SLEP MHE Inspection Maintenance Requirements 6K-Diesel Lift Truck - Attachment.docx

SERVICE LIFE EXTENSION PROGRAM (SLEP)

HYSTER 6K DIESEL LIFT TRUCKS

-Inspection / Planned Maintenance Action Requirements-

ALL MSC FORKLIFTS ARE EQUIPPED WITH A FOOT OPERATED FOUR-WHEEL BRAKE SYSTEM.

References

(a) Management of Materials Handling Equipment (MHE) and Shipboard Mobile Support Equipment (SMSE), NAVSUP Pub 538, Rev 6, 0530-LP-642-6711, 01 July 2010

(b) Handling Ammunition and Explosives with Industrial Materials Handling Equipment (MHE), NAVSEA SW023-AH-WHM-010, Rev 8, 0640-LP-111-4504, 01 Oct 2009.

(c) Hydraulic and Mechanical Drum Brakes, Rockwell Procedure 4H, Apr 96.

(d) MSC Shipboard Diesel Forklift Labeling Diagram, May 2020

GENERAL

(a) Contractor shall not dispose of any parts removed prior to receiving Government approval.

(b) The contractor shall coordinate with the Government for witnessing of any task that includes a “TEST”. The Government reserves the right to witness any inspection, test or other production process included in this PWS.

(c) For all CONTRACTOR FURNISHED ITEMS, the contractor shall ensure that all parts are OEM certified and identified with the OEM’s part number.

(d) Condition Found Reports shall include the following information:

1. INITIAL INSPECTION AND CLEANING.

(a) Inspect the truck’s overall condition and perform an operational assessment of all systems and functions noting any broken, missing, inoperative or damaged parts.

(b) Perform all safety device inspections (e.g., auto-reverse, dead-man, horn etc.)

(c) Provide CFR.

(d) Clean vehicle completely to remove all grease, oil, dirt, and other contaminants.

2. ENGINE

(a) Prior to engine testing, inspect the engine mounts for leaks, cracks, loose bolts or other damage.

(b) Perform compression cylinder testing (dry reading and wet reading) in accordance with Hyster Technical Manuals.

(c) Perform leak-down testing.

(d) Adjust the valve clearances.

(e) Perform a visual inspection for smoke at idle, partial and full throttle conditions.

(f) Inspect the engine for any oil, water or fuel leaks.

(g) Inspect the entire exhaust system for corrosion, cracks, leaks, incorrect routing, missing parts or other damage that would affect the performance or extended mission requirements.

(h) Inspect the air cleaner housing for distortion, corrosion, or other damage.

(i) Inspect the glow plug wiring, wire harness, and cover for cracks, corrosion, damage or deformation.

(j) Provide CFR

(k) Change oil and renew oil filter

(l) Renew all glow plugs

(m) Renew alternator.

(n) Renew starter

3. FUEL SYSTEM.

(a) Drain, clean and inspect the fuel tank.

(b) Clean and inspect the water separator.

(c) Clean and inspect all high and low pressure fuel lines and fittings. Check for deformation, corrosion, damage, contamination or other damage.

(d) Provide CFR

(e) Renew all rubber, neoprene or plastic lines

(f) Renew all clamps and hardware

(g) Renew all injectors

(h) Renew fuel injection pump.

(i) Renew the fuel tank shut-off valve.

(j) Renew the fuel-sending unit.

(k) Renew the fuel filters.

4. RADIATOR.

(a) Remove, clean via chemical immersion, paint, reinstall radiator

(b) Renew all cooling system hoses.

(c) Renew engine thermostat and gaskets

(d) Renew coolant with OEM recommended fluid.

5. RADIATOR FAN, WATER PUMP, and PULLEYS

(a) Inspect coolant fan for cracks, damage, deformation and loose fasteners or blades.

(b) Inspect the water pump for worn or noisy bearings, worn shaft, or leaks.

(c) Inspect all engine drive and idler drive pulleys for cracks, wear, deformation, separation or other wear

(d) Provide CFR

(e) Renew all engine drive belts

(f) Renew water pump

6. TRANSMISSION.

(a) Inspect the transmission for leaks, cracks or other damage. Pay particular attention to the front and rear seals. If any seepage is visible or if the seals are suspect.

(b) Inspect the transmission mounts and attaching hardware.

(c) Drain the fluid and inspect for contaminates that may indicate internal damage.

