CLARK FORKLIFT GS200 IC Genesis Series TECHNICAL TRAINING MANUAL

GS200

Introduction to the IC Genesis Series

TECHNICAL TRAINING Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Contents About this class

2

About Safety....................................................................................................

2

Genesis Introduction.......................................................................................

3

Section 1. Planned Maintenance...................................................................

4

Section2. Engine...........................................................................................

9

Section3. Cooling System..............................................................................

14

Section4. Fuel................... ........................ ........ .............................................

17

Section5. Air Induction System............ .................................................. ......

34

Section6. Transaxle................................................................................. ......

36

Section7. Electrical System....................................... ........... .............. ..........

52

Section 8. Brake System................................................................................

59

Section9. Steering System............................................................................

67

Section 10. Hydraulic System.........................................................................

73

Section 11. Uprights.......................................................................................

90

Section 12. Counterweight..............................................................................

101

Section 13. Overhead Guard..........................................................................

102

Section 14. Specifications...............................................................................

103

©Copyright CLARK Material Handling Company 1995.

Revised 1999

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Genesi Service 1

About this class

Welcome to GS-200 Introduction to the Clark Genesis series trucks.

This class consists of fourteen sections, which will provide vital information for the Testing and Troubleshooting of the Genesis.

The purpose of this class is to provide necessary background information about the Genesis series trucks, and then to take you through testing and troubleshooting the various systems on these trucks.

This training manual does not replace the service manual. Please refer to SM 598 when servicing the Genesis model truck.

About safety

The following messages may be used to emphasize important information:

Note This message is used when special information, instructions or identification is required relating to procedures, equipment, tools, pressures, capacities and other special data.

Important 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.

CAUTION This message is used as a reminder of safety practices which can result in personal injury if proper precautions are not taken.

WARNING This message is used when a hazard exists which can result in injw-y or death if proper precautions are not taken.

DANGER

This message is used when an extreme hazard exists which will result in death or serious injury if proper precautions are not taken.

Important Before working on truck: Raise the drive wheels off the floor and block up truck. Disconnect the batte1-y before working on the electrical system.

Genesi Service 2

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In 1924 CLARK built the world's first lift truck.

Eugene B. Clark had it right when he said do something new, but to be a real upsetter, do something old and easy - but do it better". Mr. Clark understood that to make design leadership something better is worthy of great effort. An effort that will benefit both users and the producer of the product.

He succeeded better than he knew.

First fork lift truck.

As an early producer of commercial axles, CLARK began manufacturing motorized material handling trucks and towing tractors to improve handling of heavy materials.

In1917 came the Tructractor, a three-wheeled load hauler. Later a platform lift was equipped with a stacking mechanism. In1924 , CLARK built the world's first industrial lift truck.

Seventy years later CLARK introduces another upsetter - The Genesis Series.

70 Years of Design Leadership 1921 - First hydraulic lift mechanism on platform truck 1924 - First stacking lift truck 1938 - First counterbalanced sit down rider lift truck 1942 - First electric truck capable of full shift operation 1955 - Powershift transmissions on 2,000 to 8,000 capacity trucks 1956 - Nested I-beam, canted roller uprights, a dramatic improvement for strength, low maintenance and load stability 1967 - America's first highly maneuverable three-wheel electric rider truck, the renowned TW Series. First to offer overhead guard as standard 1972 - Dual voltage electric trucks for varied performance demands.

1973 - Dual wheel braking on narrow aisle reach trucks 1983 - First operator restraint system for sit-down rider trucks 1988 - Efficient transistor control on electric trucks 1991 -First natural gas OEM fuel option Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Genesi Service 3

Section 1. Planned Maintenance Maintenance Schedules "Periodic Service" and "Planned Maintenance"

The term "periodic service" includes all maintenance tasks that should be performed on a regularly scheduled basis.

The term "Planned Maintenance" indicates a formalized program of basic inspec­ tions, adjustments, and lubrications that the Clark service organization provides cus­ tomers at a prescribed interval, usually 50-250 hours. The recommended basic "Planned Maintenance" procedure is given in Section 2 of SM 598.

