My $1,000 Clark FORKLIFT Was Falling Apart So I FIXED EVERYTHING
ฝัง
- เผยแพร่เมื่อ 6 ก.ย. 2024
- I've got a big forklift problem, it's been leaking since the day I bought it and now it's squealing so badly it's unusable. I bought this 2002 Clark GCP25 for only $1,000 and now I'm finding out why. Everything is leaking, the steering, one of the tilt cylinders, and the engine is absolutely covered in oil. Today we're going to fix as much of the engine as possible, then re-fill the struggling hydraulic fluid system.
Clark CGP25 Parts
Valve Cover Gasket: VS50132R
Engine Oil Filter: Wix 51064
Engine Oil Type: 5W-30
Hydraulic Fluid Type: AW-68 or MS-68
Battery: 51 Series
MERCH: shopWatchJRGo.com
Shop Motul: motul.com
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#ForkliftCertified #Clark #Forklift
When things warm up there, you might want to degrease the rest of the engine bay. That way, when you do have to work on it again, you won't get as dirty. Also, you'll be able to see if things are leaking easier.
Pour the 5 gallon bucket with the spout at 12 o clock and it pours much better. It vents that way and you avoid the glug glug glug.
Yeah I'm surprised he doesn't know this
Nahhhh if you pour the 5 gallon bucket straight up and down vertical and then spin it like a tornado that’s the fastest way to drain something especially 5 gallon jugs
Exactly what I came here to comment. It amazed me when I leaned this
@@alliancestrong6835 learned that trick owning a 500 gallon fish tank😂 but after about a year I just bought an electric siphon
In the shops that I've worked at that use forklifts, preventive maintenance means that the forklift gets fixed the same day it breaks. otherwise there is no preventive maintenance.
Oh, so my kinda maintenance 😂
Sadly, that applies to so many things, and in today's world, part shortages can extend downtime to weeks or months.
Accurate, but same week/month is more the speed of the places I worked.
If that 😂 the side shift lever on the forklift at my work broke and if you mashed it sideways and pushed one broken side against the other it would kinda work. So they said it's fine and didn't want to buy parts to fix it
Completely false
We had some 2x6's with a beveled edge that we drove the forklift at work up onto for the oil changes. It wasn't much of an improvement, but it did allow us to be able to reach in underneath them a lot easier
2 inches is 2 inches 😂 If you have sausages for fingers and meat cleaver hands then you need all the space you can get
Due to it's Utilitarian Duties, you should find & fix the Oil & Hydraulic leaks.
Then have the "Detail Crew" Degrease & Clean the lift!
And replace the Hour Meter with an "estimated" prior hours scribed next to it for a "ballpark" estimate...
Next time you are pouring from a 5 gal container, put the spout at the top. You will find that it pours way slower and smoother with less spillage. The same principal works for the large container engine oil too.
Permatex makes a sealant called aviation sealant, if you lightly coat the valve cover gasket with it, it can fill in those little imperfections. I use it on water pumps and termostat housings. Its oil, gas, coolant resistant too and stays soft.
i used that on my g/f's ls2 engine when i refreshed her rocket covers ....
A thin coat of Permatex 518 anaerobic is an option too, that stuff is amazing
Can you detail it, it would be so satisfying
Could you do that sludge cleaning treatment on the forklift like you did on the Dodge Dart?
Holy Smokes, that was some dirty engine oil. Usually a propane powered lift truck the oil stays very clean. My assumption is that oil hasnt been changed in well over 500 hours.
The maintenance schedule for engine oil is 250 hours or once a year.
The Hydraulic oil is every 1000 hrs or once every 2-3 years. Hope that helps.
if you take the lpg gas bottle off
(some swing out)
you can pop the hood/seat more 90 degrees giving you more room to work
Some new paint on the wheel rims and the body, pressure wash the engine bay, would look brand new 🙂
This episode was very uplifting.
I seeeeeeee what you did there
DUDE...use a magnet on a stick to find drain plugs in drain pans.
Read my mind -- I was thinking has he heard of a magnet.
Does your seat flip up more? if so Flip the seat up - take the LPG tank off and the hood should flip up straight or take the hood off all together (more room to work). Also- every once in a while blow off the radiator with air (your shop floor looks clean but you had a lot of dust in it ) this will keep the forklift from over heating. The next time you need tires - you may want to think about putting indoor non skid tires on the lift (these are white) they are cleaner don't leave dust on the floor. Also- periodically check your hydraulic hoses for wear and make sure they don't pinch.
Trick for pouring out of a 5 gallon container. Pour oil into a jug first. The smaller jug is easier to control. To do this: Place the 5 gallon container onto a bench or tailgate on it side with the spout at 12 o'clock. Open cap. Rotate it to 1 or 11 o'clock and oil will start coming out into your smaller jug. When you have enough, rotate back to 12 o'clock to stop the pour. Repeat until you have all the oil you need. Almost no spill or waste and no lifting
You may want to recheck your hydraulic oil level, with the forks on the floor and your mast level. It maybe over full since the forks were in the air when you topped it up
Easily in the top 5 vids you've done JR, simply fascinating giving us a window to learn something new like this!
been around guys working on forktrucks keep some wood blocks around to drive it up on to change oil. Its a good idea to service the chains too grease or lots of Belray chain lube.
Commenting every day till JR buys a 92 240.
Lol, I do like 240s 🍻
I found a couple 89’s and 93’s through AutoTempest but no 92’s
Prices are crazy. $7.5k for 230k miles
I am with you Brother.
He will cave into our demands.
He likes strange stuff. Hopefully he will appreciate the lack of a spoon engine calling out his name. Lol we will see.
@@WatchJRGo LOVE UR CHANNEL DUDE, I'VE BEEN WATCHING YOU FOREVER!!!! WISH I LIVED CLOSER!!!!
p/m is: run it till it breaks. if it ain’t broke don’t fix it!
I hope you checked the timing belt. If the valve cover gasket was never replaced, there’s a good chance they never replaced the timing belt.
Curious if you ever feel like de-greasing the inside of that engine compartment - it would be super-satisfying after seeing how clean the valve cover came in that parts-washer tbh
I bet the valve cover had warped a bit, hence why it was still leaking. Might be worth getting it leveled.
Hey John Ross love your videos I just want to let you know your number one spark plug on the forklift is popping in and out a little bit I'm don't think it's tight all the way... don't want to see you ruin the threads... when you get a minute check it not sure if anyone else had mentioned it yet I went through some of the comments I didn't see anything so you take care thanks for all you do for TH-cam and have a great day.. .
Latex gloves my friend? For the drain plug search. Anyways, would love to see an engine cleaning of that one - see the crudd pouring off!
Magnet stick even.
I always kept an eye on the bottom seal on the main mast; guys would overload that thing all the time and end up blowing out the seal. We had a maintenance contract for all 3 trucks [2 gas-1 elect.] and they would do the seal replacement. But the truck was down for some time, as he would remove the mast and take it to his shop to R&R the seal. You can do it yourself, I suppose, but I sure wouldn't want to!!
Very good JR. Take care of your tools and they will take care of you. Now, go hit the Dollar Store and buy a plastic pitcher for fluid transfers.
It’s a good idea to let the engine temp come all the way up every couple times you run it. Short cycling is bad for these IC propane engines. Tons of moisture from the propane turns the oil to chocolate milk if you don’t get it hot enough to vaporize the water.
My friend owned a business in Danvers, MA called Reith Industrial Truck (shout-out Norm) that maintained small to huge lift equipment. Their mechanics amazed me with the tricks they learned over the years.
Clark is the best and Cat was the worst where I worked, they ran 24-7 and it was nothing to see 12,000 to 15,000 Hrs before they were rotated out. If you find a forklift with clapped out fork mounts, good indication it has quite a few hours on the machine.
What about the PCV issue where oil was being blown into the vaporizer? And how to solve the hydraulic leaks? Then the Detail Dudes should be ready to do a full cleaning of that engine bay. What ever happened to the tug project: did you sell it?
Yeah I was thinking about the Tug and how the forklift handled it, if it was low on hydraulic fluid.
Do a quick restore on that forklift to make it look like new but not going too deep.
The parts aren't super high quality but "total source" is the company forklift dealers use to buy aftermarket forklift parts. Or you could have just searched your local Clark dealer in your area and bought them from them.
Probably the only forklift in the world to have motul oil.
Maybe in Germany?
How about doing a compression test on her so that you can really assess the condition of the engine.
Back when i had my ware house Fork Schedules were daily , Check all fluids in the morn b4 use, and again when done clocked and filed, fluids top when needed and changed every 6 months we very rarely had any issues , then the last two yrs of business went to stand up electric lifts and those were awessome
I can't wait to get more videos of you remodeling the shop.
Most companies idea of preventative maintenance on a forklift is to prevent wasting any time on maintenance. Now that you've done all the easy stuff, find the hydro leaks. That hydro fluid didn't evaporate
You should give that forklift a quick paint job. A couple coats of bright factory green would freshen it up.
As an old, and I do mean old mechanic, it drives me nuts that you don't power wash the cars/whatever before working on them, taking care to note where the leaks/damage is!
Then have the nerve to say after, 'oh I dragged some dirt into the rocker area.
The inside of a forklift engine that's run on propane should never ever have sludge in it, that is most definitely from dirt Ingress, in fact most things that run on propane the oil will look clear and Nearly New throughout its entire life cycle.
I generally change the oil on my forklift every 250 hours, keeps things clean. About the equivalent to 3-5k miles.
That thing probably saw a couple 750 hour oil changes
Edit: the forklift has 5500 hours and doesn’t burn a drop of oil
Twice a year is recommended. That's assuming 2k hours a year. I have some I change oil 4 times a year in. Worst thing for them is short run times.
5:36 - those were some cool edits. Nice touch!
Make sure you lubricate not only the grease fittings but also all of the moving pivots etc using oil. I see a lot of dry pivots/pins. Makes a huge difference for feel and longevity
Really cool to see those valves going... Now don't forget to record the maintenance (and part numbers!) on the machine!
I think Clark's were built out of battle Creek, mi We had them for years where I work. They're tanks and hardly ever got timely maintenance. Most we'd do is replace tires because we'd burn them off in a few months.
JR: im gonna focus on my projects for a while, I wanna get things done.
JR the next day: PUTTING A TURBO ON MY FORKLIFT
Your airport tug is one of the most valuable in the shop ! You will never have to push or pull a car or truck ever again ! Ratchet stops to pull . Make a bracket to attach the two wheels of any car or truck to lift the two wheels and move anywhere you want . Like the car dolly used on graveyard cars ! Love the show and watch every day since before the new shop !
This is why qi subscribed qll those years ago when John Ross was on rally in Lambos, putting Orbeez in engines, trying out foam to clear carbon build up, super car reviews, and FORKLIFT content! Hot damn!!!!! Remember when JR LS swapped everything? Could he LS swap a forklift? This is the hope. Back to the old content!
Yeah it seems to be a design flaw that there aren't any bolts on the outside of the valve cover. Destined to leak with all of the down pressure coming from the middle. Cool to see how a forklift engine is set in there!
Maintenance on our work hilo means putting quart of oil in a week and filling coolant up monthly 😂 but the hr meter broke at 10k hrs still works though
I as well bought $1000 Clark. Thank you very much for making this video.
First job, buy a steam cleaner. Then when clean run it for a bit to see where the leaks are.
The shop I worked at had a forklift that leaked a little and the shop who did our maintenance put a diaper on the undercarriage to catch any drops of fluid. This keeps you from slipping on the oil drops in the warehouse and keeps everyone safer. We actually had a maintenance schedule but these forklifts get a lot of hard work and the dust from the floor gets sucked in and sticks to the engine. We cleaned the floors daily but there was always dust that accumulated from trucks making deliveries. It’s just the environment that these things work in that makes everything so crudy in the engine bay. Any oil film grabs that dust or dirt. This will drive you crazy trying to keep up with the dirty engine!
If it was under a contract service account in its former life, preventative maintenance means a fund check, oil change, and visual inspection. Probably supposed to be yearly, but if the company that owned it didn't monitor it, the service provider likely skipped it several times but billed the client anyway.
Fluid check*
Flames on that oily engine I was ready for a Show...LOL
Doesn't work that way. You need big heat not those flimsy lighters
A tip for you, when you touch coupler on propane tank ,if tank is empty or extremely close to empty it will be much colder than normal
Look at the valve stem seals that go hard .done a heap of Mitsubishi engines with age on them
I worked for Raymond forklift now part of Toyota, we kept maintenance files and service manuals for very old models some on microfilm.
These 4G64 engines are notorious for valve cover leaks. the impco 100 is decent and you can get rebuild kits for them - don't chuck it out. try a heavier oil and an oil flush also. get the filter for hydraulic from clark and check the level with forks on the ground once warmed up
That would be handy to have around the house😎 For everything you do around the warehouse that thing has to be a lifesaver. One of my early jobs was being the gopher at a machine shop so boss showed me how to drive a similar sized one and pretty soon I was tearing around the place picking things up and moving them around. My training was hilarious. This makes it go up, this makes it go down, this one leaks so don't touch it and off I went.
Did you end up finding or replacing the PCV valve? That new valve cover gasket might be leaking because of the PCV valve. I've seen that a ton of times, if the PCV valve is gummed up and not working the pressure has to go somewhere and I've seen it be the valve cover many times.
a hint- use 3m yellow weather strip glue on the valve cover. Apply it in the grove the gasket goes in to, and then put the gasket on the cover like usual, then let dry overnight. Gasket wont shift or move when you go to apply it to the engine block.
Those Mitsubishi valve covers are notorious leakers, finally sealed mine with "the Right Stuff", on my 80 Dodge D50.
also for forklift parts TVH is the way to go, there is one in Olathe Kansas. You may need an account but they do counter sales, they have everything for these units
get a fluid pump that's maid for 5 gal buckets.... AutoZone sells them
Ah; the esoteric vintage heavy equipment repair content I'm here for... 🙂
On my skid steer you use the bucket to jack it up, just tilt the bucket down against the ground. I suppose the fork lift you would use the mast and some wood blocks?
Who needs an "Enclosed Parts Washer Machine" when all you need is a Dishwasher with some Purple Power Degreaser! 🤔
Just make sure you have a "Sludge Recovery System" for our Planet. 🌎
My 1994 Mitsubishi Mighty Max has the 2.4L 4G64 in it. What’s funny is, you could probably swap a 4G63 with a turbo into that thing if you really tried to. The motor mounts the exact same, all you have to do is take the brackets off of the 64 and put them on the 63. That would be a fun project to watch.
Preventitive checks are what they say. Visual inspection to find leaks. Checking pressures, all service items, damage to hoses and leads, etc. Top grade check would include engine pressure check, etc., fluid levels and quality of fluids It is really a full check over to assess what needs changing, repairing or replacing.
ATP AT-205 Re-Seal Stop Leak works for me on hydraulic leaks.
Worked on my floor jack with leaking seals
If I could work on the forklift with Watch JR Goes I would drink the shot of whiskey and the cold Bartle Skeets and puff on the Cannabis Cigars with him and get all schmoked up
Hey Jr would love to see how the little cans of moa and epr compare to the dynamic if you end up running those thru the forklift engine.
Clarks seem to have transmission trouble. We got a lot of them in as scrap metal. You will need to either add some spacers to the bolts to push the valve cover down tighter or clean it all up again and seal it with silicone. make sure the PCV works. Air should be sucked into the valve cover at the hose you had trouble getting off. The PCV sucks air from the valve cover directly into the intake manifold. There should be a vacuum in the crankcase if the PCV works properly and the rings are good. If the rings are bad, 40 weight motor oil will help. Synthetic oil might be too thin for that engine.
It just makes me crazy when you work on the floor. Best thing I made for my shop was a simple wooden work bench that rolled around on nice casters. Mine was 2’x6’. You choose the height. Don’t pile junk on it. Keep it clean and clear, and it will make every job easier. N.E.OH Bob.
If you don't need the wheels, trestle tables can be pretty strong, and take up less space when not in use, therefore less likely to accumulate the leaning tower of junk all horizontal surfaces attract out of the space time continuum. But tables, essential workshop items are. As Mechanic Yoda says.
Dang, the cell tower my phone connects to picks the worst possible times to reset. The video stalled halfway through. After you put on new plug wires send it over to the detail bay and let the detail guys give that thing a full detail. Lord knows it deserves some love after 20 plus years of abuse.
Wix will cross reference any manufacturers number on their website, that's how I found all the filters for my Clark bobcat
Also, the O'Reilly Premium Tractor Fluid in the green bucket meets Clark specs for fork trucks
The PM schedule is run it till it breaks and fix what is broke!
I've spent a lot of time on and in forklifts. Most gas trucks from that Era the seat back folded for better access. Also might want to check bolts on counterweight and the front panel. They tend to vibrate loose. I drove a Kalmar P50 that had a 1.6 liter Nissan, I personally put over 7500 hours on that truck with no engine issues. Clean that Clark up and blow out radiator and engine compartment once in awhile and she'll run for a long time.
That’s actually super low hours for its age. We run one with just over 24k hrs on it with minimal repairs outside of routine maintenance.
If it's burning oil, it's probably the valve seals, just did a head on one. Valve cover gaskets on these import engines leak, I change them 2x a year when I service. The camshaft seal and crank seal are popular leak spots. Hydraulic leaks, check all clamps on low pressure lines. Transmission filter is hard to get to, expensive and they take a special CAT Hydraulic oil. Just rebuilt an entire rear end on one too, not cheap. Also, your local clark dealer will have all those parts in stock and are usually cheaper than trying to source car parts. 4g64 in these, is the same as an eclipse sypder GS.
Friend had one that came with the warehouse they bought, a Nissan I think. About that same size unit, 4 cyl engine, propane tank and so on.
Somehow the previous owners broke the block ear to mount the alternator in it and it was kind of cobbed together letting the belt tension hold it in place. It ran okay that way, but fixing it right was going to require taking the counterweight off and just hours upon hours of labor.
PM schedule depends entirely on what the co will pay for. Most of the time its just check fluids, change oil, grease things until it stops working then fix the minimum required to make it work again. They tend to be greasy and ignored otherwise.
Degrease the engine and power wash it. You might want to use an air blow gun to knock off some of the water wherever it might gather under the hood. If there are no other serious issues with the mechanics, you got a very good deal on it!
As someone who used to work for a Crown Dealer, you aren't wrong. Even if your a dealer finding parks can get really strange and annoying out in the field
As a stop gap repair put a cheap oil catch can on that valve cover hose and vaporizer. Long term could use valve seals.
Glad it’s back up and running
20:20 former US Foods forklift. Probably spent a lot of time in cold temperatures since they keep their distribution centers below freezing inside year round.
Why did you stop using the vacuum oil changer method? I'd probably do what I can to avoid crawling under...
This video really *lifted* my spirits 😂
I like that blue color on the WRX Sti in the background at the hydraulic fluid stop!
Incredible how simple it looks when you do that job! Well done again! 👍😀
"Danger!" 🤣🤣🤣
I always put our forklifts on hoist when we service. Three Hyster H 50 XLs
The answer to your question on a PM schedule is - it depends . A big company that uses fleet of forklifts will lease the forklifts. Usually the rule of thumb is 5000 hours - if you go over that the forklift is not worth much for resale. So they don't really own them sometimes depending on the leasing agreement it will include a PM schedule that he forklift company will assign someone to maintain the forklifts ie - change the oil, the filter and check them over for wear and tear. Also, as someone has already mentioned - some companies only fix what is necessary when the forklift breaks. OSHA requires that a forklift checklist be used on each machine - each operator is supposed to do a checklist - brakes, horn, tires, e-brake, oil etc. OSHA is strict on forklifts as many people are killed or severely injured on forklifts each year. Also - if the operator discovers something not safe on the forklift they are required to tag it NOT SAFE and take the key out and give it to their supervisor. (I know right!). They even have rules on the wear and tear on the blades (forks) the underside can wear down after use and cause the forks to break. Also- the forklift is limited to how long the forks can be - a modern forklift will have that designation on the data plate. (24", 22" ) if you use longer forks on the lift it will reduce the amount of weight your forklift safely pick up.
Mitsubishi made a few engines with two screw valve covers that fasted at the top like the one in your forklift. If you hear a crack when tightening them it is all over, you just cracked the valve cover. The only way you knew is when you went for a drive or had it idling for long enough that the oil was everywhere on top of the engine, leaking down fast. It is a balance having it tight enough not to leak, and tight enough you didn't crack the valve cover. They are definitely a hand tool tighten, not an air or power tool job.
If you need parts for that lift try Berry material handling there in Wichita.
Oil change interval is one year or 300hr whichever comes first the transmission and hydraulic fluid service is every 2500 hours or 2years timing belt water pump is 3000hr or 4years , just make sure you keep coolant in that engine they're known for head gasket issues and running hot
11:24 One of us! One of us! One of us!