Lift truck repower - Engine swap

[denrep]

This forklift was just repowered with a diesel, tomorrow is gonna be test day:
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She was built in Danville IL. See the frame? In Danville, they call that "5 gauge tin" :laugh: it's 5" thick, solid! Best toughest lift ever built, -bar none- but that Fseries Continental powerplant... :realmad:

A side note - Alfred said: You know that Continental has caused so much grief and cursing; if you guys are done with it, I'd really like to take it to the scrap yard myself and watch it go through the block crusher. I told him to go ahead. When he got back he said that the new low scrap price offered was so ridiculous that he told the scale man that before he'd sell a good old reliable engine so cheap, he'd throw it off Sagamore Bridge. I don't know what happened, but he didn't come back with it.

I thought maybe mechanic-types would be interested in some pics, but I kinda lost my stride with the new camera, take 10meg pics then you gotta chop 'em down to post. :realmad:

The usual minor changes: Mounts, flywheel, exhaust, pump drive, manifolds, linkage, relocate filters...
Here's the mill:
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I didn't do the actual change, I planned it, and built some brackets. Up-front, I told the traveling mechanic who bid the job, that to collect it would have to be turn-key complete, clean, simple, and reliable, with:

No essential run/start wiring beyond the engine bonnet.
Nothing rubbing anything anywhere.
Mechanical shut off.
Air cleaner rigidly mounted directly to engine.
Filters easily accessible.
All modifications weatherproof .
Original type oil-clutch.

No time limit, but the job had to be finished and right to collect the jing.

Here's were the starter push button ended up, -as specified- weatherproof and under the hood, but the operator has to find one of a 100 holes to push his finger through.
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Another side note: Check out that small second pedal mounted on the brake pedal; it's an auxiliary throttle, I've never seen another one on anything. Anyone else? How about you Davis R? Sure beats the heel-toe trick.

The wrench did a good job, there were some setbacks, and a few things he had to redo, yesterday he wanted me to check it out and sign off on it. I found a few little shortcomings.

I guess when I mentioned the difficulty in finding the starter switch the guy had enough of my petty details. He kind of blew up at me: "Why don't you put some hair around it so you can find the ____ hole!"

Well he had made every change I had asked for, and the job really looks good, so I let the switch ride. Figured I could take care of that little detail myself.

I wanted the switch ready for Monday "test day", so I got right on it:
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He was right, it's easy to find now. That mechanic really knows his stuff!
Tomorrow we'll find out what he thinks of my work! :laugh:

[farmersamm]

Watch out for that hair, might have teeth:D:D:D Don't stick nothin' in there ya don't mind losin':D

The little button thing on the brake, aux. throttle?, is gonna be something you will really like down the road. No more trying to cover the fuel pedal, and brake pedal, at the same time when you need power, but also need to stay in one spot. On the flip side, it's gonna take some gettin' used to. New auxillary door in the shop possibly:jester:

[flatbustedbroke]

Love the fix for the hole will need to remember that one!

[denrep]

I just try to follow orders; I get yelled at to put hair around it - I put hair around! :p

The auxiliary throttle was a factory piece. But it's one of those things about like a seldom used specialty tool, when you finally do have a need for it, you either forget you have it or just skip it. Notice the yellow paint was never worn off it? Every good clutch man I know, has double jointed right ankle anyway. :laugh:

Without a stumbling conking gutless gas engine there's probably no need for the auxiliary throttle now, but it's an oddity for sure. It's an oddball even for this model truck, I'm curious to see if anyone's seen another one.

[59halfstep]

Place I used to work for had a Large four wheel drive Deere that had one on it. Damn thing would get under your winter boots and could scare the hell out of you when you release the left foot feed and the thing don't even think about slowing down.

[denrep]

How about the two pedal jobs - One for forward one for reverse, they were good for an unexpected lurch.

Today I'll check how the auxiliary links to the main accelerator.

[Tractapac]

How about the two pedal jobs - One for forward one for reverse, they were good for an unexpected lurch.

Today I'll check how the auxiliary links to the main accelerator.

I'll second that, we've got a Massey Ferguson like that. two postage stamp sized pedals on a U shaped fork, set in a recess in the floor. The fork rocks from side to side to give Forward or Reverse. Recess is 1/2" clear on either side. In the middle of the U is another pedal to operate throttle without moving the machine. Again the size of a postage stamp. Size 12/13 boots make you look where you put your foot. They must have had small feet in mind when they built the cab.

As you say good for the odd lurch or three!

[denrep]

I'll second that, we've got a Massey Ferguson like that. two postage stamp sized pedals on a U shaped fork, set in a recess in the floor...

Tractapac - The Massey Ferguson is exactly the machine I had in mind when I wrote about the tip-toe shift.

To make things more interesting, on some of the same MF turn-arounds the driver straddled an open bicycle chain that turned with the steering wheel. Oh well, you shouldn't be running a tractor when you're wearing shorts anyway. :laugh:

The diesel swap flunked the field test; keeps picking up air in the fuel system. Probably a fitting or line or seal on the suction side.

[farmersamm]

I've had problems on the intake side, and both times it turned out to be a bad seal in the manual primer pump. Your setup might not have one, but it's a thought. Good luck.

[farmersamm]

Oh, I found both leaks by putting very low air pressure in the fuel tank, then looking for leaks in the lines.

[denrep]

I've had problems on the intake side, and both times it turned out to be a bad seal in the manual primer pump. Your setup might not have one, but it's a thought. Good luck.

Thanks Samm, Has a pump integral with the lift pump.

I didn't have time to look at it myself but I overheard the talk.
If they don't find it I'll probably try your low pressure idea.

Let you know what happens

[farmersamm]

Before I get offa this thing(computer), and get some work done......

