1、 Manufacturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering Standards replace defective components.DRY TYPEa. Remove and disassemble cleaner assembl y and precleaner, ifapplicable.b. Clean metal air cleaner body and dust cup, if applicable.c. Cl
2、ean filter element by tapping against a hard surface. Ifthis process does not adequately clean element or if elementis damaged, replace.CAUTION: Do not t ap hard enough to deform the element. Donot immerse element in cleaning solvent nor blow out withcompressed air.d. Check connecting clamps, gasket
3、s, hose and hose connectionparts; replace defective components.3.1.5 ENGINE OIL AND FILTER:a. Remove th e plug and drain the oil from the crankcase withengine at operating temperature.b. Examine drain plug threads and gasket and reinstall; replaceif damaged.c. Remove and replace oil filter.d. Fill c
4、rankcase with the proper amount of specified engine oil .e. Check oil level.f. Start engine and check for leaks.Manufacturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering Standards replace defective gages and relatedparts.c. If pressure is not n
5、ormal and gages or related parts are notdefective, contact supervisor.3.1.7 CRANKCASE VENTILATION:a. Check PCV system for damage or obstruct ion.b. Remove breather filter and PCV valve, clean or replace.3.1.8 FUEL SYSTEM: Check the entire fuel system for leaks. Repair orreplace all leaking units.GAS
6、OLINE/DIESEL: Check to be sure fuel tank safety filler cap isin proper condition and protective screen is in place; repair orreplace as required.PROPANE: Check LPG hose for proper location and mounting to avoidchafing. Check tank, operation of shutoff valve, guards, locatingpin and other safety devi
7、ces. Replace defective parts asrequired.3.1.9 GOVERNOR:a. Check idle and maximum engine rpm with a tachometer.b. Adjust maximum rpm to agree with manufacturers specificationto obtain the maximum travel speed of eight (8) mph.c. Replace the seal if broken or missing.3.1.10 STARTING BATTER Y:a. Clean
8、battery and neutralize corrosion by washing with asolution of Bicarbonate of Soda.b. Check terminals and connectors.c. Check battery case for cracks; if case is cracked, replacebattery.Manufacturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering S
9、tandards replace as required.NOTE: Modi fication or repair of structural, load bearing members,or safety related components is strictly prohibited, without themanufacturers written approval.Manufacturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineer
10、ing Standards tighten or replace valve core.e. If pressure still cannot be maintained, repair or replacetire.f. Replace all missin g valve caps.g. Contact Supervisor for decision on replacement of defectivetires and applicable warranty disposition.3.1.21 BRAKES:HYDRAULIC:a. Drive truck to test brake
11、s for a smooth even stop.b. Check pedal for excessive travel, sponginess, or loss ofpressure.1. Correct excessive pedal travel by adjusting brakes.2. Correct pedal sponginess by bleeding air from lines, addingbrake fluid and adjusting brakes.Manufacturing StandardsFord Motor Company199603 INDUSTRIAL
12、 TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering Standards adjust if required.c. Maintain brake flu id to manufacturers recommended level.MECHANICAL:a. Drive truck to test brakes for smooth even stop.b. Adjust brakes as required by tightening shoe adjustments untillinings are tight to drums a
13、nd loosen adjusting nut untilwheels turn free. Note: Not required for units with selfadjusting brakes.c. Check pedal spring tension, if pedal does not return to normalposition, adjust or replace defective parts.PARK:a. Check controls to insure that the brakes can be set securely;adjust or repair as
14、required.b. Check cables and rods and repair as required.c. Drive truck to test brakes; repair and adjust brakes to holdas required.d. Be sure wheels turn freely after adjustments are made.3.1.26 CLUTCH:a. Check pedal travel, and adjust as required.b. Dri ve truck to test for proper operation. If ad
15、justment doesnot correct problem, inspect clutch assembly and repair orreplace parts as necessary.3.1.34 LIMIT SWITCHES: Test for correct operation and replace asrequired.3.1.35 LIGHTS: Inspect lamp assem blies, switches and wiring and repairor replace defective parts as required.3.1.36 HORN: Test f
16、or proper operation, repair or replace as required.Manufacturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering Standards clean and replace as required.b. Replace points and condenser as required.Manufacturing StandardsFord Motor Company199603 IND
17、USTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering Standards check belt tension and adjust as required;replace parts as required.c. Check radiator for leaks; repair or replace as required.d. Blow radiator core clear of dust and dirt using compressed airor steam.AIR: On all air-cooled equ
18、ipment use compressed air to blow dirtand dust clear of all cooling fins and girds.CAUTION: Proper protective clothing a nd eye protection must beworn.3.2.16 AUTOMATIC TRANSMISSION COOLING SYSTEM:a. Check hoses, fittings, connections for wear and leaks andreplace defective parts.b. Blow cooling unit
19、 clear of dust and dirt using compressed air.c. Check cooling unit for leaks and proper operation; repair orreplace as required.d. Check the flow of oil to make sure there is no obstruction.3.2.17 HYDRAULIC SYSTEM:a. Test operation of pump, control valves, lift and tiltcylinders.b. Check lift cylind
20、er for exterior dents , cylinder rods forscratches and mars; repair or replace as required.c. Check packing and seals for leakage and seating; replace asrequired.d. Check hoses and fittings; repair or replace as required.e. Clean breather filter element; replace as require d.f. Check level of hydrau
21、lic oil; add as required.Manufacturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering Standards repair or replace components asrequired.POWER:Make checks, adjustments and repairs listed under “Manual”, and inaddition, perform the following:a. Chec
22、k power steering pump, drive belt, oil reservoir, cylinderassembly and hoses for leaks; add oil, adjust, repair, orreplace, as required.3.2.26 CLUTCH: Same as “A”.3.2.27 TRANSMISSION - AUTOMATIC:a. Drain oil, remove bottom pan, and clean screen.b. Drain and clean oil filter and replace element.c. Re
23、-install screen and pan with new gasket, torque pan boltsand fill with specified fluid transmission fluid and check forleaks.d. Replace breather element.Manufacturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering Standards and adjust valves as re
24、quired.f. Drive vehicle for three minutes and check oil level; add asrequired.3.2.34 LIMIT SWITCHES: Same as “A”.3.2.35 LIGHTS: Same as “A”.3.2.36 HORN: Same as “A”.3.2.37 SPECIAL EQUIPMENT: Same as “A”.3.2.38 GENERAL INSPECTION: Same as “A”.3.2.39 LEAKS: Same as “A”.3.3 “C” INSPECTION - ENGINE POWE
25、RED EQUIPMENT - 1,200 OPERATING HOURS:3.3.1 OPERATING HOUR METER: Same as “A”.3.3.2 CLEAN VEHICLE: Same as “A”.3.3.3 ENGINE OPERATION: Same as “B” plus the following:COMPRESSION:a. Install a compression gauge in number one cylinder with allspark plugs removed.b. Crank engine until a maximum reading
26、is obtained.c. Repeat process on each cylinder.d. If a variation is noted, check the manufacturersspecifications for compression requirements.COIL: Test coil and replace as required.CYLINDER HEAD, MANIFOLDS AND OIL PAN:a. Re-torque nuts and bolts to specified torque.b. Replace defective gaskets.Manu
27、facturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering Standards check for oil leaks.3.3.4 AIR CLEANER: Same as “A”.3.3.5 ENGINE OIL AND F ILTER: Same as “A”.3.3.6 ENGINE OIL PRESSURE: Same as “A”.3.3.7 CRANKCASE VENTILATION: Same as “A”.3.3.8 F
28、UEL SYSTEM: Same as “A”.3.3.9 GOVERNOR: Same as “A”.3.3.10 STARTING BATTERY: Same as “A”.3.3.11 CHARGING SYSTEM: Check alternator output in conjunction withregulator checks.3.3.12 ALTERNATOR-REGULATOR: Test per manufacturers specifications;replace as required.3.3.13 STARTER: Test for proper operatio
29、n; replace as required.3.3.14 WIRING SYSTEM: Inspect all terminals, connections, fus es,protective covering and grommets; repair or replace as required.3.3.15 ENGINE COOLING SYSTEM: Same as “B”.3.3.16 AUTOMATIC TRANSMISSION COOLING SYSTEM: Same as “B”.3.3.17 HYDRAULIC SYSTEM: Same as “B” plus the fo
30、llowing:a. Drain oil, clean scree ns and sump.b. Replace hydraulic filter element and if required, screens.c. Flush tank before refilling if a large amount of dirt is foundin the system.Manufacturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering
31、Standards repair orreplace cylinders as required; replace drums or rotors whichdo no meet specification after re-facing.3.3.22 WHEEL BEARINGS:a. Clean and examine wheel bearing assemblies, seals andspindles; replace as required.b. Repack wheel bearings with specified lubricant.3.3.23 DRIVE AXLE: Che
32、ck for leaks, extraordinary noises, looseness ingears, bearings and mounting bolts; repair as required.3.3.24 STEERING SYSTEM: Same as “B”.3.3.25 WHEEL ALIGNMENT: Check wheels for proper alignment and adjust asrequired.3.3.26 C LUTCH: Same as “A”.3.3.27 TRANSMISSION:MANUAL: Check for leaks, loose sh
33、ift linkage and unusual noises;repair as required.AUTOMATIC: Same as “B”.3.3.28 DRIVE SHAFT: Check for looseness and alignment of drive shaft,support bearings and universal joint(s); replace as required.Manufacturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPEC
34、TIONSEngineering Standards replace asrequired.b. Inspect for loose or worn shackles, shock absorbers, bushings,and other mountings; repair or replace as required.3.3.30 VEHICLE FINISH:a. Inspect vehicle finish and condition of paint.b. Repair or replace damaged sheet metal parts.c. Prime and paint a
35、s required.d. Maintain in legible condition:1. Capacity rating2. Operation and maintenance instruction plates3. Equ ipment tags4. Decals and stenciled information3.3.34 LIMIT SWITCHES: Same as “A”.3.3.35 LIGHTS: Same as “A”.3.3.36 HORN: Same as “A”.3.3.37 SPECIAL EQUIPMENT: Same as “A”.3.3.38 GENERA
36、L INSPECTION: Same as “A”.3.3.39 LEAKS: Same as “A”.4. IN SPECTION PROCEDURES - ELECTRICALLY POWERED EQUIPMENT:4.1 “A” INSPECTION - ELECTRICALLY POWERED EQUIPMENT - EACH 200 OPERATING HOURS:4.1.1 OPERATING HOUR METER: Check operation of engine hour meter andrecord reading on inspection form. If mete
37、r is inoperative,replace and record the fact that the meter has been replaced andthe number of operating hours which are indicated on the replacedmeter.Manufacturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering Standards repair or replace asrequ
38、ired.a. Inspect and adjust or replace as required:1. Forks2. Uprights3. Lift Carriage4. Load Backrest5. Rollers6. Bearings7. Mounting Bolts8. Support Brackets9. Chains10. Attachments (side shift and rotators, etc.)b. Examine stressed members for cracks or other evidence ofimpending failure; replace
39、as required.NOTE: Modification or repair of structural, load bearing members,or safety related components is strictly prohibited, without themanufacturers written approval.4.1.19 LUBRICATE (To meet manufacturers specifications):a. DRIVE AXLE: Check lubricant level and fill as requi red.Clean and che
40、ck breather vent.b. STEERING GEAR: Check lubricant level and fill as required.c. HYDRAULIC SYSTEMS: Check level and fill as required.Manufacturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering Standards adjust if required.Manufacturing StandardsF
41、ord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering Standards adjust or repair as required.b. Check cables and rods and repair as required.c. Drive truck to test brakes; repair and adjust brakes to holdas required.CAUTION: Be sure wheels turn freely aft er adjus
42、tments are made.4.1.34 LIMIT SWITCHES: Test for correct operation and replace asrequired.4.1.35 LIGHTS: Inspect lamp assemblies, switches and wiring and repairor replace defective parts as required.4.1.36 HORN: Test for proper operation, repair or replace as required.4.1.37 SPECIAL EQUIPMENT: Trucks
43、 or devices designed and approved forhazardous area operation shall be maintained to insure that theoriginal approved safe operating features function properly.4.1.38 GENERAL INSPECTION:a. Examine frame, counterweight mounting and overhead guard forcracks and bent or fatigued parts.b. Determine that
44、 all nameplates and markings are in place andare in legible condition.c. Any unit found to be in unsafe operating condition shall beremoved from service.Manufacturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering Standards repair or replace as re
45、quired.4.2.17 HYDRAULIC SYSTEM:a. Test operation of pump, cont rol valves, lift and tiltcylinders.b. Check lift cylinder for exterior dents, cylinder rods forscratches and mars; repair or replace as required.c. Check packing and seals for leakage and seating; replace asrequired.d. Check hoses and fi
46、ttings; repai r or replace as required.e. Clean breather filter element; replace as required.f. Check level of hydraulic oil; add as required.4.2.18 LIFT ASSEMBLY: Same as “A“.4.2.19 LUBRICATE: Same as “A“.4.2.20 TIRES: Same as “A“.4.2.21 BRAKES: Same as “A“.NOTE: If adjustments do not provide prope
47、r brake operation,perform “C“ inspection brake inspection and service.Manufacturing StandardsFord Motor Company199603 INDUSTRIAL TRUCK SCHEDULED Z2A1MAINTENANCE INSPECTIONSEngineering Standards repair or replace components asrequired.POWER:Make checks, adjustments and repairs listed under “Manual“,
48、and inaddition, perform the following:a. Check power steering pump, drive belt, oil reservoir, cylinderassembly and hoses for leaks; add oil, adjust, repair, orreplace, as required.4.2.31 ELECTRICAL CONTROL SYSTEM:GENERAL: Service per manufacturers specif ications.CONTROLLERS:a. Remove controller co
49、ver and clean with compressed air.b. Visually check contact points and all component parts; ifcontact points or component parts are defective, adjust,repair or replace.c. Check operating levers, adjust, lub ricate, repair, or replaceas required.d. Lubricate as specified with petrolatum.e. Operation test to insure specified performance.CONTACTORS:a. Remove cover and clean panel with compressed air.b. Visually check contact points and all component parts. Ifcontact points are badly burned and/or defective parts found,replace.Manufacturing StandardsFord Motor Company1996
