Neglected Forklift Drives for the First Time in Years!

this is a clark ut60d all-terrain forklift today's the day this is a brand new starter i also bought a brand new battery and we watched a master injection pump rebuilder rebuild this injection pump i had no idea you guys had this capability so yeah that's basically it for building your pump [Applause] um [Applause] [Applause] [Music] [Applause] so [Applause] well that's an ominous sign alright folks the snow is gone the forklift is right where we left it got a few things to do before we can actually drive it and use it fuel tank's a mess we've got to deal with that the cable for the forward and reverse is frozen we've got to replace that and the tires are flat got to figure out how to put some air in those there's a few other housekeeping chores we need to change the oil check some of the other fluids give it a grease job you know the usual stuff so let's get to it [Applause] well there was a little strip of something in here not sure what this material is cork maybe it's petrified whatever whatever it happens to be anyway for some reason i had a roll of shingle starter course in my truck so we'll cut some strips off of that stick on there i don't think it's really necessary but might as well do something [Applause] all right folks we're gonna install the fuel tank it has been cleaned and repaired and that's a whole story in and of itself left off this is the fuel tank for the clark ut 60d forklift i brought it back to the shop i cleaned it up and you might want to sit down for this i found some problems this is the bottom side of the tank and this little guy right here is kind of the pad that the fuel tank rests on and yeah i don't think you're supposed to be able to see light through it once i found all the holes pinholes here i decided just to cut the bottom of the tank out this whole rusted section that way i can access the inside of the tank and clean it out a little bit more easily and the whole inside was covered in this it's a combination of rust and solids i guess from the diesel fuel plus 30 plus years of neglect this is the float for the sending unit for the fuel gauge it's got a hole in it so i went ahead and took it out i don't know if the gauge works the wiring's missing for it anyway so we're gonna go ahead and disable that and then several people commented that there should be a filter screen in the bottom of the fuel tank i think that's what's left of it well to fix this problem i busted out my super chinese harbor freight hammer and dolly set and then i channeled my inner fitzy and i made up a patch panel this is 16 gauge steel it's a little bit thicker than the original but i think it'll work i don't have any kind of a shrinker or stretcher or anything like that so i chose to just cut it where the kind of where the bends were and we'll have to weld that up but i think it'll work just fine we've got to convert my welder over to a smaller diameter welding wire i normally run 35 thousandths wire i think it's like 0.8 or 0.9 millimeter but that's overkill for sheet metal we'll have a hard time with it this is a millermatic 200 mig welder all right we had to replace this guide and the two rollers this is our drive roller kit so it comes with both rollers and the guide on the gun we have to switch over the tip and we have to replace the liner that the wire runs through this liner is for 35 to 45 thousandths wire and i have used it with thinner wire before but it's not ideal especially this is a kind of an extra long lead on it anyway this welder's been converted to a twico gun and i've always hated it it's heavy it's really kind of awkward i don't like the way the trigger works the tips are expensive the other consumables are pretty expensive and they're getting hard to find and the tips always come loose and then the biggest problem is with the nozzle so it has this ceramic isolator here and it just doesn't hold the nozzle very tight if you get the slightest amount of build up inside this nozzle and then it kind of over like this it shorts out to the tip and then you have a bad day so rather than futz with that i bought a whole new gun this is a miller mdx series gun it's fairly new on the market i think don't know that much about it but it seems a lot better it's more like the the bernard style guns which i prefer so we're gonna switch it over so if i loosen it here pull this gizmo out this is the adapter that adapts the twico gun to fit in the miller welder so you have to switch the gas hose back over don't cut yourself there we go [Applause] this is the original hose it runs over to the back side of that little clamp that we tightened up when we installed the gun there we go one more thing while we're working on this welder i noticed these panel connectors are loose this is where you switch the welder from high range to low range you actually have to unplug this big connector plug it into the other side anyway i think we can just tighten these up okay there we go now with these smaller 10-pound rolls you need a spacer this is one i made out of a tube of a little bit crude but it gets the job done [Music] rock and roll enough stalling time to weld the tank i'll be honest i've never welded a fuel tank before so i used up a lifeline and i phoned a friend this guy's forgotten more about welding than i'll ever know and he's welded hundreds possibly thousands of fuel tanks what he told me is as long as the fuel tanks only ever had diesel fuel in it you can weld it just like it is you don't need to purge it you don't need to fill it with water you don't need to do anything you'll be just fine if it's ever had any kind of gasoline or solvent or anything put inside