The current Section, "Maintenance Schedules," specifies all maintenance tasks-including Planned Maintenance tasks-that should be performed periodically, and suggests intervals at which they should be performed.

Determining Maintenance Intervals

Time intervals on the charts on the next four pages and elsewhere in this manual relate to truck operating hours as recorded on the hourmeter, and are based on experi­ ences Clark has found to be convenient and suitable under normal operation.

Standard operating condition classifications are: Normal Operation:

Eight-hour material handling, mostly in buildings or in clean, open air on clean, paved surfaces.

Severe Operation:

Prolonged operating hours or constant usage.

Extreme Operation:

In sandy or dusty locations, such as cement plants, lumber mills, and coal dust or stone crushing sites.

High-temperature locations, such as steel mills and found ries.

Sudden temperature changes, such as constant trips from buildings into the open air, or in refrigeration plants.

IMPORTANT MAINTENANCE INTERVALS. If the lift truck is used in severe or extreme operating conditions, the maintenance intervals should be shortened accord­ ingly. Since the operating environments of lift trucks vary widely, the above descrip­ tions are highly generalized and should be applied as actual conditions dictate.

Genesi Service 4

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Service Chart Lubrication Points Eve 8 - 10 hours or d ·

I

I

/

______ ;v�ry �o_--�-hpl!,� � !!l?l_thJy______ _ ' Every 450 - 500 hours or eve� months_ ,,,.-- _ --....__ \ ( / ,, Every 900 • 1000 hours or every 6 months, '\ , \ Eve 2000 hours or eve ear \ I

Rollers

Fluid

Lit Chains Tit

inder Pins AIIWheel

s

VBelts

Tlr9 Pressure

SlaerAxle

0 0 A-Engine Oil B-Hydraulic Fluid C-Engine Coolant D-MP Grease E-Transaxle Fluid Note

Check I Lubricate Drain / Flush

• Change/ Replace

(i) Check

■

Steer Axle Wheel Bearings

Overal VISUc3l Check Clean/ >Jr Clean

� Monitor lndicaior Lights

� and Service as Required

Gas/LPG l0W-30 API, CC, CD/SG, SF Diesel 15W-40 API, CC, CD/SG, SF CLARK#1802155 50/50 Mixture NLG#2 CLARK#2776236 (See Note Below)

Hydrostatic Transmission shares hydraulic system fluid.

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Genesi Service 5

Recommended Periodic Service Schedule Tilis chart lists maintenance tasks that should be done periodically, the suggested time intcivals, and the service manual Group in which the task is covered. Apply as

TASKS Perfonn Planned Maintenance inspections, lubrications. and adiustments Exhaust smoke from gas engineinsnect (blue-oil· black-fuel) Idle/governed rpm• check/adjust Mounts / brackets - inspect/tighten Oil change - drain/fill "' Oil filler cap & seal - clean/check Oil filter - replace Oil level / condition - check Stall rpm - check on standard transaxle truck: Tuneup-dctcrmineuneededbystal check and/or functional test Valve tappet adjustment - diesel emzine Coolant levd / condition • chcck:/samolc Coolant protection level hvdrometer test Coolant change - drain & flush Coolant hoses - inspect/replace Fan blades • inspect loose/damaged Fan belt(s) - check tension, wear Radiator cap • inspect/test Thermosiat • lest/replace Water pump - check leaks/Wear Carburetor idle/air- check/adjust CO level • check/adjust Diesel injectors/lines • clean/inspect Filler cap/SCICen - clcaD/1.I1Spcct Fuel filter, diesel • replace Fuel filter, gas - replace LPG lock-off valve filter lace ins LPG tank: mounting/guard• inspect LPG tank shut-off valve insnect/test LPG vaporizer/regulator/hoses insnect Throttle linkage - chcck/adjuat

appropriate for diesel, gas, and LPG trucks. Refer to Operator's Manual for Daily Checks.

