CLARK FORKLIFT IC103 Electrical Systems IC Lift Trucks TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

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CLARK FORKLIFT IC103 Electrical Systems IC Lift Trucks TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

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CLARK FORKLIFT IC103 Electrical Systems IC Lift Trucks TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

• Since the battery is common to the entire electrical system, and since a visual inspection 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 amperes for ten minutes. Correct Installation The case or cover may be broken if a battery is not properly installed. Keep the holddown bolts tight enough to prevent the battery from sliding in its holder. Do not, however, 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 battery. Corrosion on the carrier will accelerate the rate of corrosion growth on the battery. Also, keep the carrier mechanically intact in order to adequately support the battery and keep it level.

Table Of Contents:

CLARK FORKLIFT IC103 Electrical Systems IC Lift Trucks TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

About this class……………………………………………………………………………. 3
About safety………………………………………………………………………………… 4
Section 1. The Battery…………………………………………………………………. 5
Troubleshooting the Standard Battery………………………………… 6
Specific Gravity Test………………………………………………………….. 7
Three Minute Charge Test………………………………………………….. 7
Battery Load Test………………………………………………………………. 8
Jump Starting with Auxiliary Battery…………………………………. 8
Troubleshooting the Maintenance-Free Battery…………………… 9
Section 2. The Charging System……………………………………………………. 11
Charging Circuit System Components…………………………………. 11
Delco 10-SI Alternator………………………………………………………… 12
System Description and Maintenance………………………………….. 12
Delco 10-SI Parts Breakdown……………………………………………… 13
Motorola 9DB Alternator……………………………………………………. 14
Motorol Parts Breakdown…………………………………………………… 16
Alternator Maintenance Precautions…………………………………… 17
Alternator Inspection…………………………………………………………. 18
Alternator Drive (Fan) Belt………………………………………………… 18
Fan Belt Tension Specification……………………………………………. 18
Troubleshooting the Alternator…………………………………………… 19
A. Abnormal Charge Indicator Lamp Operation…………………… 19
B. Abnormal Charging System Operation…………………………… 20
Charging System Schematics……………………………………………… 22
Troubleshooting Guide……………………………………………………….. 22
Section 3. The Ignition System……………………………………………………… 23
Ignition Circuit Electronic Components……………………………….. 23
Ignition Circuit Point Components………………………………………. 23
Ignition Circuit Seconda1-y System………………………………………. 23
The Standard Ignition System……………………………………………. 23
The Distributor………………………………………………………………….. 24
Contact Points and Condensers…………………………………………… 25
Distributor Caps………………………………………………………………… 26
Distributor Rotor……………………………………………………………….. 26
Distributor Lubrication………………………………………………………. 26
The Ignition Coil………………………………………………………………… 27
The Ignition Resistor .. . … . … . .. . . … . …….. … . . .. . .. . .. … . . . . .. . . . . . .. . . . . . . . .. . . 28
The Ignition Switch……………………………………………………………. 28
The Spark Plugs………………………………………………………………… 28
The Wiring………………………………………………………………………… 29
Standard Ignition Maintenance………………………………………… 30
The High Energy Ignition System……………………………………….. 33
The Distributor………………………………………………………………….. 33
The Ignitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Distributor Parts Breakdown………………………………………………. 35

Please Note:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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