all bets are off anyway i think what we're going to do we will go ahead and fill it up with water just because it's easy to do and there'll still be a little air pocket up here at the top and then we'll go ahead and weld it he also said basically that it would have been better well it would have been better to just leave this part of the tank alone and then put a cap over it but i chose to cut it out so i could get inside and clean it he also said as far as the patch goes that i should have made it so that it overlapped instead of being a butt weld but i had already made the patch by the time i i talked to him so we'll try to struggle through that anyway let's get to it i think it's gonna be fine don't weld a gas tank please there's just no there's no way to do that safely that i know of i'll tell you guys a couple stories a few years back there was a guy locally who did some welding on a pontoon boat an aluminum pontoon boat and he started welding on one of the pontoons and he didn't know that the gas tank had dripped gas down inside that pontoon and it blew up and killed him and my dad was telling me that years ago a salvage company actually salvaged a large fuel storage tank out of the mississippi river and it had been sitting submerged under the water for years and they started cutting it with a torch and it blew up and killed the guy so yeah be careful [Applause] [Music] [Applause] [Music] [Music] i think that'll work i'm gonna clean this up a little bit and then we'll flip it over and see how much it leaks it's done it holds water i'm uh i'm over it hi lady hi we got a lot of stuff in the back there looks like maybe some goodies from area diesel service did i get another sweatshirt you might have this this looks this is kind of tiny it might fit me though i think i said medium yeah this will fit all right this is cool kiddos on golf cart detail uh yeah welding a fuel tank are you done freaking out over here i got a hat i don't think it's for you you know what there's two of them there's two of them ah sweet look at this you sent me a cup i needed a new coffee cup all right lady taking over everything here i'm trying to open this box that one doesn't look as exciting that one just has a that one just has a boring old injection pump in it all right the tank's done that did not go well let's put it that way the big problem i ran into is that i didn't cut out a big enough opening and so here it looks like solid metal but there's still significant amounts of rust and as soon as i started welding it i just started blowing holes through that rust and what i ended up doing was just putting a strip over top of the weld that i'd already made so i basically tripled the amount of welding that i had to do and then even still i was blowing through and popping holes and ended up having to add all kinds of patches and it's a mess but nobody's ever gonna see it and it's liquid tight so i think it'll be just fine but i've definitely wasted slash invested way more time than i wanted to in fixing this tank i think it points like that [Music] well it seems like clark or john deere or whoever was in charge of this end of the machine they never intended this fuel tank to come out without removing the radiator and i don't want to do that because it's a pain in the butt so i did everything everything just short of removing the radiator i took the the radiator mount bolts loose i removed the shroud and i removed the fan that allows me to scoot the radiator over just far enough that i can put the fuel tank in i think [Applause] so [Music] so well that was easy all right the fuel tank's buttoned up i went ahead and installed the fan the shroud and the radiator did have to take the upper radiator hose loose so we spilled a little bit of coolant i'll have to top that off before we get too crazy i tighten the fan belt everything on the back side of the engine is pretty much ready to go well a few people wanted to know how to time the injection pump so i'll show you how it works on this engine it's pretty straightforward down here on the side of the injection pump is a timing window this pump only has one timing window some of the standardized pumps have one on either side inside the timing window there's two timing marks one is on the cam ring that one's more or less fixed it only changes with the timing advance inside the pump and the second timing mark is on the weight basket so that one rotates with the input shaft of the pump so you want to line those two up now in this particular application someone's already marked the housing and the back of the timing cover so if we remove the pump and then reinstall it and line up these marks the timing should not change and there's not enough room for that shaft to move far enough for the gears to come out of mesh so the timing inside the cover can't change and if we line these marks up the timing inside the pump can't change but if it does change i'll show you how to check that of course every engine is different in some cases you'll find timing marks on the flywheel so there is a inspection cover here but there are no timing marks on the flywheel of this engine so on this john deere engine the timing mark is on the front crank pulley and it lines up with a pointer that's cast right into the front timing cover right there and there's two marks one's marked zero and one's marked s on this engine it was timed off of the zero mark and i know that because i set the timing before i took the pump off so if you don't know and you don't want to mess it up the best thing to do is to line up the timing marks inside the pump before you remove it and then don't touch the engine until you reinstall the pump now we're