Every 50.2S0 ftnn

Every4SO500 Henn (or3 m>mm)

lst50 li>urs GroJU1 PS • Plriodu Malnunance

(or6 nnmllli)

EverylON Jinn (orl year)

• Groll, (}() • E•,nne

• • •

• • •

•

•

• (Diesel)

• •

• (Gas/LPG)

• • Grom, 01 - Coot;., Svstem

•

• • •

• •

•

• •

•

•

Graw, 02 - Fiul System

•

•

•

• • •

* Oil change interval may be detennincd by laboratory analysis

Genesi Service 6

Every9IO-

l000!iun

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• •

•

• •

TASKS

�ery 50-250 l:lnrs

lst50 Knrs

Group 06

Air vent - inspect, clean or replace on standard transaxle Axle end lube - clean/repack AJlJe mounting bolts inspect/ti�h ten Charging pump - stall test standard 1ransaxle Clutch pack operation - stall test standard transaxle Pressure checks Fluid change - drain/fill Fluid filtc-r - replace Fluid level/condition - check/sample Inching operation - check/test Oil cooler / lines • inspect Transmission strainer - clean on standard transaxle Diesel cold starting plug - test Distributor cap/rotor - inspect Electronic ignition - test Ignition riming - check/adjust Ignition wiring - inspect Neutral start - check Parking brake interlock - check Spark plugs - regap/replace Starter motor - inspect/test Staner solenoid - inspect/test

Group 14

Wheel mounting bolts - tighten Tire pressure/condition - check

(or3 rmnths)

• •

Every900-

:&ery 2000

(or6 months)

(orl year)

• (Diesel)

• (Gas/LPG)

10001-i>in

Boin

Transaxle

•

•

.

•

• •

• •

.

• • • .

•

lenltiorr and Startin1t S,ste,n

•

•

•

.

.

Gauets

• •

•

• Rtgulator, Batttn

•

•

• •

Indicaton

Alternator

Eltctrical:

•

•

• •

Gro110 13

Alternator - inspect/test Alternator drive belts iosoect/adiust Alternator output - test Battery electrolyte level - check/add Bat1ery condition - cranking voltage test Bauery terminals/cables clean/tiRhten

-

During brake repairs

Grouo 12

Hourmeter - check Lamp check - at stan-up Wiring harness - inspect

Sot Hom

Air Intake & ExhaMSt

Grouo 02

Air filter element • replace Air hoses/clamps - inspect Exhaust pipe/muffler - inspect

:&ery 450-

.•

• •

• Grouo 22

• •

.

Wheels And Tires

•

•

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Genesi Service 7

� Operation - check Service lxake - check wear Brake lines - check Parking brake - check/adjust

lst 50 &1n

&ery

S0-250 Hom

Eveiy450500 H:>..-s

(or3 mruths)

EverylOOO

(or6 months)

(orl yeao

Hom

Grour, 23 - Braui

•

• •

• •

•

Groun 26 • Sker A.d� IUld Line,

Operation - check • Power steering relief pressure - check • Steer axle mounting - inspect • Steer wheel bearings - check Steer wheel bearings lubricatc/adiust • Steering cylinder seals - check leaka2e • Steering linkage - lubricate Grour, 29 - Hydraulic P11.,nn S11-n_ a,ul FilUr Hydraulic fluid JeveVcondition • check/sam.ple Hydraulic fluid change - drain/fill Hydraulic suction screen - clean • Hydraulic fluid filter - replace • Hydraulic tank breather • clcan/recl•cc Grouo 3'J • HydftUlUc Yall'e & Lin/carte Hydraulic system relief pressure test/adiust Group 32 - T1Jt CvliNlen • Tilt cylinder adjustment check/adiust • Tilt cylinder drift - test • Tilt cylinder mounting check/tiehten • Tilt cylinder rod ends check/tie:hten/lubricate • Tilt cylinder rod/seals - check for leaks GroaD 34 - Urwiehl Lift Cvlinden. Ctln'U e. Forb • Operation - check • Carriage and lift chain - lubricate Carriage chain condition insoect/adiust Forb, latches, stop pin inst>ect/cbeck wear • Lift chain condition - inspect/adjust • Load backrest • Upright cylinder/mounting • insoect/tiahten Upright lift cylinder downdrift - test Upright rollen • check • Upright trunnion bolts - tighten

• •

• •

Genesi Service 8

Every 900-

1000 &11'5

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• •

•

•

•

• •