If you have an old innertube laying around, cut out the valve stem area and hold it or clamp it over the filler neck on the fuel tank then give it some air.

[mark8310]

Denrep, did you do an engine swap only, or an engine/transmission swap?

[denrep]

Mark8310 - Both, but not as a unit. The manual trans is basically the same as the stock gasoline trans. Engine was out of an airplane tow tractor; it originally was fitted with an adapter that coupled it to a Ford automatic transmission.

The housing connection was the complex part, because the lift truck's clutch runs in an oil spray bath, the housing and crankshaft had to be sealed to hold oil two ways. Pump drive was a challenge as well. Electrics went from 24v to12, starter had to have an oil seal.

The fuel system's suction leak was traced to a cracked glass fuel filter bowl:
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Robbed a replacement aluminum bowl off an old twin filter set-up.

[David R]

I used to work for SHyster. Its a P80, or maybe a P60. They did come with a perkins as an option.

Nice job.

This one is for alfred.

I spent a few hours converting a clark from gas to LP. The maintenance guy was busting on me the whole time. When I was done, I had him fire it up for the first time. It started instantly.

I said "Now I know it will start for any azzhole" :)

David

[denrep]

I used to work for SHyster. Its a P80, or maybe a P60. They did come with a perkins as an option....


"SHyster" huh? Hah, they offered to come up with the obsolete adapter -have a seat- $6500 and 6 months! Somewhere they're laying in the junk pile - but where? I did my best to try to come up with used OE adapters, even thought about trying to have some duplicates cast.

There's another truck waiting in the wings for the same treatment, I have a few ideas for some changes, I'll post when it begins.

.

[denrep]

Another weary straggler crawled home for a little TLC:
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Jimmy power in this one:
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2-53 Detroit diesel.

Another donor engine showed up. The big dog looked over the latest transplant heart and said: That thing looks terrible. The guy who pulled it; how fast was he going when he hit the end of the chain?
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Alfred said, it's supposed to run real good. I told him: Ford doesn't put ‘em in without a hot-run test and their engines are new! We sure aint installing that puppy without hearing it run. If we can't give it a hot-run test; you can just take it over to Sagamore and throw it off the bridge.

So off to the "dyno room", where it was set up with fuel, and a water hose cooling system, and a "C" clamped temporary starter motor:
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It runs real nice, just a wisp of smoke when you really nail it.

She ran for at least an hour, and that's the most smoke she'd give, only when "spiked.".
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Even when we dogged it! :waving:

[David R]

Holy Chit! A 2-53? Talk about under powered. 106 Cubic Inches in a machine weighing 15,000 lbs.

Gutless eh? Just the blower, no turbo.

David

[denrep]

...106 Cubic Inches in a machine weighing 15,000 lbs....

Don't forget the load, that easily puts it over 20,000.

Only 106 cubes, but since it's 2-cycle, every stroke's a power stroke, it's not working as an air pump half the time; at least that's what GM used to say! :rolleyes:

Despite it's small size the low end torque is surprising, even at a dead idle you can't conk it with the clutch or hydraulic pump. Of course it might have a 400 pound flywheel! :laugh:

[farmersamm]

I sure like that dog.

[Dualie]

I used to have a engine drive welder with 53 series Detroit in it. I would invest in ear plugs.

we wont even talk about the KW day cab with the 12V71 in it. Mainly because I couldn't hear you anyway.


Diesel for better living...

[Tractapac]

Is this latest refugee also of the side armor plated variety? Steel must have been cheaper than cast iron, or didn't they believe in rear counterweights then?

[denrep]

I sure like that dog.

Farmersamm - You prefer grilled or broiled?

Dualie - I've often wondered what makes ‘em so loud.
Do you suppose it's the pressurized scavenging air instantly released through the cylinder ports? I remember an annual noise contest that was always won by some chain saw or other; until the year someone entered a 3-53. :laugh:

Tractapac - Yes, same cheap 5" tin frame. ;)

[enlpck]

You can muffle the 53's and 71's and they will get quieter, but it takes a lot of muffler. Tough part is not choking them. Then you have the intake noise, which is different due to the blower, but still substantial.

I love Detroits. Tough as nails, moderately easy to work on, run forever. Have one at one job that goes back a LONG time.... the serial number has three digits. Parts are still available off the shelf.

I'd love to find a 1-71 to put in a motorcycle...... Ah, to dream.

[farmersamm]

There's still quite a few oilfield pulling units here powered by the Detroits. Can hear 'em coming 2 miles away. Engine mounted at proper ear level, about 1 foot behind the single seat tin cab. What?..... I say What??

[denrep]

...I'd love to find a 1-71 to put in a motorcycle...... Ah, to dream.

I'd love to find a 12-71T to put in a motorcycle...... Ah, to dream :laugh:

I heard the 1-71 was built one year only and for the US Navy only; I'm not sure about that, but that's what I heard, I never saw one.

I really respect the Jimmy, they lasted 65 years without a major redesign, and there's still a million of 'em running; that says something for them.

[Dualie]

The best description on a two stroke Detroit I ever was told is their converters. They convert diesel fuel in to smoke and noise.

Dad had a W900 glider built up back before I was born with a Silver 12V92 in it. heavy CA spec lowbed puller. after he sold it I heard it went up to logging country in Southern Oregon. I would love to find that truck and restore it but its probably LONG gone.

[dkmc]

I realize this this thread is 4 years old, I really wish the attached pictures still worked. A buddy of mine is considering squiring a 15K Clark that will need a different engine and trans....

[Insaneride]

I wanna see the pic of the hairy teeth.:laugh::laugh::laugh:

I almost spit my coffee out all over the place when I read about using hair to find the hole. :laugh: