CLARK FORKLIFT ICllO IC Planned Maintenance TECHNICAL TRAINING MANUAL

ICllO IC

Planned Maintenance

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

Definitions ... ............. .......................... ..... ..................... ...... ............ .... .

Getting Started... .... .................... .... .... ...................... ...... ................ .... ..

Section1. Test Drive The Truck..........................................................

Section2. Engine Checks ......... ... .... ........ .......... ........ .................. .........

CarbuatorAdjustments.............................................................

GovernorAdjustments...............................................................

Stall Tests..................................................................................

Section3. Cleaning and Lubrication ................................................

Air Cleaning.................. .... ........... ....................... .... ... ..... ... .... ....

Lubrication......... ........................................................................

Section4. Engine Lubrication...... ..... .................. ............ ... ...... ...........

Engine oil and Filter........... ..... ............. .... ........... ......................

Section5. Cooling System... .................. ......... ......................................

Coolant........................................................................................

Pressure Testing.........................................................................

Belt Adjustment..........................................................................

Section6. Fuel System....... .. ... .... .... .... .... ......... .... ........... .......... .. ... ......

LPG Tank....................................................................................

LPG Lock Off Valve....................................................................

Section7. Air Intake and Exhaust......................................................

Air Filter. ............... .......... ............... ...... ... ..... ... ...................... ....

Exhaust......................................................................................

Section8. Transmission.................. .. .................... .................. .. ....... ....

Fluid and filter................. ............... ....... ........ ....... .....................

Section9. Ignition and Cranking Systems..........................................

Ignition System............................................... ...........................

Timing........................................................................................

Engine Shut DownSystem. .... ...................................................

Section10. Batteries and Cables.........................................................

CrankingVoltage Test..............................................................

Section11. Charging Systems.............................................................

ChargingVoltage Test................................................................

Section12. Gauges, Lights, and Indicators.. ................................ .. .....

Section13. DriveAxle..........................................................................

Section14. Wheels and Tires...............................................................

PressureCheck... ..... ........ .... ............ ...... ........... .. . ............... ........

Section15. Brake System....................................................................

Fluid Level Check.......................................................................

Section16. SteerAxle..........................................................................

Section17. Steering System...... ............. .... .. ...................... ... ........ .......

Section18. Hydraulic System.. ........... .... .... ...... ........ ........... ........ ...... ..

Fluid and Filter..........................................................................

Lift Cycle Test.............................................................................

Drift Tests...................................................................................

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Planned Maintenance l

Section19. Tilt Cylinders.....................................................................

Checking Racking.............................. ........................................

Adjustments.............................................. ....... ..........................

Section20. Upright and Carriage........................................................

Trunnion Check..........................................................................

Shimming................................................................................ ...

Chains.........................................................................................

Forks...........................................................................................

Section21. Load Back Rest..................................................................

Section22. Sheet Metal and Counterweight.......................................

Safety Decals..............................................................................

Data Plate......................................................... ..... ........ ............

Seat.............................................................................................

Section23. Overhead Guard.................................................................

Section24. Attachments......................................................................

Section25. Using the PM Sheet..........................................................

Purposes of the PM CheckSheet..............................................

Parts of the PM CheckSheet....................................................

How to Use a Typical PM CheckSheet ....................................

Closing out the PM ....................................................................

PM Cheet Sheet....................................................................................

©Copyright CLARK Material Handling Company 1990.

Revised 2000

Planned Maintenance 2

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About this Class

CLARK's Planned Maintenance (PM) program helps your dealership and the customer, plan o f r major o f rklift repairs, reduce unscheduled downtime, and maintain o f rklift operation safety.

As the PM service technician, it is your role to uncover and correct any forklift prob­ lems before they become expensive and time-consuming. Your perlormance of regularly scheduled inspection procedures helps to prevent unexpected loss of forklift productiv­ ity. In addition, you help protect operators and pedestrians by making sure that the o f rklift remains safe to operate.

The effectiveness of the PM program depends upon cooperation between the customer, the operator, and you.

Customers must provide the necessary time for the scheduled PM, ensure proper daily maintenance checks, and make sure repairs are made when they are needed. You can offer the customer helpful suggestions and assistance in these three areas.

Forklift operators must perlorm a daily inspection and report operational problems on the Driver's Daily Checklist(see the Operator's Manual o f r a copy of this list). Each operator at the beginning of each shift must perlorm this inspection. Before beginning the PM inspection, You should talk to forklift operator to get valuable clues about their forklift's perlormance.

You, the PM service technician, can then perform a thorough inspection and a complete PM. Note the results of the inspection on the PM check sheet, and, here's the clincher... take a few minutes and explain to the customer, anything that you may have found, and. ASK FOR THE ORDER. Encourage the customer to schedule a time for the needed repairs.

This class introduces you to the principles and procedures involved in performing an effective PM. The inst1uctor will guide you through the procedures listed here, tailor­ ing them to the specific o f rklifts you are working with.

At the end of the class you will take a testto help measure whether you have reached the objectives.

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Planned Maintenance 3

About Safety

The following messag es may be used in this text to emphasize important information: Note This messag e is used when special information, instructions, or identification is required relating to procedures, equipment, tools, pressures, capacities, and other special data.

Important This messag e is used when special precautions should be taken to ensure a correct action or to avoid damag e to or malfunction of the truck or a component.

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

WARNING This messag e is used when a hazard exists which can result in injury or death if proper precautions are not taken.

