CLARK FORKLIFT IC103 Electrical Systems IC Lift Trucks TECHNICAL TRAINING MANUAL

IC103

Electrical Systems IC Lift Trucks

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........................................................................................

About safety.............................................................................................

Section 1. The Battery............................................................................

Troubleshooting the Standard Battery.......................................

Specific Gravity Test....................................................................

Three Minute Charge Test...........................................................

Battery Load Test.........................................................................

Jump Starting with Auxiliary Battery........................................

Troubleshooting the Maintenance-Free Battery........................

Section 2. The Charging System.............................................................

Charging Circuit System Components........................................

Delco 10-SI Alternator..................................................................

System Description and Maintenance.........................................

Delco 10-SI Parts Breakdown......................................................

Motorola 9DB Alternator.............................................................

Motorol Parts Breakdown............................................................

Alternator Maintenance Precautions..........................................

Alternator Inspection...................................................................

Alternator Drive (Fan) Belt.........................................................

Fan Belt Tension Specification....................................................

Troubleshooting the Alternator...................................................

A. Abnormal Charge Indicator Lamp Operation........................

B. Abnormal Charging System Operation.................................

Charging System Schematics......................................................

Troubleshooting Guide.................................................................

Section 3. The Ignition System...............................................................

Ignition Circuit Electronic Components......................................

Ignition Circuit Point Components..............................................

Ignition Circuit Seconda1-y System..............................................

The Standard Ignition System....................................................

The Distributor.............................................................................

Contact Points and Condensers...................................................

Distributor Caps...........................................................................

Distributor Rotor..........................................................................

Distributor Lubrication................................................................

The Ignition Coil...........................................................................

The Ignition Resistor ...................................................................

The Ignition Switch......................................................................

The Spark Plugs...........................................................................

The Wiring....................................................................................

Standard Ignition Maintenance................................................

The High Energy Ignition System...............................................

The Distributor.............................................................................

The Ignitor ..................................................................................

Distributor Parts Breakdown.......................................................

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Troubleshooting the Ignition System................................................

Electronic Module Replacement.........................................................

Troubleshooting Guide.......................................................................

Ignition System Schematics...............................................................

Section 4. The Starter System......................................................................

Starting Circuit System Components................................................

The Standard Starter System............................................................

The Cranking Motor and Control Switches.......................................

Troubleshooting the Starting System................................................

Charging and Starting System Check...............................................

Slow Cranking.....................................................................................

Voltage Drop Test...............................................................................

Starter Will Not Crank.......................................................................

Starter Motor Circuit..........................................................................

Starter Relay Circuit..........................................................................

Troubleshooting the Starter Relay Circuit........................................

Starter Motor Inspection.....................................................................

Starter Drive Check..............................................................................

Delco Starter Breakdown....................................................................

Direct Drive Starter Breakdown........................................................

Reduction Starter Breakdown............................................................

Planetary Starter Breakdown............................................................

Section 5. The Accessory System..................................................................

Shut-down Module Troubleshooting...................................................

Instrument Pod Troubleshooting.......................................................

Schematic-GCX/GPX...........................................................................

Schematic-GCX/GPX-E............................................................. ..........

Schematic-CGC/CGP..........................................................................

©Copyright CLARK Material Handling Company 1989.

Revised 1999

IC 103 page 2

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About this class Welcome to Class IC-103:Clark Lift Truck Electrical Systems This class consists of four major sections, with a short fifth section, on Accessories.

•

The Battery

•

The Charging System

•

The Ignition System

•

The Starter System

•

The Accessory System

The purpose of this class is to introduce you to the electrical system and to some basic maintenance and troubleshooting methods for the different elements of the system.

The maintenance procedures will prevent most types of premature electrical failures while the troubleshooting procedures provide a means whereby a particular component can be isolated as the problem when failures do occw·.

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IC 103 page 3

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 injwJ1 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 of proper precautions are not taken.

Always familiarize yourself with the safety information in the operator's and service manuals before you operate or repair a lift truck.

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Section I. The Battery Always consider the battery as a possible trouble source when electrical trouble occurs.

The Standard Battery Since the battery is common to the entire electrical system, and since a visual inspec­ tion and a few quick tests will readily reveal the battery condition, Start all circuit checks with the battery.

Systematic battery service can prevent many electrical troubles caused by battery failures. To prevent premature battery failure, consider the following four points: Correct Application

Use the proper-sized battery for balancing the electrical load. An undersized battery will cause poor performance or early failw·e. A replacement battery should be at least equal to the original.

Proper Activation

It is extremely important to properly activate a replacment battery so as to avoid poor performance or early failure. For a 12-volt battery, give a warm-up charge of 15 am­ peres for ten minutes.

Correct Installation

The case or cover may be broken if a battery is not properly installed. Keep the hold­ down bolts tight enough to prevent the battery from sliding in its holder. Do not, how­ ever, tighten them to the point of severely stressing the battery case.

Install the battery in its carrier with the positive and negative posts in the proper position. Reversing the battery polarity can severely damage the electrical system.

When connecting battery cables, make sure the cables are long enough to prevent excessive stress on the battery posts. Connect the ground terminal last to prevent arcing. Clean cable clamps to insure good, low resistance connections. It is a good idea to coat battery posts and cable clamps with petroleum jelly to prevent corrosion of the battery cable terminals on batteries with lead post terminals.

Make sure the battery carrier is clean and free from corrosion before installing a bat­ tery. Corrosion on the carrier will accelerate the rate of corrosion growth on the bat­ tery. Also, keep the carrier mechanically intact in order to adequately support the battery and keep it level.

Periodic Servicing

Check the electrolyte level in the battery every planned maintenance period or once a month. Check more frequently during hot weather. If the level is low, add water to each cell until the liquid level rises to the split ring in the bottom of the vent well. Do not over-fill, as this will cause loss of electrolyte and consequently poor battery perforCopyrighted Material Intended for CLARK dealers only Do not sell or distribute

IC 103 page 5

mance later, as well as excessive corrosion. During service, add only water to the bat­ tery. Never allow the liquid level in the cells to decrease below the top of the plates as this will cause permanent battery damage.

Check the external condition of the battery periodically for damage such as a broken case or broken cell covers.

Keep the top of the battery clean because acid film and dirt may permit current to fl.ow between the terminals, thus discharging the battery. Clean with a baking soda solution to neutralize any acid and then flush with clean water. Keep vent caps tight so that the neutralizing solution does not enter the cells. After cleaning, make sure vents are open in caps.

Keep the battery cables clean and tight on the battery posts to insure good electrical contact. If the posts or cable terminals are corroded, disconnect the cables and clean the terminals and clamps separately with a soda solution and a wire brush.

After cleaning and assembly, apply a thin coat of petroleum jelly to the posts and cable clamps to help retard co1Tosion.

Troubleshooting the Standard Battery Testing procedw·es determine the ability of a battery to function properly. Use the following tests to determine whether the battery; (1) is good and usable

(2) requires recharging (3) is worn out and should be replaced.

WARNING Wear safety glasses when testing batteries. Batteries produce hydrogen gas. Always blow away gases before testing. Do not break electrical cir­ cuits near the battery top as a spark could cause an explosion.

Visual Inspection Check for obvious damage, such as a cracked or broken case that could permit loss of electrolyte. If obvious physical damage is noted, replace battery.

If no damage is noted and electrolyte level is below the top of the plates in one or more cells, add water to bring the level to the top of separators sufficient to take hydrometer readings but not to split the ring in the cells.

Make sure vent caps are in place when charging to prevent electrolyte from splashing out of the battery. Then charge the battery for 15 minutes at a 15 to 25 ampere rate to mix the electrolyte and water.

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If there is not obvious physical damage, check electrolyte level. If level is above the top of the plates in all cells, take a hydrometer reading of each cell.

Specific Gravity Test

The battery specific gravity indicates the battery state of charge. The specific gravity is the weight of a liquid compared to the weight of an equal volume of water.

The specific gravity of chemically pure water at 80 degree F. is ONE, (1.000).

The weight of sulphuric acid is 1.400 specific gravity.

Acid is then mixed with water to form a solution called electrolite.

The weight of electrolite is approximently 1.280 specific gravity.

As a battery becomes discharged, a portion of the acid in the solution soaks into the plates. This leaves the solution with a weaker acid content and consequently in a weaker state of specific gravity.

When the battery is recharged, the acid is driven from the plates back into the solu­ tion, restoring the solution and the specific gravity to full strength.

Therefore the higher the reading the higher the state of charge.

Use a hydrometer to determine the specific gravity of the electrolyte solution. If the state of charge is low, the hydrometer will read low. If the state of charge is high, the hydrometer will read high.

Specific Gravity Test Specific Gravity

1.260 - 1.280 1.230 - 1.250 1.200 - 1.220 1.170 - 1.190 1.140 - 1.160 1.110 - 1.130

State of Charge

100% charged 75% charged 50% charged 25% charged Very Weak Discharged

Three Minute Charge Test

Test a battery that is less than fully charged with a fast battery charger and a three minute charge test. Use a fast battery charger in conjunction with the V.O.M. for this test.

Fast charge the battery three minutes at not more than 40 amps for a 12-volt battery and 74 amps for a 6-volt battery.

With the charger in operation, observe the voltage of the battery. If the voltage exceeds 15.5 volts for a 12-volt battery, or 7.75 volts for a 6-volt battery, the battery is worn Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

IC 103 page 7

out. This indicates that the plates will no longer accept a charge under normal condi­ tions and the battery should be discarded.

Note This test is not valid if specific gravity is above 1.200.

Battery Load Test

The starter motor can be used to load test the battery.

WARNING LPG engines: Make sure to shut off the LPG service valve. Start the engine and run it until the engine runs out of fuel or stops.

1. Disconnect the high tension coil wire from the distributor cap, and connect a ground wire to one end of the coil wire, clipping the other end of the wire to an engine bolt.

2. Connect a volt meter across the battery terminals. Crank the engine for 15 seconds.

Measure the voltage on the voltmeter.

During cranking, voltage should exceed 9.6 volts. If it is less than 9.6 volts, there is trouble in the battery, cables, or starter.

Immediately after cranking, no-load voltage should recover to at least 12 volts. If the voltage recovers to at least 12 volts, the battery is fine and the trouble is with the starter or cables.

If the voltage does not recover to at least 12 volts, the battery should be charged and the test repeated.

3. Remove the ground wire and reconnect the coil wire.

4. Start and accelerate the engine. Charging system output should exceed 13.5 volts.

Jump Starting with an Auxiliary Battery When using jumper cables, treat both booster and discharged battery carefully. Follow the procedure outlined below exactly, being careful not to cause spru·ks: 1. Set parking brake and place transmission in NEUTRAL. Turn off lights and other electrical accessories.

IC 103 page 8

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