(d) Provide CFR

(e) Renew the filter and the screen.

(f) Renew fluid with OEM recommended fluid.

7. DRIVE SHAFT AND UNIVERSAL JOINT ASSEMBLY.

(a) Inspect transmission output flange, drive shaft, universal joints, and differential carrier flange for looseness, cracks, deformation or other damage.

(b) Provide CFR

(c) Renew all universal joints.

8. BRAKING SYSTEMS.

(a) Inspect and service/parking brakes.

(b) Inspect the brake linings/pads and hardware for excessive heat and contamination due to oil, grease, rust, corrosion, etc.

(c) Clean, inspect, and lubricate the cables, linkages, springs and pivot cams.

(d) Inspect the front and rear wheel cylinders

(e) Provide CFR.

(f) Renew all wheel cylinders

(g) Renew all brake linings and pads.

(h) Renew all brake hardware.

(i) Renew the brake master cylinder(s).

(j) Renew all brake flexible hoses.

(k) Drain the system and refill using the recommended fluid.

(l) Adjust all brakes in accordance with reference (c), Section 2.

9. WHEELS AND BEARINGS.

(a) Remove all wheels and inspect all bearings, seals, and associated surfaces for damage and excessive wear.

(b) Measure and record all brake drum diameters.

(c) Provide CFR.

(d) Renew all tires.

(e) Restore all wheels and tighten all lugs/lug nuts to the OEM recommended torque values..

10. DRIVE AXLE ASSEMBLY.

(a) Clean and inspect the drive axle assembly for leaks or other damage.

(b) Drain the fluid and inspect for contaminates that may indicate internal damage.

(c) Provide CFR

(d) Renew all gaskets

(e) Renew the differential oil with OEM recommended fluid.

11. STEER AXLE ASSEMBLY.

(a) Clean and inspect for any worn, loose or damaged spindles, tie-rods, king pins, spindle bearings, etc.

(b) Provide CFR

12. STEERING UNIT COLUMN.

(a) Inspect the steering unit and column for looseness, rough operation, excessive play or binding.

(b) Clean and inspect steering unit for any leaks, or worn seals and O-rings.

(c) Provide CFR.

13. HYDRAULIC TANK (Reservoir).

(a) Inspect the exterior of the tank for cracks or damage.

(b) Drain the hydraulic fluid and inspect the inside of tank for corrosion, rust or other contamination.

Inspect fluid for any indication that internal hydraulic system failure is present.

(c) Provide CFR

(d) Renew all screens and filters.

(e) Renew all tank gaskets.

(f) Renew the tank breather.

(g) Renew the hydraulic filter indicator.

(h) Renew the fluid. Use only OEM recommended fluid.

14. HYDRAULIC LINES, HOSES AND FILTER.

(a) Inspect all rubber hoses for hardening, abrasion, cuts, cracks, degradation or other damage.

(b) Inspect all metallic lines and pressure fittings for leaks and damage.

(c) Provide CFR

(d) Renew hydraulic hoses.

(e) Renew the hydraulic filter. Label filter housing with date and machine hours when changed. Labels shall be well-adhered with block letters 1/2in in height.

15. HOSE REEL.

(a) Inspect the hose reel for wear, cracks, dents, burrs, sharp edges, deformation, damage, and proper operation.

(b) Provide CFR.

16. HYDRAULIC CYLINDERS.

(a) Remove, disassemble, and inspect all hydraulic cylinders.

(b) Inspect the attaching hardware and mounts for cracks or wear.

(c) Provide CFR.

(d) Repack all cylinders using new seals and gaskets.

17. HYDRAULIC PUMP.

(a) Inspect all hydraulic pumps for any abnormal noises or leaks.

(b) Provide CFR

(c) Renew or adjust system pressure relief valve. If adjustment is elected, adjustments must be made by certified calibration technician in the presence of the Government.

18. MAIN CONTROL VALVE ASSEMBLY.

(a) Inspect the main control valve assembly for leaks or damage.

(b) Test proper operation of primary/secondary relief valve(s).

(c) Provide CFR

19. AUXILIARY CONTROL VALVE.

(a) Inspect the auxiliary control valve for cracks or leaks.

(b) Test the relief valve pressure for proper operation.

(c) Provide CFR

20. WEIGHT MONITORING SCALES.

(a) Inspect the weight gauges for corrosion, damage and proper operation.

(b) Provide CFR

(c) Drain and renew the gauge fluid. Use only OEM recommended fluid to fill gauge case.

(d) Bleed, zero, and test gauge to ensure operation. Label gauge with test and fluid fill date. Labels shall be well-adhered with block letters 1/2in in height and not obscure any part of the gauge scale.

21. ELECTRICAL COMPARTMENT AND CONTACTOR PANEL.

(a) Clean and inspect the electrical compartments control panels, and contactor panels for evidence of excessive corrosion, heat, wear or other damage.

(b) Remove, disassemble, and inspect all electrical contacts.

(c) Inspect the wiring for excess heat, cracking, loss of insulation, brittleness, tightness of connections, and other damage.

(d) Inspect gaskets and seals.

(e) Remove and inspect all fuses.

(f) Provide CFR.

(g) Preserve the electrical compartment, control panel, and related components using cleaner preservative DEOXIT Shield S - Series or equivalent.

(h) Renew the battery tray and hold-down assembly.

(i) Renew all replaceable contacts and relays.

22. CABLES AND LINKAGES.

(a) Inspect all cables and linkages for wear, fraying, or damage and correct type. Particular attention shall be directed to the end fittings and junctions for damage caused by corrosion or stress.

(b) Provide CFR.

(c) Lubricate all linkages and cables.

23. WIRE HARNESS

(a) Inspect the wire harness for corrosion, alterations, cuts, heat, brittleness or other damage.

(b) Inspect the supplementary wiring (wiring other than the main wiring harness) for splices, cuts abrasion, kinks, peeled insulation, or other defects.

(c) Provide CFR

(d) Clean and preserve all connectors and pins with cleaner preservative, DEOXIT Shield S – Series.

24. AUXILIARY LIGHTING.

(a) Inspect the all lights for rust, corrosion, clouding of the lenses, or other damage.

(b) Provide CFR

25. MAST ASSEMBLY.

(a) Inspect the mast assembly including lifting forks for cracks, deformation, missing hardware, or other damage.

(b) Inspect the mast rails for any gouges, scoring or other damage.

(c) Inspect lift sprockets, cross head, chain anchors, etc., for cracks, deformation or other damage.

(d) Inspect all the bearings for lack of lubrication.

(e) Clean, inspect, and measure the lift chains for wear and stretch in accordance with Hyster Technical manual.

(f) Measure carriage wear strips and angles for wear. Inspect for gouging, galling, established knife edges, embedded contaminants or excessive wear.

(g) Inspect forks in accordance with reference (a) section 8-6.

(h) Provide CFR

(i) Lubricate mast assembly in accordance with OEM instructions

26. COUNTERBALANCE WEIGHT

(a) Remove and inspect counterbalance weight

(b) Inspect all bolt holes and threads for wear, stretch, stripping, galling, elongating or other damage, and defects.

(c) Inspect for the presence of Heli-Coils from prior repairs

(d) Provide CFR

(e) Renew all mounting hardware

27. OPERATOR INTERFACE.

(a) Renew the seat.

(b) Renew the seatbelt.

(c) Renew foot pedal and brake control covers

(d) Renew all driver compartment cushion treads.

(e) Renew steering wheel

(f) Adjust all internal VSM settings to restore factory settings and maximum authorized speed.

28. PRESERVATION

(a) Prepare, Prime, and Paint the entire vehicle exterior, battery compartment, and mast using OEM approved coatings and application procedures. The finish color (Forklift, Mast Assembly and Rims) shall be yellow in accordance with FED-STD-595 and reference (a). Enamel Gray Primer (V2182838), Black Rust Reformer (215634) and Yellow Paint (13538). Trucks shall be yellow on all surfaces except the fuel fill cap and the hydraulic fill cap.

(b) Provide CFR with coating manufacturer, type, and lot number

(c) Renew all vehicle markings in accordance with reference (a).

29. LUBRICATION.

a. Lubricate all grease fittings. Renew any fitting that is damaged or does not seal.

****NOTE****

Prior to performing the general tests, verify all paint has been removed from the hydraulic cylinders, hoses, and wires.

30. CERTIFICATION

(a) Perform 18-month Certification Test in accordance with references (a) and (b).

(b) Perform Fork Inspection Test in accordance with references (a) and (b).

(c) Certification label in accordance with reference (a)

(d) Provide documentation forms