DANGER

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

Be sure to follow the safety precautions g iven in the procedures. Before you take any action, determine whether it could result in injury to yourself or a bystander. Addition­ ally, always follow these safety g uidelines: Wear safety g lasses when you use compressed air to clean the truck.

Never point a compressed air nozzle at anyone.

Never used compressed air at more than33 psi.

Always secure the raised uprig ht or can-iag e with a chain or oak post before working under it.

Be familiar with safe operation of the truck, as explained in the Operator's Manual, before you operate the truck.

Planned Maintenance 4

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Definitions

You shoul d be familiar with the following terms before doing the procedures: Drift

The distance a hydraulic device moves as it tries to hold a load in a fixed position.

Free play

The distance you can press down on the brake pedal before meeting any resistance. For brakes with master cylinders, free play ends when the master cylinder is activated and bubbles forms in it. On the Genesis fork lift , there is no free pl ay. However, both pedal s must be the same height.

Hour meter

Indicates the number of hours of lift truck usage. This is very helpful for customers on a scheduled maintenance pl an. By monitoring the meter, the customer can notify the dealer when the pre-established time frame has been met.

Inching

All ows the operator to vary transmission slippage through the cl utch pack so that travel speed and lifting speed can be indepen dent.

Rack ing

The twisting motion of the upright as it is til ted, or is raised to a full height position (twin secondary cylinders) caused by unequal adjustment of the cylinder rods.

Getting Started

Visible Inspection

First, inspect the easil y visibl e parts of the forklift to ensure that they are present, secured, and free from damage or excessive wear. The visual inspection gives you a general view of the truck's condition and clues you to possible problems that you may need to examine further. The visual inspection al so helps to determine whether the truck is safe to operate and whether safety features have been al tered.

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Planned Maintenance 5

Section 1. Test Drive the Truck This section of the class shows you how to check for problems that are apparent as you operate the truck. Test driving the lift truck will give you a general view of the truck's condition. The operational inspection involves checking for proper brake function, unusual drive train noise, good acceleration and deceleration, and smooth direction reversal.

CAUTION You should be familiar with safe operation of the lift truck, as explained in the Operator's Manual, before you operate it.

1. Check for drive train noise. Operate the truck in both forward and reverse and listen for any unusual noises. Check for drive train problems: operate the truck in a straight line at high speed in the forward direction and listen for unusual drive train noise.

Check the acceleration, deceleration, and top travel speed. Check direction reversal.

Drive at low speed and reverse direction. Check for delays, jerkiness, and "clunking".

2. Check steering system operation. Does the steering warnder when travelling? Is it hard to steer? Does it return to center? Steer a circle to the left and a circle to the right.

Check that the power steering is working, that the steering is smooth, and that there are no unusual noises.

3. Check the brake pedal firmness by pressing down on the service brake pedal with your foot. If the brake is spongy, there may be air in the brake system. Report brake pedal sponginess on the PM check sheet.

4. Check inching: Engage the transmission, depress the accelerator, and depress the brake pedal until the transmission disengages. While still depressing the accelerator, release the brake pedal slowly. The truck should inch forward or reverse, slowly, as you release the pedal.

5. Check the operation of the transmission. Is there a short delay when shift ed into a direction?

6. Hydraulic system operation.

7. Check engine performance. Does the engine run rough, lack power, or miss?

8. Check the parking brake: Set the brake, shift into gear, and slowly increase the engine speed. If the brake does not hold, it should be adjusted. If this adjustment does not correct the problem, then a repair is required. Note this on the PM check sheet.

9. Check the condition of the pedal pads and linkage.

10. Check that the forward and reverse directional lever is mounted securely, operates freely, and returns to neutral.

Planned Maintenance 6

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11. Check operation of l ights and alarms.

12 . Check dead engine brake. Travel slowly, turn off engine, and apply brakes. Does the truck stop properly?

. TEST DRIVE MACHINE a. Drive lirain oise b. Steering Operation c. Service Bra e Operation

d. Inching Operation e. Transmission Opera ion f. Clutch Operation

g. Hydraulic System Operation h. Engine Performance i. Parking Brake Operation j. Pedal Pads & linkages I. Lights/alarms m. Dead Engine Service Brake

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Planned Maintenance 7

Section 2. Engine

This section of the class shows you bow to check that the engine RPM and carburetor adjustments are conect. It also shows how to check RPM under various loads and to perform stal l tests that indicate engine, transmission, and electrical system perfor­ mance.

1. Check engines mounting for wear or damage.

2. Check head bol t torque as required.

Important Always remain seated when conducting stal l tests so that you will be in a position to control the truck should the vehicle begin to move.

Next, adjust the idle air fuel idle mixture:

1. Hook up a tachometer, set the parking brake, or back the truck against an immov­ able object, and set the brake.

2. Turn the idl e jet adjustment to lean or rich to obtain maximum RPM. 3. Then turn the adjustment screw to the lean side IDLE HIXTU E to drop approximately5 RPM. SCRE'J 4. Set idle RPM to specification.

On LPG fueled engines, Adjust the power jet:

1. With the transmission in either forward or reverse, run the engine to obtain maxi­ mum stall speed at full throttl e. (Make sure the throttle is going to within1 3 / 2 " of the stop for full throttle. ) 2. Turn the power jet adjustment to lean or rich to obtain maximum stall RPM. 3. Then turn the adjustment screw to the lean side of best stal l RPM to drop approxi­ mately15 -20 RPM at stall.

Planned Maintenance 8

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