Clark IC103 Electrical System IC Lift Trucks Index:

Contents
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 Secondary 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

Troubleshooting the Ignition System………………………………………… 36
Electronic Module Replacement………………………………………………… 36
Troubleshooting Guide…………………………………………………………….. 37
Ignition System Schematics……………………………………………………… 39
Section 4. The Starter System……………………………………………………………. 40
Starting Circuit System Components………………………………………… 40
The Standard Starter System…………………………………………………… 40
The Cranking Motor and Control Switches………………………………… 40
Troubleshooting the Starting System………………………………………… 43
Charging and Starting System Check……………………………………….. 43
Slow Cranking…………………………………………………………………………. 44
Voltage Drop Test……………………………………………………………………. 45
Starter Will Not Crank…………………………………………………………….. 47
Starter Motor Circuit……………………………………………………………….. 47
Starter Relay Circuit……………………………………………………………….. 47
Troubleshooting the Starter Relay Circuit…………………………………. 48
Starter Motor Inspection…………………………………………………………… 51
Starter Drive Check…………………………………………………………………… 51
Delco Starter Breakdown………………………………………………………….. 52
Direct Drive Starter Breakdown……………………………………………….. 53
Reduction Starter Breakdown…………………………………………………… 54
Planetary Starter Breakdown…………………………………………………… 55
Section 5. The Accessory System………………………………………………………… 56
Shut-down Module Troubleshooting…………………………………………… 57
Instrument Pod Troubleshooting………………………………………………. 58
Schematic-GCX/GPX………………………………………………………………… 66
Schematic-GCX/GPX-E…………………………………………………………….. 67
Schematic-CGC/CGP……………………………………………………………….. 68