gonna replace the fuel filter now this is new i did replace this last winter you guys didn't see it because i never released the video but i actually came down here and did some more work on this machine trying to get it to run and part of that effort was to replace the fuel filter but we're going to do it again based on the condition of the fuel tank i think it's a safe bet yeah yeah this is kind of a weird fuel filter design this is standard john deere stuff [Applause] oh there we go this is non-biodiesel which is not easy to get here in corn country i asked the guys at area diesel if they recommended or endorsed any kind of fuel system additive or cleaner this is what they sent me it's actually made by standard i am the same people that well it's sold by ceno9 the same people who make the pump and i think we only need three ounces for 10 gallons so a little bit goes a long way [Applause] kind of messy though [Music] gotta bump it over a little bit must be right on the cam lobe for that stupid transfer pump actually hit the drain pan this time oh i wasn't expecting that that's all right uh so well apparently the original oil cap was lost at some point so they just jammed this three-quarter fine thread bolt through some kind of a rubber bushing and stuffed it in there well that's not ideal but i was able to get a replacement straight from the john deere dealership big thanks to brian block for helping me out with the part numbers because clark clark had no idea what i was looking for this control cable is what shifts the machine from forward to reverse it's kind of a weird setup on this forklift you got a gearbox here i think it's four gears and then there's a lever on the console that shifts forward to reverse but there's no neutral position on the reverse lever like a normal forklift and there's no torque converter it uses a clutch with a hydraulic dump valve it's kind of more like a tractor or backhoe that has a reverser than a normal forklift anyway it works fine it's just a little unusual anyhow this cables froze up it's no good i called the clark dealership 350 dollars for a replacement which is insane even the parts guy was like there's no way anybody would buy that so i did some digging tried to find an equivalent i asked brian block if there was a john deere part number for it he dug a little bit couldn't find an equivalent he suggested i check out midwest control i contacted them and they kind of put together a quote for a matching cable it was still going to be like 150 which is a little crazy i think anyway what i ended up doing is buying this one from mcmaster carr it's a standard cable two inch stroke six foot length it's about five inches longer than the old cable but there's plenty of room down there i think it'll work just fine this one 75 bucks we've had some visitors inside the electrical panel that'll work i'm not set up for wiring repairs today so i don't know what we're going to do with this let's put the panel back on and forget about it electrical tape's gonna have to do for now i'm not set up for a full-on rodent exorcism [Applause] now the tilt cylinder seal is blown out [Music] yes [Applause] [Applause] [Applause] [Applause] all right guys i think that's enough i don't know why the outro is so hard i have a really hard time filming this part of the video it runs it drives it lifts but there are still some problems a big one being the clutch it slips pretty bad reverse is better but in forward it'll barely pull itself even in low gear so there must be something i missed on the adjustment for the forward reverse lever or maybe something in the linkage for the pedal is sticking i don't know i don't think the clutch itself is bad because it used to work just fine it's got to be something external but i'm out of time today it's getting dark getting cold the weather's supposed to turn on us rain and then snow and i want to get out here before that happens so yeah that's going to be it i don't know if there will be another video on this machine or not i mean there's plenty more work we could do the tilt cylinder is leaking a lot of the hoses are rotted it's leaking pretty bad from the transmission the tires go down pretty quickly yeah where do you stop i think for the time being it's good enough for what we needed to do which is kind of work around this property clean things up anyway i want to thank area diesel service again for the phenomenal job they did on that pump i just yeah i can't say enough good things about my experience working with them just a little teaser for the one or two guys who are still watching the video i did also bring the injection pump and injectors out of my oliver 1650 down to area diesel service they went through both of those or all of those and they also posted a video about it on their their youtube channel i'll put a link to that video in the description and i think they said they're working on a discount code for watch west work viewers so if you guys have something that you want them to do they have a discount code that covers the freight shipping this stuff i don't know back to you or to them or something like that i'll figure out the details i'll put that in the description box down below anyway thanks again to area diesel service and thank you guys for watching somebody explained this to me a car went off the road through the ditch and took out the fence this road is perfectly flat straight and level for at least another half mile in that direction and i would say at least five miles in that direction

Channel: Watch Wes Work

Views: 229,420

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Id: BpgMbheEo_I

Length: 32min 2sec (1922 seconds)

Published: Sat Mar 20 2021