accepted practices that aid in the safe maintenance of industrial trucks. They are listed here for the reference and safety of all workers during maintenance operations. Carefully read and understand these instructions and the specific maintenance procedure before attempting to do any repair work. This message is used when special information is required relating to procedures, equipment, tools, pressures, capacities, and other special data. When in doubt of any maintenance orocedure. please Contact vour local Clark dealer. 1. Powered industrialtruckscan become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities, trained personnel, and procedures must be provided. IMPORTANT 2. This message is used when special precautions should be taken to ensure a correct action or to avoid damage to, or malfunction of, the truck or a component. Maintenance and inspection of all powered industrial trucks shall be done in conformance with the manufacturer’s recommendations. 3. A scheduled planned maintenance, lubrication, and inspection program shall be followed. 4. A CAUTION This message is used as a reminder of safety hazards that can result in personal injury if proper precautions are not taken. Only trained and authorized personnel shall be permitted to maintain, repair, adjust, and inspect industrial trucks. Work should be performed in accordance with the manufacturer’s specifications. 5. Properly ventilate work area, vent exhaust fumes, and keep shop clean and floor dry. 6. A WARNING This message is used when a hazard exists that can result in injury or death if proper precautions are not taken. Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to checkfor level or leakage of fuel, electro- lyte, or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. 7. A DANGER This message Is used when an extreme hazard exists that can result in injury or death or serious injury if proper precautions are not taken. Before starting work on truck: a. Wear eye protection and remove all jewelry. b. Raise drive wheels off of floor or disconnect power source. Use blocks or other positive truck positioning devices. c. Disconnect battery before working on the electrical system. The above terms have been adopted by Clark Mate- rial Handling Company. The same terms may be used in different context in service literature supplied di- rectly or indirectly by vendors or truck components. 8. Before working on engine fuel system of gasoline or diesel-powered trucks, be sure the fuel shut-off valve is closed. 9. Operation of the truck to check performance must be conducted in an authorized, safe, clear area. SA-1-2 l Safety SM 619, Jan ‘98 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Group SA, Safe Maintenance 10. 11. 12. 13. 14. 15. 16. 17. 18. Before starting to drive truck: a. Be in operating position in the operator’s compartment b. Put direction control in neutral. c. Turn key switch ON. d. Be sure parking brake is engaged. e. Check functioning of direction and speed controls, steering, brakes, warning devices, and any load handling attachments. Before leaving truck: a. Stop truck. b. Put directional control in neutral. c. Apply the parking brake. d. Turn key switch OFF. e. Put blocks at the wheels if truck is on an incline. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, guards, safety devices, and frame members must be carefully and regularly inspected and maintained in a safe operating condition. Special trucks or devices designed and approved for hazardous area operation must receive special attention to ensure that maintenance pre- serves the original, approved, safe-operating fea- tures. Fuel systems must be checked for leaks and condition of parts. Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected. The truck manufacturer’scapacity, operation, and maintenance instruction plates, tags, or decals must be maintained in legible condition. Batteries, motors, controllers, limit switches, pro- tective devices, electrical conductors, and con- nections must be inspected and maintained in conformance with good practices. Special attention must be paid to the condition of electrical insulation. To avoid injury to personnel or damage to the equipment, consult the manufacturer’s procedures in replacing contacts on any battery con- nection. Industrial trucks must be kept in a clean condition to minimize fire hazards and help in the detection of loose or defective parts. 19. 20. 21. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturer’s prior written approval. Capac- ity, operation and maintenance instruction plates, tags, or decals must be changed accordingly. This is an OSHA requirement. Care must be taken to assure that all replacement parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment. Parts, including tires, are to be installed per the manufacture’s procedures. Always use genuine CLARK or CLARK approved parts. Use special care when removing heavy components from the truck, such as counterweight, seat deck, upright, etc. Be sure that lifting and handling equipment is of the correct capacity and in good condition. Also, this removal may upset stability of the truck. Theframe must always be safely blocked for major component removal. NOTE Become familiar with additional operating and maintenance safety instructions contained in the following publications: ANSI ASME 856.1 -Safety Standard for Low Lift and High Lift Trucks. Published by: American Society of Mechanical Engineers, United Engineering Center, 345 E. 47th Street, New York, NY 10017. NFPA 505 Powered Industrial Trucks. Including Type, Areas of Use, Maintenance and Operation. Available from: National Fire Protection Assoc., Inc., Batterymarch Park, Quincy, MA 02269. General Industrial Standards, OSHA 2206: OSHA Safety and Health Standards (29 CFR 1910), Subpart N-Materials Handling and Storage, Section 1910.178 Powered Industrial Trucks. For sale by: Superinten- dent of Documents, U.S. Government Printing Office, Washington, DC 20402. SM 619, Jan ‘98 Safety l SA-1-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Group SA, Safe Maintenance General Shop Precautions The following list contains general precautions that should be followed when working on a lift truck. . . . . . . . . . . Always wear safety glasses for eye protection. Remove rings, watches, loose jewelry and open clothing before working on a vehicle to avoid serious injury. Do not smoke while working on a vehicle. Put power key switch in the OFF position, unless otherwise required by the procedure. Set the parking brake. Place chocks to the front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement. Use safety stands or blocks whenever a procedure requires you to be under the vehicle. Service electric truck batteries in a well-venti- lated area to avoid the danger of lighting explo- sive gases. Follow the Safety Instructions outlined in Group 12, Battery Handling. Always discharge the capacitors prior to working on or around electrical components. Avoid contact with battery acid. The battery contains corrosive acid which can cause injury. Fol- low the instructions outlined in Group 12 and those instructions received with your battery and charger. Cautions The following is a list of “CAUTIONS” connected with the operation and maintenance of trucks equipped with solid state control panels. 1. 2. 3. 4. A CAUTION WELDING ON TRUCKS Make sure the truck has no grounds. Disconnect truck battery. Protect electrical wiring and components from weld spatter with a shield. Ventilate battery or remove battery from truck. if the above is not followed, damage can result to wiring and eiectri- cai components on a solid state control truck. A CAUTION DO NOT STEAM-CLEAN Do not steam-clean a solid state controlled truck. Excessive moisture will interfere with proper operation of the solid state components. Solid state controls should be cleaned at regular intervals. Blowing dirt off with an air (207 kPa [30 psi] max.) hose periodically will, for the most part, elimi- nate any serious cleaning problems. For a more thor- ough cleaning, water may be hosed over the control. A mild detergent may be applied, such as that used for washing dishes. The detergent should be rinsed off, and the controls must be thoroughly air-dried before putting truck into service. Periodic cleaning should preclude the need for using a degreaser. However, if a degreaser is used, we recommend Clark #1801146 Degreaser, or the equiva- lent to MS-180 Freon TF Degreaser and Cleaner. Only approved solvents should be used to clean solid state control components. A CAUTION CHECK POLARITY Battery polarity must be correct or the truck will not operate. A CAUTION USE TRUCK BATTERY ONLY Do not use a motor generator unit such as “ready power” or a battery charger to move and/or check this truck as serious damage may occur. IMPORTANT SAFETY NOTICE Read and understand ail Safety Precautions and Warnings before performing repairs on lift trucks. Appropriate service methods and proper repair procedures are essential to the safe, reliable operation of industrial trucks, as well as the personal safety of the individual doing the work. This Service Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Follow- ing them will help assure successful repair and reliable truck operation. SA-1-4 9 Safety SM 619, Jan ‘98 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

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Clark G127, GP127, G127E, GP127E Forklift Service Repair Workshop Manual

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